w.e.

f Academic Year 2012-13 ‘G’ Scheme

Course Name : Mechanical Engineering Group

Course Code : ME/MH/MI/PG/PT/FE/FG
Semester : Fifth for ME/PG/PT/FG and Sixth for MH/MI/FE
Subject Title : Advanced Manufacturing Processes
Subject Code : 17527

Teaching and Examination Scheme:

Teaching Scheme Examination Scheme

PAPER
TH TU PR TH PR OR TW TOTAL
HRS
03 -- 02 03 100 -- -- 25@ 125

NOTE:
 Two tests each of 25 marks to be conducted as per the schedule given by MSBTE.
 Total of tests marks for all theory subjects are to be converted out of 50 and to be
entered in mark sheet under the head Sessional Work (SW).

Rationale:
This is a advanced technology subject which is to be taught, after getting conversant with
the basic manufacturing processes. It is necessary for a diploma engineer to know about the
advancements in the area of manufacturing processes. This subject will impart knowledge & skills
necessary for working in modern manufacturing environment. This subject will help the student to
get familiarize with working principles and operations performed on non conventional machines,
CNC Machines, milling machines, grinding machines, surface finishing machines and maintenance
of machine tools.
Objectives:
The student will be able to:
1) Know different Nontraditional machining processes.
2) Understand the working of Broaching Machine, Milling Machine, Gear Cutting machines,
Grinding Machines, Surface finishing machines.
3) Work as a maintenance engineer.
4) Know the Operation and control of different CNC machine tools.
5) Produce jobs as per specified requirements by selecting the specific machining process.
6) Adopt safety practices while working on various machines.
7) Develop the mindset for modern trends in manufacturing and automation.

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Learning Structure:

To select appropriate nontraditional machining process, to operate indexing

mechanism for gear manufacturing, to understand the use of grinding &
Applications
super finishing operations, Broaching, Boring Machines, CNC Machines,
to select appropriate type of maintenance.

To study & observe the working and applications of non conventional

Machining, To study and observe the application of other machines and
Procedures CNC. To maintain & repair small machines or components. To study &
observe the applications of grinding machines, surface finishing machines&
universal dividing head for gear cutting.

Working principles of all nonconventional machining processes, Principle

of indexing, principle of abrasion, erosion, Maintenance schedules &
Principles alignment.

Non conventional machines using AJM, EDM, LBM, W-EDM, WJM,

Concepts PAM. Open and closed loop control. Types of maintenance, repair cycle
analysis &complexity, housekeeping, TPM, concept of Grinding & super
finishing Process. Gear hobbing & gear shaping.

Study of nontraditional machining processes, CNC machines, Shapers,

Planers, Boring machines, Broaching machines, grinding machines, honing
Facts & lapping machines, Gear hobbing & gear shaping machines and
maintenance of machine tools.

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Theory:

Topic & Content Hours Marks

Topic 1. Non Traditional Machining
Specific Objectives
 Understand different Nontraditional machining processes.
Content
1.1 Need and importance, classification 04 Marks 10 20
1.2 AJM, WJM, EDM, W-EDM - setup, working, process parameters,
advantages, disadvantages and applications. 08 Marks
1.3 PAM, LBM - setup, working, process parameters, advantages,
disadvantages and applications. 08 Marks
Topic 2: Introduction to CNC
Specific Objectives
 Know the Operation and control of CNC machine tools.
Content
2.1 Introduction, advantages of CNC, open loop and closed loop control, axis
08 16
identification, absolute & incremental coordinate system- G codes and M
codes 08 Marks
2.2 Fundamental part programming - simple lathe and milling programmes.
Dry run, Jog Mode, Block by Block execution, Safety Procedures,
Adaptive controls, Displays and indicators. 08 Marks
Topic 3: Other Machining Methods
Specific Objectives
 Understand the working of different Machines.
Content
3.1 Introduction, classification of Broaching machines, basic parts of
08 16
horizontal broaching machine & their functions, applications, advantages
and limitations of Broaching machine. 08 Marks
3.2 Capstan, turret lathe & automats, Planer and planomiller function of parts
& operations. 04 Marks
3.3 Boring Machines – types, tools and operations. 04Marks
Topic 4: Milling & Gear Cutting
Specific Objectives
 Understand the working of Milling & Gear Cutting machines.
Content
4.1 Milling: 10 Marks
Introduction, classification ,basic parts of column & knee type milling
machine & their functions, standard milling cutters, milling operations
like plain milling, side milling, straddle milling, gang milling, face 10 22
milling - slot milling, slitting. Up milling & down milling, cutting
parameters.
4.2 Gear Cutting: 12 Marks
Introduction, gear manufacturing methods, universal dividing head &
indexing methods, gear shaping & gear hobbing - setup, working,
advantages, disadvantages, applications, gear finishing methods-grinding,
shaving, burnishing.
Topic 5. Surface Finishing
Specific Objectives
06 14
 Understand the working of Grinding Machines & Surface finishing
machines.

