Casting and Moulding: Metal casting processes and equipment, shrinkage, principles of gating and riser design, Casting processes -sand, die, gravity, centrifugal, shell mould and Investment casting. Fettling and cleaning of casting. casting defects.
Introduction to bulk and sheet metal forming: Plastic deformation and yield criteria; fundamentals of hot and cold working processes, bulk forming processes – forging, rolling, extrusion, drawing and sheet forming processes – shearing, deep drawing, bending.
Metal Joining Processes: Principles of welding, brazing and soldering; Solid and liquid state joining processes – arc welding, gas welding, resistance welding, soldering, brazing and adhesive bonding. weld defects and inspection.
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.
TIG and MIG welding processes – design weld joints – welding practice –weld quality inspection.
Press working operation – hydraulic and mechanical press -load calculation: blanking, bending and drawing operations – sheet metal layout design.
Group project will be given in any one of the topics (Metal Casting / Welding / Metal forming). The student group has to design and develop product / process based on the problem statement.