A TEXT BOOK OF

MANUFACTURING PROCESS – I FOR SEMESTER - I

SECOND YEAR DEGREE COURSE IN MECHANICAL AND AUTOMOBILE ENGINEERING Strictly According to New Revised Credit System Syllabus of Savitribai Phule Pune University (w.e.f June 2016) (Also Useful for SE Production and Industrial Engineering)

Manoj V Mugale

Dr. Manmohan M. Bhoomkar

M.Tech. (Mfg. Tech.) NIT, Trichy

Ph.D. (Mech. Engg.)

Assistant Professor,

Associate Professor,

Mech. Engg. Deptt.,

Mech. Engg. Deptt.

NBN Sinhgad School of Engineering. Ambegoan (Bk), Pune.

PVG’s College of Engineering & Technology, Pune.

N3535

Manufacturing Process – I (SE MECH. & AUTO. ENGG) Second Edition ©

: :

ISBN 978-93-86084-09-5

June 2017 Authors

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PREFACE TO THE SECOND EDITION We are glad and excited to announce that the First Edition of this book received an overwhelming response from the engineering student community, compelling us to release its Second Edition within a very short period of time. This thoroughly revised Second Edition has been updated with additional matter, many solved problems, including solutions to Numerous Exercises and University Question Papers (December 2013 to May 2017) for practice. Special care has been taken to maintain high degree of accuracy in the theory and numericals throughout the book. We take this opportunity to express our sincere thanks to Dineshbhai Furia of Nirali Prakashan, a reputed pioneer in the publication field. Our special thanks to Jignesh Furia for their effective cooperation and great care in bringing out this revised edition. We also appreciate the efforts of M. P. Munde and the entire staff of Engineering Books Deptt. of Nirali Prakashan namely Mrs. Deepali Lachake (Co-ordinator) for bringing this book to the students in a timely manner. We sincerely hope that this "Second Edition" will also be warmly received by all concerned as in the past. Valuable suggestions from our esteemed readers to improve the book are most welcome and highly appreciated.

Pune

Authors

PREFACE TO THE FIRST EDITION It gives us great pleasure in publishing this text book on "Manufacturing Process – I" for the students of Second Year Degree Course in Mechanical and Automobile Engineering. This book is strictly written According to New Revised Credit System Syllabus of Savitribai Phule Pune University (2015 Pattern). As per the policy of the University, Engineering Syllabi is revised every five years. Last revision was in the year 2012. New revision is coming little earlier, as university has introduced Online system of examination from year 2012. As per the New Credit System, the In Sem (Online – 50 Marks) Examinations (Combined Phase-I and Phase-II) will be conducted based on first, second, third and fourth units. The Online examinations will have objective types of questions with multiple choices. End Semester Examination (Theory Paper 50 Marks) will be based on all the six units and that will be conducted in traditional way and the theory course will have credits. We have given Free Separate book of Multiple Choice Questions (MCQ’s) which will be very useful to the students, especially for Online Examinations. We express, our sincere thanks to our colleagues, Prof. Dr. A. K. Bewoor and Prof. A. A. Bhosale for providing necessary input for writing of this book. We take this opportunity to express our sincere thanks to Shri. Dineshbhai Furia, Shri. Jignesh Furia, MRs. Nirali Verma and Shri. M. P. Munde and entire team of Nirali Prakashan namely Mrs. Deepali Lachake (Co-ordinator), Mr. Bharat Jadhav who really have taken keen interest and untiring efforts in publishing this text. Finally, we express our gratitude to our family members for their continuous support and encouragement, thanks to all. We have no doubt that like our earlier texts, student's community will respond favourably to this new venture. The advice and suggestions of our esteemed readers to improve the text are most welcomed, and will be highly appreciated.

17th June 2016 Pune

Authors

SYLLABUS Unit I: Casting Processes

(9 Hrs)

SAND CASTING – Pattern- types, material and allowances, Molding sand- types, properties and testing, Molding – types, equipment’s, tools and machines, Core – types and manufacturing, Gating system and Riser – types and design (Numerical), Heating and pouring, cooling and solidification- process and time estimation (Numerical), Cleaning and Finishing, Defects and remedies, Inspection techniques. Die casting, Investment casting, Centrifugal Casting, Continuous Casting- Types, equipment, process parameters, material to cast. Unit II: Metal Forming Processes

(8 Hrs)

