ME 222: Manufacturing Technology I

(3-0-0-6)

Department of Mechanical Engineering

IIT Guwahati

Course Contents
Module
1 Introduction to manufacturing processes

2 Moulding materials and mould design; Pattern types and design.

Casting processes: sand casting, investment casting, pressure die casting, centrifugal casting,
continuous casting; Casting analysis; Casting defects and their remedies
3 Metal forming Processes: Various metal forming techniques and their analysis, viz., forging,
rolling, extrusion, wire drawing, sheet metal working; Super plastic deformation; Metal
forming defects
4 Metal joining processes: brazing, soldering, welding: Solid state welding; resistance welding;
arc welding; gas welding; Welding defects
5 Polymer fabrication methods viz., Injection moulding, Compression moulding, Transfer
moulding, Thermoforming
6 Composite fabrication methods viz., Compression moulding, Vacuum moulding, Prepregs
fabrication, Filament winding
7 Additive manufacturing

8 Powder metallurgy and its applications

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 Texts and References

Texts:
[1] A. Ghosh and A. K. Mallik, Manufacturing Science, Wiley Eastern, 2010
[2] P. N. Rao, Manufacturing Technology: Foundry, Forming And Welding, Tata
McGraw Hill, 2017.
[3] M. P. Groover, Introduction to Manufacturing Processes, Wiley, 2011

References:
[1] J. S. Campbell, Principles of Manufacturing Materials and Processes, Tata
McGraw Hill, 1995.
[2] M. C. Flemings, Solidification Processing, Tata McGraw Hill, 1982.
[3] P. C. Pandey and C. K. Singh, Production Engineering Sciences, Standard
Publishers Ltd., 2013.
[4] S. Kalpakjian and S. R. Schmid, Manufacturing Processes for Engineering
Materials, Pearson education, 6th edition, 2016.
3

Grading system

Assignment/Tutorial: Optional
Quiz: 20%
Mid-semester: 30%
End-semester: 50%

Section A: 220103001 – 220103070

Weekly time-table: Monday: 9 – 10 am (Room 5105)

Tuesday: 10 – 11 am (Room 5105)
Wednesday: 11 – 12 am (Room 5105)

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 Module 1

Introduction to Manufacturing Processes

 Manufacturing processes
 Materials processing technologies
 Types and properties of engineered materials
 Evaluation of properties of manufactured products

Manufacturing processes

Conversion of resource into raw materials – mining and metallurgy

Raw materials to final product – manufacturing processes

Joining
Machining
Casting Finishing
Forming
Assembly
Design – Most economic manner
Understanding of Production – Selection of important process
Manufacturing process parameters
Development of new techniques and
modification of existing technologies

Production process – can not be solved by conventional methods

Unconventional manufacturing processes 6

3
 Manufacturing processes

Basic manufacturing processes

• Casting, foundry and molding
• Forming or metalworking processes
• Machining or material removing processes
• Joining and assembly
• Surface treatment or finishing processes
• Heat treatment
• Non-Conventional processes
• Additive manufacturing

Different manufacturing processes

www.montanstahl.com
Hot rolling

www.lsengineering.co.uk
Sheet metal forming 8

4
 Different manufacturing processes

www.makeagif.com
Additive manufacturing

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Additive manufacturing www.theadditivemanufacturing.com

Classification
of
Manufacturing
Processes

Courtesy:
Principles of Modern Manufacturing,
M. P. Groover 10

5
 Selection of Manufacturing Processes
Single manufacturing process
Fabrication
of products
Multiple manufacturing processes in sequence

Shape of the
part/product

Factors decides Material properties Castability/ formability/ weldability/ machinability

the selection of
e.g., forming of hard and brittle material is difficult,
manufacturing
Change of material casting and machining may be preferred
process
properties during e.g., forming at room temperature leads to a part
manufacturing with high strength, high hardness and low ductility

Size of the e.g., limited size in additive manufacturing,

part/product micromanufacturing, nanomanufacturing

Production rate
11
Production cost

Selection of Manufacturing Processes

• Same part can be fabricated using different manufacturing processes

casting forging extrusion machining joining

or or
powder metallurgy upsetting

Courtesy:
Manufacturing Processes
for Engineering
12 Materials,
Kalpakjian and Schmid

6
 Selection of Manufacturing Processes

sheet metal machining

forming gear
hubcap

casting powder
metallurgy

Image Credit: Nuno Andre/Shutterstock.com

www.hyundaimobisin.com

crankshaft

Frying pan
casting

sheet metal
forging www.desertcart.in forming

casting •Same product can be fabricated using different

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www.carthrottle.com
manufacturing processes

How old are manufacturing processes?

