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Sr. No.

Particulars

Page Number

1 Academic Calendar

2 Time Table (Consolidated)

3 Time Table (Individual)

4 Scheme

5 Syllabus

6 Lecture Plan

7 List of Books

8 Tutorial Sheets

9 Assignments

10 Assignment Grades

11 Question Papers

12 Lecture Notes

13 Attendance Record

FACULTY NAME

SIGNATURE

Course of Study and Scheme of Examination for Batch

starting from DEC-JUNE 2016

B.E 4TH Semester (Mechanical)

Teaching Scheme Credits Examination Marks

Total Marks L T P C

Theory Marks Practical Marks

ESE

(E)

PA (M) PA (V) PA

(I) PA ALA ESE OEP

3 0 2 5 70 20 10 20 10 20 150

SSYYLLLLAABBUUSS

UNIT-I

Manufacturing Process:

Basic Introduction, Importance of Manufacturing, Economics and Technological Definition, Classification

and Selection of Manufacturing Processes.

UNIT-II

Metal Casting Processes:

Patterns, 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. Moulding practices: Green, dry and loam sand moulding, pit and floor

moulding; shell moulding; permanent moulding; carbon dioxide moulding. Metal casting: Melting furnaces:

Rotary, Pit electric, Tilting and cupola. Review of casting processes, casting design considerations,

capabilities and applications of casting processes; Gating and Rising design fundamentals, casting defects.

UNIT-III

Metal Joining Processes:

Principle of welding, soldering, Brazing and adhesive bonding. Classification of welding and allied

processes. Capabilities and applications; welding parameters, general concepts of weldability, welding

metallurgy and weldament design, Gas welding and gas cutting, Arc welding, Power sources and

consumables, Resistance welding: 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. Defects of welding and remedial actions. Numerical

Calculation of Different process parameters of welding.

UNIT-IV

Metal Shaping and Forming:

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.

Numerical Calculation of Different process parameters of metal shaping and forming.

UNIT – V

Plastic, Ceramic and Glass Processing:

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. Ceramic Structure,

Properties, and Applications, Shaping Ceramics, Glasses Structure, Properties, and Applications, Forming

and shaping of glass, Composite materials, Processing of metal matrix and ceramic matrix composites,

Processing semiconductors.

Category of

Course

Course Title Course Code Theory Paper

L T P

MECHANICAL MANUFACTURING

PROCESS-II 2141908 3 0 2

Max.Marks:70

Min. Marks:23

Duration :2:30 hours

LECTURE PLAN

Lect Topics to be covered Teaching

hours

1. Basic Introduction, Importance of Manufacturing, Economics and Technological

Definition 1

2 Classification and Selection of Manufacturing Processes. 1

3 Patterns, Types of patterns, allowances 1

4 Material used for patterns, moulding materials, moulding sands 1

5 Moulding sands; properties and sand testing: Grain fineness, moisture content,

clay content and permeability test

1

6 Core materials and core making 1

7 Moulding practices: Green, dry and loam sand moulding, pit and floor moulding 1

8 Shell moulding; permanent moulding; carbon dioxide moulding 1

9 Metal casting: Melting furnaces: Rotary, Pit electric 1

1st UNIT TEST (25% of Syllabus)

10 Tilting and cupola 1

11 Review of casting processes, casting design considerations, 1

12 Capabilities applications of casting processes 1

13 Gating and Rising design fundamentals. 1

14 Casting defects 1

15 Principle of welding, soldering, Brazing and adhesive bonding 1

16 Classification of welding and allied processes 1

17 Capabilities and applications; welding parameters 1

18 General concepts of weldability, welding metallurgy and weldament design 1

19 Gas welding and gas cutting 1

20 Arc welding, Power sources and consumables 1

21 Resistance welding: Spot, Projection and seam welding process 1

22 Atomic hydrogen, ultrasonic, Plasma and laser beam welding 1

MID SEMESTER (50% of Syllabus)

23 Electron beam welding, and special welding processes e.g. TIG 1

24 MIG, friction and explosive welding, welding of C.I. and Al 1

25 Defects of welding and remedial actions 1

26 Numerical Calculation of Different process parameters of welding. 1

REFERENCES

S. No. TITLE AUTHOR PUBLISHER / EDITION YEAR

1

Production technology R.K. JAIN Khanna publishers

2 Production technology P.C. Sharma S Chand & Co Ltd

3 Manufacturing Technology Vol. II P.N. Rao Tata McGraw Hill

4 Welding Technology O. P. Khanna Dhanpat Rai publishers

27 Metal working, Elastic and plastic deformation, Concept of strain hardening 1

28 Hot and cold working 1

29 Rolling, Principle and operations, Roll pass sequence 1

30 Forging, Forging operations, Forging: Method of forging 1

31 Forging hammers and presses, Principle of forging tool design 1

32 Extrusion, Wire and tube drawing processes 1

33 Cold working processes: Shearing 1

34 Drawing Squeezing, Blanking, Piercing, deep drawing 1

2st UNIT TEST (75% of Syllabus)

