Jharkhand University of Technology Metallurgical Engineering Diploma Syllabus 3rd Semester - PDF

Jharkhand University of Technology Ranchi, 834010 SYLLABUS For Diploma Program in Metallurgical Engineering (Effective from 2024-25) DEPARTMENT OF METALLURGICAL ENGINEERING (3rd – SEMESTER)  FOUNDRY...

Jharkhand University of Technology Ranchi, 834010 SYLLABUS For Diploma Program in Metallurgical Engineering (Effective from 2024-25) DEPARTMENT OF METALLURGICAL ENGINEERING (3rd – SEMESTER)  FOUNDRY TECHNOLOGY Subject Code -MET301 1. Rationale: Foundry technology deals with the processes of making castings by using various patterns to prepare molds, molds are formed in either regular sand method or some other means. This process is widely used for manufacturing of various components. It is important to understand the regular casting processes and advanced foundry processes to explore detailed phenomena associated with new casting process parameters helping to produce defect-free components with good quality. Hence, this course is introduced to provide hands on experience on various casting process which involves defects free in castings and sand reclamation methods to reconditioning the used foundry sand for the economic purpose. 2. Course Outcomes: At the end of the Course, the student will be able to: Prepare a mold cavity by using solid & split patterns CO-01 Practice the mold and core making methods CO-02 CO-03 Produce a casting with appropriate gating system in aluminum/steel foundry CO-04 Understand the advanced casting and sand reclamation techniques CO-05 Analyze the causes & remedies of casting defects CO-06 Analyze the importance of different test carried out on molding sand 3. Course Content Lecture Practice (Skill) (Knowledge) Week CO PO* 1. Introduction to foundry – types 1. Study of Foundry of foundry, Explain the safety Tools and Equipment-Sand precautions to be taken in Mixing by using Muller, foundries Study of cope and drag 2. Foundry mechanization- layout of mechanized foundry 2. Preparation of the 1 01 01,04,07 molds by hand cutting 3. Pattern , Functions of pattern and pattern materials 1. Explain the types of Pattern—Solid or Single Piece pattern, Split Pattern, Loose Preparation of the molds 01,04,07 Piece Pattern by using solid patterns 2 01 2. Match Plate pattern , Gated pattern , Sweep pattern 3. Pattern allowances 1. Introduction; Mold Preparation of the molds Characteristics, molding sand by using split patterns properties 01,04,07 2. Types of molds- Explain 3 01 Green Sand Mold, Dry Sand Mold 3. Loam Mold, Sodium – Silicate mold (CO2mold),  1. Types of molding methods- 1. Preparation of molds Bench Molding, Floor Molding by using core 01,04,07 2. Types of molding methods- 2. Determine the 4 02, 06 Pit Molding and Machine moisture content in the Molding molding sand by using 3. Introduction to core - Core Speedy moisture teller Making Procedure 1. Core Boxes - Split Core Box, Determine the clay Left and Right Hand Core content of the given 01,04,07 Boxes molding sand 5 02, 06 2. Types of Cores- Horizontal Core, Vertical Core 3. Hanging core; Core Prints 1. Gating system ,functions of 1. Prepare the molds using the gating system, Gates– pattern by proper gating Characteristics system for casting. 01,04,07 2. Determine the 2. Types of gates- Top gate, 6 03,06 permeability number of Bottom gate, Parting line side the standard sand gate specimen by using 3. Open riser and blind riser, permeability tester Chills-External chills, Internal chills 1. Introduction to Cupola 1. Determine the furnace & its Construction Compression strength of 2. Cupola Operations in details the standard sand 7 03,06 specimen( Green sand) in 01,04,07 3. Coreless type induction Universal sand strength furnace-Construction, testing equipment Operation 2. Melting practice 1. Introduction to Aluminium alloy foundry practice Determine the Shear 2. Drossing, Gas absorption, strength of the standard 8 sand specimen ( Green 03,06 Fluxing and Flushing, Grain 01,04,07 refinement sand) in Universal sand 3. Steel foundry practice strength testing equipment 9 1. Gravity die casting- 04,06 Determine the Permanent mold casting  2. pressure die casting- Compression strength of 01,04,07 Hot chamber die casting- the standard sand submerged plunger type specimen( Dry sand) in 3. Cold chamber die casting Universal sand strength process testing equipment 1. Centrifugal casting – True centrifugal casting Determine the Shear process strength of the standard 10 04,06 01,04,07 2. Investment mold casting sand specimen( Dry process sand) in Universal sand strength testing 3. Shell molding process equipment 1. Classification of defects. Defects caused by pattern and molding and its remedies 01,07 Identify the defects in 11 05 2. Defects due to core castings and finishing making and casting 3. Defects due to faulty heat treatment 1. Foundry sand testing’s- clay content test 1. Clay content test 01,04,07 2. AFS grain fineness test 2. AFS grain fineness 12 06 test 3. Strength test 1. Environmental challenges in foundry –Sand reclamation – Introduction, Concept, 01,04,05,07 Advantages 2. Dry reclamation-Steps Moisture content test for 13 04,06 involved in dry reclamation, reclaimed sand Drawback of dry reclamation 3. combined wet reclamation plus thermal reclamation Total in hours 39 52 Reference books: Sl.No. Description 1 Foundry technology, O P Khanna 2 “Principles of metal casting”-Heine 3 Foundry technology by K P Sinha & D B Geol 4 Principles of foundry technology by P Jain 5 Metal casting by B A Srinivas LIST OF SOFTWARES/LEARNING WEBSITES: Sl. No Description 1 https://www.youtube.com/watch?v=h-c4 Ukqgx4 2 https://www.youtube.com/watch?v=Zs9SBpday84 3 https://www.youtube.com/watch?v=yDi2B-4j1M8 4 https://www.youtube.com/watch?v=dnLLUMW0j3I 5 https://www.youtube.com/watch?v=bzSSfBgkWfc 6 https://www.youtube.com/watch?v=JLfV u8HRcY 7 https://www.youtube.com/watch?v=NlPeTp kNOE 8 https://www.youtube.com/watch?v=BX8w-GUPz1w 9 https://www.youtube.com/watch?v=qPnSb3yzytE 10 https://www.youtube.com/watch?v=QigJaQ0qp4A 11 https://www.youtube.com/watch?v=VkVu5qDgs Q 12 https://www.youtube.com/watch?v=ASXAXIrhZ3s Equipment list with Specification for a batch of 20 students Sl. Particulars Specification Quantity No. 01 Foundry tools and patterns Standard configuration 02 Speedy moisture teller Standard configuration 03 Universal Testing Machine Standard configuration 04 Clay content tester Standard configuration 05 Sieve shaker Standard configuration 