BASIC MANUFACTURING

PROCESSES
ME-2010
Credits [3-0-0]
Lesson Plan for the Subject- Basic Manufacturing Processes, 4th Semester,
B.Tech, 2019
No of Cumulative
Modules Topic/Course Content
Classes (Hrs) Classes (Hrs)
Pattern making, pattern materials, allowances , types of
2 1-2
pattern,
Sand casting types, sand cast, moulding procedure, types
2 3,4
of sand, gates and riser (basic design considerations)
Essential properties of moulding sand, core making, types
Module-1 of cores, Essential qualities, core mixtures and binder sand
Foundry Process testing, Mould and core hardness test, fineness test, clay 4 5-8
content test, permeability test, moisture content test, sand
conditioning.
Cleaning of casting and defects in casting 3 9-11

Die casting, precision investment casting, shell moulds,

3 12,13,14
centrifugal casting processes, permanent moulds casting.

Preparation of powder, properties of powder, 2 15,16

Module-3
Powder Metallurgy Fabrication methods & procedure, applications,
2 17,18
advantages.
 Lesson Plan for the Subject- Basic Manufacturing Processes, 4th
Semester, B.Tech, 2019, cont.
MID SEMESTER 2019
Hot and cold working of Metals: Basic Principles of hot and cold working of metals. 1 19
Rolling: Types of Rolling, Rolling equipments hot and cold rolling, General deformation
pattern, Pressure and forces in rolling, Distribution of roll pressure, angle of bite, effect of
rolling on microstructure, Rolling defects, Numericals on rolling load and power
4 20-23
Module-2 required for reduction.
Metal Working Process Forgings: Smith forging, Drop forging, press forging & Machine forging, Description of 2 24,25
Presses and hammers,forging defects.
Extrusion: Direct, Indirect and impact extrusion and their applications, Extrusion
defects, Determination of extrusion force.
1 26
Drawing: Wire and rod drawing, Tube drawing, Process variables in drawing process,
Deep drawing, Determination of drawing force.
1 27
Fabrication Processes: Classification, types of welding joints, 1 28
Gas welding principles, types of flames, quipment,techniques of gas cutting. 2 29,30

Electric Arc Welding: Principles of electric welding equipments and electrodes (in brief),
1 31
Module-4 Principles of Inert Gas Welding. TIG, MIG, sub-merged arc welding. Atomic hydrogen
Fabrication Processes: welding, plasma are welding. 2 32,33
Resistance Welding: Principle of forge welding, spot-seam, Projection, Upset-butt
welding, flash welding. Thermit -Welding
2 34,35
Electro-slag welding, friction welding Brazing, Soldering., Welding defects and
inspection
1 36
END SEMESTER 2019-20
Text Book:
1: Manufacturing Technology, P.N.Rao (Tata Mc-Graw Hill, Publication, Co. Ltd.)
2: Manufacturing Processes, J.Kausish, PHI (2nd Edition)

Reference Books:
1: Manufacturing Technology: Materials, Processes and Equipment: Helmi A. Youssef, Hassan A. El. Hofy and M.H.
Ahmed, CRC Press, 2015
2: Principles of Manufacturing materials and Processes, J.S Campbell, TMH
3: Welding and Welding Technology, R.Little, TMH, 43rd reprint, 2014
4: Manufacturing Science, A. Ghosh & A.K.Mallick, EWP
5: Elements of Manufacturing Processes, B.S.N. Parasar, R.K. Mittal, PHI
 Forging
Forging operations
Forging is the operation where the metal is heated and then a force is applied to
manipulate the metal in such a way that the required final shape is obtained.
This is the oldest metal-working process being practiced since the copper age.
Forging is generally hot-working operation though cold-forging may be
practiced.
Two types of forging operations are used in forging in order to arrive at the
final object configuration. They are:
Drawing out: In this operation the metal gets elongated with a reduction in the
cross-sectional area. For this purpose, the force is to be applied in direction,
perpendicular to the length axis.
Upsetting: In this operation the cross-sectional area is increased at the expense
of the length. To achieve this, the force is applied in a direction parallel to the
length axis.
 Forging cont.
Why forging is necessary?
Because of the manipulative ability in forging process, it is possible to closely
control the grain flow in the specific direction, such that the best mechanical
properties can be obtained base on specific application.

