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    Manufacturing Process-1 Lecture # 1 by Ravi Kumar K

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    kunkalamarru
    The document discusses manufacturing processes and casting. It defines manufacturing as converting raw materials into products using various production methods and techniques. It then classifies casting processes into four main categories: conventional molding processes, chemical sand molding processes, permanent mold processes, and special casting processes. Within these categories it lists some common casting techniques such as green sand molding, shell molding, die casting, and lost wax casting.

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    Manufacturing Process-1 Lecture # 1 by Ravi Kumar K

    Uploaded by

    kunkalamarru
    192 views55 pages
    The document discusses manufacturing processes and casting. It defines manufacturing as converting raw materials into products using various production methods and techniques. It then classifies casting processes into four main categories: conventional molding processes, chemical sand molding processes, permanent mold processes, and special casting processes. Within these categories it lists some common casting techniques such as green sand molding, shell molding, die casting, and lost wax casting.

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    Manufacturing Process-I

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    The document discusses manufacturing processes and casting. It defines manufacturing as converting raw materials into products using various production methods and techniques. It then classifies casting processes into four main categories: conventional molding processes, chemical sand molding processes, permanent mold processes, and special casting processes. Within these categories it lists some common casting techniques such as green sand molding, shell molding, die casting, and lost wax casting.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    192 views55 pages

    Manufacturing Process-1 Lecture # 1 by Ravi Kumar K

    Uploaded by

    kunkalamarru
    The document discusses manufacturing processes and casting. It defines manufacturing as converting raw materials into products using various production methods and techniques. It then classifies casting processes into four main categories: conventional molding processes, chemical sand molding processes, permanent mold processes, and special casting processes. Within these categories it lists some common casting techniques such as green sand molding, shell molding, die casting, and lost wax casting.

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    MANUFACTURING PROCESS-1 Lecture # 1 By

    Ravi Kumar K

    DEFINITION AND IMPORTANCE OF MANUFACTURING


    Manufacturing: the process of converting raw materials into products; encompasses the deign and manufacturing of goods using various production methods and techniques. ~ came from Latin manu factus made by hand

    Interchangeably used with production


    discrete vs continuous products

    Manufactured item has monetary worth (added value) than raw materials
    Manufacturing is closely linked to national and global economy

    DESIGN AND MANUFACTURING SEQUENTIAL PROCESS


    Design ->Manufacturing Waste resource, waste time Concurrent Process All disciplines are involved in the earliest stages of product design Progress concurrently so iterations results in less wasted effort and time Key to success: well-recognized communication among and within disciplines

    CLASSIFICATION OF MANUFACTURING PROCESSES


    Casting: expandable molding and permanent molding
    Forming and shaping: rolling, forging, extrusion, drawing, sheet forming, powder metallurgy molding Machining: turning, boring, drilling, milling, planing, shaping, broaching, grinding, ultrasonic machining; chemical, electrical, and electrochemical machining and high energy electron beam Machining Joining: welding, brazing, soldering, adhesive bonding and mechanical joining diffusion bonding,

    Micro and nano micromachining, dry electroforming

    manufacturing: surface and wet etching, and

    Finishing: honing, lapping, polishing, burnishing, deburring, surface treating, coating and plating FACTORS AFFECTING PROCESS SELECTION

    Component/part shape Materials characteristics castability, formability, machinability, weldability, etc Part size and dimensional accuracy Manufacturing and operational cost

    MATERIALS USED IN TODAYS MANUFACTURING

    Ferrous metals: carbon steels, alloy steels, stainless steels, and tool and die steels
    Nonferrous metals and alloys: Al, Mg, Cu, Ni, superalloys, Ti, refractory metals (Mb, Nb, W, beryllium, Zr, low melting alloys (lead, zinc and tin), and precious metals Plastics: Thermosets, thermoplastics, and elastomers Ceramics: Glass ceramics, glasses, graphite, and diamond Composites: Reinforced plastics, metal-matrix and ceramics-matrix composites, and honeycomb Structures

    Nanomaterials, shape-memory alloys, metal foams, amorphous alloys, super conductors and semiconductors
    Material properties: mechanical, physical, chemical, manufacturing Cost and availability Service life and recycling

    CASTING
    An object made by pouring molten metal or other material into a mold. Casting is a mass production process which involves molten materials (such as metals, plastics or resins) being poured into a mold, allowed to solidify and then extracted for use. Casting can be thought of as a method for reproducing something whether a mere part or a single unit by itself.

    Casting is a process that can be used to manufacture complex parts which would prove too expensive or time-consuming to produce using other methods such as cutting or shaping these from solid materials.

    CLASSIFICATION OF CASTING
    Casting processes can be classified into following FOUR categories: 1. Conventional Molding Processes 2. Chemical Sand Molding Processes

    3. Permanent Mold Processes


    4. Special Casting Processes

    1. Conventional Molding Processes


    Conventional Molding Processes are four types as follows:

    a. Green Sand Molding b. Dry Sand Molding

    c. Flask less Molding

    2. Chemical Sand Molding Processes:


    Chemical Molding Processes are three types as follows:

    a. Shell Molding b. Sodium Silicate Molding c. No-Bake Molding


    3. Permanent Mold Processes:

    a. Gravity Die casting b. Low and High Pressure Die Casting

    4. Special Casting Processes:


    a. Lost Wax b. Ceramics Shell Molding c. Evaporative Pattern Casting d. Vacuum Sealed Molding e. Centrifugal Casting

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