CVR Production Technology

8/10/2019 CVR Production Technology

1/28


2/28

1A2AHARLAL NEHRU TECHNOLOGICAL UNIVERSIT3, H3ERABAII 3ear B.Tech. M.E. I-Se

(54013)PRODUCTION TECHNOLOGY

UNIT ICASTING: Steps involved in making a asting Advantage o! asting and its appliations "atte#ns and "atte#n

making T$pes o! patte#ns %ate#ials &sed !o# patte#ns' patte#n allo(anes and t)ei# onst#&tion' "#iniples o!Gating' Gating #atio and design o! Gating s$stems

UNIT II

Solidi!iation o! asting Conept Solidi!iation o! pe metal and allo$s' s)o#t * long !#ee+ing #ange allo$s,

Rise#s T$pes' !&ntion and design' asting design onside#ations' speial asting p#oesses -. Cent#i!&gal /. 0ie'

1.Investment,%et)ods o! %elting: C#&i2le melting and &pola ope#ation' steel making p#oesses' speial,

UNIT IIIA. 3elding : Classi!iation o! (elding p#oess t$pes o! (elds and (elded 4oints and t)ei# )a#ate#istis' design o!

(elded 4oints' Gas (elding' ARC (elding' Fo#ge (elding' #esistane (elding' T)e#mit (elding and "lasma 5Ai# and

(ate# . (elding,

6. C&tting o! %etals: O7$ Aet$lene Gas &tting' (ate# plasma' &tting o! !e##o&s' Non8!e##o&s metals,

UNIT IVIne#t Gas (elding' TIG * %IG' (elding' F#ition (elding' Ind&tion (elding' E7plosive (elding' Lase# (elding'

Solde#ing * 6#a+ing, 9eat a!!eted +ones in (elding

3elding de!ets Ca&ses and #emedies dest#&tive nondest#&tive testing o! (elds

UNIT V

9ot (o#king' old (o#king' st#ain )a#dening' #eove#$' #e#$stallisation and g#ain g#o(t)' Compa#ison o!p#ope#ties o! Cold and 9ot (o#ked pa#ts' #olling !&ndamentals t)eo#$ o! #olling' t$pes o! Rolling mills and

p#od&ts, Fo#es in #olling and po(e# #e;&i#ements

UNIT 8 VI

Stamping' !o#ming and ot)e# old (o#king p#oesses : 6lanking and pie#ing 6ending and !o#ming 0#a(ing andits t$pes (i#e d#a(ing and T&2e d#a(ing oining 9ot and old spinning T$pes o! p#esses and p#ess tools,Fo#es and po(e# #e;&i#ement in t)e a2ove ope#ations,

UNIT8 VIIE ",N, Rao>T%9

REFERENCES :-, "#od&tion Te)nolog$ > R,=, ?ain

/, "#oess and mate#ials o! man&!ating Lind2e#g>"E

1, "#iniples o! %etal Castings > Roent)al,

@, 3elding "#oess > "a#ama# >

, "#od&tion Te)nolog$ >Sa#ma " C >B, "#od&tion Enginee#ing Ses) 0alela * Ravi S)anka# > Galgotia "&2liations "vt, Ltd,


3/28

Unit No. Topic to be covered No of

Period

s

Total No of

Periods.

UNIT 4 I

I"ro5!c&o", Se%s &"0o$0e5 &" a6&"# a cas&"#,A50a"a#e of cas&"# a"5 &s a%%$&ca&o"s, Maer&a$s!se5 for a6&"# o!$5.

1

--*aer"s a"5 *aer" a6&"# 4 T7%es of %aer"s 4Maer&a$s !se5 for %aer"s, %aer" a$$o8a"ces, Cores,Core Ma6&"#.

*r&"c&%$es of Ga&"#, Ga&"# ra&o a"5 5es" of Ga&"#s7ses

1

UNIT 4

II

So$&5&9ca&o" of cas&"# 4 Co"ce% 4 So$&5&9ca&o" of%!re ea$ a"5 a$$o7s

1

R&sers 4 T7%es, f!"c&o" a"5 5es", cas&"# 5es"

co"s&5era&o"s,

/

S%ec&a$ cas&"# %rocesses ) Ce"r&f!#a$ :) &e, ;)I"0ese".

1

UNIT 4III

2e$5&"# + C$ass&9ca&o" of 8e$5&"# %rocess 7%es of8e$5s a"5 8e$5e5 r!s&o", I%ac e>r!s&o" H75rosa&c

/


4/28

e>r!s&o".*r&"c&%$es of for#&"# 4 Too$s a"5 5&es 4 T7%es For#&"# 4S&h for#&"#, ro% For#&"# 4Ro$$ for#&"# 4 For#&"#haers+ Roar7 for#&"# 4 for#&"# 5efecs.

