Manufacturing

Engineering Centre India
Prepared by: Srinivas Rao .K Date : 25- Apr-07

Approved by: Dipankar Ghosh Version: 1.0 Slide Number 1
CONTENTS
 MANUFACTURING PROCESS
 CASTING
• SAND CASTING,DIE CASTING,CENTRIFUGAL CASTING,INVESTMENT CASTING,
MOLTEN MERCURY CASTING.
 METAL FORMING
• MACHINING OPERATIONS
• MACHINES FUNCTIONS ADVANTAGES AND LIMITATIONS (Lathe, Milling, Drilling,
Grinding, Shaper, Planing slotting, etc,.)
• SHEET METAL – (Blanking, Piercing, Slitting, Cropping, Trimming, Shaving, Lancing)
• WELDING - TIG Welding- MIG Welding- Arc Welding- Submerged arc Welding- Gas
Welding- Resistance Welding-Electron Beam welding- Plasma Arc Welding- Laser Welding
• JIGS & FIXTURES Functions, Advantages And Limitations.
• SMITHY AND FORGING Functions, Advantages And Limitations.
• COLD WORKING & HOT WORKING PROCESS Functions, Advantages And Limitations.
• PLASTICS Functions, Advantages And Limitations.
 HEAT TREATMENT
• Quenching, Full Annealing, Case Hardening, Case Carburizing, Flame Hardening,
Speroidizing, Tempering, Normalizing, Nitriding, Induction Hardening, Surface Treatment.

CLASSIFICATION
MANUFACTURING PROCESS
CASTING METAL FORMING HEAT TREATMENT

CLASSIFICATION
CASTING
SAND CASTING CENTRIFUGAL CASTING MOLTEN

MERCURY
CASTING
DIE CASTING INVESTIMENT CASTING

CLASSIFICATION
Metal Forming
Chip-forming Process Chip-less Process
Continuous-contact Intermittent
Cutting Continuous Intermittent
Cutting
(Rolling, Contact
Spinning, etc.) (Forging,
Stamping, etc.)
Single-edged
Double- Ground Chips
Cutting Sizeable
Edged (Honing,
(Turning, Swarf
Cutting Grinding,
Shaping, (Milling)
(Drilling) etc.)
Boring, etc.)

CLASSIFICATION
HEAT TREATMENT
QUENCHING,
SPHEROIDIZING
FULL ANNEALING
TEMPERING
CASE HARDNING NORMALISING
CASE CARBURISING NITRIDING
FLAME HARDNING INDUCTION HARDNING
SURFACE TREATMENTMENT

CASTING
CASTING PRINCIPLE
" Metal object obtained by allowing molten metal to solidify in a mold "

CASTING
COMPONENTS AND PATTERNS

CASTING
TYPES OF CASTING
Sand casting
Die casting
Centrifugal casting
Investment or Lost wax casting.
Molten Mercury casting

CASTING
COMPARITIVE EVALUTION OF METALS FOR PATTERNS
Factors Grey CI Steel Aluminium Brass

Availability Good Good Good Good
Castability Good Difficult Less Difficult Good
Machinability Good Good Very Good Very Good
Surface finish Good Good Very Good Very Good
Lending to Good Good Good Very Good
Modification
Weight Very Heavy Very Heavy Very Heavy Heavy
Brittleness High Low Low Low

Tendency to Yes Yes No No
Oxidation
Requiring Yes Less Not Much Not Much
machining
Cost Low Low Medium High

CASTING
MOULD

CASTING
MOULDS

CASTING
TYPES OF DIES
• Single cavity to produce one

component
• Multiple cavity to produce a

number of identical parts
• Unit die to produce different

parts at one time
• Combination die to produce

several different parts for an
assembly.

CASTING
FOUNDRY

CASTING

CASTING
BASIC OPERATIONS OF CASTING
 Obtaining the casting geometry

 Pattern making
 Core making
 Molding
 Melting and pouring
Cleaning

CASTING
Advantages: Limitations:
• Difficulty in reclaiming used

• Most intricate parts also can be
casted. sand in carbon dioxide
Moulding.
• Ideal casting is a Isotropic
solid. • high pattern, resin, equipment
cost in shell Moulding.
• Some parts construction is
simplified. • In investment casting
expensive of all respects.
• Extremely large Objects also
can be casted. • In investment casting precise
control is required in all stages.
• Best suitable for the mass
production.

