MEL2330 Manufacturing processes (Semester II, 2025-26)

Welcome to the course!! Please go through the First Course Handout (FCH) to know more about the rules and regulations.

Course schdule

3 Lectures (Monday, Tuesday and Thursday 9:00 AM to 9:50 AM) 

Course content

Module 1: Metal Casting Processes [14 Lecture]

Introduction to Casting [3 Lectures]: Casting Terminology, Types of pattern and allowances, Applications and Challenges. 

Design of various parts [4 Lecture]: Riser and Gating system design, Design principles for mould cavity. 

Solidification [3 Lecture]: Metal flow and solidification; solidification and cooling of casting. 

Types of casting process and defects [4 Lecture]: Expendable and Permanent Mould Casting Processes, Die casting and centrifugal casting, Casting defects and inspection of castings. 

Module 2: Welding [14 Lecture]: 

Introduction to Joining Processes [3 Lecture]: Basic requirements and classification of welding processes; Arc Welding Processes, Arc welding principle, Welding power source and its characteristics.

Arc Welding Processes [4 Lecture]: TIG&MIG processes and their parameters; Introduction to other welding processes such as submerged arc welding (SAW), shielded metal arc welding (SMAW) 

Advance welding processes [3 Lecture]:Resistance welding processes, friction stir welding (FSW).

Weldability and thermal aspects [3 Lecture]: Concept of weldability of materials; Thermal Effects in Welding (Distortion, shrinkage and residual stresses in welded structures); Welding defects and remedies.

Allied processes [1 Lecture]: Soldering and Brazing. 

Module 3: Metal Forming Processes [14 lecture]: 

Introduction of metal forming process [5 Lecture]: Mechanical behavior of metals in elastic and plastic deformation, stress-strain relationships, Yield criteria, Application to tensile testing, train rate and temperature in metal working; Hot deformation, Cold working and annealing. 

Metal Working Processes [5 lecture]: Fundamentals of metal working, Analysis of bulk forming processes like forging, rolling, extrusion, wire drawing by slab method, 

Other sheet metal processes [4 Lecture]: Sheet metal forming processes (Die and punch assembly, Blanking, piercing, bending etc., Compound and Progressive die), High Energy rate forming processes.

Refrences

1. Heine, R. W., Loper, C. R., and Rosenthal, P. C., (2008), Principles of Metal Casting, Tata McGraw Hill. 

2. Conne, L. P., (1989), Welding Handbook- Welding Technology Part-1, American Welding Society. 

3. Black, S. C., Chiles, V, Lissaman, A. J., and Martin, S. J., (1996), Principles of Engineering Manufacture, Butterworth-Heinemann.  

4. Kalpakjian, S., and Schmid, S. R., (2001), Manufacturing Engineering and Technology, Pearson. 6. Riggs, J. L., (1976), Production System-Planning Analysis and Control, John Wiley

Evaluations Scheme

Major exam: 40%

Minor exam: 30%

Homework problems: 10%

Regular Quizzes: 20%