Details 

about the present course

Course title: Manufacturing technology – II

Course lecturer: Dr. Degala Venkata Kiran

Room no.:213, M.I.E.D.

Email: dvkiranfme@iitr.ac.in

Phone: 01332‐285523

Number of lectures per week: 2 (Wednesday: 12.05 – 1.00 PM; Friday: 12.05 – 1.00 PM)

Credits: 4

Relative weightage: Practical sessional  25; Mid term examination  25; End term examination  50

Course objective: To develop in‐depth understanding on manufacturing processes namely casting, welding
and forming, and introduce non‐destructive examination methods

1
Course syllabus

S.No. Particulars Contact hours

1. Welding: Classification of welding processes, electric arc, ISI classification of coated 12

electrodes, special welding methods: MMAW, GTAW, GMAW‐CO2 welding, submerged arc
welding, electro‐slag welding, electron bean welding, laser beam welding, ultrasonic
welding, resistance welding, welding defects, and arc blow

2. Foundry: Sand casting process‐Steps; core; sand testing; molding processes, gating system, 10
solidification phenomena, melting furnaces, special casting methods‐centrifugal casting;
permanent mold casting; hot chamber and cold chamber fie casting; investment casting;
shell mold casting; plaster mold casting; CO2 mold casting, casting design considerations,
casting defects and remedies.

3. Non‐destructive examination: Principle and applications of common non‐destructive 2

examination methods DPT, MPT and UT of castings and weldments

4. Forming: Forging, rolling, extrusion, wire drawing and tube drawing, forging defects and 4
remedies

Total 28

2
Suggested references

S.No. Name of Authors / book / Publisher

1. Kalpakjian S. and Schmid S.R., Manufacturing engineering and technology, Pearson education

2. GrooverMikell P., Fundamentals of modern manufacturing, John Wiley and Sons Inc.

3. DeGarmoE. Paul, Black J.T., Roland A. Kohser, Materials and processing in manufacturing,
Prentice Hall of India Pvt. Limited

4. Lindberg R.A., Processes and materials of manufacturing, Prentice Hall India Limited

5. Rao P.N., Manufactring technology, Tata McGraw Hill

6. Lancaster J.F., The physics of welding, Pergamon press

7. Parmar R.S., Welding processes and technology, Khanna publications

8. Khanna O.P., Foundry technology, Dhanpat rai publications

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What is manufacturing?
The word manufacture is derived from two Latin words manu and factus

Manu (hand) and factus (make)

The combination of
these words means
Made by hand

Technologically, manufacturing is the application of Economically, manufacturing is the transformation of materials

physical and chemical processes to alter the geometry,
properties, and/or appearance of a given starting
material to make parts or products; manufacturing also
includes assembly of multiple parts to make products.
The process to accomplish manufacturing involve a
combination of machinery, tools, power, labor.
into items of greater value by means of one or more processing
and/or assembly operations.
The key point is that manufacturing adds value to the material
by changing its shape or properties.
The material has been made more valuable through the
manufacturing operations performed on it.

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Manufacturing processes

Solidification processes

Transforms a work material from one state Particulate processing

of completion to a more advanced state Shaping processes
that is closer to the final desired product. Deformation processes

Material removal

Processing  Property
Heat treatment
operations enhancing processes

Cleaning and 
Surface processing  surface treatments
Manufacturing  operations
Coating and 
processes deposition processes

Welding
Permanent joining 
Brazing and soldering
processes
Assembly  Adhesive bonding
operations
Mechanical  Threaded fasteners
Joining two or more 
components to create a new  fastening Permanent fastening methods
entity, called as assembly.

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Shaping processes – solidification processes

• The starting material is heated sufficiently to transform it into a liquid or highly plastic (semifluid) state.
• The material in liquid or semifluid form can be poured or otherwise forced to flow into a mold cavity.
• After solidification, the material take the solid shape that is same as the cavity.
• Examples are the casting and molding processes 

Pouring ladle
Sprue and 
Molten metal runner to be 
trimmed
Downsprue Parting  Solid casting
line
Mold
(sand)
(a) (b) Alloy wheel of a Nissan made SUV
Casting process

Monuments Turbo compressor Engine block

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Shaping processes – deformation processes

• The starting material is shaped by the application of forces that exceed the yield strength of the material.
• The material should be ductile to avoid fracture during deformation.
• The material is often heated before forming to a temperature below the melting point to increase the ductility.
• Examples are the forging and extrusion processes
Extruded 
Chamber cross section
v, F
Forging Ram
Aero blade load bar
Die
Flash (to
be trimmed) v, F
Die
Die
Starting billet
(a) Forging (b) Extrusion Side intrusion beam
Ford frame with 32 Al extrusions

Multi port extruded tubes in 
car heat exchanger

Extruded rubber products
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Forging – examples

Spanners
Nuts and bolts Connecting rods

Pistons Wheels

Auto parts and fastener items Forging components in aerospace
8
Permanent joining processes – welding

Electrode
Filler metal
Arc Welded joint
Shielding gas Molten pool

Base metal Penetration
Welding arc
Two parts to be welded
(base metal)
both heat and 
pressure are 
RSW sources
heat is the  SMAW
source

EW
pressure is 
the source

Welding: It is a material joining process in which two are more parts are joined
together at their contacting surfaces by a suitable application of heat alone or
pressure alone or both simultaneously.

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Welding – examples

Car body Fuel tank Aerospace

Train tracks

Pipe welding Ship building

Train compartments

10
Shaping processes – material removal

• Removes excess material from the starting workpiece so that the resulting shape is the desired geometry.
• Material removal processes tends to be wasteful of material, simply by the way they work. The material 
removed from the starting shape is waste.
• Few material removal processes are
 Machining
 Grinding
 Non‐traditional processes
• The machining process is the most important and the common material removal process. It is categorized as
 Turning
 Drilling
 Milling
Rotation
Starting  Diameter 
Feed Milling  Rotation
work  diameter Chip after turning
piece Drill bit cutter Material 
removed
Rotation work 
(work) piece work 
piece
Hole
Feed tool Single point 
cutting tool Feed
(a) Turning (b) Drilling (c) Milling

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Shaping processes – material removal
Rotation
Starting  Diameter 
Feed Milling  Rotation
work  diameter Chip after turning
piece Drill bit cutter Material 
removed
Rotation work 
(work) piece work 
piece
Hole
Feed tool Single point 
cutting tool Feed
(a) Turning (b) Drilling (c) Milling

A single‐point cutting tool removes  A work piece is fed past a rotating 
metal from a rotating work piece  cutter with multiple edges
to reduce diameter A rotating drill bit is fed into the 
work to create a round hole

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