Manufacturing Technology syllabus

Overview of casting processes including pattern types, materials, design, and allowances. Study of moulding sands, their properties, and sustainable alternatives. Core making techniques, melting furnaces, and gating system design. Numerical methods for mold filling and riser placement. Principles of cooling, directional and progressive solidification, and solidification rate estimation. Casting finishing, defect analysis, and remedies. Introduction to permanent mould, investment, centrifugal, and continuous casting methods.

Plastic deformation. Stress-strain diagram for different types of material, Hot and Cold working, Factors affecting plastic deformation, Yield criteria, Concept of flow stress, Forming Limit diagram Rolling Process: Rolling terminology, Friction in rolling, Calculation of rolling load. Smart rolling mills with adaptive control and digital twins. Forging: Open and closed die forging, Forging operations Extrusion: Types, Process parameter Wire and Tube Drawing: Wire and tube drawing process, Die profile Friction and lubrication in metal forming, Forming defects, causes and remedies for all forming processes.

Types of sheet metal operations, Press working equipment and terminology, Types of dies, Clearance analysis, Estimation of cutting forces, Centre of pressure and blank size determination, Hybrid dies. Design of strip lay-out, Blanking die design, Introduction to Drawing, Bending dies, Methods of reducing forces, Formability and forming limit diagrams.

Classification of joining processes; welding terminology and types of joints. Arc welding processes: Principles and equipment of single carbon arc welding, FCAW, TIG, MIG, SAW, hybrid laser welding. Resistance welding: Spot, seam, and projection welding; heat balance. Gas welding and cutting. Soldering, brazing, and braze welding. Welding metallurgy and heat-affected zone. Weld inspection, defects in joints, and their remedies.

Polymers: Thermoplastics, Thermosetting, Processing methods, Thermoforming (Pressure, Vacuum), Extrusion (Film, Pipe, Sheet), Composite Processing: Hand lay-up, Spray lay-up, Filament winding, Resin transfer moulding, Pultrusion. Advanced Composites: MMCs, CMCs, Carbon-carbon, Polymer matrix, Nanocomposites. Bio-based and biodegradable polymers (e.g., PLA, PHA).