Foundations in Heavy Industry Production

Welcome to the comprehensive course on “Foundations in Heavy Industry Production”, where we delve into the intricate techniques and practices essential for producing components vital to various industries.

Casting Process in Heavy Manufacturing: In the first part of this course, we explore the fascinating world of casting, a cornerstone of heavy manufacturing. Casting technology enables the production of intricate components by shaping molten metal into molds. Learners will delve into the principles of casting, including the types of castings, forgeability of materials, and casting defects. Through hands-on exercises and case studies, participants will gain insights into the diverse applications of casting across industries, from automotive to aerospace.

Forging Process in Heavy Manufacturing: The second part of the course delves into the art of forging, where metals are shaped through compression forces to create strong and durable components. Participants will explore different types of forging processes, including closed die and open die forging, and learn about the forgeability of materials and typical operations involved. With practical demonstrations and simulations, learners will develop the skills necessary to produce high-quality forged components for heavy manufacturing applications.

Welding in Heavy Manufacturing: Finally, we delve into the world of welding, a critical process for joining metals in heavy manufacturing. Participants will gain a comprehensive understanding of weld joint types, welding symbol representation, and welding positions. They will explore welding procedure specification, welder qualification, and welding consumable selection, ensuring quality and consistency in welding processes. Through case studies and hands-on training, participants will learn to identify and mitigate welding defects while adhering to industry standards and best practices.

Throughout the course, learners will engage in practical tasks, exercises, and real-world applications to strengthen their understanding of heavy manufacturing processes. By the completion of the course, students will have gained the knowledge and abilities necessary to excel in the development, building, and upkeep of heavy manufacturing components. Whenever they start the workforce or advance in their careers, graduates will be well-prepared to contribute to the creativity and efficiency of heavy industrial processes.

Join us on this journey as we unravel the complexities of casting, forging, and welding in heavy manufacturing, and unlock your potential to make meaningful contributions to the field of Heavy Engineering.

Target Learners:

 Working Professional of Mechanical, Manufacturing and Chemical Engineers

 Undergraduate students of Mechanical, Manufacturing & Chemical Engineering

 Students from Manufacturing and Automation

 Post-Graduate Students of Computer Integrated Manufacturing

 Practicing Engineers in Process Plant equipment

 Diploma students of Mechanical / Manufacturing

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What's inside

Syllabus

Introduction to Basic Manufacturing Process

To begin, ferrous materials, such as iron and steel, are the foundation of heavy construction due to their strength, durability, and adaptability. These materials go through primary manufacturing processes such as smelting and refining before being moulded into useful forms. The casting process is a fundamental component of basic manufacturing, allowing for the creation of complicated components required by a variety of process plant equipment. Casting technology is essential for converting molten metal into complicated structures using moulds. Casting is used in industries because of its capacity to make components with specific dimensions and sophisticated geometries, making it appropriate for a wide range of applications, from automotive to aerospace. The principles of gate and riser design are critical for ensuring casting quality and efficiency. Gate design controls the flow of molten metal into the mould cavity, whereas riser design helps to prevent problems like shrinkage and porosity. Special casting technologies, such as investment casting and die casting, provide advanced options for manufacturing complicated components with high accuracy and surface finish. These methods are designed to meet specific application and material constraints. Melting and pouring are crucial phases in casting production, as they ensure optimum alloy composition and quality control. Heat treatment procedures improve the qualities of castings by increasing strength, hardness, and durability to meet stringent performance requirements. Understanding the casting process and supporting technologies allows manufacturers to make high-quality components that are tailored to the specific needs of many industry sectors. From the standpoint of process plant equipment, casting remains a significant aspect of heavy manufacturing, promoting innovation and efficiency in production processes.

Forging

Forging is a crucial process in heavy manufacturing, shaping metals into strong and durable components used across various industries. Forgeability refers to the ease with which a material can be shaped through forging, with certain materials such as steel and aluminum exhibiting excellent forgeability. Different types of forging processes, including closed die forging and open die forging, offer versatile solutions for producing components of varying complexity and size. Closed die forging involves shaping metal between two dies, while open die forging manipulates metal using hammering or pressing techniques without enclosing the material completely. These processes require specialized equipment and skilled operators to ensure precise shaping and dimensional accuracy. Open die forging industries play a significant role in producing large and complex components such as shafts, cylinders, and rings. Steel melting and ingot casting are essential steps in preparing raw materials for open die forging, ensuring the quality and integrity of the final product. Typical operations involved in open die forging of shell forging include upsetting, drawing out, and bending, each aimed at achieving the desired shape and properties in the forged component. Despite their advantages, forging process can be prone to flaws including laps, seams, and cracks. Design assessment of forging dies and equipment is critical for reducing defects and increasing production efficiency in open die forging Industries. Forging temperature plays a critical role in ensuring proper material flow and shaping during the forging process, with different materials requiring specific temperature ranges for optimal performance. Finally, an overview of ASME codes for forgings provides guidelines and standards for ensuring quality and safety in forged components used in various applications, from aerospace to automotive industries. Understanding the forging process and accompanying processes allows industries to produce high-quality components with higher strength and performance, promoting creativity and effectiveness in heavy manufacturing industries.