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Content
5.1Grinding Machines 08 Marks
Classification and working of grinding machine - surface, cylindrical,
centreless, grinding wheel specifications, grinding wheel dressing &
truing. Selection criteria for grinding wheel. Balancing of grinding
wheels, safety precautions.
5.2 Super Finishing 06 Marks
Methods of surface finishing like honing, lapping, burnishing, polishing
and buffing - setup, working, advantages, limitations and applications.
Topic 6. Maintenance of Machine Tools:
Specific Objectives
 Know the maintenance methods and procedures.
Content
06 12
Need and importance of maintenance activity, Types of maintenance, Basic
maintenance practices for simple machine elements, viz Bearing, Coupling,
Shaft and pulley , gears, chains, machine belts. Repair cycle analysis, Repair
complexity, Maintenance manual, Maintenance records.
Total 48 100

Practical:
Skills to be developed:
Intellectual Skills:
1) Compare an appropriate non conventional machining process for required component.
2) Write part programming for a component.
3) Know the significance of various super finishing methods.
4) Calculations for indexing for a spur gear cutting, helical gear cutting.
5) Select the grinding machine parameters.
6) Identify the maintenance procedure for a machine.

Motor Skills:
1) Use the indexing mechanism.
2) Operate CNC Lathe & CNC milling machine.
3) Operate grinding machine
4) Carry out maintenance of machines.
5) Use and operate different hand tools required for repair and maintenance.
6) Identify and rectify the faults in the given sub assembly.

List of Practical:

1) Industrial visit to observe at least one nontraditional machining process and write a report
individually on visit.
2) One simple Job on CNC Lathe Machine and Verification on simulation software (One job /max.
four students).
3) One simple Job on CNC Milling Machine and Verification on simulation software (One job
/max. four students)
4) Industrial visit to observe Broaching machine, Boring machine, Planer machine and report on the
same.
5) One job of gear cutting (spur gear /helical gear) by using simple indexing method (max. four
students per job).
6) One job containing surface grinding / cylindrical grinding operation. (max. four students per
job).
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7) Industrial visit to observe at least one super finishing process.

8) Maintenance procedure for any two machines/machine elements with reference to type of faults,
causes & remedies. (In a group of 4-5 students)
9) Teacher can suggest topics (ind. visit/non conv. man. process etc.) for ppt files and students (4
students) should present in practical batch.

Notes:
1. The workshop instructor should prepare the specimen job in each shop as demonstration/ before
the students (as per the drawing given by subject teacher / workshop superintendent)
2. Theory behind practical is to be covered by the concerned subject teacher / workshop
superintendent.
3. Workshop diary should be maintained by each student duly signed by respective shop instructors

Sr. Group
Equipment /Software Remark
No. Size
Simulation software for Turning on One
1 Institute can establish a separate
20 PCs student
simulation, CAD, CAM, CAE,
Simulation software for Milling on
2 computational facility lab.
20 PCs
Internet facility is must. Teacher
Videos demonstrating Non
can download good videos and
3 Conventional machining and other
help students to understand the
machines on 20 PCs
principles. Students can observe
Simulation software for Grinding on
4 various videos on machining,
20 PCs
calibration, maintenance of
Videos on maintenance of machine machine tools.
5
tools

Learning Resources:
Books:
Sr.No. Author Title Publisher
S. K. Hajra Chaudary, Elements of workshop Media Promoters and
01
Bose, Roy Technology-Volume II Publishers Limited
Production Technology
02 O. P. Khanna & Lal Dhanpat Rai Publications.
Volume- II
Narosa Publishing
03 P.K.Mishra Nonconventional Machining
Houswe
04 H.P.Garg Industrial Maintenance S.Chand& Co.
Maintenance Engg.
05 L.R.Higgins McGraw Hill
Handbook
B. L. Juneja, G.S.Sekhon, Fundamental of metal
06 New age international ltd.
Nitin Seth cutting and machine tools
07 P.C.Sharma Production Engg. Dhanpat Rai Publications.
Technology of Machine
08 S.F.Krar,A.R.Gill,P.Smid Tata-McGraw Hill
Tools
09 HMT Production Technology Tata-McGraw Hill
New Age International
10 B.S.Pabla &M.Adithan CNC Machines
Ltd.

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