Mec044 Production Technology i

Lovely Professional University,Punjab Format For Instruction Plan [for Courses with Lectures and Labs

Course No

Cours Title

Course Planner

MEC044

PRODUCTION TECHNOLOGY-I

11999 :: Gulzar

Text Book:

Other Specific Book:

Lectures Tutorial Practical Credits 3

0

6

1 1 Workshop Technology by BS Raghuwanshi, Dhanpat Rai and Sons Delhi

2 1 Manufacturing Technology by M Adithan and A.B. Gupta; Wiley Eastern India Ltd. 3 2 A Text Book of Production Engineering by PC Sharma; S Chand and Company Ltd. 4 3 Manufacturing Technology- Vol 1 By P N Rao TMH

Other Reading Sr No

Jouranls atricles as compulsary readings (specific articles, Complete reference) 5 Welding journals by C. Dawes & W. Thomas 6 Moulding journals by White. Liz

Relevant Websites Sr. No. (Web adress) (only if relevant to the courses)

Salient Features

7 http://www.robot-welding.com/arc_weld_processes.htm

To know about various welding processes

8 http://www.jobwerx.com/plastics/extrusion.htm

To know about Extrusion process

9 http://www.aws.org/educators/Library/0000/00063 4.ppt#256,1,GMAW / Mig Welding

To know about MIG welding

Detailed Plan For Lectures

1

Approved for Autumn Session 2011-12

6

Week Number Lecture Number Lecture Topic

Chapters/Sections of Pedagogical tool Textbook/other Demonstration/case reference study/images/anmatio n ctc. planned

Part 1 Week 1

Week 2

Week 3

Week 4

Lecture 1

Principle, Classification of welding processes

->Reference :1,24.124.2 ->Reference :7

ppt on basics of welding

Lecture 2

Advantages and limitations of welding, Industrial applications of welding

->Reference :1,24.2

Lecture 3

Welding positions, welding joints and their symbols. ->Reference :1,24.2624.27 ->Reference :7

Lecture 4

Principle of operation, Arc welding machines and equipment

->Reference :1,24.3224.33-24.34-24.3524.36 ->Reference :7

Lecture 5

Arc blow, A.C. and D.C. arc welding, Comparison between AC and DC arc welding

->Reference :1,24.3724.38

Lecture 6

Effect of polarity, arc welding electrodes, electrode classification and coding

->Reference :1,24.4024.41

Lecture 7

selection of electrodes, advantages limitations and industrial applications of arc welding.

->Reference :1,24.42

Lecture 8

Principle, Gas welding equipment - Gas welding ->Reference :1,24.16torch, Oxy acetylene cutting torch, Blow pipe, 24.17-24.18-24.19Pressure regulators, gas cylinders, other equipment 24.20-24.21-24.2224.23

Video on gas welding

Lecture 9

Filler rods, fluxes, types of gas welding flames and their applications

->Reference :1,22.1724.23-22.19

images

Lecture 10

Oxy-acetylene cutting, advantages limitations and industrial applications of gas welding.

->Reference :1,22.18

video of oxy-acetylene

Lecture 11

Resistance Welding: Principle, working, advantages, ->Reference :1,24.5limitations 24.9 ->Reference :7

video of arc resistance welding

Lecture 12

applications of spot welding, seam welding

video of seam welding

Images

ppt on effect of polarity

Part 2 Week 4

2

->Reference :1,24.624.7-24.10

Approved for Autumn Session 2011-12

Week 5

Week 6

Week 7

Lecture 13

projection welding and percussion welding

->Reference :1,24.1324.14 ->Reference :5,7.1 ->Reference :7

video of projection welding

Lecture 14

Principle, working, advantages, limitations and industrial applications of Tungsten inert gas (TIG) welding and Metal inert gas (MIG) welding

->Reference :1,24.4424.45 ->Reference :5,12.5 ->Reference :7

video of TIG and MIG welding

Lecture 15

Principle, working, advantages, limitations and industrial applications of welding Thermit welding

->Reference :1,24.53

ppt of Thermit welding

Lecture 16

Principle, working, advantages, limitations and industrial applications of Electro slag welding

->Reference :1,24.48 ->Reference :5,12.5 ->Reference :7

video of Electro slag welding

Lecture 17

Principle, working, advantages, limitations and industrial applications of Submerged arc welding.

