Manufacturing Process

Course Objectives:

1. The students will have basic understanding of various manufacturing processes. The students will have knowledge about casting process.
2. The students will have understanding of joining processes.
3. The students will have understanding of forging and sheet metal works.
4. The students will have basic idea of powder metallurgy and manufacturing of plastic components.

Course Outcomes (CO):

• CO1 Understand casting process.
• CO2 Understand joining process.
• CO3 Understand forging and sheet metal work.
• CO4 Basic understanding of powder metallurgy and manufacturing of plastic components.

Unit I

Definition of manufacturing, Importance of manufacturing towards technological and social economic development, Classification of manufacturing processes, Properties of materials.

Metal Casting Processes: Sand casting, Sand moulds, Type of patterns, Pattern materials, Pattern allowances, Types of Moulding sand and their Properties, Core making, Elements of gating system. Description and operation of cupola.

Working principle of Special casting processes - Shell casting, Pressure die casting, Centrifugal casting. Casting defects.

Unit II

Joining Processes: Welding principles, classification of welding processes, Fusion welding, Gas welding, Equipments used, Filler and Flux materials. Electric arc welding, Gas metal arc welding, Submerged arc welding, Electro slag welding, TIG and MIG welding process, resistance welding, welding defects.

Unit III

Deformation Processes: Hot working and cold working of metals, Forging processes, Open and closed die forging process. Typical forging operations, Rolling of metals, Principle of rod and wire drawing, Tube drawing. Principle of Extrusion, Types of Extrusion, Hot and Cold extrusion. Sheet metal characteristics -Typical shearing operations, bending and drawing operations, Stretch forming operations, Metal spinning.

Unit IV

Powder Metallurgy: Introduction of powder metallurgy process, powder production, blending, compaction, sintering

Manufacturing Of Plastic Components: Types of plastics, Characteristics of the forming and shaping processes, Moulding of Thermoplastics, Injection moulding, Blow moulding, Rotational moulding, Film blowing, Extrusion, Thermoforming. Moulding of thermosets- Compression moulding, Transfer moulding, Bonding of Thermoplastics. 

Textbooks:

1. Manufacturing Technology: Foundry, Forming and Welding Volume 1, P. N Rao, , McGrawHill, 5e,2018.
2. Elements of Workshop Technology Vol. 1 and 2 by Hajra Choudhury, Media Promoters Pvt Ltd.,2008.

References:

1. Manufacturing Processes for Engineering Materials, by Serope Kalpajian and Steven R.Schmid, Pearson Education, 5e, 2014.
2. Fundamentals of Modern Manufacturing: Materials, Processes, and Systems by Mikell P. Groover, John Wiley and Sons, 4e, 2010 .
3. Production Technology by R.K.Jain and S.C. Gupta, Khanna Publishers. 16th Edition, 2001.