DAYANANDA SAGAR COLLEGE OF ENGINEERING DEPARTMENT OF AERONAUTICAL ENGINEERING LESSON PLAN

SUBJECT: Manufacturing Processes Hrs/week : 04 FACULTY : Hareesha N G Sub Code: 10AE35 Semester : 3rd sem, Aeronautical

S.N Date Details of the portions coverage UNIT 1 INTRODUCTION: 1 26/07/2012 Concept of Manuf process, its importance, Classif of Manuf processes. 2 28/07/2012 Introduction to Casting process & steps involved. Varieties of comps produced by casting process. Adv & Lim of casting process. 3 31/07/2012 Patterns: Definition, functions, Materials used for pattern 4 1/08/2012 Various pattern allowances and their importance. Classif of patterns 5 2/08/2012 Binder: Definition, Types of binder used in moulding sand 6 4/08/2012 Additives: Need, Types of additives used UNIT 2: SAND MOULDING : 7 7/08/2012 Types of base sand, requirement of base sand. Types of sand moulds 8 8/08/2012 Sand moulds: Moulding sand mixture ingredients (base sand, binder & additives) for different sand mixtures Method used for sand moulding 9 9/08/2012 Cores: Definition, Need, Types. Method of making cores,Binders used 10 11/08/2012 Concept of Gating & Risering. Principle involved and types 11 14/08/2012 Fettling and cleaning of castings. Basic steps involved 12 16/08/2012 Casting defects, causes, features and remedies 13 18/08/2012 Moulding machines : Jolt type, squeeze type, Jolt & Squeeze type and Sand slinger UNIT 3: SPECIAL MOULDING PROCESS : 14 21/08/2012 Study of important moulding processes Green sand, Core sand, Dry sand 15 22/08/2012 Sweep mould, CO2 mould 16 23/08/2012 Shell mould, Investment mould 17 25/08/2012 Metal moulds: Gravity die-casting 18 28/08/2012 Pressure die casting, centrifugal casting 19 29/08/2012 Squeeze Casting, Slush casting 20 30/08/2012 Thixocasting and continuous casting processes UNIT 4: WELDING Welding process: Definition, Principles, Classification, Application, 21 1/09/2012
Advantages & limitations of welding. Gas Welding: Principle, Oxy Acetylene welding, Reaction in Gas welding Flame characteristics, Gas torch construction & working. Forward and backward welding Arc Welding: Principle, Metal Arc welding (MAW) 24 6/09/2012 Flux Shielded Metal Arc Welding (FSMAW) 25 8/09/2012 26 13/09/2012 Inert Gas Welding (TIG & MIG) UNIT 5: PRINCIPLES OF SOLDERING & BRAZING: 27 15/09/2012 Parameters involved & Mechanism. 28 18/09/2012 Different Types of Soldering & Brazing Methods 29 20/09/2012 Inspection Methods Methods used for Inspection of casting and welding. Visual, Magnetic particle 30 22/09/2012 Fluorescent particle, Ultrasonic 31 25/09/2012 Radiography, Eddy current 32 26/09/2012 Holography methods of Inspection. UNIT 6: THEORY OF METAL CUTTING: 33 27/09/2012 Single point cutting tool nomenclature, geometry of single point cutting tool 34 29/09/2012 Merchants circle diagram and analysis Ernst- Merchants solution 35 3/10/2012

Remarks

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4/09/2012 5/09/2012

Shear angle relationship, Problems on Merchants analysis 36 6/10/2012 Tool wear & tool failure, Tool life, Effects of cutting parameters on tool life 37 9/10/2012 38 10/10/2012 Tools failure criteria, Taylors tool life equation 39 11/10/2012 Problems on tool life evaluation. UNIT 7: CUTTING TOOL MATERIALS: 40 13/10/2012 Desired properties, types of cutting tool materials 41 20/10/2012 HSS carbides, coated carbides, ceramics cutting tools 42 25/10/2012 cutting fluids, desired properties, types and selection 43 27/10/2012 Heat generation in metal cutting 44 30/10/2012 factors affecting heat generation 45 31/10/2012 Heat distribution in tool and w/p Measurements of tool tip temperature. 46 3/11/2012 UNIT 8: NON-TRADITIONAL MACHINING PROCESS: Principle, need, equipment, operation and applications of LBM 47 6/11/2012 Principle, need, equipment, operation and appl of Plasma Arc Machining 48 7/11/2012 49 13/11/2012 Principle, need, equipment, operation and appl of Electro chemical machining 50 15/11/2012 Principle, need, equipment, operation and appl of Ultrasonic Machining 51 17/11/2012 Principle, need, equipment, operation and appl of Abrasive jet machining 52 20/11/2012 Principle, need, equipment, operation and appl of Water jet machining

TEXT BOOKS: 1) Manufacturing & Technology: Foundry Forming and Welding, P.N.Rao 2nd Ed., Tata McGraw Hill, 2003. 2) Manufacturing Process-I, Dr.K.Radhakrishna, Sapna Book House, 2nd Edition 2007. REFERENCE BOOKS: 1) Manufacturing Technology, Serope Kalpakjain, Steuen.R.Sechmid, Pearson Education Asia, 5th Ed. 2006. 2) Process and Materials of Manufacturing:, Roy A Lindberg, 4th Ed. Pearson Edu. 2006.

SCHEME OF EXAMINATION: One Question to be set from each chapter. Students have to answer any FIVE full questions out of EIGHT questions, choosing at least 2 questions from part A and 2 questions from part B.

Signature of the Faculty

Signature of the HOD