Lecture Plan (2014-15)

Course: ME253
MANUFACTURING TECHNOLOGY
Class: B. Tech. (Mechanical Engineering), IV Semester
L T P: 4 0 0
Credits: 4
Teachers: Dr. A. Kumar (Sec-A) & Dr. N. Venkaiah (Sec-B)
Pre-Requisites: Nil
Course Outcomes: At the end of the course, the student will be able to:
CO1
CO2
CO3
CO4
CO5
S. No.
0
1
2

Select materials, types and allowances of patterns used in casting and analyze the
components of moulds.
Design core, core print and gating system in metal casting processes
Understand arc, gas, solid state and resistance welding processes.
Develop process-maps for metal forming processes using plasticity principles
Identify the effect of process variables to manufacture defect free products.
Module

Topic

Over view of the course, Examination and Evaluation pattern

Introduction
Engineering materials and their properties
Classification of manufacturing processes
Casting
Casting terminology, steps involved in making a
casting, advantages and applications of casting
Molding sand composition, testing sand
properties, sand preparation, reclamation of
molding sand
Patterns Types of patterns Pattern Materials,
pattern allowances
Core sands, types of cores, core prints, chaplets,
forces acting on the molding flasks
Principles of Gating, Gating ratio and design of
Gating systems, Risers Function, types,
design, casting design considerations
Solidification of casting Concept Solidification
of pure metal and alloys, short & long freezing
range alloys
Special casting processes: Centrifugal, Die
casting, Investment casting, CO2 Molding
Crucible melting and cupola operation, steel
making processes, charge calculations
Casting defects, causes and remedies
Welding
Classification of welding process
Gas welding, Gas cutting, Soldering & Brazing
and applications
Arc welding, weld bead geometry, V-I
Characteristic curves of power source and
problems
Shileded metal arc welding, submerged arc
welding
Flash butt welding, Thermit welding
Applications and advantages and disadvantages
of the above processes
Gas Tungsten arc welding, Gas Metal arc
welding
C02 welding
Applications and advantages and disadvantages

No. of
hours
1
1
1

Total No.
of hours
1
2
15

2
2
1
3
2
2
2
1
1
2
2
3
1
1
1
1
1

16

Metal Forming

Powder Metallurgy

of the above processes

Resistance welding: Spot, seam & projection
welding
Friction welding
Heat affected zones in welding, methods to
minimize HAZ
Electron beam welding, Laser welding
Hot working, cold working, strain hardening,
recovery, recrystallization and grain growth
Rolling fundamentals theory of rolling, types of
Rolling mills and products
Forces in rolling and power requirements
Basic extrusion process and its characteristics
Hot extrusion and cold extrusion - Impact
extrusion, Hydrostatic extrusion
Principles of forging Tools and dies Types of
Forging Smith forging, Drop Forging - Forging
hammers: Rotary forging forging defects
Stamping, Blanking, Bending, Drawing and
Piercing
Coining Hot and cold spinning, Hydro forming,
High energy rate forming
Types of presses and press tools, Forces and
power requirement in the above operations
Processing of Plastics: Types of Plastics,
Properties, applications and their Processing
methods & Equipment (blow & injection
modeling)
Production and characterization of powders
Compaction of metal powders: Die compaction,
hot isostatic pressing
Sintering of powder compacts, Post sintering
operations
Advantages, applications of powder metallurgy

1
1
1
1
1

14

1
2
3
2
1
1
1
2

1
1

1
1

Total No. of hours

52
Attendance requirement: 100% attendance is expected. Less than 80% attendance results in R
grade
Evaluation pattern
Exam
Assignments
(2 Nos.)
Minor 1
Mid Semester

Topic(s)

Type of Exam

Weight (%)

Tentative Time
th

Given topic

Descriptive

Up to Casting
Up to Welding

Objective (30 min)

Descriptive (2 Hrs)

7
30

4 Week of January &

th
4 Week of March
st
1 Week of February
rd
3 Week of February

Objective (30 min)

Descriptive (3 Hrs)

7
50

1 Week of April
th
4 Week of April

Minor 2
Welding & Forming
End Semester Whole syllabus
No choice in any exam.

st

Reading:
1. Ghosh, A., and Malik, A. K., Manufacturing Science, Affiliated East west Press Pvt. Ltd.,
2008. (Problems)
2. Rao PN, Manufacturing Technology, 3/e, TMH, New Delhi, 2010. (Casting & Welding)
3. Serope Kalpajian, and Steven R. Schmid, Manufacturing Engineering and Technology,
Pearson Education, Inc. 2002(Second Indian Reprint). (Plastics & Powder Metallurgy)
4. P.C. Sharma, A text book of production technology, S. Chand and Company, IV Edition,
2003. (Metal Forming)