|MANUFACTURING PROCESS – I|
|Written by Administrator|
|Sunday, 01 November 2009 15:42|
PART – A
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.
Sand Moulding : Types of base sand, requirement of base sand. Types of sand moulds.
Sand moulds: Moulding sand mixture ingredients (base sand, binder & additives) for different sand mixtures. Method used for sand moulding.
Cores: Definition, Need, Types. Method of making cores, Binders used.
Concept of Gating & Risering. Principle involved. and types.
Fettling and cleaning of castings. Basic steps involved. Casting defects-causes, features and remedies.
Moulding machines : Jolt type, squeeze type, Jolt & Squeeze type and Sand slinger.
Special moulding Process :Study of important moulding processes Green sand, Core sand, Dry sand, Sweep mould, CO2 mould, Shell mould, Investment mould.
Metal moulds: Gravity die-casting, Pressure die casting, centrifugal casting, Squeeze Casting, Slush casting, Thixocasting and continuous casting processes.
Melting Furnaces: Classification of furnaces. Constructional features & working principle of Gas fired pit furnace, Resistance furnace, Coreless Induction furnace, Electric Arc Furnace, Cupola furnace.
PART – B
Welding process: Definition, Principles, Classification, Application, Advantages & limitations of welding.
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)
Gas Welding: Principle, Oxy – Acetylene welding, Reaction in Gas welding, Flame characteristics, Gas torch construction & working. Forward and backward welding.
Special type of welding: Resistance welding - principles, Seam welding, Butt welding, Spot welding and projection welding.
Friction welding, Explosive welding, Thermit welding, Laser welding and Electron beam welding.
Metallurgical aspect in welding : 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. Welding defects – Detection causes & remedy. 6 Hours
Principles of 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.
1. “Manufacturing & Technology: Foundry Forming and Welding”, P.N.Rao 2nd Ed., Tata McGraw Hill, 2003.
2. “Manufacturing Process-I”, Dr.K.Radhakrishna, Sapna Book House, 2nd Edition 2007.
1. “Manufacturing Technology”, Serope Kalpakjain, Steuen.R.Sechmid, Pearson Education Asia, 5th Ed. 2006.
2. “Process and Materials of Manufacturing:, Roy A Lindberg, 4th Ed. Pearson Edu. 2006.
Scheme of examination:
One Question to be set from each chapter. Students have to answer any FIVE full questions out of EIGHT questions, choosing at least 2 questions from part A and 2 questions from part B.