Bachelor of Mechanical Engineering

Department of Mechanical Engineering

MANUFACTURING PROCESSES
(Date of document: 1st May 2016)

Course Code : MEFB 213

Course Status : Core
Level : Degree
Semester Taught : 3
Credit : 3
Pre-requisites : MEFB121 Manufacturing Process Lab

Assessments : Assignments 5%
Quizzes 5%
Mini projects 20%
Midterm 20%
Final Examination 50%

Lecturers : Mr. Vignesh Vicki a/l Wanatasanapan

Room BN-0-030, ext. 6330
E-mail: vignesh@uniten.edu.my

Mohamed Ansari M. Nainar, Assoc. Prof. Dr.

Room BN-1-026, ext. 2213
E-mail: Ansari@uniten.edu.my

Course Description : This course provides the scientific basis of manufacturing

processes in many aspects. This course focuses on material
properties and further expands to the different types of
manufacturing application processes. A brief overview on the
different types of machining processes example lathe, milling,
grinding with its associated calculation are being focused. A
general overview on welding process, grinding process, and press
working was introduced. Apart from traditional
manufacturing processes as mention previously other types of
non-traditional machining processes example Ultrasonic
Bachelor of Mechanical Engineering
Department of Mechanical Engineering

machining (UM), electric discharge machining (EDM) was

introduced. The syllabus concluded with the final finishing
processes and industrial practices example the application of
ISO 9001 and ergonomic methods of work handling.

Course Objectives : At the end of the course the students should be able to:
1) To educate students with fundamental of manufacturing
processes that changes the raw materials to
create products or output

2) To analyze the processes and machines element based on

materials properties

Transferrable Skills : Students are required to gain basic understanding in the different
types of manufacturing processes. Students are also exposed to
real life manufacturing industries which require them to observe a
manufacturing process, compile findings in a form of report and
also present it.

Course Outcomes (CO)

- what students to achieve and to be assessed upon completing this course

No. Upon completion of this course, the student should be able to:
Explain / describe the general aspects of manufacturing including manufacturing
CO1 model, classification steps in manufacturing, process and material selection criteria
and producibility principles
Distinguish the characteristics of each process including process parameters and
CO2
materials that can be processed

CO3 Calculate machining time, material removal rate and cutting speed accordingly

Comprehend basic non-traditional manufacturing processes and new aspects in

CO4
manufacturing.
Bachelor of Mechanical Engineering
Department of Mechanical Engineering

CO5 State the theory and principles of various manufacturing processes

CO6 Make technical and written presentations

Assess the right technique and suitable material for the appropriate manufacturing
CO7
processes

CO8 Delegate task as a team

CO9 Keep up with the latest trend and technology used in the industry
Bachelor of Mechanical Engineering
Department of Mechanical Engineering

Course Outline:

Topic 1: INTRODUCTION TO MANUFACTURING SYSTEM

 Course introduction
 Introduction to manufacturing
 Design, material and production

Topic 2: NATURE AND PROPERTIES OF MATERIAL

 Classification of materials
 Engineering properties of materials

Topic 3: FOUNDRY PROCESSES

 Sand casting and moulding processes

 Gating system and solidification characteristics
 Patterns
 Sand technology
 Composites

Topic 4: CONTEMPORARY CASTING PROCESSES

 Die casting
 Permanent mould casting
 Centrifugal casting

Topic 5: METAL CUTTING

 Metal cutting theory
 Metal cutting tools chip shape and formation
 Coolants
 Machinability
 Tool life

Topic 6: MACHINING CUTTERS, PERFORMANCE AND OPERATIONS

 Turning tools
 Drills
 Reamers
 Milling cutters

Topic 7: GRINDING AND ABRASIVE PROCESSES

 Grinding and abrasive practice
 Grinding process
 Abrasive, grinding wheel and stones
Bachelor of Mechanical Engineering
Department of Mechanical Engineering

