MANUFACTURING TECHNIQUES

Subject Code: MI-102

S. Particulars Contact
No Hours
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1 INTRODUCTION: Engineering materials, their manufacturability and 2

applications
2 CASTING : pattern materials, pattern types, allowances, molding sand, 7
composition and properties, cores, casting defects and their remedies,
plastic parts molding
3 JOINING : Welding fundamentals, types of welded joints, types of welding 6
processes, gas welding process, manual metal arc welding, welding defects
and remedies, Soldering and brazing, their applications in electronics
industry
4 MACHINING: Lathe, drilling, milling and grinding machines and their 5
operations, cutting tools used
5 FORMING : Forging, rolling, extrusion, wire drawing and tube drawing, 6
sheet metal operations, forging defects and remedies
6 ADVANCED MANUFACTURING PROCESSES: Introduction to 4
advanced manufacturing techniques and their applications
Total 30
[1] INTRODUCTION to ENGINEERING MATERIALS
and MANUFACTURING PROCESSES
[1.1] TYPES of ENGINEERING MATERIALS
All the Materials Used for the Engineering
Applications can be Put into SIX Basic

 Pure Substances (Including Metals)

 Alloys (Ferrous and Non-Ferrous)
 Polymers (Plastics and Rubber or Elastomers)
 Ceramics
 Composites
 Miscellaneous Materials (Organic and Inorganic)
 Some Recent Advances: Shaper Memory Materials
Nano-materials

MI-102: Manufacturing Techniques I. I. T. ROORKEE

Figure 1: Some of the Metallic and Non-Metallic Materials
Used in a Typical Automobile

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 Behaviour and Manufacturing Properties of
Engineering Materials

Structure Physical and Mechanical Property

of Chemical Properties Modification
Material Properties
 Strength  Heat
 Atomic Bond:  Melting Point  Ductility Treatment
Metallic,  Density  Elasticity  Annealing
Ionic,  Specific Heat  Stiffness  Tempering
 Thermal  Hardness  Normalizing
Covalent  Toughness
 Crystalline Conductivity  Hardening
 Thermal  Fatigue  Alloying
 Amorphous  Creep
or Expansion  Resistance  Reinforcem
Non-Crystalline  Electrical to Wear, ents
 Partly Conductivity Corrosion,  Composites
Crystalline  Magnetic Oxidation  Laminations
 Polymer Properties  Hot Hardness  Fillers
Chains  Oxidation and Strength  Surface
 Corrosion Treatment
MI-102: Manufacturing Techniques I. I. T. ROORKEE
 Strength: Ability to Bear a Load Before Fracture
 Ductility: Extent of Permanent or Plastic Deformation that a Material
Undergoes Before Fracture
Two Measures of Ductility: % Elongation, % Reduction in Area
 Elasticity: Ability to Restore to Original Shape and Size after Removal
of External Deforming Loads
 Stiffness: Resistance to ELASTIC (or RECOVERABLE) Deformation
Young’s Modulus is the Measure of Elasticity
 Hardness: Resistance to PLASTIC (or PERMANENT) Deformation which
Includes Indentation, Scratching, or Marking
 Toughness: Resistance to both ELASTIC and PLASTIC Deformation
 Fatigue: Permanent Deformation and/or Failure of a Component when
Subjected to Fluctuating (Both in Magnitude and Direction) Loads
i.e. Gear Teeth, Aircraft Wings, Crankshaft of an Automobile
 Fracture: Splitting of a Component into at Least Two Halves
 Creep: Permanent Deformation and/or Failure of a Component when
Subjected to High Stresses at High Temperature
i.e. Turbine Disk and Blades
MI-102: Manufacturing Techniques I. I. T. ROORKEE
 Basic Sub Sub-sub Category Typical Examples
category Category
[1.1.1] Metals Ductile: Face Al, Cu, Ni, Pb, Ag, Au, Ca, Pt,
Centered Cubic (FCC) Austenite ( - Iron)
PURE SUBS-
TANCES Hard Body Centered Cr, V, Mn, Ferrite (-Iron),
Cubic (BCC) Refractory Metals Mo, Nb
(or Columbium), Ta, W
Hexagonal Ti, Be, Cd, Co, Mg, Zn, Zr
Close-Packed
(HCP)
Non-Metals Carbon, Graphite

Semi Intrinsic Si, Ge,

Conductors Extrinsic n-type Doped with FIFTH-column
[Hard and elements, i.e. P, As, Sb
brittle]
p-type Doped with THIRD-column
Elements, i.e. B, Al, Ga, In

