Module 1 20MEE25: Primary Manufacturing Mechanical Engineering

This is about the manufacturing process, the class was taken by Prof. Kiran at GAT

1. 20MEE25
Elements of Mechanical
Engineering-Module 1
Course Instructor: R.Kiran
Course Co-Ordinator : Mr Shamanth C /Dr Prashanth T

2. Module-1
Dept of Mech Engg , Global Academy of Technology 2
8 Hr
20MEE25,AY 2020-21 Even
•PrimaryManufacturingProcesses:Casting,forging,rolling,drawing,
extrusion,presstoolwork,plasticmouldingandpowdermetallurgy
(Introductiontotheprocessandapplicationsonly)
•JoiningProcesses:Soldering,BrazingandWelding.Definitions.
WorkingprincipleofArcWelding,Oxy-AcetyleneWelding.
ComparisonoftheSoldering,BrazingandWeldingprocesses
•Introductiontoadditivemanufacturing:Definitionsandstages
involvedinAdditiveManufacturing.ApplicationsofAdditive
Manufacturing.
•DemonstrationofAdditiveManufacturing
•Practiceonmetalarcwelding(runningbead)

3. Manufacturing
•Makingofarticlesonalarge-scaleusingmachinery;industrial
production
•Rawmaterialsaretransformedintoafinalproduct/finishedgoods
•Involvesuseofmanuallabourormachines
•Denotesthefabricationorassemblyofcomponentsintofinished
productsonafairlylargescale
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4. Manufacturing..
•TheWordmanufactureisderivedfromtwoLatinwords:-
•Manu:meaningbyhand
•Factum:meaningMade(Handmaking)
•Inthepre-industrialworld,mostmanufacturingoccurredinrural
areas,wherehousehold-basedmanufacturingservedasa
supplementalsubsistencestrategytoagriculture
•ThefactorysystemwasfirstadoptedinBritainatthebeginningofthe
IndustrialRevolutioninthelate18thcentury
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5. Manufacturing…
Classification
Primary
Manufacturing
Secondary
Manufacturing
Advanced
Manufacturing
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6. Primary Manufacturing
•Usefultogiveabasicproperty,shapeandsizesothatitcanbe
furtherprocessedinthesecondarymanufacturingprocesses
•Usedtoconvertrawmaterialorscraptoabasicprimaryshapedand
sizedproduct
•Variousprimarymanufacturingprocessesare:
•Casting
•Forming,suchasForging,Rolling,Extrusion,etc.
•Joining,suchasWelding,Soldering,etc.
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7. Secondary Manufacturing
•Usedtofurthermodifytheoutputofprimarymanufacturing
processesinordertoimprovethematerialproperties
•Surfacequality
•Surfaceintegrity
•Appearance
•Dimensionaltolerance
•Varioussecondarymanufacturingprocessesare:
•Machining
•Surfaceworking
•HeatTreatment
•Coating
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8. Advanced Manufacturing
•Withtheadvancementoftechnology,anumberofnewmethodsand
technicalsystemshavebeendeveloped
•Theycandirectlyconvertrawmaterialorscrapintoproductshaving
closetoleranceanddimension,superbsurfacequality,desired
propertiesandmagnificentappearance
•Thustheseprocesseseliminatetheneedtopassaproductthrougha
numberofprimaryandsecondaryprocesses;andtherefore,
productiontimeandcostcanbereduced
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9. Advanced Manufacturing..
•Mostoftheseprocessesuseefficient,costlierandprecision
machinesinbuiltwithcomputercontrolsystem
•Variousadvancedmanufacturingprocessesare:
•PowderMetallurgy(PM)
•RapidPrototyping(RP)or3-DPrinting/Additivemanufacturing
•CNCmachines,machiningcentres
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10. Primary Manufacturing
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Casting
Forging
Rolling
Drawing
Extrusion
Press tool work
Plastic moulding
Powder Metallurgy

11. Primary Manufacturing..-Casting
•Ancientmanufacturingprocess
•Onlyprocesseswhereliquidmetalisused
•Anumberofmoderntechnologieshavebeendevelopedsuchas
•Diecasting
•Sandcasting
•Permanentmouldcasting
•Vacuumcasting
•Continuouscasting
•Electromagneticcasting
•Sandcastingisoneoftheoldestcastingtechnologiesandhaswider
applicationsinthefieldofmanufacturingtechnology
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12. Primary Manufacturing..-Casting
•Castingprocesscanbedefinedasaprimary
shapingprocessinwhichamoltenmetalis
pouredintoamouldcavity
•Allowedtosolidifyforpre-determinedtime
soastotaketheshapeofthemould
•Aftercompletesolidification,itistakenout
fromthemould
•Theproductofcastingisalsoknownas
castingandtheplacewherecastingworkis
doneisknownas‘foundryshop’
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13. Primary Manufacturing...-Casting
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14. Primary Manufacturing...-Casting
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16. Primary Manufacturing...-Casting
•Applications
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Cylinderblocks
machinetoolbeds
pistons, piston rings

