JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD

Pre-requisites

Basic Mechanical Engineering, Engineering Graphics

Course Objectives:

• To teach the process-level dependence of manufacturing systems through tolerances
• To expose the students to a variety of manufacturing processes including their typical use and capabilities.
• To teach the important effects that manufacturing processes may have on the material properties of the processed part with a focus on the most common processes.
• To teach the thermal and mechanical aspects, such as force, stress, strain, and temperature, of the most common processes.
• To provide a technical understanding of common processes to aid in appropriate process selection for the material and required tolerances
• To provide a technical understanding of common processes to aid in appropriate material selection for a predetermined process.

Course Outcomes

Understand the idea for selecting materials for patterns. Types and

allowances of patterns used in casting and analyze the components of moulds. Design core, core print and gating system in metal casting processes Understand arc, gas, solid state and resistance welding processes. Develop process-maps for metal forming processes using plasticity principles. Identify the effect of process variables to manufacture defect free products.

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 and their construction; Properties of moulding sands. Methods of Melting - Crucible melting and cupola operation – Defects in castings; Casting processes – Types – Sand moulding, Centrifugal casting, die- casting, Investment casting, shell moulding; Principles of Gating – Requirements – Types of gates, Design of gating systems – Riser – Function, types of Riser and Riser design. Solidification of casting – Solidification of pure metal – Nucleation and grain growth, casting design considerations

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, 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. Rolling fundamentals – theory of rolling, types of Rolling mills and products. Forces in rolling and power requirements Stamping, forming and other cold working processes. Blanking and piercing – Bending and forming – Drawing and its types – wire drawing and Tube drawing – coining – Hot and cold spinning. 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 and pipe making, 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.

TEXT BOOKS:

• 1. Manufacturing Technology / P.N. Rao Vol.1 & 2 / Mc Graw Hill
• 2. Manufacturing Engineering & Technology / Serope Kalpakjian / Steven R. Schmid / Pearson

REFERENCE BOOKS:

• 1. Metal Casting / T.V Ramana Rao / New Age
• 2. Production Technology / G. Thirupathi Reddy / Scitech