PROGRAMME : Diploma Programme in Mechanical Engineering(ME)

COURSE : Advance Manufacturing Processes (AMP) COURSE CODE : 6418

TEACHING AND EXAMINATION SCHEME:

Teaching Scheme Examination Scheme
Hrs / week TH Marks
Credits
TH TU PR Paper Hrs. TH TEST TH+TEST PR OR TW TOTAL
Max. 80 20 100 25 -- 50 175
04 -- 02 06 03
Min. 32 -- 40 10 -- 20 --

1.0 RATIONALE:
This is manufacturing technology course which has relevance with the courses taught earlier
namely-manufacturing processes and production processes. After getting conversant with the
basic manufacturing and production processes, it is necessary for a technician to know about
the advancements in the area of manufacturing. The course will impart knowledge and skills
necessary for working in modern manufacturing environment.
This course will help the student to get familiarized with working principles and operations
performed on non-traditional machines, advance methods of machining, machining center (CNC
milling), SPM, automated machines which imparts knowledge, skills and competencies of
modern machining tools. Also provide technical knowhow of maintenance practices of machine
tools.

2.0 COURSE OBJECTIVES:

The student will be able to
1. Know different non-traditional machining processes, CNC milling machines,
2. Understand the working of Special Purpose Machines.
3. Know maintenance practices of machine tools.
4. Know the Operation and control of different advanced machine tools and equipment’s.
5. Manufacture jobs as per specified requirements by selecting the specific machining
process.
6. Adopt safety practices while working on various machines and shop floor.
7. Develop the mind-set to adopt modern trends in manufacturing and automation.

3.0 COURSE OUTCOMES:

The course content should be taught and learning imparted in such a manner that students are
able to acquire required learning outcome in cognitive, psychomotor and affective domain to
demonstrate following course outcomes:
1. Explain working of Non conventional and advance machining methods with kinematics and
stating their applications.
2. Explain need, working principles and applications of special purpose machines and
transfer lines.
3. Differentiate automation switches and classify automation systems.
4. Outline the process and prepare a tool layout of a given component as per drawing.
5. Prepare a CNC part programming using ISO format for milling operations and operate CNC
milling machine.
6. Select, mount and set cutting tool and tool holder on machine tool.
7. Select and apply appropriate maintenance practices for machine tool.

4.0 COURSE DETAILS:

Unit Major Learning Outcomes Topics and Sub-topics Hours
(in cognitive domain)
Unit-I 1a. Appreciate use of Non- 1.1 Need of nonconventional machining 10
conventional machining and comparison between
Non methods. conventional & non-conventional
conventional machining methods.
Methods of

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 Unit Major Learning Outcomes Topics and Sub-topics Hours
(in cognitive domain)
machining 1b. Explain working principles 1.2 Classification, working principles, 08
and working parameters of application and working parameters
non-conventional of following non-conventional
machining methods. machining methods:
1c. Select a non-conventional  Electro discharge machining
machine as per (EDM): Principle of working,
requirement Setup of EDM, Dielectric fluid,
1d. Explain and select tools (electrodes), Process
appropriate powder parameters, Output
metallurgy methods for characteristics, Applications e. g.
specific application. micro hole drilling, curve hole
drilling.
 Wire cut EDM: Principle of
working, Setup of WEDM,
controlling Parameters,
Applications.
 Laser Beam Machining (LBM):
Physical principle of Laser, Laser
action in ruby rod, Types of
Lasers. Set-up for LBM.
Characteristics, controlling
Parameters, Applications:
Application of Laser Beam for
Welding (LBW)
 Other non-traditional
machines such as ECM:
Principle of working, Applications.
Water jet machining.
1.3 Criterion for selection of non- 05
conventional machining methods.
1.4 Powder metallurgy: Introduction, 03
Process steps, methods of
manufacturing powders-blending,
compacting mechanical
disintegration, atomisation,
chemical method electrolytic,
decomposition, pre sintering &
sintering. Advantages &
disadvantages of powder
metallurgy. Applications-self
lubricating bearings, filters,
permanent magnets, cemented
carbide (cermets carbides) etc.
Unit-II 2a. Identify CNC Machining 2.1 Vertical and horizontal machining 10
Centre Machine Elements. center: Constructional features of
CNC milling 2b. Know the CNC control VMC, Axis identification. Automatic
machines panel keys and Menu tool changer and tool magazine.
structure. 2.2 Part programming on VMC: ISO G
2c. Identify axes of CNC and M codes for milling-meaning
machining center. and applications of important
2d. Start the CNC Machine and codes. Use of G41 and G42,
Reference it and move the 2.3 Machine zero, home position, work
Machine Slides (Axes) in piece zero, programme zero.
JOG/INC/MPG Modes. 2.4 Canned cycle and subroutine.

