UNIT I

METAL CASTING PROCESSES -Sand Casting – Sand Mould – Type of patterns – Pattern Materials – Pattern allowances – Moulding sand Properties and testing – Cores –Types and applications – Moulding machines – Types and applications– Melting furnaces – Principle of special casting processes- Shell, Investment – Ceramic mould – Pressure die casting – Centrifugal Casting – CO2 process – Stir casting – Defects in Sand casting.

UNIT II

JOINING PROCESSES – Fusion welding processes – Type of Gas welding – Flame characteristics – Filler and Flux materials – Arc welding, Electrodes, Coating and specifications – Principles and types of Resistance welding – Gas metal arc welding – Submerged arc welding – Electro slag welding – Gas Tungsten arc welding – Electron Beam Welding- Weld defects – Brazing and soldering – methods and process capabilities – Adhesive bonding, Types and applications.

UNIT III

METAL DEFORMATION PROCESSES– Hot working and cold working of metals – Forging processes – Open, impression and closed die forging – Characteristics of the processes – Typical forging operations – rolling of metals – Types of Rolling – Flat strip
rolling – shape rolling operations – Defects in rolled parts – Principle of rod and wire
drawing – Tube drawing – Principles of Extrusion – Types – Hot and Cold extrusion
UNIT IV
SHEET METAL PROCESSES – Sheet metal characteristics – Typical shearing, bending
and drawing operations – Stretch forming operations – Formability of sheet metal– Metal
spinning – Introduction of Explosive forming, magnetic pulse forming, peen forming, Super
plastic forming – Micro forming.
UNIT V
MANUFACTURE OF PLASTIC COMPONENTS- Types and characteristics of plastics –
Moulding of thermoplastics – working principles and typical applications – 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.
TEXT BOOKS:
1.Elements of workshop Technology, S.K Hajra Chouldhary and AK Hajra Choudhury,
Volume I and II, Media promoters and Publishers Private Limited, Mumbai, 1997
2.Manufacturing Technology Foundry, Forming and Welding, P.N. Rao, , 4th Edition,
Tata Mc Graw Hill, 2003
3.Manufacturing Technology, Kalpakjian, Pearson Education India Edition, 2006
REFERENCES:
1.Production Technology, R.K. Jain, Khanna Publishers, 17th edition, 2012
2.Materials and Processes, in Manufacturing, Paul Degarma E, Black J.T and Ronald A.
Kosher, 8th Edition, Prentice – Hall of India, 1997.
3. Principles of Metal Castings, Rosenthal, 2nd Edition, Tata Mc Graw Hill, 2001
4. Manufacturing Technology, R.K. Rajput, 1st Edition, Laxmi Publishers, 2007