ME - 204 Manufacturing Processes – I 3rd Semester and 2nd Year

Credit and Hours: Teaching Theory Practical Total Credit Scheme Hours/week 4 2 6 5 Marks 100 50 150 A Objective of the Course: • To introduce the students various manufacturing and fabrications techniques. • To provide background for higher level subjects in Engineering like B Production Technology. Out line of the Course: Sr. No. 1. Title of the Unit Minimum number of hours 08

Introduction to Metal Casting 2. Melting Practices 10 3. Casting Processes 12 4. Principles of Welding 02 Processes 5. Gas Welding 06 6. Electric Arc Welding 05 7. MIG welding 05 8. TIG welding 05 9. Resistance welding 07 Total hours (Theory): 60 Total hours (Lab): 30 Total: 90 C Detailed Syllabus: 1. Introduction to Metal Casting 08 20 Hours 1. 1 1. 2 Metal Casting, Sand Casting, Patterns, Cores, Gating & Risering Systems, Casting Defects & Inspection %

Gas Cutting Processes 05 Hours 6. Principle of Arc. and reverberate furnace 12 Hours 15 % 3. 1 3. Soldering and Brazing Centrifugal Casting. crucible furnace. Arc Welding Equipment 10 % ISI electrode classification. construction 10 Hours 15 % Other Furnaces working of induction furnace. Vacuum-Sealed casting process 02 Hours 10 % 02 07 % Hours Gas Welding. Casting Processes 3. Melting Practices 2. current and voltage selection for electrodes 05 07 Hours % Process details. electrode wires. Continuous casting Shell molding. Gas Welding 5. Carbon dioxide molding process Investment casting. Die casting. 2 7. shielding gases. 1 2. Oxy-Acetylene Welding Equipment and techniques. MIG Welding 7. TIG Welding . 1 Classification of Welding. 2 3. 1 6. their sizes. Fuel Gases.2. 3 4. 1 Types of Arc Welding. 1 5. Principles of Welding Processes 4. and welding current ranges 05 06 8. Electric Arc Welding 6. 2 Cupola: Charge calculations.

selection of welding currents Voltages. It carries a weightage of 5 Marks as a part of internal theory evaluation. electrode cooling. 1 8. Two internal exams will be conducted and average of the same will be converted to equivalent of 15 Marks as a part of internal theory evaluation. shielding gases. electrode sizes and materials Current carrying capacities of different electrodes. OHP etc. 1 9. projection welding Electrode materials. Experiments/Tutorials related to course content will be carried out in the laboratory. power sources requirements. shapes of electrodes. Process details and working principle of spot. various application of resistance welding processes. prerequisite of the subject will be discussed. black board. 3 D Instructional Methods and Pedagogy: • At the start of course. application of process 07 10 Hours % General principle of heat generation in resistance welding. manufacture of resistance seam welded (RSW) tubes by seam welding.8. the course delivery pattern. The course includes a laboratory. 9. Attendance is compulsory in lectures and laboratory which carries 5 Marks weightage. seam. . • • • Surprise tests/Quizzes/Seminar will be conducted which carries 5 Marks as a part of internal theory evaluation. Assignments based on course content will be given to the students at the end of each unit/topic and will be evaluated at regular interval. 2 Hours % Process details. 2 9. and. where students have an opportunity to build an appreciation for the concepts being taught in lectures. • • • • Lectures will be conducted with the aid of multi-media projector. Resistance Welding 9.

students will be able to understand casting and welding processes.R. “Manufacturing Technology – Foundry. “Manufacturing Science”. “Materials and Processes in Manufacturing”.. 2.. G. W. http://nptel.ias.. New Delhi http://www. Rao P. Lindberg R. Production Engineering (IE) http://www..htm 2. Tata McGraw Hill 5. Pye R. Vol. Forming & Welding”. Essex. Tata McGraw-Hill 2004 2. T. Groover M..ac.Hall of India 2.iitm. 3rd Edition. “Introduction to Manufacturing Processes”.ac. Prentice Hall PTR 2001/ 9780135526057 3.. A. and Mallik A. “Processes and Materials of Manufacture”. and Schmid S. N.. “Injection Mold Design”. P. Journal of Material Processing Technology (Elsevier Publication) 2. ISBN – 0136081681 Reference books: 1. 6th Edition.ipcourseline.in/sadhana/ . Longman Scientific & Technical. A. 1989 Reading Materials. Schey J. Prentice Hall. Ghosh A. DeGarmo E. F Recommended Study Material: Text Books: 1. P. K.org 3. Prentice-Hall of India 4. E • Student Learning Outcomes : After learning the course. and Kohser R.• In the lectures and laboratory discipline and behavior will be observed strictly. Sadhna http://www. web materials with full citations: 1. Kalpakjian S.foundry info-india. Prentice .. Foundry Informatics Centre. “Fundamentals of Modern Manufacturing”. “Manufacturing Engineering and Technology”. John Wiley & Sons 3. Black J.in/courses/Webcourse-contents/IITROORKEE/MANUFACTURING-PROCESSES/index..org Other materials 1.

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