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    Lecture 6-Common Manufaturing Processes I

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    Kamal Suren
    This document provides an overview of various manufacturing processes, including casting, moulding, forming, machining, powder metallurgy, joining, surface treatments, and additive manufacturing. It describes casting and moulding as near-shape processes where a material is brought to a fluid state and poured into a cavity to take the shape. Common casting methods like sand casting, die casting, and lost wax casting are listed. Requirements for the casting process including mould cavity, melting, pouring, solidification, and cleaning are outlined. Injection moulding, blow moulding, compression moulding, and transfer moulding are described as key plastic moulding techniques.

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    Lecture 6-Common Manufaturing Processes I

    Uploaded by

    Kamal Suren
    13 views29 pages
    This document provides an overview of various manufacturing processes, including casting, moulding, forming, machining, powder metallurgy, joining, surface treatments, and additive manufacturing. It describes casting and moulding as near-shape processes where a material is brought to a fluid state and poured into a cavity to take the shape. Common casting methods like sand casting, die casting, and lost wax casting are listed. Requirements for the casting process including mould cavity, melting, pouring, solidification, and cleaning are outlined. Injection moulding, blow moulding, compression moulding, and transfer moulding are described as key plastic moulding techniques.

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    This document provides an overview of various manufacturing processes, including casting, moulding, forming, machining, powder metallurgy, joining, surface treatments, and additive manufacturing. It describes casting and moulding as near-shape processes where a material is brought to a fluid state and poured into a cavity to take the shape. Common casting methods like sand casting, die casting, and lost wax casting are listed. Requirements for the casting process including mould cavity, melting, pouring, solidification, and cleaning are outlined. Injection moulding, blow moulding, compression moulding, and transfer moulding are described as key plastic moulding techniques.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    13 views29 pages

    Lecture 6-Common Manufaturing Processes I

    Uploaded by

    Kamal Suren
    This document provides an overview of various manufacturing processes, including casting, moulding, forming, machining, powder metallurgy, joining, surface treatments, and additive manufacturing. It describes casting and moulding as near-shape processes where a material is brought to a fluid state and poured into a cavity to take the shape. Common casting methods like sand casting, die casting, and lost wax casting are listed. Requirements for the casting process including mould cavity, melting, pouring, solidification, and cleaning are outlined. Injection moulding, blow moulding, compression moulding, and transfer moulding are described as key plastic moulding techniques.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 29

    5505ICBTME

    Automotive Materials & Manufacturing Processes

    Lecture 6-Manufacturing
    Processes-I
    Definition
    What is Manufacturing?
    • Make?? OR Technology??
    Make? One or Few items, usually designer himself is
    the maker. Often made by craftsmen with their
    technical knowhow. Use hand or power operated
    hand tools / simple machinery and equipment.
    Technology ? Often traditional. No separate or
    documented designs. May modify the design while
    making. Only one person or small group involved
    Manufacturing Process
    • The term process can also refer to a sequence of
    steps, processes, or operations for production of
    goods and services.
    • A manufacturing process converts unfinished
    materials to finished products, often using
    machines or machine tools.
    • Basic Manufacturing and Assembly Processes
    depend on several Factors : Materials used, Shape
    and Dimensions, Number of pieces required
    • Final or near final (Near shape) may be obtained in
    ONE operation, or may need SEVERAL operations
    Common Manufacturing Processes
    • Casting & Moulding Processes
    • Forming or Metalworking processes
    • Machining (material removing) processes
    • Powder Metallurgy
    • Nano, micro and nontraditional processes
    • Joining and Assembly
    • Surface treatments (Finishing)
    • Additive manufacturing or 3D printing
    • Heat treating & other
    Casting & Moulding Processes
    Moulding, casting and similar processes can
    be classified as ‘near shape processes’ as the
    product is obtained in its final form or shape,
    or very close, with very little or no further
    processing needed to get the final dimensions
    In casting and moulding processes the
    material is brought to a fluidic state, either to
    liquid or plastically flowing, and made to
    obtain its final shape inside a cavity of
    required shape
    Casting
    • Materials brought to a fluidic state; Transferred in to a cavity
    made to the required final shape of the product, allow
    material to harden or solidify within that cavity
    • The cavity made to the required shape of the product is
    called the ‘Mould’. Mould is made in a manner to withstand
    not only the temperatures involved but also the stresses
    • basically involves pouring of molten metal into a mold cavity
    where, upon cooling down & solidification, it takes the
    shape of the cavity
    Methods of converting materials into the
    fluidic state

    • Melting
    • Mixing of two or more materials is the
    other method of achieving the required
    fluidic state of materials.
    • Cast products are used in Automobile
    industry Ship-building industry, Aerospace
    industry, Manufacturing industry and
    Household appliances

    • Types of material used for casting:


    Ferrous metals:- Cast iron, Wrought iron, Alloy cast
    iron, Steel, etc.
    Non-ferrous metals:- Copper alloys, Aluminium
    alloys, Magnesium alloys, Tin alloys, et
    Basic Requirements of casting process
    1. Mould Cavity: Should be in desired shape &
    size, ability to compensate for shrinkage of the
    solidifying metal, ability to reproduce the
    desired detail

    Expandable Mould (a): Made of sand, plaster or ceramics.


