Manufacturing Processes: Classification & Selection & Fundamentals of Casting Process
Manufacturing Processes : Classification
1. Metal Casting Processes
2. Metal Forming Processes/Metal Working Processes
3. Fabrication Processes
4. Material Removal Processes
5. Powder Metallurgy
6. Special Processes
7. Non-traditional Processes
Brief of the Main Processes
Metal Casting Processes
• Alloy Making & Melting
• Mould Making
• Pouring
• Cooling & Solidification
• Removal of Runners & Risers
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Investment Casting a Turbine Rotor

presented by:
Tejas Jadhav

Guided by-
Prof. P.G.Kulkarni

abstract:-

Investment casting is an industrial process based on lost-wax casting. Investment casting is an advanced metal forming process used to produce metal parts in high quality, functionality and cost-effectiveness. Lost wax casting process is a one-to-one process in which one disposable pattern produces one metal part. When combined with ....etc

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Most metal parts are manufactured by either fully-liquid (e.g., casting) or fully-solid (e.g., forging) processes. Semi-Solid Metalworking (SSM) incorporates elements of both casting and forging for the manufacture of near-net-shape discrete parts. Applications are fuel rails, suspension arms, engine brackets, steering Knuckles,rear axle components and motor cycle upper fork plates.



SSM casting was selected for each of these applications for different reasons - high integrity, pressure tightness and design simplification. In eac ....etc

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Moulds in Casting of Plastics and Thermoforming


Plastics today are larger serving as substitute material in the field of tooling and prototype parts but are being used as engineering materials in their own lights and in many applications, they are doing better job then any other material could do, some authorities claim that the rapid advancement of plastic tooling would have been impossible without the versatility of the epoxyresin.
Plastic tooling offers several advantages over conventional metal tooling. These includes:


1. Lowest ....etc

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DIRECT SHELL PRODUCTION CASTING

Nandish Datti


DSPC is a proprietary technology developed at Soligen.

Its core technology is based on Three Dimensional Printing (3DP) a patented technology invented at the Massachusetts Institute of Technology (MIT), and licensed exclusively to Soligen for the metal casting field of use.

Direct Shell Production Casting (DSPC) fabricates ceramic shells (molds) that can be used to cast metal parts.

The system creates ceramic shells directly from 3-D CAD designs and no too ....etc

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Metal Casting
 Create liquid metal - Melting
 Combustion used to melt material
 Electricity used to melt material
 Create solid shape - Casting
 Permanent mold casting
 Semi Permanent mold casting
 Consumable mold casting

Oxy-fuel Furnace
 Uses a fuel gas such as propane, natural
gas or acetylene
 Oxygen or atmosphere is blown in and
combined with fuel
 Heat from combustion melts the charge

Resistance Furnace
 A current passed through a material
re ....etc

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SAND CASTING

Sand Casting
In this process, sand mixed with binder and water is compacted around wood or metal pattern halves to produce a mould. The mould is removed from the pattern, assembled with cores, if necessary, and metal is poured into the resultant cavities. After cooling, moulds are broken to remove the castings. This process is suitable for a wide range of metals (both ferrous and non-ferrous), sizes and shape complexity



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Introduction

Plastics today are larger serving as substitute material in the field of tooling and prototype parts but are being used as engineering materials in their own lights and in many applications, they are doing better job then any other material could do, some authorities claim that the rapid advancement of plastic tooling would have been impossible without the versatility of the epoxyresin.
Plastic tooling offers several advantages over conventional metal tooling. These includes:


1. Lowest cost
2. Less time.
3. Light weig ....etc

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Plastics today are larger serving as substitute material in the field of tooling and prototype parts but are being used as engineering materials in their own lights and in many applications, they are doing better job then any other material could do, some authorities claim that the rapid advancement of plastic tooling would have been impossible without the versatility of the epoxyresin. Plastic tooling offers several advantages over conventional metal tooling. These includes:

1. Lowest cost

2. Less time.

3. Light weight, easily handled ....etc

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SEMINAR REPORT ON SINGLE CRYSTAL CASTING OF HPTR BLADE FOR AL-31FP ENGINE

Presented by,
Dillip Kumar Das Mohapatra
Mechanical Engg.
Regd No.-0721101016
7th Semester
VSSUT,BURLA





SINGLE CRYSTAL HP TURBINE BLADE

HPTR blades are hollow and of single crystal structure. This enhance creep resistance, thermal fatigue and hence enhances the life of the blade.
the shape of the turbine blade has a larger relative thickness and curvature compare to compressor blade




Turbine blade ....etc

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