Session: July-December
Course Number: MEM103
Course Title: MANUFACTURING PROCESSES I
Course Teachers: Prof. Rahul Swarup Sharma,
Dr. Gurmukh Das,
Dr. Kumar Ratnakar
Class: B.Tech.
Status of Course: Major Course, Approved since session: 2024-25
Total Credits: 3
Periods (55 mts. each)/week:3 (L:3+T:0+P:0+S:0), Min.pds./sem.:39
COURSE OBJECTIVE
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.
UNIT 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.
UNIT 2: SOLIDIFICATION PROCESSES
Pattern: Materials, types allowances and color codes. Elements of gating system.
Moulding: Process, tools, sand, materials, classification of moulds, methods (Shell, Sodium silicate-CO
2 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.
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: 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.
UNIT 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.
SUGGESTED READINGS:
MANUFACTURING PROCESSES FOR ENGINEERING MATERIALS: Serope Kalpakjian & Steven R. Schmid (Pearson Eduction)
DEGARMO’S MATERIALS & PROCESSES IN MANUFACTURING: J.T. Black & Ronald A. Kohser (John Wiley & Sons, Inc.)
MANUFACTURING PROCESSES: B.H. Amstead, Phillip F. Ostwald & Myron L. Begeman (John Wiley & Sons, Inc.)
PROCESSES AND MATERIALS OF MANUFACTURE: Roy A. Lindberg (PHI Learning Pvt. Ltd.)
WORKSHOP TECHNOLOGY (Vol. I to II): B.S. Raghuwanshi (Dhanpat Rai & Co.)
WORKSHOP TECHNOLOGY (Vol. I to III):W.A.J. Chapman (CBS Publishers & Distributors Pvt. Ltd.)
MANUFACTURING SCIENCE, Amitabh Ghosh & Ashok Kr Mallik (Affiliated East West Press Pvt. Ltd.)
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 Attendance | 10 |
| (Attendance Policy: below 65% = 0, 65% - 75% = 2, 75% - 85% = 4, 85% - 90% = 6, 90% - 95% = 8, 95% -100% = 10) | |
| Internal Marks | 150 |
| End Semester Examination | 50 |
| Total | 200 Marks |
Subsequently above numerical marks shall be converted to grades.