06 Pyrometer Standard configuration 07 Melting furnace Standard configuration 08 Sand Muller Standard configuration 09 Muffle furnace Standard configuration 10 Permeability tester Standard configuration  IRON MAKING Subject Code -MET302 1. Rationale This course will provide a good foundation in iron making, with the relevant knowledge that is necessary to any Metallurgist to pursue the higher levels of study. The course develops the student’s understanding of iron making through a learning progression beginning with introduction of iron making blast furnace and ending with alternative route of iron making. Thus, the subject deals with the description of raw materials and agglomeration along with their properties. This follows with the charging of materials in the blast furnace, which leads to the description of various physico-chemical phenomena along with transport processes that are occurring in the various zones of a blast furnace. Further it discusses about the productivity and irregularities aspects of the blast furnace along with the environmental impact and carbon capturing. Finally, the course ends with a brief overview of the various alternate processes which are emerging out to produce iron. 2. Course Outcomes: At the end of the Course, the student will be able to: CO-01 Understand the beneficiation processes and raw materials used in iron making CO-02 Understand the methods of burden preparation for agglomeration methods CO-03 Understand the construction of modern blast furnace plant CO-04 Explain the operational procedure in blast furnace CO-05 Analyze the irregularities and their remedies in blast furnace CO-06 Understand the various alternative methods of iron making. 3. Course Content Lecture Practice (Skill) (Knowledge) Week C PO* O 1. Introduction to metallurgy- Define metallurgy, metal and Make a chart on alloy, properties of metals and metals & alloys used 1 01 01,07 alloy, divisions of metallurgy in day to day life. 2. Describe operations of mineral dressing-Brief explanation of Combination 3. Crushing and Grinding 1. Concentration – Principle of Magnetic separation , Gravity concentration process, Pneumatic Collect & identify of classifier 2 01 01,07 raw materials in 2. Define sample and sampling context of iron 3. Raw materials for Iron making industry Making - Iron Ores, Minerals of iron, Classification of iron ores 1. Metallurgical coal and coke. Decomposition of 2. Flux – Limestone and flux (limestone) 3 01 01,07 Dolomite 3. Raw material storage and handling system  1. Agglomeration process – Agglomeration of Sintering : principles of iron ore fines by 01,4,5,07 sintering using disc pelletizer 4 02 2. Dwight-Lloyd sintering machine 3. Pelletization process- Disc pelletizer-Green ball production, 1. Theory of bonding , Size segregation of mechanism of ball formation green balls & conduct 02 2. Induration of pellets - a drop test 5 1,7 Drying , Pre hearting , firing 3. Schematic diagram of Blast 03 1,7 Furnace 1. Furnace details - Foundations, Hearth, Bosh, Prepare a blast furnace Mantle or columns, Stack model by using 6 03 1,7 2. Furnace details - Tuyers & suitable Bustle pipe, Bell & Hopper, Off material – takes, 3. Explain Hot Blast stove , Gas Cleaning system 1. Pig casting machine, Liquid 03 1,7 products disposal Virtual 7 2. Essentials of Blast Furnace tour/industrial process visit 3. Blast operations - Blowing 04 1,7 in procedure : drying, filling 1.Lighting and operating until routine practice 8 Virtual 04 1,7 established 2.Banking, blowing out tour/industrial visit 3. Fanning, back draughting 1. Irregularities in blast Virtual 9 05 1,7 furnace operation- their Causes tour/industrial visit and remedies – hanging  2. Scaffolding, slip, chilled hearth, 3. channeling, Pillaring, 1 Introduction to Direct reduction (DR)and Smelting reduction(SR) processes - Definition of Sponge Iron 10 06 1,7 2. Sponge Iron Processes- Sponge iron plant Physical chemistry of DR visit process 3. Coal based DR process – Rotary kiln process – Equipment 1. Coal based DR process – Rotary kiln process – Operation 2.Advantages and Limitations 06 Sponge iron 11 1,7 of coal based DR process plant visit 3. Gas based DR process: Production of reducing gas. (Reforming of natural gas.) 1. Introduction : Midrex process 2. Smelting reduction processes Virtual 12 06 1,7 (SR PROCESS)- Concept of tour/industrial smelting Reduction Process visit 3. Introduction - Corex process- Equipment 1. Corex Process- Operation 2. Corex process reactions Virtual 13 06 1,7 3. Corex process Advantages tour/industrial visit and limitations Total in hours 39 52 Reference Books: Sl. Description No. 1 Elements of metallurgy : By Dr. Swaroop 2 Principles of mineral dressing : By A.M.Gaudin 3 Mineral Processing : By S.K.Jain CBS Publications Material science and metallurgy : By O.P.Khanna 4 5 Iron Making and Sttel Making : By Ahindra Ghosh & Amit Chatterjee Modern Iron Making : Dr. R.H. Tupkary & V.R. Tupkary 6 Iron Making : Bash Forth 7 8 A First Course in Iron and Steel Making : By Dipak Mazumdar Alternative methods of iron making : Prof. Sujay kumar dutta and & Rameshwar sah 9 4. LIST OF SOFTWARE/LEARNINGWEBSITES 1. Jaw crusher https://www.youtube.com/watch?v=yTIePG1E-kY 2. Ball mill https://www.youtube.com/watch?v=L6sgGXXYdEU 3. Froth flotation https://www.youtube.com/watch?v=xmHE4gr7Bh0 4. Harz jig https://www.youtube.com/watch?v=dauNWfbEBkM 5. https://www.youtube.com/watch?v=wFNdtzUEXns 6. https://www.youtube.com/watch?v=8s8rcnxqLIw 7. https://www.youtube.com/watch?v=ftOGG0KVapE 8. https://www.youtube.com/watch?v=7Em6DR24mqQ 9. https://www.youtube.com/watch?v=EmJ1RwGPkM0 10. https://www.youtube.com/watch?v=rbg-SXFniGg 11. https://www.youtube.com/watch?v=BCDSofHltBI 12. https://www.youtube.com/watch?v=jHEmtzy82UM 13. https://www.youtube.com/watch?v=K Ah3QPwA I 14. https://www.youtube.com/watch?v=raElobm5JNA 15. https://www.youtube.com/watch?v=USbZMBxuZJE 16. https://www.youtube.com/watch?v=ROlmDHB Rkg 17. https://www.youtube.com/watch?v=9tOKFffTIj0 18. https://www.youtube.com/watch?v=Hx3qbGC85m4 19. https://www.youtube.com/watch?v=ygRgbGy8kC4 20. https://www.youtube.com/watch?v=IsUQ1HXfEcI 5. Equipment/software list with Specification for a batch of 20 students Sl. No. Particulars Specification Quantity Disc pelletizer Standard 01 02 Heating furnace  Non Ferrous Extractive Metallurgy Subject Code -MET303 1. Rationale: Entire range of metals and alloys are grouped under two headings “ferrous” and “non- ferrous”. Non-ferrous group consist of a very large number of diverse and useful group of materials and alloys, with their distinct metallurgies. Diploma metallurgical Engineers are responsible for production - operation processes, optimization of the process parameters and maintain the metallurgical quality of the end product. This forms an important subject in the study of metallurgical engineering to acquire the knowledge about various extraction methods used for common non ferrous metals. This course is introduced to provide hands on experience on various Extraction process and refining process used in the area of non ferrous extractive metallurgy domain. 2. Course Outcomes/Skill Sets Understand the concepts of thermodynamics aspects and extraction process of CO-01 Aluminium CO-02 Understand the steps involved in extraction process of Zinc CO-03 Understand the steps involved in extraction process of Copper CO-04 Understand the steps involved in extraction process of Nickel CO-05 Understand the steps involved in extraction process of Lead and Tin CO-06 Understand the steps involved in extraction process of Gold 3. Course Content Practice Lecture (Performance Criteria) (Knowledge Criteria) Wee CO PO k 1. Make a chart on gy nonferrous metals & alloys iations of ores from oxides and properties & day 1 01 1,7 sulphides to day applications 2. Virtual lab 3. Concentration of ore- http://vlabs.iitb.ac.in/ Crushing , grinding, Froath vlabs- Flotation, dev/labs/nitk labs/ge ology- lab/experiments/iden tification-of-minerals- nitk/simulation.html 1. Concentration of ore - Virtual lab on Roasting of the Ore, concentration of ore Calcination of the ore https://phet.colorado.  2. Thermodynamics terms- edu/en/simulation/co Internal energy, heat ncentration capacity, enthalpy, entropy http://vlabs.iitb.ac.in/ vlabs- 2 01 1,7 dev/labs/nitk labs/Tr 3. Entropy changes for various ansportation Engineer processes, free energy and its ing Lab/experiments/ significance, free energy crushing-value-of- change as a function of aggregate- temperature nitk/simulation.html features 2. Extraction of Aluminium: Purification of Bauxite - Virtual tour/Industrial 3 01 1,7 Bayer’s process visit 3. Extraction of Aluminium: Purification of Bauxite – Deville Pichaney process 1. Production of Aluminium - Hall and Herault (reduction cell) 4 01 1,7 2. Refining of Aluminium - Virtual tour/Industrial Hoope’s process visit 3. Aluminium Alloys – Mangalium, Aluminium Bronze, Duralumin 1. Extraction of Zinc: Distillation -Horizontal Retort process 5 02 1,7 2. Extraction of Zinc: Virtual tour/Industrial Distillation - Vertical Retort visit process 3. Production of Zinc through Blast Furnace 1. Refining of Spelter- double distillation (redistillation) Virtual 6 02 1,7 2. Properties and Uses of Zinc tour/Industrial visit 3. Galvanizing process 1. Extraction of copper - Virtual tour/Industrial 7 03 1,7 Roasting – Multiple hearth visit Roaster  2. Copper Smelting – Blast furnace process 3. Converting of Matte into Blister Copper 1. Refining of Blister copper - Fire Refining, Electrolytic Refining To carryout electro 8 03 1 , 4,7 2. Copper zinc alloys refining/electro plating of (Brasses) -Gilding Copper, copper Cartridge brass, Muntz metal 3. Copper-tin alloys(bronzes) - Phosphor Bronze, Bell metal 1. Extraction of Nickel: Orford process 2. Electrolyte Refining of Virtual tour/Industrial 9 04 1 , 7 Impure Nickel from orford visit process 3. Extraction of Nickel: Mond’s process 1. Properties of Nickel, Uses of Nickel 2. Alloys of Nickel -Stainless Virtual tour/Industrial 10 04 1 , 7 steel, Monel, German silver, Inconel visit 3. Extraction of Lead-Roasting & Sintering furnace- Dwight- Lloyd sintering machine 1. Smelting in the lead Blast Furnace 2. Refining of Base Bullion or Virtual tour/Industrial 11 05 1 , 7 work lead - Softening of Base visit Bullion 3. Parke’s process, Recovery of silver (cupellation) 1. Vacuum dezincing, Properties of Lead, Uses of Lead Virtual tour/Industrial 12 05 1 , 7 2. Extraction of Tin: Smelting- Ore smelting, Slag smelting visit 3. Refining of Tin- Electrolyte Refining of liquated Tin , Properties of Tin, Uses of Tin 1. Extraction of Gold : Electro winning of metals: From aqueous salts (Au) 2 Extraction of Gold : Electro Virtual tour/Industrial 13 06 1 , 7 refining of metals: From aqueous salts (Au) visit 3. Environmental pollution and its address related to various metal extraction processes in general.  Total in hours 39 52 Reference Books: Sl. Description No 1 Principles of engineering metallurgy– L Krishna reddy 2 Material Science and Metallurgy – O. P. Khanna Extraction of Non - Ferrous Metals by H.S. Ray, R. Sridhar& K.P. Abraham, Affiliated East 3 West Press, New Delhi. 4 Introduction of Metallurgical Thermodynamic, 2nd Edition, David R Gaskel 5 Metallurgy of Non-Ferrous Metals - WH Dennis. 6 Elements of Metallurgy – Dr. Swarup & Dr. Sexena 7 General Metallurgy – B. Kuznetsov 8 Extraction of Non-Ferrous metal – H.S. Ray, R. Sridhar & Abraham 6. LIST OF SOFTWARE/LEARNINGWEBSITES Sl. No Description 1 https://www.youtube.com/watch?v=sOCm88c9xcI 2 https://www.youtube.com/watch?v=KBPv2p7T1wo 3 https://www.youtube.com/watch?v=yTtwBxj2zsI 4 https://www.youtube.com/watch?v=LM4VOW6xZ5Y 5 https://www.youtube.com/watch?v=0tBDiFh6bpI 6 https://www.youtube.com/watch?v=6fzLVK-9eMU 7 https://www.youtube.com/watch?v=Tk4t-v3ZrdI 8 https://www.youtube.com/watch?v=kzAN5f0m5H4 9 https://thermocalc.com/academia/free-educational-package/ 10 https://www.doitpoms.ac.uk/tlplib/ellingham diagrams/index.php 7. Equipment/software Sl. Particulars Specification Quantity No. 1 Electrolysis equipment Standard  Machine Tool Technology Subject Code -MET304 1. Rationale: Diploma Engineers are responsible for supervising production processes to achieve production targets and for optimal utilization of resources. For this purpose, knowledge about various machining processes is required to be imparted. The students are to be trained and equipped with adequate theoretical and practical knowledge about Metal Cutting Phenomenon and various processes like turning, drilling, milling, grinding etc. Hence, this course is introduced to provide hands on experience on various machine tools used in the manufacturing stream and to provide foundation for diploma engineers who want to further specialise in the field of precision manufacturing 2. Course Outcomes: At the end of the Course, the student will be able to: List relevant work place Occupational health and safety standards and explain the importance