Course Coordinator 2019-2020 & SEM-I(ME2104) L T P C

CH VASU Subject Name: Manufacturing Processes 3 0 0 4

Total Contact Hours– 90
Prerequisite : None
Course Learning Objectives: The objective of this course is to
1. To have proper knowledge on various manufacturing processes.
2. To have proper knowledge on cost effective material options based on the near net
shape and surface finish.
3. To understand the problems of a component during its manufacturing.
4. To understand the steps involved in manufacturing a component.
5. To understand the effect of manufacturing processes on properties of a component.
6. To communicate more effectively with the industrial people in manufacturing
terminology.

******Lecture Plan*****

Lecture Topics to be Contact Monthly Refe e-Resources

covered Hours test rence Video Study
resources material
UNIT-I
Introduction
L-1 Introduction: 1 1,2,3
Engineering
materials and its 1. NPTEL, IIT-
properties Roorke, RGUKT
L-2 Classification of 1 1,2,3 Manufacturing Course
manufacturing Content
Process
processes Unit1&2 and
MT-1 URL: https://nptel.
L-3 Definitions of 1 1,2,3
Casting, welding, https://nptel.ac.i ac.in/courses
forming ,powder n/courses/11210 /nptel_downl
metallurgy. 7145/# oad.php?
subjectid=11
UNIT-II
2104195
Casting URL:https://npt
L-4 Introduction, 1 1,2,3 el.ac.in/courses
Advantages of /112104195/1
casting and its
applications
L-5 Steps involved in 1 1,2,3
making a casting,
Patterns and Pattern
making:
L-6 Types of patterns, 1 1,2,3
Materials used for
patterns, Pattern
allowances,
L-7 Moulding sand: 1 1,2,3
Molding sand
composition, Testing RGUKT
sand properties, Course
Sand Content
preparation
L-8 Reclamation of 1 1,2,3
molding sand, Core:
Core sands, Types of
cores
L-9 Core prints, 1 1,2,3
Chaplets, Forces
acting on the
molding flasks
L-10 Gating, Gating ratio 2 1,2,3
and Design of
Gating systems,
Core, Core print.
Crucible melting and
cupola operation,
Steel making
processes, Charge
calculations
L-11 Solidification of 2 1,2,3
casting, Concept,
Solidification of pure
metal and alloys,
L-12 Risers, Types 1 1,2,3
function and design,
Casting design
considerations,
L-13 Centrifugal, Die, 1 1,2,3
Investment,
L-14 CO2 Molding. 1 1,2,3
Casting
defects, Causes and
remedies.
UNIT-III
 Welding
L-15 Classification of 1 1,2,3
welding process, Arc
welding
L-16 Weld bead geometry, 2 1,2,3
V-I Characteristic
curves of power
source Unit 3
L-17 V-I Characteristic 1 MT-2 1,2,3
L-18 SMAW 1 1,2,3
L-19 SAW 1 1,2,3
L-20 GTAW,GMAW 2 1,2,3
L-21 CO2 welding, Gas 1 1,2,3
welding cutting
L-22 Resistance welding, 1 1,2,3
seam spot, projection
L-23 Upset and flash butt 1 1,2,3
welding
L-24 Heat affected zones 2 1,2,3
in welding, Methods
to minimize HAZ
L-25 Soldering & 1 1,2,3
Brazing: Types and
its applications
L-26 Thermit welding, 1 1,2,3
Friction welding,
Diffusion Bonding
L-27 Electron beam 2 1,2,3
welding, and Laser
beam welding.
Unit 4 Metal
Forming
Metal
L-28 Forming: Nature of 1 1,2,3
plastic deformation
L-29 Hot and cold 2 1,2,3
working, Strain Unit 4
hardening, Recovery, MT-3
Recrystallization and
grain growth
L-30 Rolling: Principle, 1 1,2,3
Types of rolling
mills
L-31 passes, Forces in 1 1,2,3
rolling and power
requirements
L-32 Extrusion: Basic 1 1,2,3
extrusion process
and its
characteristics
L-33 Hot extrusion 1 1,2,3
and cold extrusion,
L-34 Impact extrusion, 1 1,2,3
Hydrostatic
extrusion
L-35 Forging: Principles 2 1,2,3
of forging, Tools and
dies
L-36 Types: Smith 1 1,2,3
forging, Drop
Forging, Forging
hammers
L-37 Rotary forging, 1 1,2,3
forging defects
L-38 Wire Drawing. Sheet 1 1,2,3
metal forming
L-39 Spring back effect, 1 1,2,3
Stamping
L-40 Blanking, Bending, 2 1,2,3
Drawing, Piercing
L-41 Coining, Embossing, 1 1,2,3
Stretch forming
L-42 Hot and cold 1 1,2,3
spinning. Special
forming
L-43 Hydro forming, High 2 1,2,3
energy rate forming.
Unit 5 Powder
metallurgy
L-44 Powder metallurgy: 2 1,2,3
Introduction,
Production
L-45 characterization of 1 1,2,3
powders,
Compaction
L-46 Die compaction, and 1 1,2,3
Hot Isostatic
pressing
L-46 Sintering of powder 1 1,2,3
compacts
L-47 Post sintering 2 1,2,3
operations
 L-48 Applications. 1 1,2,3

Learning resources
Text book:
1. M. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and
Systems, 6th Edition, John Wiley & Sons 2016
References:
1. Savitha Sharma, Manufacturing processes, international publications 4th edition, 2011.
2. P.C. Sharma, “A text book of production technology”, S. Chand and Company, 4 th edition,
2003.
3. Rajendra Singh, Introduction to basic manufacturing processes: new age publications: 2 nd
edition, 2014.
Web resources:
1. Web resources:NPTEL, December 31, 2009, “Manufacturing Processes”
URL: https://nptel.ac.in/courses/112107145/
2. NPTEL, IIT- Kanpur, Introduction to Manufacturing Processes
URL: https://nptel.ac.in/courses/112104195/1
3. RGUKT Course Content
Course outcomes: At the end of the course, the student will be able to
CO 1 Explain various manufacturing processes.
Select the type of casting process one has to adopt for manufacturing a designed
CO 2 component.
CO 3 Choose the types of joining process required for joining of metals
CO 4 Demonstrate the deformation behavior of a material during processing.
CO 5 Define the advantages and applications of powder metallurgy
CO 6 Illustrate the operations of metal forming and forging.

For Theory courses only:

Course Nature Theory
Assessment Method
Assessment Weekly tests Monthly tests End Semester Test Total
Tool
Weightage (%) 10% 30% 60% 100%