Grain Structure Comparison

Fig : A part made by three different procedures, showing grain flow (a)
casting (b) machining (c) forging
 Forging cont.
Grain Structure Comparison
 Forging cont.
Typical forging operations a,b - To shape the ends of the bars to
gather metals.

c- Fullering is used to reduce the

cross –sectional area of a portion of
the stock.

d- the reduction in cross section of the

work with concurrent increase in
length is called drawing.

e. If the drawing-down operation is

carried out with a concave dies so as
to produce a bar of smaller diameter
is called swaging

Forging operations: (a, b) edging,

(c) fullering, (d) drawing, (e) swaging,
(f) piercing, (g) punching
 Forging cont.
Typical forging tools
 Forging cont.
Forging types
There are four main types of forging methods which are generally used:
Smith forging: This is the traditional forging operation done openly or in open
dies by the village black smith or modern shop floor by manual hammering or
by power hammers.
Drop forging: this is the operation done in closed impression dies by means of
drop hammers. Here, the force for shaping the component is applied in a series
of blows.
Press forging: Similar to drop forging, also done in closed impression dies with
the exception that the force is a continuous squeezing type applied by the
hydraulic press.
Machine forging: Unlike the drop or press forging where the material is drawn
out, in machine forging, the material is only upset to get the desired shape.
 Forging cont.
Smith forging
The process of smith forging involves heating the stock in the blacksmith’s
hearth and then beating it over an anvil. To get the desired shape, the operator
has to manipulate the component in between the blows. The types of operations
available are: (a) fullering, (b) flattening, (c) bending, (d) upsetting, and (e)
swaging.
Open-Die Forging
• Is the simplest forging process
• Sizes can very from very small parts to very large parts

• Upsetting or flat-die forging – a solid work

piece is placed between flat dies and is
compressed
• Defects Associated with Open Die forging
• Barreling
– caused by frictional forces at the die-work
piece interfaces
– Can be minimized if a lubricant is used
– Thermal effects caused by barreling can
be minimized by using heated dies
 Forging cont.
Smith forging cont.
The types of operations available are: (a) fullering, (b) flattening, (c) bending, (d)
upsetting, and (e) swaging.

To obtain specific
shapes such as round,
square, hexagon, etc.,
open general purpose
dies called swages are
used.

Smith forging involves a lot of skill on the part of the operator and also is time
consuming, however, is cheaper in case of small lots, or in trial production.
fullering
If the drawing-down operation is carried
out with a concave dies so as to produce a
bar of smaller diameter is called swaging
 Forging cont.
Drop forging
Drop forging utilizes a closed impression die to obtain the desired shape of the
component. The shaping is done by the repeated hammering given to the
material in the die cavity; the equipment used for delivering the blows are called
drop hammers.
Impression-Die & Closed-Die Forging
• The drop forging die consists of two halves; the lower half is fixed to the
anvil and the upper half is fixed to the ram. The work piece acquires the shape of
the die cavities while being forged between the two shaped dies.

Step-1 Step-2 Step-3

 Forging cont.
Drop forging cont.
In closed die forging, the blank to be forged is prepared by: (a) cutting from a bar
stock, (b) preformed blank, (c) casting, or (d) preformed blank from prior forging.

