MANUFACTURING AND PRODUCTION PROCESSES 5.3.

Forging practice and Technology; Press and hammers, tooling design,

ME 551 manufacture wear
Lecture : 3 Year : II 5.4. Design of Forgings; Characteristics and defects in forgings
Tutorial : 0 Part : II 5.5. Flat Rolling; Characteristics and defect in forgings
Practical : 4 5.6. Shape Rolling: Process and Products
5.7. Extrusion
Course Objectives: 5.8. Wires, Bar and Tube Drawing
To impart knowledge and skills in the field of manufacturing and production
6. Sheet Metal Product Manufacturing Process (4 hours)
processes. To make students familiar with different metal forming processes along
6.1. Shearing and Punching Operations
with advanced manufacturing techniques used in modern industries.
6.2. Sheet Metal and Tube Bending: Technology and Practices
6.3. Deep Drawing and Hydro forming
1. Overview of Manufacturing (2 hours)
6.4. Spinning Operations and Capabilities
1.1. Introduction
6.5. Formability Assessment
1.2. Product Cycle
1.3. Material Flow and Processing
7. Material Removal Processes: “ Chip-forming” (6 hours)
1.4. Information Flow
7.1. Modeling the cutting process
1.5. Evolution of Organization for Manufacture
7.2. Force, Power and Productivity Relationship
7.3. Cutting tools Materials: Characteristics and Economics
2. Manufacturing Properties of Materials (3 hours)
7.4. General Purpose Machine Tool Types
2.1. Mechanical Properties of Solids
2.1.1 Operation of Lathes, Milling, Shapers and Drilling Machines
2.2. Deformation of Solids
2.1.2 Application of Shaping, Planning and Slotting Machines
2.3. Thermo Fluid Properties of Liquids
7.5. Methods of mounting of jobs and cutting tools in machine tools
2.4. Tribology in Manufacturing
7.6. Uses of various attachments in machine tools
7.7. Control of Machine Tools and Product Properties
3. Properties of Manufactured Products (3 hours)
7.8. Cutting off Process: Saws, flame cutting, arc cutting
3.1. Geometrical Description and Tolerances
3.2. Dimensioning and Tolerances Control
8. Material Removal Processes: “Abrasive and Non-Traditional” (3 hours)
3.3. Surface Configurations
8.1. Abrasive Based Tooling
3.4. Residual Stresses
8.2. Grinding Technology and Practice
8.3. Electrical discharge machining
4. Solidification Process and Powder Metallurgy (6 hours)
8.4. Electrochemical machining
4.1. General Characteristics of Casting Process and Products
4.2. Solidification Phenomena and Associated problems
9. Numerical Control of Machine Tools (3 hours)
4.3. Sand Casting: Process Characteristics and Capabilities Pattern design
9.1. Need for Flexible Automation and Numerical controls
4.4. Investment Casting: Characteristics and Capabilities; Pattern Design and
9.2. CNC Machine tool description; technology and practices
Manufacturing
9.3. Introduction to CNC Machine Par Programming
4.5. Permanent Mould and Pressure Die Casting: Process characteristics and
9.4. Justification of CNC process
capabilities Part design
9.5. Industrial Robots
4.6. Continuous Casting Characteristics and Capabilities
4.7. Introduction to Powder Metallurgy
10. Jigs and Fixtures for Machine Shops (2 hours)
5. Bulk Deformation Process (6 hours)
10.1. Purpose of jigs and fixtures
5.1. General Characteristics of Bulk Deformation Process and Products
10.2. Design and application of typical jigs and fixtures
5.2. Force, Energy and Deformation: Sensitivity to frictions, geometry, temperature
and deformation rate
11. Screw Threads and Gear manufacturing Methods (3 hours)
 11.1. Production of Screw Threads by Machining, Rolling and Grinding 2 4&8 all 16
11.2. Manufacturing of Gears 3 5&9 all 16
12. Material Joining Processes (4 hours) 4 6, 10 &12 all 16
12.1. Principle of Material Joining Process, Types 5 7 & 11 all 16
12.2. Mechanical vs. welded/brazed Connections Total 80
12.3. Introduction to the Metallurgy of welding
12.4. Characterization of Energy Sources
12.5. Arc-welding Processes
12.6. Combustion Torch Processes
12.7. Resistance welding processes
12.8. Design Considerations and Defects Analysis

Practical:
1. Workshop Practical should include the following processes:
2. Solidification and Bulk Deformation Processes
3. Sheet Metal Working
4. Engine Lathe Operations
5. Shaper Operations
6. Milling Machine Operations
7. Drilling Machine Operation
8. Grinding Machine Operation
9. Arc Welding
10. Gas Welding

References:
1. Serope Kalpakjian and Steven R. Schmid, “Manufacturing Engineering and
Technology”, Addison Wesley Longman (Singapore) P. Ltd.
2. Serope Kalpakjian and Steven R. Schmid, “Manufacturing Processes for Engineering
Materials”, Pearson Education, Fourth Edition.
3. J. A. Schey, “Introduction to Manufacturing Processes”, McGraw Hill.
4. L. E. Doyleetal, “Manufacturing Processes and Materials for Engineers”, Prentice
Hall.
5. M. C. Shaw, “Metal Cutting Principles”, Oxford University Press.
6. B.S. Nagendra Parashar and R. K. Mittal, “Elements of Manufacturing Processes”,
Prentice Hall of India Pvt Ltd, New Delhi.

Evaluation Scheme:
The questions will cover all the chapters of the syllabus. The evaluation scheme will
be as indicated in the table below:

Unit Chapter Topics Marks

1 1, 2 & 3 all 16