->Reference :1,24.47 ->Reference :7

video of submerged arc welding

Lecture 18

Welding defects, Methods of controlling welding defects

->Reference :1,1Ch24/ images of welding 24.52 deffects

Lecture 19

Pattern making: Introduction, Types of pattern, Pattern materia

->Reference :1,12.112.3-12.10

Lecture 20

Pattern allowances, functions of a pattern

->Reference :1,12.712.9

Lecture 21

introduction to cores, core prints, core boxes, and core making procedure.

->Reference :1,12.2612.27

images

MID-TERM Part 3 Week 8

Week 9

3

Lecture 22

Moulding procedure, moulding boxes, Elements of gating system, Pouring basin, sprue, runner, gates, Types of risers

->Reference :1,15.1images 15.2-15.12-15.15-15.16 -15.18-15.19 ->Reference :6,1

Lecture 23

Directional solidification. Hand tools for mould making, mould materials, properties of foundry sands, and types of foundry sands, Testing of moulding sand

->Reference :1,13.214.3-14.4-14.12

Lecture 24

Moulding sand binders and additives, Moulding processes: Bench moulding, floor moulding, pit moulding and machine moulding, types of moulds

->Reference :1,14.814.9-15.4-15.5-15.615.7

Lecture 25

moulding machines- squeeze machine, jolt squeeze ->Reference :1,13.6 machine and sand slinger

images

Lecture 26

Charging a furnace, melting and pouring both ferrous and non ferrous metals, construction and working of cupola furnace and electric furnace.

images of furnaces

->Reference :1,16.116.2-16.4

images

Approved for Autumn Session 2011-12

Week 9

Lecture 27

Casting defects, their causes and remedies, cleaning of castings.

->Reference :1,18.1-18 images of casting -2-18.3-18.4-18.5-18.6- deffects 18.7

Week 10

Lecture 28

Special Casting Methods: Principle, working and applications of Die casting

->Reference :1,17.117.2-17.5

video of die casting

Lecture 29

Hot chamber and cold chamber, lost wax process, centrifugal casting.

->Reference :1,17.517.6-17.14

images

Lecture 30

FORMING: Principle, hot working and cold working of metals

->Reference :1,20.119.2

video of forging

Lecture 31

FORMING billet, slab, plate, and sheet.

->Reference :1,20.36

Lecture 32

Rolling - Principle, Types of rolling mills

->Reference :1,19.419.5-19.7

Lecture 33

Rolling defects and remedies. Advantages, limitations and industrial applications.

->Reference :1,19.15

Lecture 34

Forging: Basic forging operations, cold and hot forging. Open die forging, closed die forging

->Reference :1,20.120.3-20.21

Lecture 35

forging defects and remedies. Advantages, limitations and industrial applications.

->Reference :1,20.39

Lecture 36

Extrusion and Drawing: Type of extrusion- Hot and Cold, Direct and indirect. Tube drawing, wire drawing.

->Reference :1,19.1119.17 ->Reference :8

Part 4 Week 10

Week 11

Week 12

video of types of rolling mills

video of various types of forging

video of extrusion and drawing

Spill Over Week 13

Lecture 37

Press working: Press Operations-Shearing, piercing, ->Reference :1,10.4trimming, punching 10.5-10.6

Lecture 38

Notching, shaving, embossing, stamping, Types of presses, type of dies.

video

->Reference :1,10.1410.16

Details of homework and case studies Homework No.

