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Anna University Mechanical Engineering III sem core course

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
4
TEXT BOOK
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.
REFERENCE BOOKS
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.

ME 2207 MANUFACTURING TECHNOLOGY LAB – I 0 0 3 2


(Only for Mechanical)
OBJECTIVE
To gain hands on experience on working of general purpose machine tools and on
various manufacturing processes.
UNIT I
LATHE
1.1. Facing, plain turning and step turning
1.2. Taper turning using compound rest, Tailstock set over, etc
1.3. Single and Multi-start V thread, cutting and knurling
1.4. Boring and internal thread cutting.
UNIT II
WELDING EXCERCISES
2.1.Horizontal, Vertical and Overhead welding.
2.2. Gas Cutting, Gas Welding
2.3. Brazing - for demonstration purpose
UNITIII
SHEET METAL WORK
3.1. Fabrication of sheet metal tray
3.2. Fabrication of a funnel
UNIT IV
PREPARATION OF SAND MOULD
4.1. Mould with solid, split patterns
4.2. Mould with loose-piece pattern
4.3. Mould with Core
UNIT V
PLASTIC MOULDING
5.1 Injection Moulding- for demonstration purpose
Total Number of Periods: P=45 Periods
Anna University Mechanical Engineering IV sem core course

ME 2252 MANUFACTURING TECHNOLOGY – II 3 0 0 3


OBJECTIVE
To understand the concept and basic mechanics of metal cutting, working of standard
machine tools such as lathe, shaping and allied machines, milling, drilling and allied
machines, grinding and allied machines and broaching
To understand the basic concepts of computer numerical control (CNC) machine tool
and CNC programming.
UNIT I THEORY OF METAL CUTTING 9(L)
Introduction: material removal processes, types of machine tools – theory of metal
cutting: chip formation, orthogonal cutting, cutting tool materials, tool wear, tool life,
surface finish, cutting fluids.
Unit II CENTRE LATHE AND SPECIAL PURPOSE LATHES 9(L)
Centre lathe, constructional features, cutting tool geometry, various operations, taper
turning methods, thread cutting methods, special attachments, machining time and
power estimation. Capstan and turret lathes – automats – single spindle, Swiss type,
automatic screw type, multi spindle - Turret Indexing mechanism, Bar feed mechanism.
UNIT III OTHER MACHINE TOOLS 9(L)
Reciprocating machine tools: shaper, planer, slotter - Milling : types, milling cutters,
operations - Hole making : drilling - Quill mechanism , Reaming, Boring, Tapping -
Sawing machine: hack saw, band saw, circular saw; broaching machines: broach
construction – push, pull, surface and continuous broaching machines
UNIT IV ABRASIVE PROCESSES AND GEAR CUTTING 9(L)
Abrasive processes: grinding wheel – specifications and selection, types of grinding
process – cylindrical grinding, surface grinding, centreless grinding – honing, lapping,
super finishing, polishing and buffing, abrasive jet machining - Gear cutting, forming,
generation, shaping, hobbing.
UNIT V CNC MACHINE TOOLS AND PART PROGRAMMING 9(L)
Numerical control (NC) machine tools – CNC: types, constructional details, special
features – design considerations of CNC machines for improving machining accuracy –
structural members – slide ways –linear bearings – ball screws – spindle drives and feed
drives. Part programming fundamentals – manual programming – computer assisted
part programming.
Total Number of Periods: L=45 T= 0 45 Periods
TEXT BOOKS
1. Hajra Choudry, “Elements of Work Shop Technology – Vol. II”, Media Promoters.
2002
2. HMT – “Production Technology”, Tata McGraw-Hill, 1998.
18
REFERENCE BOOKS
1. Rao, P.N. “Manufacturing Technology”, Metal Cutting and Machine Tools, Tata
McGraw–Hill, New Delhi, 2003.
2. P.C. Sharma, “A Text Book of Production Engineering”, S. Chand and Co. Ltd, IV
edition, 1993.
3. Shrawat N.S. and Narang J.S, ‘CNC Machines’, Dhanpat Rai & Co., 2002.
4. P.N.Rao, ‘CAD/CAM Principles and Applications’, TATA Mc Craw Hill, 2007.
5. M.P.Groover and Zimers Jr., ‘CAD/CAM’ Prentice Hall of India Ltd., 2004.
6. Milton C.Shaw, ‘Metal Cutting Principles’, Oxford University Press, Second Edition,
2005.
7. Rajput R.K, ‘Atext book of Manufacturing Technology’, Lakshmi Publications, 2007.
8. Philip F.Ostwald and Jairo Munoz, ‘Manufacturing Processes and systems’, John
Wiley and Sons, 9th Edition,2002.
9. Mikell P.Groover, ‘Fundamentals of Modern Manufacturing,Materials, Processes and
Systems’, John Wiley and Sons, 9th Edition,2007.
10. Chapman. W. A. J and S.J. Martin, Workshop Technology, Part III, Viva Books
Private Ltd., 1998

ME 2258 MANUFACTURING TECHNOLOGY LAB II 0 0 3 2


OBJECTIVE
To give a practical hands on exposure to students in the various metal cutting operations
using commonly used machine tools
EXERCISES
1. Two or More Measurements in Metal Cutting Experiment (Example: Shear Angle,
Cutting Force, Tool Wear etc.)
2. One or More Exercises in Shaper, Slotter, Planner, Drilling, Milling Machines
(Example: Round to Square, Dovetail in shaper, Internal keyway cutting in Slotter,
Round to square in Planner, Drilling, reaming and tapping in Drilling machine, Gear
Milling and Keyway milling in Milling machine.)
3. Two or More Exercises in Grinding / Abrasive machining
(Example: Surface Grinding, Cylindrical Grinding.)
4. Two or More Exercises in Assembly of Machined Components for different fits.
(Example: Parts machined using Lathes, Shapers, Drilling, Milling, and Grinding
Machines etc.)
5. One or More Exercises in Capstan or Turret Lathes
6. One or More Exercises in Gear Machining
(Example: Gear Milling, Gear Hobbing etc.)
LIST OF EQUIPMENT
(For a batch of 30 students)
1. Centre Lathes - 2 Nos.
2. Turret and Capstan Lathes - 1 No
3. Horizontal Milling Machine - 1 No
4. Vertical Milling Machine - 1 No
5. Surface Grinding Machine - 1 No.
6. Cylinderical Grinding Machine - 1 No.
7. Shaper - 2 Nos.
8. Slotter - 1 No.
9. Planner - 1 No.
10. Radial Drilling Machine - 1 No.
11. Tool Dynamometer - 1 No
12. Gear Hobbing Machine - 1 No
13. Tool Makers Microscope - 1 No
Total Number of Periods: P = 45
BPUT Mechanical Engineering IV sem core course

PCME4206 Basic Manufacturing Process


Module - I (12 Lectures)
1. Foundry :
(a) Types of patterns, pattern materials and pattern allowances.
(b) Molding Materials - sand molding, metal molding, investment molding, shell molding.
(c) Composition of molding sand, Silica sand, Zircon sand, binders, additives, Binders -
clay, binders for CO2 sand, binder for shell molding, binders for core sand.
(d) Properties of molding sand and sand testing.
(e) Melting furnaces - cupola, resistance furnace, induction and arc furnace.
(f) Solidification of castings, design of risers and runners, feeding distance, centre line
freezing resistance chills and chaplets.
(g) Degasification and inoculation of metals.
(h) Casting methods like continuous casting, centrifugal casting, disc casting.
(i) Casting defects.
Module – II (12 Lectures)
2. Welding and cutting: Introduction to gas welding, cutting, Arc welding and equipment’s. TIG
(GTAW) and MIG (GMAW) welding, resistance welding and Thermit welding. Weldablity
Modern Welding methods like plasma Arc, Laser Beam, Electron Beam, Ultrasonic,
Explosive and friction Welding, edge preparation in butt welding.
Brazing and soldering, welding defects.
Destructive and non-destructive testing of castings and welding.
3. Brief introduction to powder metallurgy processes.
Module – III (14 Lectures)
4. Plastic deformation of metals: Variables in metal forming and their optimization. Dependence of
stress strain diagram on Strain rate and temperature. Hot and cold working of metals,
classification of metal forming processes.
5. Rolling: Pressure and Forces in rolling, types of rolling mills, Rolling defects.
6. Forging: Smith Forging, Drop and Press forging, M/c forging, Forging defects.
7. Extrusions: Direct, Indirect, Impact and Hydrostatic extrusion and their applications, Extrusion
of tubes.
8. Wire drawing methods and variables in wire-drawing, Optimum dies shape for extrusion and
drawing.
9. Brief introduction to sheet metal working: Bending, Forming and Deep drawing, shearing.
10. Brief introduction to explosive forming, coating and deposition methods.
Text Books
1. Manufacturing technology - by P.N.Rao, Tata McGraw Hill publication.
2. Welding Technology by R.A. Little, TMH
3. Manufacturing Science by A.Ghosh and A K Malick, EWP

Reference Books
1. Fundamentals of metal casting technology by P.C. Mukherjee, Oxford PIBI.
2. Mechanical Metallurgy by Dieter, Mc-Graw Hill
3. Processes and Materials of Manufacture by R.A Lindberg, Prentice hall (India)
4. A Text Book of Production Engineering by P.C.Sharma, S.Chand
UPTU Mechanical Engineering IV Sem core course

EME- 402 : MANUFACTURING SCIENCE-I


Unit-I
Introduction :
Importance of manufacturing. Economic & technological considerations in
manufacturing. Classification of manufacturing processes. Materials &
manufacturing
processes for common items. 2
Metal Forming Processes :
Elastic & plastic deformation, yield criteria. Hot working vs cold working. 2
Analysis (equilibrium equation method) of Forging process for load estimation
with sliding friction sticking friction and mixed condition for slab and disc.
Work required
for forging, Hand, Power, Drop Forging 5
LTP
310
22
Unit-II
Metal Forming Processes (continued):
Analysis of Wire/strip drawing and maximum-reduction, Tube drawing,
Extrusion
and its application. 3
Condition for Rolling force and power in rolling. Rolling mills & rolled-sections.
2
Design, lubrication and defects in metal forming processes. 2
Unit-III
Sheet Metal working :
Presses and their classification, Die & punch assembly and press work
methods
and processes. Cutting/Punching mechanism, Blanking vs Piercing.
Compound vs
Progressive die. Flat-face vs Inclined-face punch and Load(capacity) needed.
4
Analysis of forming process like cup/deep drawing. Bending & spring-back. 3
Unit-IV
Unconventional Metal forming processes :
Unconventional metal forming processes such as explosive forming,
electromagnetic,
electro-hydraulic forming. 2
Powder Metallurgy :
Powder metallurgy manufacturing process. The need, process, advantage
and
applications. 2
Jigs & Fixtures :
Locating & Clamping devices & principles. Jigs and Fixtures and its
applications. 2
Manufacturing of Plastic components :
Review of plastics, and its past, present & future uses. Injection moulding.
Extrusion of plastic section. Welding of plastics. Future of plastic & its
applications.
Resins & Adhesives. 2
Unit-V
Casting (Foundry)
Basic principle & survey of casting processes. Types of patterns and
allowances.
Types and properties of moulding sand. Elements of mould and design
considerations,
Gating, Riser, Runnes, Core. Solidification of casting,. Sand casting, defects &
remedies
and inspection. Cupola furnace. 7
Die Casting, Centrifugal casting. Investment casting, CO2 casting and Stir
casting etc. 3
Books :
1. Manufacturing Science by Ghosh and Mallik
2. Production Engg. Science by P.C. Pandey
23
3. Production Technology by R.K. Jain
4. Manufacturing Technology by P.N. Rao., TMH
5. Materials and Manufacturing by Paul Degarmo.
6. Manufacturing Science by KM Moeed.
7. Manufacturing Engineering & Technology by Kalpakjian, Pearson Pub.

EME-452 : MANUFACTURING SCIENCE-1 LAB L T P


003
Experiments :
Say minimum 8 experiments out of following (or such experiment).
25
1. Design of pattern for a desired casting (containing hole)
2. Pattern making
3. Making a mould (with core) and casting.
4. Sand testings (at least one such as grain fineness number determination)
5. Injection moulding with plastics
6. Forging hand forging processes
7. Forging - power hammer study & operation
8. Tube bending with the use of sand and on tube bending m/c.
9. Press work experiment such as blanking/piercing, washer, making etc.
10. Wire drawing/extrusion on soft material.
11. Rolling-experiment.
12. Bending & spring back.
13. Powder metallurgy experiment.
14. Jigs & Fixture experiment.
15. Any other suitable experiment on manufacturing science / process /
technique.

