The course focuses on understanding the science behind technology of primary production processes namely casting, forming and welding. Conventionally, the courses on manufacturing processes deal with study of operational procedures. However, it is desirable to know how any process occurs and the products are finally manufactured, the basic principles behind these processes are required to be highlighted. The course will make the students aware with the theoretical aspects of the different manufacturing processes mentioned above. The course has been divided into three sections namely casting, forming and welding, each being covered in 4 weeks of time. The underlying principles of solidification, fluidity, gating, risering, melting etc. will be covered in casting section whereas mechanics of metalworking, analysis of different metal working processes will be covered in the second section i.e. forming. In the third section i.e. welding, principles of welding processes, thermal effects, weldability etc. will be covered. The course will enable the students be conversant with working principles so that they can use the knowledge gained towards increasing the productivity of manufacturing industries in the long run.
Syllabus 12
Week 1
Introduction to Theory and Practice of Casting
Theory of Solidification: Cooling Curves
Solidification of Pure Metals and Alloys
Factors Affecting Solidification Process
Fluidity of Liquid Metals
Week 2
Technology of Patternmaking: Pattern Materials
Patternmaking: Types of Pattern & Allowances
Molding sand Ingredients and Sand Testing Methods
Sand Molding Methods
Coremaking: Properties and Types of Cores
Week 3
Gating System Design: Types of Gates
Gating System Design: Pouring Time Calculation
Introduction to Riser Design
Risering Methods
Problem Solving on Gating Design and Risering Methods
Week 4
Theory of Melting: Types of Furnaces
Melting and Production of Iron Castings
Production of Steel and Non-Ferrous Castings
Casting Design Considerations
Casting Defects: Types, Causes and Remedies
Week 5
Concept of Stress and Strain, Elastic and Plastic Behavior
State of Stress in Two and Three Dimensions, Mohr's Circle
Description of Strain at a Point
Mean and Deviator Stresses, Elastic Stress Strain Relationships
Theory of Plasticity: True Stress and True Strain, Flow Curve
Week 6
Yield Criteria for Ductile Materials
Flow Rules, Plastic Stress Strain Relationships
Classification of Metal Working Processes
Mechanics of Metal Working
Temperature in Metal Working: Hot and Cold Working
Week 7
Rolling Process: Classification, Hot and Cold Rolling
Analysis of Rolling Operation: Forces and Geometrical Relationships
Introduction to Forging Process: Classification and Equipments
Analysis of Forging Process
Problem Solving on Rolling and Forging Processes
Week 8
Extrusion Process: Classification and Analysis
Drawing of Rods, Tubes and Wires
Analysis of Drawing Operation
Sheet Metal Operations
Metal Forming Defects
Week 9
Classification of Joining Processes
Heat Flow in Welding
Metallurgy of Fusion Welds
Heat Affected Zone in Welding
Heat Treatment Processes in Welding
Week 10
Principle of Shield Arc Welding Processes
Principle of Gas Shield Arc Welding Processes
Principle of Resistance Welding
Principle of Solid State Welding Processes
Brazing, Soldering and Adhesive Bonding
Week 11
Residual Stresses in Welding
Methods of Controlling Residual Stresses in Welding
Welding Distortion
Control of Welding Distortion
Preheat and Postweld Heat Treatment of Weldments
Week 12
Weldability of Metals
Weldability of Steels
Weldability of Cast Iron
Weldability of Non-Ferrous Materials
Welding Defects
Advantages and disadvantages
Advantages
Taught by IIT and IISc professors, and it follows the Indian university syllabus closely.
All videos and assignments are free on NPTEL and SWAYAM.
The certificate is recognised by many Indian universities for credit transfer and by GATE aspirants.
Great for GATE and semester exam preparation.
From Indian Institute of Technology Roorkee, a well-regarded name.
Completely free.
Self-paced: start any time.
A clear syllabus (12 parts) you can see before you start.
Disadvantages
The certificate needs a proctored exam at a centre, which has a fee.
Recorded classroom lectures: thorough, but slower than made-for-online courses.
New runs start on fixed dates (January and July).
Learning is free, but the certificate costs money.
Some points apply to every course of this kind; see how we rank.
Free to learn
Free: Every video and assignment is free on NPTEL and SWAYAM. Enrol when the next run opens.
Certificate: Optional. It needs a proctored exam at a centre, which has a fee.
Before you start
Introduction to manufacturing technology or manufacturing processes.
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