Birla Institute of Technology & Science, Pilani

Work Integrated Learning Programmes Division

Manufacturing Processes
Digital Learning Handout

Course Title Manufacturing Processes

Course No(s) ETZC235/PEZC236)(S2-23)
Credit Units 4
Credit Model 1+1+2
Instructor-In-Charge Tufan Chandra Bera (Pilani)
Instructor Karthikeyan (Goa)
Version Number Ver 1.1
Date 20th June 2016

Course Objectives:
• Enrich the knowledge of the students in conventional, advance and non-conventional manufacturing
processes adopted across various industrial domains through experiential learning.
• Developing skill set for selection of manufacturing processes for various types of materials and
products. Transforming the workplace into a learning platform that will enable student to judge the
considerations in process selection and economics behind it.
• Developing skill set to judge the need for automation of processes and how to achieve it for overall
growth of the industry and society.

Text Book(s):
T1 Serope Kalpakjian, Steven R. Schmid, “Manufacturing Processes for Engineering Materials”,
Pearson Education 5th Edition, 2011

Reference Book(s) & other resources:

R1 J. T. Black, Ronald A. Kohser “DeGarmo's Materials and Processes in Manufacturing”
R2 Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, John Wiley & Sons
R3 Amitabh Ghosh & A. K. Mallik, “Manufacturing Science”, Affiliated East-West Press Pvt. Ltd.
R4 P. N. Rao, “Manufacturing Technology Vol-I and II”, Tata McGraw-Hill Publications, III Edition,
New Delhi

LEARNING OUTCOMES
LO1 Explain all the scientific and technical aspects behind various manufacturing processes

LO2 Select manufacturing processes considering factors like cost, technology, manufacturing
 practices and skill set of available.

LO3 Reengineer processes using innovative ideas and automation.

LO4 Benchmark suitable processes to manufacture a particular product.

Experiential Learning Components:

1. Lab work: Describe the lab infrastructure needed, number of lab exercises
needed, etc.
• Analysis of various forming processes - Analysis of forging, rolling etc. by using
ANSYS student version 2024 software.
• The links for video tutorials of ANSYS student version 2024 will be provided to students. The
students can watch these videos to carry out the lab assignments.
2. Project work: None
3. Case study: None.
4. Work integrated Learning Exercise: Describe how the course will integrate with the work the
student is doing at his / her work place.
5. Design work/Field work: Students to visit their workshops & foundries for gaining real time
exposure.

Content Structure:

Contact Hour List of Topic Title Sub-Topics

Introduction to • What is manufacturing,
Manufacturing processes • Lean and agile manufacturing
1-2
and Mechanical Behavior • Mechanical behaviour of materials
of Materials • Cold working on hot working
• Pattern Allowances
• Types of patterns
3-4 Metal Casting • Properties of moulding sand
• Solidification of metals
• Design of gating elements
• Casting processes
5-6 Metal Casting • Design consideration
• Defects in casting
• Introduction to bulk deformation processes
Bulk deformation • Forging
7-8
processes • Types of forging
• Miscellaneous forging operations
• Rolling
Bulk deformation
9-10 • Extrusion
processes
• Swaging
 • Die manufacturing methods
• Sharing
Sheet metal forming • Bending of sheet and plate
11-12
processes • Deep drawing
• Equipment upset metal forming
• Machining
• Necessity of manufacturing operations
13-14 Metal removing process
• Mechanics of cheap formation
• Chip morphology, Orthogonal and Oblique cutting
• Cutting forces
15-16 Metal removing process • Cutting force calculation
• Review session
• Specific Energy
• Temperature.
17-18 Metal removing process
• Flank Wear.
• Creater Wear.
• Chipping and cutting tool material
• Surface finish and surface integrity
19-20 Metal removing process
• Turning Parameters.
• Drilling, reaming and tapping
• Milling Operations.
• Machining and turning centres
• Abrasives
21-22 Metal removing process
• Mechanics of grinding
• Finishing operation
• Deburring
• Fundamentals
• Arc welding
• Oxy –fuel gas welding
23-24 Joining process • Friction welding, resistance welding, explosion
welding
• Soldering and Brazing, adhesive bonding and
mechanical fastening

