Manufacturing Technology - I (1BME305)

Manufacturing Technology - I

Course Code 1BME305 
Scheme 2025
Type of Course PCC 
Semester III
Teaching Hours/Week (L:T:P) 3:0:0 
CIE Marks 50
Total Hours of Pedagogy per semester L:T:P:SL:TW 42:0:0:38:10 
SEE Marks 50
Credits 3 
Total Marks 100
Examination type (SEE) Theory 
Exam Hours 3

Module-1

Metal Casting: Introduction, Types of Foundries. basic steps in making sand castings.

Patterns: Patternmaking, Types of Patterns, Pattern Allowances, Functions of Patterns, Core Boxes.

Molding Process and Materials: Introduction and classification of Molding Process, Sand Casting: Greensand Molding, Dry sand molds, Floor and Pit molding, Cement-bonded Sand Molds, Core sand or Core Molds, Shell Molding, Investment Casting. Permanent Molds: Die Casting, Centrifugal Casting.

Casting Defects: Gas Defects, Shrinkage Cavities, Molding Material Defects, Pouring Metal Defects, Metallurgical Defects.

Module-2

Solidification of Metals: Introduction, solidification variables; Freezing of a Pure Metal: Skin Effect; Solidification in a Mold, Nucleation and Growth, Shrinkage. Directional solidification-need and methods. Pouring and Feeding Castings: Introduction, Pouring Ladles; Gating System: Elements of Gating System; Types of Gates: Parting Gate, Bottom Gate, Horn Gate; Design of Gating System: Fluid Flow, Factors involved in Gating Design, Pouring time, Choke Area, Sprue Design, Sprue-runner-gate Ratios. Risers: Primary Function of a Riser, Theoretical Considerations, Riser Shape, Riser size as a Function of Casting Shape, Location of Risers, Blind Risers, Internal Risers; Numerical Problems on Gates and Risers.

Melting Practices: Cupola, Electric Arc Furnace, Crucible Furnace, Induction Furnace, and Reverberatory Furnace.

Module-3

Mechanical Working of Metals: Introduction; Nature of Plastic Deformation, Hot Working and Cold Working: Principal Methods, Advantages and Disadvantages.

Rolling: Principle of Rolling, Rolling-Stand Arrangements; -High, Two-High Reversible, Three-High, FourHigh and Cluster Rolling Mills. Rolling Load, Rolling Passes, Rolling Defects.

Smithing and Forging: Introduction, Forging Materials, Heating Devices, Smith Forging Operations, Forging Processes; Hand Forging, Power Forging; Power Hammers, Impression Die Forging, Drop Hammers, Press Forging.

Extrusion: Principle of Extrusion; Types of Extrusion: Direct or Forward Extrusion, Indirect or Backward Extrusion, Impact Extrusion, Extruding Tubes, and Hydrostatic Extrusion, Wire Drawing.

Module-4

Sheet Meal Operations: Introduction, Metals used in Sheet Metal Work. Press Tool Operations: Classification of Press Tool Operations; Shearing Action, Blanking and Piercing: Stripping Force, Punching Force and Shear Force; Numerical Problems. Trimming, Shaving, Nibbling, Notching and Lancing Operations. Drawing: Draw Die Design, Draw Radius on Die, Blank Size, Drawing Force, Ironing Force, Percentage Reduction, Drawing Speed; Numerical Problems. Bending: Bending Allowance, Bending Force; Numerical Problems. Stretch Forming, Embossing and coining operations.

Sheet Metal Design: Types of Dies; Progressive Dies, Compound Dies and Combination Dies. Die Construction; Screws and Dowels, Die Block. Punch Design: Plain Punches, Pedestal Punches and Punches Mounted in Punch Plate.

Module-5

Welding Process: Definition, classification, application, advantages & limitations of welding, weldability.

Gas Welding: Oxy-Acetylene Welding, Air-Acetylene Welding, Oxy-Hydrogen Welding.

Arc Welding: Carbon-arc, Metal arc, Metal-inert-gas (MIG), Tungsten-inert-gas (TIG), Atomic Hydrogen, Plasma-arc, Submerged-arc, Flux-cored arc, Electro-slag welding.

Resistance Welding: Butt, Spot, Seam, Projection and Percussion welding;

Thermit Welding; Solid State Welding Methods: Diffusion, Ultrasonic, Friction and Explosive Welding; Welding Defects.

Suggested Learning Resources:

Textbooks:

1. P N Rao, “Manufacturing Technology”, Vol. 1 – Foundry, Forming, and Welding, 5th Ed., McGraw Hill Education (India) Private Limited, 2018.

2. S K Hajra Choudhury, A.K. Hajra Choudhury, Nirjhar Roy, “Elements of Workshop Technology Vol 1: Manufacturing Processes”, 15th Ed., Media Promoter and Publishers Pvt. Ltd., 2019

Reference books / Manuals:

1. Serope Kalpakjian and Steven R. Schmid, “Manufacturing Engineering and Technology”, Pearson Education, 8th Ed, 2023.

2. Amitabha Ghosh, Asok Kumar Mallik, “Manufacturing Science”, Affiliated East-West Press Private Limited, New Delhi; Second Edition, 2022

3. Richard W. Heine, Carl R. Loper Jr., Philip C. Rosenthal, “Principles of metal casting”, 3rd Ed., McGraw Hill Education (India).