BITS PILANI K K Birla Goa Campus

First Semester 2016-2017

(Course Handout Part II)

Date: August 1, 2016

In addition to Part-I (General Handout for all courses appended to the
timetable) this portion gives specific details regarding the course.
Course No.
Course Title
Instructor-in-charge

: ME F243
: Production Techniques I
: Varinder Singh

Team of Instructors(Lab)

: P M Singru, G Karthikeyan, Nikhil Kadam

Course description:
Metal casting processes and analysis, Metal cutting processes and
machine tools e.g. lathe, shaper, planer, drilling and grinding; Introduction
to metal forming processes, Joining Processes, shop practice involving
machining, foundry and non destructive testing, etc.
1. Scope and Objective of the Course:
This scope of the course is to provide an exposure to the basic
manufacturing processes and their applications to produce different kinds
of manufactured goods. The casting and machining processes are to be
covered in detail while the discussion on forming processes is going to be
introductory while its detailed treatment is left to the next level course.
The discussion on joining processes, non destructive testing (NDT) as well
as Joining processes will also be included. The objective is to develop a
sense of comparison for choosing appropriate manufacturing process to
meet the requirements and also to make the student competent to
establish appropriate process parameters for different processes.
The course has structured lab exercises for imparting hands on
experience on different basic manufacturing and allied processes.
Exercises on testing of foundry sand, Non destructive testing, welding and
machining have been particularly incorporated.
Books:
(i)

Textbook
1. Serope Kalpakjian and Steven Schmid, Manufacturing Processes
for Engineering Materials, Pearson education, India
2. Amitabha Ghosh and Ashok Kumar Mallik, Manufacturing
Science, Affiliated East-West Press, New Delhi.

(ii)

Reference Books
1. E. Paul Degarmo, J.T. Black, Ronald A. kosher, Materials and
processes in Manufacturing, PHI 2005.

2. Mikell P. Groover, Fundamentals of Modern Manufacturing, Third

edition, John Wiley& sons Pvt Ltd.
3. Campbell J.S., Principles of Manufacturing Materials and
Processes, Tata McGraw-Hill, New Delhi, 1995 print.
4. Richard R. Kibbe et all, Machine Tool practices, Sixth edition,
Prentice Hall of India Pvt. limited, New Delhi, 2003.
5. S K Hajra Choudhary et al. Elements of Workshop Technology,
Media Promotors and Publisher Pvt.Ltd.
2. Course Plan
Module
Name

Subtopics to be
covered

Learning
Outcome

Introduction
to
Manufacturi
ng Processes

Basics
of
Manufacturing;
Different
manufacturing
processes,
comparisons and
applications
Fundamentals
of
material
science
and metallurgy for
production
processes

Student will be
able to list and
compare
different
manufacturing
processes and
their applications
Student will learn
about major
material science
fundamentals
affecting
manufacturing
processes
Student will be
made aware of
the basic
techniques used
in casting and
defects possible
Student will learn
about analysis
useful for design
of moulds for
avoiding defects
Student will be

Engineering
Materials

Metal
Casting

(i)Introduction
to
Casting
process,
patterns
and
cores, sand casting
moulds,
casting
operation
(ii) Gating design,
cooling
and
solidification; riser
design
and
placement,
(iii) Die casting,

Text
book/
Referen
ce bookChapter
No.
Lecture
slides

No. of
Lecture
s+
Tutorial
s

T-2/1,
T1/3

T-2/2

T-2/2

T-1/5

Metal
Cutting and
Machine
Tools

Joining
Processes

Metal
Forming
processes

Metrology

other
casting
processes, casting
defects.
(i)Introduction
to
material removal
processes, process
of chip formation,
cutting tool and its
nomenclature,
cutting
tool
materials, tool life,
(ii)Machine
tools
such
as
lathe,
drilling m/c, milling
m/c,
shaper,
planer and work
holding
devices;
Grinding process,
grinding
wheel;
honing,
lapping,
super
finishing,
polishing
and
buffing. CNC m/c.
Welding processes
such as SMAW,
GTAW,
SAW,
Resistance welding
and
oxyfuel
welding;
Arc
welding
power
characteristics;
HAZ; Brazing and
soldering;
Mechanical joining.
Introduction
to
bulk deformation
processes
like
rolling,
forging,
extrusion
and
drawing,
thread
rolling,
Forging,
Deep Drawing.
Dimensions
and

made aware of
the advanced
casting methods
Student will learn
about basic
theory and
analysis behind
the metal cutting
operation.

T-1/8 and
class
notes

Student will be
able to select
appropriate
machine tool
from various
choices and learn
about for their
operating
procedures.

T-1/8 and
class
notes

Student will be
made aware of
various joining
processes
available, their
specific
applications and
their limitations.

T-1/12

Student will be
made aware of
basic forming
operations and
their
comparative pros
and cons

T-2/3; T1/ 6,7

Student will learn

T-1/4 and

and Quality
Control

Tolerances, surface
roughness, effect
of manufacturing
processes
on
surfaces, Gauges
for
inspection,
typical
tolerance
limits of common
mfg. processes.
3. Evaluation Scheme:

about the
standards for
defining
tolerances and
fits as well as QC
techniques

Class
notes

Component

Duration

Mar
ks

Date and
Time

Ven
ue

Test I

1 Hour

25

Test II

1 Hour

25

Class exercises

10min

20

Continuous

3 Hrs.

80

End of
cycle

30

Continuous

WS

20

See lab
notice

WS

Comprehensive
Examination
Lab work and report
writing
Practical Examination

Total
* consult time table booklet

Remarks

Open
book
Closed
book
Open
book
Closed
book
Open
book
Closed
book

200

4. Chamber consultation hour:

Wednesday 5:00-6:00PM.
5. Others: Any creative activity to promote the understanding of the
subject is encouraged. The students can come up with simple projects
to familiarize themselves with various manufacturing practices. For
this, the students can consult the Instructor/ the Instructor in Charge /
the Workshop Superintendent.
6. Make-up Policy: Make-up may be granted after ascertaining the
genuineness of the request.

Instructor-in-charge

ME F243