PROCESS AND MANUFACTURING TECHNOLOGY

(TME21903)
ASSIGNMENT 1

Received Date : 4th March 2023

Submission Date : 12th March 2023
Date received : 12 MARCH 2023
Weightage : 10%
Semester : FEB 2023

Instruction to students :
 This is an INDIVIDUAL assignment
 Complete this cover sheet and attach it to your assignment (first page)

Student declaration :
I declare that :
 This assignment is my own work
 I understand what is meant by plagiarism
 My lecturer has the right to deduct my marks in the case of
- Late submission
- Any plagiarism found in my assignment

Name Student ID
FADHIL MUHAMMAD 012022091033
Lecturer’s Mohd Arif Fahmi Bin Rosli

TOTAL

MARKS
/ 30
A. INSTRUCTIONS

a. Mode: Individual
b. Form of submission: Hardopy and softcopy through lecturer and eKlass respectively
c. Date of submission: March 2023
d. Provision for submission
- If you have any difficulties in submitting the assignment, please come and see
(whatsapp) me for consultation
e. Course Outcome
CO1 Describe the common manufacturing processes with relative
advantages/disadvantages of those processes (C2, PLO1)
f. Content of assignment
I. Identify and describe various of manufacturing processes
II. Describe casting parts and typical defects in manufacturing.
g. Format
The ASSIGNMENT must be neatly written
Answer must be in A4 paper for hardcopy
Cover: a. MSU Logo
b. Title of Assignment
c. Name & ID
d. Lecturer’s name
h. Marks
This assigment will carry 10% of your coursework marks. The marking process based on
answer scheme provided.
**Marks will be deducted for late submission. (1 mark for 1 day)

B. QUESTIONS

a) Answer the following (some questions have multiple answers that are correct)
1. Which of the following processes starts with a material that is in a fluid or semi fluid
state and solidifies the material in a cavity:
(a) casting, (b) forging, (c) machining, (d) molding, (e) pressing, and, (f) turning?
(2 marks)
2. Deformation processes include which of the following:
 (a) casting, (b) drilling, (c) extrusion, (d) forging, (e) milling, (f) painting, and, (g)
sintering?
(2 marks)
3. High-volume production of assembled products is most closely associated with which
one of the following layout types:
(a) cellular layout, (b) fixed position layout, (c) process layout, or, (d) product layout?
(1 marks)
b) Label the blanks below.

(4 marks)
c) Your friend is new to the manufacturing processes. Describe how you will explain to
him/her about open, closed, expandable, and permanent molds.
(7 marks)
d) Expandable mold usually used in sand casting. Explain the type of expandable-mold
casting processes for which these molds can be made.
(8 marks)
e) Sand blow is the typical defect found in sand casting due to the low permeability, poor
venting, and high moisture content of the sand mold. Explain other three usual defects
found in sand casting.
(6 marks)
C. ANSWER

a) 1. Casting (for molten metal), molding (for hot polymer)

2. Deformation process: the material is initially a ductile solid then deformed to a desired
shaped. ANS: Forging, Extrusion (metal that is pressed out and extruding from chamber)
3. Product layout

b) a. Pouring basin (cup)

b. Vent
c. Cope
d. Drag
e. Runner
f. Parting line
g. Sprue
h. Flask

c) Open Mold Processes

The distinguishing feature of this family of FRP shaping processes is its use of a
single positive or negative mold surface to produce laminated FRP structures. Other
names for open mold processes include contact lamination and contact molding. The
starting materials (resins, fibers, mats, and woven rovings) are applied to the mold in
layers, building up to the desired thickness. This is followed by curing and part removal.
Common resins are unsaturated polyesters and epoxies, using fiberglass as the
reinforcement. The moldings are usually large (e.g., boat hulls). The advantage of using
an open mold is that the mold costs much less than if two matching molds were used.
The disadvantage is that only the part surface in contact with the mold surface is
finished; the other side is rough.
There are several important open mold FRP processes. The differences are in the
methods of applying the laminations to the mold, alternative curing techniques, and other
variations. In this section we describe the family of open mold processes for shaping
fiberreinforced plastics: (1) hand lay-up, (2) spray-up, (3) automated tape-laying
machines, and (4) bag molding.
Closed Mold Processes
These molding operations are performed in molds consisting of two sections that open
and close during each molding cycle. The name matched die molding is used for some of
these processes. One might think that a closed mold is about twice the cost of a
comparable open mold.However, tooling cost is even greater owing to the more complex
equipment required in these processes.Despite their higher cost, advantages of a
closedmold are (1) good finish on all part surfaces, (2) higher production rates, (3) closer
control over tolerances, and (4) more complex three-dimensional shapes are possible.
We divide the closed mold processes into three classes based on their counterparts in
conventional plastic molding, even though the terminology is often different when
polymer matrix composites are molded: (1) compression molding, (2) transfer molding,
and (3) injection molding.

