Manufacturing Processes detailed Syllabus for Mechanical Engineering (ME), I – scheme has been taken from the MSBTE official website and presented for the diploma students. For Subject Code, Subject Name, Lectures, Tutorial, Practical/Drawing, Credits, Theory (Max & Min) Marks, Practical (Max & Min) Marks, Total Marks, and other information, do visit full semester subjects post given below.
For all other Diploma in Mechanical Engineering (ME) Syllabus for 4th Sem I – Scheme MSBTE, do visit Diploma in Mechanical Engineering (ME) Syllabus for 4th Sem I – Scheme MSBTE Subjects. The detailed Syllabus for manufacturing processes is as follows.
Rationale:
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Competency:
The aim of this course is to help the student to attain the following industry identified competency through various teaching learning experiences:
- Produce components using conventional manufacturing processes.
Course Outcomes:
The theory, practical experiences and relevant soft skills associated with this course are to be taught and implemented, so that the student demonstrates the following industry oriented COs associated with the above mentioned competency:
- Produce jobs using lathe and drilling machines.
- Produce jobs using shaping and slotting operations.
- Prepare product using different casting processes.
- Prepare product using different forming processes.
- Use joining process to produce jobs.
Suggested Practicals/Exercises:
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Instruments Required:
The major equipment with broad specification mentioned here will usher in uniformity in conduct of experiments, as well as aid to procure equipment by authorities concerned.
Equipment Name with Broad Specifications
- Center Lathe Machine (Length between centers : 2000 mm.
- Radial drilling machine (Drill diameter : upto 40 mm.
- Shaping/Slotting machine (Maximum stroke length : upto 150 mm.
- Pattern making, moulding and casting shop with necessary equipments.
- Plastic Hand Moulding Machine
- Rolling mill made for Laboratory work
- Hardness Tester with standard specification of Rockwell Hardness
- Metallurgical Microscope ideal for examining Large and Single Side polished Metal samples
- Extruder and extrusion dies
- Feed system mechanism.
- Forging press
- Dies and punches for press forging
- Reheating furnace
- TIG/MIG welding set up with suitable specification
- Soldering machine
Unit 1
Fundamentals of Machining and Machining Operations
Total Teaching Hours – 12
Distribution of Theory Marks
R Level – 04
U Level – 04
A Level – 08
Total Marks – 16
Unit Outcomes (UOs) (in cognitive domain)
- Identify different machining operations to be performed for the given job with justification.
- Explain with sketches the procedure of performing the given lathe machine operation on a job.
- Explain with sketches the procedure of performing the given Drilling machine operation on a job.
- Select the relevant turning and drilling process parameters for the given job with justification.
- Explain with sketches to measure cutting speed, feed, and depth of cut for the given job in turning and drilling operations.
Topics and Sub-topics
- Machining Process: Mechanics of Chip formation, Single point cutting Tool and its geometry. Methods of Machining, Types of Chips, Principal elements of Metal Machining.
- Lathe: classification, specifications of center lathe; Basic parts of center lathe and their functions; Lathe accessories: chucks (three jaw, tour jaw, and magnetic chuck), mandrels, rests, face plates, centers, and angle, plates; Lathe operations like facing, plain turning, taper turning, thread cutting, chamfering, grooving, knurling. Cutting tool nomenclature and tool signature. Cutting parameters – speed, feed, depth of cut and machining time.
- Drill Machine: Classification, specifications of radial drilling machine. Basic parts of radial drilling machine, sensitive drilling and their functions. Drilling machine operations like drilling, reaming, boring, counter sinking, counter boring, spot facing. Cutting parameters – speed, feed, depth of cut and machining time.
Unit 2
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Unit 3
Casting Processes and Plastic Moulding
Total Teaching Hours – 12
Distribution of Theory Marks
R Level – 04
U Level – 06
A Level – 08
Total Marks – 18
Unit Outcomes (UOs) (in cognitive domain)
- Design a pattern for the given job.
- Design a mould for the given the job.
- Explain with sketches the given casting process with skethes.
- Select the relevant furnace for the given raw material with justification.
- Select the relevant plastic moulding process for the given job with justification.
Topics and Sub-topics
- Pattern making: Basic steps in making pattern, types, materials and allowances.
- Color coding of patterns
- Moulding: Types of moulding sands, properties of sand, moulding methods, cores and core prints. Elements of gating system. Bench and floor moulding methods.
- Casting: Safety practices / precautions in foundry shop. Furnaces, construction and working of cupola furnace, electric arc furnace. Centrifugal casting-method and applications. Casting defects – Causes and remedies.
- Plastic- 1 ypes of plastics: Plastic processing like Calendering and vacuum forming.
- Plaslic moulding methods Compression moulding. Injection moulding. Blow moulding and b.xlrusioii. Applications of plastic moulding methods.