UPTU Mechanical Engineering V Sem core course

EME-503 : MANUFACTURING SCIENCE-II


Unit-I
A Metal Cutting and Machine Tools
Metal Cutting-
Mechanics of metal cutting. Geometry of tool and nomenclature .ASA system
Orthogonal vs. oblique cutting. Mechanics of chip formation, types of chips.
Shear angle
relationship. Merchant’s force circle diagram. Cutting forces, power required.
Cutting
fluids/lubricants. Tool materials. Tool wear and tool life. Machinability.
Dynamometer.
Brief introduction to machine tool vibration and surface finish. Economics of
metal
cutting. 9
Unit-II
Machine Tools
(i) Lathe : Principle, construction, types, operations, Turret/capstan,
semi/Automatic, Tool layout. 2
(ii) Shaper, slotter, planer : Construction, operations & drives. 1
(iii) Milling : Construction, Milling cutters, up & down milling. Dividing head &
indexing. Max chip thickness & power required. 2
(iv) Drilling and boring : Drilling, boring, reaming tools. Geometry of twist
drills. 2
Unit-III
Grinding & Super finishing
(v) Grinding : Grinding wheels, abrasive & bonds, cutting action. Grinding
wheel
specification. Grinding wheel wear - attritions wear, fracture wear. Dressing
and Truing. Max chip thickness and Guest criteria. Surface and Cylindrical
grinding. Centerless grinding. 4
(vi) Super finishing : Honing, lapping, polishing. 1
Standardization & Interchangeability, Limits, Fits & Tolerance and
Surfaceroughness:
Introduction to Standardization & Interchangeability Limits, Fits, Tolerances
and
IS standards, Limit-gauges, and surface-roughness. 3
Unit-IV
B. Metal Joining (Welding)
Survey of welding and allied processes. Gas welding and cutting, process and
equipment. Arc welding : Power sources and consumables. TIG & MIG
processes and
their parameters. Resistance welding - spot, seam projection etc. Other
welding
processes such as atomic hydrogen, submerged arc, electroslag, friction
welding.
Soldering & Brazing . 8
Thermodynamic and Metallurgical aspects in welding and weld,.
Shrinkage/residual stress in welds. Distortions & Defects in welds and
remedies. Weld
decay in HAZ. 2
LTP
310
29
Unit-V
C. Introduction to Un-conventional Machining and Welding
Need & benefits, application and working principle of EDM, ECM, LBM, EBM,
USM. AJM, WJM. Similarly, non-conventional welding applications such as
LBW, USW,
EBW, Plasma-arc welding, Diffusion welding, Explosive welding/cladding. 6
Books
1. Manufacturing science by Ghosh and Mallik
2. Fundamentals of Metal Cutting and Machine tools by Boothroyd
3. Production Technology by R.K. Jain
4. Production Technology - H.M.T.
5. Production Engineering Science by P.C. Pandey
6. Modern Machining Processes by P.C. Pandey & H.S. Shan
7. Manufacturing science by Degarmo
8. Fundamentals of metal cutting & machine tools - Juneja & Shekhon
9. Process & materials of manufacturing - Lindburg.
10. Advanced Machining Process - VK Jain

EME-553 : MANUFACTURING SCIENCE -II – LAB


LTP
003
Say, min 8 experiments out of the following
(or such experiment along-with study of the machines/processes)
32
1. Shear-angle determination (using formula) with tube cutting (for
orthogonal) on
lathe machine.
2. Bolt (thread) making on Lathe machine
3. Tool grinding (to provide tool angles) on tool-grinder machine.
4. Gear cutting on Milling machine.
5. Machining a block on shaper machine.
6. Finishing of a surface on surface-grinding machine.
7. Drilling holes on drilling machine and study of twist-drill.
8. Study of different types of tools and its angles & materials.
9. Experiment on tool wear and tool life.
10. Experiment on jigs/Fixtures and its uses
11. Gas welding experiment
12. Arc welding experiment
13. Resistance welding experiment.
14. Soldering & Brazing experiment
15. Experiment on unconventional machining.
16. Experiment on unconventional welding.
17. Experiment on TIG/MIG Welding.
18. Macro and Microstructure of welding joints, HAZ.

JNTU, HYDERABAD, Mechanical Engineering, B.Tech. II Year I-Sem T P C


4+1* 0 4
PRODUCTION TECHNOLOGY
UNIT – I
CASTING : Steps involved in making a casting – Advantage of casting and its applications. – Patterns
and Pattern making – Types of patterns – Materials used for patterns, pattern allowances and their
construction, Principles of Gating, Gating ratio and design of Gating systems

UNIT – II
Solidification of casting – Concept – Solidification of pure metal and alloys, short & long freezing range
alloys.
Risers – Types, function and design, casting design considerations, special casting processes 1) Centrifugal
2)Die, 3) Investment.
Methods of Melting : Crucible melting and cupola operation, steel making processes, special.