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 Basic Sub- Subsub Category Typical Examples
category category
[1.1.2] Ferrous Cast Irons (CI) Gray, White, Malleable, Nodular (SG),
Alloys and Compacted
ALLOYS Plain Carbon Steels Low (Mild Steel), Medium, and High
Carbon Steels
Homogen
ous Alloy Steels Constructional and High-Strength Low
Mixture Alloy (HSLA) Or Micro-Alloyed
of two or Stainless Steels Ferritic, Martensitic, Austenitic, and
more Duplex
than two Tool Steels Seven Basic Families Including HSS
Elements
Non- Cu-based Alloys Brasses, Cupronickel, Bronzes,
Ferrous Constantan, Etc.
Alloys Al-based Alloys Duralumin, Hindalium, Magnalium
Ni-based Alloys Monel, Nichrome
Ti-based Alloys , , And -Type
Co-based Alloys Stellite
Super- Ni-based Inconel, Rene, Hastelloy, Waspaloy,
alloys Udimet
Co-based Haynes, Etc.
Fe-Ni Based Illium, Incoloy, Etc.
MI-102: Manufacturing Techniques I. I. T. ROORKEE
 Basic Sub Category Sub-sub Typical Examples
category Category
[1.1.3] PLASTICS Thermoplastics ABS (Acrylonitrile-butadiene-
[Natural or (Flexible and Styrene), Acetal, Nylon,
POLYMERS Synthetic Tough) Vinyl, Fluorocarbons
Resins or their (Teflon), Acrylics (Plexiglass
[Long-Chain Compounds]
or Lucite), Polyethylene,
Molecules or
Macro- Polypropylene, Polystyrene,
molecules Polycarbonate, etc.
Formed by Thermosetting Plastics, Epoxies, Bakelite,
Linking and (Strong and Phenolics, Melamines,
Cross-linking Brittle) Polyester, Silicone, Urea,
of Different
Monomers] ELASTOMERS Natural Natural rubber
OR Artificial or
RUBBER
EDPM (Ehtylene Propylene),
Synthetic Styrene Butadiene (SBR),
[Special Class
of Linear Urethanes, Silicone Rubber,
Polymers] Neoprene, Polyacrylate,
Polyisoprene,
Polybutadiene, Polysulfide,
Fluoroelastomers, Ebonite
MI-102: Manufacturing Techniques I. I. T. ROORKEE
 Basic Sub Sub-sub Category Typical Examples
category Category
[1.1.4] Crystalline Refractories Acidic Silica (SiO2), and Alumina
structure type (Al2O3) based
CERAMICS Basic Magnesite (MgO), Olivine
type (Mgo-SiO2) based
Compounds
of Metallic Neutral Chromite (Cr2O3), and
and Non- type Chromite-magnesite
Metallic Abrasives Natural Diamond, Quartz, Emery,
Elements in Garnets, Sand, Corundum
the Form of
Carbides, Artificial Aluminum Oxide, Silicon
Oxides, Carbide (SiC), Silicon Nitride
Nitrides (Si3N4), Cubic Boron Nitride
(CBN), Boron Carbide, Poly
Crystalline Diamond (PCD)
Structural Ceramics Artificial Abrasives, Sialon,
Zirconia, Titanium Diboride
Insulators Porcelain
Precious Mineral Ruby, Sapphire, Topaz,
Stones Emerald, Coral, Agate, Mother
of Pearl, etc.
Sheet Structure Mica (Muscovite)
Double chain Structure Asbestos (Tremolite)
MI-102: Manufacturing Techniques I. I. T. ROORKEE
 Basic Sub Category Sub-sub Typical Examples
category Category
[1.1.4] Amorphous or Glasses Silica, Borosilicate, Soda-lime,
Non-crystalline Magnesia, Vycor-type glasses,
CERAMICS Structure etc.
(Contd.) Crystalline and Glass Ceramics Pyroceram, etc.
Amorphous Cermets Ceramics in Metallic Binder
both

MI-102: Manufacturing Techniques I. I. T. ROORKEE

Basic category Sub-category Sub-sub Typical Examples
Category
[1.1.5] Laminar or Laminates Plywood, Safety Glass,
layered type Arall, Formica, etc.
COMPOSITES [having distinct Bimetallic Strips Alclad, US coinage, etc.
layers of
[Heterogeneous materials bonded Sandwich Corrugated Cardboard,
Solid of Two or together] Materials Honeycomb Structures
More Materials
Particulate type Coarse Particles Cemented or Sintered
Bonded Together
Mechanically or [Discrete particles Carbides
Metallurgically] of one material Concrete, Asphalt
surrounded by
matrix of another ] Dispersion TD-nickel, Sintered
Strengthened Aluminum Powder (SAP)
Materials
Fiber-Reinforced Wood, Bamboo, Steel-
Composites Reinforced Concrete,
(FRC) Glass Fiber Reinforced
Plastics (GFRP),
Fiberglass
MI-102: Manufacturing Techniques I. I. T. ROORKEE
Basic category Sub-category Sub-sub-category Typical Examples
[1.1.5] Advanced Polymer Matrix Glass-epoxy, Boron-epoxy,
FRC Composites (PMC) Graphite-epoxy, Kevlar-
COMPOSITES Or epoxy composites
(Contd..) Fiber Reinforced
Plastics (FRP)
Metal Matrix Aluminum reinforced with
Composites (MMC) graphite, Al2O3 , or SiC
Carbon Carbon Graphite fibers in carbon
Composites (CCC) matrix
Ceramic Matrix Silicon nitride reinforced
Composites (CMC) with silicon carbide, etc.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

