24MEI102 –

Manufacturing Technology
UN SDG’s
“This course is mapped with UN Sustainable Development Goals (SDGs)“

These SDGs highlight the importance of integrating sustainable practices and

innovative technologies in manufacturing to achieve broader economic, social,
and environmental goals.
Course Outcomes
1. Apply fundamental knowledge of casting processes for quality castings.
2. Analyze different welding techniques and their applications to select appropriate
methods for joining various materials.
3. Analyze the principles of forming processes to design sheet metal products.
4. Demonstrate the ability to apply powder metallurgy techniques to produce components
with desirable mechanical properties.
5. Explore the principles and applications of additive manufacturing to understand its
impact on modern manufacturing practices.
6. Execute experiments involving casting, welding, forming, and powder metallurgy to
fabricate components, assess their quality, and interpret the results for process
improvement.
 Assessment methods
Direct

1. Continuous Assessment Test I, II

2. Mini-Project, Presentations, Activity and Learning Task(s), MCQ, Lab Workbook, Experimental Cycle
tests, viva-voce, etc…
3. End Semester Examination
Indirect

Course-end survey
Science – Engineering –
Technology
 How it differs?

Source: https://durofy.com/the-difference-between-science-engineering-and-technology/sciengtech/#prettyPhoto/0/
Manufacturing & Production
Manufacturing
Manufacturing
1. Manual
production to
machine-based
manufacturing.
Smart 2. Mass production
Manufacturing following chain
production.
3. Computer and
automation.
4. Human &
Machine (Robot)
interface

Source: https://www.velatia.com/en/blog/what-are-the-keys-to-industry-4-0/
Manufacturing
Manufacturing is the process of creating finished goods from raw materials

Source: https://engineeringproductdesign.com/knowledge-base/manufacturing-processes/#processing
Manufacturing

Source: https://engineeringproductdesign.com/knowledge-base/manufacturing-processes/#processing
Manufacturing
Processing operations are primarily performed on distinct components, sometimes
assembled parts.

These Processing operations can be broadly categorized into three primary types:

1. Shaping Processes
2. Property Enhancement Processes
3. Surface Processing Operations

Source: https://engineeringproductdesign.com/knowledge-base/manufacturing-processes/#processing
Manufacturing
Processing operations add
value by transforming a part
from one state to another.

By Changing its
1. shape
2. property
3. appearance and
4. surface texture

Energy as a source
(mechanical, thermal, electrical and chemical)
Source: https://engineeringproductdesign.com/knowledge-base/manufacturing-processes/#processing
Manufacturing
Shaping Processes – As the name suggests, this alters the geometry of the workpiece by
primarily applying heat, mechanical force or a combination of both.

Source: https://engineeringproductdesign.com/knowledge-base/manufacturing-processes/#processing
 Manufacturing
Solidification Processes – Manufacturer melts raw materials to transform them into
semi-fluid or liquid. This melted material then cools down and solidifies to form a 3D
shape.

•Additive manufacturing
•Glass working
•Metal casting
•Plastic processing

Metal Casting Additive Manufacturing

Source: https://engineeringproductdesign.com/knowledge-base/manufacturing-processes/#processing
Classification of solidification
processes
Casting
 Casting
Casting is a manufacturing process that involves pouring a liquid material into a mold and
allowing it to solidify, creating a solid object and the solidified part is called a casting.

Casting is used to create complex shapes that would be difficult or expensive to make
using other methods.

It's used in many industries, including automotive, aerospace, and construction.

Source: https://www.cdocast.com/induction_blog/jewelry-casting-equipment/
Parts Made by Casting
Big parts

Engine blocks and heads for automotive vehicles, wood-burning stoves, machine frames,

railway wheels, pipes, church bells, big statues, pump housings

Small parts

Dental crowns, jewelry, small statues, frying pans

Disadvantages
Different disadvantages for different casting processes:

• Limitations on mechanical properties

• Poor dimensional accuracy and surface finish for some processes; e.g., sand casting

• Safety hazards to workers due to hot molten metals

• Environmental problems
Overview of Casting
Technology
Casting is usually performed in a foundry, which is a factory equipped for

• Making molds

• Melting and handling molten metal

• Performing the casting process

• Cleaning the finished casting

Workers who perform casting are called foundrymen.