Expandable Mold Processes

Expendable mold casting is a process that utilises reusable molds, for low volume or
single use production to produce metal components. There are four main types of
expandable mold casting techniques: gravity, slush, low-pressure, and vacuum. The
casting process involves pouring molten metal into a mould where it cools and solidifies.
The mould is then opened, with the casting removed, and then the mould is reused. The
mould is usually made from sand or plaster, which can withstand recurring heating and
cooling primarily with low volume production.
There are several advantages as to why you should use expendable mold casting (1)
Very cost-effective process. (2) Low tooling cost, but small one-off production runs. (3)
A wide variety of metals can be utilised. (4) Large parts can be cast. There are a few
disadvantages also to consider. (1) Less accuracy when compared to permanent mold
castings. (2) Large tolerances required. (3) Process usually exceeds the calculated
weight.

Permanent Molds Processes

Permanent mould casting is a process for producing a large number of castings using
a single reusable mould. The casting process simply involves pouring molten metal into a
mould where it cools and solidifies. The mould is then opened, the casting removed, and
the mould is reused. The mould is made from a high-temperature metallic material, such
as cast iron or hot work die steel, which can withstand the repeated heating and cooling
involved with large volume production.

Steps in shell molding: (1) a match-plate or cope-and-drag metal pattern is heated and
placed over a box containing sand mixed with thermosetting resin; (2) box is inverted so
that sand and resin fall onto the hot pattern, causing a layer of the mixture to partially
cure on the surface to form a hard shell; (3) box is repositioned so that loose, uncured
particles drop away; (4) sand shell is heated in oven for several minutes to complete
curing; (5) shell mold is stripped from the pattern; (6) two halves of the shell mold are
assembled, supported by sand or metal shot in a box, and pouring is accomplished. The
finished casting with sprue removed is shown in (7)

Vacuum Molding
Vacuum molding, also called the V-process, was developed in Japan around 1970. It
uses a sandmold held together by vacuumpressure rather than by a chemical
binder.Accordingly, the term vacuum in this process refers to the making of the mold
rather than the casting operation itself. Because no binders are used, the sand is readily
recovered in vacuum molding. Also, the sand does not require extensive mechanical
reconditioning normally done when binders are used in the molding sand. Since no water
is mixed with the sand, moisturerelated defects are absent from the product.
Disadvantages of the V-process are that it is relatively slow and not readily adaptable to
mechanization. The steps of the process are explained in Figure.
 Steps in vacuum molding: (1) a thin sheet of preheated plastic is drawn over a match-
plate or cope-and-drag pattern by vacuum—the pattern has small vent holes to facilitate
vacuum forming; (2) a specially designed flask is placed over the pattern plate and filled
with sand, and a sprue and pouring cup are formed in the sand; (3) another thin plastic
sheet is placed over the flask, and a vacuum is drawn that causes the sand grains to be
held together, forming a rigid mold; (4) the vacuum on the mold pattern is released to
permit the pattern to be stripped from the mold; (5) this mold is assembled with its
matching half to form the cope and drag, and with vacuum maintained on both halves,
pouring is accomplished. The plastic sheet quickly burns away on contacting the molten
metal. After solidification, nearly all of the sand can be recovered for reuse.

