Primary forming processes

Report for mechanical engineering

Semester 1

Dany Degheady

16/09/2023
Introduction:
In the realm of mechanical engineering, primary forming processes hold a pivotal position,
serving as the cornerstone for various manufacturing sectors worldwide. These processes play a
fundamental role in producing a diverse range of products, spanning from intricate aircraft
components to everyday consumer goods. With their wide array of techniques, they effectively
transform raw materials into intricate structures and forms, exerting a significant impact on the
shaping of the contemporary world. It is through these essential methods that the modern
manufacturing landscape is forged.

The attainment of exact dimensions, mechanical qualities, and surface finishes in designed
components is contingent upon the primary forming processes, which are of utmost importance
in mechanical engineering. Engineers can optimize the mechanical properties of a variety of
materials, conform them to precise performance specifications, and reshape and consolidate
them using processes such as extrusion, forging, casting, and others.
The primary forming techniques used in mechanical engineering are examined in this report,
along with their benefits, drawbacks, applications, and guiding principles. The goal is to present
a thorough analysis of these procedures, highlighting the important part they play in the creation
and production of goods that spur innovation and advancements in a wide range of sectors.
Engineers and other experts in the field can improve product quality, make well-informed
judgments, and boost the field of mechanical engineering by familiarizing themselves with the
following primary forming processes.
Now while there are several primary forming processes, this paper aims to focus on the most
prominent of them. Casting and forging will be the two processes discussed, as they are the most
commonly used processes in the industry today.

Casting:
In mechanical engineering, casting is an elementary method that employs the laws of
thermodynamics and material science to precisely shape and structure raw materials. It has its
origins in the solidification of molten substances during their change from liquid to a solid state,
including metals, polymers, and composites. The fundamental concepts of heat transfer, phase
transitions, and fluid dynamics drive this transformation, which depends on thoughtful creation
and use of molds.
Casting's scientific foundation can be divided into multiple essential elements:
- Material selection:
An important scientific decision is selecting the material to be cast. The material's qualities that
affect its behavior throughout the casting process are considered, including its heat capacity,
thermal conductivity, and melting point. An effective cast depends on the understanding of the
various solidification properties of the materials.
A way this could be done is by analyzing the following diagram, which describes the properties
of varied materials.

- Melting and pouring:

Melting the material is the first step in the casting process. Thermal energy must be added for
this phase change from solid to liquid. Once melted, the substance is then poured into a mold;
when the liquid fills the mold, fluid dynamics are involved in this pouring process. The quality of
the casting can be greatly impacted by the molten material's temperature and flow velocity.

- Mold design:
The molten substance changes phases back into a solid state when it cools. Heat is released
during the exothermic phase transition. Since it influences the final casting’s mechanical
qualities and microstructure, the process by which this solidification takes place is curtailed. To
reduce flaws and guarantee acceptable qualities, it is essential to regulate the casting’s rate of
solidification and the direction of heat flow
 - Defect analysis:
The examination of flaws including porosity, shrinkage, and inclusions is necessary. These flaws
may result from poor mold design, careless material selection, or casting process mistakes. To
analyze such faults, it is required to have a deep understanding of the fundamental physics of
solidification

- Quality control:

To guarantee the quality and integrity of castings, scientific methods like mechanical testing,
non-destructive testing, and metallography are used. These techniques supply insight on the
microstructures, qualities, and performance traits of the material.

Types of casting:
The two most important casting types are die casting and sand casting.
1. Sand casting:
Among the oldest and most used casting techniques in mechanical engineering and production
is sand casting. It entails building sand molds that are then filled with molten metal to create a
variety of metal components in both simple and sophisticated designs. It has a reputation of
being adaptable, affordable, and suitable for both small- and large-scale production. Often,
molds are created by patterns.
Patterns are a replica of the final product which is used to create a mold. Typically, the pattern
is made of either wood, metal, plastic, or other materials, and is used to make a negative
impression in the mold material, which is then used to cast the final product.
It is important to note that the pattern's quality directly affects the product's quality, hence it is
necessary to ensure that the pattern is exact and free of defects. Generally, defects revolve
around the idea of thermodynamics and heat transfer. Maintaining temperature control during
the casting process is crucial. This management is essential to prevent problems of overheating,
which in metallurgical concerns like grain coarsening, or early solidification, which can produce
faults such as cold shuts. Achieving the appropriate material properties in the casting process
therefore requires careful temperature control.

