METAL CASTING FORMING & JOINING PROCESS (IPCC) (21ME32)

METAL CASTING FORMING & JOINING PROCESS (IPCC)

Course Code:21ME32
CIE Marks :50
Teaching Hours/Week (L:T:P: S) 3:0:2*:0 
SEE Marks:50
Total Hours of Pedagogy 40 hours Theory + 12 Lab slots 
Total Marks:100
Credits:04 
Exam Hours:03

MODULE-1

Introduction & basic materials used in foundry: Introduction: Definition, Classification of manufacturing processes. Metals cast in the foundry-classification, factors that determine the selection of a casting alloy. Introduction to casting process & steps involved – (Brief Introduction)-Not for SEE Patterns: Definition, classification, materials used for pattern, various pattern allowances and their importance. Sand moulding: Types of base sand, requirement of base sand. Binder, Additive’s definition, need and types; preparation of sand moulds. Molding machines- Jolt type, squeeze type and Sand slinger. Study of important moulding process: Green sand, core sand, dry sand, sweep mould, CO2mould, shell mould, investment mould, plaster mould, cement bonded mould. Cores: Definition, need, types. Method of making cores, Concept of gating (top, bottom, parting line, horn gate) and risers (open, blind) Functions and types.

MODULE-2

Melting furnaces: Classification of furnaces, Gas fired pit furnace, Resistance furnace, Coreless induction furnace, electric arc furnace, constructional features & working principle of cupola furnace. Casting using metal moulds: Gravity die casting, pressure die casting, centrifugal casting, squeeze casting, slush casting, thixocasting, and continuous casting processes. Casting defects, their causes and remedies.

MODULE-3

METAL FORMING PROCESSES; Introduction of metal forming process: Mechanical behaviour of metals in elastic and plastic deformation, stress-strain relationships, Yield criteria, Application to tensile testing, train rate and temperature in metal working; Hot deformation, Cold working and annealing. Metal Working Processes: Fundamentals of metal working, Analysis of bulk forming processes like forging, rolling, extrusion, wire drawing by slab method, Other sheet metal processes: Sheet metal forming processes (Die and punch assembly, Blanking, piercing, bending etc., Compound and Progressive die), High Energy rate forming processes.

MODULE-4

JOINING PROCESSES: Operating principle, basic equipment, merits and applications of: Fusion welding processes: Gas welding - Types – Flame characteristics; Manual metal arc welding – Gas Tungsten arc welding - Gas metal arc welding – Submerged arc welding.

MODULE 5

Weldability and thermal aspects: Concept of weldability of materials; Thermal Effects in Welding (Distortion, shrinkage and residual stresses in welded structures); Welding defects and remedies. Allied processes: Soldering, Brazing and adhesive bonding Advance welding processes: Resistance welding processes, friction stir welding (FSW).

PRACTICAL COMPONENT OF IPCC
Sl.NO Experiments

1 Studying the effect of the clay and moisture content on sand mould properties

2 Preparation of sand specimens and conduction of the following tests: 1. Compression, Shear and Tensile tests on Universal Sand Testing Machine.

3 To determine permeability number of green sand, core sand and raw sand.

4 To determine AFS fineness no. and distribution coefficient of given sand sample.

5 Use of Arc welding tools and welding equipment Preparation of welded joints using Arc Welding equipment L- Joint, T-Joint, Butt joint, V-Joint, Lap joints on M.S. flats

6 To study the effect of heat affected zone on the microstructure of steel weldment using MMAW.

7 Preparing minimum three forged models involving upsetting, drawing and bending operations

8 Sheet metal punch/die design and layout optimization Demo experiments for CIE

9 To study the defects of Cast and Welded components using Non-destructive tests like: a) Ultrasonic flaw detection b) Magnetic crack detection c) Dye penetration testing

10 Mould preparation of varieties of patterns, including demonstration

11 To generate plastic curve of a given metal strip at room temperature and at recrystallization temperature during rolling. Observe the changes in metal characteristic after rolling.

12 Demonstration of material flow and solidification simulation using Auto-Cast software

Suggested Learning Resources:
Books

1. Ghosh, A. and Mallik, A. K., (2017), Manufacturing Science, East-West Press.

2. Parmar R. S., (2007), Welding Processes and Technology, Khanna Publishers.

3. Little R. L. – ‘Welding and Welding Technology’ – Tata McGraw Hill Publishing Company Limited, New Delhi – 1989

4. Grong O. – ‘Metallurgical Modelling of Welding’ – The Institute of Materials – 1997 – 2nd Edition

5. Kou S. – ‘Welding Metallurgy’ – John Wiley Publications, New York – 2003 – 2nd Edition.

6. Serope Kalpakjian and Steven R. Schmid – ‘Manufacturing Engineering and Technology’ – Prentice Hall – 2013 – 7th Edition

7. Principles of foundry technology, 4th edition, P L Jain, Tata McGraw Hill, 2006.

8. Advanced Welding Processes technology and process control, John Norrish, Wood Head Publishing, 2006. 

Web links and Video Lectures (e-Resources):

 (Link:http://www.springer.com/us/book/9781447151784http://nptel.ac.in/courses/112

 105127/)

 http://www.astm.org/DIGITAL_LIBRARY/MNL/SOURCE_PAGES/MNL11.htm

 http://www.astm.org/DIGITAL_LIBRARY/JOURNALS/COMPTECH/PAGES/CTR10654J.htm

 MOOCs: http://nptel.ac.in/courses/112105126/.

Activity Based Learning (Suggested Activities in Class)/ Practical Based learning

 Metal Casting: Design pattern/core for a given component drawing and develop a sand mould with optimum gating and riser system for ferrous and non-ferrous materials. Melting and casting, inspection for macroscopic casting defects.

 Welding: TIG and MIG welding processes – design weld joints – welding practice –weld quality inspection.

 Metal Forming: Press working operation – hydraulic and mechanical press -load calculation: blanking, bending and drawing operations – sheet metal layout design.