21ME32 Metal casting, Forming and Joining Processes syllabus for ME

Introduction & basic materials used in foundry:

Introduction: Definition, Classification of manufacturing processes. Metals cast in the foundry-classification, factors that determine the selection of a casting alloy. Introduction to casting process & steps involved – (Brief Introduction)-Not for SEE

Patterns:

Definition, classification, materials used for pattern, various pattern allowances and their importance.

Sand moulding:

Types of base sand, requirement of base sand. Binder, Additive’s definition, need and types; preparation of sand moulds. Molding machines- Jolt type, squeeze type and Sand slinger.

Study of important moulding process:

Green sand, core sand, dry sand, sweep mould, CO2mould, shell mould, investment mould, plaster mould, cement bonded mould. Cores: Definition, need, types. Method of making cores, Concept of gating (top, bottom, parting line, horn gate) and risers (open, blind) Functions and types.

Melting furnaces:

Classification of furnaces, Gas fired pit furnace, Resistance furnace, Coreless induction furnace, electric arc furnace, constructional features & working principle of cupola furnace.

Casting using metal moulds:

Gravity die casting, pressure die casting, centrifugal casting, squeeze casting, slush casting, thixocasting, and continuous casting processes. Casting defects, their causes and remedies.

METAL FORMING PROCESSES

Introduction of metal forming process: Mechanical behaviour of metals in elastic and plastic deformation, stress-strain relationships, Yield criteria, Application to tensile testing, train rate and temperature in metal working; Hot deformation, Cold working and annealing.

Metal Working Processes:

Fundamentals of metal working, Analysis of bulk forming processes like forging, rolling, extrusion, wire drawing by slab method,

Other sheet metal processes:

Sheet metal forming processes (Die and punch assembly, Blanking, piercing, bending etc., Compound and Progressive die), High Energy rate forming processes.

JOINING PROCESSES

Operating principle, basic equipment, merits and applications of:

Fusion welding processes: Gas welding - Types – Flame characteristics; Manual metal arc welding – Gas Tungsten arc welding - Gas metal arc welding – Submerged arc welding.

Weldability and thermal aspects:

Concept of weldability of materials; Thermal Effects in Welding (Distortion, shrinkage and residual stresses in welded structures); Welding defects and remedies.

Allied processes:

Soldering, Brazing and adhesive bonding

Advance welding processes:

Resistance welding processes, friction stir welding (FSW).

PRACTICAL COMPONENT OF IPCC

Course objectives:

• Impart fundamental understanding of various casting, welding and forming processes
• To provide in-depth knowledge on metallurgical aspects during solidification of metal and alloys
• Discuss design methodology and process parameters involve in obtaining defect free component

Experiments

1 Studying the effect of the clay and moisture content on sand mould properties

2 Preparation of sand specimens and conduction of the following tests: 1. Compression, Shear and Tensile tests on Universal Sand Testing Machine.

3 To determine permeability number of green sand, core sand and raw sand.

4 To determine AFS fineness no. and distribution coefficient of given sand sample.

5 Use of Arc welding tools and welding equipment Preparation of welded joints using Arc Welding equipment LJoint, T-Joint, Butt joint, V-Joint, Lap joints on M.S. flats

6 To study the effect of heat affected zone on the microstructure of steel weldment using MMAW.

7 Preparing minimum three forged models involving upsetting, drawing and bending operations

8 Sheet metal punch/die design and layout optimization

Demo experiments for CIE

9 To study the defects of Cast and Welded components using Non-destructive tests like: a) Ultrasonic flaw detection b) Magnetic crack detection c) Dye penetration testing

10 Mould preparation of varieties of patterns, including demonstration

11 To generate plastic curve of a given metal strip at room temperature and at recrystallization temperature during rolling. Observe the changes in metal characteristic after rolling.

12 Demonstration of material flow and solidification simulation using Auto-Cast software

Course outcome (Course Skill Set)

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

1. Select appropriate primary manufacturing process and related parameters for obtaining initial shape and size of components.

2. Design and develop adequate tooling linked with casting, welding and forming operations.

3. Appreciate the effect of process parameters on quality of manufactured components

4. Demonstrate various skills in preparation of molding sand for conducting tensile, shear and compression tests using Universal sand testing machine.

