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DEPARTMENT OF PHYSICS GDC ARKI

DEPARTMENT OF PHYSICS GDC ARKI. PHYSICS WORKSHOP SKILL COURSE CODE- PHYS203. PRESENTED BY: PROF. HEM CHAND. Statue of Buddha. Great Bell of China. Iron Bridge. CLASSIFICATION OF CASTING PROCESS. SAND CASTING: Casting process in which sand is used in mold making.

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DEPARTMENT OF PHYSICS GDC ARKI

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  1. DEPARTMENT OF PHYSICSGDC ARKI PHYSICS WORKSHOP SKILL COURSE CODE- PHYS203 PRESENTED BY: PROF. HEM CHAND

  2. Statue of Buddha

  3. Great Bell of China

  4. Iron Bridge

  5. CLASSIFICATION OF CASTING PROCESS • SAND CASTING: Casting process in which sand is used in mold making. • PLASTER MOLD CASTING: Mold is made from Plaster of Paris. • INVESTMENT CASTING: Casting process involving wax pattern for complex structure. • PERMANENT MOLD CASTING: Reusable molds are used in which molten metal is casted.

  6. DIE CASTING: A casting process in which a permanent mold or die is filled with metal by pressure or gravity. • CENTRIFUGAL CASTING: A casting process in which molten metal is centrifuged in the mold.

  7. VIDEOS

  8. ADVANTAGES OF CASTING • Economical process with little wastage. • It can produce parts with complex geometrical features, hollow sections, complex parts. • High speed production can be achieved. • Very good surface finish can be achieved. • Closer dimension tolerance can be obtained.

  9. DISADVANTAGES • High labour intensive. • High requirement of raw material. • Large capital investment required to set up a die casting process. • High energy consumption and environmental pollution.

  10. APPLICATIONS • Automotive parts like block, cylinder, manifolds etc. • Aerospace casting. • Electric motor housings. • Kitchen ware such as pressure cooker. • Pump parts etc.

  11. CUPOLA FURNACE

  12. BULK DEFORMATION PROCESS • The deformation process shapes a final part by plastic deformation with the application of pressure and with or without the assistance of heat. • Forging, rolling, hot working, cold working, extrusion are common example of bulk deformation process.

  13. MACHINING • Form of subtractive manufacturing. • Sharp cutting tool is used to physically remove material to achieve desired geometry. • Example- Gears, bolts, screws, nuts are manufactured by machining process.

  14. Machining broadly classified in two main categories: • Conventional Machining: In this type of machining process tool material must be harder than work material. It follows the principle of relative hardness. • Non Conventional or Advanced Machining: In this type of machining process material is removed by melting, evaporation, chemical and electrochemical actions.

  15. VIDEO

  16. FABICATION PROCESS • The process of joining two or more elements to make a single part is called fabrication process.

  17. 1- ADHESIVE BONDING • It is a process of joining materials in which an adhesive(liquid or semi solid material) is placed between two surfaces to be joined. Either heat or pressure is applied to get bonding.

  18. STEPS TO MAKE ADHESIVE JOINT • 1) Preparing the surface: Work piece surface is cleaned either by grinding, filling wire brushing, sanding. • Water break test is done. Smooth spread of water is an indication that surface is chemically clean, while the collection of droplets indicates presence of oil film.

  19. 2) Application of Adhesive to surface: Adhesive are applied on the work piece surface by hand brushing, spraying or dipping etc. • 3) Assembly of Work piece- After application of adhesive work pieces are assembled and held together by means of clamps or other fixtures.

  20. 4) Curing the Joint: Curing is the process in which adhesive changes from liquid to solid state. It can be done either by applying pressure or temperature.

  21. 2.- RIVETING • Rivets are used to connect two pieces of heavy section of metal. It makes permanent joint.

  22. VIDEO

  23. 3.- NUTS AND BOLTS • Bolts are used to join pieces together either permanently or temporarily.

  24. 4.- WELDING • It is a fusion process in which interface of joining parts is heated to a temperature above the melting point and then solidify to obtain permanent joint.

  25. ELECTRIC ARC WELDING

  26. OXY ACYTYLENE GAS WELDING

  27. RESISTANCE WELDING: • In Resistance welding coalescence is produced by heat obtained from the resistance of joining metal to flow of current in it.

  28. RESISTANCE WELDING

  29. Video

  30. ELECTRON BEAM WELDING • It is a fusion process in which coalescence is produces by heat obtained from a concentrated beam of high velocity electrons. • When high velocity electrons strike the work piece kinetic energy is transformed into thermal energy causing heating melting of metal.

  31. LASER BEAM WELDING • It is a fusion welding process in which coalescence is achieved by utilizing the heat obtained from a concentrated coherent beam light and impinging upon surface to be joined.

  32. SOLID STATE WELDING • In this process joining of parts takes place by application of pressure alone or a combination of pressure and heat. No filler metal is used.

  33. TYPES OF SOLID STATE WELDING • 1- DIFFUSION WELDING:

  34. 2.- FRICTION WELDING: • It generates heat through mechanical friction between work piece in relative motion to one another .

  35. Video

  36. 3.- ULTRASONIC WELDING: • High frequency ultrasonic vibrations are applied to work piece being held together under pressure to create a solid state weld.

  37. Frequency of ultra sonic waves is 20000 to 30000 Hz. • In it no external heat is added to welding. • Ultrasonic vibrations creates dynamic shear between the contacts of work piece. • Transducer will convert high frequency electrical signal into high frequency mechanical vibrations. • Mechanical vibrations are further supplied to booster which amplifies the vibrations and supply it horn. • Horn is a device which supply these amplified vibrations to welding plates.

  38. TYPES OF WELDING JOINTS

  39. WELDING DEFECTS • The defect in the weld may be defined as irregularities in the weld due to incorrect welding parameters or wrong welding procedures or wrong combination of parent and filler metal.

  40. POROSITY: is the technical term for gas bubbles. • Porosity in welding is caused by presence of gases which gets entrapped during solidification process. • For this reason some of shielding gases are used in welding.

  41. CRACKS: may be of macro or micro size. • Cracks appear when stresses are produced during welding.

  42. CRATER CRACK: may develop whenever a welder neglects to backfill a crater left behind. • Its standard practice to weld a little past the end of joint or to go backward and weld over to prevent a crater.

  43. SLAG INCLUSION: slag formed by reaction of fluxes gets entrapped in the weld pool during solidification.

  44. UNDERCUTTING: It is due to improper welding technique. This appear like smooth notch in the weld interface.

  45. OVERLAP: This is opposite extreme to undercutting. Here the weld metal may flow across the base metal without producing any fusion.

  46. DISTORTION: Because metal expands when heated and then shrink after cooling the two sides of joint may shift position causing distortion.

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