35 Coining and embossing, cold heading, Riveting 1

36 Metal working defects 1

37 Thread rolling bending and forming operation 1

38 Numerical Calculation of Different process parameters of metal shaping and

forming 1

39 Classification of Plastics, Ingredients of Moulding compounds 1

40 General Properties of Plastics, Plastic part manufacturing processes such as

compression moulding 1

41 Transfer moulding, Injection moulding, Extrusion moulding, Blow moulding 1

42 Calendaring, Thermoforming, slush moulding, laminating. 1

43 Ceramic Structure, Properties, and Applications, Shaping Ceramics 1

44 Glasses Structure, Properties, and Applications, Forming and shaping of glass,

Composite materials 1

45 Processing of metal matrix and ceramic matrix composites, Processing

semiconductors. 1

PUT 100% SYLLABUS

ASSIGNMENT TOPICS

S. No. TOPIC

1 Introduction to Manufacturing Process

2 Metal Casting Processes

3 Metal Joining Processes

4 Metal Shaping and Forming

5 Plastic, Ceramic and Glass Processing

ASSIGNMENT: 1

Name of Subject : MANUFACTURING PROCESS II Date:

Subject Code : 2141908

Chapter/Unit: INTRODUCTION OF MANUFACTURING PROCESS

Sr.

No. Name of Question Remarks

1 Define Manufacturing process and Give the broad classification of manufacturing

process

2 Discuss various factors involved for selection of manufacturing process for producing a

given component.

3 For each of the following applications, suggest most suitable major manufacturing process or combination of major manufacturing processes (like welding, casting, forming, heat treatment etc.): 1. A power transmission gear of a reduction gear box 2. Housing of a reduction gear box (gear case) 3. Automobile body 4. A comb 5. Inner race/Outer race of a ball bearing 6. Lathe bed 7. A ceramic tipped cutting tool

ASSIGNMENT: 2

Name of Subject : MANUFACTURING PROCESS II Date:

Subject Code : 2141908

Chapter/Unit: FOUNDARY TECHNOLOGY

Sr.

No. Name of Question Remarks

1 List out various pattern materials. Explain any four material with their advantages and

limitation

2

Define following terms:

1. core

2. drag

3. core

4. chaplet

3 Explain precision investment casting stating its application, advantages and limitation

4 List out the casting defects and give their causes and remedies.

5 Sketch the cross section of a sand mould which is ready for pouring and label the

important part.

6 Different between hot chamber and cold chamber die casting.

7 Explain centrifugal casting process. What is the main difference between semi-

centrifugal and centrifuging casting process.

8 Define the term pattern. List out materials commonly used for pattern. State advantages

of wood as pattern.

9 State the types of furnace used in foundries. Discuss in brief the working of electrical

furnace.

10 Sate the principle of centrifugal casting and explain its working with neat sketch and

also give its advantages and limitation.

11 List the essential properties of moulding sand. State the each effect of each property on

casting.

12 Define pattern allowances. list various pattern allowances. State purpose of each

allowance.

13 What is gating system? What are its function? State types of gate with its advantages

14 Explain investment casting process. State its advantages and application.

15 What is pattern? List different types of patterns and explain them with neat sketch.

16

Explain the following.

1. Rapping allowances

2. Distortion allowances

17 List factor which affect salvaging of casting. Also list various salvage techniques of

casting and explain them.

18 Explain shell moulding.

19 Explain die casting.

20 Explain the properties of moulding sand.

21 List various materials used for pattern describe them in details with their advantages

and disadvantages.

22 Describe core making and core material briefly.

23 Explain centrifugal casting method with neat sketch along with its advantages over

conventional green sand moulding.

24 Explain cupola furnace with its sketch.

25 List out different sand testing techniques and explain any two in detail.

ASSIGNMENT: 3

Name of Subject : MANUFACTURING PROCESS II Date:

Subject Code : 2141908

Chapter/Unit: METAL JOINING PROCESS

Sr.

No. Name of Question Remarks

1

Define following terms

1. Flux

2. Filler materials

3. Electrode

4. Shielding gas

5. Edge preparation

2 Describe the types of flame obtained in oxy-acetylene gas welding with neat sketch.

3 Explain electrode beam welding process and state its advantages and limitation.

4 State the function of flux in soldering and brazing.

5 Explain gas welding process with neat sketch and state its advantages and limitations.

6

Calculate the melting efficiency in the case of arc welding and resistance welding of

steel with potential of 20v and a current of 200amp. The travel speed is 5mm/s and the

cross section of the joint is 20mm2. Heat required to melt steel may be taken as

10j/mm3 and heat transfer efficiency as 0.85. assume resistance, r= 100 micro ohms.

7 Discuss different between MIG and TIG

8 Classify the metal joining process. Explain the principle of gas welding process with

advantages and limitation.

9 Classify the electrode used in arc welding and explain its code used to specify it.

10 Explain the principle of arc welding with neat sketch. State the parameter affecting the

arc

11 Explain with sketch TIG welding process with its application, advantages and

limitation.