CASTING
DIE CASTING DIES

• Very high rate of production is • Not economical for small runs.

achieved.
• Close dimensional tolerances
of the order of0.025mmis • Only economical for nonferrous
possible. alloys.
• Surface finish of0.8 microns
can be obtained. • Heavy castings cannot be cast.
• Very thin sections of the order
of 0.50mm can be cast. • Cost of die and die casting
• Fine details may be produced. equipment is high.
• Longer die life is obtained.
• Less floor space is required. • Die castings usually contain
• Unit cost is minimum. some porosity due to the
entrapped air.

CASTING
DIE CASTING

CASTING
TYPES OF CENTRIFUGAL CASTING
• Centrifugal
• Semi Centrifugal
• Centrifuging

CASTING

CASTING

CASTING

CASTING


CLASSIFICATION
Metal Forming
Chip-forming Process Chip-less Process
Continuous-contact Intermittent
Cutting Continuous Intermittent
Cutting
(Rolling, Contact
Spinning, etc.) (Forging,
Stamping, etc.)
Single-edged
Double- Ground Chips
Cutting Sizeable
Edged (Honing,
(Turning, Swarf
Cutting Grinding,
Shaping, (Milling)
(Drilling) etc.)
Boring, etc.)

METAL FORMING
 Machining (Lathe,  Smithy and Forging

Milling, Drilling,  Cold working and Hot
Grinding, Shaper, working
etc,.)  Plastics
 Sheet metal  Heat treatment
 Welding
 Jigs & fixtures

METAL FORMING
 Lathe operations,  Smithy and Forging

 Cold working and Hot working
 Milling operations
 Plastics
 Drilling operations,  Heat treatment
 Grinding operations,  Surface treatment
 Shaper operations,
 Sheet metal
 Welding
 Jigs & fixtures


MACHINING
MACHINING OPERATIONS
TURNING OPERATION:-
Turning in a lathe is to remove
excess material from the work piece to produce a cone-
shaped or a cylindrical surface.
DRILLING OPERATION:-
Drilling is the operation of
producing a cylindrical hole in a work piece by the
rotating cutting edge of a cutter known as the drill.

REAMING OPERATION:-
Reaming is the operation of finishing
and sizing a hole which has been previously
drilled or bored. The tool used is called the
reamer, which has multiple cutting edges.
BORING OPERATION:-
Boring is the operation of enlarging
and truing a hole produced by drilling, punching,
casting or Forging. Boring cannot originate a
hole.

MILLING OPERATION:-
Milling is the operation of
removing metal by feeding the work against a
rotating cutter having multiple cutting edges.
GRINDING OPERATION:-
Grinding is the operation of
removing metal in the form of minute chips by
feeding the work against a rotating abrasive
wheel known as the grinding wheel.

SHAPING OPERATION :-
Shaping operation is intended
primarily to produce flat surfaces. These
surfaces may be horizontal, vertical, or
inclined.
PLANING OPERATION :-
A Planing operation is intended

primarily to produce flat surfaces and
capable of machining heavy work pieces
which cannot be accommodated on a shaper
table.
BROACHING OPERATION:-
Broaching is a method
of removing metal by pushing or pulling a cutting
tool called a broach which cuts in a fixed path.
The tool may be pulled or pushed through the
surfaces to be finished. Surfaces finished by
broaching may be flat or contoured and may be
either internal or external. broaching is generally
limited to the removal of about 6 mm of stock or
less.

MACHINING
• Lathe machine
• Drilling machine
• Milling machine
• Boring machine
• Shaping machine
• Planing machine
• Slotting machine
• Grinding machine
• Broaching machine
MACHINING
LATHE MACHINE
Function
• The main function of a lathe

is to remove metal from a
piece of work to give it the
required shape and size.
• This is accomplished by
holding the work securely and
rigidly on the machine and
then turning it against a cutting
tool which will remove metal
from the work in the form of
chips.

MACHINING
LATHE OPERATION
• Straight turning • Knurling

• Shoulder turning • Filing
• Taper turning • Polishing
• Eccentric turning • Grooving
• Chamfering • Spinning
• Thread cutting • Spring Winding
• Facing • Forming

MACHINING
• It produces circular surfaces, • It is not possible to produces

very easily with smooth finish. flat surfaces.
• Holding the work by a check • Each and every operation

or a faceplate of an angle separate tool is required.
plate possible to perform • Obtainable range of surface
drilling ,reaming, boring, roughness Ra 0.2-1.6 microns
counter boring, taper boring, with difficult 1.6-6.3 microns
internal thread cutting, normal 6.3-50 microns for
tapping, under cutting roughing.
parting-off.
• Tolerance grade obtained by
lathe machining processes
• By using special attachment is 7-13(IT grade) value 16i-
grinding and milling is also 250i, IT stands for ISO series
possible. of tolerance.

