DOC/LP/00/21/01/2005

LESSON PLAN

Sub Code &Name : ME2201 – Manufacturing Technology - I

Unit: I Branch: Mechanical Engineering Semester: III

LP – ME2201

LP Rev. No: 00

Date: 01/07/10

Page: 1 of 6

UNIT I METAL CASTING PROCESSES Sand casting – Sand moulds - Type of patterns – Pattern materials – Pattern allowances – Types of Moulding sand – Properties – Core making – Methods of Sand testing – Moulding machines – Types of moulding machines - Melting furnaces – Working principle of Special casting processes – Shell, investment casting – Ceramic mould – Lost Wax process – Pressure die casting – Centrifugal casting – CO2 process – Sand Casting defects – Inspection methods Objective: To introduce the students the concepts of metal cas ting processe

Session No

Topics to be covered Time (Min)

Ref. Teaching Method

1 Sand casting – Sand moulds - Type of patterns 50 Text Book

1,2 BB

2 Pattern materials, Pattern allowances 50 Text Book

1,2 BB

3 Types of Moulding sand, Properties, Core Making 50 Text Book

1,2 BB

4 Methods of Sand testing 50 Text Book

1,2 BB

5 Moulding machines – Types of moulding machines, Melting furnaces 50

Text Book 1,2

BB

6 Working principle of Special casting processes– Shell, investment casting 50

Text Book 1,2

BB

7 Ceramic mould, Lost Wax process 50 Text Book

1,2 BB

8 Pressure die casting, Centrifugal casting , CO2 process 50 Text Book

1,2 BB

9 Sand Casting defects and Inspection methods

50 Text Book

1,2 BB

DOC/LP/00/21/01/2005

LESSON PLAN

Sub Code &Name : ME2201 – Manufacturing Technology - I

Unit: II Branch: Mechanical Engineering Semester: III

LP – ME2201

LP Rev. No: 00

Date: 01/07/10

Page: 2 of 6

UNIT II JOINING PROCESSES

Fusion welding processes – Types of Gas welding – Equipments used – Flame characteristics – Filler and Flux materials - Arc welding equipments - Electrodes – Coating and specifications – Principles of Resistance welding – Spot/butt, seam welding – Percusion welding - Gas metal arc welding – Flux cored – Submerged arc welding – Electro slag welding – TIG welding – Principle and application of special welding processes - Plasma arc welding – Thermit welding – Electron beam welding – Friction welding – Diffusion welding – Weld defects – Brazing and soldering process – Methods and process capabilities – Filler materials and fluxes – Types of Adhesive bonding.

Objective: To introduce the students the concepts of metal Joi ning processses

Session No

Topics to be covered Time (Min)

Ref. Teaching Method

1 Fusion welding processes – Types of Gas welding, Equipments

50 Text Book

1,2 BB

2 Flame characteristics – Filler and Flux materials 50 Text Book

1,2 BB

3 Arc welding equipments – Electrodes - Coating and specifications

50 Text Book

1,2 BB

4 Principles of Resistance welding – Spot/but,t seam welding, Percusion welding

50 Text Book

1,2 BB

5 seam welding – Percusion welding Gas metal arc welding – Flux cored Welding,

50 Text Book

1,2 BB

6 Submerged arc welding , Electro slag welding , TIG welding 50 Text Book

1,2 BB

7 special welding processes - Plasma arc welding – Thermit welding – Electron beam welding

50 Text Book

1,2 BB

8 Friction welding , Diffusion welding, Weld defects 50 Text Book

1,2 BB

9 Brazing and soldering process, Adhesive Bonding 50 Text Book

1,2 BB

CAT I

DOC/LP/00/21/01/2005

LESSON PLAN

Sub Code &Name : ME2201 – Manufacturing Technology - I

Unit: III Branch: Mechanical Engineering Semester: III

LP – ME2201

LP Rev. No: 00

Date: 01/07/10

Page: 3 of 6

UNIT III BULK DEFORMATION PROCESSES Hot working and cold working of metals – Forging processes – Open, impression

and closed die forging – Characteristics of the process – Types of Forging Machines – Typical forging operations – Rolling of metals – Types of Rolling mills - Flat strip rolling – Shape rolling operations – Defects in rolled parts - Principle of rod and wire drawing - Tube drawing –– Principles of Extrusion – Types of Extrusion – Hot and Cold extrusion –– Equipments used.

