Manufacturing Technology

Course Objective:
To make the students knowledgeable and familiar about different aspects of manufacturing technologies and processes. After this, students can perform and choose the adequate process and procedure for the metal process.

1. The Casting Process (8 hours)
1. Introduction to Manufacturing process, classification and importance.
2. Introduction to Casting process & steps involved.
3. Varieties of components produced by casting process.
4. Advantages & Limitations of casting process.
5. Patterns:Definition, functions, Materials used for pattern
6. Various pattern allowances and their importance.
7. Binders: Definition, Types of binder, functions and uses
8. Additives: Need, Types, functions and uses


2. The Moulding Process (10 hours)
1. Types of base sand, requirement of base sand
2. Types of sand moulds
3. Sand moulds: Moulding sand mixture ingredients (base sand, binder & additives) for different sand mixtures. Method used for sand moulding.
4. Cores: Definition, Need, Types and Method of making cores
5. Concept of Gating & Risering: Principle involvedand types
6. Fettling and cleaning of castings,basic steps involved
7. Casting defects, causes, features and remedies
8. Moulding machines: Jolt type, squeeze type, Jolt & Squeeze type and Sand slinger
9. Important moulding processes: Green sand, Core sand, Dry sand, Sweep mould, CO2 mould, Shell mould, Investment mould
10. Metal moulds: Gravity die-casting, Pressure die casting, Centrifugal casting, Squeeze casting, Slush casting, Thixocasting and Continuous casting processes.


3. Furnaces (6 hours)
1. Classification of furnaces
2. Constructional features & working principle of Gas fired pit furnace, Resistance furnace, Coreless Induction furnace, Electric Arc Furnace, Cupola furnace


4. Welding (10 hours)
1. Definition, Principles, Classification, Application, Advantages & limitations of welding
2. Arc Welding: Principle, Metal Arc welding (MAW), Flux Shielded Metal Arc Welding FSMAW), Inert Gas Welding (TIG & MIG) Submerged Arc Welding (SAW) and Atomic Hydrogen Welding processes (AHW)
3. Gas Welding: Principle, Oxy – Acetylene welding, Reaction in Gas welding, Flame characteristics, Gas torch construction & working. Forward and backward welding
4. Resistance welding - principles, Seam welding, Butt welding, Spot welding and projection welding
5. Friction welding, Explosive welding, Thermit welding, Laser welding and Electron beam welding.


5. Metallurgical aspect in welding (5 hours)
1. Structure of welds, Formation of different zones during welding
2. Heat affected zone (HAZ)
3. Parameters affecting HAZ
4. Effect ofcarbon content onstructure and properties ofsteel,Shrinkage in welds & Residual stresses
5. Concept of electrodes, filler rod and fluxes
6. Welding defects, detection, causes & remedy


6. Soldering & brazing (6 hours)
1. Parameters involved & Mechanism
2. Different Types of Soldering & Brazing Methods


7. Inspection Methods (4 hours)
1. Methods used for Inspection of casting and welding: Visual, Magnetic particle, Fluorescent particle, Ultrasonic, Radiography, Eddy current, Holographymethods ofinspection

Practical:

1. Machining
1. Automatic Turning and external threading using single point tool
2. Angular shaping
3. Simple indexing (Hexagonal) on milling machine
2. Welding and Fabrication
1. Foundry Practice
2. Casting of metal
3. Welding:
4. Practice on brazing and bronze wielding
5. Practice on oxy-acetylene gas wielding for butt joint.
6. TIG, MIG, Resistance wielding.
7. Metal Forming
8. Practice on metal drawing process

References:

1. N.Rao “Manufacturing & Technology: Foundry Forming and Welding”, 2nd
2. Ed., Tata McGraw Hill, 2003.
3. Dr. K. Radhakrishna “Manufacturing Process-I”, , Sapna Book House, 2nd Edition 2007.
4. Serope Kalpakjain, Steuen.R.Sechmid, “Manufacturing Technology”, Pearson
5. Education Asia, 5th Ed. 2006.
6. Roy A Lindberg, “Process and Materials of Manufacturing:, 4th Ed. Pearson Edu. 2006.

Evaluation Scheme:
The questions will cover all the chapters of the syllabus. The evaluation scheme will be as indicated in the table below: