1. INTRODUCTION
Manufacturing is a process of producing goods in large quantities with the help different types of machinery. These are complex activities, which combines human expertise with automation. The process that is used, differ from product to product depending on the customer requirements and resource availability. Each process has its advantages and disadvantages and manufacturer can choose a process which is most suitable for their product. Normally in a production line one or more manufacturing processes are used to make a finished product.
Manufacturing processes are deals with numerous aspects of workshops procedures, basic working awareness, concepts of production criteria, traits and uses of numerous testing instruments and calibrating or inspecting units for checking materials or products to meet the commercial environment. These processes involve use of several hand tools, machinery and diverse methods of production which transform raw materials into appropriate usable forms.
Manufacturing processes can be mainly classified under two categories.
1. Processing operations
2. Assembly operations
Shape or the appearance of the material is transformed into a advance state trough the processing operations and in the assembly operations two or more different components are joined together to make a new product. In both of these cases value is added to the working material. Apart from the above classification, manufacturing processes can be considered under six different groups,
1. Primary shaping processes
2. Secondary shaping processes
3. Metal forming processes
4. Joining processes
5. Surface finishing processes
6. processes effecting change in properties.

In this report below listed shaping and forming processes will be discussed.
1. Metal casing
2. Metal rolling
3. Metal forging
4. Metal drawing and extrusion
5. Sheet metal forming
6. Power metal processes
7. Production processes of ceramic, glass and superconductors

2. METAL-CASTING
Casting is a shaping process and it has been used since 4000 B.C. In this process, molten metal is poured into a mold cavity and allows it to solidify. After the molt is solidified, it is taken out from the cavity by breaking or taking the mold apart. Today we can find different types of casting processes and each of them has its own advantages and disadvantages.
2.1. Mechanics of the process
a. Make the pattern – A replica of the exterior of the casting is called as a pattern and normally these are made of metal, wood or plastic. this step has to be done under careful attention to make a precise pattern for the casting.
b. Making the core – to make the hollow sections in a casting an additional piece of sand or metal is needed. This is referred as the core and they are breakable so they can be easily removed from the casting.
c. Molding –Molding sand is used to form a mold around the pattern. This is the cavity which is used to form the shape of the casting.
d. Making the casting – liquid metal is melted and then poured into the mold and keep that to solidify. Once solidified, sand is removed from the casting and this sand is collected and reused to make more castings.
e. Cleaning – as the final step, rough edges are removed and molding material is cleaned from the object to improve the appearance of the object.

2.2. Design considerations
Every manufacturing process require specific set of instructions to create a product and these helps to improve the quality and productivity of the process. All casting processes have basic similar characteristics and set of different steps which are made them specialized in certain way. Similarly, each method has its own design considerations. For an example, in die casting special attention has to be made with heat cracking of dies and less attention with mold erosion.
Geometric features and mold features are the main two design issues in casting and to have a robust design following steps need to be followed.
• Model the object to cast easily – sharp corners, smaller or too large fillets, larger flat areas and sharp angles need to be avoided as much as possible and sections in casting should blend smoothly into each other. Further, allowances for shrinkage and wide dimensional tolerance are two things that has to be there in the final model.
• Select a suitable casting process and material – casting process has to be selected considering the application, production capacity, available resources, environmental factors and cost of the process.
• Locate the parting line of the mold – parting line separates the upper and the lower halves of the mold. For low dense metals this should be placed as low as possible while for denser metals it should be placed around the mid plane of the casting.
• Create gates to allow uniform feeding into the cavity – gates connect runners with the casting object. These should be connected to the thick sections of the casting and multiple gates are preferred to reduce the pouring temperature.
Select a suitable runner

Chapter 1: Factual Review Questions Question 1: What is total qual...