The Mold in Casting
Contains cavity whose geometry determines part shape

• Actual size and shape of the cavity must be slightly enlarged to allow

for shrinkage of metal during solidification and cooling

• Molds are made of a variety of materials, including sand, plaster,

ceramic, and metal.

Open and Closed Molds
Two forms of mold:

(a) open mold and (b) closed mold

for more complex mold geometry with a gating system leading into the cavity
Two Categories of
Casting Processes
1. Expendable mold processes – use an expendable mold that must be destroyed to

remove casting

• Mold materials: sand, plaster, and similar materials, plus binders

2. Permanent mold processes – use a permanent mold that can be used to produce

many castings

• Made of metal (or, less commonly, a ceramic refractory material

Advantages and Disadvantages
1. More intricate geometries are possible with expendable mold

processes

2. Part shapes in permanent mold processes are limited by the

need to open the mold

3. Permanent mold processes are more economical in high-

production operations
 Casting
The development of modern casting technology, the casting process has led to a
broad of different, specialized casting methods.
Mainly there are 3 Different Types of Casting processes.

Sand Casting Investment Casting Die Casting

High Temperature Alloy, High Temperature Alloy, Complex High Temperature Alloy,
Complex Geometry, Geometry, Moderately Smooth Moderate Geometry,
Rough Surface Finish Surface Finish Smooth Surface
Sand Casting
Sand casting is a process where a mold made of sand is used to form metal castings.

It’s one of the oldest and most versatile methods for producing metal parts.

Product manufactured using sand casting employ techniques that produce shaped
parts of nearly any design, including very large parts and those with internal
passageways.
 chaplet

Mold
cavity
 Sand Casting
• Flask: A framework made of metal or
wood that serves as a container for
creating molds.
• Cope: The upper section of the flask,
also known as the cope.
• Drag: The lower section of the flask,
also known as the drag
• Core: A component used to create an
internal hollow space within the final
product.

Source: https://testbook.com/mechanical-engineering/casting-process-definition-and-types
 Sand Casting
• Vents: Openings intentionally
created in the mold to allow gases
produced when the molten metal
interacts with the sand to escape.
• Mold cavity: The empty space within
the mold where the metal part is
formed.
• Riser: A reservoir of molten metal
that provides additional material to
compensate for any shrinkage.

Source: https://testbook.com/mechanical-engineering/casting-process-definition-and-types
 Sand Casting
• Runner: A passageway through
which the flow of molten metal can
be controlled before reaching the
mold cavity.
• Pouring Cup: A container or basin
used for pouring molten metal into
the mold.
• Pattern: A replica of the required
shape used in the molding process.

Source: https://testbook.com/mechanical-engineering/casting-process-definition-and-types
 Sand Casting
• Sprue: A channel through which
molten metal flows downward.
• Parting Line: The boundary
separating the mold's cope and drag
sections.

Source: https://testbook.com/mechanical-engineering/casting-process-definition-and-types
 Sand Casting
Heating furnaces are used to heat the
metal to molten temperature sufficient
for casting
The heat required is the sum of:
• Heat to raise temperature to the
melting point
• Heat of fusion to convert from solid to
liquid
• Heat to raise molten metal to the
desired temperature for pouring

Source: https://testbook.com/mechanical-engineering/casting-process-definition-and-types
 Sand Casting
Pouring the molten metal – For this
step to be successful, metal must flow
into all regions of the mold, most
importantly the main cavity, before
solidifying

Factors that determine success:

• Pouring temperature
• Pouring rate
• Turbulence
Transformation of molten metal back into solid state – Solidification differs depending on whether the metal is
• A pure element or
• An alloy
Source: https://testbook.com/mechanical-engineering/casting-process-definition-and-types
 Sand Casting
A. Producing the Pattern – Desired
product
B. Producing the Pattern – Gates
and risers: The metal delivery
system
C. Creating the mold
D. Pouring the metal into the mold
E. Shakeout
F. Final operations

Source: https://www.metaltek.com/blog/what-is-sand-casting/
Sand Casting
A. Producing the Pattern –
Desired product
B. Producing the Pattern –
Gates and risers: The metal
delivery system
C. Creating the mold
D. Pouring the metal into the
mold
E. Shakeout
F. Final operations
 Sand Casting
Key Steps in Sand Casting:
1. Pattern Making: A pattern,
typically made of wood, metal, or
plastic.
2. Mold Making: The pattern is
placed in sand to create a mold. The
sand is packed around the pattern.
3. Core Making: If the casting
requires internal cavities, cores
made of sand are placed inside the
mold.

