MEE205 Version No.

Prerequisite Objectives:

FUNDAMENTALS OF MANUFACTURING PROCESSES

1.01 To help students acquire knowledge about the behaviour and manufacturing properties of all engineering materials and basic concepts of foundry and casting processes. 2. To teach students various methods of welding, cold and hot working and forming. 3. To enable students understand forging, molding and powder metallurgy processes in detail. Expected Student will be able to Outcome: 1. Demonstrate an understanding of various materials and their properties employed in different manufacturing processes. 2. Understand the principles of foundry and casting. 3. Choose materials in a manufacturing process based on their properties. 4. Study in detail about the modern welding processes followed in industries. 5. Conduct experiments on various manufacturing processes and to automate them. 6. Design gating system, dies for forging and powder metallurgy processes. 7. Demonstrate an ability to solve engineering problems in welding and powder metallurgy processes pertaining to the selection of process parameters. 8. Demonstrate an ability to use manaufacuring techniques for economic production. 9. Choose correct manufacturing process for a particular engineering application. Unit I Metal Casting Processes Manufacturing- selecting manufacturing process global competitiveness of manufacturing costs Fundamentals of materials- their behavior and manufacturing properties Ferrous metals and alloys Non ferrous metals and alloys Fundamentals of metal casting Fluidity of molten metal Solidification time Sand casting Shell mold casting Investment casting - Plaster mold casting Ceramic mold casting Die casting Centrifugal casting Melting practice and furnaces - Defects in sasting Testing and inspection of casting. Unit II Joining Processes Metal fusion welding processes Oxyfuel gas welding Arc welding processes Consumable electrode: SMAW- SAW GMAW FCAW Electro gas welding Electro slag welding Non-consumable Electrode: GTAW- AHW- PAW EBM LBM Solid state welding processes: Ultrasonic welding Friction welding Friction stir welding Resistance welding Weld quality Testing welded joints. Unit III Metal Forming Processes Cold and Hot working: Rolling Forging Extrusion Drawing Sheet metal forming

processes High Energy Rate Forming Processes: Explosive Forming Electro Hydraulic Forming Electro Magnetic Forming. Unit IV Processing of Powder Metals, Ceramics and Glass Production of metal powders: Compaction Sintering and Finishing Design considerations for powder metallurgy and Process capability Shaping of ceramics Forming and shaping of glass Design considerations for ceramics and glass Processing of superconductors. Unit V Processing of Plastics and Composite Materials Types of Plastics Types of Molding: Injection molding Blow molding Compression molding Transfer molding Thermoforming Reinforced plastics Metal Matrix Composites Ceramic Matrix Composites. Text Books W.A.J.Chapman (1999), Manufacturing Technology, Vol 1, Arnold Publisher. References 1. 1. S.Kalpakjian and S.R.Schmid, (2004), Manufacturing Engineering and Technology, 4th Edition, Pearson Education (Singapore) Pte Ltd. 2. P.N.Rao. (1998), Manufacturing Technology Foundry, Forging and Welding, Tata McGraw Hill Publishing Company Ltd., New Delhi. 3. Hajra Choudhury S.K. (2000), Elements of Manufacturing Technology, Vol. - I, Media Publications. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on: 31-10-2009 Date of Approval by the Academic Council: 27-11-2009