14

7
History of Materials and Manufacturing Processes

Courtesy:
Manufacturing Processes
for Engineering
15 Materials,
Kalpakjian and Schmid

History of Materials and Manufacturing Processes

Courtesy:
Manufacturing Processes
for Engineering
16 Materials,
Kalpakjian and Schmid

8
 History of Materials and Manufacturing Processes

Courtesy:
Manufacturing Processes
for Engineering
17 Materials,
Kalpakjian and Schmid

Different
casting
processes

Courtesy:
Manufacturing Engineering and18Technology,
Kalpakjian and Schmid

9
 Different
bulk-deformation
processes

Courtesy:
Manufacturing Engineering
and Technology,
Kalpakjian and19Schmid

Different
Sheet-metal
forming
processes

Courtesy:
Manufacturing Engineering and20Technology,
Kalpakjian and Schmid

10
Different
joining
processes

Courtesy:
Manufacturing Engineering and21Technology,
Kalpakjian and Schmid

Different
Polymer-
processing
processes

Courtesy:
Manufacturing Engineering and
Technology, 22
Kalpakjian and Schmid

11
 Different
machining
and
finishing
processes

Courtesy:
Manufacturing Engineering and23Technology,
Kalpakjian and Schmid

Length-scale of
manufacturing
processes

Macromanufacturing

Micromanufacturing

Nanomanufacturing

Courtesy:
Manufacturing Processes
for Engineering Materials,
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Kalpakjian and Schmid

12
 Materials processing technologies

Materials processing - manufacture of raw-materials into finished goods

Industrial processes - various mechanical or chemical procedures, and produce
large quantities or batches.

Raw materials - either extracted from minerals or produced from basic chemicals or
natural substances.
Metallic raw materials - crude ore is processed to increase the concentration of the
desired metal
It involves crushing, roasting, magnetic separation, flotation, and leaching.

Additional processes - smelting and alloying are used to produce the metal that is to
be fabricated into parts that are eventually assembled into a product

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Materials processing technologies

Iron – Found as mineral compound, such as ores
Iron ores – iron oxides + impurities

Chemical reducing reactions is used to extract metallic iron

Ore + limestone + coke + air – reacted in furnace

Oxides are reduced, but other elements are mixed with iron such as

Carbon – 3 – 4.5%
Manganese – 0.15 – 2.5%
Phosphorus – 0.1 – 2.5 Pig iron
Silicon – 1 – 3 %
Sulfur – 0.05 – 0.1 %

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13
 Materials processing technologies

Pig iron is cast into shape – which is called cast iron

Other impurities forms the slag

Steel: made by an oxidation process that decrease the amount of carbon,

Mn, P, S from molten pig iron and steel scrap

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Types of engineered materials

Metals/metallic materials Ceramics & Glasses

• good conductors of electricity and heat • thermally and electrically insulating
• lustrous appearance • resistant to high temperatures and harsh
• susceptible to corrosion environments
• strong, but deformable • hard, but brittle

Composites Polymers
• consist of more than one material type • very large molecules
• designed to display a combination of • low density, low weight
properties of each component • maybe extremely flexible

Ceramics: Al2O3, SiC, SiO2 (oxides, nitrides and carbides) - bricks, refractories
Polymer: Plastic and rubber materials, organic – C, H2, other non metallic materials
Composites: Concrete, plywood, fiberglass

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 Metals and alloys

Metals & Alloys

Ferrous Non-ferrous
Steels Cu-Alloys
Ni-Alloys
Cast Irons Al-Alloys
Ti-alloy
Plain Carbon Steels Superalloy
Alloy Steels

White Cast Iron

Malleable Cast Iron
Grey Cast Iron

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Metals and alloys

Plain Carbon Steels: Iron + carbon
Small amount of P, S, Mn, Si
Low carbon steel < 0.3% C
Structure are usually ferrite and pearlite

