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
75
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.
76
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