KTU 2024 Scheme · Semester 3 · Program Core — Mechanical Engineering
Manufacturing Processes (PBMET304) Syllabus
Official KTU 2024 Scheme syllabus for Manufacturing Processes, Semester 3, Program Core — Mechanical Engineering (Mechanical Engineering).
Course Code
PBMET304
Credits
4
Teaching Hours
3:0:0:1 (L:T:P:R) — Project Based Learning (PBL)
CIE Marks
60
ESE Marks
40
Exam Duration
2 Hrs 30 Min
Prerequisites
None
Semester
Semester 3
Course Objective
To gain theoretical and practical knowledge in manufacturing processes and develop an understanding of the dependent and independent variables which control a production process; to provide a detailed discussion on welding processes and the physics of welding; and to generate solutions to problems that may arise in manufacturing engineering.
Module-wise Syllabus
Module 1
9 contact hoursGeneral classification of manufacturing processes. Casting: characteristics of sand, design of patterns, cores, chaplets, solidification of metals and Chvorinov's rule, elements of the gating system, risers, chills, defects in castings. Special casting processes: shell moulding, precision investment, die casting, centrifugal casting, continuous casting and squeeze casting. Powder Metallurgy: powder production, powder characteristics, mixing, compaction methods, sintering.
Module 2
9 contact hoursWelding: classification, fusion and solid-state welding processes. Gas welding — oxyacetylene welding chemistry, types of flame and applications. Arc welding — applications, process parameters, consumable and non-consumable arc welding (SMAW, GTAW, GMAW, SAW, AHW, PAW). Thermit welding, friction welding, electro slag welding, ultrasonic welding, electron beam welding, laser beam welding. Resistance welding: applications, process parameters. Heat affected zone, weldability of ferrous and non-ferrous metals, residual stresses and distortion, defects in welding. Brazing, soldering, adhesive bonding.
Module 3
9 contact hoursMetal Forming: plastic deformation and yield criteria, hot and cold working processes. Rolling: flat-rolling process, rolling force and power, types of rolling mills, rolling defects, miscellaneous rolling processes. Sheet metal operations: press tool operations — shearing, tension, compression, applications. Types of dies: progressive, compound and combination dies. Forging: forging load, various methods, applications, defects.
Module 4
9 contact hoursWire, rod and tube drawing: mechanics of rod and wire drawing, drawing force and power, drawing defects, deep drawing. Bending: details, determination of work load, estimation of spring back. Extrusion: metal flow, mechanics of extrusion, miscellaneous processes, defects, applications. Includes a mandatory mini-project applying manufacturing-process knowledge to a socially relevant problem.
Course Outcomes
- CO1Classify different techniques of casting.
- CO2Summarize powder metallurgy processes.
- CO3Categorize welding processes according to welding principles and materials.
- CO4Determine forming load associated with rolling, forging, drawing, extrusion, and sheet metal forming.
- CO5Develop products, processes or technologies for socially relevant applications.
Assessment Pattern (CIE: 60 marks, ESE: 40 marks)
Continuous Internal Evaluation (CIE)
| Attendance | 5 |
| Project | 30 |
| Internal Examination 1 (Written) | 12.5 |
| Internal Examination 2 (Written) | 12.5 |
End Semester Examination (ESE)
Total 40 marks, 2 Hrs 30 Min. See the official KTU syllabus document for the exact Part A / Part B question pattern for this course.
Textbooks & Reference Books
Textbooks
- Manufacturing Science — Amitabha Ghosh, Asok Kumar Mallik (Affiliated East-West Private Limited, 2nd edition, 2010)
- Manufacturing Engineering and Technology — Serope Kalpakjian, Steven R. Schmid (Pearson / Tata McGraw Hill, —)
- Manufacturing Technology Volume-1 — P N Rao (—, —)
Reference Books
- American Society for Metals - ASM Metals Handbook, Vol. 14: Forming and Forging — Joseph R. Davis, S. L. Semiatin (ASM International, 1989)
- Tool Design — Donalson Cyril, LeCain, Goold, Ghose (McGraw Hill / ASM International, 2004)
- Cold and Hot Forging Fundamentals and Applications — Taylan Altan, Gracious Ngaile, Gangshu Shen (Butterworth-Heinemann, —)
- Foundry Technology — Peter Beeley (—, —)
Frequently Asked Questions
How many credits is KTU Manufacturing Processes (PBMET304)?
4 credits, with 3:0:0:1 (L:T:P:R) — Project Based Learning (PBL) teaching hours per week, under the KTU 2024 Scheme.
How many modules are in the PBMET304 syllabus?
4 modules, 36 total contact hours.
What is the CIE and ESE mark split for this course?
CIE (Continuous Internal Evaluation): 60 marks. ESE (End Semester Examination): 40 marks, 2 Hrs 30 Min. Total: 100 marks.
What are the recommended textbooks for PBMET304?
Manufacturing Science (Amitabha Ghosh, Asok Kumar Mallik); Manufacturing Engineering and Technology (Serope Kalpakjian, Steven R. Schmid); Manufacturing Technology Volume-1 (P N Rao).
Is this syllabus specific to one branch, or common to others too?
This Semester 3 course is listed under Program Core — Mechanical Engineering at KTU under the 2024 Scheme — check the course header above for which branches it's common to.
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