Document Sample
Course Instructor:
Suraj Pandey (Department of Mechanical Engineering, Kathmandu University)

Course Introduction:
This is a portfolio designated course which requires you to submit a sample of your
writing to the electronic portfolio database. You must satisfy this requirement as part
of earning a grade for this course. Submitting the paper as instructed will ensure that
you receive a grade commensurate with your work in the course.

Manufacturing Processes is a study of the manufacturing processes used in the
metals industry. Areas of instruction will include casting, hot and cold metal forming,
machine tool operation, and welding. Laboratory activities will include hands-on
experience in each of the areas discussed in the classroom.

Course Objective:
Technology and production are interdependent; the technologist must develop
practical and economical production processes before a product can be made.
Additionally, the technologist must continuously improve the product and the process
and adopt, where feasible, the latest methods and procedures. Hence, the
technologist must be familiar with the basic manufacturing equipment and production
practices and with associated terminology. This course will survey basic
manufacturing methods, procedures and equipment.

Course Reading Materials:

   The first two books J.S. Campbell:“Principle of manufacturing, TMH Publications &
   Co. and Raghavan: “Workshop technology I”, are the main course books. These
   books are available in Library. These are excellent books, covering all the
   topics addressed in the course, including also practical, numerical problems.
   The following list identifies the main as well as some additional useful,
   course related books:
   1. J.S. Campbell: “Principle of manufacturing, TMH Publications & Co.

   2. Raghavan: “Workshop technology I”

   3. Raghuwanshi: “Workshop technology I”, Dhanpatrai & Sons

   4. Begman & Amsteed: “Manufacturing processes”

   5. SK Hajra Choudhary & SK Rose: “Elements of workshop technology, Vol. I”,

      Media Publishers.
                                  Components of the Course:
    Course Credit : 3
          Lecture Hour : 4 hours a week.
                 Thursday 1:00-3:00 p.m.
                 Friday 091:00-3:00 p.m.

          Assignment:
              o Problems are due in the following week (7 days) after they are assigned.
              o Problems will be graded only if they are written neatly.
              o Cooperation on understanding and doing the homework is allowed, but the
                 final presentation must be your own (no copying of homework).
              o No late assignment! There will be a “No Questions Asked/No Excuses
                 Needed” policy of dropping your lowest assignment grade to cover any
                 special circumstances.
              o Your assignment covers 60 % of the total Internal Marks.

          Preparation and Responsibilities:
              o You are responsible to know all sections in the main course book as addressed
                 and covered during the classes according to the course outline.
              o Please look through the sections that will be covered in class before coming to
              o Please read both the main course books and the class notes before coming to
                 our office during office hours if you have any queries or questions.
              o Please make an honest attempt at solving the problems before coming to our
                 office during office hours.

      Grading policy:
       There will be periodical, class lecture related, weekly short assignments given. They
have to be handed in latest by the next weekly lecture. They count towards the final course
grades. Your final grade will be calculated on the basis of attendance, class participation in
discussions, periodical weekly short assignments and your grades on the two exams.

           Total Marks: 100
   1. Internal Marks : 25 out of 100
                 Two Exams                                              40 %
                 Assignments                                            60 %

Note: Attendance should be above 80% otherwise the student is not allowed to appear in the
end semester exam as per the university rule.

   2. End semester exam : 75 out of 100

Additional information
             Please feel free to come to our office during the office hours, or to contact us
              before or after class for an appointment, if you have any questions.
             Make up exams – only for a documented (a doctor's written testimony) health
              reason or with our prior permission. If you cannot come to an exam, you must
              inform us at least one day before the exam that you will be absent. Make ups will
              be scheduled at the professor’s convenience.
             The pass mark for the course is > =40 %.
Course Outline and Topics

Introduction to Machine Tools And Classification Of Machine Tools:

Lathe: types of lathe, lathe parts, work holding devices: chucks face plate. Lathe
operations: facing, turning, drilling, and boring. Taper turning: calculation and
problems. Thread cutting; gear calculation; use of dial indicator. Method of cutting
multiple threads, thread chaser, cutting metric threads. Eccentric turning. Capstan and
turret lathes. Layout of turret tooling.

Shaping, Planning, Slotting & Milling Machines: Gear Generation:

Shaping machine: parts and their functions Principle of crank shaper and hydraulic
shaper, speeds and feeds, table-feeding mechanism.

Slotting Machine: description of slotting machines and their function

Planers: types and their relative merits, difference between planer, shaper and slotter.

Milling Machines: types and principles of milling, milling cutter terminology, milling
operations, gear cutting, indexing: simple, compound, differential indexing and

Gear generation methods: gear shaping and gear hobbing

Other Machine Tools

Drilling Machines: types of drilling machines, parts and their functions. Twist drill
terminology, machining time calculation.

Boring machines: types & uses.

Broaching Machines: types & uses

Grinding Machines: designation of grinding wheel, grinding operations, speeds and
feeds, balancing, truing and dressing of grinding wheel, types of wheel shapes, coolant

Metal Working:

True Stress, True Strain, Plastic Deformation, Hot Working, Hot Working Temperatures,
Cold Working. Rolling, Principle, Equipment, Angle of Bite, Calculation for slip. Forging,
Principle, Flow Stresses, Strain, Extrusion, Principle, Hot & Cold Extrusion, Wire Drawing,
Principle, Tube Drawing, Sheet Metal Working, Definitions of Various Operations like
Shearing, Blanking, Piercing Trimming, Shaving etc., Forging Hammer’s and Presses.


Foundry hand tools. Foundry sand and their control additives. Core and types of core.
Pattern materials and types of patterns. Shrinkage allowances. Molding process
pouring. Knockout and cleaning of casting. Brief description of special casting methods
as shell molding, CO2 molding and centrifugal molding, Permeability, hardness,
flowability. Tensile compression, shear strength and moisture content. Defects in sand
casting. Cupola.


Welding: Soldering, brazing and braze welding advantages and limitations. Welding
processes and applications. Defects in welding

Gas Welding: Principles, Types of gases used, Types of Flames, Welding Techniques,
Filler Rods, Principles Position of Torch, Precautions and Safety

Electric Arc Welding: Principles, A.C./D.C. Welding, Edge Preparation, , Welding
Electrodes, Manual Metal Arc Welding, Carbon Arc Welding, Inert Gas Shielded Arc
Welding, TIG & MIG, Submerged Arc Welding, Atomic Hydrogen Arc Welding, Plasma Arc
Welding, Stud Arc Welding, Arc Cutting.

Resistance Welding: Principles, Electrodes, Spot Welding, Seam Welding, Projection
Welding, Upset Welding, Flash Welding.

Fusion Welding Processes: Thermit Welding, Electro Slag Welding, Electron Beam and
Laser Beam Welding


Plagiarism is the use of someone else’s writing and/or work without giving
proper credit–or perhaps without giving any credit at all to the writer of the
original material. Whether plagiarism is intentional or unintentional, it
represents a serious academic offense that can be easily avoided by adhering
closely to the following advice. A student must document his/her source of
information whenever he/she:

1. Uses direct quotations.
2. Copies a table, chart, or diagram.
3. Constructs a table from data provided by others.
4. Paraphrases a passage in his/her own words.
5. Presents specific examples, figures, or factual information taken from a
specific source and uses to explain or support his/her judgments (James M.
McCrimmon, Writing With a Purpose, p. 499).

Shared By: