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
Drawing
Wire drawing
A wire by definition, is circular with small diameters so that it is flexible. A
process of wire drawing is to obtain wires from rods of bigger diameter through a
die. Wire drawing is always a cold-working process.
The equipment for wire-drawing consists of a die of conical shape. The end of the
rod/wire to be drawn is made into a point shape and is inserted through the die
opening which is then gripped by the gripper at the other end and is pulled
through the die. The wire is then coiled.
The stock material needs preparation like annealing since it has to be ductile for
being pulled by tensile force. Since no pushing force is applied, the front end of
the feed rod is made pointed by means of rotary swaging or by simple
hammering.
Approach angle about 6 to 20
Back relief angle about 30
Drawing cont.
Wire drawing cont.
The other aspect of preparation needed is the cleaning of the wire and lubricating
it as it flows through the die. Cleaning means to remove the scale/rust formed on
the surface, otherwise, it will severely affect the die. It is done by acid pickling.
Lubrication is a serious problem because the pressure acting at the interface of the
die and the metal is very high. Therefore, special methods of lubrication is done:
(a) Sulling: a thin coat of ferrous hydroxide is
provided, which when combined with lime
acts as afiller for the lubricant.
(b) Phosphating: a thin film of Mn-, iron-, Zn-
phosphate is applied on the wire; thus, the
lubricant sticks to the wire reducing friction
and drawing load.
(c) Coppering: for very thin wires, electrolytic
coating of copper is used to reduce friction.
(d) Liming: a lime coat is given which neutralizes
remnant acid after pickling and also helps
the lubricant to be adsorbed.
The lubricant normally used is soap solution.
Drawing cont.
Wire drawing cont.
The dies used for wire drawing are severely affected because of high stresses and
abrasion. The various dies used are:
(a) Chilled cast iron: used for small runs. (b) Diamond: used for very fine wires.
(c) Tool Steels: alloy steels are used for making dies for very large scales.
(d) Tungsten carbide: most commonly used for medium-size wires and large
production.
Tungsten dies are preferred because of their long life; 2 to 3 times that of alloy
steel dies.
Drawing cont.
Wire drawing cont.
Some of the commercially available tungsten carbide dies
Pellet dia, Pellet height, Bearing dia, Entrance bell Entrance Drawing
D, mm H, mm d, mm dia, d1, mm Radius, R, mm angle, 0
8 - 30 6 - 24 0.2 – 9.0 5 - 26 4 - 14 8 - 18
Drawing cont.
Wire drawing cont.
Wire drawing improves mechanical properties due of cold working. The material
loses ductility, thus, for repeated drawing, intermediate annealing is needed.
The drawing machines can be arranged in tandem so that the wire coming from
one die is coiled up to a sufficient length before it re-enters into the next die. Thus,
the speed of wire drawing in a die can be adjusted easily. Since there is no change
in volume, successive drawing have to be done at higher speed.
Drawing cont.
Rod drawing
Rod drawing is similar to wire drawing except for the fact that the dies are bigger
because the rod size is bigger than the wire. Further, the rod drawn in coil form is
to be straightened first and then cut into proper length.
For larger stock (bars), heavy straight-drawing equipments (a table with rollers)
feed the stock into the die head after pointing; and after the die, a carriage having
an endless chain with grip pulls the drawn bars. Usually, the length of the bar
coming out of the die is short so that these are completely drawn and transported.
Bar drawing is generally in a batch mode
while the wire drawing is in general in a continuous mode.
Drawing cont.
Tube drawing
Tube drawing is also similar to other drawing processes. The main difference is
that it requires a mandrel of the requisite diameter to form the internal hole of the
tube. The tubes are also first pointed and then entered through the die where the
point is gripped in a similar way as the bar drawing and is pulled through in the
form desired along a straight line. There may be more than one pass; at the end,
the tube may be annealed and straightened.
The practice of drawing tubes without an internal mandrel is called sinking.
Drawing cont.
Tube drawing cont.
