Manufacturing process for engineeringPPT

MANUFACTURING TECHNOLOGY-I
[ME6302]
III SEMESTER / II YEAR – ‘B’ SECTION
MECHANICAL ENGINEERING
[Academic Year: 2014-2015 – Batch: 2013-2017]

 ‘Manufacturing’ is derived from the Latin,
manus = hand and factus = made,
that is, the literal meaning is “made by hand”.
‘Manufacturing’ means the making of goods and articles by
hand and/or by machinery.
 ‘Manufacturing Technology’ or “Production Technology”
can be defined as the study of the various processes
required to produce parts and to assemble them into
machines and mechanisms.

 SAND CASTING
 Sand moulds
 Type of patterns
– Pattern materials
– Pattern allowances
 Moulding sand
– Types
– Properties
– Testing
 Core making
– Types
– Applications
 Moulding machines
– Types
– Application
 MELTING FURNACES
– Blast
– Cupola
 SPECIAL CASTING PROCESSES
– Shell
– investment casting
– Ceramic mould
– Lost Wax process
– Pressure die casting
– Centrifugal casting
– CO2 process
– Stir Casting
(Working principle)
 DEFECTS IN SAND CASTING

Cold curing CO2 Process
 To make good Quality castings
in large numbers.
 Binder – Pure dry silica sand +
Sodium silicate liquid
 Moisture content – Should not
exceed 3 %
 Additives – Sawdust about
1.5%, Asbestos powder – up to
5%, Graphite powder –
deformable & collapsible

 CO2 gas is passed through the core for 30 sec
at 140 KN/m2
.
 CO2 + Sodium silicate = Sodium carbonate +
Silica jell
 Silica jell binds the sand.

(MOULDING) SAND TESTING METHODS
1. Moisture content test
2. Clay content test
3. Grain fitness test
4. Permeability test
5. Strength test
6. Deformation or Toughness test
7. Hot strength test
8. Refractoriness test
9. Mould hardness test

(CORE) SAND TESTING METHODS
1. Green strength test
2. Baked strength test
3. Retained strength test
4. Core strength test
5. Moisture content test

MOULDING
Moulding is the process of making a mould
cavity by packing prepared moulding sand
around the pattern and removing the pattern
from the mould to form the mould cavity.
Types:
1.Green sand mould
2.Dry sand mould
3.Loam sand mould

MOULDING METHODS
1. Bench Moulding
2. Floor Moulding
3. Pit Moulding
4. Sweep Moulding
5. Plate Moulding

MELTING FURNACE
1. Cupola – CI
2. Open hearth – Steel
3. Crucible – Non-Ferrous
a) Pit type
b) Coke fired stationary
c) Oil fired tilting
4. Pot
5. Electric
a) Direct arc
b) Indirect arc
c) Induction

SPECIAL CASTING PROCESSES
1. Shell Mould Casting
2. Investment Casting
3. Ceramic Mould Casting
4. Lost Wax Process

5. Pressure Die Casting
1) Hot chamber Die Casting
2) Cold chamber Die Casting
6. Gravity Die Casting
7. Centrifugal Casting
8. Continuous Casting process

 5 to 10% - Phenolic resin mixed with fine dry silica
(Mixer – dry oil or presence of alcohol)
No water
 230 – 600◦
C
Release Agent – Silicone (sprayed over pattern)
Thickness of shell – time of contact of the mixture
with the heated pattern (Ex: 20-30 sec, 6 mm)
Then the mould is heated in an Oven at 300◦
C for 15-
60 sec.
After cooling &Solidification, the shells are broken or
shaken away from the castings.
Brake drums, Bushings, Cams, Cam shaft, rollers etc.,

Manufacturing process for engineeringPPT

PRESSURE DIE CASTING
PDC - HOT CHAMBER

GRAVITY DIE CASTING
(Permanent mold casting)

OTHER CASTING METHODS
• LOST WAX PROCESS
• CERAMIC MOULD CASTING

DEFECTS
1. Shrinkage
2. Blow holes
3. Scab
4. Swell
5. Hard Spots
6. Run out
7. Honey combing
8. Cracks
9. Shift
10. Cold Shut
11. Inclusions
12. Fins
13. Dress
14. Rat tail
15. Blister

INSPECTION METHODS
1. Visual Inspection
2. Pressure Test
3. Magnetic Particle Inspection
4. Dye-Penetrant Inspection
5. Radiographic Inspection
6. Ultrasonic Inspection
7. Thermography Inspection

(QB) ASSIGNMENT - I
Two Marks
1.What are the different types of patterns used in
foundry?
2.Define: Foundry, Casting, Mould, Pattern
3.Generally sweep patterns are used in _________
moulding.
4.What do you understand by core setting?
5.What is a core print? Mention its purpose.
6.Mention the specific advantages of CO2 process?
7.What are the properties of good moulding and core
sand.

7. Write the composition of good moulding sand
8. List out any five moulding tools.
9. What are chaplets?
10. List the factors to be considered in the choice of
metal melting furnaces.
11. What are the types of alloys cast in cold chamber
die casting machines?
12. What is the need for providing chills in casting?
13. Blow holes in castings occur due to ___________
14. How casting defects are identified?
15. Give any two casting defects and its reason and
remedies.

16 marks
1. What are the pattern allowances? Explain briefly
each.
2. Discuss the properties of moulding sand.
3. What are the different types of furnace used in
foundry? Describe in detail with neat sketches any two
of them.
4. State the different types of mould. Write a short
notes on ‘Green sand Mould’ and ‘Shell moulding’.
5. Explain briefly the various moulding methods used in
foundaries.
6. Describe the various types of casting process.

ASSIGNMENT – I
7. Explain various testing methods Moulding sand and
Core sand.
8. Enumerate the various casting defects and suggest
suitable remedies.
9. Explain various inspection methods of cast products.
5x2 = 10
3x16 = 48
58
Given Date: 07.08.2013 Last Date: 12.08.2013

Manufacturing process for engineeringPPT

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