Subject Code :
10ME838
|
Hours/Week :
04
|
Total
Hours : 52
|
IA
Marks : 25
|
Exam
Marks : 100
|
Exam
Hours : 03
|
PART
– A
UNIT - 1
Foundry
Metallurgy:
Oxidation
of liquid metals, gas dissolution in liquid metals, methods of degassing, fluidity,
factors affecting fluidity, fluidity tests, hot tearing, shrinkage of liquid
metals.
06 Hours
UNIT - 2
Casting Design:
Introduction to
casting design, redesign considerations, design for minimum casting stresses,
design for directional solidification, design for metal flow, safety factors,
design for low pattern cost and model making as an aid in design.
06 Hours
UNIT - 3
Solidification
Of Castings:
Crystallization
and development of cast structure - nucleation, growth and dendritic growth.
Structure of castings – significance and practical control of cast structure,
grain shape and orientation, grain size, refinement and modification of cast
structure. Concept of progressive and directional solidification,
solidification time and derivation of Chvorinov’s equation, influence on mold
characteristics and cast metal.
07 Hours
UNIT - 4
Risering And
Gating:
Need
for risering, general considerations of risering, riser shapes, riser size, and
location. Requirements of a riser. Sand, insulating, and exothermic materials
used for risers. Riser feeding distance and theory of risering. Internal
chills, external chills, use of mould materials of different chill capacities,
padding for directional solidification. Open type and blind risers. Riser
treatment using exothermic and insulating compounds. Gating system –
theoretical consideration of gating, laws of fluid flow, turbulence in gating
system, use of ceramic foam filters in gating, need for tapered sprue, gating
ratio, simple problems.
07 Hours
PART
– B
UNIT - 5
Special Moulding
Techniques:
Principles,
materials used, process details and application of no-bake sand systems, vacuum
moulding, flaskless moulding, and high pressure moulding.
Cupola melting: Developments in
cupola melting – hot blast cupola, water cooled cupola, balanced blast cupola,
cokeless cupola, cupola charge calculations.
07 Hours
UNIT - 6
Ferrous Foundry:
Melting
procedures, casting characteristics, production, specification, and properties
of some typical steels, grey cast iron, malleable iron, and spheroidal graphite
cast iron castings.
07 Hours
UNIT - 7
Non-Ferrous
Foundry:
Melting
procedures, casting characteristics, production, specification, and properties
of some typical aluminum, copper, and magnesium based alloy castings.
06 Hours
UNIT - 8
Modernization
And Mechanization Of Foundry:
Need for modernization, and
mechanization, moulding and core making, melting, pouring, shake out equipment
and fettling, dust and fume control, material handling equipments for sand moulds
and cores, molten metal and castings, reclamation of sands. Pollution control –
norms, and agencies.
06 Hours
TEXT BOOKS:
- Principles of metal casting, Heine Loper & Rosenthal TMH - 2005
- Principle of Foundry Technology, P. L. Jain, 5th Ed., TMH – 2006.
REFERENCE BOOKS:
- Castings, John Campbell, Second edition, Elseivier
- Foundry Technology, P. N. Rao
- Manufacturing Process, I, Dr. K. Radha Krishna 5th Edn. Sapna Book House, Bangalore
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