Note for Manufacturing Science and Technology - MST By MR NOTE
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N.P.R. COLLEGE OF ENGINEERING & TECHNOLOGY N.P.R. Nagar, Natham - 624 401, Tamil Nadu, India. AN ISO 9001:2008 Certified Institution (Approved by AICTE, New Delhi, Affiliated to Anna University, Tiruchirappalli) No. : 04544 - 291333, 291334, 245422, 245423 & Fax No.: 04544-245392, 93 Website: www.nprcet.org, www.nprcolleges.org E-Mail: nprgc@nprcolleges.org ISO 9001:2008 PR1204 – MANUFACTURING TECHNOLOGY – I III SEMESTER MECHANICAL ENGINEERING Prepared by S. Paul Singarayar, Lecturer Department of Mechanical Engineering, N.P.R.College of Engineering and Technology, Natham. MT-I/SPS /MECH/NPR Page 1
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PR1204 – MANUFACTURING TECHNOLOGY I LTPC 3003 UNIT I METAL CASTING PROCESSES 9 Sand casting – Sand moulds - Type of patterns – Pattern materials – Pattern allowances – Types of Moulding sand – Properties – Core making – Methods of Sand testing – Moulding machines – Types of moulding machines - Melting furnaces – Working principle of Special casting processes – Shell – investment casting – Ceramic mould – Lost Wax process – Pressure die casting – Centrifugal casting – CO2 process – Sand Casting defects. UNIT II JOINING PROCESSES 9 Fusion welding processes – Types of Gas welding – Equipments used – Flame characteristics – Filler and Flux materials - Arc welding equipments - Electrodes – Coating and specifications – Principles of Resistance welding – Spot/butt – Seam – Projection welding – Percusion welding – GS metal arc welding – Flux cored – Submerged arc welding – Electro slag welding – TIG welding – Principle and application of special welding processes – Plasma arc welding – Thermit welding – Electron beam welding – Friction welding – Diffusion welding – Weld defects – Brazing – Soldering process – Methods and process capabilities – Filler materials and fluxes – Types of Adhesive bonding. UNIT III BULK DEFORMATION PROCESSES 9 Hot working and cold working of metals – Forging processes – Open impression and closed die forging – Characteristics of the process – Types of Forging Machines – Typical forging operations – Rolling of metals – Types of Rolling mills – Flat strip rolling – Shape rolling operations – Defects in MT-I/SPS /MECH/NPR Page 2
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rolled parts – Principle of rod and wire drawing – Tube drawing – Principles of Extrusion – Types of Extrusion – Hot and Cold extrusion – Equipments used. UNIT IV SHEET METAL PROCESSES 9 Sheet metal characteristics – Typical shearing operations – Bending – Drawing operations – Stretch forming operations –– Formability of sheet metal – Test methods – Working principle and application of special forming processes – Hydro forming – Rubber pad forming – Metal spinning – Introduction to Explosive forming – Magnetic pulse forming – Peen forming – Super plastic forming. UNIT V MANUFACTURING OF PLASTIC COMPONENTS 9 Types of plastics – Characteristics of the forming and shaping processes – Moulding of Thermoplastics – Working principles and typical applications of – Injection moulding – Plunger and screw machines – Compression moulding – Transfer moulding – Typical industrial applications –Introduction to Blow moulding – Rotational moulding – Film blowing – Extrusion – Thermoforming –Bonding of Thermoplastics. Total: 45 TEXT BOOKS 1. Hajra Choudhury, “Elements of Workshop Technology, Vol. I and II”, Media Promotors Pvt Ltd., 2001 2. S.Gowri, P.Hariharan, and A.Suresh Babu, “Manufacturing Technology I”, Pearson Education,2008. REFERENCES 1. B.S. Magendran Parashar & R.K. Mittal, “Elements of Manufacturing Processes”, Prentice Hall of India, 2003. 2. P.N. Rao, “Manufacturing Technology”, 2nd Edition, Tata McGraw-Hill Publishing Limited, 2002. 3. P.C. Sharma, “A Text Book of Production Technology”, 4th Edition, S. Chand and Company, 2003. MT-I/SPS /MECH/NPR Page 3
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UNIT I Metal Casting Process Manufacturing • Manufacturing in its broadest sense is the process of converting raw materials into useful products. • It includes i) Design of the product ii) Selection of raw materials and iii) The sequence of processes through which the product will be manufactured. Casting Casting is the process of producing metal parts by pouring molten metal into the mould cavity of the required shape and allowing the metal to solidify. The solidified metal piece is called as “casting”. Types of casting Casting Conventional Methods Green sand mould Dry sand mould Unconventional Methods CO2 Moulding (Strong mould) Permanent (Metal mould) Shell Moulding (Thinn mould) Investment casting (Precision) Centrifugal (without core) Continuous Casting (Open) Advantages • Design flexibility • Reduced costs • Dimensional accuracy • Versatility in production Disadvantages • Lot of molten metal is wasted in riser & gating • Casting may require machining to remove rough surfaces Sand Casting MT-I/SPS /MECH/NPR Page 4
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