Madda Walabu University

College of Engineering
Department of mechanical
Engineering
Manufacturing
Engineering I (Meng 3192)
 Chapter One
Introduction
• Definition of Manufacturing Engineering

• Manufacturing Engineering is the branch of Engineering

focused on designing, analyzing, and optimizing
production processes and systems to efficiently
transform raw materials into finished products.
• Integrates principles of engineering, materials science,
and business to create effective manufacturing methods,
ensuring products are high-quality, cost-effective, and
made to scale.
 Key Areas in Manufacturing Engineering

• Process Design and Optimization: Developing and refining

production processes to maximize efficiency and minimize
waste.
• Product Design for Manufacturability (DFM): Designing
products to ensure they are easy and cost-effective to
manufacture.
• Automation and Robotics: Implementing automation
technologies to improve productivity and precision.
• Quality Control and Assurance: Setting up quality standards
and inspections to maintain high product standards.
• Lean Manufacturing and Continuous Improvement:
Applying lean principles to reduce waste and continuously
 Professional works of Manufacturing
Engineer
• Manufacturing Engineers work across industries, from
automotive and aerospace to electronics and consumer
goods, driving innovation in production techniques and
system efficiency
• Manufacturing Engineers work at the intersection of
design, production, and quality assurance, leveraging
technical skills and problem-solving abilities to create
optimized and sustainable manufacturing systems
Categories of Manufacturing Engineering

• Manufacturing processes can be broadly

categorized into several main types, each involving
different techniques and machinery tailored to
specific types of materials and products. Here are
the primary categories of manufacturing
 Categories …,
1. Casting and Foundry
• In casting, molten material (typically metal or plastic) is poured
into a mold where it cools and solidifies into a specific shape.
• Examples: Sand casting, die casting, and investment casting.
2. Forming and Shaping
• Forming processes reshape materials without adding or removing
any material. Common methods include:
– Forging: Shaping metal using compressive forces, often with a hammer
or press.
– Rolling: Reducing material thickness by passing it through rollers.
– Extrusion: Pushing material through a die to create long objects with a
fixed cross-sectional profile.
– Stamping: Forming parts from sheet metal by punching, bending, or
 Categories …,
3. Machining
• Machining removes material from a work piece to shape it precisely.
– Turning: Uses a lathe to rotate the work piece against a cutting tool.
– Milling: A rotating cutting tool removes material from a stationary workpiece.
– Drilling: Creates round holes in a work piece.
– Grinding: Abrasive machining for very fine finishes and precise dimensions.
4. Joining and Assembly
• This includes methods for joining two or more components to make a
finished product.
– Welding: Fusing materials, usually metals, by heating.
– Brazing and Soldering: Joining with a filler material at a lower temperature than
welding.
– Adhesive Bonding: Using glues or epoxies to bond materials.
 Categories …,
5. Additive Manufacturing
• Also known as 3D printing, this process builds objects layer by layer
from digital designs. It’s used for creating complex, customized, or
prototype parts.
– Examples: Stereo lithography (SLA), Selective Laser Sintering (SLS), and
Fused Deposition Modeling (FDM).
6. Surface Treatment and Finishing
• Processes that improve the appearance, durability, or functionality of
a surface.
– Plating: Applying a thin layer of metal, such as chrome or zinc.
– Anodizing: An electrochemical process used to increase the thickness of
the natural oxide layer on the surface of metal parts, commonly aluminum.
 – Painting and Powder Coating: Coatings applied for
aesthetics or protection.
– Polishing: Smoothing and shining surfaces for a better finish.
7. Advanced and Hybrid Manufacturing
• This includes new and advanced techniques that
combine multiple processes or use cutting-edge
technology.
– Laser Machining: Using lasers to cut, engrave, or alter
materials.
– Electrical Discharge Machining (EDM): Using electrical
discharges to shape hard materials.
• Hybrid Manufacturing: Combining additive and
subtractive processes for complex parts
 Roles of Manufacturing

