SR GUDLAVALLERU ENGINEERING

COLLEGE
(An Autonomous Institute with Permanent Affiliation to JNTUK, Kakinada)
SeshadriRao Knowledge Village, Gudlavalleru – 521 356.

Department of Mechanical Engineering

HANDOUT
for
MANUFACTURING SCIENCE

Prepared by
Dr P. Ravindra Babu
Professor and Advisor to the Management
And
Dr A Jawahar Babu
Professor
 MANUFATURING SCIENCE
Class & Sem. : II B.Tech – II Semester Year:2023-24
Branch : ME Credits: 3
Regulation : R20
===================================================================
=========
Brief History and Scope of the Subject
In today's highly technological society, we encounter a vast array of
manufactured goods daily, spanning from household items to vehicles, electronics,
and furniture. These products are the result of various manufacturing processes
conducted in factories worldwide, shaping our modern world of consumer goods.
Manufacturing, fundamentally, is the application of physical and chemical processes
to transform raw materials into finished products, often involving machinery, tools,
power, and labor. This value-adding activity has ancient origins, with processes like
casting, forging, and grinding dating back thousands of years.
The history of manufacturing unfolds in two main dimensions: the evolution
of materials and processes, and the development of production systems. Over
millennia, techniques such as casting and forging have evolved from artisanal crafts to
more sophisticated methods. Key milestones include the Industrial Revolution, which
ushered in machinery and steam power, revolutionizing economies, particularly in
England. Concepts like Adam Smith's division of labor and Eli Whitney's
interchangeable parts further propelled manufacturing advancement. The Second
Industrial Revolution introduced mass production, scientific management, assembly
lines, and factory electrification. Ford's assembly line innovation made complex
products more affordable, while electricity supplanted steam as the primary power
source.
The course "Manufacturing Science" offers a comprehensive exploration of
fundamental manufacturing processes, including metal casting, welding, and metal
forming. Mathematical models and analytical equations are utilized to deepen
understanding. Serving as a sequel to "Materials Engineering," this course provides a
sequential learning experience in the second year of study.

1. Pre-Requisites
 Classification of materials and their properties.
 Solidification of metals and alloys.
 Fundamentals of Engineering Workshop.
2. Course Objectives:
 To introduce the principles of manufacturing processes to convert materials
into desired shapes and sizes.
3. Course Outcomes:
Upon successful completion of the course, the students will be able to
CO 1: select appropriate molding method based on the geometry and quantity.
CO 2: design a pattern and gating system for producing a casting.
CO 3: choose appropriate type of welding process for joining of metals.
 CO 4: list out various welding defects and propose remedial measures.
CO 5: distinguish between hot working and cold working processes.
CO 6: identify suitable metal forming technique to impart desired geometry to the
product.
4. Programme Outcomes:
Engineering Graduates will be able to:
1. Engineering knowledge: Apply the knowledge of mathematics, science,
engineering fundamentals and an engineering specialization to the solution of
complex engineering problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze
complex engineering problems reaching substantiated conclusions using first
principles of mathematics,
natural sciences, and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering
problems and design system components or processes that meet the specified needs
with appropriate consideration for the public health and safety, and the cultural,
societal, and environmental considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and
research methods including design of experiments, analysis and interpretation of data,
and synthesis of the information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources and
modern engineering and IT tools including prediction and modeling to complex
engineering activities with an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge
to assess societal, health, safety, legal and cultural issues and the consequent
responsibilities relevant to the professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional
engineering solutions in societal and environmental contexts, and demonstrate the
knowledge of, and need for sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and
responsibilities and norms of the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member
or leader in diverse teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities
with the engineering community and with society at large, such as, being able to
comprehend and write effective reports and design documentation, make effective
presentations, and give and receive clear instructions.
11. Project management and finance: Demonstrate knowledge and understanding of
the engineering and management principles and apply these to one’s own work, as a
member and
leader in a team, to manage projects and in multidisciplinary environments.
 12. Life-long learning: Recognize the need for, and have the preparation and ability
to engage in independent and life-long learning in the broadest context of
technological change.

