MEE1007 Manufacturing Processes

LTPJC
2 0203

Pre-Requisite: None
Module

Topics

Manufacturing
Manufacturing- The Role of Manufacturing Development in the growth of a
country Classification of manufacturing processess
Casting processes
Casting: Fundamentals of metal casting Pattern and mould making-Different
casting techniques-Melting practice and furnaces - Defects in casting Testing
and inspection of casting.
2
Joining Processes
Fusion welding processes-Solid state welding processes-Advanced welding
techniques-Weld quality Testing welded joints.
3
Metal forming Processes
Cold and Hot working-Bulk metal forming -Sheet metal forming High Energy
Rate Forming Processes: Explosive Forming Electro Hydraulic Forming
Electro Magnetic Forming.
4
Processing of Powder Metals, Ceramics, Glass and Plastics
Powder metallurgy- Shaping of ceramics-Glass-Processing of plastics: Injection
molding Blow molding Compression molding Transfer molding
Thermoforming.
5
Process selection
Systematic process selection-Process selection charts-Ranking process cost-Cost
modelling
Case studies
Aluminum Connecting Rod, Fan leaf with nylon material, Airbag canisters,
Joining a Steel Radiator, Car bonnet, Spark Plug Insulators, Ceramic knife,
Devices to open corked bottle, Aircraft wing spar, Forks for a racing bicycle,
Spark plug insulator, Insulation for refrigerator,etc.
Total Lecture Hours
# Mode of teaching: Flipped Class Room, [Lecture to be videotaped], Use of physical and
computer models to lecture, Visit to Industry, Min of 2 lectures by industry experts
# Evaluation mode: Quiz/Assignment /Exam.

L
Hrs

SLO

17

17

17

17

6,17

30

Lab

1. Plaster mould casting- Create a mould for slip casting of the given component
using suitable material and fabricate the component using slurry casting technique
2. Metal casting: Preparation of Green sand mold using different levels of moisture
content.
3. Join the given GI pipes as per the diagram and make it leak proof for supply of
water.
4. Arc welding Join the given thick metal sheets using suitable welding process.
The weld finish quality is not a constrain.
5. TIG welding: Prepare the TIG weldment of steel with 316 stainless steel.Find out
the efficiency of the weldment by tensile test
6. Make a Tray as per the given dimensions using sheet metal. The corners of the tray
has no leack proof constraint.
7. Identify the thickness variation of a sheet metal bend sample for different loading
conditions and observe the changes in microstructure using optical microscope.
8. Finding the stress level of the sheet metal component before and after annealing
9. To find the Green Density & Strength (hardness) of Cold-compacted/sintered
metal powder
10. Carpentry Dove tail joint: Join the given two wooden slabs perpendicular to each
other in their longer edges by selecting suitable joint which gives maximum
strength.
11. Make an wooden book stand without doors using suitable joints.
12. Demonstration of pouring the Non Ferrous Metal by using Crucible Tilting
Furnace
13. Finding out the optimum method of producing a WC tool.

Evaluation mode: Marks distribution for:

(i) selection of suitable process/materials
(ii) completion and finishing quality of the exercise
(iii) viva & record
Total lab hours 30

6,17