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UNIT I METAL CASTING PROCESSES


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


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


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 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


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


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.