UNIT – III
A) Welding : Classification of welding process types of welds and welded joints and their
characteristics, design of welded joints, Gas welding, ARC welding, Forge welding, resistance
welding, Thermit welding and Plasma (Air and water ) welding.
B) Cutting of Metals: Oxy – Acetylene Gas cutting, water plasma. Cutting of ferrous, non-ferrous
metals.

UNIT – IV
Inert Gas welding, TIG & MIG, welding, Friction welding, Induction welding, Explosive welding, Laser
welding, Soldering & Brazing. Heat affected zones in welding;
welding defects – causes and remedies – destructive nondestructive testing of welds.

UNIT – V
Hot working, cold working, strain hardening, recovery, recrystallisation and grain growth, Comparison of
properties of Cold and Hot worked parts, Rolling fundamentals – theory of rolling, types of Rolling mills and
products. Forces in rolling and power requirements.

UNIT - VI
Stamping, forming and other cold working processes : Blanking and piercing – Bending and forming –
Drawing and its types – wire drawing and Tube drawing – coining – Hot and cold spinning – Types of
presses and press tools. Forces and power requirement in the above operations.

UNIT- VII
EXTRUSION OF METALS : Basic extrusion process and its characteristics. Hot extrusion and cold
extrusion - Forward extrusion and backward extrusion – Impact extrusion Hydrostatic extrusion.
Forging processes: Principles of forging – Tools and dies – Types Forging – Smith forging, Drop Forging
– Roll forging – Forging hammers : Rotary forging – forging defects.

UNIT - VIII
Processing of Plastics: Types of Plastics, Properties, applications and their Processing methods &
Equipment (blow &injection modeling)

TEXT BOOKS :
1. Manufacturing Engineering and Technology/Kalpakjin S/ Pearson Edu.
2. Manufacturing Technology / P.N. Rao/TMH
REFERENCES :
1. Production Technology / R.K. Jain
2. Process and materials of manufacturing –Lindberg/PE
3. Principles of Metal Castings / Roenthal.
4. Welding Process / Paramar /
5. Production Technology /Sarma P C /
6. Production Engineering – Suresh Dalela & Ravi Shankar / Galgotia Publications Pvt. Ltd.

JNTU, HYDERABAD II Year B.Tech. M.E.II-Sem T P C


0 3 2
PRODUCTION TECHNOLOGY LAB

Minimum of 12 Exercises need to be performed


I. METAL CASTING LAB :
1. Pattern Design and making - for one casting drawing.
2. Sand properties testing - Exercise -for strengths, and
permeability – 1
3. Moulding Melting and Casting - 1 Exercise
II WELDING LAB :
1. ARC Welding Lap & Butt Joint - 2 Exercises
2. Spot Welding - 1 Exercise
3. TIG Welding - 1 Exercise
4. Plasma welding and Brazing - 2 Exercises
(Water Plasma Device)
III MECHANICAL PRESS WORKING :
1. Blanking & Piercing operation and study of simple, compound and progressive press tool.
2. Hydraulic Press : Deep drawing and extrusion operation.
3. Bending and other operations
IV PROCESSING OF PLASTICS
1. Injection Moulding
2. Blow Moulding

Pune University Mechanical Engineering III sem core course

211045 MANUFACTURING PROCESSES I


Teaching Scheme: Examination Scheme:
Lectures: 3 Hrs/week Theory: 100 Marks
UNIT 1
Pattern Making, Moulding and Casting 5 Hrs
Sand casting, Pattern types, materials, pattern making allowances, Moulding sand
types, properties and testing, hand and machine moulding process and equipments,
core-type and manufacturing, Furnaces – types- cupolas – construction, operation ,
zones, chemistry etc. Gating systems. Cleaning and finishing, Defects in casting.
Special moulding and casting processes – lost foam process, shell moulding,
investment cast5ing, Die casting, Centrifugal casting, Continuous casting.
Processing of Plastics 2 Hrs
Introduction to plastic moulding - Various plastic moulding processes and
materials.
UNIT 2 Hot Working and Cold Working Processes 7 Hrs

