Syllabus For The Subject Manufacturing Technology

MANUFACTURING TECHNOLOGY

Contents

1 Concept of manufacturing

Introduction

Manufacturing system

General aspects

Classification of manufacturing processes

Selection of a manufacturing process

Process planning

Analysis of manufacturing system

Types of production

Control systems

Introduction

System

Control system

Classification of control systems

Open-loop control systems

Closed-loop control system

Automatic control systems

Organization, administration and management

Plant organization

Scientific management

Definition

Principles

Aims

Functions of management

Plant location

Plant layout

Production ,planning and control

Definitions

Functions of PPC

Advantages of production control

Constituents of production control

Questions with answers

Highlights

Objective type questions

Theoretical questions

 

 

2 casting processes

Introduction

Patterns

Definitions

Requirements of a good pattern

Pattern materials

Types of patterns

Pattern allowances

Mould making

General aspects

Types of moulds

Pattern allowances

Mould making

General aspects

Types of moulds

Moulding processes

Types of sand moulding

Core

Core making

Types of cores

Core prints

Core box

Moulding sand

Properties of modeling sand

Types of moulding sand

Composition of the green sand

Sand testing

Melting equipment

Crucible furnace

Reverberatory or air furnace

Open heart furnace

Electric furnace

Cupola furnace

Melting and pouring

Melting

Pouring

Gating system

Cooling and solidification

Casting

Advantages and disadvantages of casting process

Preparation of a casting

Basic rules for good casting design

Casting processes

Sand casting shell-mould casting

Plaster-mould casting

Ceramic mould casting

Vacuum casting

Evaporative-pattern casting

Investment casting

Slush casting

Pressure casting

Die casting

Centrifugal casting

Squeeze casting

Semisolid metal forming

Continuous casting

Defects in castings

Cleaning of castings

Inspection of castings

Questions with answers

Highlights

Objective type questions

Theoretical questions

 

3 Metal forming processes

Introduction

Cold and hot working

Cold working

Hot working

Comparison of cold working and hot working processes

Rolling

Principle and mechanism of rolling

Rolling stand arrangement

Defects in rolling

Forgoing

Introduction

Advantages and disadvantages of forging

Classification of forgoing

Basic categories of forging

Methods of forgoing

Other forgoing processes

Defects in forgoing

Cleaning and finishing of forgings

Heat treatment of forgings

Design considerations

Extrusion

Introduction

Advantages, limitations and applications of extrusion process

Classification of extrusion processes

Hot extrusion processes

Extrusion equipment

Extrusion defects

Wire drawing

Tube drawing

Tube making

Metal stamping and forming

Introduction

Bending

Deep drawing

Strength forming

Metal spinning

Shear forming and flow forming

Blanking

Piercing

Embossing and coining

Roll forming

Rubber press forming

Hydro mechanical forming

Defects in sheet metal formed parts

Shot peening

Types of dies

Classification of dies

Causes of failure of dies in metal working operations

Presses

Classification of presses

Cutting forces and energy in press work

Comparison of metal forming processes

Highlight

Objective type questions

Theoretical questions 

 

4 Powder metallurgy

Definition

Advantages , disadvantages of powder metallurgy

Applications of powder metallurgy

Manufacture of parts by powder metallurgy

Production of metal powders

Blending of metal powders

Pressing of compaction of metal powders

Sintering

Finishing operations

Design considerations for powder metallurgy

Questions with answers

Highlights

Objective type questions

Theoretical questions

5 Processing of plastics

Introduction to plastics

Definition of plastic

Classification of plastics

Characteristics properties of plastics

Computing materials

Fiber glass reinforced plastics

Trade names and typical applications of some important plastics

Processing of plastics

General aspects

Plastic processing methods

Compression moulding

Injection molding

Expandable bead moulding

Rotomoulding

Blow moulding

Extrusion

Thermoforming

Calendaring

Casting

Machining of plastics

Joining of thermoplastics

Plastic design rules

Questions with answers

Highlights

Objective type questions

Theoretical questions

 

6 Ceramic and composite materials-their structure

And processing

Introduction to ceramic materials

Classification of ceramics

Advantages of ceramic materials

Applications of ceramics

Properties of cernamic ,materials

Structure of crystalline ceramics

Silicate structures

Types of silicate structures

Polymorphism

Glass

Definition and structure

Constituents of glass and their functions

Properties of glass

Glass furnaces

 Fabrication of glass

Classification of glass

Uses of glass

The glass industry in India

Advanced ceramics

Processing of ceramics

General aspects

Shaping processes

Drying and firing

Finishing operations

Design considerations for ceramics

Introduction to composite materials

Classification

Particle-reinforced composite

Fibre-reinforced composites

Structural composites

Production of composite structures

Questions with answers

 Highlights

Objective type questions

Theoretical questions

 

