Manufacturing Process DA-1

Name- Suhas Athreya

Reg No. - 18BME0123
Slot- G2

Answers-

A1. A well-designed gating system is a perquisite for achieving perfect casting. The key
objective of a gating system is to ensure smooth and complete flow of molten metal from ladle
to the casting cavity.The design of a gating system depends on both the metal and mould
compositions. The gating design for a ceramic mould is quite different from that normally used
for a permeable sand mould. Broadly, gating designs can be classified into three categories,
namely- (i) ver​tical gating, (ii) bottom gating, and (iii) horizontal gating. In vertical gating, the
liquid metal is poured vertically to fill the mould with atmospheric pressure at the base. In bottom
gating, on the other hand, the liquid metal is filled in the mould from bottom to top, thus avoiding
the splashing and oxidation associated with vertical gating. Simple calculations based on
principles of fluid flow, Bernoulli's equation can lead to an estimate of the time taken to fill up a
mould.

Aspiration effect- For a mould made of a permeable material (e.g., sand), care should be taken
to ensure that the pressure anywhere in the liquid metal stream does not fall below the
atmospheric pressure. Otherwise, the gases originating from baking of the organic compounds
in the mould will enter the molten metal stream, producing porous castings.Another situation
where aspiration effect comes into the picture is associated with a sudden change in the flow
direction.
The common items employed in a gating design to prevent impurities in the casting are as
follows
i) Pouring Basin:
This reduces the eroding force of the liquid metal stream coming directly from the furnace. A
constant pouring head can also be maintained by using a pouring basin.

(ii) Strainer:
A ceramic strainer in the sprue removes dross.

(iii) Splash Core:

A ceramic splash core placed at the end of the sprue also reduces the eroding force of the liquid
metal stream.

(iv) Skim Bob:

It is a trap placed in a horizontal gate to prevent heavier and lighter impurities from entering the
mould.

Effects of Friction and Velocity Distribution:

The velocity of a liquid metal in the sprue and the gate is uniform across the cross-section. In
fact, the velocity of a fluid in contact with any solid surface is zero and is maximum at the axis of
the conduit.
The velocity distribution within the conduit depends on the shape of the conduit and the nature
of the flow (i.e., turbulent or laminar).

A2. The properties of a good mould are -

1. Permeability/porosity - to allow the escape of air/gases/moisture present in the mould.
During solidification, large amount of gases are expelled from the mould.
2. Plasticity- It is the ability of the mould to attain any shape under pressure and retain the
same when the pressure is removed.
3. Adhesiveness - Moulding sand particles should be able to adhere to other particles i.e.
the sand should be able to stick to the sides of the box.
4. Cohesiveness - The sand particles must be able to stick together.
 5. Green Strength - The Moulding sand particles with moisture are called green sand. They
must be able to stick to each other to impart sufficient strength.
6. Dry strength- When molten metal is poured into the mould, the sand becomes dry
because of the heat of the metal.
7. Refractoriness- ability to withstand high temperatures without breaking down.
8. Collapsibility - so that during contraction of solidified casting it doesn't provide any
resistance, which can lead to crack formation.
9. Chemical resistivity - Moulding sand shouldn't chemically react with the metal as the
casting will be distorted
10. Fineness - prevents metal penetration, results in smoother surfaces.

A3. There are some allowances which are responsible for the difference in the dimensions of
the casting and the pattern. These allowances are considered when a pattern is designed for
casting.
The types are -
1. Shrinkage allowance - After solidification of the metal from further cooling (room temp.)
dimensions of the patterns increases. So pattern size is bigger than that of the finished
cast products. This is known as shrinkage allowance.
2. Draft/taper allowance- Pattern draft is the taper placed on the pattern surfaces that are
parallel to the direction in which the pattern is withdrawn from the mould (that is
perpendicular to the parting plane), to allow removal of the pattern without damaging the
mould cavity.
3. Distortion allowance- This allowance is taken into consideration when casting products
of irregular shapes. When these are cooled they are distorted due to metal shrinkage.
4. Machining allowance- Machining allowance or finish allowance indicates how much
larger the rough casting should be over the finished casting to allow sufficient material to
insure that machining will "clean up" the surfaces.
5. Shaking/rapping allowance- To take the pattern out of the mould cavity it is slightly
rapped to detach it from the mould cavity. So the cavity is increased a little.

