About Manufacturing Processes (PBMET304)
Manufacturing Processes (PBMET304) is a third-semester course in the KTU B.Tech 2024 scheme for Mechanical Engineering. It covers how metal parts are actually made: casting, powder metallurgy, welding, and forming processes such as rolling, forging, drawing, bending and extrusion. It's a project-based course, so students also develop a product, process or technology for a real-world application during the semester.
Syllabus
- Module 1: Classification of manufacturing processes, casting (sand properties, patterns, cores, gating systems, risers, Chvorinov's rule and casting defects), special casting processes such as die and centrifugal casting, and powder metallurgy.
- Module 2: Welding: gas welding, arc welding processes (SMAW, GTAW, GMAW, SAW and others), resistance welding, laser and electron beam welding, the heat affected zone, welding defects, and brazing, soldering and adhesive bonding.
- Module 3: Metal forming: plastic deformation, hot and cold working, rolling and rolling mills, sheet metal press operations, and progressive, compound and combination dies.
- Module 4: Forging, wire, rod and tube drawing, deep drawing, bending and springback, and extrusion, with forming load calculations.
Exam pattern
As a project-based course, internal assessment carries more weight: 60 marks, of which 30 come from the project, plus attendance and two internal exams. The end-semester exam is for 40 marks: 8 short questions of 2 marks each, plus 4 questions of 6 marks each, one from each module.
Study tips
Learn each process with a neat labelled diagram, since most theory answers need one. Practise the numerical problems on Chvorinov's rule, welding parameters, rolling force, forging load, drawing force and extrusion. Start your project early, as it's half your internal marks, and solve previous question papers to spot repeated questions.
Notes and resources
Find module-wise notes, solved problems, previous year question papers and the syllabus for PBMET304 here, shared by KTU students and teachers.