Hot and Cold Working – Concepts and comparative study, Material behavior in metal forming, strain rate sensitivity, friction and lubrication in metal forming Rolling – Types of rolling mills, flat rolling analysis, power required per roll for simple single pass two rollers. (Simple Numerical) Forging – Types, process parameter, Analysis of open die forging (Numerical) Extrusion – Types, process parameter, Extrusion dies, Shape factor (Numerical), Drawing – Wire drawing and its analysis (Numerical), tube drawing Unit III: Plastic Processing

(6Hrs)

Molding – Compression molding, Transfer molding, Blow molding, Injection molding – Process and equipment. Extrusion of Plastic – Type of extruder, extrusion of film, pipe, cable and sheet Thermoforming – Principle, pressure forming and vacuum forming. Unit IV: Joining Processes

(6Hrs)

Surface preparation and types of joints. Welding Classification Arc welding – Theory, SMAW, GTAW, FCAW, Submerged arc welding, Stud welding. Resistance welding – Theory, Spot, seam and projection weld process. Gas welding. Soldering, brazing and braze welding. Joint through Adhesive – classification of adhesive, types of adhesive, applications. Weld inspection, Defects in various joints and their remedies. Unit V: Sheet Metal Working

(7Hrs)

Types of sheet metal operations, Types of dies and punches, material for dies and punches, Die design for Progressive and Drawing Die, clearance analysis, center of pressure, blank size determination (Numerical), strip layout, sheet utilization ratio (Numerical), method of reducing forces Unit VI : Centre Lathe

(7Hrs)

Introduction to centre lathe, types of lathe, construction and working of lathe, attachments and accessories, various operations on lathe, taper turning and thread cutting methods (numerical), machining time calculation (numerical)

CONTENTS

Unit I: Casting Processes

1.1 – 1.56

1.1

Introduction

1.1

1.2

Terminology Used in Casting

1.2

1.2.1

1.3

Gating System

1.3

Patterns

1.4

1.4

Pattern Materials

1.4

1.5

Types of Pattern

1.6

1.6

Pattern Allowances

1.11

1.7

Core

1.13

1.8

1.9 1.10

1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19

1.7.1

Types of Core

1.13

1.7.2

Core Box

1.16

1.7.3

Color Codification for Patterns and Core Boxes

1.18

Gating System

1.18

1.8.1

Functions of Gating System

1.19

1.8.2

Parts/ Elements of Gating System

1.19

Moulding Sand

1.21

1.9.1 Constituents of Moulding Sand Moulding Sand/Foundry Sand 1.10.1 Types of Moulding Sands 1.10.2 Important Characteristics of Sand 1.10.3 Properties of Moulding Sands 1.10.4 Sand Testing Methods and Sand Testing Equipment The Mold 1.11.1 Mould Making Machine Moulding Heating, Pouring, Solidification and Cleaning Casting Quality 1.14.1 Defects in Casting Investment Casting/ Lost Wax Casting Die Casting 1.16.1 Two Main Types Continuous Casting Centrifugal Casting Gating System Design • Solved Examples • Exercise • University Questions

1.21 1.22 1.23 1.24 1.24 1.26 1.28 1.28 1.30 1.32 1.35 1.35 1.40 1.42 1.42 1.44 1.46 1.47 1.49 1.54 1.55

Unit II: Metal Forming Processes

2.1 – 2.40

2.1

Introduction

2.1

2.1.1

2.2

Recrystallisation Temperature

2.2

Hot Working

2.3

2.3

Cold Working Process

2.4

2.4

Material Behavior in Metal Forming

2.5

2.5

Rolling

2.8

2.6

2.7

2.8

2.9

2.5.1

Rolling Mills

2.9

2.5.2

Shape Rolling

2.13

2.5.3

Thread Rolling

2.13

2.5.4

Ring Rolling

2.13

Analysis of Flat Rolling

2.14

2.6.1

Assumptions in Rolling

2.15

2.6.2

Backward Slip (Slip in Lagging Zone)

2.16

•

Solved Examples

2.18

Forging

2.19

2.7.1

Types of Forging

2.19

2.7.2

Classification

2.20

2.7.3

Closed Die-Forging Operations

2.24

2.7.4

Die Materials and Lubrication for Forging

2.25

2.7.5

Lubrication

2.25

2.7.6

Defects in Forging

2.26

2.7.7

Other Operations

2.27

2.7.8

Analysis of Forging

2.27

•

Solved Examples

2.28

Extrusion

2.29

2.8.1

Classification of Extrusion Processes

2.30

2.8.2

Impact Extrusion

2.32

2.8.3

Hydrostatic Extrusion

2.33

2.8.4

Analysis of Extrusion

2.33

2.8.5

Defects in Extrusion

2.34

•

Solved Examples

2.35

Drawing Process

2.37

•

Exercise

2.39

•

University Questions

2.40

Unit III: Plasting Processing

3.1 – 3.18

3.1 3.2

3.3

3.4

Introduction

3.1

3.1.1

3.2

Types of Plastic

Moulding

3.3

3.2.1

Compression Moulding

3.3

3.2.2

Transfer Moulding or Gate Moulding

3.5

3.2.3

Injection Moulding

3.6

3.2.4

Blow Moulding

3.8

3.2.5

Extrusion Blow Moulding

3.8

Extrusion of Plastics

3.10

3.3.1

Film Extrusion

3.11

3.3.2

Pipe Extrusion

3.12

3.3.3

Wire/Cable Extrusion

3.12

3.3.4

Sheet Extrusion-Calendaring

3.13

Thermoforming

3.13

3.4.1

Vacuum Thermoforming

3.14

3.4.2

Pressure Thermoforming

3.15

3.4.3

Mechanical Thermoforming

3.16

•

Exercise

3.17

•

University Questions

3.17

Unit IV: Joining Processes

4.1 – 4.26

4.1

Introduction

4.1

4.2

Welding Processes

4.1

4.3

Types of Welding Processes

4.1

4.4

Classification of Welding Processes

4.2

4.5

Types of Weld Joint

4.3

4.6

Edge Preparation Methods

4.3

4.7

Types of Welds

4.4

4.8

Welding Processes

4.5

4.9

ARC Welding Processes

4.7

4.9.1

Process using Consumable Electrodes

4.7

4.9.2

Processes using Non-Consumable Electrodes

4.9

4.10 Gas Welding Process (Oxy-Acetylene)

4.11

4.10.1 Types of Gas Flames

4.12

4.10.2 Gas Welding Techniques

4.13

4.11 Electric Resistance Welding (ERW)

4.15

4.11.1 Classification Electric Resistance Welding Processes

4.15

4.12 Inspection of Welds

4.18

4.13 Soldering and Brazing

4.19

4.13.1 Soldering

4.19

4.13.2 Brazing

4.20

4.14 Welding Defects

4.22

4.15 Adhesive Bonding

4.23

4.15.1 Adhesives: Types and Classification: Types

4.23

4.15.2 Desirable Properties of Adhesives

4.23

•

Exercise

4.24

•

University Questions

4.25

Unit V: Sheet Metal Working

5.1 – 5.40

5.1

Introduction

5.1

5.2

Press Working Terminology

5.1

5.3

Mechanism of Metal Cutting

5.3

5.4

Metal Cutting Operations

5.3

5.5

Types of Dies

5.9

5.6

Presses for Sheet Metal Working

5.13

5.6.1

Classification of Presses

5.13

5.6.2

Specifications and Attributes of a Press

5.15

5.7 5.8 5.9

Design of Press Tools

5.15

5.7.1

5.15

Requirements of Press Tool Design

Strip Layout

5.16

5.8.1

5.17

Clearance

Cutting Forces

5.18

5.9.1

5.19

Methods of Reducing Cutting Forces

5.10 Blanking Die Design

5.20

5.10.1 Die Block

5.20

5.10.2 Die Opening

5.21

5.10.3 Fastening of Die Block

5.21

5.10.4 Punch

5.21

5.11 Centre of Pressure

5.22

5.11.1 Pilots

5.23

•

Solved Examples

5.22

5.12 Drawing Operations and Design of Dies

5.24

5.12.1 Deep Drawability 5.13 Design of Die

5.25 5.25

5.13.1 Number of Draws Required in Drawing 5.13.2 Determination of Blank Size for Drawing 5.13.3 Force Required in Drawing Operation • Solved Examples • Exercise • University Questions Unit VI: Centre Lathe 6.1 Introduction 6.2 Types of Lathe 6.2.1 Bench Lathe 6.2.2 Engine Lathe 6.2.3 Turret Lathes and Capstan Lathe 6.2.4 Toolroom Lathe 6.2.5 Computer Numerical Controlled Lathe 6.3 Construction of Lathe Machine 6.3.1 Introduction to Lathe Parts 6.4 Work Holding Devices/ Accessories of Lathe 6.4.1 Rests 6.4.2 Angle Plate 6.5 Operations Performed on a Lathe 6.5.1 Facing 6.5.2 Turning 6.5.3 Chamfering 6.5.4 Grooving 6.5.5 Forming 6.5.6 Knurling 6.5.7 Undercutting 6.5.8 Taper Turning 6.5.9 Thread Cutting 6.5.10 Apron Mechanism of a Lathe 6.6 Cutting Speed, Feed and Depth of Cut 6.7 Machining Time • Solved Examples • Exercise • University Questions

