Course Details
Subject {L-T-P / C} : ME2202 : Primary Production Processes { 3-0-0 / 3}
Subject Nature : Theory
Coordinator : Prof. Susanta Kumar Sahoo
Syllabus
Introduction: Classification and importance. Foundry : Introduction to patterns and foundry process, Sand binders and different additives, Sand testing and melting furnaces for ferrous and non-ferrous metals such as cupola, Induction furnace, Arc furnace & Resistance Furnace. Solid fiction of castings, Continuous casting process: Precision investment casting, centrifugal casting, Die casting, Casting defects. Welding and cutting: Introduction to gas welding, cutting, Arc welding and equipment’s. TIG (GTAW) and MIG (GMAW) welding, resistance welding and thermit welding. Weldability, Newer Welding methods like plasma Arc, Laser Beam, Electron Beam, Ultrasonic, Explosive and friction welding. Brazing and soldering, welding defects. Destructive and non-destructive testing of castings and weldings. Brief introduction to powder metallurgy processes. Plastic deformation of metals: Variables in metal forming and their optimization. Dependence of stress strain diagram on Strain rate and temperature. Hot and cold working of metals. Rolling: Pressure and Forces in rolling, types of rolling mills, Rolling defects. Forging: Smith Forging, Drop and Press forging, M/c forging. Forging defects. Extrusions, Direct, Indirect, Impact and Hydrostatic extrusion and their applications. Extrusion of tubes. Wire drawing methods and variables in wire-drawing. Optimum die shape for extrusion and drawing. Brief introduction to sheet metal working: Bending, Forming and Deep drawing. Additive Manufacturing (AM): Classification, Polymer and metal based AM. Surface modification processes: Mechanics of Wear, flame and induction hardening, plating and thin film coating.
Course Objectives
- Understand fundamental concepts in materials processing.
- To be acquainted with different influencing factors, and the methods of controlling, the quality of products, in particular soundness, microstructure, inclusion levels and dimensional accuracy.
- Analyze potential cast/weld/forming defects and failure mechanisms with reference to specific production method and industrial problems.
- Relate theory of elasticity/plasticity to manufacturing
Course Outcomes
CO1: Knowledge will be gained on the subject matter. <br />CO2: Able to apply the theory to practical problems. <br />CO3: Knowledge will be enhanced to implement the concept for product development. <br />CO4: Take care of design modification before production <br />CO5: Able to calculate load and capacity requirements for production machines.
Essential Reading
- P N Rao, Manufacturing Technology, TMH , -
- S. Kalpakjian, Manufacturing Engineering and Technology, Pearson India , -
Supplementary Reading
- A. Ghosh and A. K. Mallik,, Manufacturing Science, East West Press , -
- P.P. Date, Introduction to Manufacturing Technologies: Principles & Practice,, Jaico Publication, 2012 , -