MANUFACTURING PROCESS LAB III

PI 441
List of experiments
1

Study of TIG, MIG & CO2 gas welding.

2.

Prepare at least one job on each type of welding machines.

Study of CNC systems.

4 Prepare a programme on CNC machine for any one type of operation on

lathe machine.

Study of pipe joints

.
6

Prepare a pipe joint using differents types of tools.

Study of different types of Gears

.
8

Study of lathe, drilling programming machines.

Manufacturing Processes - III

PI 401
Unit I
Mass Production Lathes: Turret lathes, ram type and saddle type, vertical turret
lathe, turret lathe tooling, screw machines, single and multi spindle screw
machines, automatic lathes, single and multispindle automatic lathe, cycle time.
Unit II
Milling: Types of milling operations, milling machines, cutter-types, geometry,
materials, size specifications, milling machine accessories, dividing heads,
simple, compound, differential and angular indexing and calculations for cutting
of different types of gears.
Unit III
Thread and gear manufacturing and machines used for cutting threads and
gears. Broaching, geometry of the broaching tool, broaching machines. Grinding
and other abrasive processes, types of abrasives and their properties, selection
of grinding wheels, grinding machines, cylindrical and surface grinders, centreless grinding, grinding fluids.
Unit IV
Modern foundries: Planning and layout of modern mechanized foundries,
machine moulding, core moulding, shell moulding, investment moulding, plaster
moulding, permanent mould casting, die casting and centrifugal casting,
moulding machines, Forging : Drop, horizontal, press and upset forging, forging
hammer and presses, extrusion, piercing, drawing , coining composing, coupling.
Super finishing Operations, Hot working of Materials
Unit V
Introduction to Numeric Control Systems, CNC Control Systems, CNC
Programming, CNC Lathe, CNC Drilling, CNC Milling and CNC Work Station.
Books Recommended:
(1)
(2)
(3)

Computer Numeric Control by Jon S. Stenerson and Kelly Curran,

2006 Edition, Pearson
Introduction to Manufacturing Processes by John Schey, 2000, MH
Industrial Automation & Process Control by Jon Stenerson, 2002,
Pearson

Production Engineering Lab

PI 442

1.

Design of Drilling Jig.

2.

Design of a Milling Fixture.

3.

Rigidity Test on a Lathe Machine.

4.

Part Programming on CNC Lathe

5.

Part Programming on CNC Milling / Drilling Machine

6.

Preparation of Tool Layout on Capstan / Turret Lathe.

7.

Types of Chips under different cutting conditions.

8.

Study of Oil Hydraulic Power Press System.

Production Engineering
PI 403
Unit I
Metal cutting theory, geometry of cutting tools, metal machining, chip formation,
types of chips, force analysis, velocity relationship, stress and strain analysis,
power and energy relationships, thermal aspects, dynamometers for turning and
drilling.
Unit II
Machinability: Evaluation of Machinability, tool life, flank wear, crater wear,
cutting forces, surfaces finish, economics of metal machining, functions of cutting
fluids, requirements of good cutting fluid, cutting tool materials.
Unit III
Machine Tools System: Design analt drives in machine tools, layout of gear box,
stepped regulators, stepless regulators, hydraulic regulators, Tooling principles
and tool layouts for turrets, automates, operation planning considerations,
designing of cams.
Unit IV
Tool Design: Design of single point cutting tools, rigidity, Design of Chip
Breakers, dynamic chip breaking, design of press dies, component of die, cutting
Action in a die, clearance, cutting forces, shear, center of pressure, Jigs and
Fixtures: Usefulness of jigs and fixtures, principles of design, locating and
Clamping, diamond pin locator, Materials for jigs and fixtures, economics of jigs
And fixtures.
Unit V
Standardization, interchangeability, limits, fits, BIS, BSS and naval system,
selection of fits as per Indian standards, metrology, and various types of
comparators, design of limit gauges, tolerance, wear allowances and quality
control. Need, Analysis and Description of Various Unconventional Machining
Processes.
Books Recommended:
(1) A Text Book of Production Engineering by Pandey & Singh
(2) Tool Design by Donaldson, McGraw Hill
(3) Manufacturing Engineering and Technology by Kalpakjian, 5E, 2005, Pearson
(4) Introduction to Manufacturing Processes by John Schey, 2000, MH

Industrial Design
PI 402
Unit I
General Design Considerations, Defining and solving design problems,
Formulating a design problem, Concept Design, Selecting materials,
Selecting manufacturing processes, Configuration design, Parametric design,
Unit II
Building and testing prototypes, Design for X: Failure, Safety, Tolerances,
Environment, Human factors/ergonomics, Introduction to engineering economics,
Detail Design, Projects, Teamwork & Ethics, Professional and Social Context of
Design, Probabilistic Considerations in Design, Optimum Design.
Unit III
Types of Loadings, Criteria for Failure, Design Approaches for Static and Fatigue
loading and their influences on design criteria, Designing against Fatigue, Creep
and Impact Loading.
Unit IV
Stress Concentration and Stress Concentration Factors. Residual Stresses and
their determination, Stress Intensification in presence of Sharp Notches and
Cracks, Design of Machine Elements in presence of Cracks.
Unit V
Power Transmission, Belt Drives, Chain Drives, Gear Drives, Design of Shafts,
Selection of Bearings, Electric Motors, Pneumatic and Hydraulic Drives, Fluid
Power Systems, Pumps and Accessories, Circuit Design and Applications,
Power Transmission in Machine Tools.
Books Recommended:
(1) Engineering Design by Rudolph J. Eggert, 2005, Prentice Hall
(2) Fundamentals of Engineering Design by Barry Hyman, 2/E, 2003, Prentice
Hall
(3) Engineering Design by George Dieter, 4E, 2008, McGraw Hill
(4) Machine Design by Timothy H. Wentzell, 2003 Edition, Cengage Learning
(5) Fluid Power with Applications by Anthony Esposito, 6E, 2004, PHI
(6) Fluid Power Circuits and Controls by John S. Cundiff, 2001, CRC Press
(7) Shigleys Mechanical Engineering Design by Richard D. Budynas, 8E,
2007, McGraw Hill