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September 23, 2023

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Description

Theory of Production Processes. Instructor: Prof. Pradeep Kumar Jha, Department of Mechanical Engineering, IIT Roorkee.

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. 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. (from nptel.ac.in)

Course Curriculum

  • Lecture 01 – Introduction to Theory and Practice of Casting Unlimited
  • Lecture 02 – Theory of Solidification: Cooling Curves Unlimited
  • Lecture 03 – Solidification of Pure Metals and Alloys Unlimited
  • Lecture 04 – Factors Affecting Solidification Process Unlimited
  • Lecture 05 – Fluidity of Liquid Metals Unlimited
  • Lecture 06 – Technology of Pattern Making: Pattern Materials Unlimited
  • Lecture 07 – Pattern Making: Types of Pattern and Allowances Unlimited
  • Lecture 08 – Molding Sand Ingredients and Sand Testing Methods Unlimited
  • Lecture 09 – Sand Molding Methods Unlimited
  • Lecture 10 – Core Making: Properties and Types of Cores Unlimited
  • Lecture 11 – Gating System Design: Types of Gates Unlimited
  • Lecture 12 – Gating System Design: Pouring Time Calculation for Different Types of Gates Unlimited
  • Lecture 13 – Introduction to Riser Design Unlimited
  • Lecture 14 – Risering Methods Unlimited
  • Lecture 15 – Problem Solving on Gating Design and Risering Methods Unlimited
  • Lecture 16 – Theory of Melting: Types of Furnaces Unlimited
  • Lecture 17 – Melting and Production of Iron Castings Unlimited
  • Lecture 18 – Production of Steel and Non-ferrous Castings Unlimited
  • Lecture 19 – Casting Design Considerations Unlimited
  • Lecture 20 – Casting Defects: Types, Causes and Remedies Unlimited
  • Lecture 21 – Concept of Stress and Strain, Elastic and Plastic Behavior Unlimited
  • Lecture 22 – State of Stress in Two and Three Dimensions, Mohr’s Circle Unlimited
  • Lecture 23 – Description of Strain at a Point Unlimited
  • Lecture 24 – Mean and Deviator Stresses, Elastic Stress-Strain Relationships Unlimited
  • Lecture 25 – Theory of Plasticity: True Stress and True Strain, Flow Curve Unlimited
  • Lecture 26 – Yield Criteria for Ductile Materials Unlimited
  • Lecture 27 – Flow Rules, Plastic Stress-Strain Relationships Unlimited
  • Lecture 28 – Classification of Metal Working Processes Unlimited
  • Lecture 29 – Mechanics of Metal Working Unlimited
  • Lecture 30 – Temperature in Metal Working: Hot and Cold Working Unlimited
  • Lecture 31 – Rolling Process, Classification, Hot and Cold Rolling Unlimited
  • Lecture 32 – Analysis of Rolling Operation: Forces and Geometrical Relationships in Rolling Unlimited
  • Lecture 33 – Introduction to Forging Process: Classification and Equipments Unlimited
  • Lecture 34 – Analysis of Forging Process Unlimited
  • Lecture 35 – Problem Solving on Rolling and Forging Processes Unlimited
  • Lecture 36 – Extrusion Process: Classification and Analysis Unlimited
  • Lecture 37 – Drawing of Rods, Tubes and Wires Unlimited
  • Lecture 38 – Analysis of Drawing Operation Unlimited
  • Lecture 39 – Sheet Metal Operations Unlimited
  • Lecture 40 – Metal Forming Defects Unlimited
  • Lecture 41 – Classification of Joining Processes Unlimited
  • Lecture 42 – Heat Flow in Welding Unlimited
  • Lecture 43 – Metallurgy of Fusion Welds Unlimited
  • Lecture 44 – Heat Affected Zone in Welding Unlimited
  • Lecture 45 – Heat Treatment Processes in Welding Unlimited
  • Lecture 46 – Principle of Shield Arc Welding Processes Unlimited
  • Lecture 47 – Principle of Gas Shield Arc Welding Processes Unlimited
  • Lecture 48 – Principle of Resistance Welding Unlimited
  • Lecture 49 – Principle of Solid State Welding Processes Unlimited
  • Lecture 50 – Brazing, Soldering and Adhesive Bonding Unlimited
  • Lecture 51 – Residual Stresses in Welding Unlimited
  • Lecture 52 – Methods of Controlling Residual Stresses in Welding Unlimited
  • Lecture 53 – Welding Distortion Unlimited
  • Lecture 54 – Control of Welding Distortion Unlimited
  • Lecture 55 – Preheat and Postweld Heat Treatment of Weldments Unlimited
  • Lecture 56 – Weldability of Metals Unlimited
  • Lecture 57 – Weldability of Steels Unlimited
  • Lecture 58 – Weldability of Cast Iron Unlimited
  • Lecture 59 – Weldability of Non-ferrous Materials Unlimited
  • Lecture 60 – Welding Defects Unlimited

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