Course Code: MEC303

Course/Subject Name: Production Processes

Credits: 04

Module No. Details Hrs

1 Introduction to Production Processes and Metal Casting: Classification of 4
Production Processes and applications areas Machine moulding, Types of
riser, types of gates, solidification
Special casting processes: CO2 and shell moulding, Investment casting, Die
casting, Vacuum casting, Inspection
2 Joining Processes: Classification of various joining processes; Applicability, 5
advantages and limitations of Adhesive bonding, Mechanical Fastening;
Welding and allied processes, Hybrid joining processes. Classification and
Working of various welding methods: Chemical, Radiant, Solid State,
Welding Joints, Welding Positions and their remedies.
Module No. Details Hrs
3 Forming processes: Introduction and classification of metalworking 3
processes, hot and cold working processes. Defects in rolled and forged
components, Classification and analysis of wire and tube drawing processes.
Sheet metal working processes: Classification of Sheet metal operation
4 Machine Tools and Machining Processes: Grinding Machines and selection of 3
grinding wheel (Dressing and Truing), Broaching machines, Lapping/Honing
machines (Super Finishing Operations) and planning Machines.
Gear Manufacturing Gear milling, standard cutters and limitations,
Tool Engineering Taylor’s tool life equation
5 Polymer Processing: Polymer Moulding Techniques for thermoplastic and 5
thermosetting plastics. Applications of Plastics in engineering field. Powder
Metallurgy: Introduction to PM, Powder making processes, Steps in PM.
Compaction and Sintering processes. Secondary and finishing operations in PM
Intelligent manufacturing in the context of Industry 4.0, Cyber-physical systems
(CPS) 5 Internet of Things (IoT) enabled manufacturing Cloud Manufacturing
Grinding wheel:-
• A Grinding wheel is a multi - tooth cutter made up of many hard particles known
as abrasive which have been crushed to leave sharp edges which do the cutting.
• The abrasive grain are mixed with a suitable bond, which acts as a matix or
holder when the wheel is in use.
• The wheel may consist of of piece or of segments of abrasive blocks built up
into a solid wheel.
• The performance of a grinding wheel is usually evaluated in term of the grinding
ratio (G) which is defined as:
G = Volume of material required / Volume of wheel wear
 Dressing of Grinding wheel:
Grinding wheel cutting edges will become blunt
after some period of operation due to loading or
may be glazing, sharpening of wheel again is
called wheel dressing.
In the process of sharpening wheel may loose its
circular cross section, making it again circular is
called wheel truing.
This is done to make the wheel true concentric
with the bore.
Truing & dressing are done with the same tool,
but not for the same purpose.
• Selection of Grinding Wheel:-

• Selection of proper grinding wheel is very important to obtain good results in

grinding operations. It may be required to perform various different functions like
quick removal of stock material, give a good surface finish, maintain close
dimensional tolerance etc.
• The factors to be considered while selecting the grinding wheel are classified as:-
• Constant factors
• Variable factors
Constant factors:-
1. Material to be ground 2. Amount of stock to be removed
3. Area of contact 4. Type of grinding machine
Variable factors:-
1.Wheel speed 2.Work speed
3.Condition of the grinding machine 4.Personal factors
Material to be ground:- This influence the selection of:
a) Abrasive b) Grain size
c) Grade & d) Structure
a. Abrasive:- Either of the abrasive is hard enough grind most of the materials. But,
silicon carbide is most suitable for grinding materials of low tensile strength, while
aluminium oxide is most efficient when applied to hard, tough materials.
b. Grain size:- The grain size will largely influence the finish given to the work & the
freeness with the wheel cut.
c. Grade:- The general rule for determination of the most suitable grade is “a” hard
wheel for soft work & a soft wheel for hard work.
d. Structure: Generally soft, tough & ductile materials and heavy cuts require an
open structure, whereas hard and brittle materials & finishing cuts require a dense
structure.
Amount of stock to be removed: Coarse grains are used for fast removal of metal &
fine grains for good finish.
Area of contact: When area of contact is large coarse grains and wide grains spacing
are employed. Where as, fine grain & close grain spacing are useful where the area of
contact involved is small.
Type of Grinding machine: Light machines subject to vibration & machine in poor
condition require harder wheels than heavy, rigidity constructed and well maintained
machines.
Wheel speed: Generally, higher the wheel speed in relation to work speed, the softer
the wheel should be.
Work speed: A high work speed means more material ground in a given time & greater
wear on the wheel.
Condition of the Grinding machine:- Loose spindle bearings, shaky conditions etc
require the use of harder wheel to overcome rapid wheel wear.
Personal factor:- A skilled operator can work with softer wheel than one who is not
skilled & hence obtain better & more economical production.
Gear Cutting by Milling
• Gear Cutting by a Formed Disc Cutter:
 Spur, helical, worm and straight bevel gears can be cut on a milling machine with the
help of a dividing head. With proper attachment racks can also be cut on a milling
machine.
 Spur gear are cut on a plain or universal milling machine by the use of a rotating milling
cutter.
In cutting spur gears the following procedure is adopted:
• The dimension and proportions of the gear tooth element are determined.
• The gear blank is prepared to the required size
• A proper module or D. P. cutter is selected and mounted on the arbor.
• Proper speed of the cutter, feed of the table, and the depth of cut are determine.
• The dividing head and tailstock are bolted on the table.
• The mandrel on which the gear
blank is mounted is fixed on the
centres of dividing head spindle
and tailstock.
• The proper index plate is bolted on
the dividing head and the position
of the crank pin and sector arm
adjussted.
• Fig shows a typical set up for
cutting a spur gear by a disc cutter
and fig. illustrates spur gear
cutting operation.
• The cutter is properly adjusted so that its plane of
rotation is radial with respect to the gear blank.
• The indexing movements are determined and the
setor arms and crank pin adjusted accordingly.
• The table is then moved upwards to adjust the
required depth of cut.
• The longitudinal feed of the table is then engaged.
• The gear blank moves under the rotating cutter and
the tooth space is cut.
• After this, the gear blank is indexed to the next
position for cutting the second tooth space.
• This procedure is repeated until all the teeths are
cut on the periphery of the blank.
Gear Cutting by a Formed end mill:
• For cutting teeth of coarse pitch gear or
finishing the teeth of cast gears end mill cutters
are used.
• The cutting edges of the end mill cutter are
formed to correspond to the tooth space of a
gearcto be cut.
• The cutter is mounted straight on the milling
machine spindle through a chuck.
• The cutting process is similar to that of a gear
cutting by a disc cutter.
Limitations:
• It is not a production process, since each tooth space is machined separately and
tme is lost in returning to its initial position.
• The pitch accuracy is very much dependent upon the accuracy of the dividing
head.
• Internal teeth can not be cut.
Types of milling cutters:

1. Plain milling cutters. 6. Anglular milling cutters.

2. Face milling cutters. 7. Metal slitting cutters.
3. Profile milling cutters. 8. Wood ruff-key milling cutters.
4. End milling cutters. 9. T-slot milling cutters.
5. Side milling cutters.
Nomenclature of a milling cutter
Plain milling cutters: