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TA202A: Introduction to

Manufacturing Processes(2017-18, 1st semester)

Instructor-in-Charge

Dr. J. Ramkumar

Department of Mechanical Engineering

IIT Kanpur

Email:jrkumar@iitk.ac.in

Course Schedule

Lectures:

Schedule :Tuesday (8:00-9:00 AM)

Venue: L-20

Labs:

Schedule: Monday-Friday (2:00-5:00 PM)

Venue: TA202 ME Lab

Goal: The course aims to impart the basic knowledge about thefundamental manufacturing techniques employed to convert araw material into final product.

Course Contents

1.Introduction: Introduction to manufacturing, evolution of

manufacturing, classification of manufacturing, Materials in

Manufacturing.[2]

2.Conventional Material Removal Processes: Theory of chip

formations, generation of surfaces, force and power relationships,

cutting tool material and its geometry, tool wear and tool life,

fundamentals of machine tools, types of machining operations. [3]

3.Unconventional Material Removal Processes: Introduction, need for

advanced machining processes, classifications: mechanical energy

processes, thermal energy processes, electro chemical machining

etc. [3]

Course Contents

4.Layered/Generative Manufacturing Processes: Fundamentals of

layered manufacturing, layered manufacturing technologies,

classifications of additive manufacturing processes.[2]

5.Computer Numerical Control and Programming: Basics of numerically

controlled machines, programming for NC machines. Programming

examples including turning, drilling, milling etc.[1]

7. Engineering Metrology: Dimensions, limit, fit and tolerances,

surfaces, structure and properties, surface texture and roughness,

engineering metrology and instrumentation.[2]

Reference Books

1. Fundamental of Modern Manufacturing: Materials, Processes and

Systems: M. P. Groover (John Wiley).

2. Manufacturing Science: A. Ghosh and A.K. Mallik (East- West Press).

3. Advanced Machining Processes: V. K. Jain (Allied Publishers).

4. Fundamental of Manufacturing Processes: G. K. Lal and S. K.

Choudhuary (Narosa).

5. Introduction to Micromachining: Ed. V. K. Jain (Narosa).

6. Micro manufacturing Processed: Ed.: V. K. Jain (CRC Press).

7. Manufacturing Processes for Engineering Materials: S. Kalpakliam and

S. R. Schmid (Prentice Hall).

TutorsName Photograph Day Email

Dr. Arvind Kumar Monday arvindkr@iitk.ac.in

Dr. J. Ramkumar Tuesday jrkumar@iitk.ac.in

Dr. S.K. Chaudhury Wednesday choudhary@iitk.ac.in

Dr. Niraj Sinha Thursday nsinha@iitk.ac.in

Dr. Shantanu Bhattacharya Friday bhattacs@iitk.ac.in

Lab (TA202)

Lab Training first five turns:

1st Turn: Project groups should be formed. (Emphasize in class)

2nd Turn : Project groups name should be given to the tutor.

3rd Turn : Project discussion with Technical Staff / Guide with Material List.

4th Turn : Prototyping submission

5th Turn : Manufacturing drawing submission

6th Turn : The work should start without any loss of time

Topics:

1. Agriculture,

2. Healthcare,

3. Energy,

4. Machines and Mechanisms for play toys

Turning (1 Turn), Milling and Shaper (1 Turn), Drilling Fitting (1 Turn), CNC

demonstration and job design (1 Turn), CNC practice (1 Turn)

Staff Members: TA202 Lab

Ph. No. 7984

P C GOND

pcgond@iitk.ac.in

LAB INCHARGE

G SREENIVASULU

gaddam@iitk.ac.in

H P SHARMA

hpsharma@iitk.ac.in

ANIL KUMAR JHA

anilkjha@iitk.ac.in

AMAN SINGH

amans@iitk.ac.inRAKESH THAPLIYAL

trakesh@iitk.ac.in

NAFE SINGH

nafes@iitk.ac.inNAMDEO B MURKHE

nbmurkhe@iitk.ac.in

Staff Members :TA202 Lab

KULDEEP VISHWAKARMA

kvish@iitk.ac.inARUN KUMAR DUBEY

arunkd@iitk.ac.inRABINDRA NATH TUDU

rntudu@iitk.ac.in

DHEERAJ KUMAR SONI

dheerajk@iitk.ac.in

RAHUL

rahul@iitk.ac.inMAHESH KUMAR

mahesh@iitk.ac.inKISHAN BABU PRAJAPATI

kishan@iitk.ac.in

GREESH PRATAP

CHATURVEDI

gpratap@iitk.ac.in

Staff Members :TA202 Lab

PANKAJ KUMAR

pankajkm@iitk.ac.inNEERAJ AWASTHI VIPIN KUMAR

Lab Report Template

Grading policy

Theory

(50Marks)

Marks

Mid Semester

Exam

End Semester

Exam

20

30

Lab (50Marks) Marks

Lab Quiz

Lab Exercises

Lab Reports

Guide’s Evaluation

Mid Semester Evaluation

End Semester Project

End Semester report

10.0

02.5

02.5

05.0(Weightage)

10.0

20.0

05.0

To pass this course, one should score

Minimum theory marks ≥ 20% (10/50)

Total marks ≥ 40 %

Information About the Course

TA202A: Introduction to Manufacturing Processes

TA: Technical Arts.

Introduction: Latin verb introducere, refers to a beginning.

Manufacturing: Something made from raw materials by hand or bymachinery.

