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## GUJARAT TECHNOLOGICAL UNIVERSITY

## Program Name: Diploma Engineering

## Level: Diploma

## Branch: Mechanical Engineering Subject Code: DI05019011

Subject Name:  Manufacturing Engineering - III

w. e. f. Academic Year:

2026-27

Semester:

5 th

Category of the Course:

PCC

To  successfully  engage  with  this  course,  the  students  must  have  a  strong foundation  in  Manufacturing  Engineering-I  &amp;  II,  specifically  demonstrating proficiency  in  the  conventional  machining  operations  like  turning,  milling  and drilling. Competency in Computer-Aided Design (CAD) is essential for creating and  interpreting  3D  geometric  models,  while  a  fundamental  understanding  of Engineering Materials ensures proper material selection for various production processes. The prior workshop experience with machining tools, equipment and safety practices will help in effective learning of the manufacturing operations.

Prerequisite:

Rationale:

Manufacturing Engineering -III provides knowledge and practical understanding of modern manufacturing methods used in present-day industries. The course covers gear and thread manufacturing, jigs and fixtures, press  tools,  non-conventional  machining  processes,  advanced  manufacturing systems and additive manufacturing technologies. It also introduces students to automation, flexible manufacturing systems, MEMS and Industry 4.0 concepts used in the smart manufacturing environments. The course develops the ability to  select  suitable  manufacturing  processes  based  on  the  material,  required accuracy, productivity and cost requirements. This course helps in bridging the gap  between  conventional  and  advanced  manufacturing  technologies  and prepares  the  students  for  modern  manufacturing  industries  aligned  with  the vision of 'Make in India.'

## Course Outcomes:

After completion of the course, the student will be able to:

|   No | Course Outcomes                                                                                                                                     |
|------|-----------------------------------------------------------------------------------------------------------------------------------------------------|
|   01 | Design a jig/fixture/press tool layout for a given simple component.                                                                                |
|   02 | Select suitable gear and thread manufacturing processes based on accuracy, production rate  and application.                                        |
|   03 | Select appropriate non-conventional machining processes and apply basic MEMS concepts  in engineering applications.                                 |
|   04 | Identify  suitable  advanced  manufacturing  systems  to  improve  a  given  conventional  production setup for better productivity and efficiency. |

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## GUJARAT TECHNOLOGICAL UNIVERSITY

## Program Name: Diploma Engineering Level: Diploma

## Branch: Mechanical Engineering

Subject Code: DI05019011

Subject Name:  Manufacturing Engineering - III

05

Select suitable additive manufacturing processes/materials/parameters for simple component.

## Teaching and Examination Scheme:

| Teaching Scheme  (in Hours)   | Teaching Scheme  (in Hours)   | Teaching Scheme  (in Hours)   | Total Credits  L+T+ (PR/2)   | Assessment Pattern and Marks   | Assessment Pattern and Marks   | Assessment Pattern and Marks   | Assessment Pattern and Marks   | Total  Marks   |
|-------------------------------|-------------------------------|-------------------------------|------------------------------|--------------------------------|--------------------------------|--------------------------------|--------------------------------|----------------|
| L                             | T                             | PR                            | C                            | Theory                         | Theory                         | Tutorial / Practical           | Tutorial / Practical           |                |
| L                             | T                             | PR                            | C                            | ESE(E)                         | PA(M)                          | PA (I)                         | ESE (V)                        |                |
| 3                             | 0                             | 2                             | 4                            | 70                             | 30                             | 20                             | 30                             | 150            |

## Course Content:

|   Unit  No. | Content                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                             |   No. of  Hours |   % of  Weightage |
|-------------|-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|-----------------|-------------------|
|           1 | Production Tooling: Jigs, Fixtures & Press Tools  Principles of Location and Clamping  1.1 Need for jigs and fixtures  1.2 Degrees of freedom and 3-2-1 location principle  1.3 Locator (pin, button, V, nest locator) and Clamps (strap and C-clamp)  Jigs:  1.4 Types, construction and applications (plate, box, leaf and channel jig)      1.5  Drill bushes: Types (fixed and renewable) and applications  Fixtures:   1.5 Milling, turning, welding and assembly fixtures.  Press Tools:  1.6 Construction, working and application of press tool  1.7 Sheet metal operations (shearing, blanking, piercing and bending)  1.8 Types of dies: simple, compound and progressive |              10 |                22 |
|           2 | Gear & Thread Manufacturing Processes Gear Manufacturing Processes 2.1 Types and applications of gears  2.2 Gear terminology  2.3 Classification of gear manufacturing  2.4 Gear Forming Processes  • Gear milling using form milling cutter.  (Principle, indexing, advantage and limitations)                                                                                                                                                                                                                                                                                                                                                                                     |              09 |                20 |

