PROGRAM : BACHELOR OF ENGINEERING

(HONOURS) MECHANICAL (EM 220)

COURSE : MANUFACTURING PROCESSES
COURSE CODE : MEM560
CREDIT HOURS : 3
LECTURER : Dr. Kausalyah Venkatason
CONTACT : 03-55436275 / 012-4596293
EMAIL : kausalyah@salam.uitm.edu.my/ kausalyah@hotmail.com,
ROOM : T1- A16 2A

COURSE
DESCRIPTION

This course covers the different types of manufacturing processes and technology usually
employed in industries. It includes the study of metal forming and shaping processes,
metal casting, sheet-metal working, joining, traditional and non-traditional machining, jig
and fixture, metrology and manufacturing of semiconductor devices. This course also
emphasizes the competitiveness aspects of manufacturing processes.

COURSE CONTENT AND COMPLETION PERIODS

Week TOPICS
1 INTRODUCTION:
Course Briefing: Syllabus, Methods of Instruction, Evaluation, Final
Examination Grading

1 1.0 Overview of Manufacturing Processes and Technology (2 hours)

1.1 Role of Manufacturing in Nations Economy
1.2 Competitiveness Aspects of Manufacturing Processes
1.3 Manufacturing Cost
1.4 Awareness of Value Engineering

MEM560 Course 1
Outline
 2 2.0 Introduction to Metrology and Instrumentation (2 hours)
2.1 Tolerance, Limits and Fits
2.2 Linear Measurement using Tools such as Dial Gauges,
Micrometer, and Callipers
2.3 Angular Measurement using Profile Projector
2.4 Straightness, Flatness, and Roundness Measurement
2.5 Surface Roughness Measurement
2.6 Measurement using GO and NO GO Concept
2.7 Coordinate Measuring Machine

MEM560 Course 2
Outline
2,3,4,5 3.0 Metal Forming and Shaping Processes (8 hours)
3.1 Classification
3.2 Open-Die Forging
3.3 Impression-Die and Closed-Die Forging
3.4 Extrusion
3.5 Drawing
3.6 Rolling
3.7 Sheet-metal Working Processes
3.8 Process Design Considerations

5,6,7 4.0 Metal Casting (6 hours)

4.1 Introduction
4.2 Sand Casting: Pattern Making, Mould Making, Melting and
Pouring, Cooling and Solidification, Cleaning and Finishing
4.3 Shell Moulding
4.4 Investment Casting
4.5 Die Casting
4.6 Advantage and Limitation of processes

7,8,9 5.0 Technology of Joining (6 hours)

5.1 Welding Processes
5.2 Soldering, Brazing
5.3 Adhesive Bonding
5.4 Mechanical Fasteners
5.5 Joining Processes selection

9,10,11 6.0 Traditional Machining (6 hours)

6.1 Introduction to Traditional Machines
6.2 Machine Tools System
6.3 Machining Operations
6.4 Metal Cutting Process
6.5 Chip Formation
6.6 Cutting Tools
6.7 Tool Life and Wear
6.8 Cutting Fluids
6.9 Machinability
6.10 Economics of Metal Cutting

11,12 7.0 Non-Traditional Machining (NTM) (4 hours)

7.1 Electrochemical Machining (ECM)
7.2 Electrical-Discharge Machining (EDM)
7.3 Ultrasonic Machining (USM)
7.4 Electron-Beam Machining (EBM)
7.5 Other NTM such as CNC, Laser cutting, and Water-jet cutting
 12,13 8.0 Processing of Plastics (5 hours)
8.1 Classification of Polymers
8.2 Extrusion
8.3 Injection Moulding
8.4 Blow Moulding
8.5 Thermoforming
8.6 Process Design Considerations

14 9.0 Powder Metallurgy (3 hours)

9.1 Introduction
9.2 Production of Metals Powder
9.3 Compaction of Metal Powder
9.4 Secondary and Finishing Operation
9.5 Powder Metallurgy Products
9.6 Process Design Considerations

COURSE OUTCOMES

Upon completion this course, students should be able to:

CO1 Determine manufacturing processes and technology for various manufacturing

products.
CO2 Evaluate quality of manufacturing products using appropriate techniques and
methods.
CO3 Select suitable manufacturing processes and technologies for particular products.
CO4 Share knowledge and observation on manufacturing processes and technologies
through group presentation in a professional manner.

Related Program Outcomes (POs):

PO1: Able to apply knowledge of mathematics, science, engineering fundamentals and

an engineering specialisation to the solution of complex engineering problems.

PO2: Able to identify, formulate, research literature and analyse complex engineering
problems reaching substantiated conclusions using first principles of mathematics,
natural sciences and engineering sciences.

PO4: Able to conduct investigation into complex problems using research-based

knowledge and research methods including design of experiments, analysis and
interpretation of data and synthesis of information to provide valid conclusions.

PO10: Able to function effectively as an individual, and as a member or leader in diverse

teams in multi-disciplinary settings.
TEACHING METHODOLOGY:

Lecture:
Lectures are given to cover the basic principles of each topic.

Industrial Visit:
At least one visit to the related industry. Share the industrial visit experience with others
colleague through presentation.

Assignment/ Problem Based Learning (PBL):

Students are encouraged to take responsibility for their group and organize and direct the
learning process with support from a lecturer.

ASSESSMENTS

The overall assessment for the course will be as follows:

Course Work : 40%

Test 1
: 10% Test 2
: 10% Assignment/PBL
: 10% Industrial visit +
report : 10%
Final Examination :
60% Total :
100%

MARKING SCALES: Range Code M3

4.0 A+ 90 100 2.3 C+ 55 59

4.0 A 80 89 2.0 C 50 54
0
3.6 A- 75 79 0
1.6 C- 47 49
7
3.3 B+ 70 74 7
1.3 D+ 44 46
3
3.0 B 65 69 3
1.0 D 40 43
0
2.6 B- 60 64 0
0.6 E 30 39
7 7
0.0 F 0 29
0

RECOMMENDED TEXTBOOK

Manufacturing Engineering and Technology, Serope

Kalpakjian, 10th Edition, Prentice Hall, 2010.

REFERENCES
th
1. Groover, M.P., Principles of Modem Manufacturing, SI Version, 4 Edition, John
Wiley and Sons, Inc 2011.
2. P. N. Rao, Manufacturing Technology, Foundary, Forming and Welding, 2" Edition,
Institut Teknologi MARA, Malaysia, McGraw Hill, 1998.
 th
3. John A.Schey, J.A., Introduction to Manufacturing Processes, 5 Edition, McGraw
Hill, 2000.