Lovely Professional University,Punjab

Format For Instruction Plan [for Courses with Lectures and Labs

Course No MEC044

Cours Title PRODUCTION TECHNOLOGY-I

Course Planner 11999 :: Gulzar

Lectures Tutorial Practical Credits 3 0 6 6

Text Book:

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

Other Specific Book:

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) 7 http://www.robot-welding.com/arc_weld_processes.htm 8 http://www.jobwerx.com/plastics/extrusion.htm 9 http://www.aws.org/educators/Library/0000/00063 4.ppt#256,1,GMAW / Mig Welding Salient Features To know about various welding processes To know about Extrusion process To know about MIG welding

Detailed Plan For Lectures

Approved for Autumn Session 2011-12

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 Lecture 1 Principle, Classification of welding processes ->Reference :1,24.124.2 ->Reference :7 ->Reference :1,24.2 Images ppt on basics of welding

Lecture 2 Lecture 3

Advantages and limitations of welding, Industrial applications of welding

Welding positions, welding joints and their symbols. ->Reference :1,24.2624.27 ->Reference :7 Principle of operation, Arc welding machines and equipment ->Reference :1,24.3224.33-24.34-24.3524.36 ->Reference :7 ->Reference :1,24.3724.38 ->Reference :1,24.4024.41 ->Reference :1,24.42

Week 2

Lecture 4

Lecture 5 Lecture 6 Week 3 Lecture 7 Lecture 8

Arc blow, A.C. and D.C. arc welding, Comparison between AC and DC arc welding Effect of polarity, arc welding electrodes, electrode classification and coding selection of electrodes, advantages limitations and industrial applications of arc welding.

ppt on effect of polarity

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 Filler rods, fluxes, types of gas welding flames and their applications Oxy-acetylene cutting, advantages limitations and industrial applications of gas welding. ->Reference :1,22.1724.23-22.19 ->Reference :1,22.18

Video on gas welding

Lecture 9 Week 4 Lecture 10

images video of oxy-acetylene

Part 2
Week 4 Lecture 11 Resistance Welding: Principle, working, advantages, ->Reference :1,24.5limitations 24.9 ->Reference :7 applications of spot welding, seam welding ->Reference :1,24.624.7-24.10 video of arc resistance welding video of seam welding

Lecture 12

Approved for Autumn Session 2011-12

Week 5

Lecture 13

projection welding and percussion welding

->Reference :1,24.1324.14 ->Reference :5,7.1 ->Reference :7 ->Reference :1,24.4424.45 ->Reference :5,12.5 ->Reference :7 ->Reference :1,24.53 ->Reference :1,24.48 ->Reference :5,12.5 ->Reference :7 ->Reference :1,24.47 ->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 Principle, working, advantages, limitations and industrial applications of welding Thermit welding Principle, working, advantages, limitations and industrial applications of Electro slag welding Principle, working, advantages, limitations and industrial applications of Submerged arc welding. Welding defects, Methods of controlling welding defects Pattern making: Introduction, Types of pattern, Pattern materia Pattern allowances, functions of a pattern introduction to cores, core prints, core boxes, and core making procedure.

video of TIG and MIG welding

Lecture 15 Week 6 Lecture 16

ppt of Thermit welding video of Electro slag welding video of submerged arc welding

Lecture 17 Lecture 18 Week 7 Lecture 19 Lecture 20 Lecture 21

->Reference :1,1Ch24/ images of welding 24.52 deffects ->Reference :1,12.112.3-12.10 ->Reference :1,12.712.9 ->Reference :1,12.2612.27 images

MID-TERM Part 3
Week 8 Lecture 22 Moulding procedure, moulding boxes, Elements of gating system, Pouring basin, sprue, runner, gates, Types of risers Directional solidification. Hand tools for mould making, mould materials, properties of foundry sands, and types of foundry sands, Testing of moulding sand Moulding sand binders and additives, Moulding processes: Bench moulding, floor moulding, pit moulding and machine moulding, types of moulds ->Reference :1,15.1images 15.2-15.12-15.15-15.16 -15.18-15.19 ->Reference :6,1 ->Reference :1,13.214.3-14.4-14.12