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## GUJARAT TECHNOLOGICAL UNIVERSITY

Program Name: Diploma Engineering Level: Diploma Branch: Mechanical Engineering Subject Code: DI05019011

Subject Name:  Manufacturing Engineering - III

|    | 2.5 Gear Generating Processes  • Gear hobbing and gear shaping using  pinion cutter       (Working    principle,  tool  geometry,  application,  advantage  and  limitation)   2.6 Gear Finishing Processes (need and types)  2.7 Gear  shaving  and  grinding  (principle,  applications,  achievable  accuracy)  Thread Production Processes  2.8 Thread terminology and application   2.9 Thread cutting   • By single-point cutting tool   • By taps and dies  2.10 Thread rolling   • By flat-die  • By cylindrical-die                                                                                                                                                                                                                                                                                                                                            |    |    |
|----|-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|----|----|
|  3 | Non-conventional and Advanced Methods of Machining.  3.1 Need of non-conventional machining and comparison between  conventional & non-conventional machining methods.  3.2  Classification, working principles, application and working  parameters of the following non-conventional machining methods:   Electro chemical machining (ECM).   Electro discharge machining (EDM) including wire cut and dies  sinking.   Ultrasonic machining (USM).   Laser beam machining (LBM).   Abrasive jet machining (AJM).   Plasma arc machining (PAM)   Water jet machining (WJM)  3.3 Criterion for selection of non-conventional machining methods.  3.4 Introduction to MEMS and its characteristics  3.5 Materials used in MEMS   3.6 Basic micro-fabrication techniques (lithography, etching, deposition)  3.7 Applications of MEMS in engineering and industry | 10 | 22 |

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## GUJARAT TECHNOLOGICAL UNIVERSITY

Program Name: Diploma Engineering Level: Diploma Branch: Mechanical Engineering Subject Code: DI05019011

Subject Name:  Manufacturing Engineering - III

| 4.1 Group Technology and Cellular Manufacturing  1. GT - concept, definition & benefits.  2. GT Layout - concept, need, benefits, comparison with  conventional layout with examples  3. Part features - concept, types and examples.   4. Part family - concept, approach to form cell using part families.  4.2 Computer Integrated Manufacturing (CIM)  1. CIM concept: Need, block diagram and functional areas covered  and their importance   | 18   |
|-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|------|
| Additive Manufacturing & Modern Trends  5.1 Introduction to Additive Manufacturing  5.2 Principle, AM Process Chain, STL File Format (Concept), AM  Materials Overview  5.3 Polymer-Based AM Processes: Fused Deposition Modelling (FDM),                                                                                                                                                                                                           |      |

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## GUJARAT TECHNOLOGICAL UNIVERSITY

## Program Name: Diploma Engineering

## Level: Diploma

## Branch: Mechanical Engineering

Subject Code: DI05019011

Subject Name:  Manufacturing Engineering - III

| predictive maintenance, process optimization - introduction   |    |     |
|---------------------------------------------------------------|----|-----|
| Total                                                         | 45 | 100 |

## Suggested Specification Table with Marks (Theory):

| Distribution of Theory Marks   | Distribution of Theory Marks   | Distribution of Theory Marks   | Distribution of Theory Marks   | Distribution of Theory Marks   | Distribution of Theory Marks   |
|--------------------------------|--------------------------------|--------------------------------|--------------------------------|--------------------------------|--------------------------------|
| R Level                        | U Level                        | A Level                        | N Level                        | E Level                        | C Level                        |
| 20                             | 24                             | 26                             | 00                             | 00                             | 00                             |

Where R: Remember; U: Understanding; A: Application, N: Analyze and E: Evaluate C: Create (as per Revised Bloom's Taxonomy)

## References/Suggested Learning Resources:

|   Sr.  No | Title of Book                                                | Author                                    | Publication with place, year  and ISBN             |
|-----------|--------------------------------------------------------------|-------------------------------------------|----------------------------------------------------|
|         1 | Manufacturing Science                                        | Amitabha Ghosh & A. K.  Mallik            | East-West Press,   New Delhi                       |
|         2 | Modern Machining Processes                                   | P.C. Pandey & H.S. Shan                   | McGraw Hill Education,  New Delhi, Latest Edition, |
|         3 | Machine tools technology                                     | G. S. Kandasami                           | Khanna Publishers                                  |
|         4 | Workshop Technology I & II                                   | Raghuwanshi                               | Dhanpat Rai and Company  Pvt. Limited              |
|         5 | Production Technology (Manufacturing  Process)               | Dr. P.C. Sharma                           | S. Chand                                           |
|         6 | Advanced Machining Processes                                 | V. K. Jain                                | Allied Publishers,   New Delhi                     |
|         7 | Rapid Prototyping Technology                                 | C. P. Paul                                | McGraw Hill, India                                 |
|         8 | Computer Integrated Manufacturing                            | K. K. Singh                               | Khanna Publishing House,  India                    |
|         9 | Production Technology                                        | R. K. Jain and S. C.  Gupta               | Khanna Publishers                                  |
|        10 | Elements of Workshop Technology  Volume No. II Machine Tools | Hajra Choudhary, Bose  S. K., Roy Nirjhar | Media Promoters and  Publishers Pvt. Limited       |

