BASIC MECHANICAL BASIC MECHANICAL ENGINEERINGENGINEERING

MANUFACTURING MANUFACTURING PROCESSESPROCESSES

MANUFACTURING PROCESSES

• Shaping Processes – Casting,

Forging, Rolling, Extruding etc.

• Machining processes – Turning,

Shaping, Drilling etc.

• Joining Processes – Welding,

Brazing, Soldering etc.

• Finishing Processes –

Electroplating, Galvanizing etc.

• Property Changing Processes –

Annealing, Normalizing etc.

CASTINGCASTING

CastingCasting - Process of Producing - Process of Producing

Metallic Parts by Pouring Molten Metallic Parts by Pouring Molten

Metal in to a Mould having a Metal in to a Mould having a

Cavity of the Part to be Cast and Cavity of the Part to be Cast and

then Allowing the Molten Metal then Allowing the Molten Metal

to Solidify.to Solidify.

MouldingMoulding – Process of Making a – Process of Making a

Mould Using a Pattern.Mould Using a Pattern.

PatternPattern – A Model or Replica of – A Model or Replica of

the Part to be Cast.the Part to be Cast.

CASTING

• Sand Mould Casting – Molten

Metal is Poured in to the Cavity

of the Mould without Applying

External Pressure (Gravity

Feed).

• Permanent Mould Casting -

Gravity Die Casting

• Die Casting – Molten Metal is

Forced under very high

Pressure in to the Die (Metallic

Mould).

– Hot Chamber Die Casting

– Cold Chamber Die Casting

CASTING

CASTING

CASTING

FORGINGFORGING

• Hot Forging – Changing the Shape

of Metals, when it is in Plastic, by

Applying Compressive Force.

• Cold Forging - Changing the Shape

of Metals, when it is at Room

Temperature, by Applying Large

Compressive Force.

– Hand Forging

– Drop Forging (Closed Die Forging)

– Press Forging (Open Die Forging)

– Machine Forging

Examples: Upsetting, Drawing,

Bending, Welding, Cutting,

Punching, Swaging etc.

ROLLINGROLLING

• Forming Metals in to Desired Forming Metals in to Desired

Shapes by Passing the Metal in Shapes by Passing the Metal in

between a Pair of Rolls.between a Pair of Rolls.

– Two High MillTwo High Mill

– Three High MillThree High Mill

– Four High MillFour High Mill

– Cluster MillCluster Mill

WELDINGWELDING

• Electric Resistance Welding – Electric Resistance Welding –

Mechanical Pressure Applied while Mechanical Pressure Applied while

a Strong Current Passes through a Strong Current Passes through

the Metalthe Metal

– Spot Welding (Lap Welding)Spot Welding (Lap Welding)

– Butt WeldingButt Welding

– Flash WeldingFlash Welding

– Seam WeldingSeam Welding

• Arc WeldingArc Welding

• Gas Welding – CommonlyGas Welding – Commonly Using Using

Oxy Acetylene FlameOxy Acetylene Flame

EXTRUSIONEXTRUSION

• Forming Products of Uniform Forming Products of Uniform

Cross Sectional Shapes in Cross Sectional Shapes in

Convenient Length, by Convenient Length, by

Compressing the Metal inside a Compressing the Metal inside a

Chamber and Forcing it Chamber and Forcing it

through a Die.through a Die.

– Direct Extrusion (Forward Direct Extrusion (Forward

Extrusion)Extrusion)

– Indirect Extrusion (Backward Indirect Extrusion (Backward

Extrusion)Extrusion)

SOLDERING - BRAZINGSOLDERING - BRAZING

• Soldering – Joining Metals by

Using Another Metal or Alloy

(Solder) Heated, by a Soldering

Iron Using Electric Current, to

its Melting Point.

• Brazing – Making Joints Using a

Filler Material (Brazing Solder –

Mixture of Copper, Zinc and

Tin) Heated to its Melting Point