BASIC MECHANICAL ENGINEERING. MANUFACTURING PROCESSES.
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Transcript of BASIC MECHANICAL ENGINEERING. MANUFACTURING PROCESSES.
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BASIC MECHANICAL BASIC MECHANICAL ENGINEERINGENGINEERING
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MANUFACTURING MANUFACTURING PROCESSESPROCESSES
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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.
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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.
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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
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CASTING
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CASTING
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CASTING
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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.
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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
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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
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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)
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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