ME2201 MANUFACTURING TECHNOLOGY I LT PC

3003
OBJECTIVE
To introduce the students the concepts of some basic manufacturing processes and
fabrication techniques, such as metal casting, metal joining, metal forming and plastics
component manufacture.
UNIT I METAL CASTING PROCESSES 9
Sand casting Sand moulds - Type of patterns Pattern materials Pattern
allowances Types of Moulding sand Properties Core making Methods of Sand
testing Moulding machines Types of moulding machines - Melting furnaces
Working principle of Special casting processes Shell, investment casting Ceramic
mould Lost Wax process Pressure die casting Centrifugal casting CO 2 process
Sand Casting defects Inspection methods
UNIT II JOINING PROCESSES 9
Fusion welding processes Types of Gas welding Equipments used Flame
characteristics Filler and Flux materials - Arc welding equipments - Electrodes
Coating and specifications Principles of Resistance welding Spot/butt, seam
welding Percusion welding - Gas metal arc welding Flux cored Submerged arc
welding Electro slag welding TIG welding Principle and application of special
welding processes - Plasma arc welding Thermit welding Electron beam welding
Friction welding Diffusion welding Weld defects Brazing and soldering process
Methods and process capabilities Filler materials and fluxes Types of Adhesive
bonding.
UNIT III BULK DEFORMATION PROCESSES 9
Hot working and cold working of metals Forging processes Open, impression and
closed die forging Characteristics of the process Types of Forging Machines
Typical forging operations Rolling of metals Types of Rolling mills - Flat strip rolling
Shape rolling operations Defects in rolled parts - Principle of rod and wire drawing -
Tube drawing Principles of Extrusion Types of Extrusion Hot and Cold extrusion
Equipments used.
UNIT IV SHEET METAL PROCESSES 9
Sheet metal characteristics - Typical shearing operations, bending and drawing
operations Stretch forming operations Formability of sheet metal Test methods
Working principle and application of special forming processes - Hydro forming
Rubber pad forming Metal spinning Introduction to Explosive forming, Magnetic
pulse forming, Peen forming, Super plastic forming.
UNIT V MANUFACTURING OF PLASTIC COMPONENTS 9
Types of plastics - Characteristics of the forming and shaping processes Moulding of
Thermoplastics Working principles and typical applications of - Injection moulding
Plunger and screw machines Compression moulding, Transfer moulding - Typical
industrial applications Introduction to Blow moulding Rotational moulding Film
blowing Extrusion - Thermoforming, - Bonding of Thermoplastics.
TOTAL: 45 PERIODS
23
TEXT BOOKS
1. Hajra Choudhury, Elements of Workshop Technology, Vol. I and II, Media
Promotors Pvt Ltd., Mumbai, 2001
2. S.Gowri, P.Hariharan, and A.Suresh Babu, Manufacturing Technology 1, Pearson
Education , 2008.
[

REFERENCES
1. B.S. Magendran Parashar & R.K. Mittal,Elements of Manufacturing Processes,
Prentice Hall of India, 2003.
2. P.N. Rao,Manufacturing Technology,Tata McGraw-Hill Publishing Limited, II
Edition, 2002.
3. P.C. Sharma, A text book of production technology,S. Chand and Company, IV
Edition, 2003.
4. Begman, Manufacturing Process, John Wilely & Sons, VIII Edition, 2005.
5. Serope Kalpajian, Steven R.Schmid, Manufacturing Engineering and Technology,
Pearson Education, Inc. 2002(Second Indian Reprint).
6. Beddoes.J and Bibby M.J, Principles of Metal Manufacturing Processes, Elsevier,
2006.
7. Rajput R.K, A text book of Manufacturing Technology, Lakshmi Publications, 2007.

STAFF STRUCTURED SYLLABUS

Basics/ Fundamentals: Define, List

Concepts: Explain, Compare, Differentiate

Applications: Derive

UNIT I METAL CASTING PROCESSES

Sand casting Sand moulds - Type of patterns Pattern materials Pattern
allowances Types of Moulding sand Properties Core making Methods of Sand
testing Moulding machines Types of moulding machines - Melting furnaces
Working principle of Special casting processes Shell, investment casting Ceramic
mould Lost Wax process Pressure die casting Centrifugal casting CO2 process
Sand Casting defects Inspection methods

To explain Sand casting

To explain Sand moulds
To list the Type of patterns
To define Pattern materials

To define Pattern allowances

To explain Types of Moulding sand

To explain Core making

To explain Methods of Sand testing
To define Moulding machines
To list the Types of moulding machines
To explain Melting furnaces
To explain Working principle of Special casting processes
To explain Shell, investment casting
To define Lost Wax process

To define Inspection methods

UNIT II JOINING PROCESSES

Fusion welding processes Types of Gas welding Equipments used Flame
characteristics Filler and Flux materials - Arc welding equipments - Electrodes
Coating and specifications Principles of Resistance welding Spot/butt, seam
welding Percusion welding - Gas metal arc welding Flux cored Submerged arc
welding Electro slag welding TIG welding Principle and application of special
welding processes - Plasma arc welding Thermit welding Electron beam welding
Friction welding Diffusion welding Weld defects Brazing and soldering process
Methods and process capabilities Filler materials and fluxes Types of Adhesive
bondingTo define metrology
To define Fusion welding processes
To define Equipments used
To list the Types of Gas welding
To explain Filler and Flux materials
To explain Arc welding equipments