MACHINING
CAPSTAN AND TURRET LATHE
 Used for mass

production
 More Number of
tools(11) can be
positioned
Series of machining
operations can be
performed in a
regular sequence.
MACHINING
DIFFERENCE BETWEEN TURRET AND CAPSTAN LATHE
TURRET LATHE CAPSTAN LATHE
• It is suitable for light and heavy • It is suitable for light work.

works.
• Its main turret is mounted on
• Its main turret is mounted on a sub bed.
the bed.
• It has no support to hold the
• It has a support to hold the job. job.
• The main turret may be
• The main turret is operated operated manually.
automatically.

MACHINING
DRILLING
Functions
• In a drilling machine
holes may be drilled quickly
and at a low cost.
• The holes is generated by the
rotating edge of a cutting tool
known as the drill which exerts
large force on the work
clamped on the table.
• As the machine exerts vertical
pressure to originate a hole.

MACHINING
DRILLING MACHINE OPERATIONS
 Drilling  Tapping
 Reaming  Spot facing
 Boring  Lapping
 Counter boring  Trepanning
 Counter sinking

MACHINING
DRILLING
Advantages:
Limitations:
• In a drilling machine holes may be • It is not possible to produce
drilled quickly and at a low cost. precise holes.
• Portable drilling machining is • Obtainable range of surface
used for drilling holes in work roughness Ra3.2-6.3 microns with
piece in any position. difficult 6.3-25 microns normally.
• Sensitive drilling machine is used
for drilling small holes at high
speed in light jobs. • Tolerance grade obtained by
drilling machine processes is 10-
• Up right drilling machining is 13(IT grade) value 64i-250i.
used for drilling up to 50mm
diameter.
• Gang drilling machining is
suitable for large work piece to
drill no of holes at a time.
• Multi spindle drilling machine can
perform no of holes with the help
of single motor.
MACHINING
MILLING MACHINE
Function:
 A milling machine is a machine

tool that removes metal as the
work is fed against a rotating
multipoint cutter.
 The cutter rotates at a high
speed and because of the
multiple cutting edges it
removes metal at a very fast
rate.
 The machine can also hold one
or more number of cutters at a
time.

MACHINING
MILLING MACHINE OPERATIONS
Plain milling End milling

Face milling Saw milling
Side milling Milling Keyways
Straddle milling Grooves and slots
Angular milling Gear cutting
Gang milling Helical milling
Form milling Cam milling
Profile milling Thread milling.
MACHINING
MILLING
Limitations:
Advantages:
• It is not possible to produce
• It produces flat surfaces, very circular components.
easily with smooth finish.
• If a tooth is broken in multipoint
• It has multipoint cutter for cutter the entire tool is not useful
smooth finish. for cutting the material.
• Obtainable range of surface
• It is possible to perform more roughness Ra0.8-1.6 microns with
no of operations by using difficult 1.6-12.5 microns normal
vertical milling ,universal 12.5-50 microns for roughing.
milling, High speed milling,
slotting, universal spiral • Tolerance grade obtained by
milling, etc, milling machining processes
is 10-13(IT grade) value 64i-250i, .

MACHINING
BORING MACHINE
Functions:
 The boring
machine is one of the
most versatile machine
tools used to bore holes
in large and heavy parts
such as engine frames,
steam engine cylinders,
machine housings, etc.,

MACHINING
TYPES OF BORING MACHINES

Horizontal Boring Machine Vertical Boring Machine
Operations: Operations:
 Face Milling Operation  Machining flat surfaces
 Drilling Operation  Turning cylindrical surface
 Boring by tool head
 Boring by boring bar
 Cutting off and necking
operation
 Forming operation
 Taper boring operation
 Taper turning operation

MACHINING
BORING Limitations:
Advantages:  It is not economical and faster
 It accommodates the large when small quantities are to be
size jobs for boring machined.
operations.
 Boring is an operation to
 Quick return mechanism
makes the return stroke faster enlarge the previously drilled
than the cutting stroke thus hole not for drilling a hole.
time is saved for machining a
job.  Obtainable range of surface
 roughness Ra0.2-1.6 microns
Grinding head & Milling head
attachment also used. with difficult 1.6-6.3 microns
normal 6.3-50 microns for
 It is fit for mass production. roughing.
 It saves the time for
machining.  Tolerance grade obtained by
 It brings the production cost boring machining processes is
cheaper. 08-13(IT grade) 25i-250i.

MACHINING
JIG BORING MACHINE

Functions
 The jig boring

machines are
designed to produce
precision dies, gauge,
and jigs.