Examples of tube-drawing operations, with and without an internal mandrel. Note
that a variety of diameters and wall thicknesses can be produced from the same
initial tube stock (which has been made by other processes).
Drawing cont.
Swaging
Swaging is a mechanical deformation technique of reducing or shaping the cross-
section of rods or tubes by means of repeated impacts or blows. It is achieved by
dies which are given the requisite external shape; and these dies by intermittently
hammering the stock produce: (a) the necessary shape, (b) good surface qualities,
(c) better grain structure, (e) higher tensile strength. It is simple and can be carried
out by un-skilled operator.
Since the dies have necessary taper,
the work should be completely clean
and dry and without any lubricant
(presence of lubricant makes the work
slip under the tapered portion and
feed backwards).
Tubes can be swaged with or without
mandrels. However, the required
internal diameter may not be possible
without a mandrel.
Swaging is generally used for preparing the pointed tip of the wire before drawing.
Drawing cont.
Rotary swaging
Rotary swaging is the operation where the two dies which are free to move
radially are held in a spindle which rotates continuously. On the internal side the
die gives the shape and the external side is simply cylindrical. The dies are free to
move radially and held in position with the spindle by means of a retainer plate fixed to the
housing. There is a cage between housing and spindle similar to ball-bearing cage.
Wherever, the rolls come to the top of the die, a blow is given to the work (fed between the
dies continuously), and when the die comes between the rolls, it is opened. For every
rotation, the dies will hit the work as many times as the number of rolls.
Rotary swaging is able to produce external surfaces which are axi-symmetric.
Drawing cont.
Seamless tube making
To obtain seamless tubes, extrusion can be used (described earlier). It is also
possible to obtain seamless tubes by a variation of rolling called roll piercing.
Here, the billet or round stock is rolled between two rolls, both of them rotating in
the same direction with their axes at an angle of 4.5 to 6.5 degree. These rolls have
a central cylindrical section with the sides tapering slightly; there are two small
side rolls which help in guiding the metal.
Because of the angle, in addition to the rotary motion, an axial advance brings
the metal into the rolls. This cross-rolling action makes the metal friable at the
centre which is then easily pierced and given a cylindrical shape by the central
piercing mandrel.
The tube obtained in the roll-piercing mill is further processed in a plug mill (a
two-high-reversing stand with a central mandrel) to obtain the desired size.
Drawing cont.
s pd
s pd
σ
σ
Stresses and drawing pressure
ε
ε
variation in deformation zone.
Drawing
die angle α
Drawing die
(deformation2zone)
3
1
Ao Af
Af
ε= Effective strain variation
Stress and strain ln(Ao/Af)
in deformation zone.
development in wire
and rod drawing process
Drawing cont.
Sheet metal drawing
Sheet metal drawing is the process by which cups, shells, and similar articles are
drawn from metal blanks. The set-up is similar to that used for blanking except
that the die are provided with the necessary rounding at the corners.
The drawing may be (a) shallow drawing (the cup height is less than half of its
diameter), and (b) deep drawing (the cup height is more than half of its diameter).
Ductile materials are easier to be drawn into deeper cups.
Drawing cont.
Sheet metal drawing cont.
The set-up consists of a punch, die, blank holder. The draw ratio is important.
Drawing cont.
Sheet metal drawing cont.
The set-up consists of a punch, die, blank holder. The draw ratio is important.
Drawing cont.
Sheet metal drawing cont.
Deep drawing: The cup height is more than half of its diameter.
Ductile materials are easier to be drawn into deeper cups.
Drawing cont.
Sheet metal drawing cont.
In deep drawing, because of the radial flow of material, the side walls increase in
thickness as the height is increased. To make it uniform, an operation called
ironing is carried out on the drawn cups.
Ironing is a severing operation because the clearance between the die and punch is
smaller than that used in drawing operations, hence, the material is compressed
severely to reduce the thickness and increase the height.
Drawing cont.
Sheet metal drawing cont.
Ironing operation can reduce the wall thickness to as much as 50% in a single
operation. Yet, some times, several stages of drawing is used to produce thinner
side wall and longer height.
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