Class overview

Manufacturing Technology - I (Course Code: 1BME305) is a 3-credit professional core course in the third semester of the Bachelor of Engineering in Mechanical Engineering program. It spans 42 lecture hours along with 38 self-learning and 10 term work hours, and is evaluated through a 50% Continuous Internal Evaluation (CIE) and 50% Semester End Examination (SEE) structure.

The course covers the following core manufacturing domains across five modules:

• Module 1 - Metal Casting & Molding: Introduces foundational foundry terminology, patternmaking (types, functions, and allowances), sand molding processes (green sand, dry sand, floor/pit, cement-bonded, shell, and investment casting), permanent mold casting (die and centrifugal), and casting defects.

• Module 2 - Metal Solidification & Gating Design: Covers pure metal freezing, skin effect, nucleation and growth, directional solidification, gating system elements and design calculations (choke area, sprue-runner-gate ratios), riser design and location, numerical problems on gates/risers, and industrial melting furnaces (Cupola, Electric Arc, Crucible, Induction, and Reverberatory).

• Module 3 - Bulk Metal Working: Explores plastic deformation, hot and cold working principles, advantages/disadvantages, principal rolling stand arrangements, rolling loads/passes/defects, smithing and forging operations (hand, power, impression die, drop, and press forging), and extrusion types (direct, indirect, impact, hydrostatic) along with wire drawing.

• Module 4 - Sheet Metal Operations: Focuses on sheet metal press tool operations, shearing action, numerical problems on blanking, piercing (stripping, punching, and shear forces), secondary operations (trimming, shaving, nibbling, notching, lancing), drawing design and force calculations, bending allowances, and die construction (progressive, compound, combination dies).

• Module 5 - Joining Processes & Weldability: Examines welding classifications, principles, advantages, limitations, and weldability alongside specific joining methods including gas welding (oxy-acetylene, air-acetylene, oxy-hydrogen), arc welding (MIG, TIG, atomic hydrogen, plasma-arc, submerged-arc, etc.), resistance welding (spot, seam, projection, butt), thermit welding, solid-state welding (diffusion, ultrasonic, friction, explosive), and welding defects.