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SYLLABUS

Unit - I :

LAW METAL CASTING PROCESSES Sand Casting : Sand mould – Type of patterns – Pattern materials – Pattern allowances –Moulding sand Properties and testing – Cores –Types and applications – Moulding machines – Types and applications. Melting furnaces : Blast and Cupola Furnaces; Principle of special casting processes : Shell – Investment – Ceramic mould – Pressure die casting - Centrifugal Casting - CO2 process – Stir casting. Defects in sand casting

UNIT - II :

JOINING PROCESSES Operating principle, basic equipment, merits and applications of: Fusion welding processes: Gas welding – Types – Flame characteristics, Manual metal arc welding – Gas Tungsten arc welding – Gas metal arc welding – Submerged arc welding – Electro slag welding. Operating principle and applications of: Resistance welding – Plasma arc welding – Thermit welding – Electron beam welding – Friction welding and Friction Stir Welding – Brazing and soldering – Weld defects: types, causes and cure.

UNIT - III :

METAL FORMING PROCESSES Hot working and cold working of metals – Forging processes – Open, impression and closed die forging – 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.

UNIT - IV :

SHEET METAL PROCESSES Sheet metal characteristics – 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.

UNIT - V :

MANUFACTURE OF PLASTIC COMPONENTS Types and characteristics of plastics – Moulding of thermoplastics – Working principles and typical applications – Injection moulding – Plunger and screw machines – Compression moulding, transfer moulding – Typical industrial applications – introduction to blow moulding – Rotational moulding – Film blowing – Extrusion – Thermoforming – Bonding of Thermoplastics.