Basics of Mechanical Engineering

Chapter
Manufacturing
3 Lecture by:

Dr. Rajesh Maithani

Processes

Department of Mechanical Engineering,

University of Petroleum and Energy Studies,
Dehradun.
 Materials
Metals: Materials in this group are composed of one or more metallic
elements (such as iron, aluminum, copper, titanium, gold, and nickel), and
often also nonmetallic elements (for example, carbon, nitrogen, and oxygen)
in relatively small amounts.

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Ceramics: Ceramics are compounds between metallic and
nonmetallic elements; they are most frequently oxides, nitrides,
and carbides. For example, some of the common ceramic

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Polymers: Polymers include the familiar plastic and rubber materials. Many
of them are organic compounds that are chemically based on carbon,
hydrogen, and other nonmetallic elements (viz.O,N, and Si).

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Composites: A composite is composed of two (or more) individual materials—
viz., metals, ceramics, and polymers. The aim is to achieve a combination of
properties that is not displayed by any single material, and also to incorporate
the best characteristics of each of the component materials.

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What Are the Mechanical Properties of Metals?
The measurable properties that allow a metal to resist external forces without failing
are its mechanical properties.

Hardness
A material’s power to resistance to scratching, abrasion or cutting is known as
hardness. For example, hard metals are used to make drills and files.

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Brittleness
Brittleness is the likelihood that a material will fail or fracture under a relatively
small shock, force, or impact. Hardness and brittleness have a direct relationship
as a metal’s hardness is increased so does its brittleness.

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Ductility
When you bend a piece of aluminum foil, it usually remains that way because it
is ductile. Ductility is the capability of a metal to be permanently bent, twisted, or
otherwise manipulated without breaking or cracking. Soft steel, copper,
aluminum, and zinc are all considered ductile metals.

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Toughness
Toughness is the capacity of a metal to not break until a significant force is
applied.

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 Metal Forming
Metal forming
Materials are converted into finished products though different
manufacturing processes. Manufacturing processes are classified into
casting, forming, joining, and coating, machining etc.

BULK FORMING
SHEET FORMING

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 BULK FORMING
ROLLING

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FORGING

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EXTRUSION

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WIRE/ROD DRAWING

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SHEET FORMING
BENDING

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DEEP/CUP DRAWING

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SHEARING

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Punching and blanking

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 Metal cutting
Metal cutting is the process of
producing a job by removing a layer of
unwanted material from a given
workpiece.

The basic elements involved in this process are:

(i) A block of metal (work piece).
(ii) Cutting Tool.
(iii) Machine Tool.
(iv) Cutting Fluid.
(v) Cutting speed (Primary Motion).
(vi) Work holding and Fixturing.

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The essential conditions for successful metal cutting
are:

(a)Relative motion between work and cutting tool.

(b) Tool material must be harder than work material.
(c) Work and tool must be rigidly held by jig and fixtures.
(d) Sharp Cutting edge of cutting tool.
(e) Primary Motion (Cutting Speed).

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Turning:

Milling:

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Drilling:

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Boring:

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 Chips
Single point cutting tool

Chuck

Tool post
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Multi-point cutting tool

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 Joining processes
Joining is one of the manufacturing processes by which two or more
materials can be permanently or temporarily joined or assembled together
with or without the application of external element in order to form a single
unit.

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Reviting joints

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Bolted joints

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 Welded joints
A welding joint is a point or edge where two or more pieces of metal or plastic are joined
together. They are formed by welding two or more workpieces according to a particular
geometry.

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Welding classification

1.Arc Welding
2.Gas Welding
3.Spot/ seam welding
4.Soldering/Brazing

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 Arc welding Arc Welding: Arc welding is a type of welding process using an
electric arc to create heat to melt and join metals. A power supply creates an electric arc
between a consumable or non-consumable electrode and the base material using either
direct (DC) or alternating (AC) currents.

The temperature of the arc is about 5,000°C to 20,000°C

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Gas Welding: Oxyfuel gas welding is a process that joins metals by combustion
of a fuel gas, oxygen, and air mixed in a nozzle and directed at the work surface. The
most common fuel gas used is acetylene. The fumes generated in this type of welding
originate from the base metal, filler metal, and fluxes.

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Brazing: process of joining two pieces of similar or dissimilar metals. In this case as non-
ferrous metal or alloy in the molten form is supplied in between the metals to be joined and
allowed to solidify. The melting point of filler material is above 427°C but which is lower than
the melting point of parent metals. During brazing the parent metal parts do not melt.
The various brazing metals and alloys are Copper, Brass, Bronze, Silver alloys, Aluminium
alloys etc.

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Soldering: Soldering is a process of joining two pieces of metals. In this case a molten
fusible metal called solder is supplied and allowed to solidify. The melting point of solder is
below 427° C. Some of the solders are:
(i) Soft Solder. Lead 37% and tin 63%.
(ii) Medium Solder. Lead 50% and tin 50%.
(iii) Electricians Solder. Lead 58 % and tin 42 %.

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Spot welding

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Seam welding

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