A4. Typically, materials used for pattern making are wood, metal or plastics. Wax and Plaster of
Paris are also used, but only for specialized applications. Fiberglass and plastic patterns have
gained popularity in recent years because they are waterproof and very durable. Metal patterns
are long lasting and do not succumb to moisture, but they are heavier, more expensive and
difficult to repair once damaged. Wax patterns are used in a casting process called investment
casting. A combination of paraffin wax, beeswax and carnauba wax is used for this purpose.
Metal materials :
Advantages -
● Durable, good strength
● Can sustain rough handling
● Fixed shape, does not warp in storage
 ● Can be machined
● Smooth surface finish can be obtained
Disadvantages -
● Expensive
● Hard to shape
● Can get rusted
● Excessive weight
● Can't be repaired easily
Wooden materials:
Advantages -
● Ease of use
● Availability
● Cheapness
● Light weight
● Surface can be smoothened by sanding
● Can be cut and fabricated easily
Drawbacks-
● Affected by moisture easily, changes shape
● Improper storage leads to warping
● Low strength, breaks on rough usage

A5.

Directional solidification is solidification that occurs from farthest end of the casting and works its
way towards the sprue. Directional solidification can be used as a purification process. Since
most impurities will be more soluble in the liquid than in the solid phase during solidification,
impurities will be "pushed" by the solidification front, causing much of the finished casting to
have a lower concentration of impurities than the feedstock material, while the last solidified
metal will be enriched with impurities. This last part of the metal can be scrapped or recycled.

A6. Classification of metal joining process-

● Solid state welding process
● Fusion welding process
● Advanced welding techniques
Gas welding - Gas welding is an important type of welding process. It is done by burning of fuel
gases with the help of oxygen which forms a concentrated flame of high temperature. This flame
directly strikes the weld area and melts the weld surface and filler material. The melted part of
welding plates diffused in one another and create a weld joint after cooling.

Advantages-
● Easy to operate
● Relatively low cost
● Portable equipment
● Can be used for gas cutting
Disadvantages
● Provides low surface finish
● Safety issue
● Slow metal joining rate
● Suitable only for soft, thin sheets

Arc welding- In arc welding, the arc is used to create intense heat and this heat is used to join
metals together. the arc is brought in between two metal pieces and due to the heat generated,
the metals melt and when it cools a strong welded joint is formed.
Advantages -
● High efficiency /speed
● Consistent weld quality
● Fast and reliable
● Portable
● Forms strong bond between metals
● Inexpensive power source
Disadvantages
● High skilled operator is required

A7. Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an
arc welding process that uses a non-consumable tungsten electrode to produce the weld. The
weld area and electrode is protected from oxidation or other atmospheric contamination by an
inert shielding gas (argon or helium), and a filler metal is normally used. A constant-current
welding power supply produces electrical energy which is conducted across the arc through a
column of highly ionized gas and metal vapors known as a plasma. It is most commonly used to
weld thin sections of stainless steel and non-ferrous metals such as aluminum, magnesium, and
copper alloys.

Application -
● Used to weld aluminium and alloys
● Used to weld dissimilar metals
● Used in the aerospace industry
● Used to weld stainless steel, carbon base alloys, copper base alloy, nickel base alloy
etc.

MIG arc welding - It is an arc welding technique in which a consumable electrode is used to
weld two or more workpieces.
The workpiece to be welded and the consumable electrode (in the form of wire) are connected
to the Power Supply (D.C or A.C). Whenever the consumable electrode is brought near the
workpiece (with a small air gap), an arc is produced. This arc melts the electrode. The melted
electrode fills uniformly over the required regions of the workpiece.

An inert gas supply is provided around the electrode (hence the name ‘Metal Inert Gas
Welding’) during the welding process. It forms a gas shield around the arc and the weld. This is
intended to protect the weld from the external atmosphere.

The type of electrode used and the shielding gas used primary depends on the material to be
welded. In many cases the shielding gas used is a mixture of many gases.

Applications-
● Fabrication of sheet metal
● Deep groove welding

A8. Types of resistance welding -

● Resistance spot welding
● Resistance projection welding
● Resistance butt welding
● Flash butt joint
● Resistance seam welding

Sean welding - Welding of similar/dissimilar metals by supplying an electric current- it leads to

the formation of nuggets.
Spot welding - process in which contacting metal surface points are joined by the heat obtained
from resistance to electric current
A9. Two methods of arc welding - TIG and MIG
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc
welding process that uses a non-consumable tungsten electrode to produce the weld. The weld
area and electrode is protected from oxidation or other atmospheric contamination by an inert
shielding gas (argon or helium), and a filler metal is normally used. A constant-current welding
power supply produces electrical energy which is conducted across the arc through a column of
highly ionized gas and metal vapors known as a plasma. It is most commonly used to weld thin
sections of stainless steel and non-ferrous metals such as aluminum, magnesium, and copper
alloys.

MIG arc welding - It is an arc welding technique in which a consumable electrode is used to
weld two or more workpieces.

