Unit 1
Importance of manufacturing, economic and technological definition of manufacturing, survey of manufacturing
processes.
Foundry Technology: Patterns practices, Types of patterns, allowances and material used for patterns,
moulding materials, moulding sands, Moulding sands, properties and sand testing, grain fineness, moisture
content, clay content and permeability test, core materials and core making, core print, core boxes, chaplets,
gating system design, Moulding practices, green, dry and loam sand moulding, pit and floor moulding, shell
moulding, permanent moulding, carbon dioxide moulding.
Casting practices: Fundamental of metal casting, sand casting, shell-mould casting, mold casting (plaster and
ceramic), investment casting, vacuum casting, permanent mould casting, slush casting, pressure casting, die
casting, centrifugal casting, continuous casting, squeeze casting, casting alloys, casting defects, design of
casting, gating system design, and riser design, melting furnaces-rotary, pit electric, tilting and cupola.
Unit 2
Metal Joining Processes: Principle of welding, soldering, brazing and adhesive bonding, Survey of welding
and allied processes, Arc welding, power sources and consumables, Gas welding and cutting, Processes and
equipments. Resistance welding, principle and equipment, spot, projection and seam welding process, Atomic
hydrogen, ultrasonic, plasma and laser beam welding, electron beam welding, and special welding processes
e.g. TIG, MIG, friction and explosive welding, welding of C.I. and Al, welding defects. Electrodes and Electrode
Coatings.
Unit 3
Forming and Shaping Processes: Metal working, elastic and plastic deformation, concept of strain hardening,
hot and cold working, rolling, principle and operations, roll pass sequence, forging, forging operations,
extrusion, wire and tube drawing processes. Forging, Method of forging, forging hammers and presses,
principle of forging tool design, cold working processes - shearing, drawing, squeezing, blanking, piercing, deep
drawing, coining and embossing, metal working defects, cold heading, riveting, thread rolling bending and
forming operation.
Unit 4
Powder Metallurgy: Powder manufacturing, mechanical pulverization, sintering, electrolytic process, chemical
reduction, atomization, properties of metal powders, compacting of powders sintering, advantages and
applications of P/M.
Rapid Prototyping Operations: Introduction, subtractive processes, additive processes, virtual prototyping
and applications.
Unit 5
Plastic Technology: Introduction, classification of plastics, Ingredients of moulding compounds, general
properties of plastics, plastic part manufacturing processes such as compression moulding, transfer moulding,
injection moulding, extrusion moulding, blow moulding, calendaring, thermoforming, slush moulding, laminating.
Suggested Readings:
1. Manufacturing Technology, Rao P.N., Tata McGraw-Hill, New Delhi.
2. Manufacturing Engineering and Technology, Kalpkajin, Addison Wesley Publishing Company.
3. Processes and Materials of Manufacture, Lindberg R. A., Prentice Hall of India.
4. Principles of Manufacturing Materials and Processes, Campbell J.S., McGraw Hill