To list the Principles of Resistance welding

To explain Percusion welding

To define Gas metal arc welding

To define Flux cored , Submerged arc welding
To define Electro slag welding ,TIG welding
To explain Principle and application of special welding processes
To explain Weld defects, Brazing and soldering process

To list the Types of Adhesive bondingTo define metrology

To explain Methods and process capabilities ,Filler materials and fluxes

UNIT III BULK DEFORMATION PROCESSES

Hot working and cold working of metals Forging processes Open, impression and
closed die forging Characteristics of the process Types of Forging Machines
Typical forging operations Rolling of metals Types of Rolling mills - Flat strip rolling
Shape rolling operations Defects in rolled parts - Principle of rod and wire drawing -
Tube drawing Principles of Extrusion Types of Extrusion Hot and Cold extrusion
Equipments used.
To explain Hot working and cold working of metals

To define Forging processes

To explain Characteristics of the process

To explain Types of Forging Machines

To explain Typical forging operations

To explain Rolling of metals and Types of Rolling mills

To define Flat strip rolling

To define Shape rolling operations

To explain Defects in rolled parts

To explain Principle of rod and wire drawing

To define Tube drawing and Principles of Extrusion

To define Types of Extrusion

To explain Hot and Cold extrusion

To define Equipments used.

UNIT IV SHEET METAL PROCESSES

Sheet metal characteristics - Typical shearing operations, bending and drawing
operations Stretch forming operations Formability of sheet metal Test methods
Working principle and application of special forming processes - Hydro forming
Rubber pad forming Metal spinning Introduction to Explosive forming, Magnetic
pulse forming, Peen forming, Super plastic forming.

To define Sheet metal characteristics

To explain Typical shearing operations, bending and drawing operations

To explain Stretch forming operations

To explain Formability of sheet metal

To define Working principle and application of special forming processes

To explain Hydro forming

To explain Rubber pad forming

To define Metal spinning

To explain Introduction to Explosive forming,

To define Magnetic pulse forming, Peen forming, Super plastic forming.

UNIT V MANUFACTURING OF PLASTIC COMPONENTS

Types of plastics - Characteristics of the forming and shaping processes Moulding of
Thermoplastics Working principles and typical applications of - Injection moulding
Plunger and screw machines Compression moulding, Transfer moulding - Typical
industrial applications Introduction to Blow moulding Rotational moulding Film
blowing Extrusion - Thermoforming, - Bonding of Thermoplastics.
.

To explain Types of plastics

To list the Characteristics of the forming and shaping processes

To define Moulding of Thermoplastics

To explain Working principles and typical applications of

To define Plunger and screw machines

To explain Compression moulding, Transfer moulding

To explain Introduction to Blow moulding

To explain Rotational moulding, Film blowing ,Extrusion ,Thermoforming, Bonding of

Thermoplastics.

ALPHA COLLEGE OF ENGINEERING

Lesson Plan- Fifth Semester

Name of the staff : Mr.E.RAVI KUMAR,

Department : MECH

Name of the subject : MANUFACTURING TECHNOLOGY I

Class : III sem MECH

Date No. of Specific Instructional objectives

Periods
Unit 3 To explain Hot working and cold working of
1 metals

01.09.14 06.09.14 To define Forging processes

 1 To explain Characteristics of the process
To explain Types of Forging Machines

1 To explain Typical forging operations

08.09.14 12.09.14 To explain Rolling of metals and Types of

Rolling mills

1 To define Flat strip rolling

To define Shape rolling operations

1 To explain Defects in rolled parts

1 To explain Principle of rod and wire drawing

1 To define Tube drawing and Principles of

Extrusion

1 To define Types of Extrusion

To explain Hot and Cold extrusion

1 To define Equipments used

15.9.14 20.9.14

Unit 4 To define Sheet metal characteristics

1
To explain Typical shearing operations, bending
and drawing operations
22.9.14 30.9.14 1 To explain Stretch forming operations

1 To explain Formability of sheet metal

1 To define Working principle and application of

special forming processes

1 To explain Hydro forming

1 To explain Rubber pad forming

1.10.14 3.10.14
1 To define Metal spinning

To explain Introduction to Explosive forming,

1 To define Magnetic pulse forming, Peen
forming, Super plastic forming.
6.10.14 11.10.14 Unit 5 To explain Types of plastics
1
1 To list the Characteristics of the forming and
shaping processes

1 To define Moulding of Thermoplastics

1 To explain Working principles and typical
applications of

1 To define Plunger and screw machines

13.10.14 20.10.14 1 To explain Compression moulding, Transfer

moulding

1 To explain Introduction to Blow moulding

1 To explain Rotational moulding, Film

blowing ,Extrusion ,Thermoforming, Bonding
of Thermoplastics.
University practical examination
23.10.14 3.11.14
Revision
Model Exam