• Manufacturing plays a critical role across various

sectors, providing essential products and services that
meet the needs of consumers, industries, and
governments. Here are some key applications of
manufacturing across different industries
• 1. Automotive Industry
• Application: Manufacturing is fundamental to
producing vehicles and automotive components,
including Engines, frames, electronics, and body
panels.
• Processes: Assembly lines, stamping, welding,
machining, and quality control systems
2. Aerospace and Defense
• Application: Manufacturing produces aircraft, spacecraft,
satellites, and defense equipment such as missiles and
military vehicles.
• Processes: Precision machining, casting, composite
fabrication, and additive manufacturing for complex parts,
often using advanced materials.
3. Electronics and Technology
• Application: Manufacturing creates components like
semiconductors, circuit boards, sensors, and consumer
electronics, including phones, laptops, and appliances.
• Processes: Surface-mount technology, assembly, micro-
fabrication, and clean-room environments for component
4. Healthcare and Medical Devices
• Application: Manufacturing is used to create medical devices
(e.g., MRI machines, ventilators), surgical instruments,
prosthetics, and pharmaceutical products.
• Processes: Precision machining, injection molding, additive
manufacturing for custom prosthetics, sterilization, and strict
quality control.
5. Construction and Infrastructure
Application: Manufacturing produces construction materials like
steel beams, concrete, windows, and plumbing systems, as well
as pre-fabricated building components.
Processes: Rolling, forging, casting, and welding for structural
elements, along with material treatment for durability
6. Consumer Goods
• Application: Manufacturing creates everyday products,
including clothing, footwear, toys, furniture, and household
appliances.
• Processes: Injection molding, assembly, automated sewing,
extrusion, and quality testing to ensure durability and safety
standards.
7. Energy and Power Generation
• Application: Manufacturing provides essential equipment for
the energy sector, including wind turbines, solar panels,
nuclear reactors, and fossil fuel extraction equipment.
• Processes: Precision machining, casting, welding, and surface
8. Agriculture and Food Processing
• Application: Manufacturing enables large-scale food
processing and packaging, as well as the creation of
agricultural machinery like tractors and irrigation systems.
• Processes: Processing, filling, sealing, labeling, and packaging,
along with equipment fabrication for machinery used in food
production.
9. Textiles and Apparel
• Application: Manufacturing produces fibers, fabrics, and
clothing through both automated and manual processes, often
including dyeing and finishing.
• Processes: Weaving, knitting, dyeing, cutting, and sewing,
along with quality control for durability and consistency.
10. Pharmaceuticals and Chemicals
• Application: Manufacturing is essential in producing
medications, vaccines, industrial chemicals, and consumer
products such as cleaning agents and cosmetics.
• Processes: Chemical synthesis, formulation, packaging,
and rigorous quality and safety testing.
11. Renewable Energy and Environmental Solutions
• Application: Manufacturing supports renewable energy by
producing equipment like solar cells, wind turbine
components, and bio fuel processors.
• Processes: Fabrication of photovoltaic cells, precision
manufacturing for wind turbine blades, and assembly for
eco-friendly solutions.
 CHAPTER TWO

2. Introduction to Basic Casting Processes

2.1. What is Casting
Definition: Casting is a manufacturing process where a liquid material,
typically metal, is poured into a mold and allowed to solidify.
The shape of the final object is determined by the cavity of the mold.
Purpose: Casting is widely used to produce complex shapes and large,
solid objects that would be difficult or uneconomical to make by
other manufacturing methods.
Applications: Common in industries like automotive (Engine blocks,
brake drums), Aerospace (Engine parts), construction, and art.
 2.2. Basic Steps in the Casting Process

3. Casting involves several key stages

A) Pattern Making: A model or pattern of the part is created. Patterns are
typically made of wood, plastic, or metal.
B) Mold Making: The pattern is placed in a mold material (often sand) to form
the mold cavity. In permanent casting, molds are made from metals and are
reusable.
C) Melting: The metal or other material is melted in a furnace.
D) Pouring: The molten material is poured into the mold cavity.
E) Cooling and Solidification: The molten material cools and solidifies in the
shape of the mold.
F) Mold Removal: The mold is broken or separated to remove the solidified
casting.
G) Finishing: The casting is cleaned, inspected, and sometimes polished or
machined for final touches.
 3. Types of Casting Processes