of the need CO-01 to comply with them. Explain the importance of Cutting tool Geometry, list various Cutting Parameters, the role and use of the right CO-02 Coolants and Lubricants for the given machining processes. CO-03 Demonstrate turning operation for a given component drawing and object, prepare a process chart Demonstrate milling and drilling operation needed as per a given component drawing, list all the machine tools CO-04 needed for the operation, prepare a process chart CO-05 Understand the concept of non-traditional machining 3. Course Content Lecture Practice (Knowledge) (Skill) Week CO PO* 1.Read and interpret the safety signs displayed in the Machine shop 1. Educate about Safety standards Instructor has to show various Practiced in the machine Shop - Safety sign charts and PPE and Importance of housekeeping and good ask the trainees to identify and Shop floor Practices(5S) record in the dairy 2.Read and interpret the Personal 2. Understand the Principles of First Protective Aid Equipment. 1 01 05 Preventive measures to be taken during First aid and basic training Fire and Electrical emergency Types of Identify and Segregate waste Fire extinguisher (Class A,B,C,D) material (cotton waste, metal chips, burrs etc.) Arrangement of waste in bins 3.Hazards 3. Knowledge about Safety and identification and avoidance Environment Regulations Preventive measure for electrical accidents Select the fire extinguisher according to type of fire 4.Operate the Fire extinguisher an extinguish the fire Preventive measure for Oil leakages and related Hazards Practice the safety norms while working on Deferent Machine Tool  1. Identify the type of Chips formed 2. Instructor has to display all 1. Theory of metal Removal- the Coolants and Lubricants Traditional & Non Traditional used in the section and brief material removal process- Chip about its uses forming & Non chip forming Select the use of right lubricant and Cutting fluids. 2. Types of cutting tools- Single point Demonstrate the lubrication of tools-Multi point tools – Specification various machine parts. 2 02 01,04 of Single Point Cutting Tool, Parting , Demonstrate the cutting fluids Knurling Tool, V- tool used for various operations. Ask the trainees to record in the 3. Tool Geometry-Tool materials and Dairy Designation-Tool life & Wear - 3. Instructor has to show all the Concept of Cutting speed-Depth of tools, machineries and cut-Feed measuring instruments used in the machine shop and brief about its uses. Ask the trainees to record in the Dairy 1. Cutting Fluids- Selection of cutting fluids- Lubrication- Need of Lubrication- Selection of Lubricant as per ISO standard. 1. Identify the Raw materials used in machine shop and 2. Grinding- Abrasives- Applications of Record in the Dairy Natural abrasives-stand stone (Quartz), Corundum and Emery Diamond and 3 02 01,04 Garnets- Application of Manufactured Abrasives- Silicon Carbide, Aluminum Oxide Cubic boron Nitride 3. Explain – Grit, Grade, Structure, 2. Grinding Practice of Single point Bond, Type tool as per tool Geometry ISO Designation of Grinding Wheels 1. Identify the main Parts of Lathe and its functions 1.Introduction to Surface Texture- 2. Identify the movements in Indication of Roughness Symbols- Lathe Parts Complete surface symbol chart, Grade and Numbers,- Tolerances-  Carriage Unilateral and Bilateral  Cross Slide 4 03 01,04 2. Introduction to Lathe-Types of  Tail Stock lathe- Capstone and Turret Lathe, 3. Remove the Chuck from Spindle Nose and again mount 3. Automatic Lathe and others - on it Specification of a Center Lathe 4. Demonstration of holding Work piece in 3-Jaw and 4- Jawchuck 5.Idle operation of Lathe. Rotation of spindle in  Clockwise and Counter clockwise direction 6.Identify the Lubrication Parts in Lathe 7. Set the Spindle speed and Feed Lever Position. Practice on Plain Turning and Step turning a) Demonstrate the conversion of units in Linear measurement (conversion of mm-cm-Inch- Feet). Information on FPS System. 1. Explain the various operations performed on Lathe- Facing, Plain Turning, Step Turning, Taper b) Read and Understand the Turning ,Parting, Knurling ,Thread given Drawing cutting c) Demonstrate the specified tolerances in the Drawing 2. Work holding Devices- Tool c) Select the suitable Raw Holding Devices material 5 03 01, 04 d) Fix the given material between headstock and Tail Stock after performing Facing 3. Preparation of Process chart as per and Countersinking. the given drawing for Plain Turning e) Set the tool to perform plain and Step Turning turning and Step Turning f) Select the Speed and Feed g) Turn the given material to the required diameter and length as per given drawing h) Measure the Diameter and Length using measuring instruments i) Observe and Identify the Chip Formation Taper turning operation Demonstrate the setting of Compound rest as per calculation 1. Explain Taper turning operations by a) Read and Understand the different methods- given Drawing b) Mark the required 2. Calculate Taper angles for different dimensions as per the given Taper turning component Drawings drawing for Taper turning 6 03 01, 04 c) Fix the given material between headstock and Tail 3. Preparation of Process chart as per Stock the given drawing for Taper Turning d) Select and Set the tools to perform Taper turning e) Select the Speed and Feed f) Perform the Taper Turning operations g) Measure the dimensions using measuring instruments 1.Thread cutting Mechanism Thread cutting , Knurling and a) Half Nut Mechanism Chamfering operation b) Tumbler Gear Mechanism a)Read and Understand the given 7 03 01,04 Drawing 2. Number of Pass for Different b) Fix the given material Materials- Calculation of Thread between headstock and Tail cutting time Stock  3. Knurling and Chamfering per the c) Select and Set the appropriate given Drawing tools to perform the above operations d) Select the Speed ,Feed and lubricant e) Measure the dimensions using measuring instruments a) Identification of Milling machine Parts and its Usage b) Demonstrate the working 1. Introduction to Milling – Types of Principle of Milling machine milling machine and movements of Table and – Specification of a Milling machine Arbor c) Setting of Vice and Job on the 2. Types of Milling cutters and their Table of Milling Machine 8 04 01,04 uses- Milling Cutter Nomenclature- d) Set the Cutter on the Arbor Specification of Milling Cutter e) Illustrate the safety points to be observed while working on 3. Methods of Milling-Up