Aim-study different manufacturing process and select

manufacturing process for protected type rigid flange coupling

suitable

Generally selection of suitable manufacturing process for any component is difficult

because of variety of process, for manufacturing of rigid flange coupling and its
different parts we use following manufacturing process-

product

Available manufacturing
process

shafts

Casting,rolling,machining

2
3

flanges
Casting, forging.
Nut& bolts Forging, machining.

key

Casting, forging, machining.

Preferred
manufacturing
process
All in special
order
casting
Both process in
special order
Forging
and
machining

What is manufacturing?

Manufacturing is the process of converting raw materials into products by

means of a variety of processes and methods. It encompasses the design and
production of goods, using various production methods and techniques.
Manufacturing is generally a complex activity, involving people who have a
broad range of disciplines and skills and a wide variety of machinery,
equipment, and tooling with various levels of automation, including computers,
robots, and materials handling equipment.More the manufactured parts in final
product assembly more its cost.

Basic Manufacturing processes

For producing of products materials are needed. It is therefore important to know the
characteristics of the available engineering materials. Raw materials used
manufacturing of products, tools, machines and equipments in factories or industries
are extracted from ores. The ores are suitably converted the metal into a molten form
by reducing or refining processes. In foundries. This molten metal is poured into
moulds for providing commercial castings, called ingots. Such ingots are then
processed in rolling mills to obtain market form of material supply in form of bloom,
billets, slabs and rods. These forms of material supply are further subjected to various
manufacturing processes for getting usable metal products of different shapes and
sizes in various manufacturing shops. All these processes used in manufacturing
concern for changing the ingots into usable products may be classified into six major
groups as primary shaping processes, secondary machining processes, and metal
forming
Processes, joining processes, surface finishing processes and processes effecting

Primary Shaping Processes

Primary shaping processes are manufacturing of a product from an amorphous
material. Some processes produces finish products or articles into its usual form
whereas others do not, and require further working to finish component to the desired
shape and size. Castings need re-melting of scrap and defective ingots in cupola or in
some other melting furnace and then pouring of the molten metal into sand or metallic
moulds to obtain the castings. Thus the
Intricate shapes can be manufactured. Typical examples of the products that are
produced by casting process are machine beds, automobile engines, carburettors,
flywheels etc. The parts produced through these processes may or may not require to
undergo further operations.
Some of the important primary shaping processes is:
(1) Casting, (2) Powder metallurgy, (3) Plastic technology, (4) Gas cutting, (5)
Bending and (6) Forging. Change in properties. These are discussed as under.

(2)

Secondary or Machining Processes

As large number of components require further processing after the primary
processes. These components are subjected to one or more number of
machining operations in machine shops, to obtain the desired shape and
dimensional accuracy on flat and cylindrical jobs. Thus, the
Jobs undergoing these operations are the roughly finished products received
through primary shaping processes. The process of removing the undesired or
unwanted material from the work piece or job or component to produce a
required shape using a cutting tool is known as machining. This can be done by
a manual process or by using a machine called machine tool (traditional

machines namely lathe, milling machine, drilling, shaper, planner, slotter). In

many cases these operations are performed on rods, bars and flat surfaces in
machine shops.
These secondary processes are mainly required for achieving dimensional
accuracy and a very high degree of surface finish. The secondary processes
require the use of one or more machine tools, various single or multi-point
cutting tools (cutters), job holding devices, marking and measuring instruments,
testing devices and gauges etc. for getting desired dimensional control and
required degree of surface finish on the work pieces. The example of parts
produced by machining processes includes hand tools machine tools
instruments, automobile parts, nuts, bolts and gears etc. Lot of material is
wasted as scrap in the secondary or machining process. Some of the common
secondary or machining processes are
(1) Turning, (2) Threading, (3) Knurling, (4) Milling, (5) Drilling, (6) Boring,
(7) Planning, (8) Shaping, (9) Slotting, (10) Sawing, (11) Broaching, (12)
Hibbing, (13) Grinding, (14) Gear cutting, (15) Thread cutting and (16)
Unconventional machining processes namely machining
With Numerical Control (NC) machines tools or Computer Numerical Control
(CNC) machines tools using ECM, LBM, AJM, USM setups etc.