Evidently, the number of patterns used in casting are numerous, and the following six are
examples of patterns and their uses.
1. Sweep pattern:
Rotational homogeneous casting is carried out by this pattern. A board with the necessary mold
profile, when rotated around a suitable spindle or guide, creates the desired mold in a sweep
pattern.

Usually, two are needed, one for the drag profile and the other for the cope profile. This allows
for the simple manufacturing of circular parts.

2. Skeleton pattern:
This pattern does not necessarily produce a completely solid structure. It is made of a wooden
frame and a rib construction (skeleton), to form a partially exterior or interior outline of the
casting so that the general contour and size of the desired casting may be produced. They
consist of strips and frames made of wood, which allows excess sand to be extracted.

This type of pattern allows to produce large parts and is commonly used in the nuclear industry.

3. Single- piece pattern

This pattern is made up of a single solid piece used to create an impression in the mold to
manufacture casting in the sand-casting process. After completion, the pattern should be taken
out of the mold, leaving behind the mold cavity which would eventually be used by pouring
molten metal within.
However, for more complex shapes or bigger castings, this pattern would be impractical due to
limitations in size or handling, which is why it is highly effective in creating small and simple castings.

- Two-piece pattern:

This is the type of casting used by engineers when single-piece patterns would not be the correct choice.
It is used by parting planes with flat or irregular surfaces, which helps with the determination of the
exact position of the plane.

It consists of two components, the drag and the cope. The cope contains the dowl pin, which when
pulled, would help in the alignment of the two separate parts. This pattern would then be more efficient
in creating larger and more complex castings.

- Shell mold pattern:

Here, the cast consists of a thin-walled shell, created by applying a sand-resin mixture around the
pattern. This is useful as it allows for ferrous and non-ferrous metals. Yet, this patten requires high
accuracy, which is why gear-housings, cylinder-heads, connecting rods and lever arms are used.
This pattern is the most effective when it comes to high production rates, as one mold can be
continuously used multiple times with the help of the sand-resin mixture.

- Match plate pattern:

The cope and drag in match plate patterns are placed on opposing sides of a plate, commonly a metallic
one, called the match plate.

The industry benefits from this since plate changeover is effective and ideal for high-accuracy short- to
medium-run casting manufacturing. Nevertheless, it is incapable of handling larger castings.

2. Die casting:
In the manufacturing sector, die casting is a high-pressure casting technique that is often used
to precisely create complicated and established metal parts. This method includes applying
intense pressure to molten metal as it is forced into a reusable steel mold or die. The
production of parts with tight tolerances and efficiency are well-known attributes of die casting.
Hence, the procedure for such would be:

1. Tooling design:
he die, a two-part mold usually made of hardened steel, is designed and fabricated before the
die casting process can start.

The die’s two halves are installed in a die casting machine after being carefully machined to
take on the required shape in the finished product.

2. Die casting machine:

Heat and pressure can be applied to die-casting machines with great precision. A stationary
platen and a moving platen make up their composition.

A sealed cavity is created when the die is placed on top of these platens.

3. Injection system:
An injection system, usually consisting of a metal furnace, a short chamber, and a plunger, is a
feature of the die casting machine.
The metal (often alloys of magnesium, zinc, or aluminum) is transformed into a molten
substance with the furnace. The plunger subsequently inserts the molten metal into the die
cavity.

4. Clamping:
To seal the mold chamber, the die’s two parts join. The clamping phase is the term for this
process.to stop the molten metal from escaping out of the mold, clamping pressure is essential.