There are various casting methods, each suited for different applications and
materials:
A. Sand Casting
– Description: The most common method, sand casting uses a sand-based mold,
which is easy to shape and inexpensive.
– Advantages: Cost-effective, suitable for large castings, adaptable to different
metals.
– Applications: Engine blocks, large machine parts, heavy machinery components.
B. Investment Casting (Lost-Wax Casting)
– Description: Uses a wax pattern coated with a ceramic material. Once hardened,
the wax is melted out, leaving a cavity for casting.
– Advantages: High accuracy, fine details, and smooth surface finish.
– Applications: Jewelry, aerospace components, art, medical instruments.
C. Die Casting
  Description: Involves forcing molten metal into a metal mold under high
pressure, suitable for high-volume production.
 Advantages: High dimensional accuracy, smooth surfaces, and reusable
molds.
 Applications: Automotive parts, electronics casings, small machinery
components.
D. Permanent Mold Casting
– Description: Uses a reusable metal mold, typically for simple, repetitive
shapes.
– Advantages: Good surface finish, fast cooling due to metal molds, cost-
effective for high-volume production.
– Applications: Wheels, pistons, and small automotive parts.
E. Centrifugal Casting
– Description: The mold is rotated at high speed, forcing the metal to the
outer edges, ideal for cylindrical shapes.
– Advantages: High mechanical strength, minimal impurities.
– Applications: Pipes, rings, and other cylindrical components.
 4. Advantages and Limitations of Casting

• Advantages of Casting:
 Complex Shapes: Casting can create intricate shapes and internal
cavities that would be challenging to machine.
 Versatility: Suitable for both large and small production volumes.
 Material Flexibility: Applicable to almost all metals and various
alloys.
• Cost-Effectiveness: Lower costs for large-scale production.
Limitations of Casting:
• Surface Quality: Cast surfaces may require further finishing (e.g.,
grinding, polishing).
• Defects: Potential for defects like shrinkage, porosity, and
inclusions if not properly controlled.
• Initial Setup Costs: Some methods, like die casting, require high
initial costs for molds
 5. Common Defects in Casting

• Porosity: Small holes or voids due to trapped

gas.
• Shrinkage: Reduction in volume during
cooling, leading to potential cracking.
• Misruns: Incomplete filling of the mold,
causing an unfinished part.
• Cold Shuts: Incomplete fusion of metal flow
fronts, causing weak spots
 Design of Castings in Mechanical Engineering

• Introduction to Casting Design

• Definition: Casting design refers to the process
of creating detailed blueprints and models for
casting parts. Effective casting design ensures the
final product meets desired specifications,
minimizes defects, and is cost-effective.
• Objective: To produce a high-quality part with
good mechanical properties, minimal defects, and
optimized manufacturing efficiency
 Principles of Casting Design
Successful casting design involves several core principles:
• Simplicity: Design the casting with as few complex features
as possible to reduce the risk of defects and make
manufacturing easier.
• Uniform Section Thickness: Maintain consistent wall
thickness to prevent issues like hot spots, which can lead to
uneven cooling, shrinkage, and defects.
• Draft Angles: Include slight tapers or draft angles (typically
1-3°) on vertical surfaces to facilitate easy removal from the
mold.
• Fillets and Radii: Avoid sharp corners; instead, use rounded
edges and fillets to reduce stress concentrations and improve
the flow of molten metal
• 3. Key Design Considerations for Casting
A. Material Selection
– Select casting materials based on required mechanical
properties, thermal properties, and cost considerations.
– Common casting materials include iron, aluminum, magnesium,
steel, and brass.
B. Shrinkage Allowance
– All metals shrink upon solidification and cooling. Designers
must account for this by slightly increasing the dimensions of
the pattern to ensure the final cast matches desired dimensions.
– Shrinkage allowances vary by material (e.g., aluminum shrinks
more than iron).
C. Draft Angle
– Draft angles allow the casting to be removed from the mold
without damaging the mold or part. Typical draft angles range
from 1-3° depending on the complexity and depth of the feature.
D. Tolerances
– Cast parts have less precision than machined parts. Designers should
specify tolerances that are achievable by the casting process to avoid
costly post-casting machining.
– For critical dimensions, additional finishing may be required to
achieve tighter tolerances.
E. Risers and Feeders
– Risers (or feeders) are extra reservoirs of molten metal added to the
mold to feed the casting as it cools and shrinks. They help prevent
shrinkage defects in critical areas.
– Proper riser placement and design are essential to avoid
solidification defects.
F. Gating System Design
– The gating system controls the flow of molten metal into the mold
cavity. Good design ensures smooth flow, reduces turbulence, and
minimizes defects.
• Typical components include sprues, runners, and gates, each
designed to maintain optimal flow rate and pressure
 5. Design Features in Castings
• A) Holes and Cores
– Holes: Small holes can be drilled after casting, but larger or complex internal features require cores.
– Cores: Cores are sand or metal inserts placed in the mold to create hollow sections or complex
internal geometries. They are removed after casting.
– Core Prints: Support elements in the mold that hold the core in place during casting.
• B) Parting Line
– The parting line is where the two halves of the mold meet. It should be placed on the casting’s
widest part to facilitate mold separation and ensure proper alignment.
– Avoid complex parting lines, as they increase mold complexity and potential for defects.
• C) Ribs and Bosses
– Ribs: Thin, flat sections added to provide structural strength without adding excessive weight.
– Bosses: Raised cylindrical sections often used to add material around holes or threaded areas to
strengthen the connection.
• D) Heat Sinks and Chills

