ME 1406 : MANUFACTURING PROCESS

Syllabus

Module I
Metal casting process: Introduction-advantages and limitations-applications-casting terms Patterns: Pattern allowance-pattern materials-types of patterns- colour codes Moulding materials: Moulding sand composition-testing sand properties-sand preparation-moulding sand properties-types of sand moulds-moulding machines Cores: Core sand, types of cores, core prints, chaplets, forces acting on the moulding flasks
Gating system: Elements of gating system, gates, pouring time, sprue, gating ratio, slag trap system, risering design-caine’s method, modulus method, chills-feeding aids

Module II
Product design for sand casting: designing for economical moulding –designing for eliminating defects-features to aid handling, Casting cleaning and casting defects-fettling-defects in casting Special casting process: Shell moulding –precision investment casting –permanent mould casting –die casting –centrifugal casting-continuous casting Casting metallurgy

Module III
Metal forming process: nature of plastic deformation-hot working and cold working Rolling: principle, rolling stand arrangement, rolling load, roll passes Forging: operations, smith forging, drop forging, press forging, machine forging, forging defects, forging design Extrusion-hot and cold extrusion, tube extrusion, wire drawing swaging Sheet metal operation- shearing operation, drawing, spinning, bending, stretch forming, embossing and coining

Module IV
Metal fabrication process: introduction to fabrication process, gas welding and cutting. Electric arc weldingprinciple of arc, arc welding equipment, electrodes, carbon arc welding, TIG GMAW, SAW, arc cutting Resistance welding: principle –spot, seam, projection, upset, flash welding Other welding process: Thermit welding, electro slag welding, EBW, laser beam welding, forge welding, friction welding, diffusion welding, explosion welding Welding design: heat input, heat flow, distortion, metallurgy of welding, defects in welding, brazing, braze welding and soldering

References:

1) Campbell, J.S , Principles of Manufacturing and Process, McGraw Hill, NewYork *
2) Cox, LL , Beginner’s Guide to Pattern Making, Newnes, London,
3) Heine, RW, CR Lpoer and PC RosenthalPrinciples of Metal Castings , McGraw Hill, New York *
4) Chvorinv,N, Theory of Solidification of castings, Geisserei
5) Tselikov, AI and VV Smirnov, Rolling Mills, Pergamon Press, Oxford
6) Rowe, GW, Elements of metal working theory , Edward Arnold, London
7) Pearson, CE and RN Parkins , The extrusion of Metals, Chapman & Hall London
8) Hinman,CW , Prss Working of Metals, McGraw Hill , New York
9) Little ,RL Welding and welding technology, McGraw Hill , New York *
10) Patte, HE Technological Advances in welding and other joining process, Battelle Press, Columbs
11) Manufacturing Process Science M I Khan & Srejul Haque,PHI
12) Manufacturing Process: Kaushik, PHI
13) Manufacturing Technology –Vol 1:P.N Rao,Tata McGraw Hill
* can be used as text book

Type of Questions for University Exam.

Q 1.Eight short answer questions of 5 marks with two questions from each of the four modules. (8x5 = 40 marks)
Q 2. to Q.5 : Two questions A & B of 15 marks from each modules with option to answer either A or B. (4x15 = 60 marks)