Swayam Central

Fundamentals of manufacturing processes

By Prof. D K Dwivedi   |   IIT Roorkee
It is proposed to include fundamental of following aspects of manufacturing technology 
A) Understanding Manufacturing: concept of manufacturing, need, scope, advantages, limitation, application, materials and manufacturing, classification of manufacturing, process capabilities, selection, break even analysis of manufacturing processes 
B) Casting: approach, steps, pattern, molding, gate and riser, melt treatment, solidification, casting processes: sand mould, shell mould, permanent mould casting, casting defect and their remedy 
C) Forming: approach, hot and cold forming, rolling, forging, extrusion, drawing, sheet metal forming, press, dies, types of dies and die set sheet metal operations punching, blanking, notching, nibbling 
D) Joining: approach, need, principle of fusion welding, gas welding, thermit welding, arc welding  common arc welding processes, resistance welding, weldability of metals, solidification of weld, weld discontinuities and their remedy 
E) Machining: approach, mechanism, classification, cutting tool, tool material, heat generation, cutting fluid, grinding, internal and external surface grinding, centerless grinding designation and selection of grinding wheel, trueing and balancing, honing, reaming, lapping, polishing etc. 
F) Improving properties: heat treatment of steel and aluminum alloys, Fe-C diagram, TTT diagram, and CCT diagram, heat treatment processes annealing, normalizing, quenching tempering, surface modification methods namely without change chemistry, changing chemical composition and development of coating and cladding.

INTENDED AUDIENCE : Any interested learners

Learners enrolled: 1521


Course Status : Upcoming
Course Type : Core
Duration : 12 weeks
Start Date : 20 Jul 2020
End Date : 09 Oct 2020
Exam Date : 18 Oct 2020
Enrollment Ends : 27 Jul 2020
Category :
  • Mechanical Engineering
  • Level : Undergraduate/Postgraduate
    This is an AICTE approved FDP course


    Week 1 : Understanding Manufacturing
    Fundamental approaches of manufacturing
    Manufacturing process specific advantages and limitation
    Materials and manufacturing processes
    Classification of manufacturing processes

    Week 2 : Selection of manufacturing processes 
    Application of manufacturing processes 
    Effect of manufacturing processes on properties of metals
    Break-even point analysis in manufacturing processes
    Metal Casting: Introduction & Suitability

    Week 3 : Metal Casting: Steps of casting processes
    Metal Casting: Terminology
    Metal Casting: Pattern allowances I
    Metal Casting: Pattern allowances II
    Metal Casting: Sand Moulding I

    Week 4 : Metal Casting: Sand Moulding II
    Metal Casting: Core & Core Prints 
    Metal Casting: Gating System 
    Metal Casting: Yield 
    Metal Casting: Riser Design

    Week 5 : Metal Casting: Cleaning of casting
    Metal Casting: Casting defects & their prevention
    Metal Casting: Shell molding  
    Metal Casting: Investment and permanent mould casting
    Metal working processes: Hot and cold working 

    Week 6 : Metal working processes: Rolling
    Metal working processes: Forging 
    Metal working processes: Extrusion
    Metal working processes: Wire Drawing
    Metal working processes: Press

    Week 7 : Metal working processing: Sheet metal operations (Shearing)
    Metal working processing: Sheet metal operations II
    Metal working processing: Sheet metal operations III
    Metal working processing: Dies and die set
    Material removal processes: Machining

    Week 8 : Material removal processes: Mechanism of the metal cutting
    Material removal processes: Chip Formation
    Material removal processes: Types of chips and power consumption
    Material removal processes: Heat generation
    Material removal processes: Tool failure and tool life

    Week 9 : Material removal processes: Tool materials
    Material removal processes: Cutting fluids
    Material removal processes: Grinding I
    Material removal processes: Grinding II
    Material removal processes: Grinding III

    Week 10 :Material removal processes: Grinding operations
    Joining of metals: Fundamentals I
    Joining of metals: Fundamentals II
    Joining of metals: Welding processes I
    Joining of metals: Brazing, soldering and weldability

    Week 11 :Joining of metals: Weldability and welding defects
    Heat treatment: Fundamentals   
    Heat treatment: Fundamentals II
    Heat treatment: Fundamentals III
    Heat treatment: Normalizing and hardening

    Week 12 :Heat treatment: Tempering
    Improving surface properties: Introduction
    Improving surface properties: Surface modification processes I
    Improving surface properties: Changing chemical composition
    Improving surface properties: Coating


    M P Grover, Modern Manufacturing Processes, John Wiley (2002). 
    S Kalpakkajian, S R Schmid, Manufacturing Engineering and Technology, Pearson (2000)DeGarmo et al. Materials and Processes in Manufacturing, Prentice Hall of India, (1997).
    R S Parmar, Welding process and technology, Khanna Publisher, New Delhi (2004).
    P N Rao, Manufacturing Technology Vol. I & II, Tata McGraw Hill (2009).


    Prof. D K Dwivedi

    IIT Roorkee
    D K Dwivedi obtained BE (mechanical engineering), in 1993 from GEC Rewa, ME (welding engineering) from Univ. of Roorkee in 1997 and PhD in Met. Engineering from MNIT, Jaipur in 2003. He has about 9 years teaching experience at NIT Hamirpur and 14 years at IIT Roorkee in subjects related with manufacturing at UG level and welding engineering related subjects at PG level. He has published more than 120 research papers in SCI/SCIE indexed journals and undertaken 20 sponsored research and 50 industrial consultancy projects. He has authored two books entitled Production and Properties of Cast Al-Si Alloys with New Age International, New Delhi (2013) and Surface Engineering with Springer, New Delhi (2018).


    The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.
    The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).
    Date and Time of Exams: 18 October 2020 Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.
    Registration url: Announcements will be made when the registration form is open for registrations.
    The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.
    Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.


    Average assignment score = 25% of average of best 8 assignments out of the total 12 assignments given in the course.
    Exam score = 75% of the proctored certification exam score out of 100

    Final score = Average assignment score + Exam score

    YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75. If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.

    Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Roorkee.It will be e-verifiable at nptel.ac.in/noc

    Only the e-certificate will be made available. Hard copies will not be dispatched.

    Once again, thanks for your interest in our online courses and certification. Happy learning.

    - NPTEL team