| Lecture 1. | What is manufacturing?, types of production systems, professionalism and ethics, evolution of manufacturing, socio-economic role of manufacturing, sustainable manufacturing, types of manufacturing processes. |
| Lecture 2. | General shop safety, safety guidelines for hand tools, safety helmet, ear protectors, face mask, eye protectors, welder's face mask, gloves and gauntlets, welder's apron, accidents - what to do, common hazards and their sources, emergencies - what to do, safety in - wood working, foundry, forging, welding, machine tools, electrical equipment, material handling equipment. |
| Lecture 3. | Properties of Materials, Engineering Materials, Type of materials, Chemical, Dimensional, Physical, Mechanical Properties. |
| Lecture 4. | Stress strain curve. Problems on strength of materials. |
| Lecture 5. | Ferrous metals & alloys. |
| Lecture 6. | Heat treatment process. |
| Lecture 7. | Non-Ferrous metals & alloys. |
| Lecture 8. | Review of unit-1, self check quiz of unit 1. |
| Lecture 9. | Introduction to casting process, advantages of casting process, applications, sand casting process, and production steps in a sand-casting process. |
| Lecture 10. | Casting terminology, gating system. Problems on gating system. Cupola furnace. |
| Lecture 11. | Pattern: making, functions, material, factors for selection of material, types, allowances. Problems on calculation of allowances. |
| Lecture 12. | Moulding, moulding sand, properties of moulding sand, types of moulds, moulding tools, procedure for making a mould, core. Moulding machines. |
| Lecture 13. | Casting defects. |
| Lecture 14 | Expendable-mould processes (Sand, plaster, ceramic, rubber and expendable-graphite mould casting, lost-wax and lost-form processes), Multi-use-mould processes (Gravity & pressure-die casting and centrifugal casting). |
| Lecture 15. | Expendable-mould processes (expendable-graphite mould casting, lost-wax and lost-form processes). |
| Lecture 16. | Expendable-mould processes (Multi-use-mould processes (Gravity & pressure-die casting and centrifugal casting). |
| Lecture 17. | Expendable-mould processes (Multi-use-mould processes centrifugal casting). |
| Lecture 18. | Review of unit-2, self check quiz of unit 2. |
| Lecture 19. | Fundamentals of metal forming, benefits & applications of forging, common metal forming processes, state of stress, cold and hot working. |
| Lecture 20. | Forging, open die hammer forging, impression die drop forging, press forging, drawing down or swaging, setting down, cutting out, punching and drifting, bending, welding or shutting, riveting. |
| Lecture 21. | Upset forging , swaging, rotary forging, roll forging. |
| Lecture 22. | Equipments of forging shop, forging hammers. |
| Lecture 23. | Drop hammers- mechanical friction board and belt type. |
| Lecture 24. | Wire drawing, wire drawing terms, die pull, drawing equipment. |
| Lecture 25. | Rolling process. |
| Lecture 26. | Spinning process. |
| Lecture 27. | Review of unit-3, self check quiz of unit 3. |
| Lecture 28. | Machining processes, lathe, constructional features of lathe. |
| Lecture 29. | Cutting tool for lathes, shapes of standard cutting tool. Types of lathe, turning, operating conditions in turning. |
| Lecture 30. | Milling, milling machine, constructional features of milling machine, classification of milling. Methods of milling. |
| Lecture 31. | Operating conditions in milling. |
| Lecture 32. | Shapers and planers, constructional features of shapers and planers, Shaping operation, slotters, planing operation. |
| Lecture 33. | Operating conditions in shaper. |
| Lecture 34. | Drilling, drilling machine (drill press), constructional features of drilling machine, types of drilling machines. |
| Lecture 35. | Cutting tool for drilling machine, nomenclature of twist drills. Operating conditions in drilling. |
| Lecture 36. | Review of unit-4, self check quiz of unit 4. |
| Lecture 37. | Principles of welding, advantages, disadvantages, applications, weldability, types and classification of welding process, autogeneous welding, heterogeneous welding, pressure welding, non-pressure welding, solidstate welding, fusion welding. Features of the completed weld, features of joints, types of welds and welded joints, types of fillet weld, size of the weld, welding positions, tips for arc welding, tips for gas welding. |
| Lecture 38. | Gas welding, welding techniques for gas welding, advantages, disadvantages, process variables for oxy-fuel welding, oxy-acetylene flame types, oxy-acetylene gas welding process, equipment used in oxy-acetylene welding, fluxes, characteristics of a good flux, filler metals. Features of a good fusion wield. |
| Lecture 39. | Basic electricity fundamentals, arc, arc welding, characteristics of manual arc welding process. Arc welding procedure, mechanics of arc, metal transfer in arc welding process from the tip of the electrode, polarity in welding, comparison between ac and dc arc welding, arc welding electrodes, arc welding equipment. Welding defects. |
| Lecture 40. | Resistance welding, characteristics of resistance welding, advantages, disadvantages, applications, Types of resistance welding, spot welding, seam welding, projection welding, flash welding, upset welding. |
| Lecture 41. | INTRODUCTION TO ADDITIVE MANUFACTURING (AM). |
| Lecture 42. | Classification of AM TECHNOLOGIES. |
| Lecture 43. | Review of unit-5, self-check quiz of unit 5. |
| Lecture 44. | Review of course. |