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Metal Casting Forming & Joining Process (21ME32)

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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 furnaces, Resistance furnaces, Coreless induction furnaces, electric arc furnaces, constructional features & working principle of cupola furnaces. 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 metalworking, 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).