Milling and the Milling machine Down Milling- Work holding devices f) Identify and Select the different Milling Cutters g) Demonstrate the Up- milling and Down – Milling Process a) Perform Plain Milling of Six 1. Explain Plain Milling Operation faces of a Solid Block Read and understand the component b) Check the accuracy of the Job drawing with suitable Measuring 01,02, 2. prepare the process chart for Plain Instruments 9 04 04 Milling 3. Explain Key way and V- slot a) Milling of Keyway and V Slot Operation- Read and understand the Check the dimensional accuracy component drawing with suitable Measuring Instrument a) Demonstrate Indexing Head b) Set and Align Indexing 1. Explain Gear cutting by Head with reference to Indexing Methods the Job on Milling machine Table 04 c) Cut Gear Teeth on a 2. Introduction to Drilling – Blank by Simple Types of Drilling Machines- Indexing Method 10 01,04 d) Identification of Drilling machine Parts 3. Specification of Drilling e) Demonstrate the Machines-Specification of working Principle of Drill Bit, Reamer , Die and Drilling machine Taps f) Set the Vice and Job on the Table of Drilling machine  1. Nomenclature of Drill Bit, Reamer, Die and Taps- a) Identify and Select the Standard sizes of Drill Bits different Drill Bits b) Set the Drill bits on the spindle. 2. Explain Operations c) Drilling Equally spaced performed in Drilling holes(Circular/Square/ Machines- Drilling, Counter Rectangular plate) 11 4 01,04 sinking, Reaming, Boring, d) Finish the pre-drilled Tapping hole with a Reamer e) Illustrate the safety points to be observed 3. Preparation of Process chart while working on the for the given component Drilling machine Drawing 1. Introduction to Nontraditional machining -classification 2. Laser beam machining 12 05 01 Virtual lab/videos Principle & operation 3. Advantages, disadvantages & applications 1. Electro discharge machining (EDM) Principle & operation 2. advantages ,disadvantages & 13 05 01 applications Virtual lab/videos 3. distinguish between traditional & nontraditional machining Total in hours 39 52 References Sl. No. Description 1 Mechanical estimation and costing T.R.Banga and S.C.Sharma Khanna publishers 2 Mechanical Estimation Malhothra Industrial Organisation and Engineering 3 Economics T.R.Banga and S.C.Sharma Khanna publishers 4 Mechanical Estimation NITTTR Chennai NITTTR Chennai 5 Mechanical costing and Estimation. Singh and Khan Khanna Publishers 6 Process Planning & Cost Estimation M.Adithan New age International 7 Rao, P.N., Manufacturing Technology, Vol I & II, Tata Mcgraw Hill Publishing Co., New Delhi, 1998 Seropekalpakjian, Steven R SchmidManufacturing Engineering and Technology- Pearson Education-Delhi 8 Sharma, P.C., A Textbook Of Production Technology – Vol I And II, S. Chand & Company Ltd., New Delhi, 9 1996 10 HMT – “Production Technology”, Tata Mcgraw-Hill, 1998 8. LIST OF SOFTWARES/ LEARNING WEBSITES: 1.http://calculatoredge.com/index.htm#mechanical 2.www.nptel.ac.in/courses/112105126/36 3.www.youtube.com/watch?v=T5gjkYvMg8A 4.www.youtube.com/watch?v=ESKoaZtoB1E 5.www.freevideolectures.com 9. Equipment list Sl. No. Particulars Specification Quantity Max 50mm Dia Holding capacity 01 Center lathe With all accessories and attachments(Gear driven) 500mm Center distance.Swing over dia 200mm 02 HSS cutting tool 20*20*150MM 03 HSS cutting tool 10*10*150MM 04 Cemented carbide tipped tools with holder brazed For turning 05 Knurling tool Rough Standard 06 Knurling tool Smooth Standard 07 Vernier calipers 300mm 08 Outer caliper 5omm OD 09 Steel scale 300mm 10 Dial gauge for setting of work Standard 6mm Taper 11 Counter sunk Drill Bit shank Upto 24mm drill 12 Upright Drilling Machine With all attachament Upto 18mm 13 Sensitive Drilling Machine drill 14 Machine Vice (To hold Job) 120mm Jaw Gap 15 Drill Bit set 6mm to 24mm 16 Marking Divider 200mm dia 17 Marking punch Standard 18 Combination Set Square Standard 19 Surface plate 300*300mm.Table Travel of 800mm Column and Knee type Vertical MILLING machine With all attachments 20.24mm cutters Bore dia (ID)  Standard Size 21 Plain milling Cutter 24mm ID/Slab milling for Practice 22 Key way cutter 6mm 23 Key way cutter/Slot cutter 12 Standard Size 24 Gear cutter (Spur teeth) for Practice Standard for 25 Concave Milling cutter Size Practice Standard Size 26 Convex Milling cutter for Practice 27 Key way Milling cutter 40mm dia 28 End Milling Cutter 24mm dia 300mm wheel 29 Bench Grinder dia Rough and Smooth (4th – SEMESTER)  PHYSICAL METALLURGY Subject Code -MET401 1. Rationale: Physical metallurgy is the science of making useful products out of metals. Metal parts can be made in a variety of ways, depending on the shape, properties, and cost desired in the finished product. Most notable of the first-period accomplishments was the development of the first accurate iron-base phase diagram, which organized ferrite allotropes and carbides with the constraints imposed by the Gibbs phase rule. It is important to know the effect of chemical composition, heat treatment and production process on the final component in order to achieve components with optimal properties. This field of expertise, comprise all the steps from solidification to final product. Physical metallurgists study how a metal inter behavior structure in different conditions including in a hot environment or when it's put under stress 2.Course Outcomes: At the end of the Course, the student will be able to: CO-01 Analyze the crystal structure of metals and diffusion in solids CO-02 Understand the deformation mechanisms in metals CO-03 Analyze the Iron – Carbide equilibrium diagram CO-04 Understand the solidification of metals and alloys CO-05 Analyze the Binary equilibrium diagrams of Metals and Alloys CO-06 Analyze the microstructure, properties & applications of Cast iron family 3.Course Content Lecture Practice (Skill) (Knowledge) Week C PO* O 1. Introduction, crystal systems and To study the different Bravais lattice systems crystal structures by using ball, ball and 2. Effective number of atoms stick or wire models. 1 01 01 , 07 and packing factor for: i) BCC ii) FCC 3. Effective number of atoms and packing factor for: iii) HCP crystal structure  1. Types of crystal imperfections , point imperfections Metallurgical 2. Dislocation -Screw dislocation, Microscope: 2 01 01, 07 edge dislocation Principles and 3. Explanation and procedure of Operations miller indices of planes and direction. 1. Diffusion, types of diffusion Diffusion mechanisms, Factor experiments can do affecting the diffusion. 