– Heat Sinks: Design elements that dissipate heat, helping control the cooling rate and avoid hot
spots.
– Chills: Metal inserts placed within the mold to absorb heat and promote faster solidification in
certain areas. Chills help reduce shrinkage defects.
 Common Casting Defects and How to Prevent Them

• Porosity: Small holes caused by trapped gases or shrinkage.

– Prevention: Proper venting, controlling the metal pouring rate, and
using risers.
• Shrinkage Defects: Caused by uneven cooling or lack of material
to fill voids.
– Prevention: Use risers, avoid thick sections, and apply chills to control
cooling.
• Misruns and Cold Shuts: Occur when molten metal doesn’t
completely fill the mold cavity.
– Prevention: Design for smooth flow, use appropriate pouring
temperatures, and avoid thin sections.
• Hot Tears: Cracks due to uneven cooling and solidification stress.
– Prevention: Maintain uniform section thickness, use rounded edges, and
avoid abrupt changes in thickness.
 6. Best Practices for Effective Casting Design

• Keep It Simple: Avoid intricate designs that

complicate mold making or introduce casting
defects.
• Consider Machining Allowances: Add extra
material in certain areas to allow for post-casting
machining for precision dimensions.
• Plan for Easy Mold Removal: Use draft angles and
place the parting line thoughtfully to avoid damage
to the casting or mold.
• Account for Solidification Patterns: Design risers
and gates to control how the part cools to minimize
shrinkage defects and promote even solidification
 Casting Defects and Their Remedies
1. Introduction to Casting Defects

• Definition: Casting defects are imperfections that

occur in cast parts due to issues in the casting
process. These defects can arise from improper
design, material handling, or environmental factors.
• Impact: Defects can affect the structural integrity,
appearance, and performance of cast components,
often necessitating rework or rejection of the part
 A. Gas-Related Defects

1. Porosity
– Description: Small holes or bubbles formed due to trapped gas
within the metal.
– Causes: Excessive moisture in the mold, high metal pouring
temperature, poor venting, or gas absorption by molten metal.
– Remedies:
• Ensure molds are dry before casting.
• Use proper venting channels in the mold to allow gas to escape.
• Decrease the pouring temperature if feasible.
• Degas the molten metal (remove dissolved gases).
2. Blowholes
– Description: Smooth, rounded cavities or holes formed in the
cast due to trapped gas.
– Causes: Moisture in molds or cores, improper venting, excessive
mold binder.
 – Remedies:
• Dry the molds and cores thoroughly before use.
• Improve mold ventilation to allow gas to escape.
• Reduce the binder content in mold material
3. Pinholes
– Description: Very small, dispersed holes on or below
the surface of the casting.
– Causes: Gas absorbed by the molten metal or reaction
with impurities in the mold.
– Remedies:
• Use proper degassing methods for molten metal.
• Avoid contaminants in the mold material.
• Increase the permeability of the mold.
 B. Shrinkage-Related Defects

