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Contact: rajeshbabu.c@reva.edu.in
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Experience: Teaching
Experience: Teaching since 2009
& Research since 2009
T o p ic o f t h e L e c tur e
4
INTRODUCTION TO ENGINEERING MATERIALS
Elastomers Laminates
Rubber, Silicones, Oxides, Nitrides, Graphite etc.,
Polyurethanes
Reinforced Plastics
CLASSIFICATION OF ENGINEERING MATERIALS
What is “Manufacturing”?
❑The word “manufacturing” is delivered from the Latin manu factus, meaning made by hand.
❑“Economic terms for making goods and services available to satisfy customer” – (by T. Black,
1991)
INTRODUCTION TO MANUFACTURING
• Technology – This process to accomplish manufacturing involve a combination of
machinery, tools, power and manual labor.
• Steps:
(1)FLASK:- The Flask is the box that contains the moulding aggregate.
(2) Pattern:-It is the replica of the final object to be made with some
modification.
(3) Parting Line:-This is dividing line b/w two parts of flask that makes the sand moulds.
(4) Facing sand:- The Small amount of carbonaceous sand material sprinkle on the internal mould
surface of cavity to give better surface finish to the casting.
(6) Moulding Sand:- It is Freshly Prepare refractory use for making the mould cavity.
(7) Pouring basin:- A Small Funnel Shaped Cavity at the top of mould in to inch the molten metal is
poured.
(8) Core:- A core is used in Casting and moulding Process to produce internal hollow cavities in final
product.
CASTING TERMINOLOGY
(9) Cope and Drag: In foundry work, the terms cope and drag refer
respectively to the upper and lower parts of a two-part casting flask,
used in sand casting.
(10) Sprue:- It is Vertical Cavity in the moulds to flow the molten metal from the pouring basin.
(11)Runner:- The pass way in the parting line through which molten metal regulated before they reach to mould
cavity.
(12) Riser :- It is reservoir of molten metal provided in casting show that metal can flow back into the more cavity
there is a reduction in volume of metal due to solidify.
CASTING VIDEO
Advantages
• Complex forms, low cost
• Certain shapes cannot be
machined
• One piece parts vs. multiple
piece parts
• Design changes are easily
incorporated
• High volume, low skilled labor
• Large, heavy parts can be made
easily
Disadvantages
• Problems with internal
porosity
• Dimensional variations due
to shrinkage
• Trapped impurities, solids
and gasses
• High-tolerance, smooth
surfaces not possible
• More costly than stamping
or extruding in some cases
Applications of casting
• Automotive sector: A few parts like brake drum,
cylinder, cylinder linings, pistons, engine blocks,
universal joints, rocker arms, brackets, etc.
• Aircraft: Turbine blades, casting, etc.
• Marine: Propeller blades
• Machining: Cutting tools, machine beds, wheels and
pulleys, blocks, table for supports, etc.
• Agriculture & rail road equipments: Pumps and
compressor, frames, valves, pipes and fittings for
construction.
• Steel utensil & a wide variety of products.
Metal Cutting
I n t r oduc tion
METAL CUTTING
Introduction
Several metal cutting operations are carried out to produce a part of required shape
and size.
The metal cutting operations may be carried out either manually by using hand tools
such as chisels, files, saws, or using metal cutting machines.
METAL CUTTING
Introduction
Machine
I n t r oduc tion
MACHINE
Introduction
A machine (or mechanical device) is a mechanical structure that uses power to apply
forces and control movement to perform an intended action.
Machine Tool
I n t r oduc tion
MACHINE TOOL
Introduction
A machine tool is defined as a power driven machine which accomplishes the cutting or
machining operations on it.
When machines perform the metal cutting operations by the cutting tools mounted on
them, they are called "machine tools".
The fundamental machine tools that are used for most of the machining processes are,
❑ Lathe,
❑Drilling,
❑Milling,
❑Shaping and
❑Grinding machines.
MACHINE TOOL
Introduction
Grinding machine
WORKING PRINCIPLE AND CLASSIFICATION OF LATHE
Lathe – Introduction
LATHE – INTRODUCTION
Introduction
Lathe is the oldest of all machine tools and perhaps the most basic tool used in
industries.
Definition: Lathe is a machine tool used to remove metal from the work piece, to a
required shape and size
Principle of Lathe
Classification of Lathe
CLASSIFICATION OF LATHE
Types of Lathe
• Based on the construction and Functions, Lathes are classified as
❖Speed Lathe
❖Bench Lathe
1. Bed
2. Headstock
3. Tailstock
4. Carriage
5. Tool Post
6. Lead Screw
7. Feed Rod
MAJOR PARTS OF LATHE MACHINE
Bed
MAJOR PARTS OF LATHE MACHINE
Headstock (Live Centre)
MAJOR PARTS OF LATHE MACHINE
Tailstock (Dead Centre)
MAJOR PARTS OF LATHE MACHINE
Carriage
MAJOR PARTS OF LATHE MACHINE
Carriage
Compound rest
Carriage assembly Cross-slide
Single tool holder tool post Multi tool holder tool post
Compound rest with tool post
MAJOR PARTS OF LATHE MACHINE
Feed rod and Lead screw
MAJOR PARTS OF LATHE MACHINE
Legs
LATHE OPERATIONS
Operations that can be performed on Lathe Machine
▪Facing
▪Turning – (a) Simple Turning (b) Taper Turning
▪Threading
▪Chamfering
▪Knurling
▪Drilling
▪Grooving / Parting
LATHE OPERATIONS
Facing
Facing is the process of removing metal from the end of a workpiece to produce a flat
surface.
Function: To make flat surface and reduce length
LATHE OPERATIONS
Turning (a) Simple Turning
Turning is the removal of metal from the outer diameter of a rotating cylindrical
workpiece.
Function: To reduce the diameter of the workpiece usually to a specified dimension,
and to produce a smooth finish on the metal.
LATHE OPERATIONS
Turning (b) Taper Turning
Taper turning is a machining operation, which means that the diameter of a cylindrical
workpiece gradually decreases from one part to another.
LATHE OPERATIONS
Threading
Thread cutting on the lathe is a process that produces a helical ridge of uniform
section on the workpiece.
This is performed by taking successive cuts with a threading tool, the same shape as
the thread form required.
LATHE OPERATIONS
Chamfering
Chamfering: Chamfering removes the burrs and sharp edges, and thus makes the
handling safe. Chamfering can be done by a form tool having angle equal
to chamfer which is generally kept at 45°
LATHE OPERATIONS
Knurling
Drilling is one of the machining operations of producing circular hole in the work-
piece by using a rotating cutter called drill-bit or twist drill.
LATHE OPERATIONS
Grooving
The term grooving usually applies to a process of forming a narrow cavity of a certain
depth, on a workpiece. The groove shape, or at least a significant part of it, will be in
the shape of the cutting tool.
Introduction to Drilling
D r illing – I n t roduction
INTRODUCTION TO DRILLING
Drilling machine
The process of making a cylindrical hole in a solid workpiece by means of revolving tool
called drill bit and the process is known a drilling.
INTRODUCTION TO DRILLING
Drilling machine
• The drilling machine is one of the most important machine tools in a workshop. As
regards its importance it is second only to the lathe.
• The hole is generated by the rotating edge of a cutting tool known as the drill bit or
twist drill which exert large force on the work clamped on the table.
Drill bit
Classifications of Drilling Machines
D r illing Mac hine– Ty pes
CLASSIFICATIONS OF DRILLING MACHINE
Drilling Machine– Types
Drilling machines are made in many different types and sizes, each designed to handle
a class of work or specific job to the best advantage. The different types of drilling
machines are :
Portable Drilling Machine
Bench or Sensitive Drilling Machine
Radial Drilling Machine
Upright Drilling Machine
Multi-spindle Drilling Machine
Gang Drilling Machine
Automatic Drilling Machine
Computer Numerical Controlled (CNC) Drilling Machine
INTRODUCTION TO DRILLING
Types of drilling machine
Construction
1. Base
2. Work Table
3. Vertical Column
4. Electric Motor
5. Drill Head
6. Radial Arm
7. spindle
Drilling Operations
O p e r a t i o n s p e r f o r me d o n d r i l l i n g m a c h i n e
DRILLING OPERATIONS
Operations performed in drilling machine
• Drilling
• Reaming
• Boring
• Counterboring
• Countersinking
• Spot facing
• Tapping
Drilling is a cutting process where a
DRILLING OPERATIONS drill bit is spun to cut a hole of
Drilling circular cross-section in solid
materials. The drill bit is usually a
rotary cutting tool, often multi-point.
The bit is pressed against the work-
piece and rotated at rates from
hundreds to thousands of revolutions
per minute.
Reaming is a sizing operation that removes a small
DRILLING OPERATIONS amount of metal from a hole already drilled. It is done
Reaming for two purposes: to bring holes to a more exact size and
to improve the finish of an existing hole.
The boring operation is equivalent to turning, but is
performed exclusively on internal surfaces. It is used
DRILLING OPERATIONS for roughing (sometimes referred to as 'hogging'), semi-
Boring finishing, or finishing of castings or drilled holes
DRILLING OPERATIONS Counterboring is the process of using counterbores on
Counterboring a milling machine to create a hole over the screw
clearance. This newly formed hole is designed to let the
screw rest in its place and not stick out. Creating
counterbores is achieved by using the milling machine,
which uses drill bits that have a tip.
DRILLING OPERATIONS
Countersinking is a process that
Countersinking creates a V-shaped edge near the
surface of a hole. It is often used to
deburr a drilled or tapped hole, or to
allow the head of a countersunk-head
screw to sit flush or below a surface.