Welding

Welding is a key component of heavy manufacturing, connecting metals to make robust and long-lasting structures for a variety of industries. Different types and categories of weld joints, including as butt joints, lap joints, and fillet joints, provide varied solutions for combining metal components with different geometries and needs. Welding symbol representation is essential for communicating welding specifications and requirements on engineering drawings, ensuring clarity and uniformity in fabrication processes. Welders have specific challenges and considerations while welding in different locations, such as flat, horizontal, vertical, and overhead, which necessitate the use of specialized techniques and equipment for the best outcomes. Understanding the qualities of base metals, filler metals, and weld metals is critical for selecting the right materials and attaining the necessary Mechanical and Metallurgical properties in welded joints. Welding Procedure Specification (WPS) and Procedure Qualification Records (PQR) provide standardized guidelines and documentation for welding processes, ensuring consistency and quality in fabrication. Welder qualification ensures that welders possess the necessary skills and competence to perform welding tasks effectively and safely. Welding consumable specifications, estimation, and selection adhere to industry standards such as ASME Sec II-C, ensuring compliance with material requirements and quality assurance. Welding defects, such as porosity, cracks, and incomplete fusion, can compromise the integrity of welded joints, highlighting the importance of good Engineering practices and quality control measures. Precautions such as pre-heating and post-heating are employed to minimize welding defects and mitigate the risk of distortion in welded structures, ensuring dimensional accuracy and structural integrity. By adhering to good Engineering practices and employing proper precautions, manufacturers can achieve high-quality welded structures that meet stringent industry standards and regulatory requirements, driving innovation and efficiency in heavy manufacturing.

Good to know

Know what's good

, what to watch for

, and possible dealbreakers

Builds a strong foundation for those learning about welding concepts for the first time

Strengthens existing foundation for intermediate learners with review of welding concepts and additional depth

Covers basic manufacturing processes, which are foundational to welding in heavy manufacturing

Provides advanced options for complicated components with special casting technologies like investment casting and die casting

Prepares learners to produce high-quality forged components for heavy manufacturing applications

Guided by Subject Matter Experts, who are recognized in the heavy industry production field

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Activities

Be better prepared before your course. Deepen your understanding during and after it. Supplement your coursework and achieve mastery of the topics covered in Foundations in Heavy Industry Production with these activities:

Review Engineering Drawing Concepts

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Sharpen your understanding of the fundamentals of engineering drawing, such as orthographic projections, dimensioning, and geometric tolerancing, these concepts are crucial for building a strong foundation in manufacturing processes.

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Develop a Casting Process Manual

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Create a comprehensive manual that outlines the casting process, including best practices and troubleshooting techniques.

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Gather information from various sources
Organize and structure the content
Write clear and concise instructions
Include illustrations and diagrams
Proofread and revise the manual

Practice Open and Closed Die Forging

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Complete a series of practice exercises to improve your ability to perform open and closed die forging techniques.

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Identify different types of forging processes
Practice open die forging techniques
Practice closed die forging techniques
Troubleshoot common forging defects

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Practice Forging Calculations

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Engage in problem-solving exercises to solidify your understanding of the mathematical concepts used in forging, including force calculations, deformation analysis, and material properties.

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Exercises on Casting Design

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Practice applying principles of casting design through exercises that involve designing gating systems, determining riser placement, and analyzing casting defects.

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Explore Advanced Welding Techniques

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Enhance your welding skills by following guided tutorials on advanced techniques, such as TIG and MIG welding.

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Research different advanced welding techniques
Find online tutorials or workshops
Practice the new techniques under the guidance of an expert

Practice casting design principles

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Complete the design of a casting component using the principles learned in the course

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Select a component to design
Determine the functional requirements of the component
Sketch out a design for the component
Analyze the design for manufacturability
Finalize the design and prepare drawings

Practice welding simulations

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Practice simulating the welding process using virtual reality systems

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Setup the simulation environment
Select a welding process
Practice welding different types of joints
Analyze the results of the simulations
Adjust the welding parameters and repeat the simulations

Practice heat treatment processes

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Experiment with different heat treatment processes to improve the properties of a metal

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Select a metal to heat treat
Determine the desired properties for the metal
Research different heat treatment processes
Perform the heat treatment process
Test the properties of the metal after heat treatment

Develop a Materials Selection Plan

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Create a comprehensive plan that outlines the material selection process for a specific heavy manufacturing component, considering factors such as strength, durability, and cost.

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Design and Fabricate a Welded Structure

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Apply your knowledge and skills to design and fabricate a welded structure, showcasing your understanding of welding principles.

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