Medium carbon steel 0.3 – 0.8% C

Form bainite or Martensite

High carbon steel > 0.8% C

Can form Martensite

 Strength increases with increasing carbon content

 Ductility, toughness – decreases with increasing carbon content

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 Metals and alloys
Alloy steel: Alloying elements are added to steels in small quantity (usually less than 5%)
to improve strength or hardenability
- Alloying elements is added to much quantity (upto 20%) to produce special
properties (such as corrosion resistance)

Alloying elements: Mn, Si, Cu, Cr, Ni, Mo, V, W, Co, B, P, S

HSLA steel – structural application (bridges and building)

Microalloyed steel – substitutes for heat treated steel
Maraging steel – super high strength and toughness
Stainless steel – corrosion resistance
Tool steel – wear resistance, toughness and high strength
Silicon steel – electric and magnetic application

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Metals and alloys

Cast iron: Alloys more than 2% carbon
- Mo and Ni are frequently added to improve hardenability
- Properties decided by the formation of graphite of cementite

Gray cast iron – low ductility, excellent compressive strength, machinability, wear
resistance, sound and damping characteristics
- carbon in the form of graphite flakes
White cast iron – carbon in the form of carbide
- very hard and brittle
- applied where abrasion resistance is required
Malleable cast iron – controlled heat treatment of white cast iron
- Cementite dissociates and forms regular graphite spheroids
- greater ductility than gray cast iron

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 Metals and alloys - Summary
• Ferrous: iron as main constitute
• Non ferrous: other than iron as main constitute
• Steel: carbon less than 2 %
• Cast iron: carbon more than 2%
• Cu alloy: Pure Cu – electrical industry
• Al alloy: Automotive frame
• Ni alloy: Outstanding strength and corrosion resistance
• Ti alloy: High temperature engineering material
• Superalloys: High strength, creep resistance, oxidation and corrosion resistance, fatigue
resistance even at high temperature
- Jet engine, rocket and nuclear application
- Ni based – Inconel, Hastelloy
- Iron-based
- Cobalt- based 33

Polymer
Thermosetting: at elevated temperature it is soften with increasing temperature.
When it cooled, becomes harder and stronger. No chemical change is involved.
Thermosetting polymer is significantly stronger and more rigid than thermoplastic
Thermoplastic: Soften over a range of temperature. It is formed by injection molding.
Large amount of permanent deformation is available. Having useful strength.
Thermoplastics have low melting points and low tensile strength. Thermosetting plastics
have high melting points and tensile strength.

Thermoplastics can melt under heat after curing while thermoset plastics retain their form
and stay solid under heat once cured

Thermoplastic - heat forming

Thermoset - heat setting
Thermoplastic - bonds are covalent
Thermoset - bonds are covalent and crosslinked 34

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 Elastomers
Elastomer: Elastic polymer, special class of linear polymer that display large
amount of elastic deformation
Acquire crosslinked structure

Natural rubber – oldest elastomer

Polyurethanes - Used in the textile industry for the manufacture of elastic
clothing
Polybutadiene - used on tires of vehicles
Neoprene – wetsuits, wire insulation, industrial belts
Silicone - Medical prostheses

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Composites
Comprised of two or more physically distinct materials with at least one material providing
reinforcing properties

Natural Composites: Bone, Wood, Bamboo

Engineering Composites: Glass fibers, carbon fibers, synthetic fibers, metal

fibers, ceramic fibers

Composites
Laminar
Particle Reinforced
Fibre Reinforced

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 Ceramics and Glasses
 Complex compounds and solutions that contain both metallic and
nonmetallic elements (C, N, O, P, or S)
 typically hard and brittle
 exhibit high strength and high melting points
 exhibit low thermal and electrical conductivity
 Good chemical and thermal stability, good creep resistance
 Can be made amorphous structure with a random pattern, like glass
(silicates)

