Manufacturing

Process

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 What Is It ???
Manuf: Made by hand
Definition: It is defined as process by which Raw
material is converted in to sellable Finish product.

Classification of Mfg. Process

Casting
Forming
Machining
Joining
Polishing
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 Methods of Manufacture

Various methods of making a simple part: (a) casting or powder metallurgy,

(b) forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces.
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 Unit 1
Metal Casting

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 Fundamentals of Casting
Casting, one of the oldest manufacturing processes,
dates back to 4000 B.C. when copper arrowheads were
made.
Casting processes basically involve the introduction of a
molten metal into a mold cavity, where upon
solidification, the metal takes on the shape of the mold
cavity.
Simple and complicated shapes can be made from any
metal that can be melted.
Example: Frames, Structural parts, Machine
components, Engine blocks, Valves, Pipes.
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Casting Examples 6
 General Steps in Casting
1. Preparing a mold cavity of the desired shape with
proper allowance for shrinkage.(pattern making)
2. Melting the metal with acceptable quality and temp.
3. Pouring the metal into the cavity and providing
means for the escape of air or gases.
4. Solidification process, must be properly designed
and controlled to avoid defects.
5. Mold removal.
6. Finishing, cleaning and inspection operations.
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 Pattern Making
Pattern is the principle tool during the casting process.
A pattern is a model or the replica of the object (to be
casted).
It is embedded in molding sand and suitable ramming of
molding sand around the pattern is made.
The pattern is then withdrawn for generating cavity
(known as mold) in molding sand.
In other word pattern can be defined as a model or form
around which sand is packed to give rise to a cavity
known as mold cavity in which when molten metal is
poured, the result is the cast object.
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 Functions of the Pattern
A pattern prepares a mold cavity for the purpose of
making a casting.
A pattern may contain projections known as core
prints if the casting requires a core and need to be
made hollow.
Runner, gates, and risers used for feeding molten
metal in the mold cavity may form a part of the
pattern.
If patterns is properly made and having finished and
smooth surfaces reduces casting defects.
A properly constructed pattern minimizes the overall
cost of the castings.
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 Pattern Material
There are several materials by which pattern can be
made.
Wood, wax, metal, alloys, plaster of Paris, plastic
and rubbers etc
Pattern Material Properties:
Easily worked, shaped and joined
Light in weight
Strong, hard and durable
Resistant to wear and abrasion
Resistant to corrosion, and to chemical reactions
Dimensionally stable and unaffected by variations
in temperature and humidity
Available at low cost 10
Pattern

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 Types of Patterns
Single Piece Pattern
Split Pattern
Match Plate Pattern
Cope and Drag Pattern
Sweep Pattern
Skeleton Pattern
Gated Pattern

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 Single Piece Pattern
A pattern that is made without
joints, partings or any loose
pieces in its construction is called
Single Piece Pattern.
This pattern is not attached to
any frame thus it is also called as
Loose pattern.
This pattern is cheaper.

Moulder has to cut its own runner feeding gate and riser
for this kind of pattern (time consuming)
These patterns are used for large castings and simple
shapes.

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 Split Pattern
Many Patterns cannot be
made in single piece
because of the difficulties
encountered in moulding
them. To eliminate such
problem and for castings
of intricate design or
unusual shape, split These patterns are usually made
patterns are used. in to two parts
These two parts may be or may not be a same in size, shape, are
held together tightly by means of dowel-pins fastened in one piece
The surface form at the line of separation of the two parts usually
at centerline of the pattern is called Parting Surface.
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 Match Plate Pattern
When split patterns are
mounted with one half
on one side of a plate
and the other half
directly opposite on
the other side of the
plate, the pattern is
called as Match Plate
Pattern.
This pattern is made up of metal and the plate which makes parting
line may be either wood or metal. (Aluminium)
This type is used for producing small castings in large quantities.
Advantages: more accurate and rapid production.
These patterns are expensive to construct but initial cost is justified
by quality and rapid production. 15
 Cope and Drag Pattern
In the production of
large/ heavy castings,
the complete moulds
are too difficult to
move, therefore, cope
and drag patterns are
used to ease operation.
The patterns are made in halve, split at convenient joint line
separating cope and drag from each other.
Cope (Upper Half) and Drag (Lower Half) are mounted on
individual plates or boards.
This arrangement allows one group of operator to prepare cope half
of the mould and another group of operator to prepare drag half of
the mould. 16
 Sweep Pattern
Symmetrical moulds and cores
of large sizes are shaped by
means of sweep patterns.
The sweep patterns are consist
of a board having a shape
corresponding to the shape of
desires casting and arrange to
rotate about a central axis.
The sand is rammed in the place and sweep board is moved around
its axis of rotation to give the moulding sand the desire shape.
Sweep patterns are employed for moulding part having circular
section.
The basic advantage of this system is that it eliminates
expensive pattern construction. (Rim, Wheel) 17
 Skeleton Pattern
Skeleton Pattern is used for
very large castings (a more
timber)
It is employed to give the
general contour and the size
of the desired castings.

