GOVERNMENT POLYTECHNIC, NAGPUR.

(An Autonomous Institute of Govt. of Maharashtra)

COURSE CURRICULUM

PROGRAMME : DIPLOMA IN AUTOMOBILE ENGG.

LEVEL NAME : PROFESSIONAL COURSES
COURSE CODE : AE404E
COURSE TITLE : AUTOMOBILE MANUFACTURING PROCESS
PREREQUISITE : NIL
TEACHING SCHEME : TH: 03; TU: 00; PR: 02(CLOCK HRs.)
TOTAL CREDITS : 04 (1 TH/TU CREDIT= 1 CLOCK HR., 1 PR CREDIT = 2 CLOCK HR.)
TH. TEE : 03 HRs
PR. TEE : 02 HRs (External)
PT. : 01 HR

 RATIONALE:

There are many advances in manufacturing processes and equipments with the advent
of technology. The knowledge of these advances is essential for a diploma student engaged in
manufacturing organizations. As an Automobile Engineering Technician, a pass out of this
diploma programme, gets job either in assembly shop ACM or AM sector in Retailing,
Servicing, and Repairs sector and as he/she is required to analyses function of assembly and
failure of parts. Students should know basic & advance manufacturing process used.

 COURSE OUTCOMES:
After completing this course students will be able to–
1. Identify the advanced machining processes used in auto. manufacturing.
2. Select the different plastic processing methods.
3. Analyze the stages of manufacturing of metallic powder.
4. Perform the key way and gear cutting operations.
5. Apply the different surface cleaning and coating processes.
6. Use and operate the press for different operations.

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 AE404E Automobile Manufacturing Process 2016

 COURSE DETAILS:
A. THEORY :

Units Specific Learning Outcomes Topics and subtopics Hrs

(Cognitive Domain) .
1 Material 1. Classify the lathe. 1.1 Metal cutting operation:
10
Removal 2. Describe different types of Mechanics of metal cutting, types
Process chips. of chips
3. State the applications of 1.2 Lathes and lathe work:
Milling. Classification, Lathes operations.
4. Differentiate between 1.3 Drilling Machine: Types, drill
Lapping and Honing tools & applications
1.4 Milling machine: Types, milling
cutters, applications
1.5 Grinding, Lapping, Honing:
Machines, tools, & applications
2 Advanced 1. State the advantages of 2.1 Electric-discharge machining
08
EDM. (EDM)
Machining
Processes 2. Describe the AJM process. 2.2 Ultrasonic machining (USM)
3.List the applications of 2.3 Abrasive-jet machining (AJM),
ECM 2.4 Plasma arc machining (PAM)
2.5 Laser-beam machining (LBM)
2.6 Electrochemical machining (ECM)
2.7 Electron beam machining (EBM)
(Machine tools, process and
applications)
1. Describe Extrusion of 3.1 Extrusion of plastics
3Plastic 07
processing plastics. 3.2 Injection moulding – Plunger and
2. State industrial screw machines
applications of Transfer 3.3 Compression moulding
moulding. 3.4 Transfer moulding – Typical
3. Classify Injection industrial applications
moulding machines 3.5Blow moulding
4. Define Blow moulding.
1. State various processes used 4.1 Introduction
4 08
in Production of metallic 4.2 Production of metallic powder
Power powder. 4.3 Processing methods
Metallurgy 2. Enlist Advantages and 4.4 Advantages and Disadvantages
Disadvantages of Power and applications
Metallurgy. 4.5Secondary operations
3. Describe designing of Power
Metallurgy.
1. Define tumbling. 5.1-Selection and use of Surface
5 08
2. Describe electroplating. treatment and cleaning processes
Surface 3. State the applications of 5.2 Surface cleaning processes- Sand
treatment galvanizing. blasting, tumbling, alkaline, acid
4List the Surface finishing and electrolytic cleaning
process. 5.3 Surface coating processes-
electroplating, galvanizing, metal

