Manufacturing and Production Processes

Course Objectives
To impart knowledge and skills in the field of manufacturing and production processes. It deals with different metal forming processes along with advanced manufacturing techniques that are used in modern industries.

1. Overview of Manufacturing(2 hours)
1. Introduction
2. Product Cycle
3. Material Flow and Processing
4. Information Flow
5. Evolution of Organization for Manufacture


2. Manufacturing Properties of Materials(3 hours)
1. Mechanical Properties of Solids
2. Deformation of Solids
3. Thermo Fluid Properties of Liquids
4. Tribology in Manufacturing


3. Properties of Manufactured Products(3 hours)
1. Geometrical Description and Tolerances
2. Dimensioning and Tolerances Control
3. Surface Configurations
4. Residual Stresses


4. Solidification Process and Powder Metallurgy(6 hours)
1. General Characteristics of Casting Process and Products
2. Solidification Phenomena and Associated problems
3. Sand Casting: Process Characteristics and Capabilities Pattern design
4. Investment Casting: Characteristics and Capabilities; Pattern Design and Manufacturing
5. Permanent Mould and Pressure Die Casting: Process characteristics and capabilities Part design
6. Continuous Casting Characteristics and Capabilities
7. Introduction to Powder Metallurgy


5. Bulk Deformation Process(6 hours)
1. General Characteristics of Bulk Deformation Process and Products
2. Force, Energy and Deformation: Sensitivity to frictions, geometry, temperature and deformation rate
3. Forging practice and Technology; Press and hammers, tooling design, manufacture wear
4. Design of Forgings; Characteristics and defects in forgings
5. Flat Rolling; Characteristics and defect in forgings
6. Shape Rolling: Process and Products
7. Extrusion
8. Wires, Bar and Tube Drawing


6. Sheet Metal Product Manufacturing Process(4 hours)
1. Shearing and Punching Operations
2. Sheet Metal and Tube Bending: Technology and Practices
3. Deep Drawing and Hydro forming
4. Spinning Operations and Capabilities
5. Formability Assessment


7. Material Removal Processes: “ Chip-forming” (6 hours)
1. Modeling the cutting process
2. Force, Power and Productivity Relationship
3. Cutting tools Materials: Characteristics and Economics
4. General Purpose Machine Tool Types
1. Operation of Lathes, Milling, Shapers and Drilling Machines
2. Application of Shaping, Planning and Slotting Machines
5. Methods of mounting of jobs and cutting tools in machine tools
6. Uses of various attachments in machine tools
7. Control of Machine Tools and Product Properties
8. Cutting off Process: Saws, flame cutting, arc cutting


8. Material Removal Processes: “Abrasive and Non-Traditional” (3 hours)
1. Abrasive Based Tooling
2. Grinding Technology and Practice
3. Electrical discharge machining
4. Electrochemical machining


9. Numerical Control of Machine Tools(3 hours)
1. Need for Flexible Automation and Numerical controls
2. CNC Machine tool description; technology and practices
3. Introduction to CNC Machine Par Programming
4. Justification of CNC process
5. Industrial Robots


10. Jigs and Fixtures for Machine Shops(2 hours)
1. Purpose of jigs and fixtures
2. Design and application of typical jigs and fixtures


11. Screw Threads and Gear manufacturing Methods(3 hours)
1. Production of Screw Threads by Machining, Rolling and Grinding
2. Manufacturing of Gears


12. Material Joining Processes(4 hours)
1. Principle of Material Joining Process, Types
2. Mechanical vs. welded/brazed Connections
3. Introduction to the Metallurgy of welding
4. Characterization of Energy Sources
5. Arc-welding Processes
6. Combustion Torch Processes
7. Resistance welding processes
8. Design Considerations and Defects Analysis

Practical:

1. Workshop Practical should include the following processes:
2. Solidification and Bulk Deformation Processes
3. Sheet Metal Working
4. Engine Lathe Operations
5. Shaper Operations
6. Milling Machine Operations
7. Drilling Machine Operation
8. Grinding Machine Operation
9. Arc Welding
10. Gas Welding

References:

1. Manufacturing Engineering and Technology – Serope Kalpakjian and Steven R. Schmid – Addison Wesley Longman (Singapore) Pte. Ltd.,
2. Manufacturing Processes for Engineering Materials – Serope Kalpakjian and Steven R. Schmid – Pearson Education, Fourth Edition
3. Introduction to Manufacturing Processes - J. A. Schey – McGraw Hill,
4. Manufacturing Processes and Materials for Engineers – L. E. Doyleetal - Prentice Hall,
5. Metal Cutting Principles – M. C. Shaw – Oxford University Press
6. Elements of Manufacturing Processes – B.S. Nagendra Parashar and R. K. Mittal – Prentice Hall of India Pvt Ltd, New Delhi

Evaluation Scheme
The questions will cover all the chapters of the syllabus. The evaluation scheme will be as indicated in the table below:

Chapters	Hours	Marks Distribution*
1 & 2	5	8
3 & 4	9	16
5	6	10
6	4	10
7	6	10
8 &9	6	10
10 &11	5	8
12	4	8
Total	45	80

*Note: There may be minor deviation in marks distribution.