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
Extrusion
 Extrusion cont.
Extrusion principle
Extrusion: Extrusion is the process of confining the metal in a closed cavity and
then allowing it to flow from only one opening so that the metal takes the shape of
the opening.
The equipment consists of:
(1) A container that hold the billet
(2) A die and a die-holder
(3) A plunger or ram which will compress
(4) A dummy block – a steel disc of about
40 mm (0.50 to 0.75 of diameter) thickness,
with a diameter slightly less than the
container, is kept between the hot billet and
the ram to protect it from heat and pressure.
Advantages:
(1) Components having a constant cross-section of any length can be made.
(2) Complexities of parts obtained in extrusion is more than that of rolling.
(3) It is because the die in extrusion is simple and easy to make.
(4) Extrusion is a single pass unlike rolling.
 Extrusion cont.
Extrusion principle cont.
Advantages cont.:
(5) The amount of reduction possible in extrusion is large.
(6) Brittle materials can also be easily extruded.
(7) It is possible to produce sharp corners and re-entrant angles.
(8) It is also possible to get shapes with internal cavities by using spider dies.
(9) Large diameter and thin-walled tubular products with excellent
concentricity and tolerance characteristics can also be produced.
(10) Grain structure and strength enhancement is possible.
(11) Very low material wastage.

Typical extrusion shapes

 Extrusion cont.
Extrusion principle cont.
The flow of metal in the extrusion process is towards the die opening and
subsequently along with the extruded material.
The extrusion ratio is defined as the ratio of (cross-sectional area of the billet) /
(cross-sectional area of the extruded section). The typical values of extrusion ratio
are 20 to 50. Low extrusion ratios are used for intermediate operations when the
billets are extruded to a give diameter before the final extrusion.

Typical flow of metal in

extrusion process
 Extrusion cont.
Extrusion principle cont.
The extrusion pressure for a given material depends on the extrusion temperature,
the reduction in area and the extrusion speed.
Typical extrusion T: 500 to 12000C Typical Pressure: 35 to 1000 MPa
Extrusion speed depends on the work material:
Some of the light alloys: 0.05 m/s Copper alloys: up to 4.50 m/s
Too high extrusion speed may cause excessive heat generation in the extruded
material generating lateral cracks.
Typical extrusion pressures

Materials Pressure, MPs Materials Pressure, MPs

Soft lead 275 – 420 Hard copper alloys Up to 850
Copper-bearing leads 300 – 500 Silicon bronze 950
Tin-bearing alloys 420 – 620 Al-base alloys 70 – 700
Tin-base alloys 275 – 700 Mg-base alloys 35 – 350
Soft copper alloys About 200 Zinc-base alloys 700 - 850
Extrusion cont.
 Extrusion cont.
Hot extrusion processes
Forward (Direct) hot Extrusion: Flow of material in forward direction (same as
the ram motion). Friction between billet and cylindrical wall is the problem
specifically with steel where the T is high. To reduce this, lubricants are used. At
low T, a mixture of oil and graphite can be used; they too get into problem at high
T. Hence, at high T, molten glass is used which remain molten and besides
providing lubrication, also provides necessary heat insulation to the hot billet.

To reduce damage to the wall, extrusion is completed quickly and the

cylinder is cooled before further extrusion.
 Extrusion cont.
Hot extrusion processes cont.
Backward (Indirect) hot Extrusion: Flow of material in backward direction
(through the die in the plunger or ram). Billet is static, hence no friction between
billet and wall, extrusion pressure is not affected by the length of billet, surface
quality is also good since no heat cracking due to friction. The disadvantages are:
the surface defects of the billet end up in the final product.

The process is not extensively used since handling of the extruded

material coming through the moving ram is difficult.
 Extrusion cont.
Cold extrusion processes
Forward (Direct) Cold Extrusion: The forward cold extrusion is similar to that
of the forward hot extrusion except for the fact that the extrusion ratios possible
are lower and extrusion pressures are higher than that for the hot extrusion. It is
normally used for simple shapes requiring better surface finish and to improve
mechanical properties.

Material Extrusion Pressure, MPa

Pure Al 600 to 1100

Soft brass 450 to 800

Soft copper 400 to 1100

C10 steel 800 to 2500

C20 steel 900 to 3100

Examples: cans, various aluminum brackets, shock-absorber cylinders,

rocket motors and heads etc.
 Extrusion cont.
Cold extrusion processes cont.
Impact Extrusion: The backward cold extrusion, also called Impact extrusion, is
much more common for softer materials such as aluminum and its alloys. The
work (slug) is placed in the die and the punch gives an impact such that the metal
is extruded through the gap between the die and the punch. The height of the side
walls is controlled by the amount of metal in the work (slug).

This process is more commonly used for making collapsible tubes for
housing pastes, liquids and similar articles.
 Extrusion cont.
Cold extrusion processes cont.
Cold Extrusion Forging: Cold extrusion forging is similar to impact extrusion
with difference that the side walls are much thicker and their height is smaller.
The punch slowly descends over the slug kept on the die, thus forging some metal
between the punch and the die and the rest being extruded through the clearance
between the punch and the die side walls. Afterwards, the component is ejected by
means of the ejector pin provided in the die.

The backward cold extrusion

processes are different from
other extrusion processes in
that each stroke of the punch
prepares a directly usable
single component which may
not necessarily have a
uniform cross-section over its
length. Further, it is used for
smaller size work of non-
ferrous metals.
 Extrusion cont.
Extruding tubes
Hollow objects such as tubes and other shapes can also be obtained by forward
hot extrusion. First, the solid ram moves through the heated metal billet creating
a hole in the centre; later, the hollow ram moves the metal billet through the die.
 Extrusion cont.
Extruding tubes cont.
Another way of obtaining hollow shapes is by using a spider extruding die. The
spider die is essentially an extrusion die with a stub mandrel, for the hollow
portion to be generated. It is held to the die by means of thin ribs simulating the
spider legs.
 Extrusion cont.
Hydrostatic Extrusion
In this process, the metal billet is compressed from all sides by a liquid rather
than a ram. Thus, (a) lubrication is eliminated, (b) uniform pressing from all sides
(highly brittle metals can be extruded), pressure range: 1110 to 3150 MPs.

Fluids used: Castor oil with 10% alcohol, SAE 30 mineral lubricating oil, glycerin,
ethyl glycol, iso-pentane. Applications: reactor fuel rods, cladding of metals,
making wires of less ductile metals.
Extrusion cont.
Extrusion cont.
 Extrusion cont.
Process variables in direct extrusion
Factors Influencing the Forces:
-Friction
-Material Properties
-Reduction In Area
-Speed
-Temperature
-Geometry Of The Die

Variation of Ram
Force with ram
stroke and die
angle.
Optimum Die Angle
 Extrusion cont.
Extrusion defects

a) Centre-burst: internal crack due to excessive tensile stress at the centre

possibly because of high die angle, low extrusion ratio.
b) Piping: sink hole at the end of billet under direct extrusion.
c) Surface cracking: High part temperature due to low extrusion speed and
high strain rates.
 Extrusion cont.
Extrusion defects cont.
b) Schematic illustration of rigid and
Chevron cracking (central burst) in
extruded round steel bars. Unless
the products are inspected, such
internal defects may remain
undetected, and later cause failure of
the part in service. This defect can
also develop in the drawing of rod,
of wire, and of tubes.
plastic zones in extrusion. The
tendency toward chevron cracking
increases if the two plastic zones do
not meet. Note that the plastic zone
can be made larger either by
decreasing the die angel or by
increasing the reduction in cross-
section (or both).
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