MACHINING
JIG BORING MACHINE OPERATIONS
 They can be used as a measuring machine to

check up a job already manufactured in other
machines.
 Boring tools are used for enlarging holes.
 Single point tools are preferred than multipoint

tools as a single point tools enables maximum
accuracy in locating holes and produces better
surface finish.
MACHINING
SHAPER MACHINE
Functions:
 The Shaper is a
reciprocating type of machine
tool intended primarily to
produce flat surfaces. These
surfaces may be horizontal,
vertical, or inclined.
 A shaper is a versatile
machine tool primarily
designed to generate a flat
surface by a single point
cutting tool.

MACHINING
SHAPER OPERATIONS
Machining Horizontal Surface

Machining Vertical surface
Machining angular surface
Cutting slots
Grooves and keyways
Machining irregular surface
Machining splines or cutting gears.

MACHINING
SHAPER
• It is suitable for small and • Only one tool can be used at

medium size jobs. a time.
• It is not economical and
• It has quick return faster when large quantities
mechanism 3:2. are to be machined.
• Obtainable range of surface
roughness Ra1.6-12.5
microns normally.
• Tolerance grade obtained by
shaper machining processes
is 10-13(IT grade) value 64i-
250i.
MACHINING
PLANING MACHINE
Functions
 A planer is very
large and massive
compared to a shaper
and capable of
machining heavy work
pieces which cannot be
accommodated on a
shaper table.

MACHINING
PLANER OPERATIONS
Planing flat horizontal surface

Planing vertical surfaces
Planing at an angle Machining dovetails
Planing curved surfaces
Planing slots and grooves

MACHINING
PLANER
 Planer is more economical  It is not suitable for small sized
and faster when large jobs.
quantities are to be
machined.  It is not economical when only
single component is loaded.
 More than one tool can be
used at a time.  Obtainable range of surface
roughness Ra 1.6-12.5
microns normally.
 It is suitable for large jobs.
 Tolerance grade obtained by
 The feed is not given to the planer machining processes
tool. is 10-13(IT grade) value 64i-
250i.

MACHINING
SLOTTING MACHINE
Functions
 The Slotting machine falls
under the category of
reciprocating type of machine
tools similar to a shaper or a
planner.
 It operates almost on the same

principle as that of a shaper.
 The ram can be swiveled not

more than 5 degrees to the
vertical.

MACHINING
SLOTTING OPERATIONS
Machining flat surface

Machining cylindrical surface
Machining irregular surface and cam
machining
Machining slot, keyways and grooves.

MACHINING
SLOTTING
• The ram can be swiveled not more than
5 degrees to the vertical. • Horizontal operations are not possible
because Slotter ram reciprocates vertically.
• The Slotter is used for cutting grooves,
Keyways and slots of various shapes, for • Tool is not released in return stroke.
making regular and irregular surfaces
both internal and external gears. • Slotter is not having longitudinal movement.
• Precision slotter is used for light cuts • Obtainable range of surface roughness
giving accurate finish. Ra0.4-1.6 microns with difficult 1.6-12.5
microns normal 12.5-100 microns for
roughing.
• Tolerance grade obtained by slotting

machining processes is
10-13(IT grade) value 64i-250i,.

MACHINING
GRINDING MACHINE
Function:
• Grinding is a metal cutting operation

performed by means of a rotating
abrasive wheel that acts as a cutting
tool.
• This is used to finish work pieces

which must show a high surface
quality, accuracy of shape and
dimension.
• Mostly grinding is the finishing

operation because it removes
comparatively little metal, usually 0.25
to 0.50mm in most operations and the
accuracy in dimensions is in the order
of 0.000025mm.

MACHINING
TYPES OF GRINDING
• Cylindrical grinding
• Internal Grinding
• Surface Grinding
• Centerless Grinding

MACHINING
CENTERLESS GRINDING AND SURFACE GRINDING

MACHINING
CENTERLESS GRINDING OPERATIONS

MACHINING
GRINDING

MACHINING
GRINDING
Limitations:
Advantages:
 By using dry grinding,
Wheel wears are rapidly, poor
 Grinding is used to finish surface finish and it makes the
work pieces which must surface hard.
show a high surface quality,
accuracy of shape and  Obtainable range of surface
dimension. roughness Ra0.025-0.4 microns
with difficult 0.4-3.2 microns
 normal 3.2-6.3 microns for
Grinding is also done to roughing.
machine materials which are
too hard for other machining  Tolerance grade obtained by
methods that use cutting cylindrical grinding machining
tools. processes is 05-07(IT grade)
value 7i-16i.
 By using wet grinding,
increases life of the wheel,  Tolerance grade obtained by
gives high surface finish, surface grinding machining
saves the time, brings the processes is 05-08(IT grade)
production cost cheaper. value 7i-25i,.
MACHINING
BROACHING MACHINE

MACHINING
BROACHING OPERATION
 Pull broaching operation.
 Push broaching operation.
 Surface broaching operation.
 Continuous broaching operation.

