Engineering Materials and methods of manufacturing_ppt.ppt

Introduction to engineering materials,and methods of manufacturing such as casting method, molding method, forming method, it's advantages and disadvantages...

1. Engineering Materials
Manufacturing

2. Materials
Over 70,000 different kinds and grades of
engineering materials
This number grows daily
1,000 different materials
make up an
automobile

3. The Three Basics:
Metals
Polymers
Composites
Ceramics

4. Metal
Cast Iron
Steel
Mild steel, medium carbon steel, high carbon steel
Specialty steel
Stainless (tin plated or galvanized)
Alloys (two or more pure metals)
Steel= iron & carbon
Brass= copper & zinc
Bronze= copper & tin

5. Polymers
Natural
Animal cellulose
Synthetic-
Thermoplastics
Thermosets

6. Natural Composites
Hardwood
Deciduous Trees
Softwood
Coniferous

7. Ceramics
Clay based
Structural clay-tile, brick
Porcelain
Refractories
Heat resistant (fire bricks)
Glasses
Inorganic cements

8. Hardwoods
Ash
Beech
Birch
Cherry
Mahogany
Maple
Oak
Poplar
walnut

9. Softwoods
Cedar
Cypress
Fir
Pine
Redwood
Spruce

10. Manufactured Wood
Particle Board
flake board, particle board
Laminar
plywood, laminated beams

11. Lumber Facts

12. Manufacturing is defined as the conversion of raw
materials into the finished goods on a large scale using
man and machine whereas manufacturing processes are
defined as the methods used for conversion of raw
materials into finished products. Based on the product
requirement there different types of manufacturing
processes which are used to get the requiredoutput.
In this article, you are going to learn about the seven
types manufacturing processes and their subtypes with
examples.

13. Types of Manufacturing Processes
Some websites mention four types of
manufacturing processes while some mention
five types of manufacturing processes.
Although,Wikipedialists 7 main types of
manufacturing processes which we are going to
discuss below.

14. 7 Main types of Manufacturing Processes and
their subtypes

15. 1. Casting
Castingis a process of pouring liquid metal into
a moldcontaining the hollow shape of the
desired outcome. It uses sprue, gates, and
runners to pour the metal. The main types of
manufacturing processes undercasting are:-

16. Centrifugal Casting
Centrifugal casting is a process of pouring molten
metal into a spinning die.Spinning die creates high
g-forces to the molten metal which gives it the
cylindrical shape. Moreover, spinning let the
impurities (less dense material) to float at the inner
diafrom where it is removedlater. Spinning can
either be on a vertical or horizontal axis depending
on the configuration of the desired part such as
vertical rotation is used to cast ring and cylinder
and horizontal rotation is used to cast tubular
shapes.

17. Example: Some examples of centrifugal castinginclude jet engine
compressor cases,petrochemical furnace tubes, military products,
and other high-reliability applications.

18. Die Casting
Die casting is a manufacturing process used
for producing metal parts where high
precision is required. This process is
accomplished by forcing molten metal under
high pressure into reusable metal dies. High
volume production is done using this process.

20. Process
•Steel moldscapable of producing several castings
at once are produced.
•Moldsare mounted securely in a die casting
machine and are arranged so that one is stationary
while the other is moveable.
•The die cavityis injected with molten metal and
allowed to solidify and the part is ejected.
Example: Die casting process is used for producing
precise non-ferrous metal parts.Some examples of
die casting include engines, clutch housings, and
covers of a four-wheeled vehicle.

21. Sand Casting
Sand casting is ametal castingprocess that uses
sandas themoldmaterial. This process has a low
production rateas the sand moldmust be
destroyed in order to remove the part. Although, it
is a cheap process when low volume production is
required.

23. Process
•Furnace, metal, pattern, and sand moldare
used in the sand casting process.
•The molten metal is poured using ladle into the
cavity of the sand mold, which is made from the
pattern.
•The casting is allowed to solidify and then
removed by breaking the mold.

24. Example: More than 70% of all metal castings are
produced via sand casting process. Some
examples of sand casting process include engine
blocks, machine tool bases, cylinder heads, pump
housings, valves, gears, pulleys, crankshafts,
connecting rods, and propellers.

25. Permanent MoldCasting
Permanent moldcastingis a manufacturing
process that offers reusability of metal molds
which makes it eligible for high volume
production. This process uses gravity or
vacuum or gas to fill the mold.

27. Process
•The moldis preheated and a ceramic coating is
applied to the moldcavity surfaces to facilitate
part removal.
•The molten metal is poured from a ladle and
gravity or vacuum is used to raise the molten
metal into the moldassembly.
•The casting is allowed to solidify and then
removed by opening the moldassembly.

28. Example: Some examples of permanent mold
casting include gears, pipe fittings, fuel injection
housings, splines,wheels,gear housings,
enginepistons.
Note the difference:Sand casting uses an
expendable moldwhich is destroyed after each
cycle whereas permanent moldcasting and die
casting uses a metal moldthat is reused for several
thousand times. Permanent moldcasting process is
considerably slower, and not as precise as die
casting. Also, an external force is used to inject
molten metal in die casting as compared to gravity
or vacuum in permanent moldcasting.

29. Investment Casting
Investment casting is metal casting
process of pouring molten metal into an
expendable ceramic mold. This process is
also known as “lost-wax casting” as the
wax pattern is melted out of the mold
when molten metal is poured. Complex
parts are made using this process.

31. Process
•The wax pattern is prepared and
surrounded/invested by the ceramic slurry that
hardens it and converts it into a mold.
•The moldis preheated to evaporate the wax and
the molten metal is poured from a ladle into the
mold.
•The casting is allowed to solidify and then the
moldis broken and the casting removed.
Example:Some examples of investment casting
include turbine blades, airplane parts, firearm
components and military equipment.