BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI, K.K.

BIRLA GOA CAMPUS

SECOND SEMESTER 2023-24
Course Handout Part I
Date: 10/01/2024

Course No. : MEF112

Course Title : Workshop practice
Instructor-in-Charge : Rajiv A. Shinde

Course description:
Shop practice involving machining (turning, facing, thread cutting, drilling, and grinding etc.)
casting, metal forming, welding, fitting and wood-working etc. Demonstrations of metal
cutting machines, e.g., shaper and CNC machines

1. Scope and Objective of the Course:

This course is an entry level course for all first degree students. The course will provide an
overview of the techniques and applications of basic manufacturing processes required to
produce a finished product from raw materials.

The primary objective of this course is to learn how a product is manufactured and to gain
technical knowledge and skills involved in the processes. This knowledge will be useful in
whatever discipline a student belongs to.
The manufacturing processes covered include Machining, Casting, Joining processes, metal
forming, Sheet metal work processes. The students are exposed to modern manufacturing
machines like CNC. A brief review of the properties of engineering materials and of
measuring and gauging tools are also included.
The course is practical orientated and requires that basic skills in handling of tools, machines
and machine tools used in different manufacturing processes are acquired through the
hands-on experience.

Practical classes will be conducted in the Workshop, and they are intended to provide hands-
on experience in handling of basic tools, machines, machine tools and produce simple utility
jobs.

2. Reference books

Text Book
I. B S Nagendra Parashar and R K Mittal, Elements of Manufacturing Process, Prentice Hall
of India, 2008.
Reference Books
I. Campbell J.S., Principles of Manufacturing Materials and Processes, Tata McGraw-Hill,
New Delhi, 1995 print.
 II. Richard R. Kibbe et all, Machine Tool practices, Sixth edition, Prentice Hall of India Pvt.
limited, New Delhi, 2003.
III. E. Paul Degarmo, J.T. Black, Ronald A. kosher, Materials and processes in Manufacturing,
PHI 2005.
IV. Mikell P.Groover, Fundamentals of Modern Manufacturing, Second edition, John Wiley&
sons Pvt Ltd.

3. Course Plan:

A) Practical Part

Exercise No. Description No. of Jobs

1 Metrology 4 Experiments
2 Metal Turning Lathe 1
3 Milling machine 1
4 Fitting 1
5 Electric Arc Welding 1
6 Gas Welding 1
7 Carpentry 1
8 Foundry Practice 1
9 Pipe Threading & Bending 1
10 Demonstration of the CNC machines ---------
11 Demonstration of Shaper machine --------

B) Theory Part

Lech. Ref.
Learning objectives Topics for syllabus
No. [book]-Ch.
1 Course Instructions Basics of manufacturing, types of production systems. T-1
Mechanical properties of material, Poisson’s ratio,
Mode of fracture, FOS, Stress strain curve for ductile
2 Engineering Materials and brittle material, Common engineering material, T-2
Selection of material and numerical examples on
stress, change in length and % elongation
3 Role of measurements in Metrology, inspection, measuring, gauging, limits &
T-3
manufacturing fits. numerical examples on type of fits
 Theory of metal cutting Machine tool classification, Tool material, Types of T-4
tool, Tool geometry, Tool signature, Left and right hand
4
tools, Orthogonal oblique cutting, Type of chips, cutting
fluids
Production of cylindrical Lathe machine tool, operating conditions, various T-5
surfaces: machine tool operations on a lathe and Machining time calculation
5 and operations and numerical examples
Production of cylindrical Drilling machine, drill, operating conditions, boring,
holes and allied reaming, tapping, Machining time in drilling numerical T-6
6 operations examples
Production of flat Shaping machines, operations on shapers and planers
T-7
surfaces: shaping
7 Production of complex Milling machine, type of milling processes &
T-8
and flat surfaces operations
8 Abrasive machine, abrasives, grinding, grinding wheel,
Obtaining surface finish T-9
grinding machines and fine finishing operations.
9 Casting processes, pattern making, moulding sand,
Production of parts by
moulding process, cores, casting defects, advantages T-11
casting
and disadvantages of casting, Special casting process
Production of parts by Metal forming processes, rolling, extrusion, and
T-12
10 forming forging processes.
Production of sheet
Punches & dies, sheet metal operations. T-13
metal parts
11 Mechanical joining Mechanical joining, arc welding, gas welding,
T-15
processes soldering, brazing and mechanical fastening.
12 Manufacturing process, Production of powder, mixing,
Powder Metallurgy T-14
compaction, sintering, Advantages and limitation
13 Types of plastic, forms of raw plastic material,
Plastic processing and
Methods of processing, Introduction to additive T-16
additive manufacturing
manufacturing,
14 Revision

4. Evaluation Scheme:

Duration Nature of
Component Marks (%) Date & Time
(Min) Component
Laboratory Practical
Evaluation by Staff /
Regular Class Work + Continuous 50% Regular
Instructor
Laboratory Report
Laboratory Practical Will be announced Evaluation by
90 25%
Comprehensive Exam later Staff / Instructor
 Offline Classroom &
Comprehensive Exam 90 25% 20/05/24(AN)
Closed Book

5. Workshop Practice and some points of Safety:

Since the students may not be fully conversant with the operating mechanisms of the
machinery of the workshop, direct handling of the machines should always be avoided.
They should do it with supervision of the concerned Workshop staff and faculty only.

The student must wear apron meant for the practical. The aprons should be stitched
within the first week of the admission. The students should wear shoes during lab hours.
If any student is found without the apron or shoes, he/she will not be admitted to the
workshop and will lose attendance. Any loose garment which can hangout and thus
endanger the personal safety of the student, are not allowed in the workshop. Therefore
admission to workshop is conditional on the basis of these conditions of the protective
wear. Instructor In Charge / Workshop Superintendent’s discretion is final.

6. Make-up Policy:
Make up for shop practice will not be permitted. In case of a genuine difficulty, the
student can complete his practical in some other batch, by taking prior permission from
the concerned instructor as well as the instructor of the practical batch in which student
is going to work.
Make up will not be given for Quiz exam in any case.

7. Notices:
All notices concerning the course will be displayed either on Workshop Notice Board or on
course folder ‘Announcement’ of Quanta.

8. Others:
Any creative activity to promote the understanding of the subject is encouraged. Students
can come up with simple projects to familiarize themselves with various manufacturing
practices. For this, the students can consult the Instructor/ the Instructor in Charge /
Workshop Superintendent.
INSTRUCTOR-IN-CHARGE