MACHINING
BROACHING
 High tool cost. A broach usually
 Rate of production is very high. does only one job and is
 Little skill is required to perform expensive to make and sharpen.
a broaching operation.  The surface to be broached
cannot be used for the removal of
 High accuracy and high class of a large amount of stock.
surface finish is possible. A  Broaching cannot be used for the
tolerance of 0.0075mm and a removal of a large amount of
surface finish of about 0.8 stock.
microns can be easily obtained
in broaching.  Obtainable range of surface
roughness Ra0.2-0.8 microns with
 Both roughing and finishing cuts difficult 0.8-3.2 microns normal
are completed in one pass of 3.2-6.3 microns for roughing.
the tool.  Tolerance grade obtained by
 The process can be used for broaching machining processes is
either internal or external 5-8 (IT grade) value 7i-25i,.
surface finishing.

MACHINING

MACHINING
PROCESS SHEET

MACHINING
PROCESS SHEET

MACHINING
PROCESS SHEET

MACHINING

MACHINING

MACHINING

MACHINING
NATURE OF RELATIVE MOTION FOR VARIOUS CUTTING OPERATIONS
OPERATION MOTION OF JOB MOTION OF CUTTING TOOL
Turning Rotary Forward translation
Boring Forward translation Rotary
Drilling Fixed Rotation as well as translatory

feed
Planing Translatory Intermittent
Milling Translatory Rotation


SHEET METAL
PRESS TOOL

SHEET METAL
 Blanking  Bending
 Piercing  Curling
 Slitting  Deep-drawing
 Cropping  Press-braking
 Trimming  Collar-drawing
 Shaving  Calibrating
 Lancing  Embossing

SHEET METAL
BLANKING
 Cutting required
shape in a strip of
blank.
 Punching are the
products.

SHEET METAL
PIERCING
 Cutting required
shape in a strip of
blank.
 Punching are
considered as
waste.

SHEET METAL
SLITTING
 Partial shearing of the
sheet

SHEET METAL
CROPPING
 Cutting off a part from
the stock strip without
cutting sides of the
blank.

SHEET METAL
TRIMMING
 Cutting of excess
stock from forged or
pressed component,
getting the exact
profile.

SHEET METAL
SHAVING
 Post cutting in
opposite direction to
the initial cut in order
to smoothen the side
s of a profile and to
achieve closer
tolerances.

SHEET METAL
LANCING
 Partial shearing and
bending.

SHEET METAL
BENDING
 Forming with a
bending tool.

SHEET METAL
 Bending operation
done by bending dies
or sliding presses.

SHEET METAL
DEEP-DRAWING
 Forming between
enclosed punch & die.

SHEET METAL
PRESS-BRAKING
 Bending of longer
profiles enabling as
series of bending
operations.

SHEET METAL
COLLAR-DRAWING
 Pushing a collar
through a pre-pierced
hole or profile.

SHEET METAL
CALIBRATING
 Repressing operation
on formed products in
order to achieve exact
sizes and forms.

SHEET METAL
EMBOSSING
 Changing the
thickness of the stock
without any
deformation on the
opposite side.

SHEET METAL
SHEET METAL ASSEMBLY

SHEET METAL
CLEARANCE BETWEEN PUNCH AND DIE
• Clearance=the measured
space between the
mating members of a die
set=c
• Clearance per side=c/2
• c=d-d1
• Clearance for Blanking &
piercing

SHEET METAL
CLEARANCE BETWEEN PUNCH AND DIE
Clearance per side(c/2)=0.01*s*100*(TB)½

where s= material thickness
TB=shear stress in kg/mm².
• Blanking: For a blank • Piercing: For a hole of

of definite diameter definite diameter,
Clearance should be clearance should be
on the punch. on the die.