5. Program Specific Outcomes :

Engineering Graduates will be able to
PSO-1: design and analyze various thermal systems used in power generation and
human comfort.
PSO-2: design, analyze and develop products by adopting best manufacturing
practices.
PSO-3: use various mechanical engineering software tools for design and analysis of
various engineering components.

6. Mapping of Course Outcomes with Program Outcomes and Program Specific

Outcomes:
Correlation Levels
1: Slight (Low) 2: Moderate (Medium) 3: Substantial (High)

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2 PSO3

CO1 1 2 1 1
CO2 3 3 2 2 1 2
CO3 2 2 1 1 2 1 2
CO4 2 2 2 2 1 2
CO5 2 3 2 2 1 1
CO6 2 3 2 1 1 2

7. Mapping of Course with Program Outcomes and Program Specific Outcomes

Correlation Levels
1: Slight (Low) 2: Moderate (Medium) 3: Substantial (High)

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2 PSO3

Manufacturing
2 3 1 1 1 2 2 2
Science

8. Prescribed Text Books

 M.P.Groover, “Fundamentals of Modern Manufacturing, Materials,
Processing and Systems”, John Wiley & sons, inc, 4th Edition..
 H.S.Shan, “Manufacturing Processes”, Cambridge, 2nd Edition.
9. Reference Text Books
 Serope Kalpakjian and Steve R.Schmid, “Manufacturing Engineering &
Technology”, Pearson Eduaction, Inc,5 th Edition.
 Lindberg/PE , “Process and materials of manufacturing “, PHI.
 Heine, Roper, Rosenthal, “Principles of Metal Castings “, Tata Mc Graw Hill
Publications, 2nd edition.
 R.S.Paramar, “Welding Engineering and Technology “, khanna Publications.

10. URLs and Other E-Learning Resources

 https://www.nptel.ac.in/courses/112107145/17
 https://www.nptel.ac.in/courses/112107145/28
 https://www.nptel.ac.in/courses/112107145/4
11. Digital Learning Materials:
 NPTEL Video lectures by Prof. Shantanu Bhattacharya, IIT Kanpur.
 NPTEL Video lectures by Prof. D K Diwedi, IIT Roorkee.

12. Lecture Schedule / Lesson Plan

No. of Periods
Topic
Theory Tutorial
UNIT –I:
Introduction: Classification of Manufacturing Processes 1
Sand Casting: Steps involved in making casting 1
2
Patterns: Pattern materials, Types of patterns, 2
Pattern Allowances, Design of pattern for a given casting 2
Molding: Molding sand, Types of molding sand 1
Properties of molding sand 1 1
Methods of molding
2
Gating System-Types and design of gating system 2
UNIT –II: Riser Design
Riser Design & Location : Types of Risers 1
Riser Design (Size & Location) 2
Design Considerations for casting. 1 1
Solidification : Progressive & Directional solidification
1
Solidification time .
Special casting processes :Centrifugal casting, Investment casting, 2
Die casting, 1
1
Shell molding, Slush casting. 1
Casting defects – Cause and Remedies. 1
UNIT - III: Metal Joining Processes
Metal Joining Processes: Classification of metal joining processes 1
Welding: Definition, types of weld joints and welds, welding
2
techniques 1
Fusion Welding: principle of oxy acetylene welding, applications, 2
arc welding, 1
Resistance welding, 2
TIG welding, MIG welding, 2
1
thermit welding, 1
Heat Transfer in various welding techniques, heat and power 2
 requirements in arc welding, resistance welding
UNIT - IV:
Metal Forming: Classification- bulk deformations- sheet metal working 1
Rolling: Principles-flat rolling and its analysis, 1 1
forces and geometrical relationship in rolling 1
analysis of rolling load, torque and power , 1
types of rolling mills, rolling defects and remedies. 2
1
Forging: Principle,types, 1
open die forging,analysis,closed die forging 2
UNIT - V:
Drawing: Wire and bar drawing, 1
analysis of drawing-tube drawing. 2
Sheet metal process: Cutting operation, Shearing, blanking and
2 1
punching,
engineering analysis of sheet metal cutting. 1
Bending: V-Bending and edge bending 1
engineering analysis of bending, 1
1
sheetmetal drawing, mechanics, analysis. 2
Total No. of Periods: 54 11

