Fundamentals of Manufacturing Processes

Applications of Manufacturing Processes

DHEERENDRA KUMAR DWIVEDI

1
 Casting
• Automotive sector: piston, cylinder, alloy wheel,
engine block, carburetor, transmission housing,
crank case, brakes, using alloys of Al, Mg, Zn and cast
iron, rail wheels
• Propellers of copper base alloys for ships
• Casing, covering and Impeller for centrifugal pumps
• Turbine blades and discs for high temperature
applications
• Large diameter shafts for hydropower plants
2
 Casting
• Gear blanks, girth gear for cement industry
• Municipality: pipes, man-hole cover, bench chair
parts using cast iron, bell casting
• Raw material: blooms, billets and strips
• Jewelry: Ornaments of gold and silver

3
Application of specific casting processes
• Sand mould casting: piston, cylinder, engine block, air
compressor frame, carburettor
• Die casting: alloy wheel, complex shape products
• Shell mould casting: gears, valves bodies, bushing,
camshafts
• Investment casting: statues, medals, jewellery, blades
for turbines, dental fixture
• Centrifugal casting: pipes, tunes, bushing, rings and
solid parts with high density
4
 Forming
• Automotive: connecting rod, crankshaft, body of
automotive, pressure vessels,
• Aircrafts: panels, fuse-lag, wings
• Tools: handle tools, spanners, wrenches, hammer,
• Raw material: sheets, plates, wires, rods, tubes,
girders, beams, rivets, springs
• Corrugated sheets as roof cover, floors,
• Hooks for materials handling

5
Application of specific forming processes
• Rolling: standard plates, sheets , I beam section,
thread and gear rolling, roll piercing for tubes
• Forging: crank shaft, connecting rod and gears,
blooms and slabs, coining
• Extrusion: uniform cross section rod and bars and
tubes
• Drawing: wires and bar, tube drawing
6
 Machining
• Machining of almost all components made by
casting, forming and welding is needed to get
desired size and shape, finish and tolerance
• Pipes, pistons, cylinders, nuts/bolts,
crankshafts, bearing, shafts, casing, gears,
engine block, carburettor etc.
7
Application of specific machining processes
• Turning: cylindrical shapes, holes, contour profiles,
taper, knurls
• Milling: flat surfaces, slots, keyways, contours, gears
• Shaping and planning: flat surfaces, slots and grooves
• Drilling: holes, counter bore and sinks, centering and
reaming
• Boring: enlarging and correcting existing holes
• Grinding: crankshaft, camshaft, flat surfaces

8
 Welding
• Automotive: car body, panels
• Petro-chemical: Gas cylinder, pipelines, LPG
carriers, steel structures,
• Railway: rails, carriage, wagons
• Construction: joining of reinforcing bar,
structures, bridges
9
 Applications of welding
• Specific area and mostly used welding process:
– Automobile: resistance welding
– Rail joints in railways: thermite welding
– Aero space and nuclear reactors: TIG welding
– Ship work: submerged arc welding
– Pressure vessel: SAW and GMAW
– Joining of metals (stainless steel, aluminium and
magnesium) sensitive to atmospheric gases: MIG
welding
 Applications of welding: specific
• Transport tankers for transporting oil, water, milk
• Welding tubes and pipes, chains, LPG cylinders
• Steel furniture, gates, doors and door frames,
body
• White goods such as refrigerators, washing
machines, microwave ovens etc.
Pressure vessel
 Bridges
• With advancement of welding
technology however, now welded
bridge structures are also
common.

Welding
 Ship
• Welding found its place in
ship building around 1920
and presently all welded Welding of ship
ships are widely used. structural parts
Underwater welding
 Building Structures
• Arc welding is extensively used for fabricating
steel structures such as trusses, towers in
construction industry.

Welding of trusses
 Transport Industry (Aerospace)
• Aircraft and Spacecraft: Spot and TIG welding
is widely used for fabrication of aircraft
structure and joining of skin sheet to body.

Welding of aircraft Welding of aircraft

Welding of rails
Repair welding
 Automotive industry
• The fabrication of automobile components
like chassis, body and its structure, fuel tanks
and joining of door hinges require welding.
 Electrical Industry
• Most of the engineering system used in electrical
industry are fabricated using welding:
– Generation: penstocks, water control gates,
condensers, turbine blades and cooling fins
– Distribution: electrical transmission towers and
distribution system equipment, transformer
– Utilization of electrical energy: electrical motor
stators
 Nuclear industry
• Welding is used for
fabrication of spheres
for nuclear reactor, pipe
line bends joining two
pipes carrying heavy
water.
 Defense industry
• For joining of many components of
– Tank bodies fabrication,
– joining of turret mounting to main body of
tanks
 Oil and Natural Gas Ind.
• Welding is used for joining
– pipes while laying of crude oil and
gas pipelines,
– construction of tankers for their
storage and transportation.
– Offshore structures,
– dockyards,
– loading and unloading cranes .
Welding of pipeline
 Micro-Joining
For joining of
– thin wire to wire,
– foil to foil and
– foil to wire, for producing junctions of thermocouples, strain
gauges .