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 AE404E Automobile Manufacturing Process 2016

spraying, painting.
5.4Surface finishing process-
polishing, buffing, burnishing.
1. Define Bending and 6.1 Introduction
6 07
forming. 6.2 Sheet metal working: Bending,
Press shop 2. Describe different types of forming & deep drawing.
process Press. 6.3 Difference between Punching,
3.Differentiatepiercing& piercing & blanking.
blanking. 6.4 Press - Types, construction &
4. List the Dies used in press. working.
6.5 Press tools-Dies, punches

Total Hrs. 48

B. LIST OF PRACTICALS/LABORATORY EXPERIENCES/ASSIGNMENTS:

Practicals Specific Learning Outcomes (Psychomotor Units Hrs.

Domain)
1 Perform different milling machine operations such Material 08
as key way cutting or gear cutting by indexing in a Removal
batch of 4 students. Process
2 Prepare a report on injection moulding (Job should Plastic 08
be selected from market utility). processing
3 Prepare metallic powder using any one production Power Metallurgy 06
method.
4 Prepare industrial visit report on different surface
Surface treatment 06
treatment and surface finishing processes.
5 Operate the Press for different operations with the Press shop 04
Batch of 4 students. process

Total Hrs. 32

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 AE404E Automobile Manufacturing Process 2016

 SPECIFICATION TABLE FOR THEORY PAPER:

Unit Units Levels from Cognition Process Dimension Total Marks

No.
R U A

Material Removal
01 04(02) 08(08) 08(00) 20(10)
Process
Advanced Machining
02 02(00) 04(00) 06(06) 12(06)
Processes
03
Plastic processing 02(00) 06(04) 00(00) 08(04)

04
Power Metallurgy 02(00) 08(00) 00(06) 10(06)

05 Surface treatment 00(02) 04(00) 00(00) 04(02)

Press shop process 06(04) 04(08) 06(00) 16(12)
06

Total 16(08) 34(20) 20 (12) 70 (40)

R – Remember U – Understand A – Analyze / Apply

 QUESTION PAPER PROFILE FOR THEORY PAPER:

Q. Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6

option
No T L M T L M T L M T L M T L M T L M
1 A 2 2 R 2 3 R 2 4 R 2 6 R 2 1 R 2
01 5/7
5 R 2
02 1 R 4 1 U 4 2 U 4 1 U 4 6 U 4 3/5
03 6 U 4 4 U 4 5 U 4 1 U 4 6 U 4 3/5
04 1 U 4 4 U 4 6 U 4 3 U 4 6 R 4 3/5
05 3 U 6 2 A 6 4 A 6 2/3
06 1 A 6 6 A 6 2 A 6 2/3
T= Unit/Topic Number L= Level of Question M= Marks

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 AE404E Automobile Manufacturing Process 2016

 ASSESSMENT AND EVALUATION SCHEME:

To Max Min Evidence Course

What Frequency
Whom Marks Marks Collected Outcomes
Two PT
Test
Progressive (average of
20 -- Answer 1, 2, 3
Assessment)
(Continuous

Test (PT) two tests will

Sheets

Students
Direct Assessment Theory

be computed)
CA

Assignment
Assignments Continuous 10 -- Book / 1, 2, 3
Sheet
Examination)
(Term End

Theory
TEE

End of the
End Exam Students 70 28 Answer 1, 2, 3
Course
Sheets

Total 100 40

Skill Rubrics &

(Continuous Assessment)

Assessment Continuous 20 -- Assessment 4,5,6

Sheets
Students
Direct Assessment Practical

CA

Journal
Writing Continuous 05 -- Journal 4,5,6

TOTAL 25 10
Examination)
(Term End

Rubrics &
TEE

End Exam End Of the Practical

Students 50 20 4,5,6
Course Answer
Sheets

After First
Indirect Assessment

Student Feedback on
Progressive Student Feedback Form
course
Test
Students 1, 2, 3, 4,5,6