Applications: Pottery, brick, tile, glass, ovenware, refractories, cutting tools

Types: Aluminum oxide, Magnesium oxide, silicon oxide, silicon nitride

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Semiconductors

 Conduct electricity intermediately (Neither good conductor nor good

insulator)
 Si, Ge, Sn in periodic table serve as a boundary between metallic and
nonmetallic elements
 Si and Ge are widely used semiconductors
 O to Te (Tellurium) and Zn to Hg (Mercury) are used with Si and Ge to form
a semi conductor
 GaAs (Gallium Arsenide) which is used as a high temperature rectifier and a
laser material
 CdS which is used as a low-cost solar cell for conversion of solar energy to
electrical energy
 Some ceramics display semi-conducting behavior, e.g., ZnO which is widely
used in color television
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 Physical properties

Thermal conductivity: Property of a material to conduct heat flow

High thermal conductivity material – Copper, Aluminum, Silver, Gold
Materials with low thermal conductance – Polymer, alumina – can be used
for insulation purpose

Thermal expansion - Change in volume in response to change in temperature

Creates thermal strain in solid
Degree of expansion per unit change in temperature is called the material's
coefficient of thermal expansion
However, it varies with temperature

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Mechanical properties
Strain 𝜺 : Change in dimension per unit original dimension
Stress 𝝈 𝒐𝒓 𝝉 : Applied force per unit area
Normal Stress and Shear stress
Strength: Ability of a material to resist the applied force without breaking or
yielding.
Stiffness: Ability of material to resist deformation under stress
Elasticity: Property of material to regain its original shape after deformation
when the external force are removed
Plasticity: Property of a material which retains permanent deformation with
the applied load

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20
 Mechanical properties
Ductility: Ability of a material enabling it to be drawn in to wire with the
application of a tensile force
Brittleness: It is property of a material opposite to ductility.
Cast iron is a brittle material
Malleability: Special case of ductility which permits materials to be rolled or
hammered in to thin sheets.
Ex. aluminum
Toughness: Property of material to resist fracture due to high impact load
Measurement - Energy absorbed before fracture
Resilience: Amount of energy when deformed elastically and release upon
unloading
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Mechanical properties
Creep: Material is subjected to a constant stress at elevated temperature for
long period of time - it creates slow and permanent deformation
Fatigue: When a material is subjected to cyclic stresses, it fails below yield point
stress
Hardness: Resistance to wear or scratching
Damping capacity – Loading and unloading path are different
Gray cast iron – high damping capacity
Steel – transmits sound and vibration

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 Other properties of materials

 Latent Heat of Material, Thermal diffusivity

 Viscosity
 Electrical conductivity, Electrical resistivity
 Magnetic properties – induction welding

 In machining, welding, casting - thermal properties of the work is

important
 Casting and welding – Fluid property is significant
 Semiconductor manufacturing - electrical properties of silicon is
important
 Mass diffusion coefficient – surface hardening or diffusion welding

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Properties evaluation

Characteristics of sample by different experimental techniques

Physical properties: Density, melting point, optical properties, thermal
properties of specific heat, coefficient of thermal expansion and thermal
conductivity, electrical conductivity, and magnetic properties
Microstructural characterization: Optical microscope, Scanning electron
microscopy, X-ray diffraction

Mechanical properties: Static properties

Uniaxial tensile testing – standard specimen
Size effect is eliminated – engineering stress-strain curve as compared to
load-deflection curve

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 Mechanical Properties
Characteristic information from stress-strain curve
Proportional limit, Young’s modulus, Resilience or Modulus of Resilience,
Yield strength, Offset yield point (0.2% strain), Ultimate tensile strength,
Fracture strength, toughness, damping capacity

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Dynamic Properties
Loading condition in engineering components
 Impact load or rapidly change in magnitude
 Repeated cycle of loading and unloading
 Frequent change in mode of loading

Impact test – to evaluate the fracture resistance of material

Charpy test – simply supported bean with notch
Izod test – cantilever beam with notch

Fatigue testing: Cyclic loading pattern is followed or entirely random variation

in stress is followed
Count number of cycles to induce failure
Stress vs. number of cycles curve
May conducted at different temperature 46

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 Creep Properties

Properties at elevated temperature subjected to constant load

Tensile specimen elongate continuously until rupture occurs even the applied
stress is below yield strength at that temperature
Important for: Gas turbine, power plant, high-temperature pressure vessel
Represented by strain vs. time curve at a particular temperature

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Thank you
for your kind attention

End of Module 1
Introduction to Manufacturing Processes

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