Manufacturing Processes

Unit I
Pattern Making & Moulding: - Pattern making: Types, materials used, Pattern
making allowances, color codes.
Moulding sand: Composition, moulding sand properties, Sand testing - Grain
fineness, moisture content, clay content and permeability test. Core making: - Types,
core material & its properties. Types of sand moulds.
Gating System & Casting Processes: - Gating design - Elements of gating systems,
riser design. Melting furnaces - Types, Electric furnace, Induction furnace, Cupola
construction & operation, Cleaning, inspection & casting defects - types, causes &
remedy. Moulding machines. Special casting processes such as Investment Casting,
Centrifugal Casting, Slush Casting, Die Casting, Shell moulding and CO2 moulding.

Unit II
Joining Processes: - Major grouping of joining processes, welding, brazing and
Soldering, Broad classification of welding processes, types and Principles.
Electrodes, weldability of Metals, Welding equipments. Fixtures, Arc Welding &
Gas Welding Processes, TIG Welding, MIG Welding, Spot Welding, Plasma Arc
welding and Electron Laser Beam welding.
Weld: Inspection, Defects in various joints and their remedies.
Joint through Adhesive – classification of adhesive, types of adhesive, applications. ,

Unit III
Forming Process for metals:- Rolling, Forging, Extrusion, Drawing, Mechanics of
forming process, Determination of Rolling pressure and roll specification force,
drive force and torque, power loss in bearing, Determination of forging forces and
stresses, Equipment (hammer/press) capacity required. (No analytical treatment)

Unit IV
Sheet metal working: - Classification, types of presses, press terminology, Force
analysis in press working, Die cutting operation, types of dies, Die and punch
allowance, introduction to shaping operations, bending, forming and drawing.

Unit V
Introduction to Plastics, Properties & types, applications, Forming & Shaping of
plastics –Extrusion, injection moulding, Blow moulding, wire drawing, Compression
moulding, Transfer moulding, Embossing, Calendaring.
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.

References:
Text Books Recommended:
1. Workshop Practice, H. S. Bawa, Tata Mc-Graw Hill
2. Manufacturing Engineering & Technology, Kalpakjian, Pearson
3. Modern Materials and Manufacturing Process, R. Gregg Bruce, John E. Neely,Pearson
Education
4. Degarmon’s Materials and Processes in Manufacturing, 11th Ed. Black, Ronald A Kohser, Wiley India
5. Workshop Technology (Volume I), Hajra Chaudhary, Media Promoters &Publishers
6. Workshop Technology (Vol. I & II), B. S. Raghuwanshi, Dhanpat Rai & Co.
7. Manufacturing technology (Vol. I), P. N. Rao, Tata Mc-Graw Hill
8. Manufacturing Science, Ghosh & Malik, East West Press.
9. Textbook of Production Engineering, P.C. Sharma, S. Chand & Co.
10. “ASM Metals Hand Book on Casting”, 1992.
11.Parmer R.S; “Welding Processes& Technology”, Khanna Publishers, 1994.
12.Lancaster J.F., George Allen and Unwin, 1991, “Metallurgy of Welding”.
13.Metals Hand Book, Vol 6,8th edition, ASM, 1971.
14.AWS Welding Hand Book,Vol 1 to 4 AWS.
Reference Books Recommended:
1. Workshop Technology, Vol I & II, WAJ Chapman, Elsevier Butterworth-Heinemann.
2. Manufacturing Processes, M. Begman.
3. Processes & Materials of Manufacturing, R. Lindberg, Allyn & Bacon.

Fluid Mechanics & Hydraulic Machines

UNIT-I Fluid Properties:
Types of fluids, Mass Density, Specific Weight, Specific Gravity, Newton’s Law of
Viscosity, Dynamic Viscosity, Stroke’s Theorem, Surface Tension, Capillarity,
Compressibility,Vapour pressure.

Introduction of Fluid Kinematics, Types of Flow- steady, unsteady, uniform, non-
uniform, laminar, turbulent.

Fluid Statics :- Pressure, Measurement of pressure using manometers, Hydrostatic
law, Pascal’s law, Pressure at a point, Total pressure, Centre of pressure, Pressure on
a plane (Horizontal, vertical, Inclined) and Curved Surfaces, Archimedes’s principle,
Buoyancy and stability of floating and submerged bodies, Metacentric height

UNIT-II Fluid Dynamics
Introduction to Navier-Stroke’s Equation, Euler equation of motion along a stream
line, Bernoulli’s equation, application of Bernoulli’s equation to pitot tube, venturi
meter, orifices, orifice meter.
Laminar And Turbulent Flow :- Definition, Relation between pressure and shear
stresses, Laminar flow through round pipe, Turbulent flow and velocity distribution.

UNIT-III Flow Through Pipes
Flow Through Pipes :TEL, HGL, Energy losses through pipe, Darcy-Weisbach
equation, Minor losses in pipes, TEL, HGL, Moody diagram, pipes in series and
parallel, Siphons, Transmission of power.
Dimensional Analysis, Dimensional Homogeneity, Rayleigh method &
Buckingham’s pi –Theorem.
Introduction to Similitude and model testing.

