Workshop Practice

TA 102
Lec 1 : Manufacturing Concepts

B Y M.L.PA V AN KISHORE

Scope and Objective of the course:

This course is designed to make the students familiar with the basic

manufacturing processes used for producing finished articles out of

wood, ferrous and non-ferrous metals. The processes covered include
Casting, Joining processes, Metal Forming, Sheet Metal work and
Modern manufacturing processes.
The students are exposed to modern manufacturing courses like the
application of non-conventional resources in manufacturing and usage
of computers in manufacturing.
A brief review of the properties and heat treatment of common
engineering materials and of measuring and gauging tools are also
included. At the end of the course the students will be familiar with
basics of all manufacturing processes.
In practical classes the student is required to acquire knowledge of
handling some of the basic general purpose machine tools, carpentry
work, foundry, fitting independently.

(a) Text Books:

B.S.Nagendra Parashar, R.K.Mittal, Elements of

Manufacturing Processes, PHI, 2010.

(b) Reference Book(s):

i) J.S.Campbell, Principles of Manufacturing
Materials and Processes Tata McGraw-Hill, 2010.
ii) WAJ Chapman, Butterworth -Heinemann
Workshop Technology Part I, II & III, 2001, 1995,
1998 respectively.
iii) E. Paul Diagram, J.T.Black Materials and
Processes in Manufacturing, PHI,9th ed., 2008.
iv) P Kannaiah & KL Narayana, Workshop Manual
SciTech Publications, 2010

Lecture-wise Plan: for Test 1

Lecture
Nos

1
2-3
4-5

6-7

Learning Objective

Topics to be covered

Reference (Chapter/Sec/Page
Nos. (of Text/Ref. Books)

Basics of
Manufacturing
Properties of
Materials
Quality aspects in
Manufacturing

Manufacturing
Concepts
Engineering
Materials
Measurements and
Quality in
Manufacturing

1.1 to1.5

Basics of metal
cutting operation

Theory of Metal
Cutting

8-10 Different operations Turning Operations

on lathe

2.1, 2.4 to 2.8

3

4.1 to 4.6, 4.10 to 4.16

5.1,5.2,5.4,5.6 to 5.11

Lecture-wise Plan: for Test 2

Lecture
Nos

Learning Objective

Topics to be covered

Reference (Chapter/Sec/Page
Nos. (of Text/Ref. Books)

11

Hole making and allied

operations
Production of flat
surfaces
Production of complex
surfaces
Operations to produce
fine surface finish
Property manipulation
of materials

Drilling and Allied

operations
Shaping, Planning and
Slotting operations
Milling Operations

12-13
14-15
16
17

7
8

Finishing Operations

9.1 to 9.5

Heat treatment and

hot and cold working
of materials for
Material Property
Manipulation

10

Lecture-wise Plan: for Test 3

Lecture
Nos
18-20
21-22
23
24
25-26
27

28

Learning Objective

Production of parts by
casting process
Production of parts by
forming process
Sheet metal working
operations
Powder metallurgy

Topics to be covered

Reference (Chapter/Sec/Page
Nos. (of Text/Ref. Books)

Casting processes

11.1 to11.7, 11.9 to11.12,11.14

Metal Forming Processes

12.1
to12.2.2,12.2.4,12.3,12.4,12.5
13.1 to13.3,13.5 to 13.9

Sheet-metal working

Powder metallurgy
manufacturing process
Joining processes like
Mechanical Joining
welding, brazing, etc
Processes
Using non conventional
Non Conventional
resources in manufacturing Resources in
Manufacturing
Applications of computers Computer Controlled
in manufacturing
Manufacturing Processes

14
15.1 to15.4.2,15.5 to 15.7
17.1 to 17.3,17.4.3,17.4.4

18.1 ,18.2, 18.5,18.7.0

Lecture-wise Plan:
Lecture
Nos

29
30

Learning Objective

Feasibility study in
manufacturing
Power transmission
process in machine
tools

Topics to be covered

Reference (Chapter/Sec/Page
Nos. (of Text/Ref. Books)