Metal Forming Processes

Forming processes encompasses a wide variety of techniques, which make use
of suitable force, pressure or stresses, like compression, tension and shear or
their combination to cause a permanent deformation of the raw material to
impart required shape. These processes are also known as mechanical working
processes and are mainly classified into two major categories i.e., hot working
processes and cold working processes. In these processes, no material is
removed; however it is deformed and displaced using suitable stresses like
compression, tension, and shear or combined stresses to cause plastic
deformation of the materials to produce required shapes. Such processes lead to
production of directly usable articles which include kitchen utensils, rods,
wires, rails, cold drink bottle caps, collapsible tubes etc. Some of the important
metal forming processes are:
Hot working Processes
(1) Forging, (2) Rolling, (3) Hot spinning, (4) Extrusion, (5) Hot drawing and
(6) Hot spinning.
Cold working processes

(1) Cold forging, (2) Cold rolling, (3) Cold heading, (4) Cold drawing, (5) Wire
drawing,
(6) Stretch forming, (7) Sheet metal working processes such as piercing,
punching, lancing, Notching, coining, squeezing, deep drawing, bending etc.

Joining Processes
Many products observed in day-to-day life, are commonly made by
Putting many parts together may be in subassembly. For example, the ball pen
consists of a body, refill, barrel, cap, and refill operating mechanism. All these
parts are put together to form the product as a pen.
More than 800 parts are put together to make various subassemblies and final
assembly of car or aero-plane. A complete machine tool may also require to
assemble more than 100 parts in various sub assemble or final assembly. The
process of putting the parts together to form
The product, which performs the desired function, is called assembly. An
assemblage of parts may require some parts to be joined together using various
joining processes. But assembly should not be confused with the joining
process. Most of the products cannot be manufactured as single unit they are
manufactured as different components using one or more of the above
manufacturing processes, and these components are assembled to get the
desired product.
Joining processes are widely used in fabrication and assembly work. In these
process two or more pieces of metal parts are joined together to produce desired
shape and size of the product. The joining processes are carried out by fusing,
pressing, rubbing, riveting, screwing or any other means of assembling. These
processes are used for assembling metal parts and in general fabrication work.
Such requirements usually occur when several pieces are to be joined together
to fabricate a desired structure of products. These processes are used developing
Steam or water-tight joints. Temporary, semi-permanent or permanent type of
fastening to make a good joint is generally created by these processes.
Temporary joining of components can be achieved by use of nuts, screws and
bolts. Adhesives are also used to make temporary
Joints. Some of the important and common joining processes are:

(1) Welding (plastic or fusion), (2) Brazing, (3) Soldering, (4) Riveting, (5)
Screwing,
(6) Press fitting, (7) Sintering, (8) Adhesive bonding, (9) Shrink fitting, (10)
Explosive welding,
(11) Diffusion welding, (12) Keys and cotters joints, (13) Coupling and (14)
Nut and bolt joints.

Surface Finishing Processes

Surface finishing processes are utilized for imparting intended surface finish on the
surface of a job. By imparting a surface finishing process, dimension of part is not
changed functionally either a very negligible amount of material is removed from the
certain material is added to the surface of the job. These processes should not be
misunderstood as metal removing processes in any case as they are primarily intended
to provide a good surface finish or a decorative or protective coating on to the metal
surface. Surface cleaning process also called as a surface finishing process. Some of
the commonly used surface finishing processes are:
(1)

Honing, (2) Lapping, (3) Super finishing, (4) Belt grinding, (5) Polishing, (6)
Tumbling, (7) Organic finishes, (8) Sanding, (9) deburring, (10)
Electroplating, (11) Buffing, (12) Metal spraying, (13) Painting, (14)
Inorganic coating, (15) Anodizing, (16) Sherardizing, (17) Parkerizing, (18)
Galvanizing, (19) Plastic coating, (20) Metallic coating, (21) Anodizing and
(22) Sand blasting.

