RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY

COURSE FILE

OF

Faculty Name: Dr. Sameer Singh

Subject: Manufacturing Science Lab

Subject Code: B037423(037)

Academic Year: 2024-2025

Semester: IVth Semester

Designation: Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

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 CONTENTS

1. Page & Content

2. Vision of the Institute and the Department
3. Mission of the Institute and the Department
4. Academic calendar
5. Scheme & Syllabus
6. Individual Time Table
7. PEOs and POs
8. Course objectives & course outcomes (COs)
9. Mapping of COs with POs
10. Question Bank Practical (Viva Voce)
11. Attendance Record of Practical
12. Assesment Process
13. 5 Sample Records
14. Internal Viva Marks
15. Sessional Marks TA

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 The vision of the institute
To contribute to the progress of the state, nation and humanity as a whole providing
education through research and innovation to the future citizens and creating a new
order of peace and prosperity

The Mission of the institute

To pave a path for the students to tread confidently, gaining knowledge and skills
through that they may use to take the nation to the pinnacles of success.

Vision of Mechanical Department

 To become the topmost programme in the state in next 5 years;

 To become able to attract quality students;

 To become able to place students at premier industries.

Mission of Mechanical Department

 To produce competent and highly motivated Mechanical Engineering graduates

by imparting quality education.

 To encourage professional training and research in cutting-edge technologies to

develop and strengthen industrial exposure.

 To encourage the spirit of professionals beyond academic excellence with high

sense of discipline and social relevance.

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 Academic Calendar

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 Scheme & Syllabus

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 Time Table

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 Programme Educational Objectives:

PEO I:

The graduate of the programme will have Strong foundation in mathematics, basic sciences and
engineering fundamentals to successfully compete for various entry level positions or pursue higher
studies in Mechanical Engineering and/or allied fields.

PEO II:

The graduate of the programme will have Contemporary knowledge and lifelong learning skill,
familiarity with modern software, machines, processes, tools and design technology.

PEO III:
The graduate of the programme will possess the required skills to successfully peruse engineering
profession including communication skills and interpersonal skills, working efficiently in
multidisciplinary teams, understanding of ethical and environmental issues etc.

Course Educational Objectives:

 Manufacturing is the backbone of any industrialized nation. The objective of the course is to

provide an overview of the different manufacturing processes which are commonly employed

in the industry to fabricate component using different materials..

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 Program Outcomes:
Program Outcomes as defined by NBA (PO)

Engineering Graduates will be able to:

1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals, and an
engineering specialization to the solution of complex engineering problems.

2. Problem analysis: Identify, formulate, review research literature, and analyze complex engineering
problems reaching substantiated conclusions using first principles of mathematics, natural sciences, and
engineering sciences.

3. Design/development of solutions: Design solutions for complex engineering problems and design system
components or processes that meet the specified needs with appropriate consideration for the public health and
safety, and the cultural, societal, and environmental considerations.

4. Conduct investigations of complex problems: Use research-based knowledge and research methods
including design of experiments, analysis and interpretation of data, and synthesis of the information to
provide valid conclusions.

5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern engineering
and IT tools including prediction and modeling to complex engineering activities with an understanding of the
limitations.

6. The Engineer and society: Apply reasoning informed by the contextual knowledge to assess societal,
health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional
engineering practice.

7. Environment and sustainability: Understand the impact of the professional engineering solutions in
societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable
development.

8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of the
engineering practice.

9. Individual and team work: Function effectively as an individual, and as a member or leader in diverse
teams, and in multidisciplinary settings.

10. Communication: Communicate effectively on complex engineering activities with the engineering
community and with society at large, such as, being able to comprehend and write effective reports and design
documentation, make effective presentations, and give and receive clear instructions.

11. Project management and finance: Demonstrate knowledge and understanding of the engineering and
management principles and apply these to one’s own work, as a member and leader in a team, to manage
projects and in multidisciplinary environments.

12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in independent
and life-long learning in the broadest context of technological change.

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 Program Specific Outcomes (PSO)

At the end of the program, the student

PSO 1: should be able to understand the concepts of Mechanical Engineering

and their applications in the field of Automobile industry , Power plants , core Mechanical &
Production industries and other relevant areas.

PSO 2: Should have an ability to apply technical knowledge and usage of modern hardware &
software tools related to Mechanization & Automation for solving real world problems.

Course Outcomes:

On successful completion of the course, the student will be able to:

1. Demonstrate the use of green sand molding process for casting.

2. Demonstrate the use of various machine tools for important machining operations.

3. Explain the tool geometry of single point cutting tool and twist drill.

4. Explain the practicability of various metal joining processes like arc welding, resistance welding,

soldering and brazing.