7 Welding and allied processes

Introduction

Advantages, disadvantages and applications of welding

Classification of welding processes

Forge welding

Resistance electric welding

General aspects

Resistance spot welding

Resistance seam welding

Resistance projection welding

Resistance butt welding

Gas welding

Fusion welding-general aspects

Advantages and disadvantages of gas welding

Applications of gas welding

Oxy-acetylene welding

Electric arc welding

Introduction

Advantages and limitations

Metallic arc welding

Carbon arc welding

Atomic hydrogen welding

Shielded arc welding

Arc blow

Comparison between A.C.arc welding

Types of welded joints

Thermit welding

Tungsten inert-gas welding

Metal inert-gas welding

Differences between TIG and MIG welding processes

Submerged arc welding

Electro –slag and electro-gas welding

Electro-slag welding

Electro-slag welding

Electron-beam welding

Ultrasonic welding

Plasma arc welding

Laser beam welding

Friction welding

Explosive welding

Diffusion welding

Induction welding

Cold welding

Stud-arc welding

Hydrodynamic welding

Under-water welding

Oxy-acetylene torch cutting

Solid/liquid-state bonding-soldering and brazing

Soldering

Definition

Classification of soldering methods

Types of solder

Selection of solder

Flux or soldering fluid

Soldering equipment

Soldering procedure

Characteristics of a good joint

Important tips for effective soldering operation

Advantages of soldering

Applications of soldering

Types of soldered joints

Electrodes

Electrode materials

Electrode’s designation

Typical data on use of mild steel electrodes

Welding of various metals

Rebuilding

Hard facing

Characteristics of good weld

Defects in welds

Weld ability

Testing of welded joints

Effects of welding on the grain size of the metal

Principles of welding design

Comparison of welding and allied process

Worked examples

Questions with answers

Highlights

Objective type questions

Theoretical questions

 

8 Metal cutting

Introduction

Chip formation

Types of chips

Cutting tools

Classification

Single point cutting tool

Tool elements and tool angles

Tool signature (or tool designation)

Orthogonal and oblique cutting

Chip control

Force of a single-point tool

Mechanics of metal cutting

Shear zone, shear plane and shear angle

Chip thickness ratio

Velocity relationship in orthogonal cutting

Forces on the chip

Stress and strain on the chip

Work done during metal cutting and specific cutting energy

Theories on mechanics of metal cutting

Friction in metal cutting

General aspects

Factors affecting temperature

Temperature distribution in metal cutting

Measurement of chip-tool interface temperature

Tool wear and failure

Tool wear

Tool failure

Tool life

Cutting speed, feed and depth of cut

Machinability  

Cutting fluids

Functions of cutting fluids

Types of cutting fluids

Cutting tool materials

Characteristics of an ideal cutting-tool material

Types of tool materials

Questions with answers

Highlights

Objective type questions

Theoretical questions

Unsolved examples

 

9 Machine tools and machining processes

Introduction

Machining processes

Machine tools

Centre/engine lathe

Introduction

Working principle

Parts of lathe

Size and specifications of lathe

Types of lathe

Lathe operations

Lathe accessories

Lathe attachments

Cutting speed, feed and depth of cut

Material removal rate

Machining time

Power required in turning

Thread cutting

Eccentric turning

Turret and capstan lathes

Introduction

Limitations of a centre lathe

Differences between a turret lathe and a centre lathe

Comparison of turret lathe and capstan lathe

Main parts of a turret or capstan lathe

Types of turret lathes

Size and specification of turret lathe

Common tools and attachments used on turret

And capstan lathes

Turret lathe operations

Turret lathe tooling layout

Automatic lathes

Introduction

Classification of automatic lathes

Automatic vertical multistation lathe

Automatic screw machines

Shaping machine

Introduction-principle of working

Advantages, limitation, and applications of shapers

Classification of shapers

Principal parts of a shaper

Specifications of a shaper

Quick return mechanism in a shaper

Shaper work holding devices

Operations performed

Cutting tools and other tools used in shaper work

Cutting speed,feed and depth of cut

Machining time

Material removal rate

Slotting machine

Introduction

Main parts of a slotter

Size and specifications

Slotter drive mechanisms

Types of slotters

Work holding devices

Slotter cutting tools

Slotter cutting tools

Slooter cutting tools

Slotter operations

Planning machine (planer)

Introduction

Principle of working-planing operation

Comparison between planer and shaper 

Types of planers

Principal parts of a planer

Size of a planer

Planer driving and feed mechanisms

Standard clamping devices

Planer tools

Planer operations

Cutting speed,feed and depth of cut

Machining time and material removal rate

Drilling machines

Introduction 

Specifications of a drilling machine

Types of drilling machines

Classification of drills

Twist drill nomenchines

Work holding devices

Drilling machine operations

Cutting speed, feed and depth of cut

Machining time in drilling

Material removal rate

Boring Machines

Introduction

Classification of boring machines

Horizontal boring machines

Vertical boring machines

Jig boring machine

Size of boring machines

Milling machines

Introduction

Milling processes-principle of milling

Classification of milling machines

Horizontal milling machine

Vertical milling machine

Universal milling machine

Universal milling machine

Omniversal milling machines

Planer type milling machines

Bed type milling machines

Drum type milling machines

Planetary milling machine

Specifications of a milling machine

Types of milling cutters

Nomenclature of a milling cutter

Milling operations

Cutting speed, feed and depth of cut

Material removal rate

Machining time

Work holding devices

Milling machine attachments

Dividing or indexing head

Grinding and finishing processes

Introduction

Grinding processes

Advantages of grinding process over other cutting processes

Special feature of grinding wheels

Grinding machines

Grinding wheel

Manufacture of grinding wheels

Wheel shapes

Mounting of wheels

Wheel truing

Material removal rate and machining time

Finishing processes

Honing

Lapping

Superfinishing

Comparison   among lapping, honing and superfinishing

Polishing and buffing

Burnishing

Comparison of grinding and finishing processes

Coolants and lubricants

Questions with answers

Highlights

Objective type questions

Theoretical questions

Unsolved examples

10 Thread manufacturing

Screw threads

Classification of threads

Elements of screw threads

Specifications of a screw thread

Forms of threads

Errors in threads

Processes for making threads

Using die heads

Thread milling

Thread rolling

Thread grinding

Thread tapping

Automatic screw machines

Highlights

Objective type questions

Theoretical questions

11 Gear manufacturing

Introduction 

Advantages and disadvantages of toothed gearing

Types of gears

Forms of gear teeth

Gear tooth terminology

Methods of making gears

Gear manufacturing by ‘’casting

Forming or form cutting

Broaching

Template methods

Generating methods/processes

Gear shaper process

Rack planning process

Hobbing process

Hobbing process

Hobbing process

Bevel gear cutting

Cutting worms and worm wheels

Gear finishing

Gear shaving

Gear burnishing

Gear grinding

Gear lapping

Gear honing

Highlight

Objective type questions

Theoretical questions

12 Unconventional machining processes

Introduction

Classification of unconventional machining methods

Selection of process

Electrical discharge machining

Electro- chemical grinding

Ultrasonic machining

Electron beam machining

Laser beam machining

Plasma arc machining

Abrasive jet machining

Chemical machining

Comparison of unconventional machining methods

Questions with answers

Highlights

Objective type questions

Theoretical questions

13 machine tools testing

Introduction

Machine tools tests

Instruments required for alignment test

Alignment tests on lathe

Leveling of the machine

Parallelism of spindle axis and bed

True running of taper socket in main spindle

Alignment of both the centres in vertical plane

Cross-slide perpendicular to spindle axis

Accuracy of pith of lead screw

Axial slip of lead screw

Alignment test on drilling machines

Alignment test on pillar type drilling machine

Alignment tests on radial drilling machines

Alignment tests on milling machine

Eccentricity of external diameter

True running of internal taper

Work table surface parallel with arbor rising towards overarm

Surface parallel with longitudinal movement

Traverse movement parallel with spindle axis central t-slots parallel with spindle axis