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 Unit Major Learning Outcomes Topics and Sub-topics Hours
(in cognitive domain)
2e. Start Spindle ON/OFF, 2.5 Importance of Computer Aided Part
Coolant On/Off, Tool Programming
Changing and do axes 2.6 Principles of computer aided part
positioning in JOG/MDI programming
Modes. 2.7 CAD CAM integration: Concept
2f. Load Parts in Work holding Steps involved in CAD/CAM
devices and Tools in tools integration, CAM software.
Magazine/ATC & Spindle.
2g. Develop part programs for
given component on
milling machine.
2h. Input/edit Part Programs
in the CNC Control and do
Graphic Simulation to
Verify /Check Part
Programs.
2i. Do Machining operations
like Face Milling, End
Milling, Pocket Milling,
Drilling, Boring and
Tapping using Automatic /
Memory Modes with block
search and
Repositioning/Restart
procedure.
2j. Interface software
application for auto part
programming.
Unit-III 3a. Explain classification, 3.1 Single spindle Automats: 08
working principles,  Need.
Machine Tool construction and operation  Constructional features.
Automation automats and Transfer  Working principle
lines.  Applications.
3b. Differentiate automation 3.2 Introduction to multi spindle
switches and systems. automates and special purpose
3c. Sketch and describe automates.
Programmable Logic 3.3 Transfer lines.
Controller.  In line and rotary.
3.4 Automation
 Elements of control system,
 Limit switches, Proximity
switches,
 Block diagram for feedback and
servo control system,
3.5 PLC
 Introduction to PLC,
 Block diagram of PLC.
 Application
Unit-IV 4a. Explain classification, 4.1 Capstan and turret lathe: 08
working principles,  Constructional features and
Special construction and operation working principle.
Purpose of capstan lathe, turret  Functions and applications.
Machines lathe automats and  Difference between capstan and
(SPM) Transfer lines. turret lathe.

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 Unit Major Learning Outcomes Topics and Sub-topics Hours
(in cognitive domain)
4b. Outline the tool layout for  Preparation of tool layout.
Capstan & Turret Lathe  Merits and demerits.
4c. Explain construction,  Turret lathe in comparison with
Principles of design of basic centre lathe.
SPM.  Work holding devices.
4d. Describe the productivity 4.2 SPM
improvement by using  Concept,
SPM  General elements of SPM,
 Productivity improvement by
SPM,
 Principles of SPM design,
 Applications of SPM.
Unit-V 5a. Explain different types of 5.1 Introduction. 06
maintenance, need and  Types of maintenance,
Maintenance their importance.  Repair cycle analysis,
of Machine 5b. Describe repair cycle  Repair complexity,
Tools complexity and analysis.  Maintenance manual,
5c. Plan and schedule the Maintenance records,
maintenance activities and Housekeeping.
keep its records.  Introduction to Total Productive
5d. Discuss the new trends of Maintenance (TPM).
maintenance i.e. TPM
Unit-VI 6a. Describe Micromachining 6.1 Micro Machining 06
methods and their  Introduction.
Advanced applications.  Definition.
methods of 6b. Explain additive  Micro drilling, micro turning,
machining manufacturing methods, micro milling, micro welding,
i.e. rapid prototyping  Application of micro machining.
working principles, 6.2 Rapid proto typing.
construction, operation  Process.
and their applications.  Materials.
 Applications.
 Advantages.
o Fused Deposition Method
(FDM)
o Stereolithography (SLA)
o Selective Laser Sintering
(SLS & DMLS)
o 3 D Printing.
TOTAL 64

5.0 SUGGESTED SPECIFICATION TABLE WITH MARKS (THEORY):

Unit Unit Title Distribution of Marks
No. R U A and above Total
Level Level Levels Marks
Unit-I -- -- -- 26
Non conventional Methods of machining
i. Electrical discharge Machining (6 ) -- 02 04
ii. Wire cut EDM (4) -- -- 04
I
iii. Laser Beam Machining (LBM) (8) 02 02 04
iv. Other non-traditional machines such as ECM 02 02 --
(4)
v. Powder metallurgy (4) -- -- 04

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Unit Unit Title Distribution of Marks
No. R U A and above Total
Level Level Levels Marks
Unit-II 04 04 06 14
II
CNC milling machines
Unit-III -- -- -- 12
Machine Tool Automation
III
Automats (4) -- -- 04
Automation system (8) -- 02 06
Unit-IV 02 02 06 10
IV
Special Purpose Machines (SPM)
Unit-V 02 02 02 06
V
Maintenance of Machine Tools
Unit-VI -- -- -- 12
Advanced methods of machining
VI
Micro machining (4) 02 02 --
Rapid Prototyping (8) 02 04 02
TOTAL 16 22 42 80
Legends: R = Remembrance (Knowledge); U = Understanding; A = Application and above
levels (Revised Bloom’s taxonomy)

Note: This specification table shall be treated as a general guideline for students and teachers.
The actual distribution of marks in the question paper may vary slightly from above table.