5. Obtain practical skills in inspection and testing of casting and welding defects.

Mapping of COs with POs

COs \ POs PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12
CO1 ✓ ✓ ✓
CO2 ✓ ✓ ✓ ✓ ✓
CO3 ✓ ✓ ✓
CO4 ✓ ✓ ✓ ✓
CO5 ✓ ✓ ✓ ✓

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 Mapping of COs with POs with Justification

S.NO. Course Outcome (CO) Mapped Program Justification

Outcomes (PO)
1. Demonstrate the use of green sand PO1: Engineering Applying engineering
molding process for casting. knowledge, knowledge to analyze
PO2: Problem analysis, and perform green sand
PO4: Conduct molding, considering
investigations of sustainability and
complex problems, environmental impact,
PO7: Environment and aligns with PO1, PO2,
sustainability PO4, and PO7.
2. Demonstrate the use of various machine PO1: Engineering Demonstrating
tools for important machining operations. knowledge, machining processes
PO5: Modern tool usage, requires understanding
PO9: Individual and machine tool principles
team work (PO1), utilizing modern
tools (PO5), and working
effectively in teams or
individually (PO9).
3. Explain the tool geometry of single point PO1: Engineering Explaining tool geometry
cutting tool and twist drill. knowledge, involves applying
PO3: engineering knowledge
Design/development of (PO1), designing
solutions, appropriate solutions for
PO10: Communication machining challenges
(PO3), and effectively
communicating technical
details (PO10).
4. Explain the practicability of various metal PO1: Engineering Evaluating metal joining
joining processes like arc welding, knowledge, PO2: techniques requires
resistance welding, soldering, and brazing Problem analysis, analyzing their
PO6: The engineer and practicality in real-world
society, applications (PO2),
PO7: Environment and understanding societal
sustainability impacts (PO6), and
addressing sustainability
(PO7).
5. Obtain practical skills in inspection and PO4: Conduct Inspection and testing
testing of casting and welding defects. investigations of align with conducting
complex problems, investigations (PO4),
PO5: Modern tool usage, applying modern testing
PO8: Ethics tools (PO5), and
adhering to professional
ethical practices during
quality checks (PO8).

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 Time Table

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 Question Bank(Viva Voice)

1. Moulding of a Multi-Piece Pattern by Green Sand Moulding

1. What is green sand, and why is it used for moulding?

2. What are the components of green sand?
3. Explain the advantages and limitations of using a multi-piece pattern.
4. What is parting powder, and what is its role in moulding?
5. How do you ensure proper alignment of multi-piece patterns?
6. What are the properties of a good moulding sand?
7. Why is venting necessary in sand moulding?
8. What is the significance of the gating system in green sand moulding?

2. Making a Mould with Core and Casting

1. What is the purpose of a core in casting?

2. Describe the steps involved in making a mould with a core.
3. What materials are used for making cores, and why?
4. What is core print, and how is it incorporated into the mould design?
5. Explain the concept of shrinkage allowance in casting.
6. What are the defects that can arise in casting due to improper core placement?
7. Why is draft angle provided in moulds?
8. How does the pouring temperature affect the quality of the casting?

3. Taper Turning in a Lathe

1. What is taper turning, and where is it used?

2. What are the different methods of taper turning?
3. Explain the formula to calculate the taper angle.
4. How is the compound rest method used in taper turning?
5. What is the difference between a steep taper and a slight taper?
6. Why is alignment important in taper turning?
7. What factors affect surface finish during taper turning?
8. What are the applications of taper turning in industries?

4. Thread Cutting in a Lathe

1. What are the components of a thread?

2. Explain the difference between single-start and multi-start threads.
3. How is the thread pitch calculated on a lathe?
4. What is the role of the lead screw in thread cutting?
5. Describe the process of setting up a lathe for thread cutting.
6. What are the common errors in thread cutting, and how can they be avoided?

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 7. What is the significance of using a thread gauge?
8. Explain the difference between external and internal threading.

5. Alignment Testing of a Lathe

1. Why is alignment testing important for a lathe machine?

2. What are the methods used for alignment testing of a lathe?
3. How do you check the alignment of the headstock and tailstock?
4. What is a dial indicator, and how is it used in alignment testing?
5. Explain the term "parallelism of the bed."
6. What are the consequences of misalignment in a lathe?
7. How often should alignment testing be performed on a lathe?
8. What is the role of leveling in maintaining lathe alignment?

6. Drilling, Boring, and Reaming of a Hole

1. What is the difference between drilling, boring, and reaming?

2. How is the size of a drill bit selected for a specific operation?
3. What are the factors affecting the accuracy of a drilled hole?
4. Why is coolant used during drilling and reaming operations?
5. Explain the difference between rough boring and finish boring.
6. What is a reamer, and how is it used to achieve precision?
7. What are the common defects in drilled holes, and how can they be avoided?
8. Describe the importance of spindle speed and feed rate in these operations.

