Aim-study different manufacturing process and select suitable

manufacturing process for protected type rigid flange coupling

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 processproduct

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

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

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
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 non-ferrous casting

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.

3) FORGING
4) 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.

5) Advantages of forging
6) Some common advantages of forging are given as under.
7) 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.

8) Disadvantages of forging
9) Few dis-advantages of forging are given as under.
10)
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.

11)

Applications of forging

12)
Almost all metals and alloys can be forged. The low and medium
carbon steels are readily hot forged without difficulty, but the highcarbon 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
13)
the parts of tractors, shipbuilding, cycle industries, railroad
components, agricultural machinery etc.

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.

The Grinding Process

Grinding is a material removal and surface generation process used
to shape and finish components made of metals and other materials.
The precision and surface finish obtained through grinding can be up
to ten times better than with either
turning or milling.Grinding employs an abrasive product, usually a
rotating wheel brought into controlled contact with a work surface.
The grinding wheel is composed of abrasive grains held together in a
binder. These abrasive grains act as cutting
tools, removing tiny chips of material from the work. As these
abrasive grains wear and become dull, the added resistance leads to
fracture of the grains or weakening of their bond. The dull pieces

break away, revealing sharp new grains that continue cutting. The
requirements for efficient grinding include:
abrasive components which are harder than the work
shock- and heat-resistant abrasive wheels
abrasives that are friable. That is, they are capable of controlled
fracturing
Most abrasives used in industry are synthetic. Aluminum oxide is
used in three quarters of all grinding operations, and is primarily
used to grind ferrous metals. Next is silicon carbide, which is used for
grinding softer, non-ferrous metals and high density materials, such
as cemented carbide or ceramics. Superabrasives, namely cubic
boron nitride or "CBN" and diamond, are used in about five percent
of grinding. Hard ferrous materials are ground with "CBN", while
non-ferrous materials and non-metals are best ground with
diamond. The grain size of abrasive materials is important to the
process. Large, coarse grains remove material faster, while smaller
grains produce a finer finish. The binders that hold these abrasive
grains together include:
vitrified bonds, a glass-like bond formed of fused clay or feldspar
organic bonds, from synthetic resins, rubber, or shellac
metal or single-layer bond systems for superabrasives
Wheels are graded according their strength and wear resistance. A
"hard" wheel is one that resists the separation of its individual grains.
One that is too hard will wear slowly and present dulled grains to the
work and overheat, affecting the final finish. If too soft a wheel is
used, it will deteriorate quickly, requiring frequent replacement.
Another aspect of grinding wheels is their pore structure or density,
which refers to the porosity between individual grains. This pore
structure createsm spaces between the grains that provide coolant
retention and areas for the chips to form. Dense wheels are best for
harder materials, while more open densities are better for the softer

metals. The three factors of grain size, bond type, and pore structure
are closely related, and together determine how well a wheel will
perform. Damaged wheels or even wheels suspected of being
damaged should not be used. Safety steps for proper use of grinding
wheels include, but are not limited to:
always having machine guards in place before turning on a grinding
wheel
running wheels for at least one minute before actual work begins
always using eye protection
properly balancing and dressing wheels before use
Wheel dressing and truing is done with special tools designed for
that purpose.
Although wheel dressing is often done manually between work
cycles, some grinding machines perform the dressing task
automatically. The application of coolants to the grinding process is
important. Coolants reduce grinding machine power requirements,
maintain work quality, stabilize part dimensions, and insure longer
wheel life. Coolants are either emulsions, synthetic lubricants or
special grinding oils. Coolants are applied by either flooding the work
area or by high pressure jet streams.
Types of Grinding
There are many forms of grinding, but the four major industrial
grinding
processes are:
cylindrical grinding
internal grinding
centerless grinding
surface grinding
In cylindrical grinding, the workpiece rotates about a fixed axis and
the surfaces machined are concentric to that axis of rotation.
Cylindrical grinding produces an external surface that may be either

straight, tapered, or contoured. The basic components of a

cylindrical grinder include a wheelhead, which
incorporate the spindle and drive motor; a cross-slide, that moves
the wheelhead to and from the workpiece; a headstock, which
locates, holds, and drives the workpiece; and a tailstock, which holds
the other end of the work. Internal diameter or "I.D." grinders finish
the inside of a previously drilled, reamed, or bored hole, using small
grinding wheels at high RPM. The principle elements of a internal
grinding machine are the workhead, which holds the work
and has its own drive; and the wheelhead, which is the internal
grinding spindle. In addition to the rotary motions of work and
wheel, an internal grinder has a traverse movement to bring the
wheel to and from the work zone, and a reciprocating spindle
movement for both the wheel's approach to the work
surface and for the feed movement of the wheel during grinding.
Several different internal contours can be produced within a
workpiece using I.D.grinding. In centerless grinding, the workpiece
rotates between a grinding wheel and a regulating drive wheel. The
work is supported from below by a fixed work-rest
blade. The two basic modes of centerless grinding are "thru-feed"
and "in-feed" or "plunge" mode. In the thru-feed mode, the work
proceeds in the axial direction through the slowly narrowing gap
between the grinding wheel and the
regulating wheel. Work is advanced by the axial force exerted on it
by the rotating surface of the regulating wheel. This is a highly
productive form of grinding in that a number of workpieces can be
ground simultaneously and in a
continuous stream. The "infeed" mode is used for work with
projecting heads that would prohibit "thru-feeding," the work is
placed on the work-rest blade while one wheel is retracted and fed
to an end stop. The wheel is then brought back, reducing the gap
between the wheels, grinding the work. Surface grinding produces
flat, angular, or contoured surfaces by feeding work in a horizontal
plane beneath a rotating grinding wheel. Work is most often

magnetically attached to the table, and may be ground by either a

traversing or rotating movement of the table. Most surface grinding
machines use a horizontal spindle which adjusts up and down
allowing either the edge or the face of the wheel to contact the
work.

ConclusionFrom the given assignment we study different type manufacturing process and
they are 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.for our design we have select casting ,rolling,.forging,machining,and
finishing process.

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