6.0 ASSIGNMENTS/PRACTICALS/TASKS:
The tutorial/practical/assignment/task should be properly designed and implemented with an
attempt to develop different types of cognitive and practical skills leading to the achievement of
the competency. (Outcomes in cognitive, psychomotor and affective domain) so that
students are able to acquire the desired programme outcome/course outcome.

Note: Here only outcomes in psychomotor domain are listed as practical/exercises. However, if
these practical/exercises are completed appropriately, they would also lead to development of
Programme Outcomes/Course Outcomes in affective domain as given in the mapping
matrix for this course. Faculty should ensure that students also acquire Programme
Outcomes/Course Outcomes related to affective domain.

S. Unit Practical Exercises Hours

No. No. (Outcomes in Psychomotor Domain)
1 I Demonstration, industrial visit. --
2 II Two job 20
Programming on CNC milling machine containing operations like, face
milling, slotting, Contour machining, Pocket milling-one job (Group of 2
students.)
a. Writing Part program by using Preparatory and miscellaneous
codes, (M codes and G codes), Co-ordinate system (absolute &
incremental), NC word, statement and block, Programming format.
b. Loading a part program on machine controller.
c. Checking for syntax error.
d. Editing part program.
e. Simulation and dry run.
f. Machine zero and work zero setting.
g. Tool offset setting
h. Machining.
i. Costing of job.
Demonstration & visit to industry.

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S. Unit Practical Exercises Hours
No. No. (Outcomes in Psychomotor Domain)
3 III Demonstration & visit to industry to observe the automation. --
4 IV a. Tool Layout 04
b. Prepare a tool lay-out of a given component for capstan and turret
lathe
c. Demonstration & visit to industry.
5 V a. Report on Dismantling, assembly and maintenance practice of simple 08
machine element of following ( any One)
1. Bearing and coupling
2. Shaft and pulley
3. Lathe Chuck and Tailstock on lathe
4. Tapping attachment on drilling machine
b. Report on mounting and Dismounting procedure of following (any
one)-
1. Milling machine arbour,
2. Vertical milling head
3. iii. Tool post
6 VI Demonstration & visit to industry. --
TOTAL 32

Notes:
a. It is compulsory to prepare workshop book of exercises. It is also required to get each
exercise recorded in workshop book, checked and duly dated signed by teacher.
b. Student activities are compulsory and are also required to be performed and noted in
workshop book.
c. Students are to be continuously assessed for competencies achieved.

Each student is required to submit the following term work

Sr.No. Practical task
1 Two job
1a. Job on CNC milling contains face milling, slotting, Contour machining, Pocket milling.
Group of two students-one job
1b. One job on simulator and one job on machine.
1c. Costing of job.
2 Assignments on
2a. One assignment on USM, CHM, EBM, AJM, WJM, PAM.
2b. Report on the tools, fixtures and cams used on automats observed during industrial
visit.
2c. Report on mounting and Dismounting procedure of following (any two)-(a)Milling
machine arbor, (b) Vertical milling head (c) Tool post.
2d. Assignment on micromachining processes.
2e. Assignment on rapid prototyping.

Note: Practical examination of all students is to be conduct on simulation software/ virtual CNC
machine (CNC milling)/trainer.

Guidelines for Practical Examination

An examiner must prepare 6 practical tasks on milling operations. Students can pick up one
task /assignment randomly. The students should write part programme, enter into machine, dry
run and manufacture the component.

Evaluation of students based on their contribution in activities like programming, setting of

machine and tools, job shall be done by the internal as well as external examiner.

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7.0 STUDENT ACTIVITIES:
Following is the list of proposed student activities like
1 Download free simulation software and check part programme on it.
2 Visit or participate in the technical events, exhibition, conference, seminar etc.
3 Collect/download at least four different machine tool catalogues including at least one
special purpose, Automat, non-conventional, CNC machine or advance machine i.e.
prototyping machine, micro machining.
4 Collect/download at least one catalogue each of cutting tool, work holding device and
tool holder on CNC milling machine.
5 Collect/Down load information of various CNC manufacturing software’s CAD CAM
software and write report on their features.
6 Identify type of CNC controllers of CNC machines in your Polytechnic workshop.
7 Prepare a report on maintenance practices of CNC machines. It should include types of
CNC machine tools maintenance, Tools required, Daily checklist, Problems related to
mechanical systems, Backlash, Causes and precautions of electronics system.

