Manufacturing Processes-I syllabus

Basics of subtractive manufacturing, operations on Lathe, Milling. Basics of metal cutting mechanics, Chip formation and types of chips, Orthogonal and oblique cutting, Shear angle and Merchant’s theory, Cutting Forces and Power Estimation, Properties of cutting tool materials, Tool signature, Tool wear and tool life, Taylor’s tool life equation

Introduction to casting processes, Patterns: Pattern materials, types of pattern, allowances pattern design, molding sand, Properties of molding sands, Core making, melting practices and furnaces, Pouring and Gating system, Cleaning and Finishing of casting, Defects and remedies. Principle and equipment of Die casting, Centrifugal casting, Investment casting, Continuous casting. Numerical estimation to find mold filling time, Riser design and placement, Principles of cooling and solidification of casting, Directional and Progressive solidification, Estimation of solidification rate

Introduction to Metal Forming- Stress-Strain Analysis in Metal Forming, Bulk Deformation Processes, Defects in Metal Forming, Rolling: Types, defects, and applications, Rolling force estimation, Torque and power requirements for rolling mills Forging: Open-die, Closed-die, and Impression-die forging, Estimation of Forging Load using uniform deformation energy equation, Sheet Metal Working: Types of sheet metal operations, Press working equipment and terminology, design of simple progressive die: strip lay-out and percentage utilization, clearance analysis, centre of pressure, estimation of cutting forces and press capacity

Joining process classification, soldering, brazing, welding symbols, types of joint, Electrodes- types and purpose of electrodes, electrode coatings (flux), welding defects, testing and inspection of welds, Working principles, applications of welding processes: Arc welding: MIG, TIG, Resistance welding: Spot, Seam, Heat generation in resistance welding, Gas Welding: Types of flames, oxy-acetylene gas welding. Solid State Welding: Friction Welding, Modern Welding Processes: Laser welding plasma arc welding, submerged arc welding, projection welding, electron beam welding, ultrasonic welding

Grinding Process: Introduction, types of grinding machines, Grinding wheel: Introduction, types, shapes, designation and selection, grit, grade & structure of wheels, mounting, glazing, loading, dressing, truing, balancing, Surface Finish Measuring Instruments. Advanced Fine finishing processes: (Construction, working and process parameters) Introduction to Honing and Lapping, Magnetic abrasive finishing, Ultrasonic finishing, Abrasive flow machining.