DPMT Semester 4

 

DPMT
SEMESTER - III

*Subjects :-

• Engineering Materials and Heat Treatment

• Plastics products and Mould Design

• Machine Shop Technology II

• Plastics processing Techniques

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ENGINEERING MATERIALS AND HEAT TREATMENT

Unit I Crystallography

Crystalline solids - Amorphous solids - Space lattice - Unit cell - Bravais lattice -

Lattice planes - Miller indices - 'd' spacing in cubic lattice - Calculation of atoms per

unit cell – Atomic radius - Coordination number and Packing factor for SC, BCC, FCC

and HCP structures

Unit II Ferrous and Non-Ferrous Metals

Ferrous Metals :

Classification of iron and steel - Manufacture of pig iron, wrought iron, cast iron and steel -

Effect of various alloying elements on steel.

Non Ferrous Metals:

Properties and uses of nonferrous metals. Important ores and properties of aluminium,

copper, zinc, tin, lead – Non ferrous alloys – Brass, Bronze, Gun metal and Beryllium

Copper - properties and applications.

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Unit III Heat Treatment

Solid solutions Substitution and interstitial – Phase diagrams - Isothermal transformation

diagrams cooling curves, Iron carbon equilibrium diagram, eutectoid and eutectic

reactions. Time & Transformation (TTT) diagram.

Heat Treatment – Purpose -Types of Heat Treatment processes- Annealing, Normalising,

Hardening - Hardening of Tool steels, Tempering – Types, Austempering & Martempering of

steel. Quenching medium – Types and application. Case hardening processes, types &

applications - carburising, nitriding, cyaniding, carbonitriding, flame and induction hardening-

Process - Permeable case depth for different types of steels.

Advanced Heat treatment techniques - Vacuum hardening, Plasma Nitriding.

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Unit IV Mechanical Properties and Testing

Mechanical properties of metals-Testing of materials under tension, compression and shear

loads – Hardness tests (Brinell, Vickers and Rockwell). Impact test - Izod and Charpy,

Fatigue and creep tests, fracture toughness tests. Hardenability, Jominy end quench test,

Non Destructive Techniques.

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FUNDAMENTALS OF PLASTICS PRODUCT

AND MOULD DESIGN

Unit I

Product Design - Plastics product design - Concepts - Essential factors - Principles -

Methodical approach -process variables vs product design. Uniform and symmetrical wall

thickness - Draft angle- Rib design - Fillets & Radius - Bosses - Holes -Threads - standard

thread forms - undercuts - Hinges - metal inserts - parting line -Tolerances- Design for

manufacturing and assembly.

Unit II

Injection Mould Design- Introduction - General mould construction- Mould design concepts

- mould elements - parting line and parting surface- construction of core and cavities-

Bolsters - mould alignment, Feed system-Sprue, runner, gate & position of gate - runner &

gate balancing, Ejection - types of ejections - mould cooling -venting- ancillary parts.

Two plate mould - three plate - external undercut- split mould, Side cores, Split and side

core actuation-Finger cam-Dog leg cam - cam track - delayed action - hydraulic, internal

undercut-form pin-collapsible core - loose cores, threaded inserts - internal and external

threads-unscrewing moulds-hot runner moulds.

Unit III

Blow Mould Design - Types of blow moulds - extrusion - injection and stretch blow moulds -

blow ratio - parison design - pinch off design - parting line - clamping force -mould venting,

mould cooling - mould alignment.

Extrusion Die Design - Principles of Extrusion- Die Geometry - Die swell – Die Land

Design- Sizing die design- Construction of Extrusion dies - blown film-pipe- profile- flat film-

sheet - Wire Coating and Co-Extrusion Dies.

Unit IV

Compression Mould Design - Types of compression mould, open flash, semi-positive type,

positive, displacement moulds, types of loading chambers, bulk factor, flash thickness, pot

design, projected area, compression pressure, clamping force, no. of impression by

technological method, heating system, types of heaters, heat loss, heat requirement &

heater capacity.

Transfer Mould Design - Types of transfer moulds, integral pot transfer mould, auxiliary

ram transfer mould, transfer pot design, projected area, transfer pressure, clamping force,

pressure pad design, design of sprue, runner and gate, advantages and disadvantages of

transfer mould - design related calculations.

