ME203: BASIC MANUFACTURING TECHNOLOGY (BMFT)

(For ME -III Semester)

Scheme
: 2013
Internal Assessment : 30
End Exam
: 70
End Exam Duration : 3 Hrs
Course Objectives:
The objective of this course is to make the students to understand the processes of casting, metal forming
processes , processing of plastics and various welding processes.

Course Outcomes:

At the end of the course the student will be able to

1. Understand the role of various casting processes in industry.
2. Understand the role of various Metal forming processes.
3. Understand the role of various Metal joining processes.
Unit-I
Casting Process : Casting, casting terms, pattern materials, types of patterns, pattern allowances,
colour code for patterns, Moulding sands, core sands, properties of moulding sand and its ingredients,
different types of moulding machines, use of chaplets, chills, riser and gating system. Design of patterns,
moulds and cores. Riser and gating design.
Unit-II
Special Casting Processes : CO2 moulding, die casting, centrifugal casting, shell moulding,
investment or lost wax process; Casting defects causes and remedies. Furnaces used in foundry
cupola, pit furnace, electric arc furnaces.
Unit-III
Forming Processes : Stress Strain in elastic and plastic deformation, hot working, cold working
process and relative advantages and disadvantages.
Rolling: Principle of rolling, types of rolling mill, Two high, three high and cluster mill, Planetary mill and
Sendzmir mill. Load estimation in Rolling.
UNIT-IV
Forging: Principle of forging, forging operations, forging types smith forging, drop forging, press
forging, machine forging. Load estimation in Forging.
Extrusion and drawing Processes : Principle of extrusion, forward and back ward, cold extrusion
forging, tube extrusion, hydro static extrusion and impact extrusion. Principle of drawing, wire drawing
and tube drawing.
Unit-V
Processing of Plastics : Classification of plastics, thermoplastics, thermosetting plastics and applications,
injection, compression and blow moulding, extrusion, calendaring and thermoforming. Welding of plastic
materials
Unit-VI
Gas Welding: Gas welding equipment, Oxyacetylene welding, types of flames, techniques of welding
and oxy- acetylene cutting.
Arc Welding: Arc welding equipment, Metal arc welding functions of electrode coating, TIG, MIG and

Submerged arc welding process (SAW),

Resistance welding: Principles of resistance welding, spot, projection, seam, butt, upset and flash welding
process. . Soldering, brazing and braze welding.
Principle and Applications of Thermit welding, Laser beam welding, Electron beam welding
Text Book :
1. P. N. Rao [2012], Manufacturing Technology: Foundry, Forming and Welding, TMH Publishers, New
Delhi.
2. P. C.Sharma [2009], A Text of production Technilogy, S Chand and Company, New Delhi
Reference Books:
1. R. K. Jain [2005], Production Technology, KhannaPublication, New Delhi.
2 Kalpak Jian, Schmid [2009], Manufacturing processes for Engineering Materials. Pearson, New Delhi
3. Roy A. Lindberg [2008], Processes and Materials of Manufacture, PHI Publishers, New Delhi.

Note:

End Exam: The question paper for end examination shall consist of One Compulsory question
consisting of objective type, fill in the blanks etc for 10 marks and for the remaining 60 marks student has
to answer any four questions out of 6 questions for 15 marks each.
Internal Assessment: The question paper for sessional examination shall have one compulsory question
carrying 6 marks and five other conventional (descriptive or analytical type) questions carrying 8 marks
each. The compulsory question consists of objective type questions like the multiple choice, fill in the
blanks etc. Apart from the compulsory question, the student has to answer any 3 from the remaining 5
conventional questions.