The workpiece to be welded and the consumable electrode (in the form of wire) are connected
to the Power Supply (D.C or A.C). Whenever the consumable electrode is brought near the
workpiece (with a small air gap), an arc is produced. This arc melts the electrode. The melted
electrode fills uniformly over the required regions of the workpiece.

An inert gas supply is provided around the electrode (hence the name ‘Metal Inert Gas
Welding’) during the welding process. It forms a gas shield around the arc and the weld. This is
intended to protect the weld from the external atmosphere.

The type of electrode used and the shielding gas used primary depends on the material to be
welded. In many cases the shielding gas used is a mixture of many gases.

A10. Friction Stirred Welding - It is a solid-state joining process that uses a non-consumable
tool to join two facing workpieces without melting the workpiece material. Heat is generated by
friction between the rotating tool and the workpiece material, which leads to a softened region
near the FSW tool.
Frictional heat is generated between the wear-resistant tool and the work pieces. This heat,
along with that generated by the mechanical mixing process and the adiabatic heat within the
material, cause the stirred materials to soften without melting. As the tool is moved forward, a
special profile on the probe forces plasticised material from the leading face to the rear, where
the high forces assist in a forged consolidation of the weld.

Advantages -
● Mechanical Properties not degraded
● Good safety level
● Environmentally safe
● No need to clean metal surface

Applications -
● Used in shipbuilding to weld the big parts
● Used in railways
● Used in automotive industry
● Used in Fabrication work.

A11. Arc blow is the, usually unwanted, deflection of the arc during arc welding. There are two
types of arc blow commonly known in the electric welding industry: magnetic and thermal.

MIG metal transfer types -

● Short circuit transfer is a transfer used when a lower voltage is used for MIG welding.
Short circuit transfer occurs when the wire contacts the metal creating short circuits.
During this short circuit the wire contacting the metal heats up and melts into the joint by
creating a puddle from contact. Then another contact begins and the process keeps
repeating many times a second.
● Globular transfer is similar to short circuit transfer. Globular transfer occurs when the
wire arcs and it creates a glob that hangs off of the wire. Then the glob falls to the metal
filling the joint and then the process begins again.
● Spray Transfer is a transfer where a higher voltage is applied and the electrode does not
contact the metal. The transfer is exactly like it sounds. The wire sprays or has very fine
mist transferring to the metal. You can also see a clean arc to the metal and will not have
any spatter
A13. Explosive forming is a metalworking technique in which an explosive charge is used
instead of a punch or press. It can be used on materials for which a press setup would be
prohibitively large or require an unreasonably high pressure, and is generally much cheaper
than building a large enough and sufficiently high-pressure press; on the other hand, it is
unavoidably an individual job production process, producing one product at a time and with a
long setup time.There are various approaches; one is to place metal plate over a die, with the
intervening space evacuated by a vacuum pump, place the whole assembly underwater, and
detonate a charge at an appropriate distance from the plate. For complicated shapes, a
segmented die can be used to produce in a single operation a shape that would require many
manufacturing steps, or to be manufactured in parts and welded together with an accompanying
loss of strength at the welds. There is often some degree of work hardening from the
explosive-forming process, particularly in mild steel.

A14. The Plastic Molding Processes:

Injection Molding
In Injection Molding, melted plastic is forced into a mold cavity. Once cooled, the mold can be
removed. This plastic molding process is commonly used in mass-production or prototyping of a
product. Injection molding machines were made in the 1930’s. These can be used to mass
produce toys, kitchen utensils, bottle caps, and cell phone stands to name a few.

Blow Molding
Blow molding is like injection molding except that hot liquid plastic pours out of a barrel vertically
in a molten tube. The mold closes on it and forces it outward to conform to the inside shape of
the mold. When it is cooled, the hollow part is formed. Examples of blow molding products are
bottles, tubes and containers.

Equipments needed in setting-up a blow molding business are relatively higher than injection
molding.

Compression Molding
In this type of plastic molding, a slug of hard plastic is pressed between two heated mold halves.
Compression molding usually uses vertical presses instead of the horizontal presses used for
injection and blow molding. The parts formed are then air-cooled. Prices of equipments used for
compression molding are moderate

Rotational Molding
Hollow molds packed with powdered plastic are secured to pipe-like spokes that extend from a
central hub. The molds rotate on separate axes at once. The hub swings the whole mold to a
closed furnace room causing the powder to melt and stick to the insides of the tools. As the
molds turn slowly, the tools move into a cooling room. Here, sprayed water causes the plastic to
harden into a hollow part. In this type of plastic molding, tooling costs are low and piece prices
are high. Cycle time takes about 40-45 minutes.