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MACHINE SHOP TECHNOLOGY - II

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Unit 1 Milling Machines

General use of milling machines, Parts of milling machines and their functions, Types of
milling machines-horizontal-vertical - universal, Cutter holding devices - arbors - collets -
adopters, Types of milling cutters - end mill, side and face cutter - shell end mill, helical end
mill, carbide tipped cutters, choice of cutter, Setting of work – work holding devices -
alignment - speed, feed and depth of cut on various materials. Milling operations - plain
milling, key and key ways, gang milling, T - slot milling, Milling methods (a) conventional
milling (b) climb milling (Up/Down milling). Construction of indexing head - Job accuracy -
Machining time, maintenance & safety - coolants used for machining - lubricants &
lubrication of machinery preventive maintenance of machine tools-Milling machine
specifications-safety while working.

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Unit II Surface Grinding

General use of surface grinding machines, Parts of surface grinding machines and their
functions, Types and working principle - wet grinding and dry grinding, work and tool holding
devices, grinding wheels - abrasives, bonds, grit, grade and structure of wheels - wheel
shapes and sizes - mounted wheels - standard marking system - selection of grinding
wheels - mounting the grinding wheels - glazing and Wheel loading - dressing and truing of
grinding wheels - balancing of grinding wheels - diamond wheels - types and uses - speed
and feed parameters – attachments –Plain surface- taper grinding - job accuracy
maintenance and safety.

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Unit III Cylindrical Grinding

General use of surface grinding machines, Parts of surface grinding machines and their
functions, Types and working principle - wet grinding and dry grinding, work and tool holding
devices, grinding wheels - wheel shapes and sizes - mounted wheels - standard marking
system - selection of grinding wheels - balancing of grinding wheels - diamond wheels -
types and usage - speed and feed parameters - attachments - concept of spark out
external and internal grinding- taper grinding - job accuracy - maintenance and safety.

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Unit IV Tool and Cutter Grinder

Types and working principle of Tool and Cutter Grinding Machine-Use of cutter grinding
accessories and attachments-Nomenclature of Single and Multipoint Cutting Tools-
Selections and Specification of Grinding Wheel for Cutter Materials-Method of Setting,
Balancing, Truing, Dressing of Grinding Wheel -Procedure of forming of Grinding Wheels for
sharpening of lathe & milling cutters.

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PLASTICS PROCESSING TECHNIQUES

Unit 1

Injection Moulding - Basic principles - Types of injection moulding machines-specifications-

Various parts of injection moulding machine and its functions - process variables

temperature - pressure - time - moulding cycle - types of clamping - Mould setting -

Shrinkage control - defects - causes and remedies of the common moulding faults - operator

safety and routine quality control.

Introduction to Advance Injection Moulding Processes-Gas assisted injection moulding,

Reaction injection moulding, Multi-colour injection moulding

Unit II

Extrusion - Introduction - Extruder parts - Extruder screw - Design features - Extruder

output - Extrusion processing parameters - Their effects on product quality - Extruded

products - Faults - Causes and Remedies.

Extrusion of film, pipe, sheet, profile and coating - dies for different extrusion process - sizing

units – hauloff units · process control systems - process variables - operator safety and

routine quality control.

Blow Moulding - Introduction to blow moulding - types - Extrusion blow moulding - injection

blow moulding - stretch blow moulding - parison programming - blow mould construction -

setting and operation - mould cooling - clamping force - cycle time - moulding faults - causes

and remedies - operator safety and routine quality control.

Unit III

Compression & Transfer Moulding - Fundamental principles - Bulk factor - Flow properties -

Processing temperature - Mould temperature control - Moulding pressure - Press tonnage -

Processing limitations - Curing time - Influence of processing parameters on the quality of the

moulding - Setting of moulding conditions for a particular job - Pelletizing

- Preheating - Defects - Causes - operator safety and routine quality control.

Unit IV

Thermoforming - Introduction - Thermo forming methods - Thermo forming moulds -

Thermo forming equipment description - Temperature control - Cycle time - Defects,

Causes and Remedies - operator safety and routine quality control.

Rotational Moulding - Basic principle - Material selection & Estimation through trial analysis

Type of machine - Process variables - Charge size - Wall thickness control - Heating and

Cooling system process requirement for the moulding of water tank - Dust Bin, etc.

Application of Rotational Moulding - Ejection & Finishing - Fault - Causes & Remedies -

Merits & Demerits of Rotational Moulding Process- operator safety and routine quality

control.

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3rd Semester

5th Semester

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