ME - 204 Manufacturing Processes I 3rd Semester and 2nd Year

Credit and Hours: Teaching Theory Practical Total Credit Scheme Hours/week 4 2 6 5 Marks 100 50 150 A Objective of the Course: To introduce the students various manufacturing and fabrications techniques. To provide background for higher level subjects in Engineering like B Production Technology. Out line of the Course: Sr. No. 1. Title of the Unit Minimum number of hours 08

Introduction to Metal Casting 2. Melting Practices 10 3. Casting Processes 12 4. Principles of Welding 02 Processes 5. Gas Welding 06 6. Electric Arc Welding 05 7. MIG welding 05 8. TIG welding 05 9. Resistance welding 07 Total hours (Theory): 60 Total hours (Lab): 30 Total: 90 C Detailed Syllabus: 1. Introduction to Metal Casting 08 20 Hours 1. 1 1. 2 Metal Casting, Sand Casting, Patterns, Cores, Gating & Risering Systems, Casting Defects & Inspection %

2. Melting Practices 2. 1 2. 2 Cupola: Charge calculations, construction

10 Hours

15 %

Other Furnaces working of induction furnace, crucible furnace, and reverberate furnace 12 Hours 15 %

3. Casting Processes 3. 1 3. 2 3. 3 4. Principles of Welding Processes 4. 1 5. Gas Welding 5. 1 Classification of Welding, Soldering and Brazing Centrifugal Casting, Carbon dioxide molding process Investment casting, Continuous casting Shell molding, Die casting, Vacuum-Sealed casting process

02 Hours

10 %

02

07 %

Hours Gas Welding, Fuel Gases, Oxy-Acetylene Welding Equipment and techniques, Gas Cutting Processes 05 Hours

6. Electric Arc Welding 6. 1 6. 2 7. MIG Welding 7. 1 Types of Arc Welding, Principle of Arc, Arc Welding Equipment

10 %

ISI electrode classification, current and voltage selection for electrodes

05

07

Hours % Process details, shielding gases, electrode wires, their sizes, and welding current ranges 05 06

8. TIG Welding

8. 1 8. 2

Hours % Process details, power sources requirements, electrode sizes and materials Current carrying capacities of different electrodes, shielding gases, application of process 07 10 Hours % General principle of heat generation in resistance welding, Process details and working principle of spot, seam, and. projection welding Electrode materials, shapes of electrodes, electrode cooling, selection of welding currents Voltages, manufacture of resistance seam welded (RSW) tubes by seam welding, various application of resistance welding processes.

9. Resistance Welding 9. 1 9. 2 9. 3

D Instructional Methods and Pedagogy: At the start of course, the course delivery pattern, prerequisite of the subject will be discussed. Lectures will be conducted with the aid of multi-media projector, black board, OHP etc. Attendance is compulsory in lectures and laboratory which carries 5 Marks weightage. Two internal exams will be conducted and average of the same will be converted to equivalent of 15 Marks as a part of internal theory evaluation. Assignments based on course content will be given to the students at the end of each unit/topic and will be evaluated at regular interval. It carries a weightage of 5 Marks as a part of internal theory evaluation. Surprise tests/Quizzes/Seminar will be conducted which carries 5 Marks as a part of internal theory evaluation. The course includes a laboratory, where students have an opportunity to build an appreciation for the concepts being taught in lectures. Experiments/Tutorials related to course content will be carried out in the laboratory.

In the lectures and laboratory discipline and behavior will be observed strictly.

Student Learning Outcomes : After learning the course, students will be able to understand casting and welding processes.

F Recommended Study Material: Text Books: 1. Rao P. N., Manufacturing Technology Foundry, Forming & Welding, Vol. 2, 3rd Edition, Tata McGraw-Hill 2004 2. Ghosh A. and Mallik A. K., Manufacturing Science, Prentice Hall PTR 2001/ 9780135526057 3. Kalpakjian S. and Schmid S.R., Manufacturing Engineering and Technology, 6th Edition, Prentice Hall, ISBN 0136081681 Reference books: 1. DeGarmo E. P., Black J. T. and Kohser R. A., Materials and Processes in Manufacturing, Prentice - Hall of India 2. Groover M. P., Fundamentals of Modern Manufacturing, John Wiley & Sons 3. Lindberg R. A., Processes and Materials of Manufacture, Prentice-Hall of India 4. Schey J., Introduction to Manufacturing Processes, Tata McGraw Hill 5. Pye R. G. W., Injection Mold Design, Longman Scientific & Technical, Essex, 1989 Reading Materials, web materials with full citations: 1. http://nptel.iitm.ac.in/courses/Webcourse-contents/IITROORKEE/MANUFACTURING-PROCESSES/index.htm 2. Foundry Informatics Centre, New Delhi http://www.foundry info-india.org Other materials 1. Journal of Material Processing Technology (Elsevier Publication) 2. Production Engineering (IE) http://www.ipcourseline.org 3. Sadhna http://www.ias.ac.in/sadhana/