DOC/LP/00/21/01/2005

LESSON PLAN
Sub Code &Name : ME2201 Manufacturing Technology - I Unit: I Branch: Mechanical Engineering Semester: III

LP ME2201 LP Rev. No: 00 Date: 01/07/10 Page: 1 of 6

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

Objective:
To introduce the students the concepts of metal casting processe

Session No 1 2 3 4 5 6 7 8 9

Topics to be covered
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 and Inspection methods

Time (Min)

Ref.

Teaching Method

50 50 50 50 50 50 50 50 50

Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2

BB BB BB BB BB BB BB BB BB

DOC/LP/00/21/01/2005

LESSON PLAN
Sub Code &Name : ME2201 Manufacturing Technology - I Unit: II Branch: Mechanical Engineering Semester: III

LP ME2201 LP Rev. No: 00 Date: 01/07/10 Page: 2 of 6

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 bonding.

Objective:
To introduce the students the concepts of metal Joining processses

Session No 1 2 3 4 5 6 7 8 9

Topics to be covered Fusion welding processes Types of Gas welding, Equipments Flame characteristics Filler and Flux materials Arc welding equipments Electrodes - Coating and specifications Principles of Resistance welding Spot/but,t seam welding, Percusion welding seam welding Percusion welding Gas metal arc welding Flux cored Welding, Submerged arc welding , Electro slag welding , TIG welding special welding processes - Plasma arc welding Thermit welding Electron beam welding Friction welding , Diffusion welding, Weld defects Brazing and soldering process, Adhesive Bonding CAT I

Time (Min)

Ref.

Teaching Method

50 50 50 50 50 50 50 50 50

Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2

BB BB BB BB BB BB BB BB BB

DOC/LP/00/21/01/2005

LESSON PLAN
Sub Code &Name : ME2201 Manufacturing Technology - I Unit: III Branch: Mechanical Engineering Semester: III

LP ME2201 LP Rev. No: 00 Date: 01/07/10 Page: 3 of 6

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.

Objective:
To introduce the students the concepts of metal working process

Session No 1 2 3 4 5 6 7 8 9

Topics to be covered Hot working and cold working of metals Forging processes Open, impression and closed die forging- Characteristics Types of Forging Machines Forging Operations Rolling Mills - types Shape rolling operations, Defects in rolled parts Rod, tube and wire drawing Extrusion principle, types Hot & Cold Extrusion Revision

Time (Min)

Ref.

Teaching Method

50 50 50 50 50 50 50 50 50

Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 Text Book 1,2 --

BB BB BB BB BB BB BB BB BB

DOC/LP/00/21/01/2005

LESSON PLAN
Sub Code &Name : ME2201 Manufacturing Technology - I Unit: IV Branch: Mechanical Engineering Semester: III

LP ME2201 LP Rev. No: 00 Date: 01/07/10 Page: 4 of 6

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.

Objective:
To introduce the students the concepts of Sheet metal working processes

Session No 1 2 3 4 5 6 7 8 9

Topics to be covered
Sheet metal characteristics

Time (Min)

Ref.

Teaching Method

50 50 50 50 50 50 50 50 50

Shearing Operations - types Bending and Drawing operations Stretch forming operations
Formability of sheet metal - Test methods

Special forming processes - Hydro forming Rubber pad

forming Metal spinning, Explosive forming, Magnetic pulse forming Peen forming, Super plastic forming.

Revision CAT II

Ref Book 2,3,5 Ref Book 2,3,5 Ref Book 2,3,5 Ref Book 2,3,5 Ref Book 2,3,5 Ref Book 2,3,5 Ref Book 2,3,5 Ref Book 2,3,5 --

BB BB BB BB BB BB BB BB BB

DOC/LP/00/21/01/2005

LESSON PLAN
Sub Code &Name : ME2201 Manufacturing technology - I Unit: V Branch: Mechanical Engineering Semester: III

LP ME2201 LP Rev. No: 00 Date: 01/07/10 Page: 5 of 6

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.

Objective:
To introduce the students the concepts of Plastic Moulding Processes

Session No 1 2 3 4 5 6 7 8 9
Blow moulding

Topics to be covered
Types of plastics - Characteristics of the forming and shaping processes Moulding of Thermoplastics - Injection moulding Compression moulding Transfer moulding

Time (Min)

Ref.

Teaching Method

50 50 50 50 50 50 50

Text Book 1,Ref 2,3,5 Text Book 1, Ref 2,3,5 Text Book 1,Ref 2,3,5 Text Book 1,Ref 2,3,5 Text Book 1,Ref 2,3,5 Text Book 1, Ref 2,3,5 Text Book 1,Ref 2,3,5 Text Book 1,Ref 2,3,5 --

BB BB BB BB BB BB BB BB BB

Rotational moulding Film blowing Extrusion, Thermoforming, Bonding of Thermoplastics.

Bonding of Thermoplastics.

50 50

Revision

CAT III

DOC/LP/00/21/01/2005

LESSON PLAN
Sub Code &Name : ME2201 Manufacturing technology - I Unit: -Branch: Mechanical Engineering Semester: III

LP ME2201 LP Rev. No: 00 Date: 01/07/10 Page: 6 of 6

Course Delivery Plan:

1 2 3 4 I 5 6 7 8 9 10 11 II 12 13 14 15 16 17 III

Hr. Units

Hr. Units

18

19

20

21 III

22

23

24

25

26

27

28

29

30

31 IV

32

33

34

35 V

Hr. Units

36

37

38

39

40

41

42 V

43

44

45

TEXT BOOK 1. 2. Hajra Choudhury, Elements of Workshop Technology, Vol. I and II, Media Promotors Pvt Ltd., Mumbai, 2001 S.Gowri, P.Hariharan, and A.Suresh Babu, Manufacturing Technology 1, Pearson Education , 2008.

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

Prepared by Signature Name Designation

Mr. S. Ponnuvel / Mr. R.Vinayagamoorthy

Approved by

Dr. N. Nallusamy Professor and HOD

Sr. Lecturer / Lecturer

DOC/LP/00/21/01/2005

ME 2201

MANUFACTURING TECHNOLOGY I

3 0 0 3

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(L) 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 UNIT II JOINING PROCESSES 9(L)

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(L) 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(L)

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(L)

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 Number of Periods: L= 45 T= 0 45

DOC/LP/00/21/01/2005

TEXT BOOK 3. Hajra Choudhury, Elements of Workshop Technology, Vol. I and II, Media Promotors Pvt Ltd., Mumbai, 2001 4. S.Gowri, P.Hariharan, and A.Suresh Babu, Manufacturing Technology 1, Pearson Education , 2008. REFERENCE BOOKS 8. B.S. Magendran Parashar & R.K. Mittal,Elements of Manufacturing Processes, Prentice Hall of India, 2003. 9. P.N. Rao,Manufacturing Technology,Tata McGraw-Hill Publishing Limited, II Edition, 2002. 10. P.C. Sharma, A text book of production technology,S. Chand and Company, IV Edition, 2003. 11. Begman, Manufacturing Process, John Wilely & Sons, VIII Edition, 2005. 12. Serope Kalpajian, Steven R.Schmid, Manufacturing Engineering and Technology, Pearson Education, Inc. 2002(Second Indian Reprint). 13. Beddoes.J and Bibby M.J, Principles of Metal Manufacturing Processes, Elsevier, 2006. 14. Rajput R.K, A text book of Manufacturing Technology, Lakshmi Publications, 2007.

DOC/LP/00/21/01/2005