13. Seminar Topics

 Vacuum molding
 Laser beam welding
 High energy rate forming
14. Continuous Evaluation Procedure
o The performance of a student shall be evaluated for 100 marks in the subject
“Manufacturing Science”. As per the R20 Curriculum, the distribution shall be
30 marks for internal evaluation and 70 marks for the end examination. •
o There shall be two mid-term examinations. Each mid-term examination
consists of
i. one online objective examination (OE) consisting of 20 multiple choice
questions for 10 marks for a duration of 20 minutes
ii. one descriptive examination (DE) consisting of 3 descriptive questions for 5
marks each a total of 15 marks for a duration of 90 minutes and
iii. one assignment(AT) for 5 marks.
o Each mid-term examination is conducted for total of 30 marks. Sum of the
80% marks of best scored mid-term examination and 20%marks of least
scored mid-term examination are scaled down for 30 marks.

15. Consultation Hours For Discussions

 Students can approach in between 3.50 p.m. to 4.30 p.m. in all working days of the
college.
https://msvs-
dei.vlabs.ac.in/mem103/Unit3Simulations.php?MEM103/Unit3/Simulations/PressureDieCast
ing.mp4
Casting simulations.

Multiple Choice Questions from Unit-I

1. Which of the following terms refer the process of converting raw materials into useful
products?
A) Manufacturing
B) Economics
C) Science
D) Simulation
2. Which of the following manufacturing processes is primarily used for shaping metal
parts by removing material?
A) Casting
B) Machining
C) Forging
D) Welding
3. In which manufacturing process is the material melted and poured into a mold to
create a desired shape?
A) Machining
B) Forging
C) Casting
D) Additive Manufacturing
4. What is the first step in sand casting?

A) Pouring molten metal into the mold

B) Creating a pattern
C) Removing the casting from the mold
D) Removing excess sand from the mold cavity
5. True replica of the casting with allowances is known as
A) Core
 B) Pattern
C) Mold
D) Ingate
6. Which of the following is taken care by oversized dimension of the pattern?
A) Liquid shrinkage
B) Solidification shrinkage
C) Solid shrinkage
D) Progressive solidification

7. Which pattern type is typically employed to manufacture axis-symmetric castings at

minimal pattern cost?
A) Split pattern
B) Loose-piece pattern
C) Sweep pattern
D) Gated pattern

8. Which step in sand casting involves compacting the sand mixture around the pattern
to form the mold cavity?

A) Pouring
B) Cooling
C) Shaking out
D) Ramming
9. Which material is commonly used for making patterns due to its low cost and ease of
fabrication?

A) Metal
B) Plastic
C) Wood
D) Ceramic
10. Which of the following patterns is more suitable to produce large symmetrical
castings?
A) Skeleton pattern
B) Gated pattern
C) Sweep pattern
D) Match plate pattern

11. Extra projection on the pattern to provide support to the core in the mold is known as
A) Core Print
B) Chill
C) Chaplet
D) Insulating pad

12. Which of the following is used for making the hollow cavities in the casting?
a) chaplet
b) vent rod
c) core
d) chill
13. Which component of the gating system controls the flow of molten metal from the
sprue to the mold cavity?

A) Runner
B) Riser
C) Gate
D) Sprue
14. In which type of gating system is the molten metal poured directly into the mold
cavity without using separate runners?

A) Bottom gating system

B) Top gating system
C) Side gating system
D) Bottom and side gating system
Correct Answer: B) Top gating system
15. Which of the following sand ramming methods result into hardest layer at the top of
the mold?
A) Jolting
B) Squeezing
C) Jolting & Squeezing
D) Slinging

16. In sand slinger molding, how is the sand delivered onto the pattern?
A) By hand shoveling
B) By gravity feed
C) By centrifugal force
D) By pneumatic pressure
Correct Answer: C) By centrifugal force
17. Which property of molding sand refers to its ability to withstand high temperatures
without deforming?
A) Refractoriness
B) Permeability
C) Compressive strength
D) Collapsibility
18. What does permeability of molding sand indicate?
A) Ability to withstand higher temperature
B) Ability to allow the gases to escape from the mold
C) Ability to undergo disintegrated mass
D) Resistance to chemical reaction with molten metal

