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SYLLABUS

UNIT-I

CASTING Steps involved in making a casting, Advantage of casting and its applications; Patterns – Pattern making, Types, Materials used for patterns, pattern allowances, Properties of moulding sands, Methods of melting – Crucible melting and cupola operation – Defects in castings ; Principles of gating – Requirements – Types of gates, Design of gating, systems – Riser – Function, Types of riser and riser design, casting processes – Types – Sand moulding, Centrifugal casting, Die-casting, Investment casting, Shell moulding ; Solidification of casting – Solidification of pure metal, Directional solidification

UNIT-II

WELDING Classification – Types of welds and welded joints, Gas welding – Types, Oxy-fuel gas cutting – Standard time and cost calculations. Arc welding, Forge welding, Submerged arc welding, Resistance welding, Thermit welding.

UNIT-III

Inert gas welding – TIG welding, MIG welding, Friction welding, Friction stir welding, Induction welding, Explosive welding, Laser welding; Soldering and Brazing; Heat affected zone in welding. Welding defects – Causes and remedies; Destructive and non-destructive testing of welds.

UNIT-IV

Hot working, Cold working, Strain hardening, Recovery, Recrystallisation and grain growth. Sheet metal operations: Stamping, Blanking and piercing, Coining, Strip layout, Hot and cold spinning – Bending and deep drawing. Rolling fundamentals – Theory of rolling, types of rolling mills and products. Forces in rolling and power requirements. Drawing and its types – Wire drawing and Tube drawing– Types of presses and press tools. Forces and power requirement in the above operations.

UNIT-V

EXTRUSION OF METALS Basic extrusion process and its characteristics. Hot extrusion and cold extrusion – Forward extrusion and backward extrusion – Impact extrusion – Extruding equipment – Tube extrusion, Hydrostatic extrusion. Forces in extrusion. FORGING PROCESSES Forging operations and principles – Tools – Forging methods – Smith forging, Drop forging – Roll forging. Forging hammers: Rotary forging – Forging defects – Cold forging, Swaging, Forces in forging operations. High Energy Rate Forming Processes : Limitations, Principles of Explosive Forming, Electro-hydraulic Forming, Electro-magnetic forming and rubber pad forming.