Sub Code : ME3393
Sub Name : MANUFACTURING PROCESSES
COURSE OBJECTIVES
- To illustrate the working principles of various metal casting processes.
- To learn and apply the working principles of various metal joining processes.
- To analyse the working principles of bulk deformation of metals.
- To learn the working principles of sheet metal forming process.
- To study and practice the working principles of plastics molding.
UNIT I
METAL CASTING PROCESSES
Sand Casting – Sand Mould – Type of patterns - Pattern Materials – Pattern allowances – Molding sand Properties and testing – Cores –Types and applications – Molding machines – Types and applications– Melting furnaces – Principle of special casting processes- Shell, investment – Ceramic mould – Pressure die casting – low pressure, gravity- Tilt pouring, high pressure die casting- Centrifugal Casting – CO2 casting –- Defects in Sand casting process-remedies
UNIT II
METAL JOINING PROCESSES
Fusion welding processes – Oxy fuel welding – Filler and Flux materials-–Arc welding, Electrodes, Coating and specifications – Gas Tungsten arc welding –Gas metal arc welding - Submerged arc welding – Electro slag welding– Plasma arc welding –– Resistance welding Processes -Electron beam welding –Laser beam Welding Friction welding – Friction stir welding – Diffusion welding – Thermit Welding, Weld defects – inspection &remedies – Brazing - soldering – Adhesive bonding.
UNIT III
BULK DEFORMATION PROCESSES
Hot working and cold working of metals – Forging processes – Open, impression and closed die forging – cold forging- Characteristics of the processes – Typical forging operations – rolling of metals – Types of Rolling – Flat strip rolling – shape rolling operations – Defects in rolled parts – Principle of rod and wire drawing – Tube drawing – Principles of Extrusion – Types – Hot and Cold extrusion. Introduction to shaping operations.
UNIT IV
SHEET METAL PROCESSES
Sheet metal characteristics – Typical shearing, bending and drawing operations – Stretch forming operations – Formability of sheet metal – Test methods –special forming processes - Working principle and applications – Hydro forming – Rubber pad forming – Metal spinning – Introduction of Explosive forming, magnetic pulse forming, peen forming, Super plastic forming – Micro forming – Incremental forming.
UNIT V
MANUFACTURE OF PLASTIC COMPONENTS
Types and characteristics of plastics – Molding of thermoplastics & Thermosetting polymers– working principles and typical applications – injection molding – Plunger and screw machines – Compression molding, Transfer Molding – Typical industrial applications – introduction to blow molding – Rotational molding – Film blowing – Extrusion – Thermoforming – Bonding of Thermoplastics- duff moulding.
TOTAL :45 PERIODS
OUTCOMES
At the end of the course the students would be able to
- Explain the principle of different metal casting processes.
- Describe the various metal joining processes.
- Illustrate the different bulk deformation processes.
- Apply the various sheet metal forming process.
- Apply suitable molding technique for manufacturing of plastics components.
TEXT BOOKS
- Kalpakjian. S, “Manufacturing Engineering and Technology”, Pearson Education India,4th Edition, 2013
- P.N.Rao Manufacturing Technology Volume 1 Mc Grawhill Education 5th edition,2018.
REFERENCES
- Roy. A. Lindberg, Processes and materials of manufacture, PHI / Pearson education, 2006.
- S. Gowri P. Hariharan, A.Suresh Babu, Manufacturing Technology I, Pearson Education, 2008.
- Paul Degarma E, Black J.T and Ronald A. Kosher, Eligth Edition, Materials and Processes, in Manufacturing, Eight Edition, Prentice – Hall of India, 1997.
- Hajra Chouldhary S.K and Hajra Choudhury. AK., Elements of workshop Technology, volume I and II, Media promoters and Publishers Private Limited, Mumbai, 1997
- Sharma, P.C., A Text book of production Technology, S.Chand and Co. Ltd., 2004