19. The ability of sand particles to stick together is denoted as

A) Cohesiveness
B) Adhesiveness
C) Permeability
D) Flowabilty
20. A mold has a down sprue whose length is 20 cm and the cross-sectional area at the
base of the down sprue is 1 cm2. The down sprue feeds a horizontal runner leading to
the mold cavity of volume 1000 cm3. The time required to fill the mold cavity will be
A) 4.05 s
B) 5.05 s
C) 6.05 s
D) 7.25 s

Questions from Unit-I

1. Explain the term “Manufacturing” and classify the manufacturing processes.
2. Illustrate the steps involved in casting process.
3. Define the term “Pattern” and explain various allowances incorporated into it.
4. Discus the ideal requirements of pattern material and describe common pattern
making materials.
5. Describe the types of patterns used in casting process.
6. Explain various properties of molding sand.
7. What are the ingredients of molding sand? Present the general percentage of each
ingredient. Also illustrate the properties being contributed by respective elements.
8. Describe machine molding methods.
9. Define Gating system. What are the ideal requirements of a Gating system?
10. With the help of a sketch explain various elements of a Gating system.
11. A mold sprue is 20 cm long, and the cross-sectional area at its base is 2.5 cm2. The
sprue feeds a horizontal runner leading into a mold cavity whose volume is 1560
cm3.Determine: (a) velocity of the molten metal at the base of the sprue, (b) volume
rate of flow, and (c) time to fill the mold.
12. A mould has a down sprue whose length is 20 cm and the cross-sectional area at the
base of down sprue is 1 cm2. The down sprue feeds a horizontal runner leading into
the mould cavity of volume 1000 cm3. What will be the time required to fill the mould
cavity?
13. Molten metal can be poured into the pouring cup of a sand mold at a steady rate of
1000 cm3 /s. The molten metal overflows the pouring cup and flows into the
downsprue. The cross-section of the sprue is round, with a diameter at the top = 3.4
cm. If the sprue is 25 cm long, determine the proper diameter at its base so as to
maintain the same volume flow rate.

Multiple Choice Questions from Unit-II

1. In which of the following casting method, the molten metal is poured and allowed to
solidify while the mold is revolving?
a) Die casting method
b) Slush casting method
c) Centrifugal casting method
d) Investment casting method
2. Which of the following statement is wrong?
a) The hot chamber die casting machine is used for casting zinc, tin, lead and other
low melting alloys
b) The cold chamber die casting machine is used for casting aluminum, magnesium,
 copper base alloys and other high melting alloys
c) The castings produced by centrifugal casting method have open and coarse
grained structure
d) The castings produced by centrifugal casting method have fine grained structure
3. The centrifugal casting method, is used for casting articles of __________
a) symmetrical shape about horizontal axis
b) symmetrical shape about vertical axis
c) irregular shape
d) sphere shape
4. In which of the following casting process the sand is mixed with a thermosetting resin
to form a mould?
a) Shell moulding
b) Squeeze casting
c) Centrifugal casting
d) Die casting
5. Ratio of volume by surface area is known as
a) Yield
b) Modulus
c) Cooling Characteristics
d) Shape factor

6. What is the ideal shape of the riser?

A) Cylinder
B) Sphere
C) Cone
D) Cube
7. With a mold constant of 970000 s/m2, the solidification time (in seconds) for a
spherical casting of 200 mm diameter is
A) 539
B) 1078
C) 4311
D) 3233
8. While cooling, a cubical casting of side 40 mm undergoes 3%, 4%, and 5% volume
shrinkage during the liquid, phase transition, and solid states, respectively. The
volume of the metal compensated from the riser is
a) 2%
b) 7%
c) 8%
d) 9%
9. Two streams of liquid metal, which are not hot enough to fuse properly, result in a
casting defect known as
a) cold shut
b) Scab
c) Sand wash
d) Core shift
10. An expendable pattern is used in
a) Investment casting
b) Slush casting
 c) Die casting
d) Centrifugal casting
11. Insufficient fluidity of liquid metal results in following defect in the casting
a) Mis run
b) Mold shift
c) Blow holes
d) Core shift
12. In which of the following processes liquid metal is injected into the mold with
pressure
a) Investment casting
b) Slush casting
c) Die casting
d) Centrifugal casting
13. Modulus of the casting is
a) Volume of the casting + Surface area of the casting
b) Volume of the casting/Surface area of the casting
c) Volume of the casting multiplied by surface area of the casting
d) Volume of the casting minus Surface area of the casting

14. Defect which occurs due to the solidification of casting is known as

a) Swell b) Misrun c) Metal penetration d) Shrinkage cavity

15. Grey cast iron block 200X100X10 mm is produced in sand molding. Shrinkage
allowance is provided for the pattern is 1%. The ratio of volume of pattern to the
volume of casting is
a) 0.97 b) 0.99 c) 1.03 d) 2.17
16. In casting, gating ratio is defined as the ratio of
a) sprue area : total runner area : total gate area
(b) total gate area : sprue area : total runner area
(c) total runner area : sprue area : total gate area
(d) total runner area : total gate area : sprue area
17. In gating system, sprue is usually tapered to
a) Avoid air aspiration effect
b) Quick fill the mould cavity
c) Prevent erosion of the mold
d) Control progressive solidification
18. Riser is designed so as to
a) Freeze after the casting freezes
b) Freeze before the casting freezes
c) Freeze at the same time as the casting
d) Minimize the time of pouring
19. A cubic casting of 50 mm side undergoes volumetric solidification shrinkage and
volumetric solid contraction of 4% and 6% respectively. No riser is
used. Assume uniform cooling in all directions. The side of the cube after solidification and
contraction
a) 48.32 mm
b) 49.90 mm
c) 49.94 mm
d) 49.96 mm
 20. A cube shaped casting solidifies in 5 min. The solidification time in min for a cube of
the same material, which is 8 times heavier than the original casting, will be
_______________
a) 10 b) 20 c) 24 d) 40

Questions from Unit-II

1. In casting experiments performed using a certain alloy and type of sand mold, it took 155
sec for a cube-shaped casting to solidify. The cube was 50 mm on a side.
(i) Determine the value Cm of the mold constant in
Chvorinov's Rule.
(ii) If the same alloy and mold type were used, find the
total solidification time TTS for a cylindrical casting
in which the diameter r = 15 mm and length h =
50 mm

2. In the casting of steel under certain mold conditions, the mold constant in Chvorinov's
Rule is known to be Cm = 4.0 min/cm2 , based on previous experience. The casting is a
flat plate whose length = 30 cm, width = 10 cm, and thickness = 20 mm. Determine how
long it will take for the casting to solidify.
3. A cylindrical riser must be designed for a sand-casting mold. The casting itself is a steel
rectangular plate with dimensions 7.5 cm 12.5 cm 2.0 cm. Previous observations have
indicated that the total solidification time (TTS) for this casting is 1.6 min. The cylinder
for the riser will have a diameter-to-height ratio 1.0. Determine the dimensions of the
riser so that its TTS is 2.0 min.
4. A cylindrical riser is to be designed for a sand casting mold. The length of the cylinder is
to be 1.25 times its diameter. The casting is a square plate, each side = 10 in and thickness
= 0.75 inch. If the metal is cast iron, and Cm = 16.0 min/in2 in Chvorinov's Rule,
determine the dimensions of the riser so that it will take 30% longer for the riser to
solidify.
5. A riser in the shape of a sphere is to be designed for a sand casting mold. The casting is a
rectangular plate, with length = 200 mm, width = 100 mm, and thickness = 18 mm. If the
total solidification time of the casting itself is known to be 3.5 min, determine the
diameter of the riser so that it will take 25% longer for the riser to solidify

6. Illustrate the process with a neat sketch, where wax is used as a pattern material.
7. Outline the process of Investment casting with neat sketches.
8. Outline the process of Centrifugal casting with neat sketch
9. What are the defects you can expect in casting? What are the Causes for them? And
suggest suitable remedies to remove those defects.
10. Illustrate the sequence of operations involved in Die casting.
11. Outline the process of Slush casting with neat sketch