Manufacturing Technology I

Objective
• Basic Manufacturing methods
• Basic engineering materials
• Basics of metal casting
• Metal casting – Important terms
• Foundry - Introduction
 Manufacturing Methods
• Metal casting
• Metal forming – change in dimension
• Machining – Metal removal
• Welding - joining
• Heat treatment
• Powder metallurgy
Engineering Materials
Engineering Materials

Metals Non Metals

Non
Ferrous Polymers Ceramics composites
Ferrous

Cu, Al, Ni,

Steel cast iron
Mg,Ti, etc
Plain
carbon
steels

Alloy steels
Engineering Materials
low carbon
steels
( <o.25%C)
medium
plain carbon
carbon steels
steels
(0.25 to 0.55%)
Steel
high carbon
Alloy steels steels (0.55%
to 2%C)

Ferrous White cast iron

Materials

Grey cast iron

cast iron Ductile iron

Malleable Cast
iron

Alloy cast iron

 Product Forms
• Cast products
• Final shape of required component
• Cast Iron products, Aluminum Casting products
• Eg. Motor bodies

• Wrought products
• Required secondary processes ( forging, rolling etc)
• Steel ingots, Aluminum ingots, Ti ingots
• Eg. Wires, shafts, connecting rod etc.,
 Metal casting
It is solidify metallic object from mould cavity.
 Metal casting – Basic steps
• Pattern design and making
• Core making
• Molding
• Melting and pouring
• Solidification
• Cleaning
• Finishing
 Metal casting – Terms
• Flask
• Pattern
• Parting line
• Molding sand
• Facing sand
• Core
• Pouring basin
• Sprue
• Gate
• Chaplets
• Riser
• Vent
 Foundry
• It is a commercial setup to manufacture casting.
• Captive foundries
• Semi captive foundries
• Production foundries
• Job order foundries

• Ferrous and Non – ferrous foundries

 Foundry – Operations

Melting plant
Sand plant Pattern shop Mould Plant

Finishing /
Heat
Machining Fettling plant Pouring plant
treatment
plant

Inspection/
quality Dispatch
control
 References
• NPTEL / Manufacturing processes I
• “Principles of metal casting” by Philip C Rosenthal
• “Manufacturing process for engineering Materials” by
Kalpakjian