/

UNIT -

VIII

*rocess&"# of *$as&cs+ T7%es of *$as&cs, *ro%er&es,

a%%$&ca&o"s1 5

*rocess&"# eho5s =E!&%e" ('$o8 =&"


5/28

0is&ss t)e va#io&s t$pes o! gates t)at a#e no#mall$ &sed,

Cal&late t)e si+e o! a $lind#ial #ise# 5)eig)t and diamete# e;&al. neessa#$ to !eed a sla2asting / / m (it) a side #ise#' asting poed )o#i+ontall$ in to t)e mo&ld, Use aines

e;&ation and take onstants in aines e;&ation as a H,-' 2 H,H1 and -,H,

UNIT-2

3#ite des#iptive notes on:5i. Solidi!iation o! asting

5ii. Steel making p#oesses,

9o( is t)e ent#i!&gal asting met)od &sed in t)e p#od&tion o! pipesD0es#i2e t)e p#oede o! making asting 2$ t)e Investment asting p#oess,

3)at is Investment astingD 3)at a#e t)e main mate#ials &sed !o# making an Investment "atte#nD

3)at a#e t)e met)ods o! appl$ing t)e Investment mate#ial to t)e patte#nD

3)$ di#etional solidi!iation is desi#a2le in t)e p#od&tion o! a ast p#od&tD

9o( do $o& &nde#stand 2$ ent#i!&gal astingD 9o( a#e t)e ent#i!&gal asting met)odslassi!iedD

0is&ss t)e advantages and disadvantages o! s)ell mo&lding p#oess,

0#a( t)e neat sket)es o! 2ottom and top gating s$stems and e7plain

0is&ss some o! t)e att#ative !eates o! t)e die asting p#oess ompa#ed to alte#native asting

met)ods,

E7plain t)e pa#amete#s ()i) a&se t)e poing time o! a given asting to va#$,

E7plain t)e (o#king o! &pola !naeD

OBJECTIVE QUESTIONS:

%at) List I (it) List II and selet t)e o##et ans(e# &sing t)e ode given 2elo( t)e lists :

List I List II

A, Conneting #ods -, 3elding6, "#esse vessels /, E7t#&sion

C, %a)ine tool 2eds 1, Fo#ming

0, Collapsi2le t&2es @, CastingCodes

A 6 C 0 A 6 C 0

5a. / - @ 1 52. 1 - @ /

5. / @ - 1 5d. 1 @ - /


6/28

Ans: (b)

Conside# t)e !ollo(ing statements:-, 9ot )am2e# ma)ine is &sed !o# asting +in' tin and ot)e# lo( melting allo$s,

/, Cold )am2e# ma)ine is &sed !o# die asting o! !e##o&s allo$s1, Rapid ooling #ate in die asting p#od&es )ig) st#engt) and ;&alit$ in man$ allo$s,3)i) o! t)ese statements a#e o##etD

5A. -' / and 1 56. - and / onl$ 5C. / and 1 onl$ 50. - and 1 onl$Ans: (a)

Conside# t)e !ollo(ing advantages o! die asting ove# sand asting :

-, Rapidit$ o! t)e p#oess

/, Smoot) s!ae1, St#ong dense metal st#&te

3)i) o! t)ese advantages a#e o##etD

5A. -' / and 1 56. - and / onl$ 5C. / and 1 onl$ 50. - and 1 onl$Ans: (b)

T)e p#ope# se;&ene o! investment asting steps is:

5A. Sl#$ oating patte#n melt o&t8S)akeo&t St&o oating

56. St&o oating Sl#$ oating S)akeo&t "atte#n melt o&t5C. Sl#$ oating St&o oating "atte#n melt o&t S)akeo&t

50. St&o oating S)akeo&t Sl#$ oating "atte#n melt o&tAns: (c)

T)e met)od o! asting !o# p#od&ing o#namental piees a#e:

5A. Sl&s) and g#avit$ asting

56. "#essed and sl&s) asting5C. G#avit$ and semi pe#manent mo&ld asting

50. Semi pe#manent mo&ld and p#essed astingAns: ()

In lig)t metal asting' #&nne# s)o&ld 2e so designed t)at:

-, It avoids aspi#ation/, It avoids t&lene

1, T)e pat) o! #&nne# is #ed&ed in a#ea so t)at &al vol&me o! !lo( t)#o&g) ea) gate takes

plae5A. - and / onl$ 56. - and 1 onl$ 5C. / and 1 onl$ 50. -' / and 1

Ans: (!)

T)e #elations)ip 2et(een total !#ee+ing time t' vol&me o! t)e asting V and its s!ae

a#ea A' ao#ding to C)vo#inovs #&le is :


7/28

3)i) o! t)e !ollo(ing is t)e most s&ita2le mate#ial !o# die astingDa. in and its allo$s

2. Coppe# and its allo$s

. al&min&m and its allo$s

d. lead and its allo$s

3)i) one o! t)e !ollo(ing asting p#oesses is t)e 2est s&ited to make 2igge# si+e )ollo(s$mmet#ial pipesD

a. 0ie asting

2. Investment asting

. S)ell molding

d. Cent#i!&gal asting

In ()i) one o! t)e !ollo(ing !naes most o! t)e non!e##o&s allo$s a#e meltedD

a. Reve#2e#ato#$ !nae

2. Ind&tion !nae. C#&i2le !nae

d. "it !nae

UNIT-"

E7plain t)e !ollo(ing (elding 4oints 2&tt' Lap' tee' o#ne#' pl&g and edge,

3)at a#e t)e ommon (elding t#o&2les' a&ses and #emedies !o# t)emDE7plain Fo#ge (elding and #esistane (elding,

0#a( a diag#am s)o(ing t)e lassi!iation o! (elding p#oess,3)at a#e t)e advantages and disadvantages o! 0C and AC (eldingD

3)at a#e t)e !o#es ating ()i) t#ans!e# t)e metal !#om t)e metal elet#ode to t)e (o#k in

(elding p#oessDE7plain Gas (elding and A# (elding,

3it) t)e )elp o! a s)emati diag#am e7plain t)e onst#&tional details and #eations involved inO7$8aet$lene (eldingD

0i!!e#entiate 2et(een JSolid ")ase 3eldingK and JLi;&id ")ase 3eldingKD

9o( does st#aig)t pola#it$ di!!e# !#om #eve#se pola#it$D E7plain t)em 2#ie!l$,

0i!!e#entiate 2et(een A# and Gas (elding (it) #espet to t)e p#iniple' ope#ation appliationand limitationsD

0es#i2e t)e appliations and p#ope#ties o!

i, Ne&t#al Flame


8/28

ii, Red&ing Flame

iii, O7idising !lame,

E7plain t)e p#iniple o! #esistane (elding (it) neat sket)DUNIT-#

E7plain t)e !ollo(ing:

5i. Advantage o! 2#a+ing

5ii. %IG * TIG (elding,5iii. E7plosive (elding,

5iv. Fo#ge (elding

5v. 3elding de!ets

5vi. 0est#&tive * non dest#&tive testing o!(elds,

3)at is t)e di!!e#ene 2et(een (elding' 2#a+ing and solde#ing p#oess,

E7plain Lase# (elding and Ind&tion (elding,

State t)e ppose o! T)e#mit (elding, 3)e#e (o&ld $o& #eommend it and ()$D

3)at is #esistane (eldingD 3)at a#e t)e main !ato#s to 2e onside#ed in Resistane (eldingD

E7plain t)e te#m 9A in (elding and its #ole in t)e s&ess o! a (eldment,


0ing plasma a#e (elding o! al&min&m' imp#oved #emoval o! t)e s!ae o7ide !#om t)e 2asemetal is o2tained (it) t$pial pola#it$ o! :5A. 0C St#aig)t 56. 0C #eve#se

5C. AC potential 50. Reve#se pola#it$ o! p)ase o! AC potentialAns: (b)

T)e (elding p#oess in ()i) 2a#e (i#e is &sed as elet#ode' g#an&la# !l&7 is &sed and t)ep#oess is )a#ate#i+ed 2$ its )ig) speed (elding' is kno(n as:

5A. S)ielded a# (elding 56. "lasma a# (elding

5C. S&2me#ged a# (elding 50. Gas metal a# (eldingAns: ()

Conside# t)e !ollo(ing statements, Cast i#on is di!!i&lt to (eld' 2ea&se o!

-, Lo( d&tilit$ /, "oo# !&sion 1, Tenden$ to #ak on ooling

3)i) o! t)ese statements a#e o##etD

5A. -' / and 1 56. - and / onl$ 5C. / and 1 onl$ 50. - and 1 onl$Ans: (a)

Conside# an elet#ode oating' pe#!o#ming t)e !ollo(ing !&ntions:


9/28

-, Sta2ili+e t)e a#

/, Cont#ol t)e #ate at ()i) t)e

elet#ode melts

1, Cont#ol t)e !lo( o! #ent,

@, En)ane t)e ;&alit$ o! t)e 4oint,

a. - and / onl$,

2. / and 1 onl$,

. 1 and @ onl$,

d. -' / and @,

6$ ()i) one o! t)e !ollo(ing met)ods g#a$ i#on is &s&all$ (eldedD

a. TIG (elding

2. %IG (elding

. Gas (elding

d. A# (elding

%at) List I (it) List II and selet t)e o##et ans(e# &sing t)e ode given 2elo( t)e lists:List8I List II

A, Lase# 2eam (elding -, Can 2e applied !o# (elding o# #e!#ato#$ metals like

nio2i&m' tantal&m' mol$2den&m and t&ngsten6, Elet#on 2eam (elding /, A so&nd and lean (elded 4oint is #eated d&e to #&22ing

o! t(o pa#ts against ea) ot)e# (it) ade;&ate speed and

p#esse p#od&ing intense )eat #aising tempe#ate a2ove

melting point,C, Ult#asoni (elding 1, Clean )eat soe #eated m&) a(a$ !#om 4o2' a na##o(

spot is )eated' (o#k )am2e# ope#ates in a )ig) va&&m,

0, F#ition (elding @, Clean )eat soe ve#$ ;&ik )eating ve#$ small !oalspot' no va&&m )am2e# is #e;&i#ed,

Codes :

A 6 C 05a. @ 1 - /

52. / 1 - @

5. @ - 1 @

5d. / - 1 @Ans: (!)

A !l&7 is &sed in (elding to

a. Remove t)e o7ides o! t)e metals!o#med at )ig) tempe#ate,

2. "e#mit t)e pe#!et o)esion o! t)e

metals

. Cool t)e metalsd. 6ot) a and 2

UNIT-5

E7plain t)e !ollo(ing:i. T)eo#$ o! #olling

ii. Re8#$stallisation and g#ain g#o(t)

iii. old (o#king p#oess,


10/28


11/28

C)oose t)e (#ong statement

a. Cold (o#king p#oess #e;&i#es g#eate# !o#e t)an )ot (o#king p#oess,

2. T)e de!o#mation o! metals takes plae 2$ t)e met)od o! slip planes in ols (o#kingp#oess,

. Cold (o#king p#od&es an imp#oved s!ae !inis) and sale o! !#ee s!ae,

d. Cold (o#king #es&lts in in#ease o! d&tilit$ and loss o! st#engt) and )a#dness o! t)emetal,

UNIT-6

E7plain t)e !ollo(ing:5i. 3i#e d#a(ing

5ii. T$pes o! p#esses and p#ess tools,

5iii. 9ot and old spinning,

0is&ss t)e advantage o! e7t#&sion p#oess,

0is&ss 0#op !o#ging and Roll !o#ging,

E7plain t)e !ollo(ing:5i. 6lanking and pie#ing

5ii. 3i#e d#a(ing and T&2e d#a(ing

0i!!e#entiate )ot spinning and old spinning p#oesses,

0is&ss va#io&s t$pes o! p#oesses &sed in metal !o#ming ope#ations,

0isting&is) 2et(een open !#ame and losed !#ame o! p#esses,

3)at a#e t)e va#io&s p#ess tool omponentsD

3)at is t)e #oll o! 2ending dieD 3)at a#e t)e di!!e#ent t$pes o! 2ending diesD 3it) s&ita2lesket)es e7plain !ollo(ing tools

5i. "#og#essive die5ii. Compo&nd die5iii.Com2ination die,

An al&min&m st#ip o! Hmm (idt) and 1mm t)ikness is 2ent into a HH angle,

T)e data given isF#ate st#ain H,/' MH,-'

EH =N>mm/' die opening 1H mm

Coe!!iient o! linea# st#ain )a#dening 5n. 1H N>mm/

0ete#mine:

5a. T)e minim&m possi2le 2ending #adi&s

52. T)e angle o! t)e 2ending p&n)' taking a#e o! t)e sp#ing 2ak5. T)e peak 2ending !o#e,

A steel (i#e is d#a(n !#om an initial diamete# o! -/, mm to a !inal diamete# o! -H,/ mm at aspeed o! Hm>min, t)e )al! one angle o! t)e die is -B and t)e oe!!iient o! !#ition at t)e 4o28die

inte#!ae is H,-, A tensile test on t)e o#iginal steel speimen gives a tensile $ield st#ess /H