SHEET METAL
CUTTING AND STRIPPING FORCE
• Cutting force (F) is the

force required to act on
the punch to cut a blank
or slug. It depends on the
shearing stress and
cutting area (A).
• F=A*fs in kgs.
• fs shear stress
• A=l*s=shear area
• S= material thickness
• l= total cutting length

SHEET METAL
CUTTING AND STRIPPING FORCE
• For diameter smaller

than stock strip
 *d * s *s
F
3 (d / s )
d  Dia of punch
σs  Tensile Strength
• Stripping force for
blanking and piercing
l * s * TB
F
10
SHEET METAL
WEB AND STEM
• The width of web and

stem depend on the
thickness of the material
to be cut and on the
length of the shear line.
s=1.5t
t=thickness of sheet

SHEET METAL
Advantages:
• Sheet metal work is Generally regarded as the
working of metal, from 16 gauge down to 30 gauge
Limitations:
with hand tools and simple machines into various
forms by cutting, forming into shape, and joining.
• More tonnage is required for thick
• It is used for mass production. components.
• By using punch and dies we can achieve different
critical shapes.
• Not suitable for single piece
• Cost of Labour, Material, Machine hour rate is production.
less.
• High dimensional accuracy can be achieved.
• Not suitable for batch production.
• Inter changeability is possible.
• Less weight and high strength.
• Initial cost of the tool is very high.
• Different type of tools are required

different component

SHEET METAL

SHEET METAL
Piercing & Blanking operation
1 Raw material 2
Bending operation Final bending

operation
3 4

SHEET METAL
Raw material notching & Blanking operation
1 2
Piercing operation Bending operation
3 4

SHEET METAL
Raw material Blanking operation
1 2
Bending operation Bending operation
3 4

Press_Tool1.exe
Progressive_tool.exe



JIGS AND FIXTURES
JIG
Jig
• A jig may be defined
as a device which
holds and locates a
work piece and
guides and controls
one of more cutting
tools.

JIGS AND FIXTURES
FIXTURE  A fixture holds and positions the

work but does not guide the tool,
whereas a jig holds, locates and as
well as guides the tool.
 The fixtures are generally heavier

in construction and are bolted
rigidly on the machine table,
whereas the jigs are made lighter
for quicker handling, and clamping
with the table is often unnecessary.
 The fixtures are employed for

holding work in milling, grinding,
planning, or turning operations,
whereas the jigs are used for
holding the work and guiding the
tool particularly in drilling, reaming
or tapping operations.

JIGS AND FIXTURES
POSITIONING OF A WORK PIECE

JIGS AND FIXTURES
 To eliminate the marking, measuring
and other setting methods  Expensive for manufacturing of few
components.
 To Increase the machining accuracy
 Chips are accumulate inside and
 To increase the production capacity
causes trouble unless provisions
 To reduce the operator’s labour are made for them.
 To improve the production quality  Only one surface can be drilled at
 To reduce the production cost one loading.
 To produce inter changeable  Shape and size of the jig and

parts fixtures are vary from component to
component.


SMITHY AND FORGING
SMITHING
Operation:
 Smithing is understood
to handle relatively small
jobs only such as can be
heated in an open fire or
hearth, and various
operations are performed
by means of hand
hammers or small power
hammers.

SMITHY AND FORGING
FORGING
Operation:
• Forging is the process by
which metal is heated and is
shaped by plastic deformation by
suitably applying compressive
force. Usually the compressive
force is in the form of hammer
blows using a power hammer or a
press.

SMITHY AND FORGING
PNEUMATIC HAMMER AND STEAM HAMMER

SMITHY AND FORGING
FORGING
• Metal can be forged to any • While forging it is necessary to

shape. heat the metal to correct
• Metal can be forged in short forging temperature. If it is
time without wasting. heated at too low temperature,
there is risk for formation of
• During forging strength and
cracks in the metal.
granular structure of steel can
be improved.
• The manufacturing cast of • If the metal is heated at too
forged parts is lesser than that high temperature, the metal
of machined parts. will loss its strength.

SMITHY AND FORGING


COLD WORKING & HOT WORKING PROCESS
 The cold and hot working processes can be distinguished by the

temperatures at which these processes are carried out.
 If mechanical working of metal is carried out at temperatures above
the lower critical temperature or the recrystallisation temperature
then it is known “hot working”.
 If the working metal is done below the recrystallisation temperature it

is “cold working” of metals.
 The refining of metal is done by heating the metal, leading to the

formation of the new grains with undistorted space lattice. This is
called “.recrystallisation”
 The temperature at which recrystallisation takes place is called

recrystallisation temperature


COLD WORKING OPERATIONS
 Drawing
 Bending
 Squeezing
 Shearing
 Extruding
 Shot peening
 Hobbing

COLD WORKING
• Accurate dimensional control • Higher pressure and heavier
can be obtained by cold equipments are needed.
working process.
• Only small sized components can
• no surface oxidation results in be easily cold worked, as for the
the process. larger sections, greater forces are
• smooth surface is obtained. required. Sections of more than
• for metals that do not respond 25mm diameter are rarely cold
to heat treatment, cold work is rolled.
a possible method to increase • As a shaping process it is limited
hardness. to ductile materials.
• the process is useful in forming • The grain structure is not refined
many articles by extrusion of and residual stresses have
ductile materials. harmful effects on certain
properties of metals.

