Manufacturing Technology-I (3-0-0-3)-UG

POWDER METALLURGY: Introduction to powder metallurgy, production of metal

powders, compaction and sintering processes, secondary and finishing operations, economics,
advantages and applications of powder metallurgy.

METAL CASTING: Introduction, brief history, advantages, limitations and applications,

patterns, pattern materials, allowances, types of pattern, sand casting, green and dry sand
casting process, types of sand, moulding sand and its properties, moulding sand composition,
use of cores, core material, core prints, special moulding processes, die casting process,
investment casting process, continuous casting process, vacuum-sealed casting process,
casting defects, causes and remedies of defects, melting practices, working of induction
furnace, crucible furnace, muffle furnace.

WELDING: Principle of welding, applications, classification of welding processes, soldering

and brazing, gas welding, types of flames, arc welding, shielded metal arc welding, gas metal
arc welding, tungsten inert gas arc welding, submerged arc welding, resistance welding,
friction stir welding, welding defects.

METAL FORMING: Elastic and plastic deformation, concept of strain hardening, hot and
cold working processes, rolling, forging, extrusion, swaging, wire and tube drawing,
machines and equipment for the processes, parameters and force calculations, test methods
for formability, sheet metal working, shearing mechanism, processes like blanking, piercing,
punching, trimming, forming processes like bending, cup drawing, coining, embossing,
presses for sheet metal working, elements of die, punch and die clearances, high energy rate
forming processes, applications of sheet formed products.

Text Books:
1. P. N. Rao, Manufacturing Technology: Foundry, Forming and Welding, Volume I, Tata
McGraw Hill, 2008.
2. A. Ghosh and A. K. Mallik, Manufacturing Science, Wiley Eastern, 1986.

Reference Books:
1. S. Kalpakjian and S. R. Schmid, Manufacturing Processes for Engineering Materials,
Pearson education, 2009.
2. J. S. Campbell, Principles of Manufacturing Materials and Processes, Tata McGraw Hill,
1995.
3. F. C. Flemmings, Solidification Processing, Tata McGraw Hill, 1982.
4. P. C. Pandey and C. K. Singh, Production Engineering Sciences, Standard Publishers Ltd.,
2003.
 Manufacturing Technology-II (3-1-0-4)-UG

INTRODUCTION: Classification of metal removal processes and machine tools, concepts

of machining, basic working principle, configuration, specification and classification of
machine tools.

MECHANICS OF MACHINING: Geometry of single point cutting tools, conversion of

tool angles from one system to another, mechanism of chip formation, orthogonal and
oblique cutting, use of chip breakers in machining, machining forces and Merchant’s Circle
Diagram (MCD), analytical and experimental determination of cutting forces, dynamometers
for measuring cutting forces, cutting temperature-causes, effects, assessment and control,
cutting fluid application.

MACHINABILITY: Concept of machinability and its improvement, failure of cutting tools

and tool life, cutting tool materials of common use, advanced cutting tool materials.

GENERAL PURPOSE MACHINE TOOLS: Kinematic systems and operations of lathe,

drilling machines, milling machines, construction, working principle and applications of
shaping, planning and slotting machines, job mounting and cutting tools in machine tools,
estimation of machining time, forces developing and acting in machine tools.

ABRASIVE PROCESSES: Basic principle, purpose and application of grinding, selection

of wheels and their conditioning, classification of grinding machines and their uses, super
finishing processes, honing, lapping.

SCREW THREADS AND GEAR MANUFACTURING METHODS: Production of

screw threads by machining, rolling and grinding, manufacturing of gears.

NON-CONVENTIONAL MACHINING: Classification of non-conventional machining

based on energy type, abrasive jet machining, water jet and abrasive water jet machining,
ultrasonic machining, electro chemical machining, electro discharge machining, electron
beam and laser beam machining.

SEMIAUTOMATIC AND AUTOMATIC MACHINE TOOLS: Numeric control,

computer numeric control machines, CNC part programming, computer integrated
manufacturing.

