Deformation of metals, stress-strain curves, temperature and strain rate effects, ductility and toughness, plane-strain deformation, mechanism of plastic deformation, control of material properties—alloying and heat treatment.
Sand casting: Pattern materials and allowances, moulding materials, properties ol moulding sand, effects of moulding ingredients on mould properties, estimation of pouring time, mechanism of solidification, rate of solidification in an insulating mould, riser design and placement, residual stresses.
Elements of plasticity—yield criteria and flow rule, plastic instability. Analysis of forming processes—forging, rolling, extrusion, wire and strip drawing, using slab method, deep drawing, blanking and piercing. Lubrication and friction in metal forming.
Metal cutting: Mechanics of orthogonal cutting, chip formation in turning, shaping, planning, milling and drilling, evaluation of surface roughness in machining, heat generation, estimation of average tool temperature, tool wear mechanism and tool life testing, variables affecting tool life machining economics—estimation of cost and optimum cutting conditions.
Metal grinding: Basic mechanics of grinding process, forces and specific energy, grinding temperature—heat sources and estimation of average temperature, wheel wear mechanism, estimation of surface roughness.
Non-conventional machining: Classification of processes, mechanism of material removal and effects of process parameters in AJM, USM, ECM, EDM, LBM, EBM and PAM.
Welding and allied processes: Bonding process in welding, principles of solid-state welding, fusion welding, soldering and brazing, effects of process parameters, metallurgy of welding stress distribution and heat affected zone.
MANUFACTURING SCIENCE -syllbus