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FD6 :
INTRODUCTION TO MANUFACTURING PROCESSES
UNIT I :
1.
MILLING MACHINES
Introduction;
classification and types; Size and specifications; Accessories
attachment; Milling cutters; Classification and types of milling
cutter.; Nomenclature of cutter; Setup-operation ; Method of feeding
work piece; Operation on milling machine; Indexing (simple compound,
differential angular) ; Helical milling cam milling ; Cutting speed
& ledge ; Machining time calculation; Milling operation compound
with other operations
2. THE
LATHE
Introduction,
Functions, Types, Descriptions & Functions of Lathe Parts, Lathe
Accessories & attachments, lathe Operations.
3.
GRINDING MACHINE
Introduction.; Types of Grading machines (Floor stand, Precision.
Plain, cylindrical, universal centrals Internal, surface disc);
Special grinding machine, (Tool and cutter grinder, cam and and
shape grinders); Shape of grinding wheel; Grinding wheel designation
as per- IS -551 -19-54; Grinding wheels ; Grinding wheel elements
(abrasives - its types, Grain sizes, Grade, structure, bonding
material etc.); Diamond wheel; Grinding wheel section; Allowances
for grinding wheel; Mounting of Grinding wheel; Dressing and
cursing, of grinding wheel
4. BORING,
BROACHING AND SAWING MACHINE
Introduction
to Boring machines ; Types of Boring machine ; Boring haps and
heads; Various operations using boring heads; Boring operations
using end supports; Introduction to Broaching machine ; Types of
Broaching machine; Broaching tool nomenclature; Types of Broaches;
Broaching options compared with other process (advantages &
limitations.); External; Lubrication and cooling; Application of
Broaching
5. GEAR
MANUFACTURING
Gear
tooth e1ement; Materials for Gears; Different methods of Gear
manufacturing ; Gear generating methods; Gear milling ; Gear
shaping (Working principal of machine tool required Gear shaping
cutters etc.) ; Gear Hibbing (Working principal of machine tool
required Gear hobbing operation) ; Gear finishing process ( Gear
sharing burnishing, grinding honing lapping
6. METAL
FINISHING PROCESS
Introduction;
Honing; Description and construction of honing tool.; Application of
honing process; Lopping; Description of Lapping compound and tool;
Application of Lapping ; Super finishing process Burnishing -
Polishing - Buffing ; Application of super finishing operations.
7. PATTERN
MAKING
Introduction,
Pattern Materials, Pattern Making Tools, Pattern Allowances, Types
of Patterns, Solid or Single Piece Pattern, Split Pattern, Match
Plate Pattern, Cope and Drag Pattern, Loose Piece Pattern, Gated
Pattern, Sweep Pattern, Skeleton Pattern, Shell Pattern, Segmental
Pattern, Follow Board Pattern, Lagged-up Pattern, Left and Right
hand Pattern, Core Boxes, Colour coding for Pattern and Core Boxes.
8.
MOULDING AND CORE MAKING
Introduction,
Moulding Materials, Moulding Sand, Sand Binders, Sand Additives,
Properties of Moulding Sand, Classification of Moulding Sand, Grain
Shape and Size of Sand, Preparation of Moulding Sand, Types of
Moulding Sand, Moulding Processes, Types of Moulds, Methods of
Moulding, Methods of Green Sand Mould by Turn Over Method, Gates and
Risers, Types of Gates, Moulding Methods with Typical Patterns,
Cores, Types of Cores, Core Binders, Core Making, Core Setting, Core
Shifting and Chaplets.
9. CASTING
PROCESSES
Introduction,
Permanent Mould Casting, Semi-permanent Mould Casting, Slush
Casting, Die Casting, Centrifugal Casting, Investment Casting, Shell
Moulding Process, Continuous Casting, Defects in Casting, Cleaning
of Castings, Inspection of Castings, Design of Castings.
10.
WELDING
Introduction,
Weldability, Advantages and Disadvantages of Welded Joints, Types of
Welded Joints, Cold Pressure Welding, Types of Welded Joints, Fillet
Welded Joints, Edge Preparation and Applications, Welding Positions,
Black Smith’s Forge Welding, Electric Resistance Welding, Types of
Electric Resistance Welding, Spot Welding, Roll Spot and Seam
Welding, Projection Welding, Butt Welding, Percussion Welding, Arc
Welding, Polarity in Arc Welding, Comparison Between A.C. and D.C.
Arc Welding, Types of Arc Welding, Electrodes for Arc Welding, Arc
Welding Equipment, Precautions in Arc Welding, Arc Welding
Processes, Carbon Arc Welding, Metal Arc Welding, Metallic Inert-gas
(MIG)Arc Welding, Tungsten Inert-gas (TIG)Arc Welding, Atomic
Hydrogen Welding, Stud Welding, Submerged Arc Welding, Plasma Arc
Welding, Flux Cored Arc Welding, Electro-slag Welding, Electro-gas
Welding, Thermit Welding, Solid State Welding, Modern Welding
Processes, Basic Weld Symbols, Supplementary Weld Symbols, Elements
of a Welding Symbol, Standard Location of Elements of a Welding
Symbol, Gas Welding, Equipment for Oxy-acetylene Gas Welding,
Welding Rods, Fluxes, Gas Flame, Gas Welding Technique, Gas or
Oxygen Cutting of Metals, Cutting Machines, Oxygen Lance Cutting,
Arc Cutting, Oxygen Arc Cutting Process, Welding of Various Metals,
Testing of Welded Joints, Braze Welding, Soldering, Brazing.
11. RECENT
DEVELOPMENT IN MANUFACTURING PROCESS
Introduction,
Working of NC Machines tools, Classification of NC Machines,
Programming for NC Machines, Methods of Listing the Co-ordinates of
points in NC System, Application of NC Machine, Advantages &
Disadvantages, Computer Numerical Control & Direct Numerical
Control.
UNIT 2 : (
ONLY FOR BF6 STUDENTS )
12.
FOUNDRY TOOLS AND EQUIPMENTS
Introduction,
Foundry Tools and Equipments, Foundry Hand Tools, Moulding Boxes
(Flasks), Moulding Machines, Melting Equipment, Pouring Equipment.
13. HOT
AND COLD WORKING PROCESS
Introduction,
Objectives, Hot Working Process, Hot Rolling, Types of Rolling
Mills, Hot Forging, Hot Spinning, Hot Extrusion, Hot Drawing or
Cupping, Hot Piercing, Cold working process, Cold Rolling, Cold
Forging, Cold Spinning, Cold Extrusion, Cold Drawing, Cold Bending,
Shot Peening.
14. POWDER
METALLURGY
Introduction, Objectives,
Characteristics of Metal Powders, Preparation of Metal Powders,
Process used for Manufacturing parts from Metal Powders, Primary
Processes, Secondary Processes, Advantages of Powder Metallurgy,
Limitations of Powder Metallurgy, Design Considerations for Powder
Metallurgy, Typical Applications of Powder Metallurgy.
15.
PLASTIC MANUFACTURING PROCESS
Introduction,
Objectives, Types of Plastics - Thermosetting Resins & Thermoplastic
Resins, Synthetic Rubber or Elastomers, Moulding Compounds,
Fabrication of Plastics, Machining of Plastics, Joining of
Plastics.
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