Manufacturing

Processes
Level : 3 Credit Hours : 3

Dr. Mohamed Abdel-Mottaleb

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 Lecture 1
• Introduction to course
• Metal casting 1

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The production cycle and CAD/CAM
(2) (3) (4)
product engineering working
concept design drawing

An engineering (5)
(1) product cycle
Customers process
and markets planning
(7)
production (6)
(8)
processes production
Quality
(Manufacture) scheduling
control
CAD : Computer Aided Design
CAM : Computer Aided Manufacturing
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Manufacturing processes (cutting)

Milling

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External turning Internal turning

Shaping Drilling 8
Manufacturing processes (non-cutting)

Metal Casting 9
 Manufacturing processes (non-cutting)

Metal Forming processes 10

 Metal joining process

Oxy Acetylene Welding Electrical Arc Welding

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Classification of Materials

Metals Ceramics & Glasses Polymers

• good conductors of • thermally and • very large molecules
electricity and heat electrically insulating • low density, low weight
• shining appearance • resistant to high • maybe extremely
• strong, but temperatures and flexible
deformable harsh environments
• hard, but brittle

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 Structure of metals

body-centered cubic crystal structure (BCC)

Face centered cubic crystal

Structure (FCC)

hexagonal close-packed crystal structure (HCP) 15

Deformation and strength
• Elastic deformation: which
means it can restore its
original shape when external
force is removed

• Plastic deformation: when the

crystal maintains its change or
deformed shape after removing
the external force

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 Mechanical properties
• Mechanical properties are physical properties that
a material exhibits upon the application of forces. Examples
of mechanical properties are the modulus of elasticity,
tensile strength, elongation, hardness and fatigue limit.

compression
Tension bending

hardness 17
1- Metal Casting Processes

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 Casting
• One of the oldest manufacturing processes – 4000 B.C. with stone
and metal molds for casting copper.
• Pour molten metal into a mold cavity to produce solidified parts that
take on the shape of the cavity
• Many different casting processes, each with its own characteristics,
applications and materials, advantages, limitations, and costs

• Casting can produce complex shapes with internal cavities or hollow

sections
• Casting can produce very large parts
• Competitive with other processes
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 Elements of casting system:
• As shown in Figure the
casting system consisted
of:
• A. Melting furnace
• B. Moulding medium
• C. Mould cavity
• D. Gating system
• E. Riser system

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Solidification process of an engineering metal &
Structure of metals

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 Explanation of Solidification of Metals & Alloys

• https://www.youtube.com/watch?v=G5z9Kkn
F_s8

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 Solidification of Pure Metals

Pure metals solidify at a constant temperature. During freezing the latent

heat of solidification is given off. Most metals shrink on solidification and
shrink further as the solid cools to room temperature.
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Solidification of alloys

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 Solid Solution Alloys

Metal alloys in which one metal is soluble in the other in the solid state.
These are also called binary alloys. Copper/Nickel alloys are typical of
this type of alloy.

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Solidification of Solid Solution Alloys
Nickel-Copper Alloy Phase Diagram

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Example 1

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Example 2

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 Solidification of Eutectic Alloy Systems
Lead-Tin Phase Diagram

Figure 4.7 The

lead-tin phase
diagram. Note that
the composition of
the eutectic point
for this alloy is
61.9% Sn-38.1%
Pb. A composition
either lower or
higher than this
ratio will have a
higher liquidus
temperature.

The metals have very limited solubility in each other 29