Objective: To introduce the students the concepts of metal wor king process

Session No

Topics to be covered Time (Min)

Ref. Teaching Method

1 Hot working and cold working of metals 50 Text Book

1,2 BB

2 Forging processes – Open, impression and closed die forging- Characteristics

50 Text Book

1,2 BB

3 Types of Forging Machines 50 Text Book

1,2 BB

4 Forging Operations 50 Text Book

1,2 BB

5 Rolling Mills - types 50 Text Book

1,2 BB

6 Shape rolling operations, Defects in rolled parts 50 Text Book

1,2 BB

7 Rod, tube and wire drawing 50 Text Book

1,2 BB

8 Extrusion principle, types – Hot & Cold Extrusion 50 Text Book

1,2 BB

9 Revision 50 -- BB

DOC/LP/00/21/01/2005

LESSON PLAN

Sub Code &Name : ME2201 – Manufacturing Technology - I

Unit: IV Branch: Mechanical Engineering Semester: III

LP – ME2201

LP Rev. No: 00

Date: 01/07/10

Page: 4 of 6

UNIT IV SHEET METAL PROCESSES Sheet metal characteristics - Typical shearing operations, bending and drawing operations – Stretch forming operations –– Formability of sheet metal – Test methods – Working principle and application of special forming processes - Hydro forming – Rubber pad forming – Metal spinning – Introduction to Explosive forming, Magnetic pulse forming, Peen forming, Super plastic forming. Objective: To introduce the students the concepts of Sheet met al working processes

Session No

Topics to be covered Time (Min) Ref. Teaching

Method

1 Sheet metal characteristics 50 Ref Book

2,3,5 BB

2 Shearing Operations - types 50 Ref Book

2,3,5 BB

3 Bending and Drawing operations 50 Ref Book

2,3,5 BB

4 Stretch forming operations 50 Ref Book

2,3,5 BB

5 Formability of sheet metal - Test methods 50 Ref Book

2,3,5 BB

6 Special forming processes - Hydro forming – Rubber pad forming

50 Ref Book

2,3,5 BB

7 Metal spinning, Explosive forming, Magnetic pulse forming 50 Ref Book

2,3,5 BB

8 Peen forming, Super plastic forming. 50

Ref Book 2,3,5

BB

9 Revision 50 -- BB

CAT II

DOC/LP/00/21/01/2005

LESSON PLAN

Sub Code &Name : ME2201 – Manufacturing technology - I

Unit: V Branch: Mechanical Engineering Semester: III

LP – ME2201

LP Rev. No: 00

Date: 01/07/10

Page: 5 of 6

UNIT V MANUFACTURING OF PLASTIC COMPONENTS

Types of plastics - Characteristics of the forming and shaping processes – Moulding of Thermoplastics – Working principles and typical applications of - Injection moulding – Plunger and screw machines – Compression moulding, Transfer moulding - Typical industrial applications – Introduction to Blow moulding – Rotational moulding – Film blowing – Extrusion - Thermoforming, - Bonding of Thermoplastics. Objective: To introduce the students the concepts of Plastic M oulding Processes

Session No

Topics to be covered Time (Min) Ref. Teaching

Method

1 Types of plastics - Characteristics of the forming and shaping processes 50

Text Book 1,Ref 2,3,5

BB

2 Moulding of Thermoplastics - Injection moulding 50

Text Book 1, Ref 2,3,5

BB

3 Compression moulding 50

Text Book 1,Ref 2,3,5

BB

4 Transfer moulding

50 Text Book 1,Ref 2,3,5 BB

5 Blow moulding 50 Text Book 1,Ref 2,3,5

BB

6 Rotational moulding – Film blowing 50

Text Book 1, Ref 2,3,5

BB

7 Extrusion, Thermoforming, Bonding of Thermoplastics.

50 Text Book 1,Ref 2,3,5 BB

8 Bonding of Thermoplastics. 50

Text Book 1,Ref 2,3,5

BB

9 Revision 50

--

BB

CAT III

DOC/LP/00/21/01/2005

LESSON PLAN

Sub Code &Name : ME2201 – Manufacturing technology - I

Unit: -- Branch: Mechanical Engineering Semester: III

LP – ME2201

LP Rev. No: 00

Date: 01/07/10

Page: 6 of 6

Course Delivery Plan:

Hr.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

I Units

II

III

Hr.

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

III V Units

IV

Hr.

36 37 38 39 40 41 42 43 44 45

V Units

TEXT BOOK 1. Hajra Choudhury, “Elements of Workshop Technology, Vol. I and II”, Media Promotors Pvt Ltd., Mumbai, 2001 2. S.Gowri, P.Hariharan, and A.Suresh Babu, “Manufacturing Technology 1”, Pearson Education , 2008.

REFERENCE BOOKS

1. B.S. Magendran Parashar & R.K. Mittal,”Elements of Manufacturing Processes”, Prentice Hall of India, 2003.

2. P.N. Rao,”Manufacturing Technology”,Tata McGraw-Hill Publishing Limited, II Edition, 2002.

3. P.C. Sharma, “A text book of production technology”,S. Chand and Company, IV Edition, 2003.

4. Begman, ‘Manufacturing Process”, John Wilely & Sons, VIII Edition, 2005.

5. Serope Kalpajian, Steven R.Schmid, Manufacturing Engineering and Technology, Pearson Education, Inc. 2002(Second Indian Reprint).