This is a ribbed construction with large number of square of

opening between the ribs and form skeleton outline.
The remaining framework is filled and rammed with the clay, sand
or loam. Then Strike board is used to scrape the excess sand out of
the spaces between the ribs.
It is usually built in two parts i.e. cope and drag. Water pipe, pipe
bend, valve bodies and boxes are few examples of castings made
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by this pattern.
 Gated Pattern

In the mass
production of
casings, multi
cavity moulds
are used.

Such moulds are formed by joining a number of patterns

and gates and providing a common runner for the molten
metal
These patterns are made of metals, and metallic pieces to
form gates and runners are attached to the pattern. 19
 Pattern Making Allowances
Patterns are not made the exact same size as the
desired casting for several reasons.
Such pattern would produce castings which are
undersize, having defects.
Therefore, allowance is necessary to avoid these
problems. Allowance is allowed for shrinkage, draft,
finish, distortion and rapping.
Pattern allowance is a vital feature as it affects the
dimensional characteristics of the casting.
The selection of correct allowances greatly helps to
reduce machining costs and avoid rejections.
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 Shrinkage Allowance
As metal solidifies and cools, it shrinks and contracts in size.
To compensate this nature of metal, pattern is made larger than
the finished casting by means of shrinkage or contraction
allowance.
While measuring the pattern, patternmaker allows this by using
shrink or contraction rule which is slightly longer than
conventional rule of the same length.
For example, when constructing a pattern for cast iron,
patternmaker uses shrink rule measuring about 10 mm longer per
meter than the conventional rule as cast iron contacts 10 mm per
meter.
Master pattern from which patterns are cast may have double
shrinkage allowance.
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 Types of Shrinkage Allowance
Liquid Shrinkage:
It refers to the reduction in volume when the metal changes
from liquid state to solid state at the solidus temperature.
To account for this shrinkage; riser, which feed the liquid
metal to the casting, are provided in the mold.

Solid Shrinkage:
It refers to the reduction in volume caused when metal loses
temperature in solid state.
To account for this, shrinkage allowance is provided on the
patterns.
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 Draft Allowance
When pattern is drawn from a mould, there is
always some possibility of injuring the edges of the
mould.
This danger is greatly decreased if the vertical
surfaces of a pattern are tapered inward slightly.
This slight taper inward on the vertical surfaces of
the pattern is known as draft.
Draft is expressed in terms of millimeter per meter
on a side or in degrees.
The amount of draft is depend upon length of
vertical side, complexity of pattern and method of
moulding.
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 Effect of Draft
Pattern having no draft allowance
being removed from the pattern.
In this , till the pattern is completely
lifted out, its sides will remain in
contact with walls of the mold, thus
tending to break it.

In this case, the moment the

pattern lifting commences, all of
its surfaces are well away from
the sand surface.
Thus the pattern can be removed
without damaging the mold
cavity. 24
 Machining Allowance
Casted components suffer from problem of surface finish.
Therefore, casted components always require machining
after that.
Rough surface of castings that have to be machined are
made to dimensions somewhat over those indicated on the
finished working product.
Extra amount of material provided on the surface to be
machined is called as Machine finish Allowance and the
edge of these surfaces are indicated by a finish mark V or F.
The amount of machine allowance is depend upon the kind
of material used, the size and shape of casting and method
of moulding.
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 Destortion Allowance
Some castings, because of their size, shape and type of metal,
tend to wrap or distort during the cooling period.
This is because of uneven shrinkage and is due to uneven
metal thickness or it may be because of one surface is
exposed than another, causing it to cool more rapidly.
So, the shape the pattern is bent in opposite direction to
overcome this distortion. This feature is called as Distortion
Allowance.
As an example, a casting shaped like letter U will be distorted
with the legs diverging, instead of parallel. To compensate
this problem, the pattern is made in such a way that legs
converge, but when casting cools after it remove from the
mould, legs remain straight.
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Distortions in Casting
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 Rapping Allowance
Before withdrawing the pattern it is rapped and thereby
the size of the mould cavity increases.
Actually by rapping, the external sections move outwards
increasing the size and internal sections move inwards
decreasing the size.
This movement may be insignificant in the case of small
and medium size castings, but it is significant in the case
of large castings.
This allowance is kept negative and hence the pattern is
made slightly smaller in dimensions 0.5-1.0 mm.

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 Core and Core Prints
Castings are often required to have holes, recesses, etc. of
various sizes and shapes. These impressions can be obtained
by using cores.
So where coring is required, provision should be made to
support the core inside the mold cavity. Core prints are used
to serve this purpose.
The core print is an added projection on the pattern and it
forms a seat in the mold on which the sand core rests during
pouring of the mold.
The core print must be of adequate size and shape so that it
can support the weight of the core during the casting
operation.
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Typical Job, its Pattern and the Mold Cavity

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