International Islamic University
Department of Mechanical Engineering, ICT, Faculty of Engineering & Technology
-------------------------------------------------------------------------------------------Course:
MT-284, Manufacturing Processes (Theory & Practical)
Class:
B.Tech - Mechanical (Semester # 04)
Class time:
Instructor: Shamraiz Ahmad
shamraiz_88@yahoo.com
Marks Distribution
Quizzes …………………………………………..…….10
Assignments…………………………………..………10
Presentation…………………………………………..05
Class Participation…………………………………..05
Mid Term Exam……………………………….………30
Final Examination…………………………………...40
____________________________________
Total…………………………………………….……….100
Prerequisites:
Workshop practice and basic knowledge of machining operations
Objectives:
Enable the student to know about different types of machine tools used in
production/manufacturing
Course Outline:
Module Title
Introduction to
course and basics
of Material
Removal
Topics
Week # s
Lecture 1
- Introduction to the Course
- Discussion of Course Objectives
- Formation of Groups (5-members = Max)
Theory:
-
Mechanics of chips formation
Types of chips produced
Chip breakers
Orthogonal & Oblique cutting
1,2
Lecture 2
Theory:
-
Cutting forces in conventional turning
Friction & heat sources in cutting
3,4,5
Material Removal
-
Surface finishing processes, Lapping,
Honing, Super finishing, Polishing, Buffing,
Electroplating, Galvanizing, Metal Spraying.
Practical:
- Study of Broaching machine
Lecture 3
Theory:
Cutting Tools
-
Single point tool Geometry
Multi point tools
Tool life & wear, Tool failure, Factors
affecting tool life, Measuring tool life
Tool material & its characteristics
Cutting fluids, Purposes, Types &
properties of cutting fluids.
6,7,8
Practical:
- Study of Press machine
Lecture 4
Theory:
Machining
Processes
-
Broaching & broaching machines
Press machine, Types of Press machines,
Press work operations
9,10
Practical:
- Practice on press machines to make
different shapes
11
MID-TERM EXAMS
Lecture 5
Theory:
Sheet Metal
Forming
Sheet metal characteristics, Formability of
sheet metals, Bending sheet & plate, Tube
bending & forming, Deep drawing, Super
plastic forming
12,13
Practical:
- Study of bending machine
Lecture 6
Theory:
Jigs & Fixtures
General Design principle, Elements of Jig,
Locating Devices & Clamping Devices.
Practical:
- Bending
Sheet
metals
of
14,15
different
thickness
Lecture 7
Theory:
Non-Conventional
Machining
Processes
-
Ultrasonic machining
Abrasive-jet machining
Water-jet machining
Electrical discharge machining (EDM)
16,17
-
Electromechanical machining & grinding,
Practical:
- Practice on making of simple jigs and
clamping & locating devices.
Lecture 8
Theory:
Non-Conventional
Machining
Processes
-
Laser beam machining
Electron beam machining
Chemical milling
Chemical Blanking
Chemical Engraving.
18,19
Practical:
-
Mini Project on making a simple Jig or
Fixture.
FINAL EXAM
Books Recommended:
1. Elements of Workshop Technology Vol. II by SK Hajra Choudry.
2. Manufacturing Processes BH Amstead & PF Ostwald
20