Unit 1: Casting Processes

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Sections

Quick Formula Reference
Shrinkage Allowance
ΔL = L × α × ΔT
Volume of Casting
V = l × w × h
Solidification Time
t = K × (V/A)²
Practice Problems
50+ ProblemsCasting Processes
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Introduction to Manufacturing

Section 1 of 7

What is Manufacturing?

Manufacturing is the process of converting raw materials into finished products through various operations.

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Raw MaterialsProcessingFinished Product

Primary Shaping

Direct production of usable forms like castings, ingots

Examples: Cast products, rolled bars

Secondary Shaping

Further refinement through machining, finishing

Examples: Turning, milling, polishing
Real-World Examples
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Car Parts
Casting
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Utensils
Forming
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Phone Cases
Molding
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Tools
Machining
Exam Notes & Key Points

Important Definitions

Manufacturing: The application of physical and chemical processes to alter the geometry, properties, and/or appearance of a starting material to make parts or products
Primary Shaping: Processes that create the basic shape from raw materials (casting, forging, rolling)
Secondary Shaping: Processes that refine the shape and dimensions (machining, grinding)
Tertiary Processes: Finishing operations (polishing, coating, heat treatment)

Exam Questions & Answers

Q: What are the three main categories of manufacturing processes?
A: 1) Shaping processes, 2) Property-enhancing processes, 3) Surface processing operations
Q: Distinguish between discrete and continuous manufacturing.
A: Discrete: Individual parts (automotive, electronics). Continuous: Bulk materials (chemicals, steel)
Q: What factors influence manufacturing process selection?
A: Material properties, part geometry, production volume, quality requirements, cost considerations

Formula & Calculations

Production Rate: R = N/T (parts per unit time)
Manufacturing Cost: C = Material + Labor + Overhead + Tooling
Efficiency: η = (Actual Output / Theoretical Output) × 100%
Volume of Casting: V = l × w × h
Surface Area of Casting: SA = 2(lw + lh + wh)
🏭Manufacturing Basics Quiz
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What is manufacturing?

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