Unit 1 Foundry Technology

10 lecture hours

• Pattern Practices: Types of patterns
• pattern allowances, and materials used for patterns
• Moulding materials and moulding sands
• properties of moulding sand, and sand testing methods such as grain fineness
• moisture content
• clay content, and permeability
• Core materials and core making
• core prints
• core boxes, and chaplets
• Moulding practices including green sand
• dry sand, and loam sand moulding
• pit and floor moulding
• shell moulding
• permanent moulding
• and carbon dioxide (CO₂) moulding
• Casting Practices: Fundamentals of metal casting
• sand casting
• shell mould casting
• plaster and ceramic mould casting
• investment casting
• vacuum casting
• permanent mould casting
• and slush casting
• Pressure casting and die casting
• centrifugal casting
• continuous casting
• and squeeze casting
• Casting alloys
• casting defects, and design of castings including gating system and riser design
• Melting furnaces such as rotary
• pit electric
• tilting, and cupola furnaces

Unit 2 Metal Joining Processes

10 lecture hours

• Principles of welding
• brazing, and adhesive bonding
• Classification of welding and allied processes
• Gas welding and gas cutting
• including oxy-acetylene welding equipment
• Arc welding
• power sources, and consumables
• Resistance welding processes such as spot
• projection, and seam welding
• Advanced welding processes including atomic hydrogen
• plasma arc, laser beam, and electron beam welding
• Special welding processes such as TIG, MIG, friction, and explosive welding
• Welding of cast iron (C.I.) and aluminium (Al)
• Welding defects
• electrodes and electrode coatings, and welding positions

Unit 3 Forming and Shaping Processes

• Metal working
• elastic and plastic deformation
• hot and cold working
• concept of strain hardening
• Cold working processes such as shearing
• deep drawing
• coining, and embossing
• Rolling: principle and operations, and roll pass sequence
• Extrusion, and 10 Program Name: Bachelor of Engineering Level: UG Branch: Automobile Subject Code: BE05002041 Subject Name: Advance Manufacturing Technology wire and tube drawing processes
• Forging: methods of forging
• forging hammers and presses, and principles of forging tool design
• Metal working defects
• cold heading
• thread rolling
• bending, and forming operations

Unit 4 Unconventional Machining Processes

10 lecture hours

• Mechanical Energy Based Processes: Abrasive Jet Machining (AJM)
• Water Jet Machining (WJM)
• Ultrasonic Machining (USM)
• Working Principles – equipment used – Process parameters – MRR- Applications
• Electrical Energy Based Processes: Electric Discharge Machining (EDM)- working Principle- equipment used -Process Parameters - Surface Finish and MRR - electrode / Tool – Power and control Circuits-Tool Wear – Dielectric – Flushing – Wire cut EDM – Applications
• Chemical and Electro-Chemical Energy Based Processes: Chemical machining and Electro - Chemical machining (CHM and ECM) - Etchants – Maskant - techniques of applying maskants - Process Parameters – Surface finish and MRR - Applications
• Principles of ECM - equipments-Surface Roughness and MRR Electrical circuit-Process Parameters- ECG and ECH - Applications
• Thermal Energy Based Processes: Laser Beam machining (LBM)
• Plasma Arc machining (PAM) and Electron Beam Machining (EBM)
• Principles – Equipment – Types - Beam control techniques – Applications

Unit 5 Plastic Technology

5 lecture hours

• classification of plastics
• ingredients of moulding compounds
• general properties of plastics
• plastic part manufacturing processes such as compression moulding
• transfer moulding
• injection moulding
• extrusion moulding
• blow moulding
• slush moulding, and laminating