PRODUCTION TECHNOLOGY-1

Course Code: 12ME36 CIE Marks: 100+50

Hours/Week: L: T: P: S = 3:0:2:1 SEE Marks: 100+50
Credits: 5 SEE Duration: 3+3Hours

Course Learning Objectives

By the end of the course the student should be able to:
1. Explain the different types of patterns
2. Evaluate various machine moulding techniques
3. Analyze casting methods
4. Define the various defects of casting and its causes
5. Demonstrate the skill of using forging tools
6. Explain the influence of load and pressure on rolled products
7. Define the process of deformation in extrusion
8. Identify the different welding methods
9. Recognize the metallurgical aspects of welding

UNIT-1 07Hrs
Introduction: Concept, classification and importance of manufacturing processes. Introduction to casting
process & steps involved. Advantages & limitations of casting process.
Patterns: Definition, materials used, allowances and classification
Binder: Definition, types, Additives: Need, types of additives used.
Sand moulding: Types and requirements of base sand. Sand moulds: Moulding sand ingredients. Cores:
Definition, need, types. Method of making cores, binders used.
Gates and risers: Principle involved and types.
Moulding machines: Jolt type, Squeeze type, Jolt & squeeze type, Sand slinger.
UNIT-II 07 Hrs
Types of moulds: Green sand mould, core sand mould, dry sand mould, CO2 mould, shell mould,
investment mould.
Casting processes: Gravity die-casting, pressure die casting, centrifugal casting, and continuous casting
processes. Fettling of casting.
Casting defects: Causes, features and remedies
UNIT-III 07 Hrs
Forging: Classification of forging processes. Forging machines and equipments. Expressions for forging
pressures & load in open die forging for sliding friction. Material flow lines in forging. Forging defects.
Simple problems
Rolling: Classification of rolling processes. Types of rolling mills, Roll separating force, power required
for rolling. Geometric relationship in rolling. Parameters in rolling (roll diameter, friction, deformation
resistance, roll tension) Defects in rolled products
UNIT-IV 06 Hrs
Extrusion: Types of extrusion. Extrusion equipments & dies, deformation, lubrication & defects in
extrusion, extrusion of seamless pipes & tubes.
Sheet metal forming: Dies & punches. Types of dies (progressive die, compound die, combination die),
rubber forming, blanking, piercing, stretch forming, bending. Economic strip layout.
 UNIT-V 06 Hrs
Arc welding: Principle, Shielded Metal arc welding (SMAW), Flux Cored arc welding (FCAW), Inert Gas
arc Welding (TIG & MIG), Submerged Arc Welding (SAW), Atomic Hydrogen Welding (AHW).
Metallurgical aspect of welding: Structure of welds, formation of different zones during welding, Heat
Affected Zone (HAZ), parameters affecting HAZ. Concept of electrodes, filler rod and fluxes. Welding
defects – Detection, causes and remedies.

References:
1. Roy A. Lindberg- Manufacturing process and materials of manufacture, Prentice Hall of India, fourth
edition. ISBN 10: 8120306635.
2. P.N.Rao Manufacturing Technology I, Tata McGraw Hill, 2008, ISBN-10: 0070087695
3. Serope Kalpakjain, Steven R. Schmid- ―Manufacturing processes for Engineering Materials, Pearson
Education, 2007, ISBN-10: 0132272717
4. G.E.Dieter -―Mechanical Metallurgy (SI Units) ‖, McGraw Hill Publication, 2001 ISBN: 978007100406
5. S.K. Hajra Choudhury, A.K. Hajra Choudhury, Nirjhar Roy, ―Elements of Workshop Technology (Vol-
1)‖, 2009, Media Promoters, ISBN-10: 8185099146

Course Outcome: ONLY four

Upon completion of the course the student will be able to
1. Define the terms associated with metal casting.
2. Classify different types of sand moulds.
3. Understand the working principle of metal forming processes
4. Summarize various operations that can be performed in Metal forming processes.
5. Classify welding process and summarize various defects in welding
6. Summarize the extrusion phenomenon of seamless pipes and tubes.

PO & CO Mapping

PO1 PO2 PO3 PO4 PO5 PO6

CO1 H M
CO2 M H M
CO3 H M
CO4 L M H
CO5 M H
CO6 H M

Course Assessment Method Assessment Intervals

1 2 3
Quiz X X X
Tests X X X
Seminar / Presentation X
Lab X
Semester End Examination X
Scheme of CIE (100 marks):
CIE consists of Three Tests each for 40 marks (15 marks for Quiz + 25 marks for descriptive) of which
best two will be considered. In addition, self-study component carries 20 marks.
Scheme of SEE (Theory, 100 marks):
The question paper consists of Part A and Part B. Part A is for 20 marks covering the complete syllabus
and is compulsory. Part B is for 80 marks consisting of 5 questions carrying 16 marks each.
The examiner has to set TWO questions from each unit, out of which the student has to answer ONE
question.
Scheme of Semester End Examination for Practical:
Laboratory examination is conducted for 50 marks, Laboratory examination consists of one question from
section 1 for 15 marks, one question from section 2 for 25 marks and Viva Voce for 10 marks.
 Department of R. V. College of Engineering
(An autonomous institution affiliated to VTU, Belagavi)

Course Title: PRODUCTION TECHNOLOGY-1 Course Code: 12ME36

Total Contact Hours: 33+11 Credites:05
SEE Marks: 100+50 CIE Marks: 150
Semester: III Academic Year: 2014-15
Lesson Plan Authors: RATNAPAL (A-SEC) RAMAKRISHNA Date: 01-08-2014
HEGDE(B-SEC) KESHAVAMURTHY YC (C-SEC)
Checked By: Duration of SEE: 3Hrs
Prerequisites:
 BME
 CAED
Course Learning Objectives:
1. Explain the different types of patterns
2. Evaluate various machine moulding techniques
3. Analyze casting methods
4. Define the various defects of casting and its causes
5. Demonstrate the skill of using forging tools
6. Explain the influence of load and pressure on rolled products
7. Define the process of deformation in extrusion
8. Identify the different welding methods
9. Recognize the metallurgical aspects of welding
Blooms Course
Week Days Unit Main Topics Sub Topics Taxonomy Outcomes
Levels (L) (CO)
Concept, classification and
1 Introduction importance of manufacturing L1 CO1
processes
Introduction to casting process &
01
2 Casting process steps involved. Advantages & L1 CO1
limitations of casting process
Definition, materials used,
3 Patterns L1 CO1
allowances and classification
I
Definition, types, Additives: Need,
1 Binder L1 CO1
types of additives used.
Types and requirements of base
CO1
2 Sand moulding sand. Sand moulds: Moulding sand L1
02 ingredients. CO2
Definition, need, types. Method of
making cores, binders used. Gates CO1
3 Cores L2
and risers: Principle involved and CO2
types.
 Jolt type, Squeeze type, Jolt & CO1
1 Moulding machines L2
squeeze type, Sand slinger. CO2
CO1
03 2 Classification L1
CO2
Green sand mould, core sand CO1
3 L1
mould, CO2
Types of Moulds
CO1
1 Dry sand mould, CO2 mould, L1
CO2
04 CO1
2 II Shell mould, investment mould. L1
CO2
Gravity die-casting, pressure die
3 L1 CO1
casting,
Centrifugal casting, and continuous
1 L1 CO1
Casting processes casting processes.
Fettling of casting.
05 2 Casting defects: Causes, features L1 CO1
and remedies
Classification of forging processes. CO3
3 L1
Forging machines and equipments. CO4
Expressions for forging pressures &
CO3
1 Forging load in open die forging for sliding L5
friction. CO4
06 Material flow lines in forging. CO3
2 L4
Forging defects. Simple problems CO4
CO3
3 Classification of rolling processes. L1
III CO4
Types of rolling mills, Roll
CO3
1 separating force, power required for L1
rolling. CO4
Rolling Geometric relationship in rolling.
07 Parameters in rolling (roll diameter, CO3
2 L3
friction, deformation resistance, roll CO4
tension)
CO3
3 Defects in rolled products L1
CO4
Types of extrusion. Extrusion CO3
1 L1
equipments & dies CO4
08 Extrusion Deformation, lubrication & defects CO3
2 L1
in extrusion CO4
Extrusion of seamless pipes &
3 L3 CO6
tubes.
IV CO3
1 Dies & punches. L1
CO4
Types of dies (progressive die, CO3
09 2 Sheet metal forming L1
compound die, combination die), CO4
Rubber forming, blanking, piercing,
CO3
3 stretch forming, bending. Economic L2
strip layout CO4
Principle, Shielded Metal arc
10 1 V Arc welding L1 CO5
welding (SMAW)
 Flux Cored arc welding (FCAW),
2 Inert Gas arc Welding (TIG & L1 CO5
MIG),
Submerged Arc Welding (SAW),
3 L1 CO5
Atomic Hydrogen Welding (AHW).
Metallurgical aspect of welding:
1 Structure of welds, formation of L2 CO5
different zones during welding,
Heat Affected Zone (HAZ),
11 2 L3 CO5
parameters affecting HAZ.
Concept of electrodes, filler rod and
3 fluxes. Welding defects – L2 CO5
Detection, causes and remedies

References:
1. Roy A. Lindberg- Manufacturing process and materials of manufacture, Prentice Hall of India, fourth
edition. ISBN 10: 8120306635.
2. P.N.Rao Manufacturing Technology I, Tata McGraw Hill, 2008, ISBN-10: 0070087695
3. Serope Kalpakjain, Steven R. Schmid- ―Manufacturing processes for Engineering Materials, Pearson
Education, 2007, ISBN-10: 0132272717
4. G.E.Dieter -―Mechanical Metallurgy (SI Units) ‖, McGraw Hill Publication, 2001 ISBN: 978007100406
5. S.K. Hajra Choudhury, A.K. Hajra Choudhury, Nirjhar Roy, ―Elements of Workshop Technology (Vol-
1)‖, 2009, Media Promoters, ISBN-10: 8185099146
Course Outcome:
Upon completion of the course the student will be able to
1. Define the terms associated with metal casting.
2. Classify different types of sand moulds.
3. Understand the working principle of metal forming processes
4. Summarize various operations that can be performed in Metal forming processes.
5. Classify welding process and summarize various defects in welding
6. Summarize the extrusion phenomenon of seamless pipes and tubes.

Course unitization for CIE and Semester End Examination

No of Questions in No of
Teachin
Unit Chapter Questions
g Hours CIE-1 CIE-2 CIE-3
in SEE
Introduction to manufacturing
I 07 03 X X 02
processes
II Types of Moulds 07 02 01 X 02
III Forging 07 X 03 X 02
IV Extrusion 06 X 01 02 02
V Arc welding 06 X X 03 02

Faculty In-charge Head of Department

Date: