MANUFACTURING TECHNOLOGY-2 4TH SEM DIPLOMA MECHANICAL ENGINEERING

MANUFACTURING TECHNOLOGY - II

Subject Title                           :           Manufacturing Technology-II
Subject Code                         :           M-
Hours Per Week                    :           04
Hours Per Semester              :           64

 

TOPIC ANALYSIS:


Sl.No

Major Topics

Hours
Weightage of Marks

SECTION-I



1

Shaper, Planer &  Slotter

09
24
2
Grinding & Surface finishing
10
25

SECTION-II


3
Milling machine
10
25
4
Modern Machining
08
20

SECTION-III


5
Jigs and Fixtures
05
15
6
Plastic processing
05
15
7
Powder metallurgy
05
15
8
Cutting fluids and coolants
03
06
9
Industry institute interaction
05

10
Test and Revision
04


Total
64
145

Objectives :
On completion of the course the students should be able to:
1. Understand the various Rectilinear machine tools like Shaper, Planer & Slotter, their uses, mechanisms  & applications.
2.  Understand the concepts of grinding, their techniques & super finishing processes & applications.
3.  Understand milling machines, their construction, operations, indexing methods & milling cutters.
4.  Understand Non-conventional machining methods, applications & limitations in manufacturing
5.  Understand the importance of jigs & fixtures, methods & applications in manufacturing
6.  Understand the plastic processing methods, applications & limitations in manufacturing
7. Understand the concepts of powder metallurgy, methods, process & applications in manufacturing.
8.  Understand the importance & purpose of cutting fluids & coolants & their types & uses.

CONTENTS
1.0           Shaper, Planer & Slotter
1.1        Introduction to Shaper  & Classification
1.2        Specifications of Shaper
1.3        Principal parts of shaper.
1.4        Shaper Mechanisms &Shaper Operations
1.5        Cutting Speed, Feed, Depth of cut & Machining time.
1.6        Simple problems.
1.7        Introduction to Planer & Classification
1.8        Specifications of Planer
1.9        Principal parts of Planer
1.10    Planer Mechanisms & Operations
1.11    Differences between Planer & Shaper
1.12     Introduction to Slotter & Classification
1.13     Principal parts of  Slotter
1.14     Specifications of Slotter
1.15     Slotter Mechanisms & Operations
1.16     Difference between Planer & Slotter.

2.0           Grinding  & Surface finishing
2.1         Introduction to grinding & Classification
2.2         Plain Cylindrical grinding machines
2.3         Grinding  wheels
2.4         Abrasives & classification.
2.5         Bond & bonding.
2.6         Grit, Grade & Structure of wheels.
2.7         Specification of wheels.
2.8         Types of grinding wheels.
2.9         Selection of grinding wheels.
2.10     Mounting of grinding wheels.
2.11     Glazing and loading of wheels.
2.12     Dressing and truing of wheels.
2.13     Balancing of wheels.
2.14     Diamond wheels.
2.15     Introduction to surface finish.
2.16     Surface finishing operations.

