MF25C01 Casting, Forming and Welding – Semester III – Mech(Smart) – R-2025

Subject Code & Name: MF25C01 – Casting, Forming and Welding

Regulation: R-2025

Semester: III (Third Semester)

Branch: B.E. Mechanical Engineering (Smart Manufacturing) (Mech(Smart))

Credits / L-T-P: 4 Credits | L-T-P: 3-0-2

Course Objectives

• To provide fundamental knowledge of casting, forming, sheet metal processing, and welding processes.
• To develop the ability to understand, analyze, and select suitable manufacturing methods for engineering applications.

Full Unit-wise Syllabus

Unit I – Casting Fundamentals

Sand casting, Moulding sand, pattern and its type, Design of pattern, Allowances and its type, solidification and cooling, core, riser, and gating design, sand casting defects, Introduction to casting simulation tools.

Practical: 1. Evaluation of moulding sand properties for casting 2. Sand mold preparation using solid, split pattern.

Unit II – Special Types of Casting Process

Investment casting process, Shell molding process, Pressure Die casting process, Centrifugal casting process, Squeeze casting, stir Casting

Unit III – Forming – Bulk Deformation processes

Plastic Deformation & Yield Criteria, Hot and Cold working, Rolling, Forging, Extrusion, Wire and Tube Drawing - working principle and load estimation.

Practical: 1.Analysis of thickness reduction during flat rolling.

Unit IV – Sheet Metal Processes

Formability of sheet metal, shearing processes, Deep Drawing, Bending, Dies and their types, Rubber pad forming, Explosive Forming, Superplastic forming.

Practical: 1. Evaluation and comparison of sheet metal formability using the Erichsen cupping test. 2. Fabrication of simple sheet metal components using standard sheet metal tools

Unit V – Welding fundamentals

Classification of welding processes, Gas Welding, welding power sources: Constant current and constant voltage power sources – characteristics and applications, Arc welding, Physics of Arc welding, SMAW, TIG, MIG, SAW, Plasma Arc welding processes, Ultrasonic Welding, Resistance welding, Brazing, soldering, adhesive bonding, weld Defects, and remedies

Practical: 1. Design and fabricate a simple welded component of a specified geometry using mild steel plates and the SMAW process, ensuring proper joint design and weld quality 2. Effect of welding current on weld bead geometry in SMAW of mild steel. 3. Effect of welding current on microstructure in SMAW of mild steel. 4. Analyze hardness variation in the fusion zone and HAZ of SMAW joints at different welding currents. Advanced welding processes: TIG Welding, Pulsed TIG Welding, CMT welding, Laser welding, Electron Beam welding, Friction welding, Friction stir welding, Diffusion Bonding

Activities: Tasks T1. An automobile manufacturer faces casting defects (porosity) in engine blocks – redesign gating and riser system to reduce rejection rate. T2. A steel plant reports cracks during rolling of sheets – analyze process parameters and suggest optimal rolling conditions. T3. A company producing fuel tanks encounters failure in deep drawing process improve die design and material selection. T4. A fabrication unit observes weak weld joints in structural frames – optimize welding current, technique, and joint design.

Course Outcomes (COs)

• CO1: Explain fundamental concepts of casting, forming sheet metal processes, welding, and machining operations including working principles and applications.
• CO2: Apply manufacturing principles to select suitable casting, forming, sheet metal, and welding processes for producing engineering components.
• CO3: Analyze various manufacturing processes to identify defects, material behavior, process parameters, and performance under different conditions.
• CO4: Evaluate and develop suitable manufacturing solutions by comparing different processes based on quality, efficiency, and industrial requirements.

Assessment Pattern (Quick Note)

• Weightage: Continuous Assessment 40% | End Semester Examinations 60%
• Internal methodology: Written Test (40%), Practical (30%), Activity (30%). Practical: Lab Experiments (50%), Tasks (50%) (Each student must complete a minimum of two tasks). Activity: Review of GATE/ESE Questions (10%), Mini Project/ Quiz/ Assignment Programs/ Flipped Class /Seminar Presentation (20%)

Source: Official Anna University – B.E. Mechanical Engineering (Smart Manufacturing) R-2025 Syllabus
Last Updated: September 2026