01 01, 07 by taking some liquids and study the rate of 3 concentration /Min. 1. Deformation by slip, Grain size Deformation by twinning measurement for 02 01,07 2. Difference between slip and different materials twinning by comparison method 1. Recovery, Recrystallization, and Grain size Grain growth. measurement for 2. Grain size and its measurement different materials by 4 02 01,07 by comparison different 3. Grain size measurement by methods different methods. 1. Iron – Iron carbide Specimen equilibrium diagram Preparation 2. Iron – Iron carbide techniques for equilibrium diagram Metallographic 5 03 01,04,07 3. Allotropic transformation in pure Analysis. iron 1. Invariant Reactions ( Peritectic , Eutectic , Eutectoid) 2. Phases of Iron –Carbide Equilibrium diagram 6 03 01,04,07 3. Salient features of upper and lower critical temperature lines in hypo and hyper eutectoid Microstructural steels and Analysis of Carbon importance. steel and Alloy 1. Transformations of different steels steels on hypo eutectoid side during slow cooling. 2. Transformations of different steels on hypo eutectoid side 7 03 01,04,07 during slow cooling. 3. Transformations of different steels hyper eutectoid side during slow cooling. 8 1. Cooling curve for pure metal 04 01,07 Case Study on  2. Cooling curve of a binary nonmetallic alloy forming solid solution inclusions in steels, 3. Solid solution- types of solid its effects on solutions-substitutional solid properties and solution quality 1. Solid solution- interstitial Microstructural solid solution Analysis of Non 9 2. Hume –Rothery Rules for ferrous metals 04 01,07 formation of substitutional solid solution 3. nucleation and grain growth 1. Basic terms: system, Phase, Number of components, Degrees of freedom or variance of the system 2. Interpretation of equilibrium diagrams – the phases that are Experiment setup to present (phase rule), check the Solid to 10 05 01,07 liquid transformation 3. Interpretation of equilibrium at different diagrams the chemical temperature composition of each phase, the relative of amount of each phase (lever rule) 1. Types of phase diagrams- eutectic system (For type-1 give examples of Bismuth- Draw Phase cadmium, Al-Si, Tin-zinc) diagram and 2. Eutectic system - For type -2 identify phases and 11 05 01,07 apply lever rule to give examples of lead-tin, lead –antimony), calculate the 3. Peritectic system, eutectoid composition of system, (give examples of Cu- phase tin, Cu-Al, Zn-Al). 1. Description of Cat Iron and it Classification Microstructural 2. Study the characteristics of Grey analysis of Grey 12 06 01,04,07 Cast Iron Cast Iron , Nodular 3. Study the characteristics of Cast Iron Nodular Cast Iron 1. Study the characteristics of Malleable Cast Iron Microstructural 2. Study the characteristics of White analysis of Malleable 13 06 01,04,07 Cast Iron Cast Iron , White Cast 3. Study the casting defects and its Iron remedies Total in hours 39 52 Reference Books:  Sl. Description No. 1 Introduction to physical metallurgy : Sidney H Avner 2 Physical Metallurgy : Vijendra singh 3 Engineering Physical Metallurgy : Prof. Y. Lakhtin 4 Principles of Engg. metallurgy : L Krishna reddy 5 The Principles of Metallographic Laboratory practice : Geroge L Kehl 6 Material science and metallurgy : O P Khanna LIST OF SOFTWARE/LEARNINGWEBSITES/ Virtual labs 2 http://vlabs.iitb.ac.in/vlabs-dev/labs/nitk labs/physical-metallurgy/labs/index.php 3 http://vlabs.iitb.ac.in/vlabs-dev/labs/nitk labs/physical-metallurgy/labs/microstructural-analysis- nitk/posttest.html 4 http://vlabs.iitb.ac.in/vlab/ 5 https://www.doitpoms.ac.uk/tlplib/diffusion/fick2.php 6 https://www.youtube.com/watch?v=5vaYfd0fekI 7 Phase Diagrams 1 - Binary Eutectics - YouTube 8 Phase Diagrams - YouTube 9 Muddiest Point- Phase Diagrams I: Eutectic Calculations and Lever Rule - YouTube 10 https://www.youtube.com/watch?v=uG35D euM-0 Equipment/software list with Specification for a batch of 20 students Sl. No. Particulars Specification Quantity Examination of inter behavior 01 Metallurgical Micro scope of different Metals and Alloys through Metallurgical Microscope 02 Image analyser software Software with CCD attachment to microscope 03 Specimen Mounting Machine Standard configuration 04 Polishing machines ( Rough and fine polishing)- belt Standard configuration type 05 Disc Polishing machines – Cloth type Standard configuration 06 Grinding Machine Standard configuration 07 Sample leveler Standard configuration 08 Hand polishing stand Standard configuration 09 Specimen cutoff machine Standard configuration 10 Specimen dryer Standard configuration  TESTING OF METALLIC MATERIALS Subject Code -MET402 1. Rationale: Testing of Metals is a comprehensive source of information on commonly used testing methods for metals and their products. In this course diploma engineers are required to analyze the mechanical properties of metals by destructive testing’s. Materials testing studies the behavior of materials under different loads. In particular, the relationship between the acting forces and the resulting deformation and the limit stresses that lead to failure of components are considered. The characteristic values obtained from the testing process are used for materials development, designing components and in quality assurance. There is a range of standardized testing methods to characterize the mechanical properties of materials as precisely as possible. 2 Course Outcomes: At the end of the Course, the student will be able to: Apply hardness testing methods to determine hardness value of different metals CO-01 CO-02 Determine tensile properties of ferrous & nonferrous metals CO-03 Determine compression , ductility properties of different materials CO-04 Understand the fatigue conditions & creep in metals Determine torsion & shear strength of metals CO-05 CO-06 Determine the impact strength of steel. 