Manufacturing Process


Dillip Mohanta


Core Courses

Course Attendees

Still no participant

Course Reviews

Still no reviews

Course Name: Manufacturing Process

Course Code: CUTM1604


Course Credits : 2-1-0

Course Objective


1. To Understand the Importance of Materials, Manufacturing Processes, Process Planning &  Design in Product Manufacturing

Learning Outcomes


Students will able to

1. Select Engineering Material for a Required Purpose

2. Identify Various Manufacturing Processes

3. Implement Modern Approaches to Process Planning, Product Design & Development

Course Syllabus


Module I: Classification of Materials (5 hrs)

Common Engineering Materials; Crystal Geometry ( Crystal Types, Crystal Structures, Crystal Defects, Recrystallization, Crystal Growth, Methods of Determining Crystal Structure, Scanning Electron Microscope).


1. Tensile, Hardness and Impact Testing of Materials


Module II: Tool Materials (4 hrs)

Engineering Alloys (Selection and Specification of Carbon and Alloy Steels for General Engineering Purpose, Specification of Materials as per Various Standards- IS, BS, AISI, APS, etc.); Steels (Case Hardening Steels, Cold Work Tool Steels, Hot Work Tool Steels, High-Speed Tool Steels; Modern Cutting Tool Materials (Carbide, Coated carbides, Ceramics, CBN, Diamond, Sialons, Impregnated tools); Introduction to Plastics (Properties of Plastics, Thermo Plastics-Thermo Setting Plastics, Methods of Processing of Plastics); Cast Iron (Grey Iron Casting IS: 210 SG Cast Iron IS: 865, Malleable Iron Castings IS: 2108 and IS: 2640); Non-Ferrous Alloys ( Zn & Al Alloys); Powder Metallurgy (Methods for Production of Powders, Powder Metallurgy Steps).


Module III: Heat Treatment (4 hrs)

Heat Treatment of Steel (Annealing, Hardening, Tempering, Surface hardening); Heat Treatment Defects.


Module IV: Manufacturing Processes (8 hrs) 

Forming Processes (Cold & Hot Working, Rolling, Forging, Drawing, Bending & Extrusion); Joining Processes (Arc Welding, Gas Welding, Resistance Welding, Thermit Welding, TIG & MIG Welding, LBW, EBW, Adhesive Bonding, Soldering & Brazing,); Casting Process (Sand Casting, Die Casting, Investment Casting, Centrifugal Casting, Vacuum Casting, Plaster Mould Casting, Lost Foam Method, Continuous Casting).


2. Pattern & Mold Making in Sand Casting.

3. Butt Joint by using Oxy Acetylene Gas Welding.

4. Joining of Metal Sheets using Spot Welding.

5. Soldering & Brazing Practice.

6. TIG Welding of Stainless Steel

7. MIG Welding Technique and Applications


Module V: Machining Processes (6 hrs)                                                                                                         

Conventional Machining Processes: Turning, Milling, Drilling, Shaping, Grinding & Finishing; Unconventional Machining Processes: EDM, AJM, LBM, etc); Rapid Prototyping 


8. EDM Working Principle and Process Parameters

9. 3D Printing


Module VI: Process Planning  (5 hrs)           

Process Planning (Concept, Manufacturing Planning, Process Design, Process Sheet, Process Selection Parameters, Computer Aided Process Planning)


10. Process Planning & Simulation in DELMIA


Module VII: Computer Aided Production Management (8 hrs)

Role of Computer in Product Design and Management(Computer in Manufacturing & Design Process, Creation of Manufacturing Data Base, Computer Integrated Manufacturing, Communication Network, Production Flow Analysis, Group Technology)

Process & Product Design (Degree of Accuracy, Finish and Tolerance, Capability Studies, Basic Product Design Rules for Casting, Forging, Machining, Sheet Metal and Welding. Physical Properties of Engineering Materials and their Importance on Products, Selection of Plastics, Rubber, Composites and Ceramics for Product Design)


11. Casting Design & Analysis using CATIA

12. Forging Design & Analysis using CATIA

Session Plan


Module I: Classification of Materials (5 hrs)

Session 1:  Common Engineering Materials

Session 2: Crystal Geometry

Session 3: Methods of Determining Crystal Structure

Session 4: Defects  in Solids

Session 5: Mechanical Properties, Mechanical Tests and Deformation of Materials


Module II: Tool Materials (4 hrs)

Session 6: Engineering Alloys

Session 7: Modern Cutting Tool Materials

Session 8: Powder Metallurgy


Module III: Heat Treatment (4 hrs)

Session 9: Heat Treatment of Steel

Session 11: Major Defects  due to Faulty Heat Treatment


Module IV: Manufacturing Processes (6 hrs) 

Session 12: Forming Processes

Session 13: Gas Welding & Arc Welding

Session 14:  MIG & TIG Welding

Session 15: Other Joining Processes

Session 16: Casting Process

 Session 17: Special Casting Process


Module V: Manufacturing Processes (6 hrs)

Session 18: Machining Process

Session 19: Rapid Prototyping


Module VI: Process Planning (5 hrs)

Session 20: Process Planning

 Session 21: Process Planning & Simulation in DELMIA


Module VII: Computer-Aided Production Management   (8 hrs)  

Session 22: Computer in Manufacturing & Design Process

Session 23: Forging Design & Analysis using CATIA

Session 24: Production Flow Analysis, Group Technology

Session 25: Casting Design & Analysis using CATIA

Session 26: Ergonomic Considerations in Product Design

Session 27: Just-in-Time and Kanban System

Session 28: Modern Approaches to Product Design


Text Books:

1. Balasubramaniam R., "Callister's Materials Science and Engineering”, 2nd Edition, Wiley.

2. Rao P.N., “Manufacturing Technology”, Volume 1, Mc-Graw Hill.

3. Chitale A.K., Gupta R.C., "Product Design & Manufacturing”, 6th Edition, PHI Learning.


Reference Books:

1. Campbell F., “Elements of Metallurgy and Engineering Alloys”, ASM International.

2. Kesavan R., Elanchezhian C., Vijaya Ramnath B., “Process Planning & Cost Estimation”, New Age International.


Course Outline Prepared by Dr. P S Rao & Prof. D Mohanta                   

Source of Reference: NSQF, Level 8, Capital Goods & Manufacturing-Sector

Case Studies

Case Studies

Our Main Teachers