Source: https://testbook.com/mechanical-engineering/casting-process-definition-and-types
 Sand Casting
Key Steps in Sand Casting:
4. Melting and Pouring: Metal is
melted in a furnace and then
poured into the mold cavity.
5. Cooling: The metal is allowed to
cool and solidify in the mold.
6. Shakeout: The sand mold is
broken apart to remove the casting.
7. Cleaning and Finishing: The
casting is cleaned to remove any
remaining sand and excess metal.

Source: https://testbook.com/mechanical-engineering/casting-process-definition-and-types
 Sand Casting
Advantages of Sand Casting:
1. Cost-Effective: Suitable for low to medium production volumes.
2. Versatile: Can produce complex shapes and large parts.
3. Material Flexibility: Can be used with a wide range of metals.

Disadvantages of Sand Casting:

1. Surface Finish: Generally rougher compared to other casting methods.
2. Dimensional Accuracy: Less precise than other methods like die casting.

Source: https://testbook.com/mechanical-engineering/casting-process-definition-and-types
Moulding Materials
Major part of Moulding material in sand casting are
• 70-85% silica sand (SiO2)
• 10-12% bonding material e.g., clay cereal etc.
• 3-6% water
Requirements of moulding
sand
• Refractoriness
• Cohesiveness
• Permeability
• Collapsibility
• Adhesiveness
• Flowability
• Strength
• Green strength
• Dry strength
• Refractoriness
• It is the ability of the moulding material to resist the temperature of the liquid
metal to be poured so that it does not get fused with the metal. The refractoriness
of the silica sand is highest.
• Cohesiveness
• The ability of the sand particles to stick with each other is called cohesiveness.
• Adhesiveness
• The ability of the sand particles to get stick with another body is called
adhesiveness.
• The sand should have sufficient adhesiveness so that it can easily get cling to the
sides of the moulding boxes and does not fall out to the box when it is removed
• Collapsibility
• The ability of the moulding sand to collapse after solidification of the molten metal
is called collapsibility.
• The moulding sand should also have collapsibility so that during the contraction of
the solidified casting it does not provide any resistance, which may result in cracks
in the castings
• Permeability
• It is the ability of sand by which it allows the gases to pass through it easily.
• During pouring and subsequent solidification of a casting, a large amount of gases
and steam is generated. These gases are those that have been absorbed by the
metal during melting, air absorbed from the atmosphere and the steam generated
by the molding and core sand.
• If these gases are not allowed to escape from the mold, they would be entrapped
inside the casting and cause casting defects.
• Flowability
• The ability of moulding sand to behave like a fluid when it is rammed is called
flowability.

• Green Strength
• The moulding sand that contains moisture is termed as green sand.
• The green sand particles must have the ability to cling to each other to impart
sufficient strength to the mold.
• The green sand must have enough strength so that the constructed mould retains its
shape.
• Dry Strength
• When the molten metal is poured in the mould, the sand around the mould cavity is
quickly converted into dry sand as the moisture in the sand evaporates due to the
heat of the molten metal.

• At this stage the moulding sand must have the sufficient strength to retain the exact
shape of the mould cavity and at the same time it must be able to withstand the
metallostatic pressure of the liquid material.
Molding Sand Composition
The main ingredients of any molding sand are:
Base sand,
Binder, and
Moisture
 A Typical Composition of Molding Sand:

Molding Sand Constituent Weight Percent

Silica sand 92

Clay (Sodium Bentonite) 5

Water 3
Additives
Additives are the materials generally added to the moulding and core sand
mixture to develop some special property in the sand.
(i) Coal dust
Coal dust is added mainly for producing a reducing atmosphere during casting. This reducing atmosphere
results in any oxygen in the poles becoming chemically bound so that it cannot oxidize the metal.

(ii) Dextrin
Dextrin belongs to starch family of carbohydrates. It increases dry strength of the molds.