5. Injection:
High pressure is used to feed the molten metal into the die cavity once the mold is closed. The
casting is kept under pressure until the substance solidifies. Hence, because of high pressure,
the molten is guaranteed to fill the whole cavity, producing the final detailed product.

6. Solidification:

The metal hardens quickly as it cools and fills the die cavity. Carefully regulating the
solidification process helps to prevent flaws and ensure the proper material qualities

7. Ejection:
The casting is released from the mold once the die has solidified. Then, the die-casting machine
is prepared for the subsequent operation
 8. Timming and finishing
During the trimming operation, flash-excess material from the ejected casting is eliminated. To
fulfill the final product criteria, other finishing techniques like coating, shot blasting, or
machining may be used.

Advantages of die casting:

- High production rates:

In a short time, using the die casting method, the process may produce many parts, depending
on shape and size.

- Good surface finish:

Die-cast components usually have a surface finish that is smooth, which eliminates the need for
further finishing procedures.

- High precision:
Dir casting makes it possible to produce pieces with precise tolerances that are both complex
and highly detailed.

Disadvantages of die casting:

- High initial tooling cost:

Die casting dies (molds) are designed and manufactured at a comparatively prohibitive cost. For
products produced in small quantities, this upfront cost may be a major obstacle.

- Limitation on part size:

Die casting works most economically when creating small to medium-sized products. Big and
heavy components could be difficult to manufacture and keep affordable.
 - Limited material selection:
Non-ferrous metals such as magnesium, zinc, and aluminum are the most appropriate for die
casting. Steel and iron (ferrous metals), have higher melting temperatures and are more
difficult to work with when utilizing traditional die casting techniques.

Other types of primary forming processes:

There are certainly different types of primary forming process used in the mechanical industry,
each serving its own purpose to produce a final product. Among these processes are:
1. Forging:
The process of forging entails exerting force on metal with a hammer or a press to shape it.
Usually, the material is heated until it becomes pliable and may be shaped.
Advantages:
- Superior grain structure and high strength
- Ideal for creating parts with large capacity to support loads.

Disadvantages:
- Compared to casting, only simpler shapes are possible.
- Increases expenses for equipment and tools.
- Cycling of heating and cooling takes a long period of time.

2. Rolling:
Rolling is a metalworking process that involves passing metal between two rolls in order to alter
its cross-sectional shape and reduce thickness.
Advantages:

- Effective in creating plates and sheets.

- Enhanced mechanical qualities as a result of grain deformation.
- High rates of production in big quantities.
Disadvantages:
 - Only available in continuous shapes.
- Requires a large upfront rolling mill investment.

Conclusion:
In summary, primary forming processes constitute the backbone of contemporary
manufacturing since they enable the transformation of raw material into a wide range of
products that power a variety of sectors. Every manufacturing method has its own advantages,
such as strength of forging, the efficiency of injection molding, and the versatility of casting. A
number of strategic variables, including the material qualities, part complexity, production
volume, and cost concerns, play a role in the decision to choose a particular forming process.
These procedures change as technology develops, guaranteeing that manufacturing stays
flexible, effective, and responsive to the constantly shifting demands of the world market.
Primary forming processes are essentially the epitome of creativity in transforming raw
materials into intricate, necessary, and functional parts that mold our environment.

Citations:
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www.minaprem.com/machining/introduction/primary-secondary-and-advanced-
manufacturing-processes-examples/. Accessed 16 Nov. 2023.

“Casting Process.” Casting Process - an Overview | ScienceDirect Topics,

www.sciencedirect.com/topics/engineering/casting-process. Accessed 16 Nov. 2023.

“What Is Forging?” Somers Forge, 10 May 2023, www.somersforge.com/what-is-forging/.

Adenwala, Noaman. “Noaman Adenwala.” Design | Engineering, 7 June 2023,

dizz.com/forming-process/.

Admin@bajrang. “Blog.” Bajrang Engineering, 29 June 2018, bajrangengineering.in/types-of-

casting-defects/.