ME2302: MANUFACTURING PROCESSES

Course objectives: Students will be able to-

1. Gain knowledge of different manufacturing processes like casting, forming, machining,

and joining, including their principles, equipment, and applications.

2. Select the most suitable manufacturing process for a given product and optimize
process parameters to achieve the desired process.

3. Eliminate waste, improve efficiency, and optimize production processes.

Course Relevance:

A Manufacturing Processes course generally aims to provide a foundational understanding of

various manufacturing methods, including metal forming, casting, machining, joining
techniques, and advanced and additive manufacturing processes. Course objectives often
include understanding the principles behind these processes, selecting appropriate tools and
parameters, and analyzing the resulting product characteristics. Possible projects could range
from designing and manufacturing a simple component using different methods to exploring
the impact of process parameters on product quality.

Selective Review Questions for your understanding

Books: 1) Manufacturing Processes for Engineering Materials, S. Kalpakjian and S. R. Schmid,
7th ed. Boston, MA, USA: Pearson, 2021. 2) Fundamentals of Modern Manufacturing: Materials,
Processes, and Systems, M. P. Groover, Hoboken, NJ: John Wiley & Sons, Jan. 7, 2010.

Unit 1: Casting, Moulding, and Forming Processes

Introduction to casting processes and equipment - Sand casting, other expendable-mold casting
processes, permanent-mold casting processes, Plastic moulding processes – Extrusion,
production of sheet, film, fiber and filament, injection moulding, compression, and transfer
moulding, blow moulding, thermoforming, Bulk deformation processes – Rolling, forging,
extrusion, wire, and bar drawing.

1) What is the difference between a pattern and a core in sand molding?

2) What is the relationship known as Chvorinov’s rule in casting?
3) What is a chill in casting? What is a chaplet?
4) Please refer to solved numericals from M.P. Groover book: Heating metal for casting
(10.1), Pouring calculations (10.2), Riser design (10.3), Rotation speed in true centrifugal
casting (11.2),
5) What is the difference between a split pattern and a match-plate pattern?
6) What properties determine the quality of a sand mold for sand casting?
 7) What is the difference between true centrifugal casting and semicentrifugal casting?
8) What are some of the operations required in sand casting after the casting is removed
from the mold?
9) What are some of the general defects encountered in casting processes? Name and
briefly describe three.
10) Briefly describe the plastic extrusion process.
11) Briefly describe the injection molding process.
12) Discuss some of the defects that can occur in plastic injection molding.
13) What kinds of products are produced by blow molding?
14) What are some of the general considerations that product designers must keep in mind
when designing components out of plastics?
15) What are the significant differences in the equipment and operating procedures
between injection molding of thermoplastics and injection molding of thermosets?
16) Please refer to solved numericals from M.P. Groover book: Flat rolling (18.1), Open-die
forging (18.2), Extrusion pressures (18.3), Stress and force in wire drawing (18.4)
17) In rolling steel, what are the differences between a bloom, a slab, and a billet?
18) List some of the products produced on a rolling mill.
19) What is a draft in a rolling operation?
20) Identify some ways in which force in flat rolling can be reduced.
21) Why is flash desirable in impression die forging?
22) Distinguish between direct and indirect extrusion.
23) Name some products that are produced by extrusion.
24) Why is friction a factor in determining the ram force in direct extrusion but not a factor
in indirect extrusion?
25) In a wire drawing operation, why must the drawing stress never exceed the yield
strength of the work metal?

Unit 2: Joining Processes

Introduction of joining processes; fusion welding processes: gas welding, arc welding, resistance
welding, high energy beam welding processes; solid-state welding processes; solid-liquid state
welding: brazing, soldering; adhesive bonding; mechanical fastening.

1) Please refer to solved numericals from M.P. Groover book: Power density in welding
(28.1), Welding travel speed (28.2), Power in arc welding (29.1), Resistance welding
(29.2), Heat generation in oxyacetylene welding (29.3)
2) What are the advantages and disadvantages of welding compared to other types of
assembly operations?
3) Name and sketch the five joint types.
 4) What is the unit melting energy in welding, and what are the factors on which it
depends?
5) What is the heat-affected zone (HAZ) in a fusion weld?
6) Describe the shielded metal arc-welding (SMAW) process.
7) Describe submerged arc welding (SAW).
8) What are the desirable properties of a metal that would provide good weldability for
resistance welding?
9) Describe the sequence of steps in the cycle of a resistance spot-welding operation.
10) What is resistance-projection welding?
11) Why is the oxyacetylene welding process favored over the other oxyfuel welding
processes?
12) Laser-beam welding and electron-beam welding are often compared because they both
produce very high power densities. LBW has certain advantages over EBW. What are
they?
13) What are some important welding defects?
14) Distortion (warping) is a serious problem in fusion welding, particularly arc welding.
What are some of the techniques that can be used to reduce the incidence and extent
of distortion?
15) What are some design guidelines for weldments that are fabricated by arc welding?

Unit 3: Sheet Metalworking

Sheetmetal operations such as cutting operations, bending operations, drawing, etc., dies and
presses for sheet-metal processes, force, and power calculations for sheet metal operations.