8.0 SPECIAL INSTRUCTIONAL STRATEGIES (If any):

Sr.No. Unit Unit Title Strategies
1 I Non conventional Methods of machining PPT Demonstration. Video clips. Live
2 II CNC milling machines examples with suitable components.
3 III Machine Tool Automation Industrial visits.
4 IV Special Purpose Machines (SPM) Show effect of process parameters.
5 V Maintenance of Machine Tools
6 VI Advanced methods of machining

9.0 LEARNING RESOURCES:

A) Books
Sr.No. Title of Book Author Publication
Manufacturing Science Amitabh Ghosh, Mallik East-West Press Pvt.
1.
Ltd.
2 Production Technology HMT, Banglore Tata McGraw Hill
3 CNC machines Pabla B. S. M. Adithan New Age int. limited.
4 Industrial maintenance H. P. Garg S. Chand & Co. Ltd.
Non-conventional Machining P. K. Mistra Narvasa Publishing
5
House
6 Maintenance Engineering Handbook Lindley R. Higgins McGraw Hill
7 Manufacturing Processes Begman, Amsted John Willey and Sons.
Fundamental of metal cutting and B. L. Juneja New age international
8
machine tools limited.
Technology of Machine Tools. Steve Krar, Albert Check McGraw-Hill
9
International.
CAD/CAM Principles and P. N. Rao Tata McGraw-Hill
10
Applications
Manufacturing Technology Metal P. N. Rao Tata McGraw-Hill
11
Cutting & Machine tools
12 Workshop Technology Hajara Chaudhari Dhanpat Rai
13 Production Technology R. K. Jain Khanna Publication
14 Hand book of machine Tool’s H. M. T. H. M. T.
15 Workshop Technology Vol. II H. S. Bava Tata McGraw-Hill
CNC Programming Hand Book Peter Smid Industrial Press, Inc.
16
New York
17 Micromachining V. K Jain Allied publisher
18 Manufacturing technology Kalpak Jain -
19 Computer Numerical Control Quesada, Robert PHI Learning, New
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Sr.No. Title of Book Author Publication
turning and machining centers Delhi.
Computer Aided Manufacturing Rao P.N. Tiwari, N.K. Tata McGraw Hill, New
20
Kundra T Delhi.

B) Software/Learning Websites
1. http://nptel.ac.in/video.php?subjectId=112105126
2. http://nptel.ac.in/courses.php?disciplineId=112
3. http://nptel.ac.in/courses/name
4. http://nptel.ac.in/courses/lecture
5. http://www.howstuffworks.com
6. http://www.youtube.com
7. http://www.swansoft.com
8. http://www.cnc.com
9. http://www. nonconvationalmachiningmethods.com
10. http://www.iid.ac.in/
11. http://www.nptl/CSE/web/112107077/models/
12. http://www.stratasys.com.in
13. http://www.3Dprinting.com
14. http://www.//en.wikipedia.org/wiki/fuseddepositionmodel
15. http://www.additively.com
16. http://www.livescience.com
17. http://www.zcorp.com
18. www.mastercam.com
19. www.mtabindia.com
20. www.swansoftcncsimulator.com
21. www.cncsimulator.info

C) Major Equipments/ Instruments with Broad Specifications

Sr. No Name Of Equipments/ Instruments Qty
Machine Shop
1 Electro Discharge machine with standard attachments & accessories. 1
2 Turret and Capstan lathe machine with standard attachments & 1
accessories.
3 Automat with standard attachments & accessories. 1
4 Required cutting tools HSS 1 Set Each
5 CNC Milling Machine with standard attachments & accessories (Trainer / 1
Production)
6 Required CNC cutting tools i.e. CNC milling cutters. 1 set each
7 Hacksaw machine. 1
8 Required Measuring and Setting tools. 1 set each
9 Required tool holders LS
10 CNC simulator software for milling operations 20 users 1
11 CNC simulator hardware with display & control panel 5
12 Virtual CNC Milling machine 1
13 Desktop computers 25
14 CNC technology teach ware 1 set
15 LCD projector with screen 1 set

Note:-Latest Technology & specifications are to consider at the time procurement.

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10.0 MAPPING MATRIX OF PO’S AND CO’S:
Course Programme Outcomes
Outcomes a b c d e f g h i j k
CO1 H H H H
CO2 M H H
CO3 M H L M M
CO4 H H H L M
CO5 M H H M
CO6 M H H M M L
H: High Relationship, M: Medium Relationship, L: Low Relationship.

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