12 Describe the explosive welding process with advantages and limitation.

13

What determine whether the certain welding process can be used for work piece in a

horizontal, vertical or an upside down position, or for all types of position? Explain

with appropriate example.

14

Two flat copper sheets of 1.2 mm thickness each are spot welded. The process

parameter are current : 5000 amp. Current flow time : 0.20 sec Dia. Of electrode: 6

mm. Estimate the heat generated in welding zone.

15 Explain the factor affected in selection of electrode in arc welding .

16

A steel tube of 76mm outer dia. And 4mm thickness is welded to a flat piece by

applying friction welding process with the following information.

Energy applied e= is 2/c, where i= moment of inertia of the flywheel, s= spindle speed

in rpm, c= proportionally constant =250, weld zone =5 mm deep and energy required to

melt the electrode= 0.14 kg-m. If the entire energy of the flywheel is used to heat the

electrode, what is the required moment of inertia of the flywheel?

17 Classify the metal joining process along with the types of welding process. Explain

oxy-hydrogen welding process with neat sketch.

18 Distinguish arc welding process and resistance welding process in brief. Explain the

resistance welding cycle.

19 What is the laser welding process? Explain the step involve in the process with its

application, merits and limitation

20 Explain with sketch MIG welding process with its application, advantages and

limitation.

ASSIGNMENT: 4

Name of Subject : MANUFACTURING PROCESS II Date:

Subject Code : 2141908

Chapter/Unit: FORMING AND SHAPING PROCESS

Sr.

No. Name of Question Remarks

1

Define following terms:

1. ingot

2. slab

3. bloom

4. billet

2 Write short note on roll pass sequence

3 Derive the equation for the roll bite angle

4 Explain coining and embossing process

5 Different between open die and close die forging.

6 Write the short not on wire drawing

7 List the factors influencing rolling process. Explain the effect of roller diameter and

metal friction on rolling process.

8 Explain why there might be a change in density of a forged product as compared to that

of the cast blank.

9 Explain how you would go about applying front and back tensions to sheet metals

during rolling.

10 It was stated that the extrusion ratio, die geometry, extrusion speed, and billet

temperature all affected the extrusion pressure. Explain why.

11 How would you go about preventing centre burst defects in extrusion? Explain why

your methods would be effective.

12 Distinguish hot working process and cold working process with merit and demerits

13 Describe the wire and tube drawing process with sketch .classify the cold working

process . Explain any two of them.

ASSIGNMENT: 5

Name of Subject : MANUFACTURING PROCESS II Date:

Subject Code : 2141908

Chapter/Unit: PLASTIC TECHNOLOGY

Sr.

No. Name of Question Remarks

1 Classify plastic material.

2

Define following terms:

1. viscosity

2. viscoelastisity

3 Explain extrusion process for thermosetting plastic.

4 Explain blow moulding process with its application , advantages and limitation.

5 Classification of plastics and its general properties

6 Different between thermoplastic and thermosetting

7 Explain process of polymerization

8

With the aid of sketches compare the principle of compression moulding, injection

moulding and extrusion moulding. Describe where each would be used in terms of

materials and components

9

Explain what is meant by term inserts, and explain where they are of use in plastic

moulding. Sketch a typical component showing the position of the inserts and explain

their purpose.

10 Explain elastic and plastic deformation process briefly

11 Describe injection moulding process of plastic with neat sketch.

12 Distinguish extrusion and thermoforming process of plastics.

Roll No.____________ Enrollment No.____________ Student sign:-_____________

Gujarat Technological University

LAXMI INSTITUTE OF TECHNOLOGY, SARIGAM

Academic year 2017-2018

Mid Semester Exam -I

B. E. – II Branch: MECHANICAL

Subject: MANUFACTURING PROCESS-II (Subject Code:2141908)

Date: Time: 09:00 am to 10:30 am Max. Marks: 30

Instructions:

1. Draw necessary figures when require.

2. All questions are compulsory.

3. Figure to the right indicates marks.

Q.1 a) Define following terms

1. Flux

2. Filler materials

3. Electrode

4. Shielding gas

5. Edge preparation

[05]

b) Classify the metal joining process. Explain the principle of gas welding process

with advantages and limitation. [05]

Q.2 a) What is the laser welding process? Explain the step involve in the process with its

application, merits and limitation [05]

b) Define following terms:

1. ingot

2. slab

3. bloom

4. billet

[05]

OR

Q.2 a) How would you go about preventing centre burst defects in extrusion? Explain

why your methods would be effective [05]

b) Explain electron beam welding process with the help of neat sketch. Also explain

applications of it. [05]

Q.3 a) Explain extrusion process for thermosetting plastic. [06]

b) Different between thermoplastic and thermosetting [04]

OR

Q3 a) Describe the wire and tube drawing process with sketch .classify the cold working

process . Explain any two of them. [05]

b) Write short note on powder coating [05]

ALL THE BEST