Manufacturing Science | Department of Mechanical Engineering

Manufacturing Science

Unit I: Metal Casting Introduction to metal casting, Solidification of Metals, Characteristics of sand casting, Patterns, Pattern allowances, Pattern materials, Types of patterns, Moulding materials, Moulding sand properties, Types of sand moulds, Cores, Gating system, Casting Defects, Special casting processes, Cast structures
Unit II: Metal Removal Processes Mechanism of metal cutting, Types of tools, Tool Geometry, Tool Signature, Orthogonal and Oblique cutting, Mechanics of chip formation, Chip morphology, Tool wear and failure, Machinability, Cutting-tool materials, Cutting fluids, Brief description of metal removal processes: Turning, drilling, boring and Milling, Material removal rate and machining time
Unit III: Metal Joining Processes Classification of joining processes, Welding technique, Different welding processes: Gas Welding, Electric Arc Welding, Tungsten Inert-gas Welding (TIG), Gas Metal-Arc Welding (GMAW), Submerged Arc Welding (SAW), Resistance Welding, Friction Stir Welding (FSW), Defects in Weldments
Unit IV: Bulk Deformation Processes Introduction to bulk deformation processes, Hot and cold working, Forging, Types of forging, Forging defects, Rolling, Defects in rolled products, Extrusion, Metal flow in extrusion, Rod drawing, Wire and Tube drawing, Swaging, Severe plastic deformation processes: Friction stir processing, Equal channel angular extrusion and high pressure torsion
Unit V: Powder Metallurgy Production of metal powders, Particle size and shape, Blending of metal powders, Compaction of metal powders, Shaping processes, Sintering, Finishing operations, Design considerations for powder metallurgy
Unit VI: Non-Conventional Machining Processes Need of non-conventional machining, Classification of non-conventional machining processes, Different non-conventional machining processes: Water jet machining, Abrasive jet machining, Chemical machining, Electrochemical machining, Electrical discharge machining, Laser-beam machining

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