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SYLLABUS

Unit-1

INTRODUCTION : Importance and selection of manufacturing processes. CASTING PROCESSES: Introduction to casting process, process steps; pattern: types, materials and allowance; Cores: Types of cores, core prints, principles and design of gating system; Solidification of casting: Concept, solidification of pure metal and alloy; Special casting processes: Shell casting, investment casting, die casting, centrifugal casting, casting defects and remedies.

Unit-2

METAL FORMING: Introduction, nature of plastic deformation, hot and cold working of metals, mechanics of metal forming; Rolling: Principle, types of rolling mill and products, roll passes, forces in rolling and power requirements; Extrusion: Basic extrusion process and its characteristics, hot extrusion and cold extrusion, wire drawing, tube drawing. FORGING: Principles of forging, tools and dies. Types: Smith forging, drop forging, forging hammers, rotary forging and forging defects. Sheet metal forming: Mechanics of sheet metal working, blanking, piercing, bending, stamping.

Unit-3

METAL JOINING PROCESSES: Classification of welding processes, types of welds and welded joints and V-I characteristics, arc welding, weld bead geometry, submerged arc welding, gas tungsten arc welding, gas metal arc welding. applications, advantages and disadvantages of the above processes, other fabrication processes. Heat affected zones in welding; soldering and brazing: Types and their applications, Welding defects: causes and remedies.

Unit-4

PLASTICS: Types, properties and their applications, processing of plastics, extrusion of plastics, transfer molding and compression molding, injection molding, thermoforming, rotational molding and blow molding CERAMICS: Classification of ceramic materials, properties and their application, ceramic powder preparation; Processing of ceramic parts: Pressing, casting, sintering; Secondary processing of ceramics: Coatings, finishing. POWDER METALLURGY: Principle, manufacture of powders, steps involved.

Unit-5

UNCONVENTIONAL MACHINING PROCESSES: Electrical discharge machining (EDM), principle and processes parameters, electro-chemical machining (ECM) Laser beam machining (LBM), plasma arc machining (PAM) and electron beam machining. Principles and process parameters of Abrasive jet machining (AJM), water jet machining, ultrasonic machining.