Expanded Polysterene Process

To create the expanded polystyrene blocks and sheets that you are familiar with,
steam is applied to tiny grains or beads of styrene that contain a minute amount of
pentane. This steam process causes the thermoplastic polystyrene to soften and expand
up to 40 times its original volume. Again using steam in the process, the expanded beads
are then moulded into a shape or large blocks which are then sliced into boards. The EPS
product is then dried and finished by a number of processes, such as hot wire cutting or
lamination.
A significant advantage for this process is that the pattern need not be removed from
the mold. This simplifies and expedites mold making. In a conventional green-sand
mold, two halves are required with proper parting lines, draft allowances must be
provided in the mold design, cores must be inserted, and the gating and riser system must
be added. With the expanded polystyrene process, these steps are built into the pattern
itself. A new pattern is needed for every casting, so the economics of the expanded
polystyrene casting process depend largely on the cost of producing the patterns. The
process has been applied to mass produce castings for automobiles engines. Automated
production systems are installed to mold the polystyrene foam patterns for these
applications.

Expanded polystyrene casting process: (1) pattern of polystyrene is coated with

refractory compound; (2) foam pattern is placed in mold box, and sand is compacted
around the pattern; and (3) molten metal is poured into the portion of the pattern that
forms the pouring cup and sprue. As the metal enters the mold, the polystyrene foam is
vaporized ahead of the advancing liquid, thus allowing the resulting mold cavity to be
filled.

Investment Casting
Investment casting, also known as precision casting or lost-wax casting, is a
manufacturing process in which a wax pattern is used to shape a disposable ceramic
mold. A wax pattern is made in the exact shape of the item to be cast. This pattern is
coated with a refractory ceramic material. Once the ceramic material is hardened, it is
turned upside-down and heated until the wax melts and drains out. The hardened ceramic
shell becomes an expendable investment mold. Molten metal is poured into the mold and
is left to cool. The metal casting is then broken from of the spent mold.
Advantages of investment casting include: (1) parts of great complexity and intricacy
can be cast; (2) close dimensional control—tolerances of ±0.075 mm (±0.003 in) are
possible; (3) good surface finish is possible; (4) the wax can usually be recovered for
reuse; and (5) additional machining is not normally required—this is a net shape process.
Because many steps are involved in this casting operation, it is a relatively expensive
process.

Steps in investment casting: (1) wax patterns are produced; (2) several patterns are
attached to a sprue to form a pattern tree; (3) the pattern tree is coated with a thin layer of
refractory material; (4) the full mold is formed by covering the coated tree with sufficient
refractory material to make it rigid; (5) the mold is held in an inverted position and
heated to melt the wax and permit it to drip out of the cavity; (6) the mold is preheated to
a high temperature, which ensures that all contaminants are eliminated from the mold; it
also permits the liquid metal to flow more easily into the detailed cavity; the molten
metal is poured; it solidifies; and (7) the mold is broken away from the finished casting.
Parts are separated from the sprue.

Plaster and Ceramic Mold Casting

Plaster-mold casting is similar to sand casting except that the mold is made of plaster
of Paris (gypsum, CaSO4–2H2O) instead of sand. Additives such as talc and silica flour
are mixed with the plaster to control contraction and setting time, reduce cracking, and
increase strength. To make the mold, the plaster mixture combined with water is poured
over a plastic or metal pattern in a flask and allowed to set.Wood patterns are generally
unsatisfactory due to the extended contact with water in the plaster. The fluid consistency
permits the plaster mixture to readily flow around the pattern, capturing its details and
surface finish. Thus, the cast product in plaster molding is noted for these attributes.
 Ceramic-mold casting is similar to plaster-mold casting, except that the mold is made
of refractory ceramic materials that can withstand higher temperatures than plaster. Thus,
ceramic molding can be used to cast steels, cast irons, and other hightemperature alloys.
Its applications (relatively intricate parts) are similar to those of plaster-mold casting
except for the metals cast. Its advantages (good accuracy and finish) are also similar.

 Penetration refers to a surface defect that occurs when the fluidity of the liquid metal
is high, and it penetrates into the sand mold or sand core. Upon freezing, the casting
surface consists of a mixture of sand grains and metal. Harder packing of the sand
mold helps to alleviate this condition.

 Mold shift refers to a defect caused by a sidewise displacement of the mold cope
relative to the drag, the result of which is a step in the cast product at the parting
line.