DOC/LP/00/21/01/2005

/ LESSON PLAN / LP – 114306
LP Rev. No: 00
Date: 30/06/11
Page: 1 of 6
Sub Code &Name : 114306 – Manufacturing Technology - I Unit: I Branch: Mechanical Engineering Semester: III

UNIT I METAL CASTING PROCESSES

Sand casting – Sand moulds - Type of patterns – Pattern materials – Pattern allowances – Types of Moulding sand – Properties – Core making – Methods of Sand testing – Moulding machines – Types of moulding machines - Melting furnaces – Working principle of Special casting processes – Shell, investment casting – Ceramic mould – Lost Wax process – Pressure die casting – Centrifugal casting – CO2 process – Sand Casting defects – Inspection methods

Objective:

To introduce the students the concepts of metal casting processe

Session
No / Topics to be covered / Time
(Min) / Ref. / Teaching Method
1 / Sand casting – Sand moulds - Type of patterns / 50 / Text Book 1,2 / BB
2 / Pattern materials, Pattern allowances / 50 / Text Book 1,2 / BB
3 / Types of Moulding sand, Properties, Core Making / 50 / Text Book 1,2 / BB
4 / Methods of Sand testing / 50 / Text Book 1,2 / BB
5 / Moulding machines – Types of moulding machines, Melting furnaces / 50 / Text Book 1,2 / BB
6 / Working principle of Special casting processes– Shell, investment casting / 50 / Text Book 1,2 / BB
7 / Ceramic mould, Lost Wax process / 50 / Text Book 1,2 / BB
8 / Pressure die casting, Centrifugal casting , CO2 process / 50 / Text Book 1,2 / BB
9 / Sand Casting defects and Inspection methods / 50 / Text Book 1,2 / BB
/ LESSON PLAN / LP – 114306
LP Rev. No: 00
Date: 30/06/11
Page: 2 of 6
Sub Code &Name :114306 – Manufacturing Technology - I Unit: II Branch: Mechanical Engineering Semester: III

UNIT II JOINING PROCESSES

Fusion welding processes – Types of Gas welding – Equipments used – Flame characteristics – Filler and Flux materials - Arc welding equipments - Electrodes – Coating and specifications – Principles of Resistance welding – Spot/butt, seam welding – Percusion welding - Gas metal arc welding – Flux cored – Submerged arc welding – Electro slag welding – TIG welding – Principle and application of special welding processes - Plasma arc welding – Thermit welding – Electron beam welding – Friction welding – Diffusion welding – Weld defects – Brazing and soldering process – Methods and process capabilities – Filler materials and fluxes – Types of Adhesive bonding.

Objective:

To introduce the students the concepts of metal Joining processses

Session
No / Topics to be covered / Time
(Min) / Ref. / Teaching Method
10 / Fusion welding processes – Types of Gas welding, Equipments / 50 / Text Book 1,2 / BB
11 / Flame characteristics – Filler and Flux materials / 50 / Text Book 1,2 / BB
12 / Arc welding equipments – Electrodes - Coating and specifications / 50 / Text Book 1,2 / BB
13 / Principles of Resistance welding – Spot/but,t seam welding, Percusion welding / 50 / Text Book 1,2 / BB
14 / seam welding – Percusion welding Gas metal arc welding – Flux cored Welding, / 50 / Text Book 1,2 / BB
15 / Submerged arc welding , Electro slag welding , TIG welding / 50 / Text Book 1,2 / BB
16 / special welding processes - Plasma arc welding – Thermit welding – Electron beam welding / 50 / Text Book 1,2 / BB
17 / Friction welding , Diffusion welding, Weld defects / 50 / Text Book 1,2 / BB
18 / Brazing and soldering process, Adhesive Bonding / 50 / Text Book 1,2 / BB
CAT I
/ LESSON PLAN / LP – 114306
LP Rev. No: 00
Date: 30/06/11
Page: 3 of 6
Sub Code &Name : 114306 – Manufacturing Technology - I Unit: III Branch: Mechanical Engineering Semester: III

UNIT III BULK DEFORMATION PROCESSES

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 –– Equipments used.

Objective:

To introduce the students the concepts of metal working process

Session
No / Topics to be covered / Time
(Min) / Ref. / Teaching Method
19 / Hot working and cold working of metals / 50 / Text Book 1,2 / BB
20 / Forging processes – Open, impression and closed die forging- Characteristics / 50 / Text Book 1,2 / BB
21 / Types of Forging Machines / 50 / Text Book 1,2 / BB
22 / Forging Operations / 50 / Text Book 1,2 / BB
23 / Rolling Mills - types / 50 / Text Book 1,2 / BB
24 / Shape rolling operations, Defects in rolled parts / 50 / Text Book 1,2 / BB
25 / Rod, tube and wire drawing / 50 / Text Book 1,2 / BB
26 / Extrusion principle, types – Hot & Cold Extrusion / 50 / Text Book 1,2 / BB
27 / Revision / 50 / -- / BB
/ LESSON PLAN / LP – 114306
LP Rev. No: 00
Date: 30/06/11
Page: 4 of 6
Sub Code &Name : 114306 – Manufacturing Technology - I Unit: IV Branch: Mechanical Engineering Semester: III

UNIT IV SHEET METAL PROCESSES

Sheet metal characteristics - Typical shearing operations, bending and drawing operations – Stretch forming operations –– Formability of sheet metal – Test methods – Working principle and application of special forming processes - Hydro forming – Rubber pad forming – Metal spinning – Introduction to Explosive forming, Magnetic pulse forming, Peen forming, Super plastic forming.