(iii) Pitch
It is distilled form of soft coal. It can be added from 0.02 % to 2% in mold and core sand. It enhances hot
strengths, surface finish on mold surfaces.

(iv) Wood flour

This is a fibrous material mixed with a granular material like sand; its relatively long thin fibres prevent the
sand grains from making contact with one another. It can be added from 0.05 % to 2% in mold and core sand.
It increases collapsibility of both of mold and core
Pattern
❖Primarily used to produce the mould cavity in sand.
❖It is the replica of the object to be made by the
casting process, with some modifications.
❖The main modifications are the addition of pattern
allowances, and the provision of core prints.
❖The quality of the casting produced depends upon
the material of the pattern, its design, and
construction.
❖It is slightly larger than the desired casting, due to
various allowances.
Functions of pattern
• A pattern prepares a mold cavity for the purpose of
making a casting.
• A pattern may contain projections known as core
prints if the casting requires a core and need to be
made hollow.
• Runner, gates, and risers used for feeding molten
metal in the mold cavity may form a part of the
pattern.
• Patterns properly made and having finished and
smooth surfaces reduce casting defects.
• A properly constructed pattern minimizes the overall
cost of the castings.
Various allowances
Material Dimension Shrinkage allowance

Grey Cast Iron Up to 2 feet 0.125

2 feet to 4 feet 0.105
over 4 feet 0.083

Cast Steel Up to 2 feet 0.251

2 feet to 6 feet 0.191
over 6 feet 0.155

Aluminum Up to 4 feet 0.155

4 feet to 6 feet 0.143
over 6 feet 0.125

Magnesium Up to 4 feet 0.173

Over 4 feet 0.155
Materials for making patterns:
a. Wood
b. Metal
c. Plastic
d. Plaster
e. Wax.
 1. Wood Patterns:
Advantages:
✓Inexpensive
✓Easily available in large quantities
✓Easy to fabricate
✓Light in weight
✓They can be repaired easily
✓Easy to obtain good surface finish
Limitations:
▪ Susceptible to shrinkage and swelling
▪ Possess poor wear resistance
▪ Abraded easily by sand action
▪ Absorb moisture, consequently get wrapped
▪ Cannot withstand rough handling
These are used where the no. of castings to
be produced is small and pattern size is large.
 2. Metal Patterns:
Advantages:
✓Do not absorb moisture
✓More stronger
✓Possess much longer life
✓Do not wrap, retain their shape
✓Greater resistance to abrasion
✓Accurate and smooth surface finish
✓Good machinability
Limitations:
▪ Expensive
▪ Not easily repaired
▪ Ferrous patterns get rusted
▪ Heavy weight
These are employed where large no. of
castings have to be produced from same patterns.
 3. Plastic Patterns:
Advantages:
✓Durable
✓Provides a smooth surface
✓Moisture resistant
✓Does not involve any appreciable change in size or shape
✓Light weight
✓Good strength
✓Wear and corrosion resistance
✓Easy to make
✓Abrasion resistance
✓Good resistance to chemical attack
Limitations:
▪ Plastic patterns are Fragile
▪ These are may not work well when subject to conditions of
severe shock as in machine molding (jolting).
4. Plaster Patterns:
Advantages:
✓It can be easily worked by using wood working tools.
✓Intricate shapes can be cast without any difficulty.
✓It has high compressive strength.

➢ Plaster may be made out of Plaster of

paris or Gypsum cement.
➢ Plaster mixture is poured into a mould
made by a sweep pattern or a wooden master
pattern, in order to obtain a Plaster pattern.
5. Wax patterns:
Advantages:
✓Provide very good surface finish.
✓Impart high accuracy to castings.
✓After being molded, the wax pattern is not taken out of the mould like other
patterns; rather the mould is inverted and heated; the molten wax comes out
and/or is evaporated. Thus there is no chance of the mould cavity getting
damaged while removing the pattern.

➢ Wax patterns find applications in Investment casting

process.
Types of Patterns:
1. Single piece pattern.
2. Split piece pattern.
3. Loose piece pattern.
4. Match plate pattern.
5. Sweep pattern.
6. Gated pattern.
7. Skeleton pattern
8. Follow board pattern.
9. Cope and Drag pattern.
Thank You