Topic 8: WELDING AND JOINING PROCESSES

 Arc welding
 Oxyfuel gas welding

Topic 9: HOT WORKING OF METALS

 Hot rolling
 Hot forging

Topic 10: COLD WORKING OF METALS

Topic 11: PRESS-WORKING AND OPERATIONS
 Bending and forming
 Shearing
 Drawing

Topic 12: NON-TRADITIONAL PROCESSES

 EDM, ECM, USM, LBM, EBM
 Powder metallurgy (p/m)

Topic 13: FINISH PROCESSES

Topic 14: QUALITY SYSTEMS
 The quality improvement system
 Process variation

15. COMPUTER NUMERICAL CONTROL SYSTEMS

16. PROCESS AUTOMATION
17. OPERATOR-MACHINE SYSTEM

REFERENCES:
Main reference(s) Manufacturing Processes and Systems. Philip
F. Ostwald & Jairo Munoz, 9 th Edition, John
Wiley & Sons, 2006.
Additional reference(s) Manufacturing Engineering and Technology,
Serope Kalpakjian & Steven Schmid Prentice
Hall International, 2006.
Bachelor of Mechanical Engineering
Department of Mechanical Engineering

Course Outcomes :

PO1 PO2 PO3 PO4 PO5 PO6 PO PO PO9 PO PO PO12

Course Outcomes
a b c a b a b c a b c a b a b 7 8 a b c 10 11 a b
CO1: Explain / describe the general aspects of
manufacturing including manufacturing model,
classification steps in manufacturing, process and 
material selection criteria and producibility
principles
CO2: Distinguish the characteristics of each process
including process parameters and materials that can 
be processed
CO3: Calculate machining time, material removal

rate and cutting speed accordingly

CO4: Comprehend basic non-traditional

manufacturing processes and new aspects in 
manufacturing.

CO5: State the theory and principles of various


manufacturing processes

CO6: Make technical and written presentations 

CO7: Assess the right technique and suitable


material for the appropriate manufacturing processes

CO8: Delegate task as a team  

CO9: Keep up with the latest trend and technology


used in the industry
Bachelor of Mechanical Engineering
Department of Mechanical Engineering

Assessment-Course Outcomes Matrix :

PO1 PO1 PO2 PO1 PO1 PO9 PO3 PO10 PO11
Assessments CO1 CO2 CO3 CO4 CO5 CO6 CO7 CO8 CO9
Quizzes (5%)     
Assignments (5%) 
Mini project report (10%)    
Project presentation (5%) 
Peer Evaluation (5%) 
Mid term (20%)    
Final Exam (50%)      

PO emphasis :
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 Total
Current Coverage (%) 36.0 16.0 17.0 0.0 0.0 0.0 0.0 0.0 0.0 7.5 4.5 0.0 100

Bloom's Coverage (%) :

Cognitive
Psychomotor Affective Total
Low Med Hi
Current Coverage (%) 24.0 45.0 0 19.0 12.0 100
 Bachelor of Mechanical Engineering
Department of Mechanical Engineering

What is Program Educational Objectives (PEO)?

PEO are objectives that UNITEN graduates should achieve after five (5) years of graduation.

Summary of BME Programme Educational Objectives (PEO)

Program Educational Objectives

PEO No.
UNITEN produces Mechanical Engineering graduates who:
PEO1 Practicing engineers in mechanical engineering with the ability to venture into energy related business.
PEO2 Hold leadership responsibilities and/or establish their own enterprises.
PEO3 Have professional qualifications/certifications in mechanical engineering related areas.
PEO4 Engages in activities to enhance knowledge in their professional works

What are Programme Outcomes (PO)?

POs are the expected traits that UNITEN students should have upon graduation.

