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ME2301E-Manufacturing Technology
(S3PE)
Lecture-1
Introduction
Course Instructors
Dr. Jinu Paul (MED)
[email protected]
9002279620
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Manufacturing Process?
Raw Manufacturing Finished
materials Processes products
Wooden
Wood Table
(Finished
(Raw Manufacturing product)
material) Processes
1. Cutting,
2. Planing,
3. Polishing
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Raw Manufacturing Cup (Finished
Material Process product)
(Sheet
metal)
Raw Manufacturing Automobile
Materials Processes (Finished product)
1. Casting
• Metals 2. Forming
• Alloys 3. Machining
• Composites 4. Welding
• Ceramics 5. Finishing/Polishing
• Plastics/Polymers 6. Painting
/Rubber 7. Assembly
Etc.
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Selection of materials
Application/ Selection of Selection of
Performance Materials Manufacturing
requirements Process
Plastic (Eg. PVC) Plastic
Table(Finish
(Raw material) ed product)
Manufacturing
Processes
Moulding/Extrusion
Selection of Manufacturing Process depends on the
Material and its properties !
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Materials in
Manufacturing
Materials in Manufacturing
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Classification of Manufacturing Processes
Primary Convert raw material • Casting
Manufacturing or scrap to a basic • Forming (Forging, Rolling,
Processes primary shaped and Extrusion, etc.)
ME2301E
sized product • Joining (Welding, Soldering, (Manufacturing
etc.) Technology)
Secondary Further improve the • Machining
Manufacturing properties, • Surface working, such as
Processes • Surface quality, Heat Treatment, Coating, etc.
• Dimensional
accuracy,
• Tolerance, etc.
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Classification of Manufacturing Processes
Material Addition Material building at Eg. Casting, Coating,
1. Processes the basic level Painting
(Additive)
Material Removal Removes materials Eg. Machining,
2. Processes from the Raw grinding
(Subtractive) materials
Forming Processes Change shape of the Eg. Forging, deep
3. raw material drawing, extrusion
Joining Processes Joins two components Eg. Welding, Soldering
4. (Assembly)
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Classification of Manufacturing Processes
Manufacturing
Processes
Processing Assembly
Operations Operations
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Classification of Manufacturing Processes
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Classification of Manufacturing Processes
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Manufacturing Process-Casting
• Raw material is heated to transform it to the liquid state.
• Raw material (metals, plastics and ceramic glasses) in the liquid state, poured into
a mold cavity
• Allowed to solidify , thus taking a solid shape that is the same as the cavity
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Manufacturing Process-Particulate Processing
• Starting materials are powders of metals or ceramics.
• The powders are first squeezed into a die cavity under a high pressure
(Pressing)
• Then heated to bond the individual particles together (Sintering).
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Manufacturing Process-Forming or Deforming
• Raw material is shaped by the application of forces that exceed the yield
strength of the material.
• Material must be sufficiently ductile to avoid fracture during deformation.
• To increase ductility (and for other reasons), the work material is often
heated before forming to a temperature below the melting point.
• Deformation processes are associated most closely with metalworking and
include operations such as forging and extrusion
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Manufacturing Process-Assembly operations
Riveted Joint
Threaded fastner
Welded Joint
Brazed Joint 19
Manufacturing Process- Machining
• Remove excess material from the starting workpart to get the desired geometry.
• Includes turning, drilling and milling, Grinding etc.
• Other special processes are known as nontraditional processes as they use lasers,
electron beams, electric discharge, etc.
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Manufacturing Processes: Microfabrication &
Nanotechnology
• Products that are so miniaturized require special fabrication technologies.
• Microfabrication refers to the processes needed to make parts and
products whose features sizes are in the micrometer range
• Nanotechnology refers to materials and products whose feature sizes are
in the nanometer scale
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ME2301E Manufacturing Technology-Syllabus
Introduction to Manufacturing Processes, Fundamental approaches in
Manufacturing, Materials and Manufacturing processes, classification, selection,
applications of manufacturing processes, Effects of manufacturing processes on
mechanical properties.
