Manufacturing Science & Technology 1
MEC-209
Introduction to sand moulding Testing of moulding sand Moulding and core making machine Design of metal moulds Gating system and its design Riser design and its placement Mould filling time Melting, Pouring and Fluidity Selection of melting furnaces Control of melt and Cupola charge calculations Solidification of pure metals and alloys Solidification time Fundamentals of Casting of complicated shapes: automotive components Casting of light alloys – Aluminium, Magnesium and Titanium alloys Other casting processes: investment, continuous, slush, squeeze casting, stir casting
Types of metal transfer in arc welding Analysis of Voltage-Arc length Characteristics Welding processes like GTAW, GMAW and SAW processes and their recent variants Plasma arc welding process: transferred and non-transferred arc welding and their applications Plasma cutting, Surfacing and plasma spray forming Explosive, Ultrasonic, Laser Beam, Electron Beam, Friction Stir, Thermit, Atomic Hydrogen welding Cold metal transfer Welding, Resistance welding, Soldering and brazing Welding of special materials – Stainless steel, Aluminium etc. Joint design, welding symbols and Joint evaluation through destructive and non-destructive testing methods Defects in welding: causes and remedies, Related numerical problems on electric arc welding and resistance welding.
Plastic deformation of metals Elements of theory of plasticity Flow curve, True stress & true strain, stress-strain relationships Yield criteria for ductile metals, Von Misses & Teresa yield criteria, combined stress tests Hot working and Cold working, Friction and lubrication in metal working Analysis of bulk forming Process: Extrusion: Analysis of extrusion process, extrusion pressure Rolling: Forces & geometrical relationship in rolling, Rolling load and torque in cold rolling Von-Karman work equation, Wire and Tube Drawing, Drawing stress, Reduction factor, Unconventional forming processes Defects in metal forming.
Classification - conventional and HERF processes-presses-types and selection of presses Formability of sheet metals- principle, process parameters, equipment and application Deep drawing, spinning, stretch forming Plate bending, spring back, press brake forming Introduction to forming, electro hydraulic forming, magnetic pulse forming Introduction to press work – coining, embossing etc., Design of sheet metal dies. Powder Metallurgy: fabrication routes, powder size determination – micro and nano level Powder consolidation routes, compacting, sintering, hot pressing, sintering, hot isostatic pressing Field assisted sintering technologies.