MECHANCIAL ENGINEERING DEPARTMENT

II YEAR – I SEMESTER

MANUFACTURING TECHNOLOGY - I
Course Code: MEC216 L T P C
4 0 0 3
Course Objective:

To make the students learn about fundamental manufacturing concepts and understand various manufacturing
processes such as casting, forming and fabrication.

Course Outcomes:

Students will be able to

CO-1 Describe and illustrate various casting processes and their components
CO-2 Design molding system and evaluate the defects in casting
CO-3 Define and design various forming and forging processes
CO-4 Understand the principles of sheet metal operations and basics of metal
joining processes
CO-5 Explain advanced welding processes and able to analyze weld defects
Mapping of Course Outcomes with Programme Outcomes. High-3, Medium-2, Low-1

COURSE PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12
OUTCOME
S
CO1 2 1 1 1 1 1 1 1 1
CO2 3 3 3 2 1 1 1 1 1
CO3 3 2 3 2 1 1 1 1 3
CO4 2 3 2 1 1 1 1 1 1
CO5 2 3 3 2 1 1 1 1 3
Course
PSO-1 PSO-2
Outcomes
CO-1 1.4 0
CO-2 2.4 1.2
CO-3 2.6 1.8
CO-4 2.4 2
CO-5 2.6 1.8
UNIT - I

Introduction to Manufacturing:

Product cycle; Job, batch and mass production; Primary and secondary manufacturing processes.

Principles of metal casting:

History of metal casting, applications and limitations, Terminology in casting, sand mould
making procedure, Patterns, Classification of patterns, pattern materials, pattern allowances, core
prints. Moulding materials, moulding sand composition, sand properties testing procedures,
moulding sand preparation and its classification, Sand moulding machines, core sands, types of
cores, chaplets. Gating system design - Elements of gating system, Risering design – Caine’s
method and Modulus method, feeding distances, chills.
UNIT - II
Metal Casting Processes & N.D.T Techniques:
Classification of Furnaces, fettling, defects in castings, Types of mould - Chemical sand
moulding, Permanent moulding processes, Special casting processes – Centrifugal casting,
Precision investment casting, Continuous casting, Plaster mould casting, Squeeze casting,
Evaporative casting, Vacuum sealed casting. Casting Defects, Non-destructive testing methods –
Visual inspection, Liquid penetrant and die penetrant test, magnetic particle inspection test,
Ultrasonic inspection and radiography tests.

UNIT - III
Introduction to Metal Forming & Bulk Forming Processes:

Nature of plastic deformation, hot working and cold working. Rolling – Principle, Rolling stand
arrangement, Rolling load. Forging – Principle, Forging operations – Smith forging, drop
forging, press forging and machine forging. Forging pressure distribution and forging force,
Extrusion – hot and cold extrusions, tube extruding, wire drawing, rod and tube drawing,
swaging.

UNIT - IV
Sheet Metal Forming & Basics of Metal Joining Processes:

Sheet metal operations,– shearing, drawing, bending, squeezing, press working and its
classification, types of dies, press tool operations – cutting operations (blanking, punching,
notching, etc.), shaping operations (embossing, coining, spinning, stretch forming, etc.), high
energy rate forming processes, Classification of fabrication processes, types of joints, Soldering,
brazing and braze welding,
UNIT - V

Metal Joining Processes:

welding terminology, Principles and processes – gas welding and cutting, Electric arc welding
(MMAW, CAW, TIG, GMAW, SAW, PAW, AHW, SW, fire cracker welding),Resistance
welding (spot, seam, projection, upset and flash welding techniques), Solid state welding – Cold
or roll welding, explosion welding, friction welding, friction stir welding, ultrasonic welding.
Thermit welding, electro slag welding, laser beam welding, forge welding, diffusion welding.
Welding defects.

Text Book:

1. Manufacturing Technology-Foundry, Forming and Welding, P.N.

Rao, 4th Edition, Tata McGraw-Hill Publishing Company.

2. Manufacturing Engineering & Technology, Kalpak Jain, 7th Edition,

Addition Wesley Edition.

Reference Books:
1. Materials and Processes in Manufacturing, De Garmo, Black and
Kohsen 4th Edition, Prentice Hall of India.

2. Manufacturing Science (English) 2nd Edition, Amithaba Ghosh and Asok

Kumar Mallik
,East West Press Pvt. Ltd.

3. Principles of Metal Casting, Hein and Rosenthol, 5th Edition, Tata McGraw Hill
India.

Web sources: www.wri.org.in

4. Hein and Rosenthol, Principles of Metal Casting, 5th Edition, Tata McGraw Hill
India.
Web sources: www.wri.org.in