3 Course Content Lecture(Knowledge) Practice (Skill) Week CO PO* 01 1. Introduction on testing of metals ,Introduction to hardness, 1. Conduct Brinell 05 importance of hardness test on 1 hardness different materials 2. brief explanation of Indentation Hardness, types of hardness 3. Brinell hardness test  1. Rockwell hardness test 1. Conduct Rockwell hardness test on different materials 2 01 01,04 2. Rebound hardness test, 2. Rebound hardness shore’s sceleroscope test 3. Vicker’s hardness test 3. Conduct Vickers hardness test on different material 1. Tensile test – Load , 3 02 01 deformation, Stress ,strain 1. Conduct the Tensile test on mild steel 2. Importance of tensile test 3. Different types of tensile specimens and its importance 1. Different types of gauge 4 02 01 length and its importance 1. Conduct the Tensile test on mild steel by 2. Stress-strain diagram for ductile varying the gauge material length 3. Stress-strain diagram for brittle material 1. Brief explanation of proof stress 1. Virtual lab on tensile test 01,02, 2. Fracture mechanism for ductile 5 02 material 04 3. Fracture mechanism for brittle material 1. Compression Test – 1. Conduct the Importance of compression compression test on 01,02, test metals or non- metals 6 03 04 2. Compression strength on ductile materials 3. Compression strength on brittle materials 1. Ductility test- Brief 1. Conduct the cupping 7 03 01,04 explanation of Erichsen test for sheet metal cupping test 2. Erichsen cupping testing Equipment 3. Variables which effect cupping test 1. Ductility test- Brief 1. Conduct the bend for 8 03 01,04,07 explanation of Bend test various materials 2. Experiment perform in bending machine 3. Types of bend test  1. Introduction to Fatigue test- 1. Conduct fatigue test 9 04 01,07 Fatigue test procedure through Virtual lab 2. Fatigue failure fracture 3. Effect of variables on fatigue test 1. Creep test-brief 01,07 1. Conduct creep test 10 04 explanation about creep through Virtual curve lab 2. Equi-cohesive temperature 3. Factors which effect creep 1. Torsion test-standard torsion 1. Conduct a 11 01,04,07 test specimen torsion test on 05 metals 2. Principle of Torsion test 3. Shear test - standard shear test specimen 1. Shear test - Principle of 12 05 Shear test ( Single shear) 01,04,07 2. Introduction to Impact test- 1. Conduct a shear test 06 types of impact test on metals 3. Izod Impact test – Explanation and test Specimens. 01,04,07 1. Charpy impact test- 1. Conduct the impact test on 13 06 Explanation and charpy test metals ( Izod and Specimens Charpy) 2. Effect of variables on impact test 3. Fracture Mechanism Total in hours 39 52 Reference: Sl.No. Description 1 Testing of Metallic Materials : A.V.K. Surya Narayan 2 Mechanical Metallurgy : Dieter Material science by O P Khanna 3 LISTOFSOFTWARES/LEARNINGWEBSITES: https://www.youtube.com/watch?v=D8U4G5kcpcM https://www.youtube.com/watch?v=RJXJpeH78iU https://www.youtube.com/watch?v=V0R5GVCxBy4 https://www.youtube.com/watch?v=tpGhqQvftAo https://www.youtube.com/watch?v=S2zdehCLYh4 https://www.youtube.com/watch?v=C19aGzday w https://www.youtube.com/watch?v=D8U4G5kcpcM https://www.youtube.com/watch?v=RJXJpeH78iU https://www.youtube.com/watch?v=V0R5GVCxBy4 https://www.youtube.com/watch?v=jIsEKtA323A&spfreload=10 Equipment list with Specification for a batch of 20 students Sl. No. Particulars Specification Quantity 01 Universal Testing Machine 02 Rockwell hardness testing machine 03 Brinell hardness testing machine 04 Vickers hardness testing machine 05 Shores sceleroscope 06 Erichsen Cupping testing machine 07 Impact testing machine  FUELS AND REFRACTORIES Subject Code -MET403 1. Rationale: The Fuels and Refractories focuses on the sources and efficient use of energy available to modern industry which help to students for their careers in metallurgy engineering where knowledge of Fuels and Refractories can be applied to the advancement of technology. All important metallurgical operations like extraction of metals, melting, heat treatment etc. are carried out in various metallurgical furnaces. Fuels are basic requirements of furnaces and play a major role in quality and cost of any metallurgical product. Optimum utilization and quality control of fuel is must in metallurgical operations. Refractories are very important material for construction of furnaces which help in the efficient utilization of heat in furnace. Knowledge of Temperature Measurement and Control is must for functioning of furnaces. Thus Fuels and Refractories will enable students to solve metallurgical problems upon graduation while at the same time, provide a firm foundation for the pursuit of graduate studies in metallurgy engineering 2. Course Outcomes: At the end of the Course, the student will be able to: CO-01 Analyze the concept of formation of Coal , metallurgical Coke CO-02 Analyze the importance and firing appliances for liquid fuels CO-03 Analyze the manufacturing of gaseous fuels and its combustion rates CO-04 Analyze the various refractories under load and it properties 3. Course Content Lecture Practice (Skill) (Knowledge) Week C PO* O Introduction & Classification of 1. To study and fuels identify the Fuel combustion, ignition different types of 1 01 01,04, 07 temperature, run of mine coal fuels (ROM), carbonization of coal Wood-Explanation, burning characteristics of wood, uses of wood Wood charcoal state, process of wood Carbonization, Uses of wood charcoal 1. Analysis of coal- Coal –Explanation, in situ determination of 2 01 01,04, 07 moisture, theory, drift theory volatile matter, Explanation of peat, lignite, ash and fixed bituminous coal, anthracite carbon in Coal by coal. proximate Analysis of coal- analysis determination of moisture, volatile matter, ash and fixed 2. Determination of carbon in Coal by proximate carbon and analysis hydrogen,  Determination of carbon and nitrogen, sulphur 3 01 hydrogen, nitrogen, sulphur And 01,04, 07 And oxygen in coal by oxygen in coal by ultimate analysis ultimate analysis Carbonization of coal, stages of carbonization Explanation of Low 1. Analyze the Temperature Carbonization Water absorbent (LTC) and High Temperature test Carbonization (HTC) of coals at low Metallurgical coke production by and high 4 01 01,04, 07 using beehive oven temperature. Calorific value –definition, higher or gross calorific value and lower or net calorific Value units of calorific value, 1. Determine the determination of calorific value calorific value by bomb calorimeter (Gross & for coal and coke Net calorific value) – Working by Bomb and observations Calorimeter. units of calorific value, 5 01 01,04, 07 determination of calorific value by bomb calorimeter (Gross & Net calorific value) – Working and observations Brief explanation of storage of coal , Advantages and disadvantages of solid fuels Introduction of liquid fuels - state 1. To determine petroleum, production of the viscosity (in Petroleum, classification of ‘Redwood Petroleum viscometer’) of a 6 02 01,04, 07 Paraffin crude petroleum, liquid naphthalene crude petroleum hydrocarbon and Explanation of viscometer effect of temperature on the viscosity. Refining of petroleum, 7 02 01,04, 07 petroleum products and their 1. To determine the uses. viscosity (in ‘Say  Petrol- brief explanation, knocking bolt viscometer’) of petrol, octane number. of a liquid hydrocarbon and Diesel- brief explanation, knocking effect of of diesel, cetane number temperature on the viscosity. Cracking –state cracking, types of cracking-thermal cracking. Flash point and fire point of liquid fuels. 