MANUFACTURING TECHNOLOGY

3 0

L T P M 0 100 3

COURSE OBJECTIVES: To make the students aware of different manufacturing processes like metal forming, casting, metal cutting processes, gear manufacturing processes. PREREQUISITES: Nil
SYLLABUS:

UNIT I 9

Casting Process

Casting types, procedure to make sand mould, types of core making, moulding tools, machine moulding, special moulding processes-CO 2 moulding; shell moulding, investment moulding, permanent mould casting, pressure die casting, centrifugal casting, continuous casting, casting defects. UNIT II 9 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. UNIT III 9 Sheet Metal: Blanking, Piercing, Punching, Trimming, Stretch forming, Shearing, Bending, Tube forming Embossing and coining, Types of dies: Progressive, compound and combination dies , presses and press working operations, classification of presses, press tools. Plastics: Types of plastics-characteristics of the forming and shaping processesMoulding of Thermoplastics - working principles and typical applications of Injection moulding - Extrusion-typical industrial applications -Thermoforming compression moulding - Transfer moulding - Bonding of thermoplastics Forming and Shaping Process Bulk Deformation Process

UNIT IV 9

Machining Process

General principles (with schematic diagrams only) of working and commonly performed operations in the following machines: Lathe, Shaper, Planer, Horizontal milling machine, Universal drilling machine, cylindrical grinding machine, Capstan and Turret lathe. Basics of CNC machines. General principles and applications of the following processes: Abrasive jet machining, Ultrasonic machining, Electric discharge machining, Electro chemical machining, Plasma arc machining, Electron beam machining and Laser beam Machining UNIT V Joining Process and Special Process for Manufacturing of Aircraft 9 Classification of welding processes. Principles of Oxyacetylene gas welding. A.C. metal arc welding, resistance welding, submerged arc welding, tungsten inert gas welding, metal inert gas welding, plasma arc welding, thermit welding, electron beam welding, laser beam welding, defects in welding, soldering and brazing. Riveting techniques and its types. Special Process: Powder Metallurgy Heat Treatment Surface finishing Introduction to Fabrication of Composites. . TOTAL : 45 Hours CONTENT BEYOND SYLLABUS 1. Special Process in Manufacturing for aerospace components 2. Specific Tools Like Jigs and Fixtures. 3. CNC Programming TEXT BOOKS 1. Harija choudry, Elements of workshop Technology, vol. I and II Media promoters and publishers pvt., Ltd., Mumbai, 2001. 2. Champman W.A.J., Production Technology, 4th Edition, Arnold Publisher, New Delhi, 1994 3. Keshu, S.C., Ganapathy K.K., Aircraft Production Techniques - Interline Publishing House, Bangalore REFERENCE BOOKS 1. H. M. T. production technology-Hand book, Tata Mc Graw-Hill, 2000 2. V. Austin, Workshop Theory, Macmillan and Co. Ltd. 3. F.H. Hallet, machine Shop Theory and Practice, Macmillan & Co. Ltd. 4. Kroes, Watkins Delp, "Aircraft maintenance and repair", McGraw Hill.

5. A & P Mechanics, "Aircraft Handbook - F.A.A. Himalayan book house, New Delhi. WEB RESOURCES : W1. http://nptel.iitm.ac.in/video.php?subjectId=112105126 W2.http://nptel.iitm.ac.in/courses/Webcourse-contents/IIT%20Kharagpur/Manuf %20Proc%20II/New_index1.html W3. http://nptel.iitm.ac.in/video.php?subjectId=112107145 W4. http://nptel.iitm.ac.in/courses/Webcourse-contents/IITROORKEE/MANUFACTURING-PROCESSES/index.htm W5. http://nptel.iitm.ac.in/courses/112107078/ W6. http://nptel.iitm.ac.in/courses/112107077/ W7. http://nptel.iitm.ac.in/courses/112104028/ COURSE OUTCOMES: At the end of the course student should be able to: 1. Study the various ways of working of metals 2. Concept of casting Technology 3. Concept of Machining with lathes and automats 4. Study of Milling machine and Gear manufacturing process 5. Various Surface finishing and Surface hardening processes. COURSE ASSESSMENT METHODS: Continuous Assessment End Semester Exam LESSON PLAN :
SL.NO TOPICS TO BE COVERED MODE OF INSTRUCTION NO OF HOURS REFER