3.0       Milling machine
            3.1       Introduction to milling and classification.
            3.2       Column and knee type milling machine & copy milling machine.
            3.3       Milling cutters and classification.
            3.4       Fundamentals of milling processes
            3.5       Milling machine operations.
            3.6       Indexing methods.
            3.7       Cutting speed, feed, depth of cut and machining time.
            3.8       Gear hobbing                             
4.0       Modern machining
            4.1       Introduction to modern machining.
            4.2       Differences between conventional and non-conventional methods.
            4.3       Classification.
            4.4       Principle of working of - Ultrasonic machining, Electric discharge machining, Abrasive jet
                        machining and Laser beam machining.
            4.5       Applications, merits and demerits of above methods.
5.0       Jigs and Fixtures
            5.1       Introduction to jigs and fixtures.
            5.2       Definition of jig and fixtures.
            5.3       Types of jigs and fixtures.
            5.4       Applications & merits of jig and fixture.
6.0       Plastic processing
            6.1       Introduction to plastics.
            6.2       Types of plastics.
            6.3       Plastic processing – Moulding process, compression, transfer, injection & Extrusion.
            6.4       Principle of thermoforming and calendaring.
7.0       Powder metallurgy
            7.1       Basic concepts of powder metallurgy.
            7.2       Methods of powder metallurgy.
            7.3       Process for powder metallurgy.
            7.4       Secondary operations for powder metallurgy.
            7.5       Applications, merits and limitations of powder metallurgy.
8.0       Cutting fluids and Coolants
            8.1       Introduction.
            8.2       Purpose and Properties.
            8.3       Coolants and lubricants for different operations.
SPECIFIC INSTRUCTIONAL OBJECTIVES
1.0           Shaper, Planer & Slotter
1.1        Classify the shapers and explain the same.
1.2        Specifications of Shaper
1.3        Draw the line diagram of standard shaper with parts.
1.4        List the shaper mechanisms and study of hydraulic shaper mechanism.- Crank & Slotted Link mechanism
1.5        List shaper operations.
1.6        Definition of cutting speed, feed, depth of cut & machining time.
1.7        Simple problems.
1.8        Classify the Planers and explain the same.
1.9        Specifications of Planer
1.10    Draw the line diagram of standard planer with parts.
1.11    List the planer mechanisms and study of open and cross belt drive mechanism.
1.12    List planer operations.
1.13    Differences between planer & shaper
1.14    Classify slotter and explain the same.
1.15    Draw the line diagram of slotter with parts.
1.16    Specifications of Slotter
1.17    List slotter mechanisms & operations
1.18    List the differences between planer & slotter.
2.0           Grinding  & Surface finishing
2.1         Introduction to grinding & Classification
2.2         Study of plain cylindrical grinding machine.
2.3         Explain grinding  wheels
2.4         Explain abrasives & their classification.
2.5         Explain bond & bonding.
2.6         Explain grit, grade & structure of wheels.
2.7         Explain specification of wheels.
2.8         List the types of grinding wheels.
2.9         List the factors for selection of grinding wheels.
2.10     Explain mounting of grinding wheels.
2.11     Explain glazing and loading of wheels.
2.12     Explain dressing and truing of wheels.
2.13     Explain balancing of wheels.
2.14     Short note on diamond wheels.
2.15     Explain lapping, honing, super finishing and electroplating with neat sketches.
2.16    Explain polishing, buffing, pickling and oxidizing.
3.0       Milling machine
            3.1       Introduction to milling and classification of milling machines.
               3.2      Sketch & Explain – 1) Column & Knee Type Milling Machine  2) Copy Milling machine
               3.3       Explain the standard  milling  cutters & classify  the milling cutters.
               3.4       Sketch & Explain Up Milling & Down Milling
            3.5        Explain different Milling machine operations – plain , end , slot , T , gear cutting, grooves & Splines.
            3.6        Explain Direct, Simple, angular & Compound Indexing.
3.7         Define Cutting speed, feed, depth of cut and machining time
3.8         Explain Gear Hobbing
3.9         Simple problems on above Indexing methods
4.0       Modern machining
            4.1       Explain non-conventional / modern machining
            4.2       Explain differences between Conventional & Non-conventional Machining methods
            4.3       Classification of Non-conventional machining methods.
            4.4       Sketch & Explain Ultra sonic machining, Electro Discharge machining, Abrasive Jet
                        Machining & Laser Beam  Machining.
            4.5       Explain Applications, merits & demerits of above methods.
5.0       Jigs and Fixtures
            5.1       Explain the jig & fixture
            5.2       Definition of jigs & fixtures, principles of location of jigs.
            5.3       Explain the different types of jigs & fixtures.
            5.4       Explain the various applications of jigs & fixtures.
            5.5       Materials used for jigs & fixtures.
6.0       Plastic processing
            6.1       Explain the importance of plastics in manufacturing process.
            6.2       Explain briefly Polymerization process – Addition Polymerization &  Condensation
                        Polymerization
6.3              Explain briefly the additive agents – Plasticizers, Fillers, Catalysts, Initiators, Dyes & Pigments & solvents.
6.4              Explain briefly plastic processing -Moulding process, Compression, Transfer, Injection &
6.5              Extrusion
6.6              Explain briefly machining of plastics
6.7              Explain briefly – Calendaring & Blow Moulding of plastics
7.0       Powder metallurgy
            7.1       Explain the concept of powder metallurgy.
            7.2       Explain the methods of  metal powder manufacturing – Atomization, Electrolytic deposition,
                         Reduction, Crushing & Milling,  Granulation & Shotting.
            7.3       Explain with sketches process for powder metallurgy – Mixing, Compacting & sintering
            7.4       Explain secondary operations -
            7.2       Methods of powder metallurgy.
            7.3       Process for powder metallurgy.
            7.4       Secondary operations for powder metallurgy.
            7.5       Applications, merits and limitations of powder metallurgy.
8.0       Cutting fluids and Coolants
            8.1       Explain importance of cutting fluids and coolants.
            8.2       Explain purpose and Properties.
            8.3       Applications of Coolants and lubricants for different operations.
            8.4       Name different cutting fluids & coolants.

Text Books:
      1. Manufacturing Technology -2 By Mohammed Saifulla Saikh. Sapna Publications.

REFERENCE BOOKS
1)      Workshop Technology by Hazara choudary VOL - I & VOL – II.
2)      Production Technology by Dr.P.C.Sharma., S Chand & Co
3)      Workshop technology by B.S.Raghuvamshi
4)      Introduction to Manufacturing Processes ,  P N Rao , Vol 1 & Vol II, Tata Mc Graw Hill Publications
5)      Production Technology by R.K.Jain.
6)      Manufacturing Technology I & II ,  Dr P C  Sharma , S Chand & Co
7)      Manufacturing Technology  - P P Date , Jaico Publishing House
8)      Foundry Technology –Dr. Radhakrishna.
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