ME104 Manufacturing Process

L-T-P-Cr: 3-1-0-4
Pre-requisite: NIL
Objective: To know the basic manufacturing processes and fabrication techniques such as metal casting,
manufacturing of plastic components, bulk deformation, powder metallurgy and welding.
Outcome: Students are able to assess product design for most suitable manufacturing processes and can
apply modern technologies to the manufacture of products and manufacturing strategies in various
industries.
Module 1: Casting Processes: Principles of pattern making, allowances in patterns and core boxes, sand
mould casting, constituents and properties of moulding sand and their tests, types of sand moulds, method
and principles of gating, rise ring, use of cores and chills, cleaning of casting, defects in casting and their
remedies, sand mould machines, melting and casting practices relating to cast iron, steel, aluminium and its
alloys. Cupola, crucible and electric furnaces, metal mould casting, gravity casting, die casting, centrifugal
casting, non-metallic mould casting-shell mould casting. Investment casting, plaster of paris mould casting.
Lectures 10
Module 2: Manufacturing of Plastic Components: Types and characteristics of plastics, Future of plastic and
its application. Working principles and typical applications of - Injection moulding, compression moulding
and extrusion moulding. Welding of plastics. Lectures 05
Module 3: Bulk Deformation Processes: Hot working and cold working of metals, their comparison and
limitation, Hot working process, forging, roll forging, rolling piercing, extrusion, cold working processes –
rolling, spinning, roll forming, cold heating, swaging, thread rolling, tube and wire drawing, coining,
embossing, tube rolling. Lectures 06
Module 4: Powder Metallurgy: Principles, method of producing power, pressing, sintering and finishing
operation – applications Lectures 06
Module 5: Welding: Classification of welding processes, Gas welding, oxy-acetylene welding, electric arc
welding, TIG and MIG welding, submerged arc welding, resistance welding and atomic - hydrogen welding.
New welding techniques - Plasma arc welding, ultrasonic welding, electro-slag welding, electron beam
welding, laser beam welding, plastic welding, friction welding, thermit welding, welding of cast iron,
aluminium and its alloys, copper and its alloys. Weld defects. Testing of weld destructive & non-destructive
tests. Flange cutting. Lectures 10
Module 6: Brazing and Soldering: Soldering process. Brazing process. Comparison of the processes and their
application. Lectures 05
Suggested Readings:
1. P.N. Rao, Manufacturing Technology: Foundry, Forming and Welding, 3rd Edition, Tata McGraw-Hill
Publishing Limited.

2. S. Kalpakjian and S.R. Schmid, Manufacturing Engineering and Technology, Pearson Education.
3. A. Ghosh and A.K. Mallik, Manufacturing Science, 2nd edition, Affiliated East West Press, New Delhi.
Reference Books:
1. Roy. A. Lindberg, Processes and Materials of Manufacture, 4th edition, Allyn and Bacon.
2. E. Paul DeGarmo, J.T. Black, Ronald A. Kohser, Anderson, Materials and Processes in Manufacturing, 8th
edition, Wiley, 1997.