• Ultrasonic machining
• Chemical machining Electrochemical machining
Unconventional electrochemical grinding
25-26
Machining Processes • Electrical discharge machining, high-energy beam
machining
• Water jet.
Automation of • Fundamentals of Numerical control
27-28 Manufacturing Processes • Programming CNC Lathe
and operations
Automation of • Programming CNC Lathe
29-30 Manufacturing Processes • Programming CNC Mill
and operations
31-32 Review Session • Review Session
Evaluation Scheme:
Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session
Evaluation Name Type (Open Weight Duration Day, Date,
Component (Quiz, Lab, Project, Mid- book, Closed Session, Time
term exam, End semester book,
exam, etc.) Online, etc.)
Assignment-I/ Quiz-I Online 5% 7 days February 19-28,
2024
Assignment-II/ Quiz-II Online 5% 7 days March 19-28,
EC - 1
2024
Virtual Lab free version Assignment 20% April 19-28,
ANSYS, Smart weld, UTM 2024
Mid-sem Closed book 30% 2 hours Saturday,
EC - 2 16/03/2024
(AN)
Comprehensive Open book 40% 2½ Saturday,
EC - 3 hours 18/05/2024
(AN)

Syllabus for Mid-Semester Test (Closed Book): Topics in Contact Hours: 1 to 16

Syllabus for Comprehensive Exam (Open Book): All topics
Important links and information:
Elearn portal: https://elearn.bits-pilani.ac.in
Students are expected to visit the Elearn portal on a regular basis and stay up to date with the latest
announcements and deadlines.
Contact sessions: Students should attend the online lectures as per the schedule provided on the Elearn
portal.
Evaluation Guidelines:
1. EC-1 consists of either two Assignments or three Quizzes. Students will attempt them through the
course pages on the Elearn portal. Announcements will be made on the portal, in a timely
manner.
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material (filed or bound)
is permitted. However, loose sheets of paper will not be allowed. Use of calculators is permitted
in all exams. Laptops/Mobiles of any kind are not allowed. Exchange of any material is not
allowed.
4. If a student is unable to appear for the Regular Test/Exam due to genuine exigencies, the student
should follow the procedure to apply for the Make-Up Test/Exam which will be made available
on the Elearn portal. The Make-Up Test/Exam will be conducted only at selected exam centres on
the dates to be announced later.
It shall be the responsibility of the individual student to be regular in maintaining the self-study schedule
as given in the course handout, attend the online lectures, and take all the prescribed evaluation
components such as Assignment/Quiz, Mid-Semester Test and Comprehensive Exam according to the
evaluation scheme provided in the handout.
 Manufacturing Process: Simulation Lab

Course Handout

Contents:

1. Scope of Lab
Objective of Lab
2. List of Simulation Experiments
Software Tool Used: ANSYS 2024 R1 student version, Smart weld, UTM app
3. Learning Outcomes of Lab
4. Instruction Schedule
5. Evaluation Scheme

Faculty Name, Ankit Sharma

Email Id & [email protected];
Contact Details 9425465393
Jayakrishnan J
[email protected]
9562228686

Scope of the lab:

• To support the theory learned in manufacturing process course with modelling and simulation to
understand the implementation of various manufacturing process and instil confidence in students to
approach the real world problems.

Objectives of Lab:
• Developing skill set to analyse the manufacturing related problems with the simulation aid to help
before actual manufacturing.

Learning Outcome of the lab

• Understand, model and analyse various manufacturing process and solve the typical manufacturing
problems.

List of simulation experiments

Tut. Tut. Name Solving Assignment Marks

No. Time

1. Analysis of Beam (1D) 1 hours

2. Single Stage Cold Forging Process (2D) 1 hours

3. Rolling Process (2D) 2 hours 10 Marks

4.
UTM App 1 hours
 5. Introduction to weld procedure optimal 1 hours

6 Selection of weld procedure 1 hours

7 Isotherm analysis of weld procedure using 10 Marks

1 hours
2D
8 Laser welding and optimization of weld
1 hours
procedure

Total 20

For lab calendar in terms of practice sessions, lab exams and other instructions please use the
following link:
https://drive.google.com/file/d/1KcG4tnpkKMQ8FWtBHd7Uf6zZMkoQs_Dt/view?usp=sharing

NOTE: Any changes in lab schedule, evaluation component or other changes related to EC-1 will
be informed by theory or lab instructor.
Instructor-in-charge

(ET ZC235)