Objective:

To introduce the students the concepts of Sheet metal working processes

Session
No / Topics to be covered / Time
(Min) / Ref. / Teaching Method
28 / Sheet metal characteristics / 50 / Ref Book 2,3,5 / BB
29 / Shearing Operations - types / 50 / Ref Book 2,3,5 / BB
30 / Bending and Drawing operations / 50 / Ref Book 2,3,5 / BB
31 / Stretch forming operations / 50 / Ref Book 2,3,5 / BB
32 / Formability of sheet metal - Test methods / 50 / Ref Book 2,3,5 / BB
33 / Special forming processes - Hydro forming – Rubber pad forming / 50 / Ref Book 2,3,5 / BB
34 / Metal spinning, Explosive forming, Magnetic pulse forming / 50 / Ref Book 2,3,5 / BB
35 / Peen forming, Super plastic forming. / 50 / Ref Book 2,3,5 / BB
36 / Revision / 50 / -- / BB
CAT II
/ LESSON PLAN / LP – 114306 Rev. No: 00
Date: 30/06/11
Page: 5 of 6
Sub Code &Name : 114306 – Manufacturing technology - I Unit: V Branch: Mechanical Engineering Semester: III

UNIT V MANUFACTURING OF PLASTIC COMPONENTS

Types of plastics - Characteristics of the forming and shaping processes – Moulding of Thermoplastics – Working principles and typical applications of - Injection moulding – Plunger and screw machines – Compression moulding, Transfer moulding - Typical industrial applications – Introduction to Blow moulding – Rotational moulding – Film blowing – Extrusion - Thermoforming, - Bonding of Thermoplastics.

Objective:

To introduce the students the concepts of Plastic Moulding Processes

Session
No / Topics to be covered / Time
(Min) / Ref. / Teaching Method
37 / Types of plastics - Characteristics of the forming and shaping processes / 50 / Text Book 1,Ref 2,3,5 / BB
38 / Moulding of Thermoplastics - Injection moulding / 50 / Text Book 1, Ref 2,3,5 / BB
39 / Compression moulding / 50 / Text Book 1,Ref 2,3,5 / BB
40 / Transfer moulding / 50 / Text Book 1,Ref 2,3,5 / BB
41 / Blow moulding / 50 / Text Book 1,Ref 2,3,5 / BB
42 / Rotational moulding – Film blowing / 50 / Text Book 1, Ref 2,3,5 / BB
43 / Extrusion, Thermoforming, Bonding of Thermoplastics. / 50 / Text Book 1,Ref 2,3,5 / BB
44 / Bonding of Thermoplastics. / 50 / Text Book 1,Ref 2,3,5 / BB
45 / Revision / 50 / -- / BB
CAT III
/ LESSON PLAN / LP – 114306
LP Rev. No: 00
Date: 30/06/11
Page: 6 of 6
Sub Code &Name : 114306 – Manufacturing technology - I Unit: -- Branch: Mechanical Engineering Semester: III

Course Delivery Plan:

Hr. / 1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14 / 15 / 16 / 17 / 18
Units / / I / / II
Hr. / 19 / 20 / 21 / 22 / 23 / 24 / 25 / 26 / 27 / 28 / 29 / 30 / 31 / 32 / 33 / 34 / 35 / 36
Units / / III / / IV
Hr. / 37 / 38 / 39 / 40 / 41 / 42 / 43 / 44 / 45
Units / / V

TEXT BOOK

1.  Hajra Choudhury, “Elements of Workshop Technology, Vol. I and II”, Media Promotors Pvt Ltd., Mumbai, 2001

2.  S.Gowri, P.Hariharan, and A.Suresh Babu, “Manufacturing Technology 1”, Pearson Education , 2008.

REFERENCE BOOKS

1.  B.S. Magendran Parashar & R.K. Mittal,”Elements of Manufacturing Processes”, Prentice Hall of India, 2003.

2.  P.N. Rao,”Manufacturing Technology”,Tata McGraw-Hill Publishing Limited, II Edition, 2002.

3.  P.C. Sharma, “A text book of production technology”,S. Chand and Company, IV Edition, 2003.

4.  Begman, ‘Manufacturing Process”, John Wilely & Sons, VIII Edition, 2005.

5.  Serope Kalpajian, Steven R.Schmid, Manufacturing Engineering and Technology, Pearson Education, Inc. 2002(Second Indian Reprint).

6.  Beddoes.J and Bibby M.J, ‘Principles of Metal Manufacturing Processes’, Elsevier, 2006.

7.  Rajput R.K, ‘A text book of Manufacturing Technology’, Lakshmi Publications, 2007.

Prepared by / Approved by
Signature
Name / Mr. S. Ilaiyavel/ Mr. S. Ponnuvel / Dr. N. Nallusamy
Designation / Asst. Professor/ Asst. Professor / Professor and HOD
Date / 30.06.2011 / 01.07.2011