CASTING
Casting process is one of the earliest metal shaping techniques known to human being.
It means pouring molten metal into a refractory mold cavity and allows it to solidify.
The solidified object is taken out from the mold either by breaking or taking the mold
apart. The solidified object is called casting and the technique followed in method is
known as casting process. The casting process was discovered probably around 3500
BC in Mesopotamia. In many parts of world during that period, copper axes (wood
cutting tools) and other flat objects were made in open molds using baked clay. These
molds were essentially made in single piece. The Bronze Age 2000 BC brought
forward more refinement into casting process. For the first time, the core for making
hollow sockets in the cast objects was invented. The core was made of baked sand.

Also the lost wax process was extensively used for making ornaments using the
casting process. Casting technology was greatly improved by Chinese from around
1500 BC. For this there is evidence of the casting activity found in China. For making
highly intricate jobs, a lot of time in making the perfect mold to the last detail so
hardly any finishing work was required on the casting made from the molds. Indus
valley civilization was also known for their extensive use of casting of copper and
bronze for ornaments, weapons, tools and utensils. But there was not much of
improvement in the casting technology. From various objects that were excavated
from the Indus valley sites, they appear to have been familiar with all the known
casting methods such as open mold and piece mold. This chapter describes the fluidity
of molten metal, different casting techniques and various casting defects occurring in
casting processes.

PERMANENT MOLD OR GRAVITY DIE CASTING

This process is commonly known as permanent mold casting in U.S.A and gravity die
casting in England. A permanent mold casting makes use of a mold or metallic die
which is permanent A typical permanent mold is shown in Fig. 13.2. Molten metal is
poured into the mold under

Gravity only and no external pressure is applied to force the liquid metal into the mold
cavity. However, the liquid metal solidifies under pressure of metal in the risers, etc.

The metallic mold can be reused many times before it is discarded or rebuilt. These
molds are made of
dense, fine grained, heat resistant cast iron, steel, bronze, anodized aluminium,
graphite or other suitable refractoriness. The mold is made in two halves in order to
facilitate the removal of casting from the mold. It may be designed with a vertical
parting line or with a horizontal parting line as in conventional sand molds. The mold
walls of a permanent mold have thickness from 15 mm to 50 mm. The thicker mold
walls can remove greater amount of heat from the casting. For faster cooling, fins or
projections may be provided on the outside of the permanent mold. This provides the
desirable chilling effect. There are some advantages, disadvantages and application of
this process which are given as under.

Advantages
(i) Fine and dense grained structure is achieved in the casting. (ii) No blow holes exist
in castings produced by this method. (iii) The process is economical for mass
production. (iv) Because of rapid rate of cooling, the castings possess fine grain
structure.(v) Close dimensional tolerance or job accuracy is possible to achieve on the
cast product.(vi) Good surface finish and surface details are obtained .(vii) Casting
defects observed in sand castings are eliminated. (viii) Fast rate of production can be
attained.(ix) The process requires less labour.

Disadvantages
(i) The cost of metallic mold is higher than the sand mold. The process is impractical
for large castings.
(ii) The surface of casting becomes hard due to chilling effect.
(iii) Refractoriness of the high melting point alloys.

Applications
(i) This method is suitable for small and medium sized casting such as carburettor
bodies, oil pump bodies, connecting rods, pistons etc. (ii) It is widely suitable for nonferrous casting

CONTINNOUS CASTING
In this process the molten metal is continuously poured in to a mold cavity around
which a facility for quick cooling the molten metal to the point of solidification. The
solidified metal is then continuously extracted from the mold at predetermined rate.
This process is classified into two categories namely Asarco and Reciprocating. In
reciprocating process, molten metal is poured into a holding furnace. At the bottom of
this furnace, there is a valve by which the quantity of flow can be changed. The
molten metal is poured into the mold at a uniform speed. The water cooled mold is
reciprocated up and down. The solidified portion of the casting is withdrawn by the
rolls at a constant speed. The movement of the rolls and the reciprocating motion of
the rolls are fully mechanized and properly controlled by means of cams and follower
arrangements.

Advantages of Continuous Casting

(i) The process is cheaper than rolling. (ii) 100% casting yield.
(iii) The process can be easily mechanized and thus unit labor cost is less. (iv) Casting
surfaces are better. (v) Grain size and structure of the casting can be easily controlled.