Economics of
manufacturing
Power transmission
in machine tools

19
21.1 to 21.2.3to21.2.5,
21.5.0,
21.5.1,21.5.3,21.5.4(up to
compound gear train)

Evaluation Scheme:
Test

Syllabus

Date

Weightage
(%)

Comp. Type

Test I

1 10

10.02.12

12

Closed Book

Test II

11 17

09.03.12

12

Closed Book

Lab Exam-I

1st Cycle

10

Closed Book

12

Closed Book

Test III

18 - 28

06.04.12

Lab Exam-II

2nd Cycle

10

Closed Book

*Day-to-day
Assessment

----

20

NA

24

Closed Book

Comprehensive

Entire syllabus

04.05.12 AN

Introduction
Recognition of need

Specifications

Design

Prototype Testing

Production

Drafting/Modeling

Manufacturing Concepts
Raw material The material as found in nature is

called Raw material

Product Any object made by us for any specific

purpose is called a product.

Manufacturing The process of making a product is

called manufacturing. It is the process of converting

Raw material into Product

For carrying out manufacturing activity we require 5 Ms

Material
Methods
Machinery
Men
Money

Manufacturing Process and its interaction with the 5 Ms

Men

Methods
Machinery

Manufacturing
Process

Material

Money

Product

Manufacturing Processes
Manufacturing Processes are broadly classified in to

five groups:
1.

Casting

2.

Machining

3.

Forming

4.

Powder metallurgy

5.

Joining

CASTING
casting may be defined as a metal object obtained by

pouring molten metal in to a mould and alloying it to

solidify.
Casting process is based on the property of liquids to take

up the shape of the vessel containing it.

Molten metal when poured in to a cavity of desired shape

(called mould) flows in to every nook and corner of the

cavity and fills all the shape.

The Casting Process

The Casting Process

Metal Cast Parts

MACHINING
The process of manufacturing a component by

removing the unwanted material using a machine is

known as Machining and when used with metals it is

referred to as metal machining or metal cutting.

Metal Cutting Operation on a Lathe

the turning operation

Machined Parts

FORMING
Shaping of a component by the application of

external forces is known as the metal forming.

Metal forming can be described as a process in which

the desired size and shape are obtained through the

deformation of metals plastically under the action of

externally applied forces.

A Typical metal forming Operation the rolling of metal

POWDER METALLURGY
Fine powdered materials are blended, pressed into a

desired shape in a die and then heated in a

controlled atmosphere to bond the contacting

surfaces of the particles and get the desired

properties.

JOINING

Two or more pieces are joined together to produce

the required shape and/or size of the product.

All joining processes can be categorized based on

the type of joint produced under two categories:

1.

Permanent Joint

2.

Temporary joint

Joining (contd.)
Permanent Joint: the joint is made such that it has the

properties similar to the base metal of the two parts.

Permanently joined parts cannot be separated in to their

original shape, size and surface finish.

A temporary joint can be easily dismantled separating

the original parts without any damage to them.

Examples of Joints made by different joining processes

ALLIED ACTIVITIES:
1.

Measurement

2.

Assembly

3.

Property changing

Measurement & Inspection

For a pencil we check diameter, length, surface

smoothness for it to perform intended function.

Specified size must be measured and checked.

ASSEMBLY
Ball pen consists of body, Refill, Barrel, cap and

refill operating mechanism.

The process of putting the parts together to form

the product, which performs the desired function,

is called assembly.

Car with Major Parts

Property Changing
We should know what materials are

available,

their strength, hardness, availability and costs.

Hard material is difficult to machine So we make it

soft by heat treatment. We anneal it. This is called

property changing.

Selection Of Manufacturing Process

The selection of suitable process is based on the

following considerations:
Volume of Production

Expected Quality and Properties of the components

Technical Viability of the process

Types of Production
Based on the quantity of Product, Manufacturing

activity can be classified under the following three

categories:
1. Job Shop Production
2. Batch Production

3. Mass Production

Types of production
JOB SHOP PRODUCTION - Low volume of

production and variety of work

BATCH PRODUCTION - The manufacture of

medium quantity of an item or product

MASS PRODUCTION - Manufacture of identical

products in Bulk quantities