The die impressions are machined in the die cavity, because of which complex
shapes can be obtained in drop forging, compared to smith forging. However, too
complex shapes can not be obtained due to limitations of withdrawal of the
finished forging from the die. The typical products obtained by drop forging are:
crank, crank shaft, connecting rod, wrench, crane hook, etc.
 Forging cont.
Drop forging cont.
A comparison of open-die and closed die forging shows:
Closed Die Forging Open Die Forging
Carried out between two die halves Carried out between flat dies
For complex shape For very simple shape
At high pressure At low pressure
For mall objects and large quantity For large objects and small quantity
Close dimensional tolerances Preprocessor for close die forging
 Forging cont.
Drop forging cont.
Depending on the shape of the component, and the desired grain flow direction,
the material should be manipulated in a number of passes; the various passes
used are: (a) Fullering impression, (b) Edging impression, (c) Bending impression,
(d) Blocking impression, (e) Finishing impression, and (f) trimming.
(a) Fullering impression: Since drop forging involves only a reduction in
cross-section with no upsetting, the very first step is to reduce the stock to the
desired size; the impression machined in the die to achieve this is called fullering
impression. Sometimes, it may be obtained in open dies without a die impression.
(b) Edging impression: Also called preform,
this stage is required to gather the exact amount
of material required in each cross section of the
finished component.
This is the most important stage,
a properly designed preform ensures:
(i) a defect-free flow of metal,
(ii) complete die fill, and
(iii)minimum flash loss.
 Forging cont.
Drop forging cont.
(c) Bending impression: This is required for
those parts, which have a bent shape. It may be
possible to get it without bending impression,
however, it will miss the grain flow direction;
thus, bending impression after edging impression is incorporated.
(d) Blocking impression: Also called semi-finishing impression, blocking is a
step before finishing. In case of deep pockets, sharp corners, material may not
flow; hence, a blocking impression with near to the final shape is provided. The
blocking impression is characterized by large corner radii and fillets but no
flash. For complex shapes more than one blocking impression is provided.
(e) Finishing impression: It is the final
impression where the final shape is obtained.
To ensure complete filling of die cavity, a little
extra metal is provided, which ends up in flash
and surrounds the forging in the parting plane.
(f) Trimming: In this stage,. the extra flash
present around the forging is trimmed to get
the forging in usable form.
Forging cont.
Purpose of Flash:
1. It acts as a safety valve to store the excess metal in the closed die cavity.
2. The thin flash increases the flow resistance to the system , so that the pressure
builds up to high to ensure that metal fills all recesses of the forging die cavity.
 Forging cont.
Press forging
Press forging dies are similar to that used in drop forging, however, the desired
shape of the component is obtained, not by series of blows as in drop forging, but
by means of a single continuous squeezing action by means of a hydraulic press.
DROP FORGING PRESS FORGING
Series of blows by drop hammer. Continuous action by hydraulic press.
Material deformation is not so Material is uniformly deformed
uniform like that in press forging. throughout the entire depth because of
continuous squeezing.
More hammer force may be The entire force is absorbed by the
transmitted to the machine frame. stock.
The draft angles used are more The draft angles used are less
compared to that in press forging. compared to that in drop forging.
Tong holds are needed. Tong holds are not needed.

The press capacity required for deforming is higher, hence smaller-sized

components only are press forged in closed impression dies, where as, there is no
such limitations for press forging in open dies.
 Forging cont.
Machine forging
Machine forging involves upsetting operations, therefore, sometimes it is
simply called upset forging. Though both drop and press forgings use
machines, historically, only upset forging is referred as machine forging.

Initially, only bolt heads were being made in a continuous fashion, however,
because of beneficial grain flow obtained from upsetting, it is used for makinggear
blanks, shafts, axles, and similar parts.
 Forging cont.
Machine forging cont.
Upsetting machines, called up-setters, are generally horizontal acting. The die set
consists of a die and a corresponding punch or a heading tool. The die consists of
two parts, one called the stationary gripper die which is fixed to the machine
frame, and the other, movable gripper die, which moves along with the die slide of
the up-setter. The stock is held between these two gripper dies by friction.
Like drop forging, the final shape comes multiple passes. The cavities for various
operations are arranged vertically on the gripper dies. The stock then moves from
one stage to another being forged with the specific heading tool in each stage.
 Forging cont.
Machine forging cont.
The upset forging cycles starts with the movable die sliding against the
stationary die to grip the stock. The two dies, when in closed position, form
the necessary die cavity. Then the heading tool advances against the stock
and upsets it to completely fill the die cavity.
 Forging cont.
Some specific cases
 Forging cont.
Hammers and presses
 Forging cont.
Hammers and presses cont.
Total Energy supplied to the blow in a power
drop hammer is given below:
 Forging cont.
Hammers and presses cont.
 Forging cont.
Hammers and presses cont.
 Forging cont.
Typical Values of Velocity for different Forging Equipments

Energy Restricted
machines
Stroke-restricted machines

Load restricted machines

High Energy rate forging - HERF

 Forging cont.
Forging defects
Though the forging process generally gives superior quality products compared to
other manufacturing processes, still some defects may come up if proper care is not
taken. Some such defects are:
(a) Unfilled sections: some portions not filled due to either improper design
or faulty forging
(b) Cold shut: small cracks at the corner of the forging; due to improper
design – the corner and fillet radii are small. Thus metal does not flow
and ends up as cold shut.
(c) Scale pits: Irregular depressions on the surface of the forging; due to
improper cleaning of the stock and the forging. Usually scales on the
stock remain and after pickling of the forging depressions remain.
(d) Die shift: Improper shape due to misalignment of the two dies.
(e) Flakes: Internal ruptures due to improper cooling of heavy forgings;
exterior cooed first causing internal cracks
(f) Improper grain flow: This is caused due to improper design of the die.

Internal Cracks
THANK YOU