5. Demonstrate skills in preparation of forging models involving upsetting, drawing and bending operations.

6. Demonstrate skills in preparation of Welding models.

Assessment Details (both CIE and SEE)

• The weightage of Continuous Internal Evaluation (CIE) is 50% and for Semester End Exam (SEE) is 50%.
• The minimum passing mark for the CIE is 40% of the maximum marks (20 marks).
• A student shall be deemed to have satisfied the academic requirements and earned the credits allotted to each subject/ course if the student secures not less than 35% (18 Marks out of 50) in the semester-end examination(SEE), and a minimum of 40% (40 marks out of 100) in the sum total of the CIE (Continuous Internal Evaluation) and SEE (Semester End Examination) taken together

CIE for the theory component of IPCC

Two Tests each of 20 Marks (duration 01 hour)

• First test at the end of 5th week of the semester
• Second test at the end of the 10th week of the semester

Two assignments each of 10 Marks

• First assignment at the end of 4th week of the semester
• Second assignment at the end of 9th week of the semester Scaled-down marks of two tests and two assignments added will be CIE marks for the theory component of IPCC for 30 marks. CIE for the practical component of IPCC
• On completion of every experiment/program in the laboratory, the students shall be evaluated and marks shall be awarded on the same day. The15 marks are for conducting the experiment and preparation of the laboratory record, the other 05 marks shall be for the test conducted at the end of the semester.
• The CIE marks awarded in the case of the Practical component shall be based on the continuous evaluation of the laboratory report. Each experiment report can be evaluated for 10 marks. Marks of all experiments’ writeups are added and scaled down to 15 marks.
• The laboratory test (duration 03 hours) at the end of the 15th week of the semester /after completion of all the experiments (whichever is early) shall be conducted for 50 marks and scaled down to 05 marks.

Scaled-down marks of write-up evaluations and tests added will be CIE marks for the laboratory component of IPCC for 20 marks. .

SEE for IPCC

Theory SEE will be conducted by University as per the scheduled timetable, with common question papers for the course (duration 03 hours)

3. The question paper will have ten questions. Each question is set for 20 marks. Marks scored shall be reduced proportionally to 50 marks

4. There will be 2 questions from each module. Each of the two questions under a module (with a maximum of 3 subquestions), should have a mix of topics under that module.

5. The students have to answer 5 full questions, selecting one full question from each module.

The theory portion of the IPCC shall be for both CIE and SEE, whereas the practical portion will have a CIE component only. Questions mentioned in the SEE paper shall include questions from the practical component).

• The minimum marks to be secured in CIE to appear for SEE shall be the 12 (40% of maximum marks-30) in the theory component and 08 (40% of maximum marks -20) in the practical component. The laboratory component of the IPCC shall be for CIE only. However, in SEE, the questions from the laboratory component shall be included. The maximum of 04/05 questions to be set from the practical component of IPCC, the total marks of all questions should not be more than the 20 marks.
• SEE will be conducted for 100 marks and students shall secure 35% of the maximum marks to qualify in the SEE. Marks secured will be scaled down to 50.

Suggested Learning Resources:

Books

1. Ghosh, A. and Mallik, A. K., (2017), Manufacturing Science, East-West Press.

2. Parmar R. S., (2007), Welding Processes and Technology, Khanna Publishers.

3. Little R. L. – ‘Welding and Welding Technology’ – Tata McGraw Hill Publishing Company Limited, New Delhi – 1989

4. Grong O. – ‘Metallurgical Modelling of Welding’ – The Institute of Materials – 1997 – 2nd Edition

5. Kou S. – ‘Welding Metallurgy’ – John Wiley Publications, New York – 2003 – 2nd Edition.

6. Serope Kalpakjian and Steven R. Schmid – ‘Manufacturing Engineering and Technology’ – Prentice Hall – 2013 – 7th Edition

7. Principles of foundry technology, 4th edition, P L Jain, Tata McGraw Hill, 2006.

8. Advanced Welding Processes technology and process control, John Norrish, Wood Head Publishing, 2006.