1) Identify the three basic types of sheet metal working operations.

2) Please refer to solved numericals from M.P. Groover book: Blanking clearance and force
(19.1), Sheet-metal bending (19.2), Cup drawing (19.3), Forces in deep drawing (19.4)
3) In blanking of a circular sheet-metal part, is the clearance applied to the punch diameter
or the die diameter?
4) What is the difference between a cutoff operation and a parting operation?
5) What is the difference between a notching operation and a seminotching operation?
6) Describe each of the two types of sheet-met al-bending operations: V-bending and edge
bending.
7) What is springback in sheet-metal bending?
8) What is an embossing operation?
9) What are some possible defects in drawn sheet-metal parts?
 10) What are the relative advantages and disadvantages of mechanical presses versus
hydraulic presses in sheet metalworking?

Unit 4: Conventional Machining Processes

Introduction of material removal processes; chip removal processes: turning, milling, drilling,
shaping, broaching, gear cutting; abrasion processes: polishing, grinding, honing, and lapping.

1) Describe the types of machining operations that can be performed on a lathe.

2) Describe the operations that can be performed on a drill press.
3) Orthogonal cutting (20.1), Shear stress in machining (20.2), Estimating friction angle
(20.3), Machining time in turning (21.1), Machining time in drilling (21.2), Machining
time in peripheral milling (21.3)
4) What is an orthogonal cutting operation?
5) Name and briefly describe the four types of chips that occur in metal cutting.
6) What is the difference between a live center and a dead center, when these terms are
used in the context of workholding in a lathe?
7) Explain how external threads are cut on a lathe.
8) Explain the functions of the saddle on a lathe.
9) What is the distinguishing feature of a radial drill press?
10) What is the difference between peripheral milling and face milling?
11) Describe the difference between up milling and down milling.
12) How does a universal milling machine differ from a conventional knee-and-column
machine?
13) Describe the different types of cutters used in milling operations and give an application
of each type.
14) What are the five basic parameters of a grinding wheel?
15) What are the principal abrasive materials used in grinding wheels?
16) Name some principal bonding materials used in grinding wheels.
17) What is wheel structure? What is wheel grade?
18) What is dressing, in reference to grinding wheels?
19) What is truing, in reference to grinding wheels?
20) Name some abrasive operations available to achieve very good surface finishes.

UNIT 5: Introduction to Advanced Machining Processes

Introduction, chemical machining, electro chemical machining, electric discharge machining,

electron beam machining, laser beam machining, abrasive jet machining, ultrasonic machining.
 1) Why are the nontraditional material removal processes important?
2) There are four categories of nontraditional machining processes, based on principal
energy form. Name the four categories.
3) How does the ultrasonic machining process work?
4) Describe the water jet cutting process.
5) What is the difference between water jet cutting, abrasive water jet cutting, and
abrasive jet cutting?
6) Identify the two significant disadvantages of electrochemical machining.
7) How does increasing discharge current affect metal removal rate and surface finish in
electric discharge machining?
8) What is meant by the term overcut in electric discharge machining?
9) Name the four principal steps in chemical machining.
10) What is a photoresist in chemical machining?
11) Explain the difference between chemical machining and electrochemical machining.
12) Explain how the EDMprocess is capable of producing complex shapes.
13) What type of workpiece is not suitable for laser-beam machining?
14) What is an undercut? Why must it be considered in chemical machining?
15) Differentiate between electron beam machining and laser beam machining.

UNIT 6: Introduction to Additive Manufacturing Processes

Importance and overview of additive manufacturing processes; classification of additive

manufacturing processes: Vat polymerization, Powder bed fusion; Material extrusion; Material
jetting; Binder jetting; Direct energy deposition; Sheet laminations.

1) Explain the importance of additive manufacturing (AM) in the context of modern

manufacturing industries.
2) Discuss the advantages of additive manufacturing processes over conventional
subtractive manufacturing methods.
3) Write a detailed note on the applications of additive manufacturing in aerospace,
medical, and automotive sectors.
4) Describe the major classifications of additive manufacturing processes as per ASTM
standards.
5) Compare and contrast the working principles of vat polymerization, powder bed fusion,
and binder jetting.
6) Illustrate with examples how different AM processes are suited to different applications.
7) Discuss the stereolithography (SLA) process with neat sketches, highlighting its industrial
applications.
 8) Compare Selective Laser Sintering (SLS) and Selective Laser Melting (SLM).
9) Describe the direct energy deposition process and its applications in repair and
maintenance of components.
10) Explain the sheet lamination process in AM.

Course outcomes:

At the end of the course student should be able to:

1. Explain various casting, moulding, and bulk deformation processes including their principles,
equipment, product design considerations, and applications.
2. Compare various joining processes considering their principles, equipment, design
considerations, and applications.
3. Calculate punch and die dimensions and press capacity for sheet metal processes.
4. Calculate the process characteristics such as machining time and material removal
rate considering the effect of process parameters for various conventional
machining processes.
5. Describe the principles, equipment, and industrial applications of various advanced
manufacturing processes.
6. Explain the most appropriate additive manufacturing process based on the type of
the material and process to be carried out.