Kathmandu University    Mechanical Engineering Department

 Course Plan (Academic Year 2004-5 : Odd Semester)

MEPP 401/Manufacturing Process III (MP III)

BE (Mechanical) Year: IV SEM: I

Instructor: R.C.Poudel (TA/MED)

Course Objective

· To make students familiar with tool nomenclature (Tool Signature), mechanism of metal cutting, chip thickness ration and forces involved in metal cutting.

· Introduction of Powder Technology, study of powder producing methods and discussion of merits and demerits of Pm products.

· To familiarize students with micro finishing processes, with considerations of merits and demerits.

· Brief discussion on unconventional machining processes.

· To make the students use the knowledge they have gained so far  to design jigs , fixtures and press tools.

· To introduce students to Computer Numerical Control in Machine tools. Brief review of history of Numerical Control, NC machine nomenclature, Part Programs, Computer Aided Part Programming. 

Internal Tests     First Internal Test will be conducted in last week of September and Second Internal Test will be conducted in last week of November.

 Attendance Norms   In continuous evaluation system, which the university follows, it is desirable and very much expected that the students attend classes regularly. Students should not only show their physical presence in the class but they should also actively participate in classroom activities and interact with the faculty. As per university rules students are required to have minimum attendance of 75% .In case the attendance falls below 75%, students will not be allowed to appear in the final examination of the subject. This rule will be strictly enforced and no consideration will be made except in genuine cases supported my valid medical certificates and other documents.

Internal Evaluation: Marks Distribution 

Lecture Plan

 Figures, inside brackets in right hand side, indicate estimated lecture hours with provision of at least one tutorial class per module. The last lecture hour in each module has been separated for tutorial.  

About sixty lecture - hours are available for the course during the semester (Aug – Nov). Two hours have been allotted for two internal tests. Besides, considerations have been made for public holidays occurring in the semester and also for the possible 'bandhs' and strikes. So, the course plan has been made with an aim of covering the syllabus within 51 lecture hours. After completion of the syllabus, remaining lecture hours, if any, will be utilized for revision and faculty-student interactions

Assigned Lecture Hours

Module One: Theory of Metal Cutting : (9)

 Lectures 1 - 2 Prerequisite: Tool Angles & Tool signature

Orthogonal and Oblique Cutting

Lectures 3 - 5 Types of Chips

Chip Thickness Ratio

Lectures  6 - 7 Shear angle and rake angle in orthogonal Machining

Velocity Relationship

Lecture          8   Merchant's Theory & Analysis of Forces in Orthogonal  Machining

Module Two:  Powder Technology: (7)

 Lectures   1 - 2 History of Powder Technology & Process Description

Lectures   3 - 4Methods of Powder Manufacturing

Lecture     5 -  6

Properties of Sintered Metal Products

Types of Powder Metallurgy Products

Merits & Demerits

Module Three: Micro Finishing Processes:(6)

 Lectures     1- 3

Lapping, Machines Used

Honing, Machines Used

 Lectures      4- 5

Super finishing

Merits & Demerits 

Module Four: Modern Methods of Machining (11) 

 Lectures  1- 6

Electric Discharge Machining

Electro Chemical Machining

Water Jet Machining

Abrasive Jet Machining

Ultrasonic Machining

LASER Beam Machining

Lectures 7 - 8

Chip less Machining, Thread Rolling & Spline Rolling

Cold Impact Extrusion

Lectures 9- 10

High Rate Forming, Explosive Forming,

Hydro Spark Forming, Magnetic Forming, Expansion Forming 

Module Five: Introduction To Computer Aided Design & Manufacturing (14)

 Lecture   1          CAD

Lectures 2-3      History of Numerical Control

Components of NC System

Lectures 4-5       Types Of Numerical Control

Functions, Advantages & Recent Trends

Nomenclature of NC Machines

Lectures 6-10    Actuating Systems, Input Medias

Program Codes, Part Program

Lecture  11-13   Computer Aided Part Programming

Module Six: Design Of Jigs, Fixtures & Press Tools (4)