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## GUJARAT TECHNOLOGICAL UNIVERSITY

## Program Name: Diploma Engineering

## Level: Diploma

## Branch: Mechanical Engineering Subject Code: DI05019011

Subject Name:  Manufacturing Engineering - III

|   Sr.  No | Title of Book                                     | Author                                  | Publication with place, year  and ISBN   |
|-----------|---------------------------------------------------|-----------------------------------------|------------------------------------------|
|        11 | M.E.M.S.: Fundamental Technology and  Application | Vikas Choudhary,  Krzysztof Iniewski    | CRC Press                                |
|        12 | Production Technology                             | Hindustan Machine  Tools) HMT           | Tata Mcgraw-Hill Publishing  Co.         |
|        13 | Workshop Technology - Part I                      | Dr. W. A. J. CHAPMAN  2011 by Routledge |                                          |
|        14 | All about Machine Tools                           | HEINRICH GERLING                        | New Age International  Private Limited   |

## Open Source Software and Websites:

- i. https://www.youtube.com/watch?v=7yzvno4AvKw
- ii. https://www.youtube.com/watch?v=vOo2MCYPsm4
- iii. https://nptel.ac.in/courses/112105127
- iv. http://nptel.iitm.ac.in/video.php?subjectId=112105126
- v. http://nptel.iitm.ac.in/courses/Webcoursecontents/IIT%20Kharagpur/Manuf%20Proc%20II/pdf/L M-01.pdf
- vi. https://www.youtube.com/watch?v=tiarT1YS-lM
- vii. https://nptel.ac.in/courses/112104181
- viii. https://nptel.ac.in/courses/112/105/112105126/
- ix. https://nptel.ac.in/content/storage2/courses/112105127/pdf/LM-32.pdf
- x. https://nptel.ac.in/content/storage2/courses/112105127/pdf/LM-31.pdf
- xi. https://nptel.ac.in/courses/112/104/112104028/
- xii. https://archive.nptel.ac.in/courses/112/104/112104289/
- xiii. https://www.me.iitb.ac.in/~ramesh/courses/ME338/non\_trad.pdf
- xiv. http://home.iitk.ac.in/~nsinha/Non-traditional-machining.pdf
- xv. http://www.youtube.com/watch?v=bmooEZyivxo
- xvi. http://www.youtube.com/watch?v=mWy9awGv6so
- xvii. http://www.youtube.com/watch?v=mKES5Fyz9l0
- xviii. http://www.youtube.com/watch?v=BgGXQUeYNKw
- xix. ihttp://www.youtube.com/watch?v=eaeEn1Gs4aQ
- xx. http://www.youtube.com/watch?v=49GpJ7yhecg
- xxi. http://www.youtube.com/watch?v=XfYXelZ4IaY
- xxii. http://www.youtube.com/watch?v=pI1QGpmKqow
- xxiii. https://www.youtube.com/watch?v=NkC8TNts4B4
- xxiv. https://www.youtube.com/watch?v=KJj8CfnC0Ek
- xxv. https://onlinecourses.nptel.ac.in/noc21\_me115/p

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## GUJARAT TECHNOLOGICAL UNIVERSITY

Program Name: Diploma Engineering Level: Diploma Branch: Mechanical Engineering Subject Code: DI05019011