Objective

Topic of the Homework

Nature of homework (group/individuals/field work

Evaluation Mode

Allottment / submission Week

Test 1

WELDING

WELDING

Individual

manual

3/4

Test 2

Gas welding

Principle, Gas welding equipment - Gas welding torch, Oxy acetylene cutting torch, Blow pipe, Pressure regulators, gas cylinders, other equipment

Individual

Manual

6/7

4

Approved for Autumn Session 2011-12

Test 3

Pattern making,Moulding

Introduction, Types of pattern, Pattern material Elements of gating Individual system, Pouring basin, sprue, runner, gates, Types of risers, Directional solidification.

Manuall

9 / 10

Scheme for CA:out of 100* Component

Frequency

Test Lab Assesment

Out Of

Each Marks Total Marks

2

3

10

20

20

22

1

20

11

40

Total :-

* In ENG courses wherever the total exceeds 100, consider x best out of y components of CA, as explained in teacher's guide available on the UMS List of suggested topics for term paper[at least 15] (Student to spend about 15 hrs on any one specified term paper) Sr. No. Topic 1 no

*Each experiment of the lab will be evaluated using following relative scheme: Component

% of Marks

J/E

50

WR

20

VIVA

30

List of experiments :Lecture Number

Lecture Topic

Pedagogical Tools Or Equipment Planned

lab Manual

Practical 1

Making of two pieces round split pattern with prior to the design requirement of a solid casting.

Engineer Steel Scale, Try Square, Marking Gauge, Saw, Iron Jack Planer, Firmer Chisel, Plastic Body Hammer, Rasp File etc./ Timber of soft wood (Fir or Partal).

Not Applicable

5

Approved for Autumn Session 2011-12

Practical 2

Preparation of a pattern with core print, highlighting its Engineer Steel Scale, Try Square, Marking Gauge, need & necessity. Saw, Iron Jack Planer, Firmer Chisel, Plastic Body Hammer, Rasp File etc./ Timber of soft wood (Fir or Partal).

Not Applicable

Practical 3

Preparation of a core box, for core, as per the design of Engineer Steel Scale, Try Square, Marking Gauge, cavity in the hollow casting. Saw, Iron Jack Planer, Firmer Chisel, Plastic Body Hammer, Rasp File etc./ Timber of soft wood (Fir or Partal).

Not Applicable

Practical 4

Making of two pieces square split pattern with prior to the design requirement of a solid casting.

Engineer Steel Scale, Try Square, Marking Gauge, Saw, Iron Jack Planer, Firmer Chisel, Plastic Body Hammer, Rasp File etc./ Timber of soft wood (Fir or Partal).

Not Applicable

Practical 5

Cutting a circular hole in M.S. Plates by gas cutting.

Gas welding equipments, Gas welding table, steel rule, scriber, files, welding goggles, apron, gloves, tongs, wire brush, lighter, clamping device, MS plates.

Not Applicable

Practical 6

Welding the M.S. plates by Gas Welding by placing the Gas welding equipments, Gas welding table, steel pieces in Vertical Position. rule, scriber, files, welding goggles, apron, gloves, tongs, wire brush, lighter, clamping device, MS plates.

Not Applicable

Practical 7

A job of T-Joint/ Butt joint/ Lap joint by spot Welding on Arc welding set and equipments, welding electrodes Not Applicable thin sheets. ,M.S plates, steel rule, scriber, files, welding goggles, apron, gloves, tongs, wire brush, clamping device, MS plates

Practical 8

Making a joint by TIG/MIG Welding.

TIG and MIG welding set and equipments. M.S plates.

Not Applicable

Practical 9

To check the moisture contents of Green Sand To check or measure the compressive strength of a given mixture of silica sand using compressive strength testing machine.

(a)Rapid Moisture Meter, Weighing Apparatus, Trowel, Sand Rammer, Specimen Tube./ Moulding Sand, Bentonite, Water, Calcium Carbide (b)Two or Three Sample of Silica Sand, Mould Holder and small Moulding Machine/ Mixture of Silica Sand

Not Applicable

Practical 10

To prepare the mould of given Split-Pattern using cope Moulding boxes, Trowel, Shovel, Vent wire, Lifter, Not Applicable and drag. Rammer, Sprue pins, Split pattern. / Moulding Sand, Bentonite, Parting sand, Water

Practical 11

To prepares the mould of solid pattern and cut the gate a) Moulding boxes, Trowel, Shovel, Vent wire, Lifter, Not Applicable sprue, runner, riser etc. Rammer, Sprue Pins. / Moulding Sand, Bentonite, Parting sand, Water. (b) Sand Mould, Moulding Hardness Tester or Core Hardness Tester. / Sand Mould.

