Welcome Student Tentative Schedule of Lectures Lecture Notes MFVSL Home

Session: July-December
Course Number: MEM103
Course Title: MANUFACTURING PROCESSES I
Course Teachers: Prof. Rahul Swarup Sharma, Dr. Gurmukh Das, Shri Kumar Ratnakar
Class:
B.Tech.
Status of Course: Major Course, Approved since session: 2013
Total Credits: 3
Periods (55 mts. each)/week:4 (L:4+T:0+P:0+S:0), Min.pds./sem.:52

Course objectives
1. To gain an understanding and appreciation of the breadth and depth of the field of manufacturing.
2. To become familiar with a variety of manufacturing processes including their typical use and capabilities.
3. To become familiar with casting, forming, welding, and machining (metal cutting) processes.
4. To learn and apply the basic terminology associated with these fields.
5. To increase your technical understanding and broaden your perspective of the manufacturing world in which many of you will contribute your talents and leadership.

Course Description

UNIT 1: INTRODUCTION TO MANUFACTURING
Manufacturing Processes and their Classification. Socio-economic role. Sustainability.
INDUSTRIAL SAFETY: Introduction, Types of Accidents, Causes and Common Sources of Accidents, Methods of Safety, First Aid.
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.
WOOD & WOOD WORKINGTimber. Classification, structure, conversion, seasoning, defects and preservation of Timber. Joinery, Painting and Varnishing. Hand tools used in carpentry. Typical operations. Artificial woods. Adhesives.

UNIT 2: PRINCIPLES OF METAL CASTING
Pattern materials, types, allowance and color codes. Elements of gating system. Moulding: process, tools, sand, materials, classification of moulds, methods (Shell, CO2 and plaster), machines. Cores. Casting defects. Cupola and its operation. Special casting methods: Die casting, Centrifugal casting, Investment casting.

UNIT 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). Forging hammers, Drop hammers (Mechanical, friction board and belt type). Metal forming defects.
Sheet Metal Processes: Introduction

UNIT 4: WELDING
Gas and arc welding processes. Fluxes. Filler materials. Electrodes, Resistance welding-spot, seam, butt, projection and percussion. Types of joints and edge preparation.

UNIT 5: BASICS OF METAL CUTTING & MACHINE TOOLS
Introduction to Metal Cutting. Nomenclature of a Single Points Cutting Tool and Tool Wear. Use of Coolants in machining. Construction, specification, working principles and operations of machine tools such as Planer, Shaper, Slotter, Drill, Milling and Lathe. Estimation of speed, feed, depth of cut and time. SUGGESTED READINGS:
MANUFACTURING PROCESSES FOR ENGINEERING MATERIALS: Serope Kalpakjian and Steven Schmid, Pearson Education, India.
MATERIALS AND PROCESSES IN MANUFACTURING: E. Paul DeGarmo, J T. Black, Ronald A. Kohser, John Wiley India, India.
MANUFACTURING PROCESSES: B H Amstead, Phillip F Ostwald, Myron L Begeman, John Wiley India, India.
MANUFACTURING SCIENCE: Amitabha Ghosh & Ashok Kumar Malik, East-West Press. WORKSHOP TECHNOLOGY: W. A. J. Chapman and E. Arnold, Part-1, 2, 3, Viva low priced Student edition India.

Course Outcome
1. Given a part to be manufactured, identify candidate processes that are capable of creating the parts features.
2. Weigh tradeoffs between similar processes based on general advantages and disadvantages.

Grading:
Lecture Class Attendance10
(Attendance Policy: below 65% = 0, 65% - 75% = 2, 75% - 85% = 4, 85% - 90% = 6, 90% - 95% = 8, 95% -100% = 10)
Internal Marks150
End Semester Examination50
Total200 Marks
Subsequently above numerical marks shall be converted to grades.