Conventional Manufacturing Process 20ME33

Prepared and Delivered by:

Vinayaka G P
Assistant Professor
Department of Mechanical Engineering
Vidyavardhaka College of Engineering, Mysuru
Ph. No :9880553655; E-Mail: vinay91gp@vvce.ac.in
 • This course deals with the fundamentals of manufacturing
process such as casting, forming, joining, and machining
Course process.

Overview • It also gives a comprehensive insight regarding the

mechanical equipment and operations involved to fulfil
various applications.
 1. To discuss fundamental concepts of manufacturing
Course Learning processes.
Objectives 2. To provide knowledge of manufacturing technology like
casting and metal joining processes.
3. To explain the constructional parts, the working principle
of manufacturing equipment.
 Module 01: Introduction to manufacturing and Moulding Sand

Manufacturing Process: Introduction, Classification of manufacturing process.

Metal Casting: Introduction about metal casting, Steps involved in making casting,

Advantages and limitations, Applications. Pattern making: Functions of pattern.

Classification of pattern, Different pattern materials.

Course Moulding sand: Types and properties of base sand, Types of binders and its functions,

Contents various types of additives and its functions. Moulding Processes- Green, Dry, Loam,

Skin dried moulding and CO2 Moulding. Core- definition and functions.
Textbook/s:
1.Manufacturing Technology Vol I by P.N. Rao, Third Edition, Tata McGraw Hill Pub.
Co. Ltd., New Delhi, 2013 (Ch.9- 9.1, 9.2.2, 9.4.1, 9.4.7, 9.4.8, 9.6, 9.7.4. Ch.10-10.1,
10.3-10.6, 10.8- 10.11)
2. Workshop Technology Vol I by B S Raghuwanshi, Dhanpat Rai & Co. (p) LTD, 2015.
(Ch.14 – 14.8, 14.9. Ch.15- 15.2, 15.25).
 Module 02:Gating System and Casting Processes

Gating System: introduction, requirements of gating system, Furnaces - Types of

furnaces, constructional features & working of Cupola, Resistance furnace,

Electric arc furnace, Induction furnace.

Course Casting Processes: Shell moulding, investment casting, Pressure dies casting,
Contents Defects in casting
Centrifugal casting, Squeeze casting, Continuous casting, Injection moulding,

Textbook/s:
1.Manufacturing Technology Vol I by P.N. Rao, Third Edition, Tata McGraw Hill
Pub. Co. Ltd., New Delhi, 2013 (Ch.5-5.1, 5.1.1, 5.1.3, Ch.6- 6.1-6.3, 6.6-6.9.)
2. Workshop Technology Vol I by B S Raghuwanshi, Dhanpat Rai & Co. (p) LTD,
2015. (Ch.15- 15.15, 15.16, 15.18, 15.19. ).
 MODULE 3: Metal forming

Metal Forming: Introduction and classification of metal forming processes. Hot and
cold working of metals.

Forging: Smith forging, drop forging and press forging, forging equipment, Defects in
forging. Rolling: Rolling process, Types of rolling mills, Variables of rolling process,
Course Rolling defects.

Contents Drawing and Extrusion: Drawing of wires, rods and pipes, classification of tube
drawing, variables of drawing process. Difference between drawing and extrusion.
Various types of extrusion processes.
Textbook/s:
1. Mechanical Metallurgy by George E. Dieter, Third edition, McGraw Hill Education,
2017. : Ch.15- 15.1, 15.4, Ch.16- 16.1, 16.2, 16.7. Ch.17- 17.1, 17.2, 17.8. Ch.18-
18.1, 18.7, 18.8. Ch.19- 19.1, 19.4
 MODULE 4: Metal Joining Processes

Metal Joining Processes: Introduction to joining processes, working principle

of Soldering and Brazing process.

Welding: Classification of Welding Processes, Types of joints, Principle of arc

Course and gas welding, Resistance welding-Spot welding, projection and seam
welding. Thermo chemical welding- thermit welding, Radiant energy welding-
Contents EBW and LBW, TIG welding, MIG welding, advantages and applications,
defects of welded joints.
Textbook/s:
1.Manufacturing Technology Vol I by P.N. Rao, Third Edition, Tata McGraw
Hill Pub. Co. Ltd., New Delhi, 2013. Ch.9- 9.1, 9.2.2, 9.4.1, 9.4.7, 9.4.8, 9.6,
9.7.4. Ch.10-10.1, 10.3-10.6, 10.8- 10.11.
 MODULE 5:Machining and Machine Tools

Metal Cutting: Introduction, Single point cutting tool nomenclature, Chip formation,
Orthogonal and Oblique cutting, Merchants circle diagram, analysis. Shear angle relationship,
tool wear and tool failure, tool life, effects of cutting parameters on tool life, Taylor's tool life
equation, numericals on Taylor's tool life equation.

Course Lathe: Parts of lathe machine, accessories of lathe machine, and various operations carried out
on lathe, Turret and Capstan lathe.

Contents Milling, Drilling :Up milling & down milling, Classification of milling machines, various
Milling operations. Drilling-Types of drilling machines, Drilling operations

Textbook/s:
1. Workshop Technology Vol II by B S Raghuwanshi, Dhanpat Rai & Co. (p) LTD, 2015. Ch.4-
4.1- 4.6, 4.12, 4.13, 4.17, 4.18, 4.26, 4.28, 4.30, 4.31. Ch.5- 5.1, 5.2, 5.4. Ch.6- 6.1- 6.3. Ch.7-
7.1, 7.14, 7.26, Ch.11- 11.1, 11.2, 11.4, 11.23, 11.28
 • A process by which individuals take the initiative, with or without the
assistance of others, in diagnosing their learning needs, formulating
learning goals, identifying human and material resources for learning,
and evaluating learning outcomes !

Self Module wise Self-Learning Outcomes

Learning
Module 01 Types of additives and its functions
Module 02 Gravity die casting
Module 03 Extrusion of seamless tubes
Module 04 Solid state welding - Friction, Explosive
Module 05 Tool signature
 1.Manufacturing Engineering and Technology by Serope Kalpakjain, Seventh Edition,

Addision Wesley Congmen Pvt. Ltd., 2018

2.Production Technology by HMT 2017

Referenc 3.Principles of metal casting by Richard W. Heine, Carl R. Loper Jr., Philip C.

e Books Rosenthal, Tata McGraw Hill Education Private Limited, 2017

4.Production Technology Vol I and II by Sharma, P.C, S. Chand & Company Ltd., New

Delhi, 2006
Course Outcomes
Upon completion of the course, the students will be able to:

CO1 Describe the fundamental principles of casting, forming, joining, and machining processes.

CO2 Apply the basic knowledge of manufacturing science to obtain the desired component.

CO3 Analyze the suitability of manufacturing processes and operations for various applications

CO4 Study the safety standards in manufacturing industries

 Course Assessment
Test 01 Test 02 Test 03
30 Marks
06 Dec 21 to 08 12-Jan-22 to 15 09-Feb-22 to 11-
Test (Avg of 03)
Dec 2021 Jan 22 Feb-22

10 Marks
CIE Mod 01 & Mod 03 &
Quiz (Avg of 02) Mod 05
50 Marks
Assessed for Mod 01 & 03
Mod 02 Mod 04

10 Marks
Activity Based Assessment 30 Marks 30 Marks 15 Marks
(ABA)

All 5 Modules
With 20 Marks each
SEE
100 Marks
(Converted to 50) Internal Choice for
Module 03 and
Module 05
 Activity Based Assessment (ABA)
• Study of accessories and safety standards used in manufacturing industries.

• This activity should be taken up after completion of module 3 or module 4.

• A batch consisting of 5-10 students will be given with a task of identification of safety practices

adopted in manufacturing firm, students shall visit an industry for this purpose.

• The activity conducted shall address the Program Outcome 06:The Engineer and the society.

• Students shall prepare a report covering the accessories and safety standards used in the manufacturing

industries and detail its impact on the effective performance of the firm, worker’s health etc.

• Students will present the report and evaluation will be done by respective course instructor.
 Massive Open Online Courses (MOOCs)
Course Title Course Course Link Program Outcome Addressed
Platform through MOOCs
Introduction to
Mechanical
https://www.coursera.org/learn/
Engineering Design
Coursera mechanical-engineering-design-
and Manufacturing
manufacturing
with Fusion 360 PO5 :Create, select, and apply
appropriate techniques, resources, and
Manufacturing modern engineering and IT tools
Process with Autodesk Coursera https://www.coursera.org/learn/ including prediction and modelling to
Fusion 360 manufacturing-process-fusion-360 complex engineering activities with an
understanding of the limitations
Simulation of
Manufacturing Coursera https://www.coursera.org/projects/
Process Using R manufacturing-simulation-r-simmer
Simmer