Lecture 23

Lecture 24

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

images

Week 9

Lecture 25 Lecture 26

moulding machines- squeeze machine, jolt squeeze ->Reference :1,13.6 machine and sand slinger Charging a furnace, melting and pouring both ferrous and non ferrous metals, construction and working of cupola furnace and electric furnace. ->Reference :1,16.116.2-16.4

images images of furnaces

Approved for Autumn Session 2011-12

Week 9

Lecture 27

Casting defects, their causes and remedies, cleaning of castings. Special Casting Methods: Principle, working and applications of Die casting

->Reference :1,18.1-18 images of casting -2-18.3-18.4-18.5-18.6- deffects 18.7 ->Reference :1,17.117.2-17.5 video of die casting

Week 10

Lecture 28

Part 4
Week 10 Lecture 29 Lecture 30 Week 11 Lecture 31 Lecture 32 Lecture 33 Week 12 Lecture 34 Lecture 35 Lecture 36 Hot chamber and cold chamber, lost wax process, centrifugal casting. FORMING: Principle, hot working and cold working of metals FORMING billet, slab, plate, and sheet. Rolling - Principle, Types of rolling mills Rolling defects and remedies. Advantages, limitations and industrial applications. Forging: Basic forging operations, cold and hot forging. Open die forging, closed die forging forging defects and remedies. Advantages, limitations and industrial applications. Extrusion and Drawing: Type of extrusion- Hot and Cold, Direct and indirect. Tube drawing, wire drawing. ->Reference :1,17.517.6-17.14 ->Reference :1,20.119.2 ->Reference :1,20.36 ->Reference :1,19.419.5-19.7 ->Reference :1,19.15 ->Reference :1,20.120.3-20.21 ->Reference :1,20.39 ->Reference :1,19.1119.17 ->Reference :8 video of extrusion and drawing video of various types of forging video of types of rolling mills images video of forging

Spill Over
Week 13 Lecture 37 Lecture 38 Press working: Press Operations-Shearing, piercing, ->Reference :1,10.4trimming, punching 10.5-10.6 Notching, shaving, embossing, stamping, Types of presses, type of dies. ->Reference :1,10.1410.16 video

Details of homework and case studies

Homework No. Objective Topic of the Homework Nature of homework (group/individuals/field work Individual Individual Evaluation Mode Allottment / submission Week 3/4 6/7

Test 1 Test 2

WELDING Gas welding

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

manual Manual

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 Test Lab Assesment Frequency 2 20 Out Of 3 22 Total :Each Marks Total Marks 10 1 11 20 20 40

* 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 J/E WR VIVA % of Marks 50 20 30

List of experiments :Lecture Number Practical 1 Lecture Topic Making of two pieces round split pattern with prior to the design requirement of a solid casting. Pedagogical Tools Or Equipment Planned 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). lab Manual Not Applicable

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). 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). 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). 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 3

Not Applicable

Practical 4

Not Applicable

Practical 5

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

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 Making a joint by TIG/MIG Welding. 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. TIG and MIG welding set and equipments. M.S plates. (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 Not Applicable

Practical 8 Practical 9

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 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.

Practical 11

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. Open Hearth Furnace, Water Tank, Pick-Up Tong, Cold Chisel, Tong, Hammer, Anvil, Flatter, Set Hammer, Engineer Steel Scale. / Mild steel Rod. Open Hearth Furnace, Water Tank, Pick-Up Tong, Cold Chisel, Tong, Hammer, Anvil, Flatter, Set Hammer, Engineer Steel Scale. / Mild steel Rod. Open Hearth Furnace, Water Tank, Pick-Up Tong, Cold Chisel, Tong, Hammer, Anvil, Flatter, Set Hammer, Engineer Steel Scale. / Mild steel Rod. 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. 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. 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. 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 14

Preparation of a Screw Driver 6 by cold forging process. To Forge a cross pane hammer head

Not Applicable

Practical 15

Not Applicable

Practical 16

To forge a straight pane hammer head

Not Applicable

Practical 17

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

Not Applicable

Practical 18

Preparation of a radius fitting (upper part).

Not Applicable

Practical 19

Preparation of a radius fitting (Lower part).

Not Applicable

Practical 20

Preparation of a T shape as per drawing.

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

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