17. Primary Manufacturing...-Casting
•Applications
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millrolls
water supply pipes and specials
Wheel housing

18. Primary Manufacturing..-Forging
•Thisistheoldestofthemetal-workingprocessesknowntomankind
sincethecopperage
•Operationwherethemetalisheated
*
andthenanintermittently
compressiveforceisappliedtomanipulatethemetalinsuchaway
thattherequiredfinalshapeisobtained
•Forgingisgenerallyahot-workingoperationthoughcoldforgingis
usedsometimes
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*heated to plastic state i,e. below its melting point

19. Primary Manufacturing..-Forging
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20. Primary Manufacturing..-Forging
•Applications
•Hand Tools
•Automotive components (Connecting rods, gears, shafts, differential gears)
•Valves,Fittings, oil field applications
•Hand tools & Hardware (Pliers, hammers,wrenches)
•Aerospace (Engine mounts,brackets,landing gear cylinders)
•Plumbing fixtures, valves and fittings
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21. Primary Manufacturing..-Rolling
•Processofreducingthethicknessorchangingthecross-sectionalarea
oftheworkpiecebymeansofrollingmills
•Forceappliediscontinuouscompressiveforce
•Veryeconomicalprocessforproducinglargevolumeofmaterialwith
constantcrosssection
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22. Primary Manufacturing..-Rolling
•Applications
•Rods, Hollow tubes
•Rail tracks
•Blooms, slab, billets
•Plates, sheets, strip
•roofing panels
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24. Primary Manufacturing..-Drawing
•Extrusion
•Processofconfiningthemetalinaclosedcavityandthenallowingittoflow
fromonlyoneopeningsothatthemetalwilltaketheshapeoftheopening
•Speeddependsontheworkmaterial
•Drawingisatypeofextrusionprocess
•Drawing
•Processofwiredrawingistoobtainwiresfromrodsofbiggerdiameter
throughadie
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25. Primary Manufacturing..-Drawing
•Applications
•Rods
•Tubes
•Electrical wires
•Wire stock for fences
•Rod stock to produce springs, nails, rivets
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27. Primary Manufacturing..-Press tool work
•Thepresstooloperationisbyfaroneofthecheapestandfastest
waystocompletelymanufactureacomponent
•Significantlyperformedonasheetmetal
•Sheetmetalisthinandflatpiecesofmetals,withthicknesslessthanabout5
mm
•Involvesmanyoperations
•Shearing
•PunchingandBlanking
•Bending
•Deepdrawing
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28. Primary Manufacturing..-Press tool work
•Applications
•Automobile components
•Computer cabinets
•Utensils
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29. Primary Manufacturing..-Plastic moulding
•Plastic mouldingis the process of shaping plastic using a rigid frame
or mould.The underlying concept of plastic moulding is placing liquid
polymerinto a hollow mouldso that the polymer can take its shape,
often with various ranges of pressure and heat required.
•Involvesdifferent techniques
•Rotational moulding
•Injection moulding
•Blow moulding
•Compression moulding
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30. Primary Manufacturing..-Plastic moulding
•Applications
•Packaging
•Bottles and caps
•Storage containers
•Automotive dashboards
•Furniture
•Most of the plastic products
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31. Primary Manufacturing..-Powder Metallurgy
•Processofmakingcomponentsfrommetallicpowders
•Usedtoreplacecastingsformetalswhichweredifficulttomelt
becauseofhighmeltingpoint
•Involvesthefollowingsteps:
•Manufacturingofmetalpowders
•Blendingandmixingofpowders
•Compacting,sintering,andfinishingoperations
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32. Primary Manufacturing..-Powder Metallurgy
•Metallicpowdersareheatedbelowtheir
meltingtemperaturestoachievethe
bonding
•Involvescompactingofmetaloralloy
powdersintothedesiredshapeafter
blending
•Thenheatinginacontrolledatmosphere
atatemperaturebelowthemeltingpoint
inordertoachievethebondingofthe
particlestogetthedesiredproperties
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34. Primary Manufacturing..-Powder Metallurgy
•Applications
•Frictionmaterials
•Gearsandpumprotors
•Refractorymaterials
•Electricalcontactsandelectrodes
•Magneticmaterials
•Cementedcarbidesforcuttingtools
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