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DI03000161 · Semester 3 · 5G scheme

Manufacturing Engineering-I

Notes and solutions following the Gujarat Technological University (GTU) syllabus for DI03000161. Independent material — not issued by the university.

Mechanical EngineeringMechatronics Engineering

Materials

Syllabus

The official syllabus this material follows.

  • Syllabus

    7 pages

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Complete Book

The whole syllabus, unit by unit, written for the exam.

Slides

Lecture slides for revision.

Past Papers

Original question papers from previous exams.

  • Summer 2026 question paper

    3 pages

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  • Winter 2025 question paper

    4 pages

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PYQ Solutions

Past university papers, fully solved.

  • Solved past papers — detailed answers

    41 pages · English + ગુજરાતી

    Premium Preview · 3 pages

Syllabus units

Unit 1: Metal casting processes
  • 1.1 Basic concept, advantages, Limitations and applications of Casting process.
  • 1.2 Steps of sand moulding process.
  • 1.3 Pattern: Definition, Types, materials, Applications and allowances, Basic numerical problems on calculation of various types of pattern allowances.
  • 1.4 Cores: Need, Types
  • 1.5 Sand : Types, properties, binders
  • 1.6 Gating system: Components, Types, Advantages & limitations.
  • 1.7 Mould making equipments.
  • 1.8 Furnaces: i. Crucible furnace ii. Pit furnace iii. Electric furnace iv. Cupola.
  • 1.9 Special Casting processes: Basic principle and applications of i. Centrifugal casting. ii. Die casting. iii. Investment casting
  • 1.10 Casting defects - types, causes, effects and remedies.
  • 1.11 Safety precautions in Casting processes.
  • 1.12 Basic numerical problems on cost estimation in pattern making and Casting process.
Unit 2: Metal joining processes
  • 2.1 Classification of metal joining processes.
  • 2.2 Working principle, equipment, consumables, advantages, limitations and applications of following metal joining processes. (i) Arc welding: Metal Arc Welding, MIG (Metal Inert Gas), TIG (Tungsten Inert Gas), Submerged arc welding. (ii) Gas welding: Oxy-acetylene Gas welding, cutting, Types of flames. (iii) Resistance welding: Spot welding set up and working only. (iv) Thermit welding.
  • 2.3 Types of weld joints
  • 2.4 Soldering: Procedure and Applications only
  • 2.5 Brazing: Procedure and Applications only
  • 2.6 Comparison of Welding, Brazing and Soldering.
  • 2.7 Safety precautions in metal joining processes.
  • 2.8 Basic numerical problems on cost estimation of Gas and Arc welding.
Unit 3: Metal Forming Processes
  • 3.1 Differences between hot and cold working processes
  • 3.2 Metal forming processes: i. Forging: Types, Applications, defects ii. Rolling: Working principle, applications, Types of rolling mills, defects iii Drawing: Types, applications iv Extrusion: Methods, applications
  • 3.3 Safety precautions in metal forming processes
  • 3.4 Basic numerical problems on cost estimation of forging including various losses.
Unit 4: Plastic Moulding Processes
  • 4.1 Plastic materials: Classification with SPI codes, Properties and applications of PETE, HDPE, PVC, LDPE, PP, PS, ABS, PC, Nylon.
  • 4.2 Construction, Working and Applications of: i. Injection moulding ii. Blow moulding iii. Extrusion moulding iv. Rotational moulding v. Compression moulding
  • 4.3 Construction of Injection mould with functions of its components.
  • 4.4 Selection of moulding process for various commonly used plastic products.
  • 4.4 Safety precautions in plastic processing.

About this course

Manufacturing Engineering-I provides essential knowledge and practical skills required to produce components and products using metal casting, metal forming, metal joining, and plastic moulding processes. A Manufacturing Engineer plays a crucial role in engineering industries and must be well-versed in these manufacturing techniques. This course emphasizes skill development through hands-on practice integrated into each topic area, thereby enabling students to understand and apply the principles effectively. Manufacturing processes are the foundation of all engineering industries, and proficiency in them is critical for the development of a robust domestic manufacturing sector-key to achieving the national vision of 'Make in India.' The processes covered-metal forming, casting, welding, and plastic moulding- are extensively used in industries such as automotive, machinery, construction, and aerospace. Hence, this course aims to equip students with industry-relevant knowledge and abilities to contribute meaningfully to such sectors.