Course11210723960 lectures
Theory of Production Processes
Prof. P. K. Jha · IIT Roorkee
About
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.
Prerequisites: Introduction to manufacturing technology or manufacturing processes.
Lectures
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
Syllabus and materials
At NPTEL, as the course publishes them.
Credits and licence
- Institution
- IIT Roorkee
- Department
- Mechanical Engineering
- Teacher
- Prof. P. K. Jha
- Level
- Undergraduate
- Language
- English
- Subjects
- Engineering
- Source
- NPTEL
- Licence
- CC BY-NC-SA, as NPTEL states it. Non-commercial use only. NPTEL's terms
- Attribution
- NPTEL states: "Distributed under Creative Commons Attribution-ShareAlike / CC BY - NC - SA", beside a BY-NC-SA badge.
- Who can watch
- NPTEL gives no rating. Invisible Network shows it to Tweens profiles and older, judged from what the source says about it. How courses are placed