18AU36 Manufacturing Process - I syllabus for AU

Introduction:

Concept of Manufacturing process, its importance. Classification of Manufacturing processes. Introduction to Casting process & steps involved. Varieties of components produced by casting process. Advantages & Limitations of casting process.

Patterns:

Definition, functions, Materials used for pattern, various pattern allowances and their importance. Classification of patterns.

Binder:

Definition, Types of binder used in moulding sand.

Additives:

Need, Types of additives used. Types of base sand, requirement of base sand. Moulding sand mixture ingredients (base sand, binder & additives) for different sand mixtures. Method used for sand molding, such as Green sand, dry sand and skin dried moulds.

Cores:

Definition, Need, Types. Method of making cores, Binders used, core sand moulding.

Gates & Risers.

Principle and types.

Fettling and cleaning of castings:

Basic steps, Casting defects, Causes, features and remedies.

Special Moulding Process & Furnaces:

Moulding Machines:

Jolt type, Squeeze type, Jolt & Squeeze type and Sand slinger.

Process:

Study of important moulding processes, No bake moulds, Flaskless moulds, Sweep mould, CO2 mould, Shell mould, Investment mould.

Metal moulds:

Gravity die-casting, Pressure die casting, Centrifugal casting, Squeeze Casting, Slush casting, and Thixocasting processes.

Furnaces:

Constructional features & working principle of coke fired, oil fired and Gas fired pit furnace, Resistance furnace, Electric Arc Furnace, Cupola furnace.

Welding Process:

Definition, Principles, Classification, Application, Advantages & limitations of welding. Welding defects – Detection causes & remedy.

Arc Welding:

Principle, Metal Arc welding (MAW), Flux Shielded Metal Arc Welding (FSMAW). Structure of welds, Formation of different zones during welding. Heat affected zone (HAZ). Parameters affecting HAZ. Effect of carbon content on structure and properties of steel. Shrinkage in welds & Residual stresses. Concept of electrodes, Filler rod and fluxes.

Gas Welding:

Principle, Oxy – Acetylene welding, Chemical Reaction in Gas welding, Flame characteristics. Gas torch construction &working. Forward and backward welding.

Resistance welding:

Principles, Seam welding, Butt welding, Spot welding and projection welding.

Other welding processes:

Working principle, advantages and disadvantages and applications of Inert Gas Welding (TIG & MIG) Submerged Arc Welding (SAW) and Atomic Hydrogen Welding processes. (AHW) Friction welding, Explosive welding, Thermit welding, Laser welding and Electron beam welding.

Soldering, Brazing:

Parameters involved & Mechanism. Different Types of Soldering & Brazing Methods.

Inspection Methods:

Methods used for Inspection of casting and welding. Visual, Magnetic particle, Fluorescent particle, Ultrasonic, Radiography, Eddy current, Holography methods of Inspection.

Course Outcomes:

At the end of the course the student will be able to:

• Define various terms associated with casting processes
• Explain methods of construction of moulds, different non-destructive testing methods.
• Select moulding machine and moulding process based on material type
• Select appropriate joining process and type of joints.

Question paper pattern:

• The question paper will have ten full questions carrying equal marks.
• Each full question will be for 20 marks.
• There will be two full questions (with a maximum of four sub- questions) from each module.
• Each full question will have sub- question covering all the topics under a module.
• The students will have to answer five full questions, selecting one full question from each module.

Textbook/s

1 Manufacturing Process Dr. K. Radhakrishna Sapna Book House 5th Revised Edition 2009

2 Manufacturing & Technology: Foundry, Forming and Welding P. N. Rao, Tata McGraw Hill 2nd Ed, 2003

Reference Books

3 Manufacturing Technology Serope Kalpak jain, Steuen. R. Sechmid Pearson Education Asia, 5th Ed. 2006

4 Process and Materials of Manufacturing Roy A Lindberg Pearson Edu. 4th Ed 2006.