Theory of Production Processes

By Prof. Pradeep Kumar Jha   |   IIT Roorkee
Learners enrolled: 717
The course focuses on understanding the science behind technology of primary production processes namely casting, forming and welding. Conventionally, the courses on manufacturing processes deal with study of operational procedures. However, it is desirable to know how any process occurs and the products are finally manufactured, the basic principles behind these processes are required to be highlighted. The course will make the students aware with the theoretical aspects of the different manufacturing processes mentioned above. The course has been divided into three sections namely casting, forming and welding, each being covered in 4 weeks of time. The underlying principles of solidification, fluidity, gating, risering, melting etc. will be covered in casting section whereas mechanics of metalworking, analysis of different metal working processes will be covered in the second section i.e. forming. In the third section i.e. welding, principles of welding processes, thermal effects, weldability etc. will be covered. The course will enable the students be conversant with working principles so that they can use the knowledge gained towards increasing the productivity of manufacturing industries in the long run.

PREREQUISITES:    Introduction to manufacturing technology or manufacturing processes.           
INDUSTRY SUPPORT:   Manufacturing Industries where casting/forming/welding takes place, for example SAIL, BHEL, Foundry and Forge industries like HEC, Bharat Forge etc.
Course Status : Completed
Course Type : Core
Duration : 12 weeks
Category :
  • Mechanical Engineering
  • Manufacturing Processes and Technology
Credit Points : 3
Level : Undergraduate
Start Date : 25 Jul 2022
End Date : 14 Oct 2022
Enrollment Ends : 08 Aug 2022
Exam Date : 30 Oct 2022 IST

Note: This exam date is subjected to change based on seat availability. You can check final exam date on your hall ticket.

Page Visits

Course layout

Week 1:Theory of casting and solidification, Fluidity of liquid metals.
Week 2:Technology of patternmaking and mouldmaking, Pattern allowances, Testing of molding sand, cores.
Week 3:Gating system design,  Risering Design, different methods of calculating riser volume, Feeding distance calculations.
Week 4:Theory of melting and production of ferrous and non-ferrous materials, Casting design, Casting defects.
Week 5:Mechanical fundamentals of metalworking: Concept of stress and strain, stress and strain tensors, Hydrostatic and deviatoric stresses, Flow curve.
Week 6:Yield criteria for ductile materials, plastic stress strain relationships, classification of metalworking, mechanics of metalworking.
Week 7:Analysis and classification of rolling and forging processes, Force calculations in rolling and forging processes.
Week 8:Analysis and classification of Extrusion process, Analysis of wire, rod and tube drawing processes, Forming defects.
Week 9:Classification of welding processes, Thermal effects in welding, Basic metallurgy of fusion welds, Heat affected zone in welding.
Week 10: Principles of welding processes: Arc welding, Gas metal arc welding, Solid state welding, Resistance welding, Soldering, Brazing and adhesive bonding.
Week 11:Residual stresses in welding, Methods of measurement of residual stresses in welding, Welding distortion and its types, Methods of reducing residual stresses and distortion in welding.
Week 12:Weldability of materials: Introduction and assessment of weldability, Test for weldability, Weldability of ferrous and non-ferrous materials.

Books and references

1.Ghosh, A., and Mallik, A.K., Manufacturing Science, Affiliated East-West Press Pvt. Ltd. 
2.Heine, R.W., Loper, C.R., and Rosenthal, P.C., “Principles of Metal Casting”, TMH 
3.Dieter Feorge E., “Mechanical Metallurgy”, McGrawHill 
4.Kuo, S., “Welding Metallurgy”, John-Wiley & Sons Inc

Instructor bio

Prof. Pradeep Kumar Jha

IIT Roorkee
Dr Pradeep K. Jha is presently working as Associate Professor in the Department of Mechanical & Industrial Engineering at IIT Roorkee. He has been teaching the courses related to manufacturing technology and theory of production processes to undergraduate and postgraduate students for more than 12 years. He is actively involved in research work related to production processes, tundish steelmaking process, mold solidification in continuous casting etc.

Course certificate

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: 30 October 2022 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

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