Unit No.

Topics to be Covered

Learning Outcomes

1.

INTRODUCTION TO MANUFACTURING: Manufacturing processes and their classification. Socio-economic role. Role of sustainability in manufacturing. Principles of Industrial Safety. Engineering Materials: Introduction, classification, properties, types and applications. Metallic materials (ferrous and non-ferrous metals & their alloys) and Non-metallic materials (Wood, ceramics & plastics). Elementary introduction to heat treatment.

Explain the classification of manufacturing processes and assess their socio-economic impact, role in sustainability and principles of industrial safety. (Understanding, Evaluating) Classify engineering materials and describe their properties, types, applications and basic heat treatment processes. (Understanding, Applying)

2.

SOLIDIFICATION PROCESSES: Pattern: Materials, types, allowances, and color codes. Elements of the gating system. Moulding: Process, tools, sand, materials, classification of moulds, methods (Shell, Sodium silicate-CO₂ and vacuum moulding). Machines. Cores. Melting furnaces and their operation. Casting: 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). Casting defects

Identify materials, types, and allowances of patterns and explain the components and design of the gating system in moulding. (Remembering, Understanding) Analyse different casting processes (expendable and multi-use moulds) and identify common casting defects. (Analysing, Applying)

3.

DEFORMATION PROCESSES: Bulk Deformation Processes: Basic concepts of plastic deformation. Hot & cold working of metals. Theory and principle of common bulk deformation processes (Rolling, forging, extrusion and drawing).  Drop forging hammers (Mechanical, friction board and belt type) and Forging presses. Metal forming defects. Sheet Metal Processes: Introduction.

Differentiate between hot and cold working of metals and explain the fundamental principles of bulk deformation processes like rolling, forging, extrusion, and drawing. (Understanding, Analysing) Examine metal-forming equipment, such as forging hammers and presses, and identify common metal-forming defects. (Analysing, Understanding)

4.

MATERIAL-REMOVAL PROCESSES: Introduction to Material-removal processes, Cutting Tools, Machine Tools, Tool Wear & Coolants. Construction, specification, working principles and operations of following machine tools: Lathe, Drill, Milling, Shaper/Planer, and Grinder. Other Subtractive Manufacturing Techniques

Describe the principles, construction and operations of machine tools (lathe, drill, milling, shaper/planer and grinder), and classify cutting tools and coolants. (Understanding, Analysing) Analyse the causes of tool wear and suggest suitable coolants for specific material-removal operations to enhance efficiency. (Analysing, Applying)

5.

JOINING AND ADDITIVE MANUFACTURING PROCESSES:  Joining Processes: Gas welding, Arc welding and Resistance welding processes, Fluxes, Filler materials, Welding defects, Introduction to Additive Manufacturing Processes.

Explain the principles, materials, and equipment involved in gas, arc, and resistance welding processes and identify typical welding defects. (Understanding,
Evaluating) Describe the basics of additive manufacturing processes and compare them with traditional manufacturing techniques. (Understanding, Analysing)