Course Title: Manufacturing Science Course Code: 20ME350A Credits: 3 Total Contact Hours (L:T:P): 39:0:0 Type of Course: Theory Category: Professional Core Course CIE Marks: 50 |SEE Marks: 100 Pre-requisite: NIL, COURSE OBJECTIVES: 1 ‘To apply the knowledge of moulding and casting processes and select appropriate method and materials for preparation of moulds to produce a casting, 2. To apply the knowledge of welding and different techniques and select appropriate method for producing a joint between two metal parts 3. ‘To apply the knowledge of parameters influencing metal deformation, stress states, forming pressure to understand metal forming, To estimate forming loads in rolling & forging processes and use the knowledge of operations to produce a formed part, 5. To analyse drawing & extrusion processes to calculate forming loads and identify tools and dies to produce a drawn or extruded product, with the knowledge of sheet metal operations, select [appropriate set of tools & dies and plan the sequence of operations to produce a sheet metal COURSE CONTENT: Unit No. Course Content No. of Hours Metal casting: Concept of manufacturing process, its importance, introduction to casting process, steps involved. Varieties of components produced by casting process. Advantages & limitations of casting process. Sand moulding: Types of sand, requirements of sand. Moulding sand mixture, ingredients for different sand mixtures. Pattems: Definition, functions, materials for pattems, various allowances and their importance. BIS colour coding of patterns, Binder: Definition, types of binder used in moulding sand. Additives: Types of additives and their properties. Cores: definition need and types. Gating & Risers: Principle and types, Casting defects: Causes, features and remedies. Metal moulds: Gravity die-casting, Pressure die casting, Centrifugal casting, Squeeze Casting, Slush casting. 08 Metal joining processes: Welding - Definition, principles, classification, applications, advantages & limitations of welding. [Arc Welding: Principle, Flux Shielded Metal Arc Welding (FSMAW), Inert Gas Welding (TIG & MIG), Submerged Arc Welding (SAW) and Atomic Hydrogen Welding processes (AHW). Resistance welding: Seam welding, Butt welding, Spot welding and Projection welding, Friction welding, Explosive welding, Thermit welding, Laser welding and Electron beam ‘welding. Solde 08 ig & brazing: Mechanism, different types of soldering & brazing methods, Introduction to metal working: Classification of metal working processes, characteristics of products produced by metal forming. Factors influencing plastic working: Effects of temperature, strain rate, friction &| 0% lubrication, hydrostatic pressure in metalworking, Residual stresses and flow stress. 32Forging: Classification of forging processes, forging machines & equipment. Tae for forging pressures & load in open die forging & closed die forging by sla! yess concepts of friction hill and factors affecting it. Forging defects, Residual stress: 4 [forging / ‘orvolling! Rolling: Classification of rolling processes, types of rolling mills, expression for rol g load, frictional losses in bearing ete., power required for rolling. Effects of - front & bac! tensions, frictions, roll diameter on rolling load, friction hill, Maximum possible reduction, and defects in rolled products. Drawing: Drawing equipment & dies, power requirement, optimal cone angle & dead zone formation. i Extrusion: Types of extrusion processes, extrusion equipment & dies, lubrication, defects 5 |in extrusion, 7 ‘Sheet metal forming: Forming methods, dies & punches, progressive die, compound die, jopen-back inclinable (OBI) press, piercing & blanking, bending, stretch forming, roll [bending & contouring. TEXT BOOKS: 1. Manufacturing Technology: Foundry, Forming and Welding, P. N. Rao, 3“ Ed., Tata McGraw Hill. 2. Process and Materials of Manufacturing, Roy A Lindberg, 4th Ed. Pearson Edu. ; 3. Manufacturing Technology, Serope Kalpakjian, Steven. R. Schmid, Pearson Education Asia, Sth Ed. REFERENCE BOOKS: 1, Principles of Metal Casting, Heine, Rosenthal & others - TMH. 2. Material and Processes in manufacturing by E Paul Degarmo & others PHI. 3. Mechanical metallurgy by G E Dieter, McGraw Hill. Web Resources: 1. https://onlinecourses.nptel.ac.in/nocl9_me44/preview COURSE OUTCOMES: After completing this course, students should be able to: cor |Apply the knowledge of moulding and casting processes and select appropriate method and materials for preparation of moulds to produce a casting, Coz |Apply the knowledge of welding and different techniques and select appropriate method for producing.a joint between two metal parts. co3 {APPLY the knowledge of parameters influencing metal deformation, stress states, forming pressure to understand metal forming. cog [Estimate forming loads in rolling & forging processes and use the knowledge of operations to produce a formed part. Analyse drawing & extrusion processes to calculate forming loads and identify tools and dies to COS |produce a drawn or extruded product, with the knowledge of sheet metal operations, select appropriate set of tools & dies and plan the sequence of operations to produce a sheet metal Course Program Outcomes PSO°s Outcomes [Poi [PO2|PO3|PO4|POS|PO6]PO7|PO8|PO9|PO10 [POI |P012|PSO1|PSO2|PSO3 co [3 2[2 [1 2 2) 3 coz | 3 2[2[1 2 2 [3 cos [3 2[2]1 2 213 cos | 3 2[2]1 2 2) 3 cos [3 2[2]1 2 2 | 3 0, No association 1—-Low association, 2— Moderate association, 3—-High association 33