Principle - Rolling, Forging-drop, press, upset. Roll forging – Extrusion, drawing,


spinning. Effects of hot working.
Cold rolling, swaging, forging, extrusion – forward, backward, impact. Roll
forming, tube drawing, wire drawing, spinning, shot peening, HERF.
Sheet metal working – types of presses, drives and different operations.
UNIT 3 Joining Processes 7 Hrs
Arc Welding – Theory, SMAW, GTAW, GMAW, FCAW, submerged arc
welding, stud welding.
Resistance Welding – Theory, spot, seam, projection welding processes.
Gas welding, friction welding, ultrasonic welding, thermit welding, electron beam
and laser welding, explosive and plasma welding.
Soldering, brazing and braze welding.
Use of adhesives for joining – Classification of adhesives, types of adhesives,
applications, surface preparation and various joints.
UNIT 4 Turning – Lathe Machines 7 Hrs
Introduction to lathe, Types, Construction, Working, Accessories, Single point
cutting tool geometry.
Various operations on lathe – Thread Cutting, Taper turning etc.
UNIT 5
Milling Machines 4 Hrs
Fundamentals of milling process, cutters – types and geometry. Operations
performed on milling machines. Dividing head, methods of indexing. Gear train
calculations for helical and cam milling.
Drilling Machines 3 Hrs
Fundamentals of drilling process, Twist drill geometry, tool holders. Types of
drilling machines. Operations performed on drilling machines. Types of drills. Reaming
process, types of reamers, and geometry. Tap and its geometry.
UNIT 6 Grinding Machines 7 Hrs
Abrasive machining process machines – types, construction and operation.
Grinding – grinding wheel – making, marking and mounting.
Special grinding machines – honing, lapping, super finishing, buffing, burnishing.
Text Books:
1. Hajara Choudhari, Bose S. K.
Elements of Workshop Technology Vol I, II
Asia Publishing House
2. P. N. Rao
Manufacturing Technology Vol I & II
Tata McGraw Hill Publishing Co
Reference Books:
1. R. K. Jain
Production Technology
Khanna Publishers
2. P. C. Sharma
Production Technology
Khanna Publishers
3. Chapman W. A. J.
Workshop Technology Vol I, II, III
ELBS Publishers
4. HMT
Production Technology
Tata McGraw Hill Publishing Co
5. Degarmo, Black and Kosherth
Materials and Processes in manufacturing 8th Edition
Prentice Hall of India

Pune University Mechanical Engineering IV sem core course


211052 MANUFACTURING PROCESSES II
Teaching Scheme: Examination
Scheme:
Lectures: 3 Hrs/week Theory: 100 Marks
UNIT 1 Theory of Metal Cutting
8 Hrs
Cutting tool, tool geometry. Concept of speed, fees, depth of cut and cutting
action and effect of these on cutting forces. Merchant’s circle of forces. Estimation of
cutting forces, machinability. Tool life for minimum cost and maximum production.
Cutting fluids.
New technology in metal cutting for higher productivity. Measurement of cutting
forces and power required.
Cutting tools: Design of single point, multi point and form tools.
UNIT 2
8 Hrs
Broaching
Types of broaching machines. Parts of the machine and their functions.
Components machined on broaching machine. Broach geometry.
Gear Manufacturing
Gear cutting processes – Gear hobbing, Gear shaping, Gear shaving, Gear lapping
and gear grinding.
Construction and working of the machines.
Thread Manufacturing
Thread cutting, chasers, and dies. Thread milling; thread rolling, thread lapping
and thread grinding.
UNIT 3 Introduction to NC, CNC Machines
8 Hrs
Introduction to NC, CNC, DNC machines. Machining centers – principles,
working, advantages, and applications. Introduction to FMS.
UNIT 4 Non Conventional Methods of Machining
8 Hrs
Introduction, Principles, Parameters and Applications of CM, ECM, EDM, EBM,
IBM, PAM, Laser cutting and welding, AJM, USM.
UNIT 5 Sheet Metal Working
8 Hrs
Study of various press tools and presses. Study of Piercing, Notching, Forming,
Coining, Drawing processes. Elements of dies and punch set. Types of dies and
punches of different press working operations.
Calculations of clearances, center of pressure, different forces, press tonnage,
blank size, number of draws, strip layout, sheet utilization ratio, methods of reducing
forces.
UNIT 6 Jigs and Fixtures
8 Hrs
Introduction, Definitions, elements, basic principles. Introduction to locators and
clamping – basic principles, types. Types of jigs and fixtures.
Text Books:
1. P. N. Rao
Manufacturing Technology Vol I & II
Tata McGraw Hill Publishers
2. P. C. Sharma
Production Engineering
Khanna Publishers
Reference Books:
1. R. K. Jain
Production Technology
Khanna Publishers
2. HMT
Production Technology
Tata McGraw Hill Publishers
3. Hoffman
Introduction to Jigs and Fixtures
Galgotia Publishers
4. S. K. Basu
Fundamentals of Tool Design
Oxford IBH
5. Tool Engineering Handbook
ASTME