6. Beddoes.J and Bibby M.J, ‘Principles of Metal Manufacturing Processes’, Elsevier, 2006. 7. Rajput R.K, ‘A text book of Manufacturing Technology’, Lakshmi Publications, 2007.

Prepared by Approved by Signature

Name Mr. S. Ponnuvel / Mr. R.Vinayagamoorthy Dr. N. Nallusamy

Designation Sr. Lecturer / Lecturer Professor and HOD

DOC/LP/00/21/01/2005

ME 2201 MANUFACTURING TECHNOLOGY – I 3 0 0 3 OBJECTIVE To introduce the students the concepts of some basi c manufacturing processes and fabrication techniques, such as metal casting, meta l joining, metal forming and plastics component manufacture. UNIT I METAL CASTING PROCESSES 9(L) Sand casting – Sand moulds - Type of patterns – Pattern materials – Pattern allowances – Types of Moulding sand – Properties – Core making – Methods of Sand testing – Moulding machines – Types of moulding machines - Melting furnaces – Working principle of Special casting processes – Shell, investment casting – Ceramic mould – Lost Wax process – Pressure die casting – Centrifugal casting – CO2 process – Sand Casting defects – Inspection methods

UNIT II JOINING PROCESSES 9(L)

Fusion welding processes – Types of Gas welding – Equipments used – Flame characteristics – Filler and Flux materials - Arc welding equipments - Electrodes – Coating and specifications – Principles of Resistance welding – Spot/butt, seam welding – Percusion welding - Gas metal arc welding – Flux cored – Submerged arc welding – Electro slag welding – TIG welding – Principle and application of special welding processes - Plasma arc welding – Thermit welding – Electron beam welding – Friction welding – Diffusion welding – Weld defects – Brazing and soldering process – Methods and process capabilities – Filler materials and fluxes – Types of Adhesive bonding.

UNIT III BULK DEFORMATION PROCESSES 9(L) Hot working and cold working of metals – Forging processes – Open, impression

and closed die forging – Characteristics of the process – Types of Forging Machines – Typical forging operations – Rolling of metals – Types of Rolling mills - Flat strip rolling – Shape rolling operations – Defects in rolled parts - Principle of rod and wire drawing - Tube drawing –– Principles of Extrusion – Types of Extrusion – Hot and Cold extrusion –– Equipments used.

UNIT IV SHEET METAL PROCESSES 9(L)

Sheet metal characteristics - Typical shearing oper ations, bending and drawing operations – Stretch forming operations –– Formabil ity of sheet metal – Test methods – Working principle and application of special formin g processes - Hydro forming – Rubber pad forming – Metal spinning – Introduction to Explosive forming, Magnetic pulse forming, Peen forming, Super plastic forming.

UNIT V MANUFACTURING OF PLASTIC COMPONENTS 9(L)

Types of plastics - Characteristics of the forming and shaping processes – Moulding of Thermoplastics – Working principles and typical app lications of - Injection moulding – Plunger and screw machines – Compression moulding, Transfer moulding - Typical industrial applications – Introduction to Blow moul ding – Rotational moulding – Film blowing – Extrusion - Thermoforming, - Bonding of T hermoplastics.

Total Number of Periods: L= 45 T= 0 45

DOC/LP/00/21/01/2005

TEXT BOOK 3. Hajra Choudhury, “Elements of Workshop Technology, Vol. I and II”, Media Promotors Pvt

Ltd., Mumbai, 2001 4. S.Gowri, P.Hariharan, and A.Suresh Babu, “Manufacturing Technology 1”, Pearson

Education , 2008.

REFERENCE BOOKS

8. B.S. Magendran Parashar & R.K. Mittal,”Elements of Manufacturing Processes”, Prentice Hall of India, 2003.

9. P.N. Rao,”Manufacturing Technology”,Tata McGraw- Hill Publishing Limited, II Edition, 2002.

10. P.C. Sharma, “A text book of production technol ogy”,S. Chand and Company, IV Edition, 2003.

11. Begman, ‘Manufacturing Process”, John Wilely & Sons, VIII Edition, 2005.

12. Serope Kalpajian, Steven R.Schmid, Manufacturing Engineering and Technology, Pearson Education, Inc. 2002(Second Indian Reprint).

13. Beddoes.J and Bibby M.J, ‘Principles of Metal Manufacturing Processes’, Elsevier, 2006. 14. Rajput R.K, ‘A text book of Manufacturing Technology’, Lakshmi Publications, 2007.

DOC/LP/00/21/01/2005