Full Syllabus & Reference Books

"L" Scheme - Manufacturing Technology I - Sub Code: 22041

UNIT TOPIC
I

CASTING PROCESSES

II

JOINING PROCESSES

III

BULK DEFORMATION PROCESSES AND HEAT TREATMENT

IV

MANUFACTURING OF PLASTIC COMPONENTS AND POWDER METALLURGY

V

CENTRE LATHE AND SPECIAL PURPOSE LATHES

Unit 1:

Patterns – definition – pattern materials – factors for selecting pattern materials – single piece solid, split patterns – pattern allowances – core prints.Moulding – definition – moulding boxes, moulding sand – ingredients – silica – clay – moisture and miscellaneous materials – properties of moulding sand – sand additives – moulding sand preparation – mixing – tempering and conditioning – types of moulding – green sand – dry sand – machine moulding – Top and bottom squeezer machines – Jolting machines – sand slinger- core – CO2 process core making – types of core – core boxes. Casting – definition – sand casting using green sand and dry sand – gravity die casting – pressure die casting – hot and cold chamber processes – centrifugal casting – continuous casting – chilled casting – malleable casting – melting of cast iron – cupola furnace – melting of non ferrous metals – crucible furnace melting of steel - arc furnaces – induction furnaces – instrument for measuring temperature – optical pyrometer – thermo electric pyrometer – cleaning of casting – tumbling, trimming, sand and shot blasting – defects in casting – causes and remedies – safety practices in foundry

Unit 2:

Arc Welding : Definition – arc welding equipment – arc welding methods – carbon arc, metal arc, Metal Inert gas (MIG), Tungsten inert gas (TIG), Atomic hydrogen, Plasma arc, Submerged arc and Electro slag welding, Gas welding : Definition Gas Welding Equipment– Oxy and acetylene welding - Three types of flame– resistance welding – classification of resistance welding – butt – spot – seam – projection welding – welding related processes – oxy and acetylene cutting – arc cutting – hard facing bronze welding – soldering and brazing special welding processes – cast iron welding – thermit welding – solid slate welding, ultrasonic, diffusion and explosive welding – explosive cladding – modern welding, electron beam and laser beam welding – types of welded joints – merits and demerits of welded joints – inspection and testing of welded joints – destructive and non destructive types of tests – magnetic particle test – radiographic and ultrasonic test defects in welding – causes and remedies – safety practices in welding .

Unit 3:

Hot working, cold working – advantages of hot working and cold working– hot working operations – rolling, forging, smith forging, drop forging, upset forging, press forging – roll forging Heat treatment processes – purpose – procedures – applications of various heat treatment processes – Iron – carbon equilibrium diagram – full annealing – process annealing stress relief annealing - spherodising annealing – isothermal annealing – normalizing – hardening – tempering – quenching medium – different types and their relative merits – case hardening – pack carburizing – cyaniding – nitriding – induction hardening and flame hardening.

Unit 4:

Plastic Components: Types of plastics-Engineering plastics – thermosets – composite - structural foam, elastomers - polymer alloys and liquid crystal polymers

Factors Influencing The Selection Of Plastics: Mechanical properties – degradation- wear resistance -frictional properties- special properties-processing – cost

Processing of Plastics: Extrusion-general features of single screw extrusion - twin screw extruders and types-Injection moulding types : Plunger type.- Reciprocating screw injection - details of injection mould - structural foam injection mould - sandwich moulding - gas injection moulding - injection moulding of thermosetting materials calendaring and rotational moulding. Design consideration for plastic components.

Powder Metallurgy : Methods of manufacturing metal powders – atomization, reduction and electrolysis deposition – compacting – sintering – sizing – infiltration – mechanical properties of parts made by powder metallurgy – design rules for the power metallurgy process.

Unit 5:

Centre Lathe: Theory of lathes – specifications – simple sketches – principal parts – head stock – back geared type – all geared type – tumbler gear mechanism – quick change gear box – apron mechanism – carriage cross slide – automatic, longitudinal and cross feed mechanism – tail stock and its functions – work holding device – face plate – three jaw chuck – four jaw chuck – catch plate and carrier – types of centres – machining operations done on lathe - straight turning – step turning-taper turning-knurling-Thread cutting-Facing- Boring-chamfering–-cutting speed-feed-depth of cut.

Semi Automatic Lathes: Types of semi automatic lathes – capstan and turret lathes – difference between turret and capstan – tools and work holding devices – self opening die head – collapsible taps

Automatic Lathes: Automatic lathe – classification of single spindle automatic lathe – principle of automatic lathes – automatic screw cutting machines – multi spindle automatic lathes

"K" Scheme - Manufacturing Process - Sub Code: 12032

UNIT TOPIC
I

Foundry

II

Forging & Welding

III

Powder Metallurgy & Heat Treatment

IV

Lathe Work, Semi Automatic & Automatic Lathes

V

Metrology & Theory of Metal cutting

Unit 1:

1.1 Patterns:
Definition – pattern materials – factors for selecting pattern materials – single piece solid, split  patterns – pattern allowances – core prints.