Central t-slots parallel with longitudinal movement

Central t-slots square with the arbor

Test on column

Overarm parallel with spindle

Alignment of the main spindle with bore of the bracket

Of the overarm

Acceptance tests for surface grinders

Practical tests

Objective type questions

Theoretical questions

14 Numerical control of machine tools and cad/cam

 Introduction to modern machine tools

Nc machines

Introduction

Working of NC machine tool

Main elements of a NC machine tool

Classification of numerical control (NC) machines

Applications of NC machines

Advantages and disadvantages of NC machines

Comparison between conventional machines and NC machines

CNC machines

General aspects

Functional of CNC

Advantages and disadvantages of

CNC machines

Applications of CNC

Comparison of NC and CNC machines

Direct numerical control

Adaptive control systems

Machining centre

Advantages and limitations of automation and computer controlled machines

Introduction to CAD/CAM

CAD

Definition

Advantages

CAM

General aspects

Advantages of CAM

Software and hardware for CAD/CAM

Functioning of CAD/CAM system

Features and characteristics of CAD/CAM system

Application areas for CAD/CAM

Questions with answers

Highlights

Objective type questions

Theoretical questions

15 Automatic Machines

Introduction

Advantages of automation

Transfer machines

Types of transfer machines

Constructional feature of a transfer machine

Advantages and disadvantages of transfer machines

Machining centers

General aspects

Types of machining centers

Characteristics of machining centers

Selection of machining center

Highlights

Objective type questions

Theoretical questions

16 jigs and fixtures

Introduction

Definitions and concept of jig and fixture

Advantages of using jig and fixture

Main components or elements of jigs and fixtures

Principles of jig and fixture design

Degrees of freedom

Principles of location

Locating devices

Clamping devices

Introduction

Basic requirements of clamping devices

Principles of clamping

Types of clamps

Materials used for making locating and clamping devices

Types of jigs

Types of fixtures

Highlights

Objective type questions

Theoretical questions

17 Metrology  

Meaning of metrology

Objectives of metrology

Standards of measurements

Line standard

End standard

Classification of standards

Relative characteristics of line and end standards

Limits, fits and tolerance

General aspects

Nominal size and basic dimensions

Definitions

Basic of fit system

Systems of specifying tolerances

Designation of holes, shafts and fits

Commonly used holes and shafts

The newall system

ISO system of limits and fits

Types of fits

Concept of interchangeability

Measuring instruments

Gauges

Classification of gauges

Description of some commonly used gauges

Linear measurements

Engineer’s steel rule

Calipers

Vernier calipers

Vernier height gauge

Vernier depth gauge

Micrometers

Advantages and limitations of commonly used

Precision instruments

Angular and taper measurements

Angular measurements

Taper measurement

Screw thread measurements

Introduction

Classification of threads

Elements of screw threads

Elements of screw thread

Forms of threads

Measuring elements of a screw-thread

Screw thread gauges

Questions with answers

Objective type questions

Theoretical questions

18 Economics of marching and manufacturing

Economic of machining

Economics of manufacturing

Highlights

Theoretical questions

19 Need for integration of design and manufacturing

  Introduction

Integration of design and manufacturing

Process selection

Process routing

Capacity planning

Intrawork cell scheduling methods

Dispatching

Basic tools for integration

Computers and microprocessors

History and development of computers

Definition of a computer

Characteristics of a computer

Classification of computers

Analog computers

Digital computers

Differences between analog and digital computers

Block diagram of a digital computer

Rating of chips

Computer peripherals

Storage devices

Hardware, software and liveware

Translators

Computer languages

Computer programming process for writing programs

Computer elements of analog computers

Microprocessors

Computer terms

Computer networks for manufacturing

Introduction

Computer network

Local area network

Manufacturing automation protocol

Computer software

Information technology

General aspects

Data and information

Information system

Questions with answers

Highlights

Objective type questions

Theoretical questions

20 Elements of integration

Computer integrated manufacturing

Mechanization and automation

Automation and production

Mechatronics and concurrent engineering

Industrial robots

Introduction

Objectives of using industrial robots

Advantages of employing robots

Robot components

Robot classification

Control system and components

Types of industrial robots

Terms related to the construction and operation of robots

Robot programming and languages

Intelligent robots

Automated guided vehicle system

General aspects

 AGVs equipment

Applications of AGVs

Automated storage systems

General aspects

Objectives of automated storage systems

Automatic storage/retrieval systems

Questions with answers

Highlights

Objective type questions

Theoretical questions

21 Product and process design for integration 

Product analysis

Concepts of process and job

Strategies for integrated product and process design

Tools and methods

Concurrent engineering

Questions with answers

Highlight

Objective type questions

Theoretical questions

22 Computer aided process planning

Introduction

Analysis and planning data required

Analysis and planning steps and considerations

Process format and content

 Computer aided process planning systems

Questions with answers

Highlights

Objective type questions

Theoretical questions

23 Group technologies

General aspects

Advantage and limitations of group technology

Part familiars

Formation and establishment of component family

Collection of production data

Classification and codification

Introduction

Basic requirements of classification and coding systems

Advantages of well-designed classification and coding system

Classification and coding for group technology

Questions with answers

Highlights

Objective type questions

Theoretical questions

24 Inspection and quality control

Inspection

Introduction

Aims of inspection

Inspection standards

Types of inspection

Inspection devices

Quality control

Definition and scope

Advantages of quality control

Objectives of quality control

Essentials or principles of quality control

Statistical quality control

Control charts

Sampling

Advantages of sampling

Acceptance sampling

Single sampling

Double sampling

Standards and specifications

Quality assurance concepts

Functions of quality assurance

Highlights

Objective type questions

Theoretical questions

25 Maintenance management, work study  and mis

Maintenance management

Work study

Definitions

Symbols used in work study

Steps involved in method study

Recording techniques used in method study

Time study

Motion study

Job analysis, job evaluation and merit rating

Wages and incentives

Purchasing

Storages and store-keeping

Inventory control

Materials handling

Financial management and budgeting

Network    analysis

Operation research

Manpower planning and control

Forecasting

Management information systems

Highlights

Objective type questions

Theoretical questions

 

 

 

 

 

 

 

  

 

 

 

 

 

 

    

 

 

 

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