ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY

12/22/2022

SCHOOL OF MECHANICAL,
CHEMICAL AND MATERIAL
SCIENCE & ENGINEERING
(SoMCME)
DEPARTMENT OF
MECHANICAL ENGINEERING
MANUFACTURING
ENGINEERING I (MEng 3205)
GROUP ASSIGNMENT I

SUBMITTED TO: Mr. YESHALEM ZEWUDE

 Manufacturing Engineering I
Assignment – I
1. Define manufacturing.
Manufacturing is a processes or set of processes that turn a starting material into a more usable and
valuable form by employing: machinery, tooling, labor and power. This generalized definition can be
dissolved to referring 2 different aspects. One is technology and the other, economy.
Economically speaking, manufacturing is defined as an operation/process that adds value to a less
valuable form of a substance. Whereas, technologically, It is an activity that turns a starting material into
a usable product.
2. Discuss the types of materials used in manufacturing.
Generally, there are four types of manufacturing materials which differ in their chemistry, mechanics,
physical properties and manufacturing techniques.
• Metals
- These are substances known for their heat and electrical conductivity, ductility and versatility.
- They are generally classified into two. i.e Ferrous and Non-ferrous
o The ferrous metals are iron and derivatives of iron. They account for 3/4th of the globe’s
total tonnage.
o The non-ferrous metals are metallic materials other than iron and its derivatives. These
include aluminum, magnesium, copper, titanium, etc…
• Polymers
- Polymers are redundant chains of sub units, called monomers, and are known for their wide range
of applications from vehicle tires to kitchen utensils and packaging materials.
- Polymers are broadly classified into three. Namely as: thermoplastics, thermosets and elastomers.
o Thermoplastic polymers are those with the capability of being recyclable, unlike thermosets.
o Elastomers are polymers with a remarkable level of elasticity.
• Ceramics
- Ceramics are materials whose beginning of practical applications dates back to primitive periods.
- They are used as refractories in different heat liberating environments.
- They are classified into two: traditional and modern
o Traditional ceramics are materials which are based on natural occurring materials such as
clay, quartz, feldspar, etc. These have been used for the purpose of making tiles, refractories,
walls, decorative parts and so on…
o Modern ceramics are engineering materials like the semiconductor silicon carbide and are
made using synthetic powders. These play an irreplaceable role in making electrical and
electronic components.
• Composites
- These are a combination of two or more of the above listed three engineering materials.
- They can be grouped into three, based on what type of material is being used as a matrix.
 3. Write at least four types manufacturing processes and explain each briefly with examples.
• Machinig
- It is a process of removing some part of a given material with a hand tool or an automated machine
to arrive at a desired form.
- Its often used as secondary shaping.
- Example : jewelry, rims
• Forming
- Is a process of producing desirable shapes by causing a metal to elongate or change shape. This can
be done in both processes of hot and cold working.
- Examples : scaffolding and heavy machinery
• Additive manufacturing
- A cutting edge innovation of creating objects by building them layer by layer, overcoming the
disadvantages subtractive manufacturing has.
- Example : eyewear, furniture
• Joining
- These are processes of permanently, or sometimes temporarily, fixing different materials together for
the sake of assembling them.
- Example : plumbing components

4. Write at least four Manufacturing Systems and explain the Characteristics and its application.
Manufacturing system Characteristics Application
1. Continuous - Is a flow production Oil and gas refinery
- Lasts 24/7 and all year round
- Has a very low variety
2. Mass - Has low variety and high Automobile plant
volume
3. Job shop - Has high variety, but small Machine shop
amount.
4. Projects production - Project for production Airport construction
- Large company business

5. What is Total Manufacturing Cost of a given product?

Total manufacturing cost is the sum total of : material, standard, operation, labor and miscellaneous
costs, that were spent in the production of a given end product in a given period of time.
6. Discuss the Classification of solidification processes.
Unike majority of the engineering applications, casting operates based on the liquid and solid
states/phases of the material to be casted. The molten material/cast changes phase as it liberates
heat energy is to its surrounding, this is the process of solidification that every casting process goes
through.
Solidification process can be classified based on a number of attributes, one is the type of material
solidifying.
 solidification
processes

processing of
casting of
glass working polymers and
metals
PMCs

extrusion and
expendable permanent
related
mold casting mold casting
processes

injection
sand casting
molding

other casting other molding

processes processes

special
processes

Since metals are the subjects of our interest in manufacturing engineering. Let us try to see the
their generalized cooling curve that portrays how their solidification proceeds.

7. What are the advantage and dis-advantages of Casting?

• Advantages of casting
- It is capable of creating complex part geometries that other manufacturing processes can’t.
- It can create both internal and external shapes.
- It produces net/near net shape.
- Capable of producing bulky parts even weighing more than hundred tons.
- Also appliceable for polymers and ceramics.
- Suitable for mass production of components.

• Disadvantages of casting
- Some of its processes yield poor dimensional accuracy and surface finish.
- It can cause environmental problems and pose danger to workers.

8. List and explain the two forms of mold cavities. (Support your answer with a net sketch.)

Open mold Closed mold

A type of mold that is formed to imitate the This one is a ,ore complicated mold that
geometrical aspect of the part to be casted. needs a gating system leading into it.

9. Mention the Steps in Sand Casting?

a. Pattern making
b. Sand preparation
c. Melting and pouring
d. Allowing to freeze
e. Cleaning and finishing
f. Heat treating (optional)

10. List the materials used for pattern in casting processes.

• Wood
• Metal or
• Plastic
 11. Explain the basic difference between Expendable Mold Processes and Permanent Mold Casting
Processes.
Expendable mold Permanent mold
a type of mold which is destroyed upon removal Here, the mold remains intact after the cast has
(ejection) of a cast. been ejected.
Commonly made out of sand. Commonly made out of metals whose melting
points greatly exceeds that of the cast.
Include : High quality of product include
- Shell molding - Basic permanent mold casting
- Expanded polystyrene process - Die casting
- Investment casting - Centrifugal casting
- Plaster mold
- Ceramic mold casting etc…

12. Discuss the Advantages and Limitations in die casting.

• Advantages
- Suitable for large scale production.
- Small grain size and good strength cast.
- Attains thin sections (if necessary).
- Good surface finish and dimensional accuracy.
• Limitations/disadvantages
- Problems may be faced if part geometry doesn’t allow removal from die.
- Usually limited to metals with low melting point to avoid melting or changing the properties of
the die.
13. Write at least three types of defect in sand casting.
• penetration
• Cold shot
• Hot tearing
• Pin holes