Manufacturing Process I (Fundamentals of Foundry and Welding)

  Sub Code : 10ME35                                 IA Marks     : 25
   Hrs/ Week : 04                                      Exam Hours : 03
   Total Hrs. : 52                                       Exam Marks : 100



UNIT – 1

Introduction: Concept of Manufacturing process, its importance. Classification of Manufacturing processes. Introduction to Casting process & steps involved. Varieties of components produced by casting process. Advantages & Limitations of casting process.
Patterns: Definition, functions, Materials used for pattern, various pattern allowances and their importance. Classification of patterns, BIS color coding of Patterns.
Binder: Definition, Types of binder used in moulding sand.
Additives: Need, Types of additives used and their properties..

     6 hours

UNIT – 2
System of Limits, Fits, Tolerance and Gauging:

Sand Moulding : Types of base sand, requirement of base sand. Moulding sand mixture ingredients for different sand mixtures. Method used for sand moulding, such as Green sand, dry sand and skin dried moulds.
Cores: Definition, Need, Types. Method of making cores, Binders used, core sand moulding.
Concept of Gating & Risers. Principle and types.
Fettling and cleaning of castings. Basic steps, Casting defects, Causes, features and remedies.
Moulding Machines : Jolt type, Squeeze type, Jolt & Squeeze type and Sand slinger.


7 hours

UNIT – 3

Special moulding Process: Study of important moulding processes, No bake moulds, Flaskless moulds, Sweep mould, CO2 mould, Shell mould, Investment mould.
Metal moulds: Gravity die-casting, Pressure die casting, Centrifugal casting, Squeeze Casting, Slush casting, Thixo-casting and Continuous Casting Processes.

7 hours 

UNIT – 4

Melting Furnaces: Classification of furnaces. Constructional features & working principle of coke fired, oil fired and Gas fired pit furnace, Resistance furnace, Coreless Induction furnace, Electric Arc Furnace, Cupola furnace.

6 hours



UNIT – 5

Welding process: Definition, Principles, Classification, Application, Advantages & limitations of welding.
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)
Gas Welding: Principle, Oxy – Acetylene welding, Chemical Reaction in Gas welding, Flame characteristics. Gas torch construction & working. Forward and backward welding.

7 hours

UNIT – 6

Special types of welding: Resistance welding – principles, Seam welding, Butt welding, Spot welding and projection welding.
Friction welding, Explosive welding, Thermit welding, Laser welding and Electron beam welding.

7 hours

UNIT – 7

Metallurgical aspect, 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.
Concept of electrodes, Filler rod and fluxes. Welding defects – Detection causes & remedy.

6  hours

UNIT – 8
Temperature and strain measurement:

Principles of soldering & brazing : Parameters involved & Mechanism. Different Types of Soldering & Brazing Methods.
Inspection Methods – Methods used for Inspection of casting and welding. Visual, Magnetic particle, Fluorescent particle, Ultrasonic, Radiography, Eddy current, Holography methods of Inspection.

6 hours

Text Books

1.   “Manufacturing Process-I”, Dr.K.Radhakrishna, Sapna Book House, 5th Revised Edition 2009.

2.   “Manufacturing & Technology: Foundry Forming and Welding”, P.N.Rao, 3rd Ed., Tata McGraw Hill, 2003.

Reference book

1.  “Process and Materials of Manufacturing”, Roy A Lindberg, 4th Ed. Pearson Edu. 2006.

2.   “Manufacturing Technology”, Serope Kalpakjian, Steuen. R. Sechmid, Pearson Education Asia, 5th Ed. 2006.

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