BAHIR DAR UNIVERSITY

BAHIR DAR INSTITUTE OF TECHNOLOGY

MECHANICAL ENGINEERING PROGRAM
Course Number MEng 3142
Course Title Manufacturing Engineering I
Degree Program B.Sc. in Mechanical Engineering
Module Manufacturing Engineering
CP 6
Contact Hours Lecturer Tutorial Practice or Laboratory Home study
2 2 4 4
Course Objective The course enables students to understand:
• Basic traditional machining processes, their principles, tool
geometry, wear of tools, force and power on traditional machine
tools and measures to achieve optimization;

• Basic nontraditional machining operation and their principles;

• Basic concept of casting process, design of cast, casting defect and
their remedies.
Course Description Systematic survey on the most important production processes in the
metalworking industry; Traditional machining processes: Selected process
principles, kinematics, geometry, forces and power, tool wear and tool life,
productivity, optimization; Nontraditional machining processes: Introduction
to electric discharge machining, chemical machining, electrochemical
machining, abrasive flow machining, abrasive jet machining, and ultrasonic
machining; Fundamentals of casting processes: types and classification,
Patterns; Molding materials; Molding sand properties; Core sands; Elements of
gating systems; Casting Design (gating systems: risers, runners, etc); Melting
practice; Cupola furnace; Special casting processes; Defects in castings.

Course Content 1. Introduction: Systematic survey on the most important production

processes in the metalworking industry.

2. Fundamentals of Casting Processes: Types and classification,

Patterns; Molding materials; Molding sand properties; Core sands;
Elements of gating systems; Casting Design (gating systems: risers,
runners, etc); Melting practice; Cupola furnace, and Defects in
 castings.
3. Special Casting Processes: Expendable mold casting processes like-
Sand mold, Shell, Expendable pattern, Plaster, Ceramic, and
Investment casting processes. Permanent mold casting Processes like-
Slush, Pressure, Die casing, Centrifugal, Squeeze and Semisolid
metal forming.

4. Traditional Machining Processes: Selected process principles,

kinematics, geometry, forces and power, tool wear and tool life,
productivity, and optimization.

5. Non-Traditional Machining Processes: Introduction to electric

discharge machining, chemical machining, electrochemical
machining, abrasive flow machining, abrasive jet machining, and
ultrasonic machining.

Laboratory Exercises 1. Molds and pattern making, sand casting of lights metals, sand casting
of ferrous metals and centrifugal casting and
2. Practicing of non-traditional machining process.

Pre-requisites Engineering Materials I

Year / Semester Year III / Semester II
Mode of delivery Semester based
Status of Course: Compulsory
Teaching and • Lectures supported by tutorials,
Learning methods
• Industrial visit (optional) and
Lab exercise.

Evaluation and 35% Continuous Assessment (Assignment, Quiz and Lab report)
Grading System 25% Mid Exam
40% Final Exam Editing is required
Attendance • Minimum of 85% attendance during lecture hours, and
Requirements • 100% attendance during practical work sessions, except for some
unprecedented mishaps.

Literature Textbook:
Mikell P. Groover, Fundamentals of Modern Manufacturing:
Materials, Processes, and Systems (5th Edition), John Wiley & Sons,
2013.
References:
1. Serope Kalpakjian & Steven R. Schmid, Manufacturing Engineering
and Technology (4th Edition), Jun 15, 2000.

2. Hwaiyu Geng, Manufacturing Engineering Handbook, Mar 1, 2004.

3. James G. Bralla, Handbook of Manufacturing Processes - How
Products, Components and Materials Are Made, Jan 15, 2007.

4. John A. Schey, Introduction to Manufacturing Processes (McGrawHill

Series in Mechanical Engineering & Materials Science), Mar 1, 2000.

5. Winkelmann, Manufacturing Engineering (Teaching materials),

Technical University of Dresden, 1982.

6. Beddoes J., Principles of Metal Manufacturing processes, John Wiles

& Sons Inc. New York, 1999.

7. Rao P.N., Manufacturing Technology, second edition, Tata McGraw

Hill Publishing Company Limited , New Delhi , 1998.