5.26 5.26 5.27 5.27 5.36 5.37 6.1 – 6.32 6.1 6.1 6.1 6.1 6.1 6.3 6.3 6.3 6.4 6.7 6.12 6.12 6.12 6.13 6.13 6.14 6.14 6.15 6.15 6.16 6.16 6.19 6.20 6.22 6.22 6.22 6.29 6.30

•

Model Questions Papers

MQP. 1 – MQP. 2

•

Solved University Question Papers

UQP. 1 – UQP. 12

•

University Question Papers (November 2016 to May 2017)

P. 1 – P. 4

Unit I

CASTING PROCESSES 1.1 INTRODUCTION Foundry is a process of producing metal castings. Casting is a process in which molten metal flows into a mold where it solidifies in the shape of the mold cavity. The part produced is also called casting. Casting is an operation of shaping metal by pouring it in the liquid state into a mold followed by solidification. •

Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods.

In some cases casting is the only method of shaping a metal or alloy: when the alloy is not malleable and therefore it’s plastic deformation is not possible or when a large detail of complex shape is to be produced. Advantages Casting process is useful for: Complex shapes Net-shape ability Very large parts Variety of metals Mass production Disadvantages Poor accuracy Poor surface Internal defects Mechanical properties Environmental impact •

Applications Big Parts: Engine blocks and heads for automotive vehicles, Wood burning stoves, Machine frames, Railway wheels, pipes, jet engine blades, Big statues, and pump housings Unit I | 1.1

MANUFACTURING PROCESS – I (SE MECH. SEM - I)

CASTING PROCESSES

Small Parts: Dental crowns, Jewelry, Small statues, Frying pans and Cameras Classification of Casting based on the mould type. Expendable Mold Processes Uses an expendable mold which must be destroyed to remove casting Mold materials: sand, plaster and ceramic Permanent Mold Processes Uses a permanent mold which can be used many times to produce many castings Mold materials: Made of metal Sand Casting •

Sand casting, the most widely used casting process, utilizes expendable sand molds to form complex metal parts that can be made of nearly any alloy.

•

The sand casting process involves the use of a Gating system, furnace, metal, pattern, sand mold etc

•

Sand casting has a low production rate.

1.2 TERMINOLOGY USED IN CASTING The casting process uses the following specialized terminology: Pattern: It is the replica of the final object to be made. Pattern is used to create mould cavity. Core: A separate part of the mould made of sand which is placed in mould to create openings and various shaped cavities in the castings. Core Print: The core has to be properly located or positioned in the mould cavity on preformed recesses or impressions in the sand Flask (Mould box): A metal or wood frame/container, without fixed top or bottom which is used to create the mould. Mould: In sand casting, the primary piece of equipment is the mould, which contains several components. The Mould is Divided into Two Halves: The cope (upper half) and the drag (bottom half), which meet along a parting line. Parting Line: The interface between the cope and drag halves of the mould, flask, or pattern. Mould Cavity: The mould cavity is formed by packing sand around the pattern in each half of the flask. The mould cavity is made with the help of pattern. Unit I | 1.2

MANUFACTURING PROCESS – I (SE MECH. SEM - I)

CASTING PROCESSES

1.2.1 Gating System It is used to feed the molten metal. It consists of pouring basin, sprue, runner, gates, riser etc. Pouring base/cup

Vent

Through riser Cope Molding flax

Sprue

Parting line Core print

Clamping pins

Drag

Runner

Mold Ingate Core (molding) cavity (gate)

Fig. 1.1: Gating system

Pouring Basin/ Cup (Feeder): A small funnel shaped cavity at the top of the mould into which the molten metal is poured. Sprue: The vertical passage through which the molten metal, from the pouring basin, reaches the mold cavity. In many cases it controls the flow of metal into the mold. Runner: The horizontal channel through which the molten metal is carried from the sprue to the gate. Ingate/Gate: A channel through which the molten metal enters in to the mold cavity. Riser/ Feed Head: A column of molten metal placed in the mold to feed the castings as it shrinks and solidifies. Steps in Sand Casting Following diagram shows various steps in sand casting. Molding

- Pattern making

1

- Core making

2

- Gating system 5

4 Sand

Melting of metal 6

Mold

Pouring into mold 7

Furnaces

3

Solidification

Casting

Heat treatment

8 Shakeout removal of risers and gates

Fettling 10 Cleaning and finishing 9 Additional heat treatment

Fig. 1.2: Steps in sand casting Unit I | 1.3

Inspection

Defects pressure tightness dimensions

310