Casting: Types of casting processes and applications; Sand casting: patterns – types,
materials and allowances; molds and cores–materials, making, and testing; design of
gating system and riser; casting techniques of cast iron, steels, and nonferrous metals
and alloys; analysis of solidification and microstructure development; Other casting
techniques: Pressure die casting, Centrifugal casting, Investment casting, Shell mold
casting; Casting defects and their inspection by non-destructive testing
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ME2301E Manufacturing Technology-Syllabus
Metal joining: classification; welding heat sources; fusion and non-fusion welding
processes; gas welding; electric arc welding; arc welding machines; physics of
welding arc; arc production; arc characteristics; metal transfer; arc blow; welding
electrode; consumable and non-consumable arc welding, SMAW; GTAW; GMAW;
SAW; AHW; PAW; resistance welding; electro slag welding; thermit welding;
ultrasonic welding; electron beam welding; laser beam welding; solid state
welding; welding metallurgy: Heat Affected Zone; weldability of ferrous and non-
ferrous metals; design of weldments; joint design; residual stresses and distortion;
defects in welding; testing of welded joints; brazing and soldering.
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ME2301E Manufacturing Technology-Syllabus
Metal Forming: Fundamental concepts of plastic deformation (stress-strain diagram,
yield criteria) − hot and cold working processes − Principle, process and equipment for
rolling, forging, drawing, extrusion, sheet metal forming − Advanced forming & near
net shaped processing technologies − Load es ma on for bulk (forging, rolling,
extrusion, drawing) and sheet (shearing, deep drawing, bending) metal forming
processes.
Powder metallurgy: Introduction to powder metallurgy, Applications, powder
fabrication methods, metallic and ceramic powders, microstructural control, powder
characterization, powder treatment: mixing granulation, degassing, coating; Powder
compaction and sintering, Secondary treatments, cold and hot isostatic pressing.
Processing of polymers – injection moulding, blow moulding, extrusion, compression
moulding, thermoforming; Processing of polymer matrix composites – moulding.
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Course Outcomes
• CO1: Identify suitable manufacturing process for a given product
based on its functional requirement.
• CO2: Apply fundamental knowledge in the analysis of casting,
forming, joining and powder metallurgy processes.
• CO3: Analyze the process characteristics and the evolution of
material properties in casting, forming joining powder metallurgy
processes.
• CO4: Estimate energy requirement and select process parameters
for casting, forming joining powder metallurgy and polymer
processes.
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Course Outcomes Assessment Plan
Sl. Evaluation Tool Marks COs to be assessed
No
.
1 Quiz - 1 5
2 Quiz - 2 5
3 Mid Semester Exam 30
4 Quiz - 3 5
5 Quiz - 4 5
6 Group Project 10
7 End Semester Evaluation 40
Total 100
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CO-PO Mapping Table
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ME2301E Manufacturing Technology-
Reference books
[1] Ghosh, A., and Mallik, A.K., 2010, Manufacturing Science, Affiliated East-West Press Pvt. Ltd.
[2] Rao, P. N., 2019, Manufacturing Technology Vol. I: Foundry, Forming and Welding, McGraw Hill.
[3] Kalpakjian. S., and Schmid, S.R., 2020, Manufacturing Engineering and Technology, Pearson.
[4] Heine, R., Loper, C. and Rosenthal, P., 2004, Principles of Metal Casting. Tata McGraw Hill.
[5] Little, R., 2004, Welding and welding Technology. Tata McGraw Hill.
[6] Hoffman, O. and Sachs, G., 2012, Introduction to Theory of Plasticity for Engineers. Literary Licensing.
[7] Flemings, M. C., 1974, Solidification Processes, McGraw Hill, American Welding Society, Welding Hand Book.
[8] Doyle, L. E., 1984, Manufacturing Processes and Materials for Engineers, Prentice Hall of India.
[9] Taylor, H. F., Flemings, M. C. and Wulff, J., 1959, Foundry Engineering, John Wiley & Sons.
[10] Olson, D.L., Siewert, T.A., Liu, S., Edwards, G.R., (eds.), 1993, ASM HandBook – Vol. 6. Welding, Brazing and Soldering,
ASM International.
[11] German, R. M., 1994, Powder Metallurgy Science, Metal Powder Industries Federation.
[12] Upadhyaya, A., and Upadhyaya, G. S., 2011, Powder Metallurgy: Science, Technology and Materials, CRC Press.
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