BITS PILANI K K Birla Goa Campus

Second Semester 2023-2024

(Course Handout Part II)
Date: Jan 11, 2023

In addition to Part-I (General Handout for all courses appended to the timetable) this portion gives
specific details regarding the course.

Course No. : ME F219

Course Title : Manufacturing Processes
Instructor(s) : Sudhy S Panicker (I/C), Biswajit Das

Course description: Metal cutting processes and machine tools e.g. lathe, shaper, planer, drilling
and grinding; Metal casting processes and analysis, Introduction to metal forming processes,
Joining Processes, shop practice involving machining, casting, foundry and testing.
1. Scope and Objective of the Course:

This scope of the course is to provide an exposure to the basic manufacturing processes and
their applications to produce different kinds of manufactured goods. The casting and machining
processes are to be covered in detail while the discussion on forming processes is going to be
introductory while its detailed treatment is left to the next level course. The objective is to
develop a sense of comparison for choosing appropriate manufacturing process to meet the
requirements and also to make the student competent to establish appropriate process
parameters for different processes.
The course has structured lab exercises for imparting hands-on experience on different basic
manufacturing and allied processes. Exercises on testing of foundry sand, welding and
machining have been particularly incorporated.

Books:
(i) Textbook
1. Serope Kalpakjian and Steven Schmid, Manufacturing Processes for Engineering
Materials, Pearson education, India
2. Amitabha Ghosh and Ashok Kumar Mallik, “Manufacturing Science”, Affiliated
East-West Press, New Delhi.
(ii) Reference Books
1. Mikell P. Groover, Fundamentals of Modern Manufacturing, Third edition, John
Wiley& sons Pvt Ltd.
2. PN Rao, Manufacturing Technology, Fourth edition, v1 and v2, McGraw Hill India
Pvt. Ltd., 2015.
3. E. Paul Degarmo, J.T. Black, Ronald A. kosher, Materials and processes in
Manufacturing, PHI 2005.
4. Campbell J.S., Principles of Manufacturing Materials and Processes, Tata
McGraw-Hill, 1995.
5. GK Lal, Introduction to Machining Science, Third edition, New Age International
Publishers, 2013.
 2. Course Plan
Module Name Subtopics to be covered Learning Outcome Text book No.
Chap No. of
Lec
Introduction to Basics of Manufacturing, Student will be able to T1 1
Manufacturing different manufacturing list and compare some
Processes processes, comparisons and manufacturing processes
applications and their applications
Metal Cutting (i) Introduction to material Student will learn about T1-8, T2-4 5
and Machine removal processes, process of basic theory and analysis
Tools chip formation, cutting tool and behind the metal cutting
its nomenclature, cutting tool operation.
materials & hardness
consideration.
(ii) Machine tools such as lathe, Student will be able to T1-8, T2-4 2
drilling m/c, milling m/c, shaper, select appropriate
planer and work holding devices; machine tool from
Grinding process, grinding various choices and learn
wheel; honing, lapping, super about for their operating
finishing, polishing and buffing. procedures.
(iii) Mechanics of basic Student will learn about T1-8, T2-4 10
machining processes, basic theory and analysis
mechanism of chip formation, behind the metal cutting
Merchant’s analysis, extension operation.
of Merchant’s analysis to various
machining processes, failure of
cutting tools.
Metal Casting (i) Introduction to Casting Student will be made T1-5, T2-2 2
process, patterns & cores, types aware of the basic
& allowances, types of moulds, techniques of casting and
melting. its nomenclatures
(ii) Gating design, cooling & Student will learn about T1-5, T2-2 6
solidification, riser design and analysis useful for design
placement. of moulds and
solidification process.
(iii) Defects in casting, various Student will be made T1-5, T2-2 2
other casting processes, aware of the casting
Inspections. methods.
Metal Forming Introduction to bulk deformation Student will be made T1-6,7,
processes processes like rolling, forging, aware of basic forming T2-3
extrusion, bending and sheet operations and their 10
metal processes like punching, comparative pros and
blanking. cons

Joining Welding processes such as Student will be made T1- , T2-5 2

Processes SMAW, GTAW, SAW, aware of various joining
Resistance welding & oxyfuel processes available, their
welding, HAZ, Brazing and specific applications and
soldering; their limitations.
 3. Evaluation Scheme:
Duration Weightage
No. Component Date and Time Remarks
(%)
Mid Semester 1 hour 30 13-03-24 (W)
1 30 Closed Book
Exam mins 11.00 AM to 12:30 PM
Comprehensive
2 3 hours 40 14-05-24 (Tue, AN) Closed Book
Examination
3 Quizzes -- 15 Announced Open Book
Practical’s (Quiz or Continuous &
4 -- 15
Assignment) Announced

4. Chamber consultation hour: Thursday 4 to 5 PM, Sudhy S Panicker (Chamber-E115);

Biswajit Das (Chamber-E107)
5. Any relevant updates will be shared. Students are advised to refer to ‘additional
information notes’ uploaded in quanta, which include any relevant updates regarding new
topics/other articles for self-study (For further understanding) on already discussed topics
in the class.
6. Students are advised also to learn from ‘reference books’ while preparing for the exams.
7. Others: Any creative activity to promote the understanding of the subject is encouraged.
The students can come up with simple projects to familiarize themselves with various
manufacturing practices. For this, the students can consult the Instructor/ the Instructor in
Charge / the Workshop Superintendent.
8. Make-up Policy: Make-up may be granted after ascertaining the genuineness of the
request and with prior permission. No Make-up for internal components will be considered.

Instructor-in-charge
ME F219