Manufacturing Process I

Course Objective:

To impart basic knowledge and understanding about the primary manufacturing processes such as casting, joining, bulk forming, sheet metal forming and powder metallurgy and their relevance in current manufacturing industry; To introduce processing methods of plastics.

Course out comes:

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

1. Design patterns, Gating, runner and riser systems

2. Select a suitable casting process based on the component

3. Learn various arc and solid state welding processes and select a suitable process based on the application and requirements

4. Understand various bulk deformation processes

5. Understand various sheet metal forming and processing of plastics

UNIT – I

Casting : Steps involved in making a casting – Advantage of casting and its applications. – Patterns and Pattern making – Types of patterns – Materials used for patterns, pattern allowances and their construction, Principles of Gating, Gating ratio and design of Gating systems

UNIT – II

Methods of melting and types of furnaces, Solidification of castings, Solidification of pure metals and alloys, short & long freezing range alloys. Risers – Types, function and design, casting design considerations, Basic principles and applications of Centrifugal casting, Die casting and Investment casting.

UNIT – III

Welding : Classification of welding processes, types of welded joints and their characteristics, Gas welding, Different types of flames and uses, Oxy – Acetylene Gas cutting. Basic principles of Arc welding, Manual metal arc welding, Submerged arc welding, Inert Gas welding- TIG & MIG welding.

UNIT – IV

Resistance welding, Solid state welding processes- Friction welding, Friction stir welding, Forge welding, Explosive welding; Thermit welding, Plasma welding, Laser welding, electron beam welding, Soldering & Brazing. Heat affected zones in welding; pre & post heating, Weldability of metals, welding defects – causes and remedies – destructive and non destructive testing of welds, Design of welded joints.

UNIT – V

Plastic deformation in metals and alloys, Hot working and Cold working, Strain hardening and Annealing. Bulk forming processes: Forging - Types Forging, Smith forging, Drop Forging, Roll forging, Forging hammers, Rotary forging, forging defects; Rolling – fundamentals, types of rolling mills and products, Forces in rolling and power requirements. Extrusion and its characteristics. Types of extrusion, Impact extrusion, Hydrostatic extrusion; Wire drawing and Tube drawing. Introduction to powder metallurgy – compaction and sintering, advantages and applications

UNIT – VI

Sheet metal forming - Blanking and piercing, Forces and power requirement in these operations, Deep drawing, Stretch forming, Bending, Spring back and its remedies, Coining, Spinning, Types of presses and press tools. High energy rate forming processes: Principles of explosive forming, electromagnetic forming, Electro hydraulic forming, rubber pad forming, advantages and limitations. Processing of Plastics: Types of Plastics, Properties, Applications and their processing methods, Blow and Injection moulding.