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Theory of Production Processes

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)

Lecture 36 - Extrusion Process: Classification and Analysis


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