1. Determinatio n 8 of flash point and 02 01,04, 07 fire point for petrol Explanation of Abels apparatus and diesel through Advantage and Disadvantage of Abels apparatus liquid fuels Introduction of gases fuels - 1. Production of Natural Gas –Explanation, Gober gas Properties & application 9 03 01,04, 07 Gober gas –production of gober gas Producer gas - its uses Water gas – its uses Liquefied petroleum gas 1. To study the (LPG) - Explanation precaution on 10 03 01,04, 07 LPG gas during utilization Liquefied petroleum gas( LGP)- properties & uses Combustion calculations – state complete and incomplete combustion, minimum air required 03 01,04, 07 in kg for complete combustion of 1 1. Conduct Abrasion kg of fuel, simple calculations test for Refractories 11 Introduction of refractories - Definition, Classification of Refractories depending upon their 04 01,04, 07 chemical nature Acid Refractories, Basic Refractories, Neutral Refractories, Requisites of good refractory for 1. Conduct the particular job Refractories under Fire clay refractories – 12 04 01,04, 07 load (RUL) test manufacturing , properties , uses Silica refractories – properties ,uses Magnesite refractories – properties ,uses Dolomite refractories – 1. Conduct 13 04 01,04, 07 properties , uses Permeability test Testing of Refractories For refractories Refractoriness under load (RUL) test, Permeability test  Total in hours 39 52 Reference Books: Sl. Description No. 1 Fuels, Furnace and Refractories – O.P.Gupta 2 Refractories – W. Trinks 3 Fuels , Solid , Liquid and gases – S. S. Brame & J.G.King 4 Refractories - F.H. Norton LIST OF SOFTWARE/LEARNINGWEBSITES 1. https://www.youtube.com/watch?v=QEa36qNo86E 2. https://www.youtube.com/watch?v= rIQxXp2IQg 3. https://www.youtube.com/watch?v=8W8SW98-sXQ 4. https://www.youtube.com/watch?v=gYnGgre83CI 5. https://www.youtube.com/watch?v=7U6mxjthKqw 6. https://www.youtube.com/watch?v=5ze5qUYrlmQ 7. https://www.youtube.com/watch?v=Y5pRrbxENWg Equipment/software list with Specification for a batch of 20 students Sl. No. Particulars Specification Quantity Standard configuration 01 Redwood viscometer 02 Abels apparatus Standard configuration 03 Bomb Calorimeter Standard configuration 04 Metallurgical Furnace Standard configuration 05 Weighing balance Standard configuration 06 Refractory Strength Testing machine Standard configuration 07 Say bolt Viscometer Standard configuration  Operations Management Subject Code -MET404 1. Rationale: The success of any organisation not only depends on quality of its products and services but also depends on the people within it. Thus, an operational manager has to play a prominent role in an organisation with human capital and machines. Therefore, managerial skills are essential for enhancing their employability and carrier growth. This course is therefore designed to provide basic concepts in operations management, forecasting techniques, capacity planning, aggregate planning, master production schedule, quality, and inventory and supply chain management for effective utilisation of resources and competitive advantage through operational excellence 2. Course Outcomes: On Completion of course, the student will be able to: Prepare a production capacity utilization plan based on demand forecasted and available production capacity CO-01 for a given product. Prepare a master production plan based on a production capacity utilization plan and a material management CO-02 plan for a given product. Prepare a process plan using time study, motion study and other appropriate methods to ensure process CO-03 efficiency. Prepare a quality assurance plan based on a given quality model which is suitable for either a product or CO-04 a service organisation. 3. Course Content Lecture Practice (Knowledge) (Skill) Week CO PO* Introduction to Operation Management 1. Introduction to Operation  Virtual Tour Organization Management - Operation Functions (You tube) 1 01 01 2. Evolutions and Historical Events in Operational Management  Problems on Productivity 3. Productivity and Competitiveness, Strategy and operation DEMAND FORECASTING Problems on 1.Demand Forecasting- Demand Behavior-Trend Cycle - Seasonal  Qualitative Forecast - Background - Steps in Forecasting Delphi method, Market Research Process 2 01 01 2. Short range and Long Range Forecast  Quantitative Forecast - Time series Method a) Moving average(Naïve forecast , Simple moving 3. Qualitative Forecast methods Average, Weighted moving Average) 1. Quantitative Forecast methods Problems on 3 01 01 2. Seasonal Adjustments b)Exponential smoothing  3. Forecast Accuracy CAPACITY AND Problems on AGGREGATE PLANNING 1. Need for Capacity Planning – Capacity  Capacity Planning, 4 01 01 expansion Strategies – Capacity planning  Aggregate planning Models. 2. Aggregate planning- Methods  Master production 3. Master production Schedule Schedule PROCESS PLANNING 1. Make or Buy Decision  Virtual Tour on Batch Outsourcing- Factors for Outsourcing ,Mass and continuous decision- Process Selection – Batch , Process 5 01 01 Mass ,Continuous  Develop an Operation Sheet indicating Process Components of e-manufacturing Plan, Process flow chart 1.Motion Study  Develop Job Process chart with Process Symbols 6 03 01 2. Man- Machine chart  Develop Man- Machine chart for a given Process 3. Concepts on Time Study  Case study on Time Study Principles INVENTORY MANAGEMENT 1. Elements of Inventory Management- Problems on Inventory Costs-Carrying, Ordering and Shortage Costs 2.Inventory Control Systems-  ABC Classification System Continuous Inventory System (Fixed- 7 02 01  Economic Order Quantity Order-Quantity System) Models Periodic Inventory System (Fixed-Time- Period System)  The Production Quantity 3. Concept on ABC Classification, Model Economic Order Quantity Models, Production Quantity Model 1. Order Quantity for A Periodic Inventory System Case study on JIT ( 8 02 01,02 Order Quantity with Variable Demand Eg:Toyoto Production 2. JIT -Pull System System) 3 Kanban’s System Supply Chain Management