SUBJECT TITLE : PRODUCTION ENGINEERING - I

(For TD)
SUBJECT CODE :
PERIODS/WEEK :5
PERIODS/SEMESTER : 90
CREDITS :5

RATIONALE:

TIME SCHEDULE

Module Topic Periods

Basic Production Processes: 20
I Fitting, metal joining techniques
Test I 2
Lathe and its operations 20
II Test II 2
Shaping, slotting, plaining and Drilling
20
III Machines
Test III
2
Grinding & Grinding wheels
22
IV Other surface finishing processes
Test IV
2
Total 90

OBJECTIVES

UNIT I

1.1.0 Appreciate the areas of application of basic production processes.

1.1.1 Discuss operations like casting, forging, forming, rolling and machining.
1.1.2 Identify fitting tools and their uses.
1.1.3 Describe various fitting operations.
1.1.4 Discuss various metal joining techniques welding, soldering and brazing.
1.1.5 Define welding, principle, classification.
1.1.6 Describe different arc welding processes. Electrodes, Tool & Equipments.
1.1.7 Describe gas welding process, different flames.
1.1.8 Frist advantages Applications and limitations of welding processes.
1.1.9 Identify welding symbols as per BIS.
UNIT II

2.1.0 Demonstrate the working of lathe and its uses.

2.1.1 State the working of a lathe.
2.1.2 Identify the parts of a lathe and their functions.
2.1.3 Specify a lathe.
2.1.4 Identify the work holding air tool holding devices.
2.1.5 Identify a single point cutting tool.
2.1.6 Define tool angles.
2.1.7 Choose correct tool angles for a specific work material and working condition.
2.1.8 Describe chip formation.
2.1.9 Describe different types of tool wear and methods of measurements of tool wear.
2.1.10 Suggest speed and feed for different work material.
2.1.11 Define different lathe operations Viz. centering, cylindrical turning, taper turning,
Thread cutting-change gear calculation.

UNIT – III

3.1.0 Demonstrate the working of machines like shaping, slotting, plaining and Drilling.
3.1.1 State the working principle of shaping m/c with line sketches.
3.1.2 Identify parts and their functions.
3.1.3 Indicate the method of fixing the working and tool and setting the machine.
3.1.4 Layout the procedure for cutting grooves, keyways etc.
3.1.5 Indicate the mode of specification of shaper.
3.1.6 State the working principle of a slotting machine with line sketch.
3.1.7 Layout the procedure for cutting keyways, splines etc in a slotting machine.
3.1.8 State the working principle of a plainer with line sketch.
3.1.9 Identify the parts and functions.
3.1.10 Indicate the method of fixing work and tool.
3.1.11 Identify different types of drilling machine with line sketch.
3.1.12 Explain different parts and their functions.
3.1.13 Explain different work holding and tool holding forces.
3.1.14 Identify drill bit angles.
3.1.15 Select speed and feed for different drilling operations.
3.1.16 Identify various reamers and their uses.
3.1.17 Discuss other drilling machines operations like Reaming, boring, counter boring,
counter sinking, tapping, spot facts etc.
3.1.18 Discuss gang drilling and multiple drillilng
3.1.19 Specify a drilling machine.
UNIT – IV

4.1.0 Recognise the use of grinding wheels and other surface finishing processes.
4.1.1 Define grinding.
4.1.2 Discuss different materials for grinding wheels.
4.1.3 Explain different bonding process for grinding wheel.
4.1.4 Select grinding wheel of suitable size, grain and grade for a given job.
4.1.5 Designate a grinding wheel.
4.1.6 Describe different surface finishing processes.
4.1.7 Explain requirement of each process viz. Hot dipping, Galvanising, Tin coating,
Parkerizing, anodizing, electroplating and metal spraying.
4.1.8 Differentiate wire processes and powder processes.

CONTENT DETAILS

UNIT I

Introduction about various production processes like metal casting, forging, forming,
rolling machines etc.

Fitting:- Definition, Tools: Measuring, Marking, Cutting tools.

Files, Scrapers, Tapes& Dies-Different types and uses.

Fitting Operations: Scribing, punching, chipping, hacksawing, Filing-Different

Filing methods, scraping, drilling, tapping & dieying-hole size.
Metal Joining:-
Different metal joints: Permanent, semi-permanent & Temporary.
Welding:- Definition, Principle, Classification-Fusion, non-Fusion, Different sub classes
of welding. Arc welding-principle, types Tool & equipments. Electrodes-types &
specifications.
Resistance welding – Principle, Different types (spot, seam, projection, butt and
persussion)

Other welding methods:- Thermist, TIG, MIG, Automatic hydrogen welding, ultrasonic
welding, plasma arc welding, Electron beam welding and Laser beam welding.
Gas Welding:- Tools, Gases, Different Flames. Gas Cutting Application, Advantages
and limitation of welding processes. Welding symbols as per BIS.
UNIT – II

Lathe:- Types-Centre Lathe, Tool Room Lathe, Special purpose lathes. Lathe
specification, Lathe parts, Accessories and their functions. Work holding and tool
holding devices. Cutting tools: Single point cutting tool- Nomenclature.
Metal Cutting Operations:- Types of chips, Different forces at cutting region. Cutting
speed, feed and depth of cut.
Tool life. Factors affecting tool life. Taylor’s equation for tool life.
Lathe Operations:- Plain Taper Thread cutting and other operations performed by a
lathe.

UNIT – III

Shaper, slotter, plainer – General use, Parts & their function, Tool & Die work holding
and drill holding devices.
Drill bits – types, Nomenclature, speed and feed for different machines. Different
drilling operations. Multiple drilling & Gang of milling.

UNIT – IV

Grinding:- Introduction. Purpose of grinding, Grinding wheels – Abrasive – types –

natural & artificial. Types of bonds, Making of grinding wheels: Vitrified, silicate,
shellac, Rubber and Bakelite.
Factors affecting selection of grinding wheels, Grade, Grit and structure of grinding
wheel. Kind of bond material – wheel shape and sizes. Specification of grinding wheel –
Meaning of each letters and numbers.

Other Surface finishing processes:- Introduction. Types of metal finishers.

Electro-plating – Basic principle – plating metals.
Hot dipping – Application, Galvanising.
Tim Coating – Parkerizing, Anodising.
Metal spraying – Wire process, Powder process – Application.

Reference Books:-

1. Production Technology - R K Jain

2. Workshop Technology Vol. I & II - Hajra Chowdary
3. Workshop Technology - W J Chapman
4. Production Technology - HMT
5. A Text Book of Production Technology – P C Sharma