MI-102: Manufacturing Techniques I. I. T. ROORKEE
APPLICATION of ADVANCED COMPOSITE MATERIALS in Boeing 757-
200 Commercial Aircraft

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 Basic Sub- Sub-sub Typical Examples
category Category Category
[1.1.6] Organic Paper
Textiles
MISCELLANE
OUS Leather Natural
MATERIALS
Synthetic
Wood Maple, Oak, Pine, Spruce, Teak,
Deal, Aspen, Knot, Fir, Hickory,
etc.
Miscellaneous Delrin, Lexan, Mylar
Inorganic Rocks Granite, Gypsum, Limestone,
Sandstone, Plaster-of-Paris, etc.
Cement
Miscellaneous Spinel

MI-102: Manufacturing Techniques I. I. T. ROORKEE

[1.2.7a] SHAPE MEMORY MATERIALS
 DEFINITION: Shape Memory Materials (SMM) are those
Materials which, After being Deformed PLASTICALLY (i.e.
PERMANENTLY) at the Room Temperature into Various Shapes,
Return to their Original Shapes upon Heating
 EXAMPLES: Typical Shape Memory Alloys are
 55% Ni-45%Ti
 Copper-Aluminum-Nickel
 Copper-Zinc-Aluminum
 Iron-Manganese-Silicon
 CHARACTERISTICS:
 SMM have Good Ductility, Good Corrosion Resistance, High
Electrical Conductivity
 Behavior of SMM can Also be Reversible i.e. Shape can
Switch Back and Forth upon Heating
 APPLICATIONS: Can be Used
 To Generate Motion and/or Force in Temperature-Sensitive
Actuators
 Eyeglass Frames, Connectors, Clamps, Fastener, and in Seals
MI-102: Manufacturing Techniques I. I. T. ROORKEE
[1.2.7b] NANO-MATERIALS
 DEFINITION: Materials with Grains, Fibers, Films, and
Composites having Particle Size of the Order of 1-100 nm
 EXAMPLES: Any Combination of Chemical Elements
 Important Compositions are Carbides, Oxides, Nitrides,
Metals and Alloys, Organic Polymers and Various Composites
 ALTERNATIVE NAMES: Nano-Crystalline Materials, Nano-
Structured Materials Nano-Phase Materials , Nano-Powders,
Nano-WiresNano-Tubes, Nano-Films
 CHARACTERISTICS:
 Since Synthesis is Done at Atomic Level, their Purity and
Homogeneity (99.9999 %), and Uniformity of their
Microstructure is Highly Controlled  Their Mechanical,
Physical, and Chemical Properties can be Precisely Controlled
 Properties such as Strength, Ductility, Hardness, Wear
Resistance, Corrosion Resistance, that Frequently Superior to
Traditional and Commercially Available Materials
 Unique Electrical, Magnetic, and Optical Properties
MI-102: Manufacturing Techniques I. I. T. ROORKEE
[1.2.7b] NANO-MATERIALS (Continued)
 APPLICATIONS: Some Current and Potential Applications are
 Cutting Tools and Inserts (Made of Nano-Crystalline Carbides
and Other Ceramics)
 Ductile and Machinable Nano-Phase Ceramics
 Powders for Powder Metallurgy Processing
 Next-Generation Computer Chips Using Nano-Crystalline
Materials with High Purity, Better Thermal Conductivity and
More Durable Interconnections
 Flat-Panel Displays for Laptop Computers (Made by
Synthesizing Nano-Crystalline Phosphorous to Improve
Resolution)
 Spark-Plug Electrodes
 Igniters for Rockets, Medical Implants
 High-Sensitivity Sensors
 Catalysts for Elimination of Pollutants
 High Power Magnets
 High Energy Density Batteries
MI-102: Manufacturing Techniques I. I. T. ROORKEE
[1.2] Types of Manufacturing Processes
 All the Manufacturing Processes can be Put into Basic SIX
Categories according to their Nature
 Primary Forming Processes [Additive or Accretion]
 Material Removal or Machining [Subtractive]
 Deforming Processes [Formative]
 Joining or Fabrication or Consolidation [Assembling]
 Finishing and Surface Treatment Processes
 Bulk Property Enhancing Processes [Heat Treatment]
 All These SIX Categories can be Sub-divided into TWO
Sub-categories
 Conventional
 Unconventional or Advanced