1. Shrinkage Cavities
– Description: Voids or cavities formed due to contraction as the metal
solidifies.
– Causes: Uneven cooling, inadequate feeding system, large section
thickness.
– Remedies:
• Design proper risers to feed molten metal as it cools.
• Ensure uniform section thickness where possible.
• Use chills (metal inserts) in areas that cool slowly to promote even solidification.
2. Hot Tears or Cracks
– Description: Cracks or tears that form due to high stress in the material as it
cools and solidifies.
– Causes: Uneven cooling rates, abrupt changes in section thickness, rigid
molds.
– Remedies:
• Use fillets or rounded corners to reduce stress concentration.
• Avoid sudden changes in wall thickness in the casting design.
 C. Mold-Related Defects

1.Misruns
– Description: Incomplete filling of the mold, resulting in missing or
incomplete sections of the casting.
– Causes: Low pouring temperature, slow pouring speed, thin sections in
the mold.
– Remedies:
• Increase the pouring temperature and speed to improve metal flow.
• Avoid thin sections in the casting design.
• Ensure the gating system promotes smooth and consistent metal flow.
2. Cold Shuts
– Description: Lines or seams on the casting where two streams of metal
meet but do not fully fuse.
– Causes: Low metal temperature, slow pouring, or interrupted metal flow.
– Remedies:
• Raise the pouring temperature and pour faster to ensure streams merge.
 3. Runouts
– Description: Occurs when molten metal leaks out of
the mold, resulting in incomplete casting.
– Causes: Damaged or improperly sealed mold, weak
mold materials.
– Remedies:
• Check mold integrity and ensure tight sealing before
pouring.
• Use materials with adequate strength and heat
resistance for the mold
 D. Inclusion-Related Defects

• 1. Inclusions
– Description: Non-metallic particles or impurities trapped within the casting.
– Causes: Impurities in molten metal, contamination from the mold or ladle.
– Remedies:
• Use high-quality, clean materials and avoid contaminants.
• Filter the molten metal to remove slag and non-metallic impurities.
• Clean the mold and ladle thoroughly before pouring.
• 2. Sand Inclusions
– Description: Sand particles embedded in the casting, often resulting in rough
surfaces.
– Causes: Erosion of the mold surface, improper handling of sand molds.
– Remedies:
• Compact the sand mold properly to prevent erosion.
• Reinforce weak sections of the mold to withstand metal flow pressure.
• Reduce turbulence during metal pouring
 E. Dimensional Defects

1. Warping or Distortion
– Description: Warping or bending of the casting due to uneven cooling or
residual stresses.
– Causes: Uneven wall thickness, poor cooling control, inappropriate mold
support.
– Remedies:
• Ensure uniform wall thickness to prevent differential cooling.
• Control cooling rates carefully and use chills if necessary.
• Provide adequate support for the mold to avoid movement during solidification.
2. Dimensions Not Within Tolerance
– Description: Casting dimensions vary from specified tolerances.
– Causes: Improper shrinkage allowance, inadequate mold and pattern
design.
– Remedies:
• Account for shrinkage rates of specific metals in pattern design.
• Use accurate patterns and quality mold-making practices.
 F. Surface Defects

1. Scabs
– Description: Raised areas on the casting surface caused by metal penetrating
a broken mold surface.
– Causes: Weak mold, improper mold compaction, and excessive moisture.
– Remedies:
• Compact molds properly to maintain integrity.
• Adjust moisture levels in the mold material.
• Strengthen the mold with better quality materials or coatings.
2. Rat Tails and Buckles
– Description: Wrinkles or folds on the casting surface caused by mold
expansion.
– Causes: Thermal expansion of the mold material due to high metal
temperatures.
– Remedies:
• Reduce pouring temperature to prevent excessive mold expansion.
• Use refractory mold materials that can withstand thermal expansion