Agenda Item 65/46 - Annexure - 42

BMEE406E Advanced Manufacturing Processes L T P C

3 0 2 4
Pre-requisite BMEE302L, BMEE302P, BMEE304L, BMEE304P Syllabus version
1.0
Course Objectives
1. To impart knowledge on the advancements of metal forming and metal casting
processes.
2. To give an insight on specialized moulding process, micromachining and finishing
processes with potential applications in medical field.
3. To facilitate students to understand the advanced machining and hybrid machining
processes.

Course Outcomes
At the end of the course, the student will be able to
1. Demonstrate the basics of advanced metal forming and metal casting processes.
2. Discuss various advanced metal casting process with industrial applications.
3. Select the appropriate machining process based on tool-workpiece interaction and
source of energy for the end product.
4. Recognize the material removal mechanism and process parameters of ultra-precision
machining process and micromanufacturing process.
5. Identify and use various hybrid machining process for state of art application.

Module:1 Advanced Metal forming Process 6 hours

Unconventional Forming Methods: Classification, Process Principle, Applications,
Equipment’s, Process Analysis and Die Design of Explosive Forming, Stretch forming,
Contour roll forming Laser Beam Bending and Laser Assisted Deep Drawing. Micro Forming
Processes: Classification, Process Principle and Applications of Conventional Micro Forming
Processes, Unconventional Micro-Forming Processes.
Module:2 Advanced Metal casting Process 5 hours
Metal mould casting basics, continuous casting, permanent mould casting, pressure die
casting, Vacuum mould casting, Evaporative pattern casting (EPC)- Hybrid and vacuum,
Ceramic shell investment casting.
Module:3 Specialized Molding Techniques 6 hours
Injection moulding using pressurized gas assistance, Injection moulding using reaction gas
assistance, Injection Moulding for Thin-Wall Applications, Multi-Material Injection Moulding,
Water-Assisted Foaming, Moulding by direct compounding, Injection Compression Moulding.
Ultrasonic Molding Technology: Recent Advances and Potential Applications in the Medical
Industry, Variable Mold Temperature Technologies, Micro injection molding-Issues in
Molding Parts with Microfeatures, Influencing Factors in Microinjection Molding, Applications.
Module:4 Welding-Based Additive Manufacturing (WAM) 6 hours
Classification of WAM by motion controller, raw material and heat source. Powder-bed AM:
Selective laser sintering (SLS), Selective Laser Melting (SLM) and Electron Beam Melting
(EBM). Wire-feed based WAM: Wire and Laser Additive Manufacturing (WLAM), Electron
Beam Freeform Fabrication (EBF3), Wire and Arc Additive Manufacturing (WAAM).
Module:5 Ultra-Precision Machining 6 hours
Diamond turning- mechanism of material removal - process Parameters and Optimization-
tool path strategies in surface generation- applications.
Module:6 Micromanufacturing 7 hours
Focused ion beam (FIB) Micro-/Nano-fabrication, Laser Micro structuring. Hot Embossing,
Hot punching, Roller Embossing, Applications-Micro optical devices, Micro fluidic devices.
Net Shape Manufacture of Freestanding Ceramic Micro-components through Soft
Lithography, micro-fields-activated sintering technology (Micro-FAST). Micromachining-
Micro turning, Micro grinding, Ultra Sonic Micromachining, Abrasive Water Jet Micro
Machining, Chemical and Electro Chemical Micro Machining – Electric discharge micro

Proceedings of the 65th Academic Council (17.03.2022) 1374

 Agenda Item 65/46 - Annexure - 42

machining, Laser Beam Micro Machining. Handling for Micromanufacturing.

Module:7 Hybrid Machining Process (HMPs) 7 hours
Classification of Hybrid Machining process, Elements of Hybrid Machining Technology
(Hybrid Machine Tools, Hybrid Tooling, Hybrid Machining Processes, Metrology System,
Work Handling System, Process Monitoring Technique). Vibration assisted grinding,
Vibration Assisted EDM, Ultrasonic assisted ECM. Heat Assisted HMPs, Laser assisted
turning, laser-assisted ECM(LAECM), Laser-Assisted EDM (LAEDM). Magnetic Field
assisted EDM, Magnetic field Assisted electro discharge deposition (EDD) process. Electro
chemical discharge machining (ECDM), Electro chemical honing, Electro chemical discharge
grinding.
Module:8 Contemporary Issues 2 hours

Total Lecture hours: 45 hours

Text Books
1. Kalpakjian and Schmid, Manufacturing Processes for Engineering Materials, 2017, 5th
edition, Prentice Hall.
2. Hassan Abdel-Gawad ElHofy, Fundamentals of Machining Processes (Conventional
and Nonconventional Processes), 2018, 3rd Edition, CRC press.
3. A. Ghosh, and A.K. Mallik, Manufacturing Science, Affiliated East-West Press Pvt. Ltd.
New Delhi.
4. V.K.Jain, Micro manufacturing processes, 2013, CRC Press.
Reference Books
1. Balasubramaniam R, Sarepaka RV, Subbiah S. Diamond turn machining: Theory and
practice. 2017, CRC press.
2. Heine R. W., Loper C. R., and Rosenthal P. C. Principles of Metal Castings, 1997, 2nd
Edition, Tata McGraw Hill, New Delhi.
3. Murty, R. L., Precision Engineering in Manufacturing, New Age International (P)
Limited, New Delhi.
4. Mark J. Jackson, Micro and Nano fabrication, 2010, CRC Press, Taylor & Francis
Group
5. Yi Qin, Micro-Manufacturing Engineering and Technology, 2010, Elsevier Publisher,
ISBN: 978-0-8155-1545-6
6. MuammerKoc, TrugelOzel, Micro manufacturing, Design and manufacturing of micro
products, 2011, Wiley Publishers
Mode of Evaluation: CAT, Written assignment, Quiz, FAT
Indicative Experiments
1. Learn the forming characteristics of sheet metal specimens with Deep Drawing
operation.
2. Extrude a cylindrical cup by backward extrusion, determine the load variation with the
thickness of the bottom of the cup.
3. Evaluate the machinability of difficult to machine materials by EDM die sinking and
EDM milling.
4. Evaluate the process parameters (Wire feed, wire tension, wire material, WWR) for
machining the given material by WEDM process.
5. Study on Electric discharge coating process by P/M tool and conventional tool.
6. Study on Micro turning process parameters on the given job.
7. Experimental investigation on metals and alloys by micro drilling process and analyzing
the responses and tool wear.
8. Experimental Analysis on drill preparation by micro drilling on natural fiber composites
and studying the roundness error.
9. Experimental study on slot preparation by micro milling on metals and alloys.
10. Experimental study on slot preparation by micro milling on natural fiber composites.
Total Laboratory Hours 30 hours

Proceedings of the 65th Academic Council (17.03.2022) 1375

 Agenda Item 65/46 - Annexure - 42

Text book
Lab manual prepared by the Faculty member
Mode of assessment: Continuous assessment, FAT, Oral examination
Recommended by Board of Studies 09-03-2022
Approved by Academic Council No. 65 Date 17-03-2022

Proceedings of the 65th Academic Council (17.03.2022) 1376