Applications of Continuous Casting

(i) It is used for casting materials such as brass, bronzes, zinc, copper, aluminium and
its alloys, magnesium, carbon and alloys etc.(ii) Production of blooms, billets, slabs,
sheets, copper bar etc. (iii) It can produce any shape of uniform cross-section such as
round, rectangular, square, hexagonal, fluted or gear toothed etc.

FORGING
Forging is an oldest shaping process used for the producing small articles for which
accuracy in size is not so important. The parts are shaped by heating them in an open
fire or hearth by the blacksmith and shaping them through applying compressive
forces using hammers. Thus forging is defined as the plastic deformation of metals at
elevated temperatures into a predetermined size or shape using compressive forces
exerted through some means of hand hammers, small power hammers, die, press or
upsetting machine. It consists essentially of changing or altering the shape and section
of metal by hammering at a temperature of about 980C, at which the metal is entirely

plastic and can be easily deformed or shaped under pressure. The shop in which the
various forging operations are carried out is known as the smithy or smiths shop. A
metal such as steel can be shaped in a cold state but the application of heat lowers the
yield point and makes permanent deformation easier. Forging operation can be
accomplished by hand or by a machine hammer. Forging processes may be classified
into hot forging and cold forgings and each of them possesses their specific
characteristics, merits, demerits and applications.

Advantages of forging
Some common advantages of forging are given as under.
1. Forged parts possess high ductility and offers great resistance to impact and fatigue
loads. 2. Forging refines the structure of the metal. 3. It results in considerable saving
in time, labor and material as compared to the production of similar item by cutting
from a solid stock and then shaping it. 4. Forging distorts the previously created
unidirectional fiber as created by rolling and increases the strength by setting the
direction of grains. 5. Because of intense working, flaws are rarely found, so have
good reliability. 6. The reasonable degree of accuracy may be obtained in forging
operation. 7. The forged parts can be easily welded.

Disadvantages of forging
Few dis-advantages of forging are given as under.
1. Rapid oxidation in forging of metal surface at high temperature results in scaling
which wears the dies. 2. The close tolerances in forging operations are difficult to
maintain. 3. Forging is limited to simple shapes and has limitation for parts having
undercuts etc. 4. Some materials are not readily worked by forging. 5. The initial cost
of forging dies and the cost of their maintenance is high. 6. The metals gets cracked or
distorted if worked below a specified temperature limit.7. The maintenance cost of
forging dies is also very high.

Applications of forging
Almost all metals and alloys can be forged. The low and medium carbon steels are
readily hot forged without difficulty, but the high-carbon and alloy steels are more
difficult to forge and require greater care. Forging is generally carried out on carbon
alloy steels, wrought iron, copper-base alloys, aluminium alloys, and magnesium

alloys. Stainless steels, nickel based super-alloys, and titanium are forged especially
for aerospace uses. Producing of crank shaft of alloy steel is a good example which is
produced by forging. Forging processes are among the most important manufacturing
techniques utilized widely in manufacturing of small tools, rail-road equipments,
automobiles and trucks and components of aeroplane industries. These processes are
also extensively used in the manufacturing of
the parts of tractors, shipbuilding, cycle industries, railroad components, agricultural
machinery etc.

Rolling
Salient points about rolling
1) Rolling is the most extensively used metal forming process and its share is roughly
90%.
2) The material to be rolled is drawn by means of friction into the two revolving roll
gap
3) The compressive forces applied by the rolls reduce the thickness of the material or
changes its cross sectional area
4) The geometry of the product depend on the contour of the roll gap
5) Roll materials are cast iron, cast steel and forged steel because of high strength and
wear resistance requirements
6) Hot rolls are generally rough so that they can bite the work, and cold rolls are
ground and polished for good finish.
7) In rolling the crystals get elongated in the rolling direction. In cold rolling crystal
more or less retain the elongated shape but in hot rolling they start reforming after
coming out from the deformation zone
8) The peripheral velocity of rolls at entry exceeds that of the strip, which is dragged
in if the interface friction is high enough.

9) In the deformation zone the thickness of the strip gets reduced and it elongates.
This increases the linear speed of the at the exit.
10) Thus there exist a neutral point where roll speed and strip speeds are equal. At
this point the direction of the friction reverses.
11) When the angle of contact exceeds the friction angle the rolls cannot draw
fresh strip
12) Roll torque, power etc. increase with increase in roll work contact length or roll
radius.