Unit 4
Forming Processes
Total Teaching Hours – 10
Distribution of Theory Marks
R Level – 02
U Level – 06
A Level – 08
Total Marks – 16
Unit Outcomes (UOs) (in cognitive domain)
- Select the relevant forming process for the given component with justification.
- Identify the point of differences between forging, rolling and extrusion process with justification and sketches.
- Explain with sketches the given extrusion process as per the given job with sketches.
Topics and Sub-topics
- Drop forging: Introduction io forging. Upset forging, press forging, open die and closed die forging operations,
- Rolling: Principle of rolling, hot and cold rolling. Types and applications of rolling mill.
- Extrusion: Direct and indirect extrusion. Advantages, disadvantages. applications of extrusion processes.
Unit 5
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Suggested Student Activities:
Other than the classroom and laboratory learning, following are the suggested student-related co-curricidar activities which can be undertaken to accelerate the attainment of the various outcomes in this course: Students should conduct following activities in group and prepare reports of about 5 pages for each activity, also collect/record physical evidences for their (students) portfolio which will be useful for their placement interviews:
- Visit a Foundry shop and observe the Centrifugal/lnvestment/Die Casting process and identify the different defects on the surface of component.
- Visit a plastic molding industry and collect information on types of molding machines, its specification and observe various activities performed in a molding process.
- Visit an industry where the operation like drop forging, rolling and extrusion are carried out. Collect information on types these machines, their specification and observe various activities performed and characteristics of output product.
- Visit a Industry/workshop to observe the process like seam, spot, TIG and MIG welding. Collect information on these machines, their specification and observe these processes critically to get information regarding various accessories (electrodes, current rating etc.) used in these processes.
- Collect information of recent advancement in manufacturing processes, machines/tools/equipment and their specifications/manufacturer and application in the industries.
- Collect information of various forming processes used in industries. Observe shape of input and output products and suggest suitable operation for various jobs.
Suggested Special Instructional Strategies:
These are sample strategies, which the teacher can use to accelerate the attainment of the various outcomes in this course:
- Massive open online courses (MOOCs) may be used to teach various topics/sub topics.
- L in item No. 4 does not mean only the traditional lecture method, but different types of teaching methods and media that are to be employed to develop the outcomes.
- About 15-20% of the topics/sub-topics which is relatively simpler or descriptive in nature is to be given to the students for self-directed learning and assess the development of the COs through classroom presentations (see implementation guideline for details).
- With respect to item No. 10, teachers need to ensure to create opportunities and provisions for co-curricular activities.
- Guide students in undertaking micro-projects.
- Demonstrate the clifleienl components ol the machine to the students thoroughly before they start doing the practice.
- Demonstrate trouble shooting practice to the students.
- Encourage students to refer different technical websites, videos of manufacturing processes to have deeper understanding of the subject.
Suggested Micro-Project:
For the complete Syllabus, results, class timetable, and many other features kindly download the iStudy App
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Suggested Learning Resources:
- Manufacturing Engineering Handbook Flwaiyu Geng McGraw Hill,New York, 2000, 1SBN:978OO71398251
- Workshop Technology, Volume-1 and 11 Raghuvanshi B.S. Dhanpat Rai Publications, New Delhi. 2009, ISBN 10:0470534915
- Production Technology (Manufacturing Processes. Sharma P.C. S. Chand and Company, 2013, New Delhi, ISBN:9788721911146
- Text book of Production Technology Khanna O.P Dhanpat Rai Publications, New Delhi, 2010, ISBN :9788189928322
- A text book of Foundry Technolgy Khanna O.P Dhanpat Rai Publications, New Delhi, 2010, ISBN :9788189928346
- Elements of workshop Technology-Volume I and Volume II Chaudhary Hajra S.K. Media Promoters and Publishers Ltd.. Mumbai, 2005 ISBN : 9788185099156
- Workshop Technology Volume-1 and II Bawa U.S. McGraw-Hill Education. New Delhi, 2011. ISBN : 13:EBK0009651
- Workshop Technology Part-1 and II Chapman W. Taylor and Francis, New Delhi, 1995, ISBN:13:9780415503020
- Materials and Processing in Manufacturing Black J.T. Kosher Ronald A. Wiley India Pvt.Ltd., New Delhi 1999. ISBN:9788126540464
Learning Websites
- http://nptel.ac.in
- www.basicmechanicalengineering.com/lathe-machine-operations-basic-turning-
- www.mechengg.net/2016/0peration-performed-on-shaping-machine.html
- www.protolabs.com/injection-molding/plastic-injection-molding/
- www.thelibraryofmanufacturing.com /forming_basics.html
- www.themetalcasting.com/casting-process.html
For detail Syllabus of all other subjects of Mechanical Engineering, I – scheme do visit Mechanical Engineering 4th Sem Syllabus for I – scheme.
For all Mechanical Engineering results, visit MSBTE Mechanical Engineering all semester results direct links.