HOT WORKING OPERATIONS
• Rolling
• Forging
• Piercing
• Drawing
• Spinning
• Extrusion

HOT WORKING
 Porosity in the metal is mostly  There is a rapid oxidation of the

eliminated.
surface due to high temperature
 Impurities in the form of of the metal which results in
inclusion are broken up and poor surface finish.
distributed through the metal.
 Fiber structure is obtained  Close tolerances can’t be
unidirectionally. obtained.
 Energy required to change the
 Tooling and handling cost is
shape is less when compared to high.
cold working.  Tool life is reduced as the tool
have to work at high
 Ductility and resistance to impact temperatures.
are improved and greater
homogeneity is developed in the
metal

PLASTICS
CLASSIFICATION OF PLASTICS
THERMOPLASTICS
 Low Density Polyethylene (LDPE)  Acetal

 Linear Low Density Polyethylene  ABS
(LLDPE)  Acrylic
 High Density Polyethylene (HDPE)
 Cellulosics
 High Molecular High Density
Polyethylene (HMHDPE)  Fep fluoroplastic
 Polypropylene (PP)  Nylon
 Polyvinylchloride (PVC)  Poly carbonate
 Polystyrene (PS)  San
 High Impact Polystyrene (HIPS)  PVC-Rigid
 Poly Methyl Methacrylate (PMMA)
 Polyurethane
 Surlyn (ionomer)
 Ethylene Vinyl Acetate (EVA)

PLASTICS
THERMOPLASTICS
• Alkyd-glass filled • Phenolic-flock filled

• Alkyd-mineral filled • Phenolic-glass filled
• Diallyl phthalate • Phenolic-fabric filled
• Epoxy glass • Phenolic-mineral filled
• Melamine-cellulise filled • Silicon glass
• Urea-cellulcse filled • Polyester premix
• Phenolic-general purpose

PLASTICS
PLASTIC MANUFACTURING PROCESS
 Injection molding
 Compression molding
 Transfer molding
 Blow molding
 Extrusion process
 Rotational moldings
 Thermo forming
 Calendaring

PLASTICS
INJECTION MOULDING
Principle
A mould in which a plasticized material is introduced from an
exterior heating cylinder into a cavity which gives the
component shape.

PLASTICS
TYPES OF INJECTION MOULDS
• Single impression injection mould

• Multi impression two plate injection mould
• Two plate injection mould
• Three plate injection mould
• Family mould
• Stack mould
• Split mould
• Side core &side cavity mould
• Internal undercut mould
• Unscrewing mould
• Runner less mould
• Hot runner mould
• Insulated runner mould

PLASTICS
PLASTICS
• Properties can be altered to suit • It cannot withstand for high
the needs loads
• Good strength/weight ratio • It is not useful for replacement of
• Tough and durable load bearing components
• Non toxic • Cannot withstand at high
• Easy process ability temperatures.
• Chemical/Moisture Resistant • Not preferable for machining
• Fire retardant process.
• Do not rust/corrode Collapsible_core.exe Unscrewing.exe Std_Stripper.exe Water_diverter.exe
• Resistant to microbes
• Attractive colors Spon_mould.exe Std_mould_with_slides.exe
Mould_with_ho_tip.exe Sensor.exe
• Good weather ability

• Practically maintenance free
• Reusable/Recyclable Jo-jo_d.exe Pressure_Meas.exe


CLASSIFICATION
HEAT TREATMENT
QUENCHING, SPHEROIDIZING
FULL ANNEALING
TEMPERING
CASE HARDNING NORMALISING
CASE CARBURISING NITRIDING
FLAME HARDNING INDUCTION HARDNING
SURFACE TREATMENTMENT
HEAT TREATMENT
HEAT TREATMENT
• Combination of heating and cooling operation in

a prescribed manner (with respect to time,
temperature and rate of heating and cooling) to
induce desired properties in a metals and alloys
in the solid state.
• The conventional heating for the hot working

does not come within the scope of heat
treatment.
HEAT TREATMENT
QUENCHING
Rapid cooling
FULL ANNEALING
Heating to and holding at some

