Dr A.P.J. Abdul Kalam Technical University, UP (AKTU), Mechanical Engineering Semester 4, Manufacturing Process Syllabus

Unit - 1 Conventional Manufacturing processes

1.1 Casting and moulding Metal casting processes and equipment Heat transfer and solidification shrinkage riser design casting defects and residual stresses

1.2 Introduction to bulk and sheet metal forming

1.3 Plastic deformation and yield criteria

1.4 Fundamentals of hot and cold working processes

1.5 Load estimation for bulkforming forging rolling extrusion drawing and sheet forming shearing deep drawing bending

1.6 Principles of powder metallurgy

Unit - 2 Metal cutting

2.1 Single and multipoint cutting

2.2 Orthogonal cutting

2.3 Various force components

2.4 Chip formation

2.5 Tool wear and tool life

2.6 Surface finish and integrity

2.7 Machinability

2.8 Cutting tool materials

2.9 Cutting fluids

2.10 Coating Turning Drilling Milling and finishing processes

2.11 Introduction to CNC machining

2.12 Additive manufacturing

2.13 Rapid prototyping and rapid tooling

2.14 JoiningFastening processes

2.15 Physics of welding brazing and soldering

2.16 Design considerations in welding

2.17 Solid and liquid state joining processes

2.18 Adhesive bonding

Unit - 3 Grinding & Super finishing

3.1 Grinding wheels

3.2 Abrasive bonds

3.3 Cutting action

3.4 Grinding wheel specification

3.5 Grinding wheel wear attritions wear fracture wear

3.6 Dressing and Truing

3.7 Max chip thickness and Guest criteria

3.8 Surface and cylindrical grinding

3.9 Centreless grinding

3.10 Honing lapping and polishing

Unit - 3 Sheet Metal Forming

3.1 Types of Sheet metal operation

3.2 Press working equipment and terminology

3.3 Types of dies

3.4 Clearance analysis

3.5 Estimation of cutting forces

3.6 Centre of pressure and blank size determination

3.7 Design of strip layout

3.8 Blanking die design

3.9 Introduction to Drawing

3.10 Bending dies

3.11 Methods of reducing forces

3.12 Formability and forming limit diagrams

Unit - 4 Metal Joining (Welding)

4.1 Survey of welding and allied processes

4.2 Gas welding and cutting process and equipment

4.3 Arc welding Power sources and consumables

4.4 TIG MIG processes and their parameters

4.5 Resistance welding spot seam projection etc.

4.6 Other welding processes such as atomic hydrogen submerged arc electro slag friction welding

4.8 Adhesive bonding

4.9 Weld decay in HAZ

Unit - 4 Welding Processes

4.1 Classification of joining processes

4.2 Welding terminology and types of joints

4.3 Arc Welding Processes

4.4 Resistance welding

4.5 Welding metallurgy and heat affected zone

4.6 Weld inspection

4.7 Defects in various joints and their remedies

Unit - 5 Processing of Polymers

5.1 Thermoplastics and Thermosetting

5.2 Processing of polymers

5.3 Thermoforming

5.4 Extrusion

5.5 Moulding

5.6 Extrusion of plastic

5.7 Pressure forming and Vacuum forming

Unit - 5 Unconventional Machining Processes

5.1 Abrasive Jet Machining

5.14 Plasma Arc Machining PAM

5.15 Electron Beam Machining

Unit - 6 Manufacturing of Composites

6.1 Introduction to composites

6.2 Composite properties

6.3 Matrices

6.4 Fiber reinforcement

6.5 Composite Manufacturing Processes

6.6 Fabrication of Ceramic Matrix Composites by Direct Oxidation

6.7 Carboncarbon composites

6.8 Polymer Matrix and nanocomposites