Subject Name:  Manufacturing Engineering - III

## Suggested Course Practical List:

|   Sr.  No. | Practical Outcomes (PrOs)                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                               |   Unit        No. |   Approx  Hrs.  Required |
|------------|-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|-------------------|--------------------------|
|          1 | Design  a  jig/fixture/press  tool  layout  for  a  given  simple  component  and  prepare the related drawings.  Production Tooling: Jigs, Fixtures & Press Tools                                                                                                                                                                                                                                                                                                                                                                                                                      |                 1 |                       08 |
|          2 | Gear cutting:  Prepare  a  simple  spur  gear  using  milling  operation  including  use  of  the  indexing head. The student will also prepare a report including:  a. Drawing of the job Gear.  b. Equations  to  find  module,  pitch  circle  diameter,  outside  diameter,  circular pitch and the number of teeth.  c. Produce  spur  gear  on  milling  machine  using  indexing  head.  Calculate/select, set, observe and record the cutting parameters.   d. List  the  cutting  tools  and  work  holding  device  you  have  used.  Also  state the specifications of each. |                 2 |                       08 |
|          3 | Non-Conventional Manufacturing Processes   Prepare a case study on any component which are manufactured by using  any Non-Convectional manufacturing processes.   Neat sketch or drawing of the component.   Working principle of the selected manufacturing process.   Materials used for the component and tool/equipment.   Process parameters used during manufacturing.  Advantages and limitations of the selected process                                                                                                                                                   |                 3 |                       04 |
|          4 | Advanced Manufacturing Systems   Analyze  a  given  case  study  of  a  conventional  manufacturing  unit  and  suggest suitable AMS elements (GT cell, CIM integration, or FMS) to  improve productivity and efficiency.  E.g.    A  small  auto  component  manufacturer  in  Rajkot  produces  15                                                                                                                                                                                                                                                                                    |                 4 |                       04 |

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## GUJARAT TECHNOLOGICAL UNIVERSITY

## Program Name: Diploma Engineering

## Level: Diploma

## Branch: Mechanical Engineering Subject Code: DI05019011

Subject Name:  Manufacturing Engineering - III

| Sr.  No.   | Practical Outcomes (PrOs)                                                                                                                                                                                                                                                                                                                                                                                                                   | Unit        No.   |   Approx  Hrs.  Required |
|------------|---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------|-------------------|--------------------------|
| 5          | different shaft variants on 8 conventional machines arranged in a process  layout. Set-up times are high, WIP inventory is large and lead time is 12  days. Suggest how AMS concepts can improve this situation. Prepare a  case study report.   Additive Manufacturing (AM)  Prepare a simple job on 3D Printer/ Additive Manufacturing (AM)  a. To develop CAD models using 3D Scanner/Software for 3D printer.  b. Use slicing software. | 5                 |                       06 |
|            |                                                                                                                                                                                                                                                                                                                                                                                                                                             | Total             |                       30 |

## List of Laboratory/Learning Resources Required:

These  major  equipment  with  broad  specifications  for  the  PrOs  is  a  guide  to  procure  them  by  the administrators to user in uniformity of practical in all the institutions across the state.

|   Sr.  No. | Equipment Name with Broad Specifications      | PrO. No.   |
|------------|-----------------------------------------------|------------|
|          1 | Milling Machine with Dividing/Indexing Head   |            |
|          2 | Spur Gear Milling Cutters (Different Modules) |            |
|          3 | Jig and Fixture Models                        |            |
|          4 | Press Tool / Die Models                       |            |
|          5 | EDM Machine / Demonstration Setup             |            |
|          6 | CAD/CAM Software                              |            |
|          7 | 3D Printer (FDM Type Preferred)               |            |
|          8 | PLA/ABS Filament Materials                    |            |
|          9 | Slicing Software for 3D Printing              |            |
|         10 | MEMS Demonstration Kit / Charts               |            |

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## GUJARAT TECHNOLOGICAL UNIVERSITY

Program Name: Diploma Engineering Level: Diploma Branch: Mechanical Engineering Subject Code: DI05019011

Subject Name:  Manufacturing Engineering - III

## Suggested Student Activities:

Other than the classroom and laboratory learning, following are the suggested student-related co-curricular activities which can be undertaken to accelerate the attainment of the various outcomes in this course. The students  should  perform  the  following  activities  in  groups  and  prepare  reports  of  about  5  pages  for  each activity.  They  should  also  collect/record  physical  evidences  for  their  (student's)  portfolio  which  may  be useful for their placement interviews:

1. Prepare a working sketch/model of a simple jig or fixture.
2. Visit nearby manufacturing industry/tool room and prepare an industrial visit report.
3. Perform indexing calculation and spur gear cutting on a milling machine.
4. Prepare seminar/presentation on the non-conventional machining processes.
5. Develop case study on EDM/ECM/WJM industrial applications.
6. Conduct group discussions on the advantages of FMS and CIM.
7. Design a simple CAD model and manufacture using 3D printer.
8. Prepare a chart/model showing Industry 4.0 concepts and smart manufacturing systems.
9. Prepare comparative studies of conventional and additive manufacturing methods.
10. Prepare a report/presentation on latest trends in additive manufacturing such as WAAM and metal 3D printing.

* * * * * * *