7. Study of Turning Tool of a Lathe

1. What are the main components of a turning tool?

2. Explain the significance of tool geometry (rake angle, clearance angle, etc.).
3. What is the difference between high-speed steel (HSS) and carbide tools?
4. How is tool wear monitored during a machining operation?
5. What is the purpose of chip breakers in turning tools?
6. How do cutting speeds and feed rates affect tool life?
7. What are the different types of tool materials used in turning?
8. Explain the importance of tool sharpening and maintenance.

8. Joining MS Plates by Arc Welding (SMAW, MIG)

1. What is the difference between SMAW and MIG welding?

2. What are the advantages of MIG welding over SMAW?
3. How is the electrode selected for SMAW?
4. What are the safety precautions to be followed during arc welding?

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 5. What are the common defects in arc welding, and how can they be prevented?
6. Explain the role of shielding gas in MIG welding.
7. What are the factors that affect the strength of the weld joint?
8. What is the significance of the arc length in welding?

9. Joining Metal Sheets by Resistance Welding

1. What is the working principle of resistance welding?

2. What are the different types of resistance welding processes?
3. How is spot welding performed?
4. What are the parameters that affect the quality of resistance welding?
5. What is the role of electrodes in resistance welding?
6. What materials are suitable for resistance welding?
7. Explain the advantages and limitations of resistance welding.
8. How is the weld strength tested in resistance welding?

10. Inspection of Casting Defects and Welding Defects

1. What are the common defects found in castings?

2. How are porosity and shrinkage defects in castings identified?
3. Explain the types of tests used to inspect welding defects.
4. What is the difference between destructive and non-destructive testing?
5. How is radiographic testing used for defect inspection?
6. What are the causes of hot tearing in castings?
7. What is ultrasonic testing, and how is it applied in welding inspection?
8. How does visual inspection contribute to identifying surface defects?

11. Study of Twist Drill

1. What are the main parts of a twist drill?

2. Explain the functions of the flutes in a twist drill.
3. What is the significance of the point angle and helix angle in a twist drill?
4. How is the size of a twist drill determined?
5. What are the common materials used for manufacturing twist drills?
6. What is the difference between a high-speed steel (HSS) drill and a carbide drill?
7. Why is proper sharpening of a twist drill important?
8. What are the common defects in drilling using a twist drill, and how can they be prevented?

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 Attendance Record

Student Name
ABDUL ARMAAN
Abhimanyu Kumar
Chaubey
Alok Kumar Singh
Dikesh Kumar Verma
Donit Kumar Chausare
Himanshu Kureshiya
Itish Tekam
Md Dayam Ahmad
Md Razza Ali Siddiquee
Md Sakib Hossain
Md Sufiyan
Pappu Singh
Pranjal Kumar Pandey
Rahul Sharma
Raj Kumar Rai
Rishabh Kumar
SANDEEP SARKAR
Shivam Yadav
SOURABH KUMAR
Sreyash Suman
Subhadeep Biswas.
Sujit Kumar
Surydev Sahu
Taha Qamer
Vibhesh Kumar Yadav

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 Assessment Process
Category Criteria Marks Description
Marks awarded based
Regularity and on consistent
Attendance 10
punctuality attendance in all lab
sessions.
Evaluation based on the
Practical skills, execution of
Lab Work 10
completion of tasks experiments, accuracy,
and time management.
Assessment of the lab
Neatness, organization, file, including proper
File Submission 10
completeness documentation and
timely submission.
Based on the quality of
Conceptual
answers during viva
Viva Voce understanding, 10
related to the
responses
experiments.

5 Sample Records
Note: Sample records to be collected during the viva voice.

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 Internal Viva Marks
Student Name Marks
ABDUL ARMAAN
Abhimanyu Kumar Chaubey
Alok Kumar Singh
Dikesh Kumar Verma
Donit Kumar Chausare
Himanshu Kureshiya
Itish Tekam
Md Dayam Ahmad
Md Razza Ali Siddiquee
Md Sakib Hossain
Md Sufiyan
Pappu Singh
Pranjal Kumar Pandey
Rahul Sharma
Raj Kumar Rai
Rishabh Kumar
SANDEEP SARKAR
Shivam Yadav
SOURABH KUMAR
Sreyash Suman
Subhadeep Biswas.
Sujit Kumar
Surydev Sahu
Taha Qamer
Vibhesh Kumar Yadav

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 Student Sessional Marks
Student Name Marks
ABDUL ARMAAN
Abhimanyu Kumar Chaubey
Alok Kumar Singh
Dikesh Kumar Verma
Donit Kumar Chausare
Himanshu Kureshiya
Itish Tekam
Md Dayam Ahmad
Md Razza Ali Siddiquee
Md Sakib Hossain
Md Sufiyan
Pappu Singh
Pranjal Kumar Pandey
Rahul Sharma
Raj Kumar Rai
Rishabh Kumar
SANDEEP SARKAR
Shivam Yadav
SOURABH KUMAR
Sreyash Suman
Subhadeep Biswas.
Sujit Kumar
Surydev Sahu
Taha Qamer
Vibhesh Kumar Yadav

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