Unit I : Metal Casting Processes (Chapter – 1)
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 : Blast and Cupola furnaces; Principle of special casting processes : Shell – Investment – Ceramic mould – Pressure die casting – Centrifugal casting – process – Stir casting ; Defects in sand casting.
Unit II : Joining Processes (Chapter – 2)
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 – Electro slag welding; Operating principle and applications of : Resistance welding – Plasma arc welding – Thermit welding – Electron beam welding – Friction welding and friction stir welding; Brazing and soldering; Weld defects : Types, Causes and cure.
Unit III : Metal Forming Processes (Chapter – 3)
Hot working and cold working of metals – Forging processes – Open, Impression and closed die forging – 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 (Chapter – 4)
Sheet metal characteristics – Shearing, Bending and drawing operations – Stretch forming operations – Formability of sheet metal – Test methods – Special forming processes – Working principle and applications – Hydro forming – Rubber pad forming – Metal spinning – Introduction of explosive forming, Magnetic pulse forming, Peen forming, Super plastic forming – Micro forming.
Unit V : Manufacture of Plastic Components (Chapter – 5)
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.