06ME35- Manufacturing Process – I
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PART – A CASTING PROCESS |
UNIT I |
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.
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UNIT II |
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 defectscauses,
features and remedies.
Moulding machines : Jolt type, squeeze type, Jolt & Squeeze type and Sand
slinger. |
UNIT III |
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. |
UNIT IV |
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 |
UNIT V |
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.
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UNIT VI: |
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. |
UNIT VII |
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.
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UNIT VIII |
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.
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REFERENCE |
TEXT BOOKS: |
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.
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Reference Books |
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.
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