    After the solidification, the mould is broken up to remove the
    casting. Prefer for small quantity production
    Permanent Mould (b): Made of metals to use repeatedly.
    Designed in such a way that the casting can be easily
    removed. Prefer for large quantity production
    Composite Mould (c): Made of two or more different
    materials such as sand, graphite & metal
    (a)

    (b)

    (c)
    2. Melting Processes:- Providing molten metal
    at the proper temperature with desired
    quantity, acceptable quantity and
    reasonable cost
    3. Pouring Techniques: Escapes of all air or gases
    in the mould
    4. Solidification Process: Proper heat removal rate
    is required and shrinkage must be compensated
    5. Mould Removal: Mould is destroyed or
    either retained

    6. Cleaning, Finishing & Inspection: Extraneous


    material removal with minor finishing operations
    and inspection of cast defects
    Types of Casting
    • Sand casting
    • permanent metal casting (g)Lost wax casting

    • die casting
    • lost wax or investment
    • shell
    • centrifugal
    • plaster
    (e)Centrifugal
    casting
    (f)Plaster casting
    (d) Shell
    casting
    Limitations in Casting
    • Surface finish & dimensional accuracy.
    • Limitations in toughness & strength.
    • Limitations in making thin & complex structures.
    • Shrinkage & porosity.
    • Casting defects
    Limitations to selection of materials
    ❖ Fluidity
    ❖ Shrinkage
    ❖ Ease with which properties can be controlled
    Moulding
    • Hot viscous liquids (plastics, glass,ceramics) under
    considerable pressure are pressed or injected into a mould
    or die where they cool and become rigid enough to be
    handled.
    • When plastics are heated they soften and become formable
    but if the temperature is further increased instead of
    becoming fluidic it will get decomposed, often known as
    burning or charring

    • Therefore, plastics have to be formed in its semi fluidic state.


    Basic requirements of Molding
    1.Mould Cavity:
    A hollow cavity and made of metal.
    Main objective is to reproduce multiple uniform copies of
    the final product
    2.Melting Process:
    In plastic molding, melt temperature must be carefully
    monitored throughout the molding process

    Other requirements are same as in casting


    Types of Molding

    • Injection moulding
    • Blow moulding
    • Compression moulding
    • Transfer moulding
    • Rotational moulding
    • Thermoforming
    Injection Moulding
    • Injection Moulding is a process used for forming a
    Thermoplastic to a required shape inside a mould.
    Heated material at softened or ‘Plastic’ state is
    forced in to the mould cavity by high pressure
    injection.

    • The material is injected under pressure into the die


    cavity at its plastic or softened state.
    Injection Moulding
    • It is commonly used for making very high
    volume custom plastic parts.

    • Large injection molding machines can mold


    car parts.

    • Injection molds are usually made from steel


    or aluminum
    Blow Moulding
    • Blowmolding is a method of making hollow, thin-walled,
    custom plastic parts. It is primarily used for making
    products with a uniform wall thickness and where the
    shape is important.
    • The machine heats up the raw plastic until it becomes
    liquid and injects air like a balloon.

    • The plastic is blown into a shaped mould, and as it gets


    bigger, it presses against the walls and starts to
    take shape. After the liquid balloon fills the mould it is
    cooled to keep its shape.

    • Uses:
    Bottles
    Fuel tanks
    Traffic cones
    Watering cans
    Compression Moulding
    • A plastic material is placed into a heated mold and
    then pressed into a specific shape. Usually, the
    plastic comes in powder state, but can also be in
    bulk.
    • Once the plastic is compressed into the right shape,
    the heating process ensures that the plastic retains
    maximum strength.
    • The final steps in this process involve cooling,
    trimming, and then removing the plastic part from
    the mold
    • Uses: Automotive parts, hoods & fenders, scoops &
    spoilers, and smaller auto parts
    Transfer Moulding
    • Transfer molding is similar to compression molding

    • The difference is, instead of loading the polymer


    into an open mold, the plastic material is pre-
    heated and loaded into a holding chamber called
    the pot.

    • The material is then forced/transferred into the


    pre-heated mold cavity by a hydraulic plunger
    through a channel called sprue. The mold remains
    closed until the material inside is cured.
    THANK YOU!!!

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