3ME07: METAL FORMING, JOINING AND FOUNDARY PRACTICES

CREDITS - 4 (LTP: 3,0,1)

Course Objective:
To illustrate technology of welding, casting and forming processes

Teaching and Assessment Scheme:

Teaching Scheme
Credits Assessment Scheme Total
(Hours per Week)
Marks
Theory Marks Practical Marks
L T P C
ESE CE ESE CE
150
3 0 2 4 60 40 20 30

Course Contents:
Unit Teaching
Topics
No. Hours
1 Introduction: 2
Objectives of a manufacturing process, Classifications of Manufacturing
Processes for metals and alloys.

2 Theory of Welding and Welding Processes: 16

Definition of a weld, a joint, Types & Parameters of weld, Types of joints,
Weldment, Welding positions,
Mechanisms of formation of weld, Metallurgical aspects of fusion and pressure
welding
Basic requirements of welding and how these requirements are fulfilled by
welding processes, Classifications of welding processes. Comparison between
welding, soldering, brazing and riveting.
Arc Welding Processes: The welding arc, Nature and Behavior of welding arc
and its relevance to the practice, Arc initiation and arc maintenance methods,
Arc welding power sources and their characteristics.
Principle of operation, characteristics, consumables, equipment, process
variables and capabilities of arc welding processes like SMAW, SAW,
GMAW, GTAW, Designing arc welding procedures.
Principle of operation, characteristics, consumables, equipment, process
variables and capabilities of processes like Resistance, LASER, Electron
Beam, Friction, Oxy-Acetylene Gas welding.
Other Joining Processes like Brazing, Soldering and Adhesive Bonding;
Thermal Cutting processes: Oxy-Acetylene gas cutting - mechanism of cutting,
effect of process variables, applications; Plasma arc cutting, LASER Beam
cutting processes.
3 Fundamentals of Metal casting and Metal casting Processes: 12
Applications of metal casting, Classification of casting processes.
Mechanism and Rate of Solidification of Metals and Alloys: Solidification of
pure metals and alloys, Factors influencing solidification of castings, Feeding
Resistance,
Gas Porosity in castings, Factors causing gas dissolution in liquid metal,
Degassing techniques.
Unit Teaching
Topics
No. Hours
Gating Design, gating ratios, Aspiration effects and its prevention, Gating
methods, Slag-Trap systems, Metal Fluidity, Factors governing metal fluidity,
Measurement of fluidity.
Feeder Design and Placement, Directional solidification in castings
Expendable Mould Production:
Pattern Construction: Types of patterns, Pattern Allowances, Design of pattern,
Moulding Material: Types of Sand, Properties, Preparation and Testing,
Moulding processes like Green sand, dry sand, CO2 moulding, Shell Moulding,
Investment casting.
Permanent Mould processes like Centrifugal casting, Pressure Die casting
Defects in castings
4 Theory of Metal Forming and Forming Processes: 12
Application of metal forming, Theory of Plastic deformation, Strain hardening,
Recovery, Recrystallization and Grain Growth, Effect of Temperature,
Composition and Strain rates on metal forming, Characteristics and
applications of Hot working and Cold working, Classification of metal forming
processes according to stresses.
Working principle, characteristic features, capabilities and application of Bulk
Metal Forming Processes like Rolling, Forging, Extrusion, Wire Drawing and
Thread Rolling.
Working principle, characteristic features, process variables, capabilities and
application of Sheet Metal Working like Shearing, Bending, Deep Drawing,
Spinning, Coining, Embossing,
Total 42
List of References:
1. Parmar, R. S., “Welding Processes and Technology”, 3rd edition, Khanna Publishers, 1996
2. Kaushish, J. P., “Manufacturing Processes”, 2nd Edition, PHI Learning Pvt. Ltd, 2010
3. Rao, P. N., “Manufacturing Technology: Volume 1 Foundry, Forming and Welding”, 5th
edition, Tata McGrawHill, 2018
4. Ghosh, Amitabh & Mullick, “Manufacturing Science”, 2nd edition, EWP, 1986.
5. Ravi, B., “Metal Casting: Computer-Aided Design and Analysis” PHI,2005
6. Flinn, R. A., “Fundamentals of Metal Casting”, Addison-Wesley
7. Houldcroft, Peter, “Welding Process Technology”, Cambridge University Press,1977
8. Cary, Howard B.,Helzer, Scott, “Modern Welding Technology”, 6th edition, Pearson, 2005
9. Kalpkjian, S, Schmid Stevens, “Manufacturing Engineering & Technology” 7th Edition,
Pearson, 2013
10. Black, J. T., & Kohser, Ronald A.; “DeGarmo’s Materials and Processes in Manufacturing”,
10th edition, John Wiley & Sons, Inc., 2007
11. Juneja, B. L., “Fundamentals of Metal Forming”, 1st Edition, New Age International (P)
Ltd.,2007

Course Outcomes (COs):

At the end of this course students will be able to …
1. Identify how the given process achieves the required shape and size along with required
properties.
2. Illustrate capabilities of welding processes and select an appropriate welding process for a
given application and hence develop a welding procedure for a given job.
3. Illustrate casting problem (melting, refining & pouring and production of a mould) and explain
process capabilities and application of casting processes. Design a “mould ready to pour”
solution for a given casting.
4. Illustrate capabilities and hence application of bulk metal forming processes and sheet metal
work.