JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD

Pre-requisites

None

Course Objectives:

• To expose the students to understand the concept of basic casting processes & furnaces.
• To provide a technical understanding of various joining processes used in the manufacturing industry.
• To impart the students to the concepts of solid-state welding processes.
• To teach the concepts of rolling and various press working operations.
• To provide a technical understanding of different metal forming processes like extrusion, forging and high energy rate forming processes.

Course Outcomes

Student will be able to:

• Elaborate the fundamentals of various moulding, casting techniques and furnaces.
• Identify the importance of permanent joining and principle behind different welding processes.
• Explain the concepts of solid-state welding processes
• Understand the concepts of rolling and sheet metal operations in metal working.
• Elaborates the uniqueness of extrusion, forging and high energy rate forming processes in metal working.

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 methods. 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

UNIT - II

Welding: Classification – Types of welds and welded joints and their characteristics, Welding Positions - Gas welding - Types, oxy-fuel gas cutting – standard time and cost calculations. Arc welding, Shielded metal arc 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: Principles of Explosive Forming, Electro-hydraulic Forming, Electro-magnetic forming and rubber pad Forming.

TEXT BOOKS:

• 1. Manufacturing Technology / P.N. Rao/ Vol.1 / Mc Graw Hill Education/ 5th Edition, 2018.
• 2. Manufacturing Engineering & Technology / Serope Kalpakjian / Steven R. Schmid / Pearson, 7th Edition,2014

REFERENCE BOOKS:

• 1. Production Technology Vol.: 1, WILEY, sreeramulu M, 2018
• 2. A Text book of Production Technology (Manufacturing Processes) / Dr.P.C. Sharma / S. Chand Publications /1st Edition, 2006.
• 3. Manufacturing processes H. S. Shan, Second Edition, Cambridge University Press, 2017.
• 4. Production Technology: Manufacturing Processes, Technology and Automation / R. K. Jain /Vol.1/Khanna Publishers /19th Edition, 2009.
• 5. Elements of Workshop Technology/ S.K. Hajra Choudhury, A.K. Hajra Choudhury, Nirjhar Roy/Vol.1/ Media Publishers & Promoters Pvt. Ltd./1st Edition,2008.