UNIT-IV Theory of turbo machines
Turbo Machine classification, Elements of hydro-electric power plant,
Impulse Turbine:- principles of operation , constructional features, Velocity
Diagram and Analysis,Design parameters, Performance characteristics, Governing.
Reaction or pressure Turbine:- principles of operation, Classification , Degree of
reaction, comparison over Pelton Turbine, Draft tube, Cavitation in Turbine,
Francis Turbine, :- Types, Constructional features, Installations, Velocity Diagram
and analysis, Design parameters, Performance characteristics, Governing.
Propeller Turbine, Kaplan Turbine: -Constructional features, Velocity
Diagram and analysis, ,

UNIT- V Hydrodynamic pumps:-
Centrifugal pumps:- Principle of operation, Classification, Component of Centrifugal
Pump, Various heads, Velocity triangles and their analysis, N.P.S.H., Cavitation’s in

pumps, Installation and operation, Performance characteristics, Introduction to self-
priming pumps

Reciprocating pump : Basic principle, Classification, Main Components, Slip, Work
Done, Indicator Diagram, Cavitation’s, Air vessels,,

References:
Text Books Recommended:
1. Fluid Mechanics, Dr. R.K. Bansal, Laxmi Publication (P) Ltd. New Delhi
2. Engineering Fluid Mechanics, Kumar K.L.,S. Chand & company Ltd. Eurasia
3. Publication House
4. Fluid Mechanics & Hydraulic Machines, R.K. Rajput, S. Chand & Company Ltd.
5. Hydraulic and Fluid Mechanics, Modi P.N. and Seth S.M., Standard Book House.
6. Fluid Mechanics & Fluid Power Engineering – D. S. Kumar, S.K. Kataria& Sons
7. Publications
Reference Books Recommended:
1. Introduction to Fluid Mechanics, James E.A., John and Haberm W.A., Prentice Hall of
India
2. Fluid Mechanics, Jain A.K., Khanna Publication
3. Engineering Fluid Mechanics, Garde R.J. and MirajGoankar, Nemchand&Bros,Roorkee,
SCITECH, Publication (India) Pvt. Ltd.
4. Fluid Mechanics and Fluid Power Engineering, Dr. D.S. Kumar, S.K. Kataria& sons
5. Fluid Mechanics, Frank M. White, McGraw Hill Publication
6. Fluid Mechanics, Cengel&Cimbla, Tata McGraw Hill
7. Fluid Mechanics, Streeter V.L. and Wylie E.B., McGraw Hill International Book co.
8. Fluid Mechanics with Engineering Applications, E. Finnemore&Franzini, Tata Mc-Graw
Hill
9. Hydraulic Machines-Theory and Design, V. P. Vasandani, Khanna Publishers
10. Fluid Mechanics, A. K. Jain, Khanna Publishers
11. Hydraulic & Compressible Flow Turbo-machines, A. T. Sayers, Mc-Graw Hill

MECHANICS OF MATERIAL

Unit I
Concept of simple stresses and strains: Introduction, stress, strain, types of stresses,
stress and strain diagram for brittle & ductile material, elastic limit, Hooks law, modulus
of elasticity, modulus of rigidity, factor of safety, analysis of tapered rod, analysis of
composite section, thermal stress and strain.
Longitudinal strain & stress, lateral stresses and strains, Poisson’s ratio, volumetric
stresses and strain with uni‐axial, bi‐axial & tri‐axial loading, bulk modulus, relation
between Young’s modulus and modulus of rigidity, Poisson’s ratio and bulk modulus
Principal stresses and strains:‐ Definition of principal planes & principal stresses,
analytical method of determining stresses on oblique section when member is
subjected to direct stresses in one plane in mutually perpendicular two planes, when
member is subjected to shear stress and direct stresses in two mutually perpendicular
planes, Mohr’s circle for representation of principal stresses

Unit II
Shear force and bending moment: ‐ Types of beam (cantilever beam, simply supported
beam, overhung beam etc.), Types of loads (Concentrated and UDL), shear force and
bending moment diagrams for different types of beams subjected to different types of
loads, sign conventions for bending moment and shear force, shear force and bending
moment diagrams for beams subjected to
couple, Relation between load, shear force and bending moment.
Stresses in beams: ‐ Pure bending, theory of simple bending with assumptions &
expressions for bending stress, derivation of bending equation, bending stresses in
symmetrical sections, section modulus for various shapes of beam sections.
Shear stresses in beams: ‐ Concept, derivation of shear stress distribution formula, shear
stress distribution diagram for common symmetrical sections, maximum and average shear
stress. ,

Unit III
Deflection of beams:‐ Deflection & slope of cantilever, simply supported, overhung beams
subjected to concentrated load, UDL, Relation between slope, deflection & radius
curvature Macaulay’s method to determine deflection of beam.
Strain energy & impact loading: ‐ Definition of strain energy stored in a body when it is
subjected to gradually applied load, suddenly applied loads & impact loads. Strain energy
stored in bending & torsion
 

Unit IV
Torsion of circular shafts: ‐ Derivation of torsion equation with the assumptions made in it.
Torsion shear stress induced in the shaft, when it is subjected to torque. Strength and
rigidity criterion for design of shaft. Torque transmitted by solid & hollow circular shaft.
Equivalent twisting and bending moment in shaft when it is subjected to bending moment,
torque & axial load.
Unit V
Column & Struts: ‐ Failure of long & short column, slenderness ratio, assumptions made in
Euler’s column theory, end conditions for column. Expression for crippling load for various
end conditions of column and derivation on column with both ends hinged. Effective length
of column, limitations of Euler’s formula, Rankine formula.