COE Programme Outcomes (PO)

Program Outcomes

PO Students graduating from the Bachelor of Mechanical Engineering (BME) program will have
No. the ability to:

Statement PO Indicators

a)Comprehend the fundamental knowledge of

mathematics, science and mechanical engineering
(C1,C2)
Apply fundamental knowledge of
b) Apply fundamental knowledge of mathematics,
mathematics, science and mechanical
science and mechanical engineering principles in
PO1 engineering principles in solving complex
solving engineering problems (C3, C4)
problems
c) Solve complex engineering problems by
WA1 (WK1-WK4)
relating/incorporating fundamental knowledge of
mathematics, science and mechanical engineering
principles. (C5,C6)

Identify, formulate, analyze and solve a) Identify, formulate and solve mechanical engineering
complex mechanical engineering problems (C3, C4)
PO2
problems b) Evaluate and synthesize the solution to complex
WA2 (WK1-WK4) mechanical engineering problems (C5,C6)
 Bachelor of Mechanical Engineering
Department of Mechanical Engineering

Program Outcomes

PO Students graduating from the Bachelor of Mechanical Engineering (BME) program will have
No. the ability to:

Statement PO Indicators

a) Illustrate solutions for mechanical engineering

Design solutions for complex
mechanical engineering problems that
meet specific needs with appropriate
PO3
consideration for public health and
safety, culture, society, and environment
WA3 (WK5)
problems with appropriate consideration for public
health and safety. (C3, C4)
b) Illustrate solutions for mechanical engineering
problems with appropriate consideration for culture,
society, and environment. (C3, C4)
c) Propose solutions for complex mechanical
engineering problems that meet specific needs with
appropriate consideration for public health and
safety, culture, society, and environment. (C5,C6)

a) Use research methods for collecting data (C1, C2)

Conduct investigations, interpret data
b) Analyze and interpret data using engineering
and provide conclusions in investigating
principles and appropriate techniques (C3,C4)
PO4 complex problems related to mechanical
c) Design & evaluate solutions to complex engineering
engineering
problems by employing research methods and data
WA4 (WK8)
interpretation skills (C5,C6)

Create appropriate techniques, select

a) Usage of modern tools to execute mechanical
resources, and apply modern
engineering activities (P1,P2)
PO5 engineering tools to execute complex
b) Manipulation of modern tool to execute complex
engineering activities
engineering activities (P3,P4)
WA5 (WK6)

Apply reasoning in assessing societal,
health, safety, legal and cultural issues
and the consequent responsibilities
PO6
relevant to professional engineering
practice
WA6 (WK7)
a) Apply reasoning in assessing societal, legal and
cultural issues and the consequent responsibilities
relevant to professional engineering practice (C3, C4)
b) Apply reasoning in assessing health and safety
issues and the consequent responsibilities relevant to
professional engineering practice (C3, C4)

Demonstrate knowledge of the impact

of professional engineering solutions in
PO7 environmental contexts and the need for No sub-attribute (C2,C3)
sustainable development
WA7 (WK7)
 Bachelor of Mechanical Engineering
Department of Mechanical Engineering

Program Outcomes

PO Students graduating from the Bachelor of Mechanical Engineering (BME) program will have
No. the ability to:

Statement PO Indicators

Demonstrate commitment to
PO8 professional and ethical principles No sub-attribute (A3)
WA8 (WK7)

a) Communicate effectively by means of oral

presentation (P3)
Communicate effectively on complex b) Communicate effectively by means of report writing
PO9 engineering activities (P3)
WA10 c) Communicate effectively by means of oral
presentation and/or report writing on complex
engineering activities (P3)
Function effectively as an individual
and in a group with the capacity to be a
PO10 No sub-attribute (A4)
leader
WA9
Acknowledge the need for, and be able
PO11 to engage in life-long learning No sub-attribute (C2)
WA12

Demonstrate knowledge on project a) Demonstrate knowledge on project management

management principles and principles (C2,C3)
PO12
entrepreneurship skills b) Demonstrate knowledge on entrepreneurship skills
WA11 (C2,C3)