temperature above the transformation
range, followed by cooling slowly
through the transformation range.
HEAT TREATMENT
CASE HARDENING
Hardening the surface by changing its
composition followed by , if necessary,
suitable heat treatment.
CARBURIZING (CASE CARBURIZING)
A process of introducing carbon into a
surface of a solid piece of steel by
heating and holding above the
transformation temperature in contact
with a suitable carbonaceous medium.
HEAT TREATMENT
FLAME HARDENING
Rapid heating of the surface by means
of an oxy-gas flame to a temperature
above the transformation range,
followed by immediate quenching.
HARDENING
Any process which increases the
hardness, for example, quenching from
or above the transformation range or
cold working.
HEAT TREATMENT
INDUCTION HARDENING
Process of hardening by induction heating to
the appropriate temperature and quenching in
suitable medium.
NITRIDING
A process of surface hardening by introducing
Nitrogen into the surface in a suitable steel by
heating and holding it at appropriate
temperature in contact with cracked ammonia
or other suitable nitrogenous medium.
HEAT TREATMENT
NORMALISING
 A process of heat treatment for improving
mechanical properties brought about by grain
refinement and uniformity in the structure.
 The process involves heating to and often

holding to a specified time at a suitable
temperature above the transformation range,
followed by cooling freely in the air.

HEAT TREATMENT
TEMPERING
 Heating to elevated temperature but

below transformation zone of hardened
steel and holding for specified time at
temperature followed by slow cooling to
develop desired mechanical properties
in these steels.

HEAT TREATMENT
SPHEROIDIZING
 A process of heat treatment to produce globular
form of carbide in steel and consists of prolonged
heating of steel to a suitable temperature within or near
the transformation range.
 This treatment improves Machinability and facilitates
finishing by cold work. It is also useful such structure is
desirable for future heat treatment in processing certain
materials.

HEAT TREATMENT
SURFACE TREATMENT
 Performed to improve mechanical or
physical properties of the work material.
 Part shape I not altered, except

unintentionally.

HEAT TREATMENT
Why surface treatment?
 Improves mechanical properties.

 Provide corrosion protection of the substrate
 Enhance product appearance e.g. color or
texture.
 Increase wear resistance and /or reduce
friction.
 Increase electrical conductivity or resistance.
 Nonmetallic materials are coated for:
-metallic appearance.
-antireflection coating.
-printed circuited boards.

HEAT TREATMENT
 Mechanical processes: steel

- peening, rolling, burnishing.
 Thermal surface treatment: steel
- case hardening, carbonizing.
 Anodizing: Al, Mg, Ti and Zin.
 Thermal spray coating
 Vapor deposition (coating).
- Physical vapor deposition (PVD)
-chemical vapor deposition (CVD)
 Electro plating.
 Plating.


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Engineering Centre India

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

CASTING METAL FORMING HEAT TREATMENT

Prepared by: Srinivas Rao .K Date : 25- Apr-07

SAND CASTING CENTRIFUGAL CASTING MOLTEN

DIE CASTING INVESTIMENT CASTING

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Chip-forming Process Chip-less Process

Prepared by: Srinivas Rao .K Date : 25- Apr-07

CASE CARBURISING NITRIDING

FLAME HARDNING INDUCTION HARDNING

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

COMPONENTS AND PATTERNS

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Factors Grey CI Steel Aluminium Brass

Brittleness High Low Low Low

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

• Single cavity to produce one

• Multiple cavity to produce a

• Unit die to produce different

• Combination die to produce

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

BASIC OPERATIONS OF CASTING

 Obtaining the casting geometry

Prepared by: Srinivas Rao .K Date : 25- Apr-07

• Difficulty in reclaiming used

Prepared by: Srinivas Rao .K Date : 25- Apr-07

DIE CASTING DIES

• Very high rate of production is • Not economical for small runs.

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

TYPES OF CENTRIFUGAL CASTING

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Chip-forming Process Chip-less Process

Prepared by: Srinivas Rao .K Date : 25- Apr-07

 Machining (Lathe,  Smithy and Forging

Prepared by: Srinivas Rao .K Date : 25- Apr-07

 Lathe operations,  Smithy and Forging

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

Prepared by: Srinivas Rao .K Date : 25- Apr-07

A Planing operation is intended

Prepared by: Srinivas Rao .K Date : 25- Apr-07

• The main function of a lathe

Prepared by: Srinivas Rao .K Date : 25- Apr-07

• Straight turning • Knurling

Prepared by: Srinivas Rao .K Date : 25- Apr-07

• It produces circular surfaces, • It is not possible to produces

• Holding the work by a check • Each and every operation

Prepared by: Srinivas Rao .K Date : 25- Apr-07