6

Approved for Autumn Session 2011-12

Practical 12

To prepares casting of split pattern mould by pouring hot metal from furnace.

a) Moulding boxes, Trowel, Shovel, Vent wire, Lifter, Not Applicable Rammer, Sprue Pins. / Moulding Sand, Bentonite, Parting sand, Water. (b) Sand Mould, Moulding Hardness Tester or Core Hardness Tester. / Sand Mould.

Mid Term Practical 13

Preparation of a forged ‘O’-Ring.

Open Hearth Furnace, Water Tank, Pick-Up Tong, Punch, Drifter, Cold Chisel, Tong, Hammer, Anvil, Round Hollow Tong, Flatter, Set Hammer, Engineer Steel Scale. / M.S. Round piece size F 22 mm. X 10 mm.

Not Applicable

Practical 14

Preparation of a Screw Driver 6” by cold forging process.

Open Hearth Furnace, Water Tank, Pick-Up Tong, Cold Chisel, Tong, Hammer, Anvil, Flatter, Set Hammer, Engineer Steel Scale. / Mild steel Rod.

Not Applicable

Practical 15

To Forge a cross pane hammer head

Open Hearth Furnace, Water Tank, Pick-Up Tong, Cold Chisel, Tong, Hammer, Anvil, Flatter, Set Hammer, Engineer Steel Scale. / Mild steel Rod.

Not Applicable

Practical 16

To forge a straight pane hammer head

Open Hearth Furnace, Water Tank, Pick-Up Tong, Cold Chisel, Tong, Hammer, Anvil, Flatter, Set Hammer, Engineer Steel Scale. / Mild steel Rod.

Not Applicable

Practical 17

Preparation of a Paper Weight with internal thread of half B.S.W

Scriber, Engineering Steel Scale, Radius Gauge, Vernier Caliper, Marking Chalk, Dot Punch, Hand Hacksaw, Bench Vice, Files, Try square, Dividers, Hammer, Surface Plate, Outside Caliper, Inside calipers, Odd leg calipers. / Mild Steel Flat.

Not Applicable

Practical 18

Preparation of a radius fitting (upper part).

Scriber, Engineering Steel Scale, Radius Gauge, Vernier Caliper, Marking Chalk, Dot Punch, Hand Hacksaw, Bench Vice, Files, Try square, Dividers, Hammer, Surface Plate, Outside Caliper, Inside calipers, Odd leg calipers. / Mild Steel Flat.

Not Applicable

Practical 19

Preparation of a radius fitting (Lower part).

Scriber, Engineering Steel Scale, Radius Gauge, Vernier Caliper, Marking Chalk, Dot Punch, Hand Hacksaw, Bench Vice, Files, Try square, Dividers, Hammer, Surface Plate, Outside Caliper, Inside calipers, Odd leg calipers. / Mild Steel Flat.

Not Applicable

Practical 20

Preparation of a T shape as per drawing.

Scriber, Engineering Steel Scale, Radius Gauge, Vernier Caliper, Marking Chalk, Dot Punch, Hand Hacksaw, Bench Vice, Files, Try square, Dividers, Hammer, Surface Plate, Outside Caliper, Inside calipers, Odd leg calipers. / Mild Steel Flat.

Not Applicable

Spill Over Practical 21 7

Making a joint by TIG/MIG Welding.

TIG and MIG welding set and equipments. M.S plates.

Not Applicable Approved for Autumn Session 2011-12

Practical 22

8

Making a joint by TIG/MIG Welding.

TIG and MIG welding set and equipments. M.S plates.

Not Applicable

Approved for Autumn Session 2011-12