Академический Документы
Профессиональный Документы
Культура Документы
L:T:P
Hrs/week : 3:0:2
UNIT II
10
Hours
WELDING PROCESS: Definition, Principles, Classification, Application,
Advantages & limitations of welding. Concept of electrodes, filler rod and fluxes.
Arc Welding: Principle, Metal Arc welding (MAW), Flux Shielded Metal Arc Welding
(FSMAW), Inert Gas Welding (TIG & MIG) Submerged Arc Welding) (SAW) and
Atomic Hydrogen Welding processes. (AHW)
Special types of welding: Working principle, advantages, limitations and
applications of Resistance welding, Friction welding, Explosive welding, Thermit
welding, Laser welding and Electron beam welding.
METALLURGICAL ASPECTS IN WELDING: Structure of welds, Formation of
different zones during welding. Heat Affected Zone (HAZ). Parameters affecting
HAZ. Effect of carbon content on structure and properties of steel. Shrinkage in
welds & Residual stresses.
Welding defects: Detection causes & remedy.
Inspection Methods: Methods used for Inspection of casting and welding. Visual,
Magnetic particle, Fluorescent particle, Ultrasonic, Radiography, Eddy current,
Holography methods of Inspection.
UNIT III
10
Hours
THEORY OF METAL CUTTING: Single point cutting tool nomenclature, tool
geometry, orthogonal & oblique cutting. Mechanics of chip formation process,
types of chips. Merchants circle diagram and analysis, Ernst Merchants solution,
shear angle relationship, numerical on Merchants analysis. Tool Wear, forms of
tool wear, wear mechanisms of cutting tools, Tool failure, tool life. Effects of
cutting parameters on tool life, Tool failure criteria, Taylors Tool life equation,
numerical on tool life equation.
CUTTING TOOL MATERIALS: Desired properties and types of cutting tool
materials HSS, carbides, coated carbides, ceramics. Cutting fluids - Desired
properties, types and selection. Heat generation in metal cutting, factors
affecting heat generation. Heat distribution in tool and workpiece and chip.
Measurement of tool tip temperature.
UNIT IV
09
Hours
LATHE, SHAPER AND PLANER: Classification, constructional features, Tool
Layout of Turret & Capstan Lathe, horizontal shaper and double housing planer.
Driving mechanisms, different operations on lathe, shaper and planer machines,
numerical on machinery time calculations
DRILLING MACHINE: Classification,
constructional features of upright, multiple spindle, deep hole & automatic
drilling machine. Types of drill & drill bit nomenclature, drill materials, numerical
on drilling. Introduction to CNC machines, Principles of operation, Axes of NC
machine, Coordinate systems, basics of Manual part programming methods.
UNIT - V
08
Hours
MILLING MACHINE: Classification, constructional features of bed type, planer,
special purpose milling machine, milling cutter nomenclature. Indexing, indexing
mechanism, Simple, compound, differential and angular indexing calculations,
numerical on simple and compound indexing
L:T:P
Hrs/week : 3:0:0
UNIT II
10
Hours
FORGING PROCESS: Classification of forging processes, Forging machines &
equipment. Expressions for forging pressures & load in open die forging and
closed die forging by slab analysis, concepts of friction hill and factors affecting
it. Die-design parameters. Material flow lines in forging. Forging defects, Residual
stresses in forging. Simple problems.
ROLLING PROCESS: Classification of rolling processes. Types of rolling mills,
expression for rolling load. Roll separating force. Frictional losses in bearing,
power required in rolling, Effects of front & back tensions, friction, friction hill.
Maximum possible reduction. Defects in rolled products. Rolling variables, simple
problems.
UNIT III
10
Hours
DRAWING PROCESS: Drawing equipment & dies, expression for drawing load
by slab analysis, power requirement. Redundant work and its estimation, optimal
cone angle & dead zone formation, drawing variables, Tube drawing,
classification of tube drawing, simple problems.
EXTRUSION & SHEET METAL FORMING: Types of extrusion processes,
extrusion equipment & dies, deformation, lubrication & defects in extrusion.
Extrusion dies, Extrusion of seamless tubes. Extrusion variables, simple problem.
Sheet Metal forming methods, dies & punches, progressive die, compound die,
combination die. Open back inclinable press (OBI press), piercing, blanking,
bending, deep drawing, LDR in drawing, Forming limit criterion, defects of drawn
products, stretch forming. Roll bending & contouring, Simple problems
UNIT IV
08
Hours
HIGH ENERGY RATE FORMING METHODS: Principles, advantages and
applications, explosive forming, electro hydraulic forming, magnetic pulse
forming, petro-forge, drop hammer & dynapak
POWDER METALLURGY: Basic steps in Powder metallurgy brief description of
methods of production of metal powders, conditioning and blending powders,
compaction and sintering application of powder metallurgy components,
advantages and limitations.
UNIT V
09
Hours
FRICTION IN METAL FORMING: Introduction & genesis of friction, basic
understanding, fundamental characterization, measuring friction in metal
forming, parameters affecting friction. FRICTION TESTS FOR BULK & SHEET
FORMING: Twist, ring, plane strain & barrel compression test, bucket test, open
die backward extrusion test, rolling test, combined forward & backward extrusion
test, strip drawing test, pinch type tests, sheet drawing test
TEXT BOOKS:
1. Manufacturing Processes by J. P. Kaushish, Prentice-Hall of India Pvt.Ltd; 2nd
edition (August 2010), ISBN-13: 978-8100340824
2. Fundamentals of Metal Forming Processes by B.L Juneja, New age
international publishers, second edition ISBN:9788102430899
3. Metal Forming Technology and process modeling by uday S.Dixit, R.Ganesh
Narayanan, Tata McGraw Hill Education Private Limited (April 26, 2013) ISBN-13:
978-1059058899
REFERENCE BOOKS:
1. Mechanical metallurgy (SI units), G.E. Dieter, Mc Graw Hill pub.2001.
2. Production Technology: Manufacturing Processes, Technology and Automation
17th Edition by R K Jain, Khanna Publishers, 2001, ISBN-13:9788174090997