1.2 Moulding:
Definition – moulding boxes, moulding sand  – ingredients – silica – clay – moisture and miscellaneous materials – properties of moulding sand – sand additives – moulding sand preparation – mixing – tempering and conditioning – types of moulding – green sand – dry sand – machine moulding – Top and bottom squeezer machines – Jolting machines – sand slinger- core – CO2 process core making –types of core – core boxes.

1.3 Casting:
Definition – sand casting using green sand and dry sand – gravity die casting – pressure die casting – hot and cold- chamber processes – centrifugal casting – continuous casting – chilled casting –malleable casting – melting of cast iron – cupola furnace – melting of non ferrous metals – crucible furnace melting of steel and arc furnaces – induction furnaces – instrument for measuring temperature – optical pyrometer – thermo electric pyrometer – cleaning of casting – tumbling, trimming, sand and shot blasting – defects in casting – causes and remedies – safety practices in foundry. 
 

Unit 2:

2.1 Hot & Cold Working:
Hot working, cold working – advantages of hot working and cold working–hot working operations – rolling.

Forging:
smith forging, drop forging, upset forging, press forging – roll forging. 

2.2 Welding: 
Welding – arc welding definition – arc welding equipment – arc welding methods – carbon arc, metal arc, Metal Inert gas (MIG), Tungsten inert gas (TIG), Atomic hydrogen, Plasma arc, Submerged arc and Electro slag welding,

Gas welding: 
Definition Gas Welding Equipment– oxy – acetylene welding  Three types of flame– resistance welding – definition – classification of resistance welding – butt – spot – seam – projection welding – welding related processes – oxy – acetylene cutting – arc cutting – hard facing bronze welding – soldering and brazing special welding processes – cast iron welding – thermit welding – solid slate welding, ultrasonic, diffusion and explosive welding – explosive cladding – modern welding, electron beam and laser beam welding – types of welded joints – merits and demerits of welded joints – inspection and testing of welded joints – destructive and non destructive types of tests – magnetic particle test – radiographic and ultrasonic test defects in welding – causes and remedies – safety practices in welding .  

Unit 3:

3.1 Power Metallurgy:
Methods of manufacturing metal powders – atomization, reduction and electrolysis deposition – compacting – sintering – sizing – infiltration – mechanical properties of parts made by powder metallurgy – design rules for the power metallurgy process.

3.2 Heat Treatment:
Heat treatment processes – purpose – procedures –  applications of various heat treatment processes – Iron – carbon equilibrium diagram – full annealing – process annealing stress relief annealing - spherodising annealing – isothermal annealing – normalizing – hardening – tempering – quenching medium – different types and their relative merits – case hardening – pack carburizing – cyaniding – nitriding – induction hardening and flame hardening.

Unit 4:

4.1 Lathe work:
Theory of lathes – specifications – simple sketches – principal parts – head stock – back geared type – all geared type – tumbler gear mechanism – quick change gear box – apron mechanism – carriage cross slide – automatic, longitudinal and cross feed mechanism –  tail stock and its functions – work holding device – face plate – three jaw chuck – four jaw chuck – catch plate and carrier – types of centres – machining operations done on lathe  straight turning – step turning-taper turning-knurling-Thread cutting-Facing-Boring-chamfering– lathe attachments – tool post grinders – milling attachments-cutting speed-feed-depth of cut.

4.2 Semi automatic lathes:
Types of semi automatic lathes – capstan and turret lathes – difference between turret and capstan – tools and work holding devices – self opening die head – collapsible taps – simple tool lay out – process sheet.

4.3 Automatic Lathes:
Automatic lathe – classification of single spindle automatic lathe – principle of automatic lathes – automatic screw cutting machines – multi spindle automatic lathes – use of cams in automats.

Unit 5:

5.1 Metrology:
Metrology, Micrometer – inside and outside vernier caliper-digital vernier-digital micrometer – vernier height gauge – digital type vernier micrometers – depth gauges – applications – plug and ring gauges – snap gauges – thread micrometers – gear tooth vernier – bevel protractor – slip gauges – sine bar – comparators – mechanical (dial gauges) – electrical, optical and pneumatic comparators – profile measurements – optical flat – surface finish measurements – profilometers.

5.2 Metal Cutting:
Cutting tool material-High carbon Steel-High Speed Steel-Stellites-Cemented carbides-ceramics-Composition and applications for the above-Single point cutting tool-nomenclature-tool life-Chip Breakers. 

Reference Books:

  1. Begeman, Manufacturing process, Edn. 5, McGraw Hill, New Delhi 1981. 
  2. WAJ Chapman, Workshop Technology, Volume I, II, & III, Vima Books Pvt. Ltd., 4262/3,  Ansari Road, Daryaganj, New Delhi 110 002.
  3. Raghuwanshi, Workshop Technology, Khanna Publishers. 
    Jain & Gupta, Production Technology, Edn. XII, Khanna Publishers, 2-B, North Market, NAI Sarak, New Delhi 110 006 - 2006 
  4. P. C. SHARMA, Production Technology, Edn. X, S.Chand & Co. Ltd., Ram Nagar, New Delhi 110 055 - 2006
  5. HMT, Production Technology, Edn. 18, published by Tata McGraw Hill publishing Co. Ltd., 7 West Patel Nagar, New Delhi 110 008. – 2001.
  6. Kalpakjian, Manufacturing Engineering & Technology 

 

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