Chamfering endmills are commonly
used to make countersinks when
CNC milling
DRILLING OPERATIONS
Spot facing
The most common application
of spotfacing (spot facing) is
facing the area around a bolt
hole where the bolt's head will
sit, which is often done
by cutting a shallow
counterbore, just deep
enough "to clean up"—that is,
only enough material is
removed to get down past any
irregularity and thus make the
surface flat.
DRILLING OPERATIONS Tapping is the operation of cutting internal threads in a
Tapping hole using a cutting tool called Tap. A tap has cutting
edges in the shape of threads. When the tap is screwed
into a hole it removes metal and cuts internal threads for
tapping the hole drilled will be smaller than the tap size.
Welding Process
Introduction
➢ Pressure Welding
The surfaces of the joint to be welded is heated to a plastic state and forced
together with external pressure to finish the joint.
Ex: Resistance Welding, Friction welding
➢ Fusion Welding
Heating the metals at the joint portion in to molten state and allowed to solidify
to form joint with or without the addition of filler material. The process is
carried out without the application of pressure.
➢ Leak-proof joining.
•Change in metallurgical properties.
•As compared to mechanical cutting, dimensional tolerances are poor.
•Working place needs to have adequate ventilation and proper fume
control.
•Cutting operation is risky to the operator, due to the expelling/blowing of
the red hot slag and other hot particles during cutting process.
• Residual stress generation, Poor vibration sustaining capability
Electric Arc Welding Setup
1 2
Arc Welding Equipments
Safety Goggles
9
2
Applications of Welding
➢Manufacturing plants
➢Construction Fields
➢Shipbuilding
➢Industrial piping
➢Railroads
➢Electric shock is one of the most serious and immediate risks facing a
welder.
• An appropriate flux must be applied to the faying surfaces and then surfaces are
heated.
• The main purpose of the flux is to prepare the metal surfaces for soldering by
cleaning and removing any oxides and impurities.
Flux Materials: Ammonium Chloride or Resin acids (Rosin), Hydrochloric acid and Zinc chloride
• Filler metal called solder is added to the joint, which distributes
between the closely fitted surfaces.
Flux
Principle in Soldering
❑Preparation / Design of Solder Joint
❑Flux Application
❑Application Solder
Capillary action is defined as the spontaneous flow of a liquid into a narrow tube
or porous material. This movement does not require the force of gravity to
occur.
Distinguish Between Welding & Soldering
History
Block Diagram
Advantages
Disadvantages
Applications
CNC Machine
H i story
HISTORY
The first NC (Numerical Control) machines were built in the 1940s and 1950s by
Prof. John. T. Parsons
“CNC is one in which the functions and motions of a machine tool are
controlled by means of a prepared program containing coded alphanumeric
data ”.
CNC can control the motions of the work piece or cutting tool, the input parameters such
as feed, speed, depth of cut and the functions such as Spindle ON/OFF, Turning coolant
ON / OFF, Cutting Tool Selection, etc.,
CNC-COMPUTER NUMERICAL CONTROL MACHINE
Continued
CNC Machining is a process used in the manufacturing sector that involves the use of
computers to control machine tools like lathes, mills and grinders.
COMPUTER NUMERICAL CONTROL MACHINES
C NC Mac hines
COMPUTER NUMERICAL CONTROL MACHINES
CNC Machines
CNC machine has:
➢Interpolation
➢Communications interface
COMPUTER NUMERICAL CONTROL (CNC) MACHINE
Block Diagram
ELEMENTS OF A CNC SYSTEM
Components
❖ Input Device
❖ Machine Tool
❖ Driving System
❖ Feedback Devices
❖ Display Unit
ADVANTAGES AND DISADVANTAGES OF CNC
Advantages of CNC
High Repeatability and Precision e.g. Aircraft
parts.
Maintenance is difficult.
CNC APPLICATIONS
CNC Laser
CNC Welding
3D Printing Technology
T o p ic o f t h e L e c tur e
TOPIC OF THE LECTURE
3D Printing
History
3D Printing - Definition
Advantages
Disadvantages
Applications
3D Printing
H i story
HISTORY
Charles Hull coined the term stereo-lithography (3D Printing) in his August 8, 1984 patent
application for "Apparatus for production of three-dimensional objects by stereo-lithography"
U.S
Additive Manufacturing
D efinition
ADDITIVE MANUFACTURING
Definition
Additive Manufacturing (AM) refers to a process by which digital 3D design data
is used to build up a component in layers by depositing material.
3D printing or additive manufacturing is the construction of a three-dimensional
object from a CAD model or a digital 3D model.[1] It can be done in a variety of processes
in which material is deposited, joined or solidified under computer control,[2] with material
being added together (such as plastics, liquids or powder grains being fused), typically
layer by layer.
INTRODUCTION
Technical Definition
Digital to Physical
INTRODUCTION
What is 3D Printing ?
3D Printing refers to a relatively new class of manufacturing methods which
quickly produce physical prototypes from 3D CAD data
manufacturing)
INTRODUCTION
3D + Printing = 3D Printing
Digital to Physical
INTRODUCTION