Roll configurations in rolling mills

1) Two-high and three-high mills are generally used for initial and intermediate
passes during hot rolling, while four-high and cluster mills are used for final
passes.
2) Last two arrangements are preferred for cold rolling because roll in these
configurations are supported by back-up rolls which minimize the deflections
and produce better tolerances.

NUT MAKING PROCESS

A nut is a piece of metal wire rod with a threaded hole used for fastening purpose. The
quality of a nut depends upon the composition of it's raw metal. The recommended
composition is carbon (0.22 to 0.23%), Phosphorus (0.40%), Manganese (0.39 to
0.60%), Sulphur (0.50%)[4]. The basic manufacturing method is the forcing of
unheated metal to flow into dies to change it's shape. Then the cleaned and treated
wire rod is connected to a forming machine (FM) for straightening. After that it goes
to the cutting machine to cut the rod into desired size for nut manufacturing. Then the
pieces go to an induction heater for heating up to 1200 C and then they are
transferred to a hydraulic hammer mechanism to give them the most common
hexagonal shape. Then the nuts are drilled and threaded into a drilling and threading
machine simultaneously
with controlled lubricating mechanism to reduce wear and tear. Now the finished nuts
are sent to an oven at 870C for about an hour. This process gives the required
strength to nuts. At last they are rapidly cooled in an oil chamber for about 5minutes
and sent to the galvanizing section. Various conveyors and sensors are used between
intermediate stage to transfer the material and to control the operation respectively.

BOLT MAKING PROCESS

Bolt is a piece of metal rod, whose one end is up settled and other end, is threaded.
The same metal rod which is used for nut making is also used for bolt making process.
The process is actually a high-speed multi-blow presses. In this process at first the
straight and treated wire rod is cut into required size for bolt making. Then the
materials are sent to cold heading machine which is actually a high-speed multi-blow
press to make hexagonal head at one end. Actually there
are series of dies in the heading machine and the unheated metal is forced to flow into
the dies to change its shape. After that the material goes to the trimming machine for
cutting the edge of the bolt. At last the bolts are fed to the threading rolling machine
for making dreads [4, 6]. Then the finished bolts are sent to the galvanizing unit. In
each of those process controlled lubrication is used to minimize wear and tear and for

cooling. Various conveyor and sensor are used between intermediate stage to transfer
the material and to control the operation respectively.

Finishing Process
Manufacturing process employed determines surface finish level. Some
processes are inherently capable of producing better surfaces than others.
The processes recognized for good surface finish are honing, lapping,
polishing and surface finishing. Tolerance and range of surface roughness
produced by different processes are given below.

Different surface finishing processes are described below.

Honing
Honing is a surface finishing operation based on abrasive action performed
by a
set of bonded abrasive sticks. It is generally used to finish bores of
cylinders of IC
engine, hydraulic cylinders, gas barrels, bearings, etc. It can reduce the
level of
surface roughness below 32 m. It produces a characteristics surface pattern
as
cross hatched which is a fit case to retain lubrication layer to facilitate
motion to
moving parts, their best example is IC engine. The honing tool used to
finish
internal surface is shown in Figure 3.2. The honing tool consists of a set of
bonded
abrasive sticks. The number of sticks mounted on a tool depends on its

circumferential area. Number of sticks may be more than a dozen.

Lapping
In lapping, instead of a bonded abrasive tool, oil-based fluid suspension of
very small free abrasive grains (aluminum oxide and silicon carbide, with
typical grit sizes between 300 and 600) called a lapping compound is
applied between the workpiece and the lapping tool.
The lapping tool is called a lap, which is made of soft materials like copper,
lead or wood. The lap has the reverse of the desired shape of the
workpart. To accomplish the process, the lap is pressed against the
work and moved back and forth over the surface in a figure-eight or other
motion pattern, subjecting all portions of the surface to the same action.
Lapping is sometimes performed by hand, but lapping
machines accomplish the process with greater consistency and efficiency.
The cutting mechanism in lapping is that the abrasives become embedded
in the lap surface, and the cutting action is very similar to grinding, but a
concurrent cutting action of the free abrasive particles
in the fluid cannot be excluded. Lapping is used lo produce optical lenses,
metallic bearing surfaces, gages, and other parts requiring very
good finishes and extreme accuracy.