MI-102: Manufacturing Techniques I. I. T. ROORKEE

 Type of Nature Examples
processes Conventional type Advanced type
Primary forming Material Casting processes, Various Rapid prototyping (RP)
processes additive or Powder metallurgy processes
accretion
Deforming Formative Different metal forming Laser bending,
processes processes of cold and 3D-laser forming,
hot working type High energy rate forming
(HERF) processes,
Hot isostatic pressing (HIP), etc.
Machining Subtractive Different conventional Various AMPs: USM, AJM,
processes machining processes: WJM, AWJM, AFM, MAF, ECM,
Turning, Milling, Drilling, EDM, EBM, LBM, PAM, IBM,
Boring, Grinding, etc. etc.
Joining Assembling Joining processes of Electron beam welding (EBW),
processes Mechanical bonding, Laser beam welding (LBW),
Atomic bonding type (ie Ultrasonic welding (USW),
welding) etc.

MI-102: Manufacturing Techniques I. I. T. ROORKEE

[1.3] MANUFACTURABILITY of ENGINEERING MATERIALS

Type of Basic Manufacturing Process Mainly Depends on:

 Type of the Work Material
 Nature (i.e. ductile or brittle) and its Hardness
 Melting Temperature of the Work Material
 Production Volume or Batch Size of the Production

Basic Nature of the Manufacturing Process Affects the

 Cost
 Properties and
 Characteristics of the Final Product

MI-102: Manufacturing Techniques I. I. T. ROORKEE

AVAILABLE INFORMATION Regarding Manufacturability Evaluation

 Types or Classification of Manufacturing Processes

 Qualitative Information Regarding Applicability of

Different Manufacturing Processes to different
Types of Engineering Materials

 Application Range of Various Manufacturing

Processes According to Melting Temperature of
the Work Material and Batch Size of Production

 Manufacturing Attributes of Different Types of

Manufacturing Processes

MI-102: Manufacturing Techniques I. I. T. ROORKEE

[1.3.1] Applicability of Different Manufacturing Processes to
Different Types of Engineering Materials

Basic Primary Deforming Material Joining Property

category of forming processes removal processes changing
material processes [Formative] processes processes
[Additive] [Subtractive] [Consolidation]
Traditi Adva Traditi Adva Traditi Adva Traditi Adva- Traditional
-onal -nced -onal -nced -onal -nced -onal nced
Metals A B* A A A A A A A

Alloys A B* A A A A A A A

Polymers A A B B B A B B C

Ceramics A C C C B A B C C

Composites A C C C B A B B C

A: Widely used; B: Not frequently used; C: Not used; *: Under research stage
[1.3.3] Manufacturing Attributes of Manufacturing Processes
Type of Manufacturing attributes
manufacturing
Cost Production Rate Quality Flexibility
process

Primary forming High capital cost High Low to medium Low

processes High tooling cost
Low labour cost
Deforming High capital cost High Low to medium Low
processes High tooling cost
Low labour cost
Material removal Medium capital cost Low (Grinding) to Medium to High
or machining Medium tooling cost Medium (Milling) high
processes High labour cost

Joining processes Low capital cost Low (Adhesives) Low to medium High
Low tooling cost to Medium
High labour cost (welding)
Finishing and High capital cost Low High High
surface treatment Medium tooling cost
processes High labour cost

Property changing High capital cost Low High Medium to

or heat treatment Low tooling cost high
processes Low labour cost
[1.3.4] Some Guidelines for Selection of Basic Manufacturing Process

[A] According to the Batch Size:

 Smaller Batch Size Requires Flexible Manufacturing

Processes like Machining, which can Produce Variety of
Geometrical Features.

 Larger Batch Size Allows use of Primary Forming and

Deforming processes so as to Offset the Relatively High
Costs of Machine Tools and Tooling
Primary Forming Processes From 75 onwards
Deforming Processes More than 1000
Machining Processes Up to 500
[B] According to Type of Work Material:
 Metals and most of the Alloys:
 Have Relatively High Melting Temperature: Can be processed in
Solid form using Machining and Deforming Processes
 For Difficult-to-Machine Metals and Alloys:
Poor Machinability: AMPs are commonly preferred

 Polymers and Epoxy-based Composites:

 Lower Melting Point: Can be Processed in Liquid State
 Some Secondary Processes like Machining is Needed to Obtain
Desired Dimensional Accuracy and Surface Quality
 Since these Materials Generally Contain Fibers and Fillers,
they Exhibit Brittle Behavior therefore AMPs are more Suitable

 Ceramics:
 Usually Brittle: Difficult to Process in Solid Form using
Conventional Machining Processes
 Primary Forming Processes are used to Create the Basic Shape
 AMPs are Used to Give Final Shape and Surface Quality