N>nm/, a simila# speimen s)o(s a tensile $ield st#ess o! @-@ N>mm/at a st#ain o! H,, Ass&ming


12/28

a linea# st#ess8st#ain #elations)ip !o# t)e mate#ial' dete#mine t)e d#a(ing po(e# and t)e

ma7im&m possi2le #ed&tion (it) t)e same die, No 2ak tension is applied,


3)i) one o! t)e !ollo(ing metal !o#ming p#oesses is &sed !o# man&!ate o! steel (i#esD

A. 0eep d#a(ing

6. Fo#gingC. Spinning

0. 0#a(ing

T)e ope#ation o! &tting a )ole 5ot)e# t)an $lind#ial. in a s)eet o! metal 2$ t)e p&n) and die iskno(n as:

a. Slitting

2. 6lanking

. "ie#ing

d. not)ing

UNIT-$

E7plain t)e !ollo(ing:i. Fo#ging )amme#s

ii. Fo#(a#d e7t#&sion and 2ak(a#d e7t#&sion,

3)at a#e di!!e#ent t$pe o! !o#ging e7plain an$ one o! t)em,

E7plain !o#(a#d e7t#&sion and 2ak(a#d e7t#&sion,

3#ite a s)o#t notes an5i. Fo#ging de!ets

5ii. 9ot e7t#&sion and old e7t#&sion

5iii. "#ess tools,

3)at a#e t)e va#io&s !o#ging de!etsD 0is&ss 2#ie!l$,

3)at is )ot e7t#&sionD In )o( man$ (a$s it an 2e pe#!o#medD

En&me#ate t)e di!!e#enes 2et(een !o#(a#d e7t#&sion and 2ak(a#d e7t#&sion,

E7plain t)e p#iniple and #elative me#its o! t)e !ollo(ing p#oesses,

i, T&2e E7t#&sionii, T&2e 0#a(ing


Fo#ging is &sed !o# making old )isels,

a. T#&e 2. !lase

3)at is t)e ma4o# p#o2lem in )ot e7t#&sionD


13/28

A. 0esign o! p&n)

6. 0esign o! die

C. 3ea# and tea# o! t)e die0. 3ea# o! t)e p&n)

UNIT-8

3)at is t)e main advantage o! in4etion mo&lding !o# t)e#mo plasti pa#ts as ompa#ed (it) )otomp#ession mo&ldingD

3)at !ato#s t)ose in!l&ene t)e aa$ to ()i) plasti pa#ts an 2e mo&ldedD

9o( do t)e#mo plastis di!!e# !#om t)e#mo setting plastisD

3)at is t)e p#inipal advantage o! t)e asting met)od o! mo&lding plasti pa#tsD

3)at a#e t)e )a#ate#istis o! t)e#mo plasti plastisD

3)at a#e t)e good p#aties in t)e design o! mo&lded plasti pa#tsD

E7plain di!!e#ent t$pes o! plastis and t)ei# p#ope#ties,

3)at is t)e main advantage o! In4et mo&lding,

0es#i2e (it) t)e )elp o! neat sket)es t)e !ollo(ing tools &sed in !o#ging ope#ation,

i, F&lle#s

ii, Tongs

E7plain t)e #easons !o# t)e !ollo(ing !o#ging de!ets and t)ei# #emedies

i, 0imensional dis#epanies

ii, 0ea#2i+ationiii, Unde# !illing

iv, C#aks,


3)i) one o! t)e !ollo(ing mate#ials is 2est p#oessed 2$ in4etion moldingD

A. All t$pes o! plastis6. T)e#moplastis

C. Non8 !e##o&s mate#ials

0. T)e#mo8setting plastis

Female )al! o! in4etion mo&ld is no#mall$ atta)ed to

5a. %oving platen52. Stationa#$ platen

5. S#e(

5d. 6a##el


14/28

T)e#e a#e !o tie 2a#s in an in4etion mo&lding ma)ine, 3)at is t)e !&ntion o! t)ese tie 2a#sD

5a. To p#ovide s&ppo#t to s#e( and 2a##el

52. To p#ovide d#inks to in4etion mo&lding ma)ine ope#ato#s5. To p#ovide s&ppo#t to stationa#$ and mova2le platen

5d. To p#ovide s&ppo#t to )oppe#


15/28


16/28


17/28


18/28


19/28


20/28


21/28


22/28


23/28


24/28


25/28


26/28


27/28


28/28

Documents

CVR Production Technology