Metal Casting and Welding for VTU BE/B.Tech Mechanical 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 | 15 ME 35 A | IA Marks | 20 |
|---|---|---|---|
| Number of Lecture Hours/Week | 4 | Exam Marks | 80 |
| Total Number of Lecture Hours | 50 | Exam Hours | 3 |
CREDITS – 04
COURSE OBJECTIVES
- To provide detailed information about the moulding processes.
- To provide knowledge of various casting process in manufacturing.
- To impart knowledge of various joining process used in manufacturing.
- To provide adequate knowledge of quality test methods conducted on welded and casted components.
COURSE OUTCOMES
| Course Outcomes | Course Level | ||
|---|---|---|---|
| CO 1 | Describe the casting process, preparation of Green, Core, dry sand molds and Sweep, Shell, Investment and plaster molds. | U | PO1 |
| CO 2 | Explain the Pattern, Core, Gating, Riser system and Jolt, Squeeze, Sand Slinger Molding Machines. | U | PO1 |
| CO 3 | Compare the Gas fired pit, Resistance, Coreless, Electrical and Cupola Metal Furnaces. | U | PO1 |
| CO 4 | Compare the Gravity, Pressure die, Centrifugal, Squeeze, slush and Continuous Metal mold castings. | U | PO1 |
| CO 5 | Explain the Solidification process and Casting of Non-Ferrous Metals | U | PO1 |
| CO 6 | Describe the Metal Arc, TIG, MIG, Submerged and Atomic Hydrogen Welding processes used in manufacturing. | U | PO1 |
| CO 7 | Explain the Resistance spot, Seam, Butt , Projection, Friction, Explosive, Thermit, Laser and Electron Beam Special type of welding process used in manufacturing. | U | PO1 |
| CO 8 | Describe the Metallurgical aspects in Welding and inspection methods for the quality assurance of components made of casting and joining process. | U | PO1 |
| Total Hours of instruction | 50 |
MODULE 1
INTRODUCTION & BASIC MATERIALS USED IN FOUNDRY
Introduction: Definition, Classification of manufacturing processes. Metals cast in the foundry-classification, factors that determine the selection of a casting alloy. Introduction to casting process & steps involved. Patterns: Definition, classification, materials used for pattern, various pattern allowances and their importance.
Sand molding: Types of base sand, requirement of base sand. Binder, Additives definition, need and types Preparation of sand molds: Molding machines- Jolt type, squeeze type and Sand slinger. Study of important molding
process: Green sand, core sand, dry sand, sweep mold, CO2 mold, shell mold, investment mold, plaster mold, cement bonded mold. Cores: Definition, need, types. Method of making cores, concept of gating (top, bottom, parting line, horn gate) and risering (open, blind) Functions and types [10 Hours]
MODULE -2
MELTING & METAL MOLD CASTING METHODS
MODULE -3
SOLIDIFICATION & NON FERROUS FOUNDRY PRACTICE
Solidification: Definition, Nucleation, solidification variables, Directional solidification-need and methods. Degasification in liquid metals-Sources of gas, degasification methods. Fettling and cleaning of castings: Basic steps involved. Sand Casting defects- causes, features and remedies. Advantages & limitations of casting process
Nonferrous foundry practice: Aluminum castings – Advantages, limitations, melting of aluminum using lift-out type crucible furnace. Hardeners used, drossing, gas absorption, fluxing and flushing, grain refining, pouring temperature. Stir casting set up, procedure, uses, advantages and limitations. 10 Hours
MODULE -4
WELDING PROCESS
Welding process: Definition, Principles, Classification, Application, Advantages & limitations of welding. Arc welding: Principle, Metal arc welding (MAW), Flux Shielded Metal Arc Welding (FSMAW), Inert Gas Welding (TIG & MIG) Submerged Arc Welding (SAW) and Atomic Hydrogen Welding (AHW).
Special type of welding: Resistance welding principles, Seam welding, Butt welding, Spot welding and Projection welding. Friction welding, Explosive welding, Thermit welding, Laser welding and electron beam welding. 10 Hours
MODULE -5
SOLDERING , BRAZING AND METALLURGICAL ASPECTS IN WELDING Structure of welds, Formation of different zones during welding, Heat Affected Zone (HAZ), Parameters affecting HAZ.Effect of carbon content on structure and properties of steel, Shrinkage in welds & Residual stresses, Concept of electrodes, filler rod and fluxes. Welding defects- Detection, causes & remedy.
Soldering, brazing, gas welding: Soldering, Brazing, Gas Welding: Principle, oxy-Acetylene welding, oxy-hydrogen welding, air-acetylene welding, Gas cutting, powder cutting.
Inspection methods: Methods used for inspection of casting and welding. Visual, magnetic particle, fluorescent particle, ultrasonic. Radiography, eddy current, holography methods of inspection. 10 Hours
TEXT BOOKS:
- “Manufacturing Process-I”, Dr.K. Radhakrishna, Sapna Book House, 5th Revised Edition 2009.
- “Manufacturing & Technology: Foundry Forming and Welding”, P.N. Rao, 3rd Ed., Tata McGraw Hill, 2003.
REFERENCE BOOKS:
- “Process and Materials of Manufacturing”, Roy A Lindberg, 4th Ed. Pearson Edu. 2006.
- “Manufacturing Technology”, Serope Kalpakjian, Steuen. R. Sechmid, Pearson Education Asia, 5th Ed. 2006.
- “Principles of metal casting”, Rechard W. Heine, Carl R. Loper Jr., Philip C. Rosenthal, Tata McGraw Hill Education Private Limited Ed.1976.
Question paper pattern:
- The question paper will have ten questions.
- Each full question consisting of 16 marks.
- There will be 2 full questions (with a maximum of 4 sub questions) from each module.
- Each full question will have sub questions covering all the topics under a module.
- The students will have to answer 5 full questions, selecting one full question from each module.
For all other BE/B.Tech 3rd Sem Subject syllabus do follow VTU 3rd Sem BE / B.Tech Syllabus CBCS (2015-16) Scheme for Mechanical Engineering Group.
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