IA Exams 15 Marks

Attendance 5 Marks

Total 20 Marks Total 80 Marks

Total 100 Marks

1 2 3 4 5 6 7 8 9

UNIT-I CASTING PROCESS Casting types, procedure to make sand mould Black Board Types of core making Black Board Moulding tolls, Machine moulding PPT Special moulding processes-co2 moulding; shell Black Board moulding, investment moulding PPT / Black Permanent mould casting, pressure die casting Board Centrifugal casting, continuous casting PPT Casting defects PPT UNIT -II BULK DEFORMATION PROCESS Hot working and cold working of metals Black Board Forging processes Open, impression and closed die Black Board forging Characteristics of the process

2 1 1 2 1 1 1 1 2 T1, T2 T1, T2

10 11 12 13 14

Types of Forging Machines Black Board Typical forging operations Black Board Rolling of metals Types of Rolling mills - Flat strip rolling Shape rolling operations Defects in rolled Black Board parts Principle of rod and wire drawing -Tube drawing Black Board Principles of Extrusion Types of Extrusion Hot and PPT/ Black Cold extrusion Board UNIT -III FORMING AND SHAPING PROCESS Sheet Metal: Blanking, Punching, Trimming, Stretch forming, Shearing, Bending, Tube forming Embossing and coining, Types of dies: Progressive, compound and combination dies cup drawing Presses and Press working operations, Classification of presses, Press tools Plastics: Types of plastics-characteristics of the forming and shaping processes- Moulding of Thermoplastics working principles and typical applications of Injection moulding Extrusion-typical industrial applications Black Board

1 1 2 1 1

15

16 17 18 19 20 21

Black Board PPT PPT PPT / Black Board PPT / Black Board

1 1 T1, T2 1 1 2

Thermoforming compression moulding - Transfer PPT 1 moulding 22 Bonding of thermoplastics Black Board 1 UNIT - IV MACHINING PROCESS General principles (with schematic diagrams only) of PPT / Black 24 working and commonly performed operations in the 1 Board following machines: Lathe PPT / Black 25 1 Shaper, Planer Board PPT / Black 26 1 Horizontal milling machine Board Universal drilling machine, Cylindrical grinding PPT / Black 27 1 T1, T2 Board machine PPT / Black 28 1 Capstan and Turret lathe. Basics of CNC machines Board General principles and applications of the following PPT / Black 29 1 Board processes: Abrasive jet machining, Ultrasonic machining Electric discharge machining, Electro chemical PPT / Black 30 1 Board machining Plasma are machining, Electron beam machining and PPT / Black 31 2 Board Laser beam Machining UNIT -V JOINING PROCESS AND SPECIAL PROCESS FOR MANUFACTURING OF AIRCRAFT 32 Classification of welding processes. Principles of PPT 1 T1, T2,

33 34 35 36 37 38

Oxyacetylene gas welding. A.C. metal arc welding Resistance welding Tungsten inert gas welding, Metal inert gas welding, Plasma arc welding Submerged arc welding , Thermit welding, Electron beam welding, Laser beam welding Defects in welding, Soldering and Brazing Riveting techniques and its types Special Process: Powder Metallurgy Heat Treatment Surface finishing Introduction to

Black Board PPT

1 1
1 1 1 1 1

T3

PPT PPT PPT Black Board PPT Video PPT Black Board

Fabrication of Composites. CONTENT BEYOND SYLLABUS 39 40 41

Special Process in Manufacturing for aerospace components Specific Tools Like Jigs and Fixtures CNC programming

2 1 1

MAPPING COURSE OUTCOMES WITH PROGRAMME OUTCOMES: COURSE OUTCOMES I II PROGRAMME OUTCOMES 1 2 3 4 5 6 7 8 9 10 11 12