Manufacturing Processes

ME3393

MANUFACTURING PROCESSES

COURSE OBJECTIVES:

1. To illustrate the working principles of various metal casting processes.

2. To learn and apply the working principles of various metal joining processes.

3. To analyse the working principles of bulk deformation of metals.

4. To learn the working principles of sheet metal forming process.

5. 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

1. Explain the principle of different metal casting processes.

2. Describe the various metal joining processes.

3. Illustrate the different bulk deformation processes.

4. Apply the various sheet metal forming process.

5. Apply suitable molding technique for manufacturing of plastics components.

TEXT BOOKS:

1. Kalpakjian. S, “Manufacturing Engineering and Technology”, Pearson Education India,4th Edition, 2013

2. P.N.Rao Manufacturing Technology Volume 1 Mc Grawhill Education 5th edition,2018.

REFERENCES:

1. Roy. A. Lindberg, Processes and materials of manufacture, PHI / Pearson education, 2006.

2. S. Gowri P. Hariharan, A.Suresh Babu, Manufacturing Technology I, Pearson Education, 2008.

3. Paul Degarma E, Black J.T and Ronald A. Kosher, Eligth Edition, Materials and Processes, in Manufacturing, Eight Edition, Prentice – Hall of India, 1997.

4. Hajra Chouldhary S.K and Hajra Choudhury. AK., Elements of workshop Technology, volume I and II, Media promoters and Publishers Private Limited, Mumbai, 1997

5. Sharma, P.C., A Text book of production Technology, S.Chand and Co. Ltd., 2004