WT1 (Diploma Mechanical Engineering 3rd)

1. Welding (16 hrs)

1.1 Welding Process

Principle of welding, Classification of welding processes, Advantages and

limitations of welding, Industrial applications of welding, Welding

positions and techniques, symbols.

1.2 Gas Welding

Principle of operation, Types of gas welding flames and their applications,

Gas welding equipment - Gas welding torch, Oxy acetylene cutting torch,

Blow pipe, Pressure regulators, Filler rods and fluxes

1.3 Arc Welding

Principle of operation, Arc welding machines and equipment, A.C. and

D.C. arc welding, Effect of polarity, current regulation and voltage

regulation

1.4 Other Welding Processes

- Resistance welding, introduction to spot and seam welding

- Modern welding methods – TIG, MIG, ultrasonic welding, laser beam

welding, robotic welding

1.5 Welding Defects

Types of welding defects, methods of controlling welding defects,

inspection of welding defects

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2. Pattern Making (03 hrs)

Types of pattern, Pattern material, Pattern allowances, Pattern codes as per B.I.S.,

Introduction to cores, core boxes and core materials, Core making procedure, Core

prints, positioning of cores

3. Moulding and Casting (16 hrs)

3.1 Moulding Sand

Properties of moulding sand, their impact and control of properties.

Various types of moulding sand.

3.2 Mould Making

Types of moulds, molding boxes, hand tools used for mould making,

molding processes, molding machines: squeeze machine, jolt squeeze

machine and sand slinger.

3.3 Casting Processes

Charging a furnace, melting and pouring both ferrous and non ferrous

metals, cleaning of castings, Principle, working and applications of Die

casting

3.4 Gating and Risering System

Elements of gating system, Pouring basin, sprue, runner, gates, Types of

risers, location of risers, Directional solidification

3.5 Melting Furnaces

Construction and working of Pit furnace, Cupola furnace, Crucible

furnace – tilting type, Electric furnace

3.6 Casting Defects

Different types of casting defects, Testing of defects through magnetic

particle inspection.

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4. Metal Forming Processes (08 hrs)

4.1 Press Working - Types of presses, type of dies, selection of press die, die

material. Press Operations-Shearing, piercing, trimming, punching,

notching, shaving, gearing, embossing, stamping

4.2 Forging - Open die forging, closed die forging, Press forging, upset

forging, swaging, up setters, roll forging, Cold and hot forging

4.3 Rolling - Elementary theory of rolling, Types of rolling mills, Thread

rolling, roll passes, Rolling defects and remedies

4.4 Extrusion and Drawing - Type of extrusion- Hot and Cold, Direct and

indirect. Pipe drawing, tube drawing, wire drawing

5. Plastic Processing (05 hrs)

5.1 Industrial use of plastics, situation where used.

5.2 Injection moulding-principle, working of injection moulding machine.

5.3 Compression moulding-principle, and working of compression moudling

machine.

5.4 Potential and limitations in the use of plastics