metal casting processes mine.pptx

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    Course Title

    Manufacturing Process (MP)

    Instructor Name: Muhammad Amjad

    Designation: Assistant Professor

    Email: [email protected]

    mailto:[email protected]:[email protected]
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    Manufacturing Processes-Course Outline

    1. Casting Processes

    2. Bulk Deformation Processes

    3. Joining Processes

    4. Plastic Shaping Processes

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    Recommended Books

    1. Fundamentals of Modern Manufacturing, Materials,

    Processes and Systems by Groover.

    2. Manufacturing Engineering and Technology by

    Kalpakjian, Shmid

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    What is manufacturing???

    Manus-hand

    Factus-make

    Technologic definition

    Economic definition

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    What is manufacturing???....

    Technologic definition manufacturing is the application of physical and

    chemical processes to alter the geometry, properties,

    and/or appearance of a given starting material to make

    parts or products; manufacturing also includes

    assembly of multiple parts to make products.

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    What is manufacturing???...

    Economic definition

    manufacturing is the transformation of materials into

    items of greater value by means of one or more

    processing and/or assembly operations

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    Manufacturing & Production

    production has a broader meaning thanmanufacturing.

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    Review

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    Manufacturing Industries

    Primary Industries

    Secondary Industries

    Tertiary Industries

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    Manufacturing Products

    Consumer Goods

    Capital Goods

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    Production Quantity

    Low volume production

    Medium volume production

    High volume production

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    Product Quality

    Soft product variety

    Hard product variety

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    Materials in Manufacturing

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    Manufacturing Processes

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    Production Systems

    Production Facilities

    Production Support Systems

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    Production Layouts

    Fixed position layout-job shop production

    Process Layout-batch production

    Cellular Layout-cellular manufacturing

    Production Layout-mass production

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    Production Layouts.

    Fixed position layout-job shop production

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    Production Layouts.

    Process Layout-batch production

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    Production Layouts.

    Cellular Layout-cellular manufacturing

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    Production Layouts.

    Product Layout-mass production

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    Manufacturing Support Systems

    Manufacturing Engineering

    Production Planning and Control

    Quality Control

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    Overview

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    Introduction to CASTING

    1. Suitability of casting process

    2. Casting terminology

    3. Types of Moulds and Moulding Processes

    4. Desirable Mould Properties

    5. Types of patterns

    6. Pattern Allowances

    7. Defects in Casting

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    1. Suitability of casting process

    Complex shapes with internal cavities and hollowsections

    Surface finish

    Size

    Cost

    Production rate

    Simple process---single piece objects

    Important engineering properties

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    2 Casting terminology

    Moulding flask Cope

    Drag

    Parting line or parting surface

    Pattern

    Mould

    Poring basin

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    2 Casting terminology contd

    Sprue Runner

    Gates

    Gating system

    Riser---------1. Blind 2. Open

    Vents

    Core

    Core box Core prints

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    2 Casting terminology contd

    Chills External chills

    Internal chills

    Castability

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    Sand Casting Process

    Click here for video

    http://localhost/var/www/apps/conversion/tmp/scratch_3/ppts%20linked%20vids%20n%20sub%20ppts/sand%20casting%20animation.FLVhttp://localhost/var/www/apps/conversion/tmp/scratch_3/ppts%20linked%20vids%20n%20sub%20ppts/sand%20casting%20animation.FLV
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    3. Types of Moulds

    Expendable moulds Permanent moulds

    Sand moulding

    Green-sand molds - mixture of sand, clay, and water;

    Green" means mold contains moisture at time of

    pouring

    Dry-sand mold - organic binders rather than clay

    And mold is baked to improve strength

    Skin-dried mold - drying mold cavity surface of agreen-sand mold to a depth of 10 to 25 mm, using

    torches or heating lamps

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    4. Desirable Mold Properties

    Strength (Cohesiveness)- to maintain shape andresist erosion

    Permeability- to allow hot air and gases to pass

    through voids in sand

    Thermal stability (Refractoriness) - to withstandhigh temperatures and to resist cracking on contact

    with molten metal

    Collapsibility- ability to give way and allow casting

    to shrink without cracking the casting Reusability- can sand from broken mold be reused

    to make other molds?

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    5. Types of patterns &6. Pattern Allowances

    Click here to go to pattern slides

    http://localhost/var/www/apps/conversion/tmp/scratch_3/ppts%20linked%20vids%20n%20sub%20ppts/casting%20patterns%20[Repaired].pptxhttp://localhost/var/www/apps/conversion/tmp/scratch_3/ppts%20linked%20vids%20n%20sub%20ppts/casting%20patterns%20[Repaired].pptx
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    6. Defects in Casting

    Click Here for Casting Defects

    http://localhost/var/www/apps/conversion/tmp/scratch_3/ppts%20linked%20vids%20n%20sub%20ppts/Casting%20Defects.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_3/ppts%20linked%20vids%20n%20sub%20ppts/Casting%20Defects.ppt
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    Casting Processes

    Click Here for Casting Processes

    http://localhost/var/www/apps/conversion/tmp/scratch_3/ppts%20linked%20vids%20n%20sub%20ppts/Types%20Casting%20Processes.pptxhttp://localhost/var/www/apps/conversion/tmp/scratch_3/ppts%20linked%20vids%20n%20sub%20ppts/Types%20Casting%20Processes.pptx