Bench Work and Fitting:

Fitting shop tools,

operation:
sawing;
chipping;
thread cutting (with taps and dies);
Marking and marking tools.

23.2 to 23. 41
23.45
23.44
23.51, 23.52,
Included in (23.2 to 23.42)

UNIT-III
Metal joining:
Welding principles,
classification of welding techniques,
Oxyacetylene Gas welding,
equipment and field of application,
Arc-welding,
metal arc,
Carbon arc welding,
submerged arc welding and
atomic hydrogen welding,
TIG and MIG welding,
Electric resistance welding:
spot;
seam;
flash;
butt and
percussion welding,
Flux:
composition;
properties and
function,
Electrodes,
Types of joints and
edge preparation,
Brazing and
soldering,
welding defects.
(T1 , T2, R, R2, R3, R4, R5)[No. of Hrs. 12 ]

24.1
24.2 fig 24.1 on pg 656
24.16, 24.17, 24.24
24.18, 24.19, 24.20, 24.21
24.32, 24.36, 24.37, 24.38
24.33, 24.34, 24.35
24.39,
24.47,
24.52
24.43 to 24.46
24.5
24.6
24.10, 24.11, 24.12
24.9
24.8
24.13, 24.14
24.23,
http://en.wikipedia.org/wiki/Flux_(metallurgy)#Co
mposition_and_properties
24.40, 24.42
24.27
24.26
24.66
24.65
24.71, 24.72

UNIT-IV
Sheet Metal Work:
Tools and equipments used in sheet metal work,
metals used for sheets,
standard specification for sheets,
Types of sheet metal operations:
shearing,
drawing,
bending.
Other operations like spinning,
stretch forming,
embossing and
coining.

Chapter 26
26.3
26.2

26.4 to 26.18
http://en.wikipedia.org/wiki/Metal_spinning
See at the end of this doc.

Not covered in second Sessional

Powder Metallurgy:
Introduction of powder metallurgy process:
Powder production,
Blending,
Compaction,
Sintering.

Chapter 21
21.1
21.3, 21.4, 21.5
21.6
21.7
21.9

Stretch forming
It is a very accurate and precise method for forming metal shapes, economically. The level of
precision is so high that even intricate multi
multi-components and snap-together
together curtainwall
components can be formed without loss of section properties oorr original design function. Stretch
forming capabilities include portions of circles, ellipses, parabolas and arched shapes. These
shapes can be formed with straight leg sections at one or both ends of the curve. This eliminates
several conventional fabrication
ation steps and welding.
The stretch forming process involves stretch forming a metal piece over a male stretch form
block (STFB) using a pneumatic and hydraulic stretch press. Stretch forming is widely used in
producing automotive body panels. Unlike deep drawing, the sheet is gripped by a blank holder
to prevent it from being drawn into the die. It is important that the sheet can deform by
elongation and uniform thinning.
The variety of shapes and cross sections that can be stretch formed is almost unlimited.
unlimi
Window
systems, skylights, store fronts, signs, flashings, curtainwalls, walkway enclosures, and hand
railings can be accurately and precisely formed to the desired profiles. Close and consistent
tolerances, no surface marring, no distortion or ripple
ripples,
s, and no surface misalignment of complex
profiles are important benefits inherent in stretch forming. A smooth and even surface results
from the stretch forming process.
This process is ideally suited for the manufacture of large parts made from aluminum, but does
just as well with stainless steel and commercially pure titanium. It is quick, efficient, and has a
high degree of repeatability.
EMBOSSING
Embossing is an operation in which sheet metal is drawn to shallow depths with male and female
matching dies, Figure.. The operation is carried out mostly for the purpose of stiffening flat panels.The
operation is also sometimes used for making d
decoration
ecoration items like number plates or name plates,
jewelry, etc.

Figure: Embossing operation with two dies. Letters, numbers and designs on sheet
sheet-metal
metal parts can be
produced by this operation.
COINING
Coining is a severe metal squeezing oper
operation
ation in which the flow of metal occurs only at the top layers of
the material and not throughout the values. The operation is carried out in closed dies mainly for the

purpose of producing fine details such as needed in minting coins, and medal or jewelry making. The
blank is kept in the die cavity and pressures as high as five to six times the strength of material are
applied. Depending upon the details required to be coined on the part, more than one coining
operations may be used.
The difference between coining and embossing is that the same design is created on both sides of the
work piece in embossing (one side depressed and the other raised ), whereas in coining operation, a
different design is created on each side of work piece.