National University of Sciences & Technology (NUST)
School of Mechanical and Manufacturing Engineering (SMME)
DME-821: Advanced Manufacturing Processes
Course Code: DME-812 Semester: Fall 2022
Credit Hours: 3+0 Prerequisite Codes: -
Instructor: Dr Muhammad Salman Khan Class: MS DME
Office: Room 202 DME building Telephone: +92 (0)51-9085-6047
Lecture Days: Monday E-mail: muhammad.salman@smme.nust.edu.pk
Class Room: 207 SMME Consulting Hours: 1700 to 2000 hrs
Lab Engineer: Nil Lab Engineer Email: Nil
Updates on LMS: Every week
Course Description:
The course covers latest topics in processing and assembly operations for manufacturing, CNC Machining,
Additive Manufacturing, Advanced Composites Manufacturing.
Course Outcomes/Objectives:
Objective:
Student shall be able to understand the operating principles and characteristics of current technologies
in manufacturing for different materials in use. Student will be able to choose a method based on the
requirements of the equipment applications. Insight into the working of processing operations, additive
manufacturing, advanced composite technologies.
Books:
Text Book: • “Fundamentals of Modern Manufacturing; Materials, Processes and Systems”, by M. P.
Groover (Textbook).
• “Advanced Modeling and Optimization of Manufacturing Processes” by R. Venkata Rao 2011
• “Precision Manufacturing” 2008 Springer
Weightage / Grading
Quizzes: 10%
Assignments/presentation: 10%
Projects 10%
Mid Term: 30%
End Semester Exam: 40%
Grading As per NUST statutes
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National University of Sciences & Technology (NUST)
School of Mechanical and Manufacturing Engineering (SMME)
Grading Policy:
Quiz Policy: The quizzes will be unannounced and normally last for ten to fifteen minutes. The question
framed is to test the concepts involved in last few lectures. Number of quizzes that will be used
for evaluation is at the instructor’s discretion. Grading for quizzes will be on a fixed scale of 0
to 10. A score of 10 indicates an exceptional attempt towards the answer and a score of 1
indicates your answer is entirely wrong but you made a reasonable effort towards the solution.
Scores in between indicate very good (8-9), good (6-7), satisfactory (4-5), and poor (2-3)
attempt. Failure to make a reasonable effort to answer a question scores a 0.
Assignment Policy: In order to develop comprehensive understanding of the subject, assignments will be given.
Late assignments will not be accepted / graded. All assignments will count towards the total
(No ‘best-of’ policy). The students are advised to do the assignment themselves. Copying of
assignments is highly discouraged and violations will be dealt with severely by referring any
occurrences to the disciplinary committee. The questions in the assignment are meant to be
challenging to give students confidence and extensive knowledge about the subject matter and
enable them to prepare for the exams.
Lab Conduct: There are no labs associated with the course, however, depending on the COVID 19 situation,
sessions on manufacturing using 3D printers will be arranged for DL mode.
Plagiarism: SMME maintains a zero tolerance policy towards plagiarism. While collaboration in this course
is highly encouraged, you must ensure that you do not claim other people’s work/ ideas as your
own. Plagiarism occurs when the words, ideas, assertions, theories, figures, images,
programming codes of others are presented as your own work. You must cite and acknowledge
all sources of information in your assignments. Failing to comply with the SMME plagiarism
policy will lead to strict penalties including zero marks in assignments and referral to the
academic coordination office for disciplinary action.
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National University of Sciences & Technology (NUST)
School of Mechanical and Manufacturing Engineering (SMME)
Course Plan for DME 811 – Advanced Manufacturing Processes
Week Lecture Hours
Introduction
1 • History of Manufacturing 2
• Manufacturing in Nature
Metal Casting Fundamentals
2 • Solidification and metals and alloys 3
Basics of casting
Conventional and Advanced Metal Casting Processes
• Sand casting
• Die casting
• Conventional Investment Casting
• Centrifugal Casting
• Twin roll casting
• Evaporative pattern casting
3 3
• Vacuum mold casting
• Continuous casting
• Squeeze casting
• Modern Investment Casting
• Metal Spinning
• Batch Casting
4 Forging and Advanced Forging
• Open die forging
• Closed die forging
• Impression die forging 3
• Upset forging
• Swaging and Radial Forging
Forging and Advanced Forging (contd.)
• Roll Forging
• Skew-Rolling Forging
5 • Orbital Forging 3
• Powder forging
• Defects in forging
Rolling and Advanced Rolling Processes
• Hot and cold rolling
• Mechanics of rolling process
• Shape rolling 3
6 • Thread rolling
• Ring rolling
• Powder rolling
• Gear rolling
• Defects in rolling process
Extrusion Fundamentals
• Direct extrusion
• Indirect extrusion
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National University of Sciences & Technology (NUST)
School of Mechanical and Manufacturing Engineering (SMME)
• Hot extrusion
7 • Hydrostatic extrusion 2
• Impact extrusion
• Factors affecting extrusion
• Metal flow in extrusion
• Defects in extrusion
Advanced Extrusion Processes
• Reinforced Extrusion
8 • Curved Profile Extrusion 3
• Twisted Profile Extrusion
• Helical Profile Extrusion
9 Mid Term
Sheet Metal Forming (SMF)
• Bending
• Bulging
10 • Shearing 3
• Stretch forming
• Rubber forming
Sheet Metal Forming (contd.)
• Sheet hydroforming
• Tube hydroforming
• Explosive forming
11 • Metal spinning 3
• Deep drawing
• Ironing
• Defects in SMF
Advanced machining processes
• Electron beam melting
• Laser beam melting
• Laser beam machining
• Plasma arc welding
12 • Plasma arc cutting 3
• Electron-beam welding
• Laser beam welding
• Laser beam cutting
• Laser beam drilling
Advanced machining processes (contd.)
13 • Electrochemical machining
• Electrical discharge machining
• Chemical machining
• Ultrasonic machining
• Water jet machining
• Abrasive jet machining 3
• Magnetic abrasive machining
• Magnetorheological machining
Rapid prototyping
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National University of Sciences & Technology (NUST)
School of Mechanical and Manufacturing Engineering (SMME)
• Stereolithography
• Solid Ground Curing
• Droplet Deposition Manufacturing
14 • Laminated Object Manufacturing 3
• Fused Deposition Modeling
• Selective Laser Sintering
• Powder 3-D Printing
CNC Manufacturing
• CNC Machine Classification
• CNC Cutting tools
• CNC Programming codes
• 3-axis CNC machining (Milling and Turning)
15 • Multi-axis CNC machining 3
• 5-axis indexed CNC milling
• Continuous 5-axis CNC milling
• Mill turning CNC Centers
• CNC Design Restrictions
Advanced Composite Manufacturing
16 • Advanced manufacturing processes for polymer matrix composites 3
• Advanced manufacturing processes for metal matrix composites
• Advanced manufacturing processes for ceramic matrix composites
17 Presentations/Project 3
18 ESE
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