Polishing and buffing

Polishing is a finishing operation to improve the surface finish by means of
a polishing wheel made of fabrics or leather and rotating at high speed.
The abrasive grains are glued to the outside periphery of the polishing
wheel. Polishing operations are often accomplished manually. Buffing is a
finishing operation similar to polishing, in which abrasive grains are not
glued to the wheel but are contained in a buffing compound that is
pressed into the outside surface of the buffing wheel while it rotates. As in
polishing, the abrasive particles must be periodically replenished. As in
polishing, buffing is usually done manually, although machines have been
designed to perform the process automatically. Polishing is used to
remove scratches and burrs and to smooth rough surfaces while butting is
used to provide attractive surfaces with high luster.

Superfinishing
Superfinishing is a finishing operation similar to honing, but it involves the
use of a single abrasive stick. The reciprocating motion of the stick is
performed at higher frequency and smaller amplitudes. Also,
the grit size and pressures applied on the abrasive stick are smaller. A
cutting fluid is used to cool the work surface and wash away chips.
In super finishing, the cutting action terminates by itself when a lubricant
film is built up between the tool and work surface. Thus, super finishing is
capable only of improving the surface finish but not dimensional accuracy.
The result of these operating conditions is mirror like finishes with surface
roughness values around 0.01 m. Superfinishing can be used to finish flat and
external cylindrical
surfaces.

LATHE ATTACHMENTS USED FOR SUPER FINISHING

Super finishing can also be carried out lathe machine. Some attachments of
centre lathe along with their capabilities and uses are listed below.
Automatic Plunge Centreless Micro-finishing Machine
It is used for finishing of piston pins, cam followers, rollers, piston rods,
etc. The surface finish can be obtained upto 0.2 (Ra) value.
Centreless Micro-finishing Machine with Roller Support and Auxiliary
Drivers
The dimensions of the job that can be processed by this attachment is
diameter 25 to 150 mm and job length upto 2000 mm. It is capable to finish
the surface of roughness of 0.3 (Ra) to 0.025 (Ra). It is used for surface

finish of hydraulic cylinder piston rods; shock absorber front fork tubes, IC
engine parts, etc.
Attachment for Finishing of Engines and Gearbox Parts
It can be used for surface finishing of IC engine parts and gears, shafts, etc.
Most of the attachments designed and developed for lathe machine meant
for some
specific purpose. With all the attachment lathe provides the following
facilities :
(a) Base to work with the workpiece.
(b) Check to hold the workpiece/tool.
(c) Tool post to hold any processing tool.
(d) It provides motive power or a controlled relative motion between the
workpiece and tool. However, there is no end of lathe attachments used for
super finishing operation. Any attachment utilizing the above mentioned
lathe facilities can be designed and developed.

ConclusionFrom the given assignment we study manufacturing process is a very wide

phenomenon and it is developing/modifying time to time, because of industrial
evolution different non-conventional process along with conventional came to picture.
Each and every manufacturing process have its own advantages over other. for
manufacturing any component only one manufacturing process is not applicable,
component must go sequentially different types of process until finishing.

References1.Hajara Choudhari, Bose S.K. Elements of workshop Technology Vol. I &II ,

Asian Publishing House
2.D. K. Singh Fundamentals of Manufacturing Engineering Anes Books. Pvt. Ltd.

3. B. Ravi Metal Casting Computer Aided design and analysis- Prentice Hall of
India
4. Reikher Casting: An analytical approach Springer
5. Wang Rapid tooling guidelines for sand casting Springer
6. J. T. Black Degormos Materials and process in manufacturing John Willey and
sons
7. M.P Grover Fundamentals of modern manufacturing: Materials and systems
8. A.S Athalye Processing of plastic Colour Publication (Pvt.)Ltd. U.K
9. Cryil Donaldson and George H LeCain Tool Design Tata McGraw Hill
Education Pvt. Ltd.
10. Dr. R. S. Parmar, Welding Processes And Technology, Khanna Publishers, New
Delhi.