Subject Code & Name: ME25C12 – Manufacturing Processes
Regulation: R-2025
Semester: III (Third Semester)
Branch: B.E. Aeronautical Engineering (Aero) / B.E. Automobile Engineering (Auto) / B.E. Industrial Engineering and Management (IEM) / B.E. Mechatronics Engineering (Mechatronics) / B.E. Mechanical and Automation Engineering (MechAuto) / B.E. Robotics and Automation (Robotics) / B.E. Aerospace Engineering (Aerospace) / B.E. Mechanical Engineering (Automobile) (Mech(Auto))
Credits / L-T-P: 3 Credits | L-T-P: 2-0-2
Course Objectives
- To impart fundamental knowledge of manufacturing processes such as casting, forming, sheet metal operations, machining, and welding.
Full Unit-wise Syllabus
Unit I – Casting Fundamentals
Overview of casting processes and applications, Sand casting: moulding sand properties, patterns, and pattern allowances, Gating and riser design – functions and basic design principles, Solidification and cooling concepts, Common casting defects and remedies
Practical: 1. Evaluation of moulding sand properties for casting 2. Sand mold preparation using solid, split pattern.
Unit II – Forming – Bulk Deformation processes
Plastic Deformation & Yield Criteria, Hot and Cold working, Rolling, Forging, Extrusion, Wire and Tube Drawing, working principle and load estimation, concepts of powder metallurgy.
Practical: Experimental analysis of thickness reduction and percentage elongation during flat rolling.
Unit III – Sheet Metal Processes
Formability of sheet metal, shearing processes, Deep Drawing, Bending
Practical: 1. Evaluation and comparison of sheet metal formability using the Erichsen cupping test. 2. Fabrication of simple sheet metal components using standard sheet metal tools
Unit IV – Welding fundamentals
Classification of welding processes, Gas Welding, welding power sources: Constant current and constant voltage power sources, characteristics and applications, Arc welding, Physics of Arc welding, SMAW, TIG, MIG, SAW, Plasma Arc welding processes, Resistance welding, Brazing, soldering, adhesive bonding, weld Defects, and remedies
Practical: 1. Design and fabricate a simple welded component of a specified geometry using mild steel plates and the SMAW process, ensuring proper joint design and weld quality 2. Effect of welding current on bead geometry, microstructure, and hardness in SMAW.
Unit V – Machining
Mechanics of machining; basic machine tools (Lathe, CNC, illing, Drilling,); single and multi-point cutting tools, tool geometry and materials, tool life and wear
Practical: 1.Perform basic lathe operations – Plain turning, taper turning 2.Spur Gear Cutting using Horizontal milling machine
Activities: Tasks T1. An automobile workshop needs to manufacture multiple engine brackets with minimum defects, design a suitable casting process and suggest methods to avoid shrinkage and porosity. T2. A construction company requires steel rods of specific diameter and strength— select an appropriate metal forming process and justify your choice based on material properties and cost. T3. A fabrication unit wants to produce metal toolboxes in bulk—design a sheet metal process plan ensuring accuracy, minimum waste, and defect control. T4. A small industry needs a welded frame structure (e.g., table or support frame)— choose a suitable welding process, define parameters, and address possible weld defects and inspection methods.
Course Outcomes (COs)
- CO1: Explain fundamental concepts of casting, forming sheet metal processes, welding, and machining operations used in manufacturing.
- CO2: Apply manufacturing principles to select appropriate processes, materials, and parameters for producing engineering components.
- CO3: Analyze various manufacturing processes to identify defects, material behavior, and process performance under different conditions.
- CO4: Evaluate and develop suitable manufacturing solutions by comparing different processes considering quality, efficiency, and industrial requirements.
Assessment Pattern (Quick Note)
- Weightage: Continuous Assessment 50% | End Semester Examinations 50%
- Internal methodology: Written Test (40%), Practical (30%), Activity (30%). Practical: Lab Experiments (50%), Tasks (50%) (Each student must complete a minimum of two tasks). Activity: Review of GATE/ESE Questions (10%), Mini Project/Quiz/Assignment Programs/Flipped Class /Seminar Presentation (20%)
Source: Official Anna University – B.E. Aeronautical Engineering R-2025 Syllabus
Last Updated: September 2026
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