End Of The
End Of Course Questionnaires
Course

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 AE404E Automobile Manufacturing Process 2016

 SCHEME OF PRACTICAL EVALUATION:

S.N. Description Max. Marks

1 Selection of equipment’s. writing procedure etc. 20

2 Drawing block diagram, 10

3 Calculation, Result, (if any ) 10
5 Viva voce 10
TOTAL 50

 MAPPING COURSE OUTCOMES WITH PROGRAM OUTCOMES:

Program Outcomes (POs) PSOs

Course Outcomes
1 2 3 4 5 6 7 8 9 10 1 2

1 - 3 3 3 - - - - - 3 3 3

2 - 3 3 3 - - - - - 3 - 3

3 - 3 3 3 - - - - - - - 3

4 - 3 3 3 - - - - -- - 3 3

5 - 3 3 3 - - - - -- - 3 3

6 - 3 3 3 - - - - - - 3 3

1- Slight (Low) 2-Moderate ( Medium) 3 –Substantianl (High)

 REFERENCE & TEXT BOOKS:

Author, Publisher, Edition
S.N. Title ISBN Number
and Year of publication
1. Elements of Workshop S. K. HajraChoudhury 8185099146,
Technology Vol. –I & II A.K. HajraChoudhury 9788185099149
Media Promoters, 1st South
Asian Edition,2009
2. Production Technology H.M.T., Tata McGraw-Hill 0070964432,
Education, 1 stEdition, 2001 9780070964433
3. Production Technology 9788174090997
R.K.Jain, Khanna Publishers,
17th Edition, 2014
4. Manufacturing Processes B. H. Amstead, Phillip F. 0471842362, 978-
Ostwald, , Myron L. 0471842361

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 AE404E Automobile Manufacturing Process 2016

Begeman, John Wiley &

Sons, 8th Edition. January
1987
5. Manufacturing Technology 9780070087699
Rao P N,TataMcgraw Hill
Vol. –II
Education Private Limited, 2nd
Edition, 2011

 E-REFERENCES:

 http://www.learnerstv.com/video/Free-video-Lecture-7700-Engineering.htm ,
assessed on 30th June 2016
 http://nptel.ac.in/courses/112104028/, assessed on 30th June 2016
 https://www.youtube.com/watch?v=Y0dWIRfwZhc, assessed on 30th June 2016
 https://www.youtube.com/watch?v=HZW5ksBvkO8, assessed on 30th June 2016

 LIST OF EXPERTS & TEACHERS WHO CONTRIBUTED FOR THIS

CURRICULUM:

S.N. Name Designation Institute / Industry

Dr.K.S.Dixit I/C, Head of Automobile Government Polytechnic,
1.
Engineering Nagpur.
Mr.Syed J.M. Lecturer in Automobile Government Polytechnic,
2.
Engineering Nagpur.
Mr.S.D. Thakare Lecturer in Automobile Government Polytechnic,
3.
Engineering Nagpur.
Mr.V.S. Kumbhar Lecturer in Automobile Government Polytechnic,
4.
Engineering Nagpur.
Mr.R.B.Tirpude Lecturer in Automobile Government Polytechnic,
5.
Engineering Nagpur.
Mr. A.A.Ozarkar Lecturer in Automobile Government Polytechnic,
6
Engineering Nagpur.
Mr K.L.Kirpane Manager Training Section Mahindra institute of
7 learning Excellence
Nagpur
Mr P.N.Wadaskar Assistant Professor Anjuman college of
8
engineering Nagpur
Mr M.D.Jadhao Head of Department GH Raisoni Polytechnic
9
Automobile Engineering Nagpur
Mr. P.C.Nichat Head Training Section Ashok Leyland Training
10
Centre Nagpur
11 Mr. Abhas Disawal Enterpreneur Kalimbi Venture Nagpur

(Member Secretary PBOS) (Chairman PBOS)