Text Books:
1. P. N. Rao, Manufacturing Technology: Foundry, Forming and Welding, Volume II, Tata
McGraw Hill, 2008.
2. A. Ghosh and A. K. Mallik, Manufacturing Science, Wiley Eastern, 1986.
3. G. K. Lal, Introduction to Machining Science, New Age International Pvt. Ltd., 2007.

Reference Books:
1. S. Kalpakjian and S. R. Schmid, Manufacturing Processes for Engineering Materials,
Pearson education, 2009.
2. M. C. Shaw, Metal Cutting Principles, MIT Press, 2004.
3. P. K. Mishra, Non-conventional Machining, Narosa Publishing House, 1997.
4. A. B. Chattopadhyay, Machining and Machine Tools, Wiley, 2011.
Computer Aided Design and Graphics (3-0-0-3) - UG
 Principles of Product Design (3-0-0-3) – UG

INTRODUCTION: Product design definition and evolution, product design morphology,

product life cycle, product policy of an organization, selection of a profitable product,
product design process, product analysis.

PRODUCT DESIGN: Flow charting, creativity techniques, translating customer needs,

product development process.

VALUE ENGINEERING IN PRODUCT DESIGN: Advantages, applications in product

design, problem identification and selection, functional analysis, functional analysis system
techniques (FAST), case studies.

PRODUCT DESIGN TOOLS: Quality function development (QFD), computer aided

design, robust design, design for excellence, design for manufacturing, design for assembly,
ergonomics in product design.

PRODUCT COSTING: Elements of product cost, life cycle costing, material selection,
metals and alloys, plastics, ceramics, rubber.

DESIGN FOR MANUFACTURING AND ASSEMBLY: Guidelines, product design for

manual assembly, design guidelines for metallic and non-metallic products to be
manufactured by different processes such as casting, machining, injection moulding etc.,
rapid prototyping, needs, advantages, working principle of stereolithography, laminated
object manufacturing, selective laser sintering.

Text Books:
1. S. Eppinger and K. Ulrich, Product design and development, McGraw Hill Higher
Education, 2015.
2. E. B. Magrab, S. K. Gupta, F. P. McCluskey and P. Sandborn, Integrated product and
process design and development: The product realization process, CRC Press, 2009.

Reference Books:
1. G. Boothroyd, Product design for manufacturing and assembly: Computer Aided Design,
26 (7), pp 505-520, 1994.
 Workshop Practice II (0-0-2-1) – UG

1. Introduction to machine tools and machining processes.

2. Types of cutting tools, selection of cutting speeds and feeds.

3. Simple machining operations on lathe, shaper, drilling, milling and grinding machines.

4. Modern trends in manufacturing, automation, NC/CNC, FMS, CAM and CIM.

Text Books:
1. H. Choudhary and N. Roy, Elements of Workshop Technology, Volume I and II, Media
Promoters and Publishers Pvt. Ltd., 2007.
2. W. A. J. Chapman, Workshop Technology, Volume I (2001), Volume II (2007) and Volume
III (1986), CBS Publishers.
3. H. Gerling, All about Machine Tools, New Age International, 1995.
 Mechanical Laboratory I (0-0-2-1) – UG

STRENGTH OF MATERIALS: Tensile testing of steel, hardness, torsion and impact

testing.

FLUID MECHANICS AND HYDRAULICS: Flow through restrictive passages like

orifice, venture-meter, weirs and notches, head losses in piping systems.
 Mechanical Laboratory VII (0-0-2-1) – UG

METALLOGRAPHY: Microscopic techniques, determination of volume fractions of

different phases in material including metals, estimation of grain sizes, study of heat affected
regions in welded steel specimens.

MACHINING PROCESSES: Measurement of tool angles and radius for single point
cutting tool, determination of cutting forces, shear plane, chip thickness ratio, profile
estimation using coordinate measuring machine.