Foundry Technology Syllabus for VTU BE/B.Tech Manufacturing Science & Engineering third sem complete syllabus covered here. This will help you understand complete curriculum along with details such as exam marks and duration. The details are as follows.
| Subject Code | 15MA35 | IA Marks | 20 |
|---|---|---|---|
| Number of Lecture Hours/Week | 04 L | Exam Marks | 80 |
| Total Number of Lecture Hours | 52 | Exam Hours | 3 |
CREDITS – 04
Course Objectives: This course provides:
- A basic understanding of foundry practice and metal casting as one of the important manufacturing processes.
- An explanation of the fundamental process of solidification of pure metals and alloys.
- Sand molding and permanent die molding are explained in detail.
- The standard foundry practices for casting of ferrous and non-ferrous alloys elaborated.
- An overview of the designing of molds, casting defects, inspection and testing of castings and modernization of foundries
Course outcomes: The student shall:
- Have an Understand the technology, variables and complexity involved in producing a casting.
- Be able to make selection of the type of furnace required for any specific casting problem and design the pattern requirement.
- Have the basic knowledge for selecting the type of sand, for molds and cores as well as the molding process.
- Know about the special molding processes and when their use is warranted.
- Have a broad knowledge of casting of ferrous and non-ferrous alloys and of the inspection techniques to detect casting defects.
UNIT-1
Introduction:Introduction to casting process and the steps involved; Components produced by casting process, Comparison of metal casting with metal joining, Advantages and limitations of casting process; Overview of the industry
Solidification of metals: Introduction, freezing of pure metals; Nucleation and Growth, shrinkage, solidification of alloys; dendritic growth and segregation; shrinkage in alloys; Alloys freezing in two stages; solidification process in eutectic and non-eutectic alloys; Properties related to the solidification mechanism – Fluidity, Hot tearing or hot cracking, Evolution of
dissolved gases, Effect of inoculation; Solidification of actual castings; Progressive and directional solidification; Centerline feeding resistance; Rate of solidification; Chvorinov’s Rule. (11 Hours)
UNIT-2
UNIT-3
Sand molding: Types and requirements of base sand; Binders and additives used – types and properties; Molding tools and equipment – hand molding tools, molding machines – Jolt type, squeeze type, Jolt and Squeeze type and Sand slinger; Cores – types, core prints, core venting and baking, core shifting and chaplets, method of making cores, binders used, core sand
molding; Gating systems – principles and types of gates and risers, gating ratios and chills, riser location and design in actual casting; Molding processes – bench molding, floor molding, pit molding, stack molding, green sand molding, dry sand molding, loam molding, machine molding. (10 Hours)
UNIT-4
Special Molding Processes: Study of important molding processes, No bake molds, Flask less molds, Sweep mold, CO2 mold, Shell mold, Investment mold. Metal Molds: Gravity die casting, Pressure die casting, Centrifugal casting, Squeeze casting, Slush casting, Thixo-casting, Continuous casting.Non-metal molding, Plaster and Ceramic molding; Expandable pattern mold casting. Finishing processes: Fettling and cleaning of castings; removal of gates and risers, grinding. Non-Ferrous Foundry practice: Casting of Al-Si and Al-Mg alloys, Cu-base casting alloys. (11 Hours)
UNIT – 5
Foundry Practices of Cast Irons, Steels, Inspection and Testing of Castings: Foundry practice for cast irons – gray iron, white cast iron; Ductile iron, malleable iron, SG iron, Steel castings – steel melting in the foundry; Metallurgy of cast steel; Casting design considerations; Inspection and testing of castings: Defects in castings – types, causes and remedies; Inspection and non-destructive testing of castings. Modernization and mechanization of foundry; Material handling; Pollution control in foundry; Application of computers in casting process; Software available for casting process simulation. (10 Hours)
TEXT BOOKS:
- R.A.Flinn, “Fundamentals of Metal casting”, Addison Wesley, 1963.
- R.W. Heine, C.R.Loper & P.C. Rosenthal, “Principles of Metal casting”, Tata McGraw Hill, 2001.
REFERENCE BOOKS
- R.A. Lindberg, “Processes and Materials for Manufacturing”, 4th Ed, Pearson Education, 2006.
- P.N.Rao, “Manufacturing Technology: Foundry, forming and welding”, 3rd Ed., Tata McGraw Hill, 2003.
- “ASM Handbook: Volume 15: Casting” 9th Ed., American Society of Metals, Ohio, 2008.
For all other BE/B.Tech 3rd Sem Subject syllabus do follow VTU 3rd Sem BE / B.Tech Syllabus CBCS (2015-16) Scheme for Manufacturing Science & Engineering Group.
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