Patterns: 1.6 Types of Moulding Sand

UNIT I METAL CASTING PROCESSES
1.1 Sand casting –

1.2 Sand moulds –
1.3 Type of patterns –

1.4 Pattern materials –
1.5 Pattern allowances-
1.6 Types of Moulding sand –

1.7 Properties –
1.8 Core making –
1.9 Methods of Sand testing –
1.10 Moulding machines –
1.11 Types of moulding machines –
1.12 Melting furnaces –
1.13 Working principle of Special casting processes –

1.14 Shell,
1.15 investment casting –
1.16 Ceramic mould –
1.17 Lost Wax process –
1.18 Pressure die casting –
1.19 Centrifugal casting –
1.20 CO2 process –
1.21 Sand Casting defects

1.22 Inspection methods.
UNIT II FABRICATION PROCESS [10]

21Fusion welding processes –
22Types of Gas welding –

23Equipments used –
24Flame characteristics –
25Filler and Flux materials –
26Arc welding equipments –

27Electrodes –
28Coating and specifications –
29Principles of Resistance welding –
210Spot/butt,
211seam welding –
212Percusion welding –
213Gas metal arc welding –

214Flux cored –
215Submerged arc welding –
216 Electro slag welding –
217TIG welding –
218Principle and application of

special welding processes –
219Plasma arc welding –
220Thermit welding –
221Electron beam welding –
222Friction welding –
223Diffusion welding –
224Flame cutting –
225Weld defects –
226Brazing and soldering process –

227Methods and process capabilities –
228Filler materials and fluxes –
229Types of Adhesive bonding
3.0 UNIT III BULK DEFORMATION PROCESSES
31Hot working and cold working of metals

32Forging processes
33Open and close die forging
34Characteristics of the process
35Types of Forging Machines
36Typical forging operations
-
37 Rolling of metals
- 38Flat strip rolling
- 39Types of Rolling mills
- 310Shape rolling operations
- 311Tube piercing
- 312Defects
313in rolled parts
-
314Principles of Extrusion
- 315Types of Extrusion
- 316Hot and Cold extrusion
-317Principle of rod and wire drawing
- 318Equipments used
UNIT IV SHEET METAL FORMING PROCESSES 8

41Sheet metal characteristics –
42 Typical shearing operations,
43 bending and
44 drawing operations –
45Stretch forming operations –
46Formability of sheet metal –
47Test methods –
48Working principle and application

of special forming processes –
49Hydro forming –
4.10Rubber pad forming –
4.11Metal spinning –
412Explosive forming –
413Magnetic pulse forming –
4.14Peen forming –
4.14Super plastic forming –
4.15Process characteristics
ME 2202 MANUFACTURING TECHNOLOGY-I

LTPC
3003
GOAL
To introduce basic manufacturing processes and to develop theoretical skill of students.
OBJECTIVES
The course should enable the students to
1. Learn Metal joining processes
2. Learn Casting processes.
3. Learn Metal forming/high energy rate forming.
4. Learn the processing of plastics
OUTCOME
The students should be able to
1. Understand the various manufacturing methods employed in the Industry.
2. Get knowledge in Basic welding & finishing operations
3. Get knowledge in Hot & cold working of metals including High Energy Rate forming
4. Get knowledge in Plastic manufacturing.
UNIT I METAL CASTING PROCESSES 10
Sand casting - Sand moulds - Type of patterns - Pattern materials - Pattern allowances- Types of
Moulding sand - Properties - Core making - Methods of Sand testing - Moulding machines - Types of
moulding machines - Melting furnaces - Working principle of Special casting processes - Shell,
investment casting - Ceramic mould - Lost Wax process - Pressure die casting - Centrifugal casting - CO2
process - Sand Casting defects - Inspection methods.
UNIT II FABRICATION PROCESS 10
Fusion welding processes - Types of Gas welding - Equipments used - Flame characteristics - Filler and Flux
materials - Arc welding equipments - Electrodes - Coating and specifications - Principles of Resistance welding
- Spot/butt, seam welding - Percusion welding - Gas metal arc welding - Flux cored - Submerged arc welding -
Electro slag welding - TIG welding - Principle and application of special welding processes - Plasma arc
welding - Thermit welding - Electron beam welding - Friction welding - Diffusion welding - Flame cutting - Weld
defects - Brazing and soldering process - Methods and process capabilities - Filler materials and fluxes - Types
of Adhesive bonding
UNIT III BULK DEFORMATION PROCESSES 10
Hot working and cold working of metals - Forging processes - Open and close die forging - Characteristics of
the process - Types of Forging Machines - Typical forging operations - Rolling of metals - Flat strip rolling -
Types of Rolling mills - Shape rolling operations - Tube piercing - Defects
in rolled parts - Principles of Extrusion - Types of Extrusion - Hot and Cold extrusion -Principle of rod and
wire drawing - Equipments used
UNIT IV SHEET METAL FORMING PROCESSES 8
Sheet metal characteristics - Typical shearing operations, bending and drawing operations - Stretch forming
operations - Formability of sheet metal - Test methods - Working principle and application of special forming
processes - Hydro forming - Rubber pad forming - Metal spinning - Explosive forming - Magnetic pulse forming
- Peen forming - Super plastic forming - Process characteristics
UNIT V FORMING AND SHAPING OF PLASTICS 7
Types of plastics - Characteristics of forming and shaping processes - Moulding of Thermoplastics -
Working principles and typical applications of - Injection moulding - Plunger and screw machines - Blow
moulding - Rotational moulding - Film blowing - Extrusion - Typical industrial applications -
Thermoforming - Processing of Thermosets - Working principles and typical applications - Compression
moulding - Transfer moulding - Bonding of Thermoplastics - Fusion and solvent methods - Induction and
Ultrasonic methods.
TOTAL : 45
TEXT BOOKS
1. Hajra Choudhury, Elements of Workshop Technology, Vol. I and II, Media Promotors Pvt Ltd.,
Mumbai, 2007
2. Serope Kalpak jain, Steven R.Schmid, Manufacturing Engineering and Technology, Pearson
Education, Inc. 4th Edition, 2009.
REFERENCES
1. Elements of Manufacturing Processes, B.S. Magendran Parashar & R.K. Mittal, Prentice Hall of
India, 2008.
2. Manufacturing Technology, P.N. Rao, Tata McGraw-Hill Publishing Limited, 2010.
3. A text book of production technology, P.C. Sharma, S. Chand and Company, 2010.
4. Manufacturing Process - Begman, John Wilely & Sons, VIII Edition, 1999.

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UNIT I METAL CASTING PROCESSES

1.1 Sand casting –

1.3 Type of patterns –

1.6 Types of Moulding sand –

1.13 Working principle of Special casting processes –

1.21 Sand Casting defects

UNIT II FABRICATION PROCESS [10]

22Types of Gas welding –

26Arc welding equipments –

213Gas metal arc welding –

218Principle and application of

226Brazing and soldering process –

3.0 UNIT III BULK DEFORMATION PROCESSES

31Hot working and cold working of metals

UNIT IV SHEET METAL FORMING PROCESSES 8

48Working principle and application

ME 2202 MANUFACTURING TECHNOLOGY-I

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