Process: A series of actions that you take in order to achieve a result.

Manufacturing (Latin word) : Manus (Made) + factus (Hands) : Made by hands.

Present perspective: Involves making products from rawmaterial by various processes, machinery, & operationsfollowing a well organized plan for each activity required.

Really fascinating products

LASER Keyboard Self stirring mug Mug with its own biscuit pocket

A pocket-sized washing machine A solar-powered camping tentFingers engraved water

glass

Prism glassPouring made E-z pan attachment

Dots that let you find

things with your phone

How products have transformed over the years

Changes in life style with product development

Cost fall of components

Tablet average global selling price Microprocessor cost per transistor cycle

Manufacturing sector in India

Make in India, structural reforms will enable

manufacturing sector to drive growth

Contribution of Manufacturing to GDP

Manufacturing & Employment Relation

Manufacturing - Technological

Application of physical and chemical processes to alter the

geometry, properties, and/or appearance of a starting material to

make parts or products

Manufacturing – Economic

Transformation of materials into items of greater value by one or

more processing and/or assembly operations

Manufacturing Industries

Industry consists of enterprises and organizations that produce or supplygoods and services

Industries can be classified as:

1. Primary industries - cultivate and exploit natural resources, e.g.,agriculture, mining

2. Secondary industries - take the outputs of primary industries and convertthem into consumer and capital goods

3. Tertiary industries - service sector

Note: Secondary industries include manufacturing, construction, and electricpower generation

For our purposes, manufacturing means production of hardware – Nuts andbolts, forgings, cars, airplanes, digital computers, plastic parts, and ceramicproducts

Classification of various Manufacturing Processes

Primary forming processes (additive or accretion)

Casting and moulding processes

Powder metallurgy, rapid prototyping

Deforming processes (formatives): (Forging, Rolling, Wire drawing,

etc.)

Secondary (Subtractive) process : Machining processes

Conventional (turning, milling, etc.)

Advanced machining processes (ECM,EDM,LBM etc.)

Joining and fabrication processes (assembly)

Welding, Revetting, Brazing, Soldering, etc.

Cont’d

Finishing and surface treatment processes

Burr removal (de-burring)

Mechanical cleaning and finishing

Chemical cleaning

Coating

Vaporized metal coating

Heat treatment or bulk property enhancing processes

Hardening

Ductility, toughness and Machinability

Strengthening

Classification of Manufacturing processes

Questions

Need to machine newly developed metals and non-metals with special properties that

make them difficult or impossible to machine by conventional methods

Need for unusual and/or complex part geometries that cannot easily be accomplished

by conventional machining.

Need to avoid surface damage that often accompanies conventional machining

Intricate shaped blind hole – e.g. square hole of 15 mm x 15 mm with a depth of 30

mm.

Difficult to machine material – e.g. same example as above in Inconel, Ti alloys or

carbides.

Low Stress Grinding – Electrochemical Grinding is preferred as compared to

conventional grinding

Deep hole with small hole diameter – e.g. φ 1.5 mm hole with l/d = 20

Machining of composites.

Select the suitable manufacturing processes for the following products.

Materials in Manufacturing

Their chemistries are different, and their

mechanical and physical properties are

different. These differences affect the

manufacturing processes that can be used

to produce products from them.

Ashby Curve

Mechanical properties

Tensile strength – Measures the force required to pull something such as rope,wire or a

structural beam to the point where it breaks

Ductility – A measure of how much strain a material can take before rupturing.

Malleability – The pproperty of a material that can be worked or hammered or shaped

without breaking

Brittleness –Breaking or shattering of a material when subjected to stress (when force is

applied to it).

Elasticity – The property of a material that returns to its original shape after stress (e.g.

external forces) that made it deform or distort is removed

Plasticity - The deformation of a material undergoing non-reversible changes of shape in

response to applied forces

Mechanical properties

Toughness – The ability of a material to absorb energy and plastically deform without

fracturing

Hardness – The property of being rigid and resistant to pressure; not easily scratched

Machinability – The property of a material that can be shaped by hammering, pressing,

rolling

Physical properties

Specific heat – The heat required to raise the temperature of one gram of a

substance by one degree centigrade (J/kg K)

Density – Mass per unit volume expressed in such units as kg/cm 3

Thermal conductivity –Rate at which heat flows through a given material (W/m

K).

Melting point – A temperature at which a solid begins to liquify

Electrical conductivity – A measure of how strongly a material opposes the

flow of electric current (Ω⋅m)

Coefficient of thermal expansion – Degree of expansion divided by the change

in temperature (m/°C)

Metals

Usually alloys, which are composed of two or more elements, at least one of

which is metallic. Two basic groups:

1. Ferrous metals - Based on iron, comprises about 75% of metal tonnage

in the world:

Steel and cast iron

2. Nonferrous metals - All other metallic elements and their alloys:

Aluminum, copper, nickel, silver, tin, etc.

Metal properties:

Good conductors of electricity and heat

Lustrous appearance

Susceptible to corrosion

Strong, but deformable

Ceramics

Compounds containing metallic (or semi-metallic) and nonmetallic elements.

Typical nonmetallic elements are oxygen, nitrogen, and carbon

For processing, ceramics divide into:

1. Crystalline ceramics – includes:

Traditional ceramics, such as clay, and modern ceramics, such as alumina (Al2O3)

2. Amorphous :Glasses – mostly based on silica (SiO2)

Properties:

Thermally and electrically insulating

Resistant to high temperatures and harsh environments

Hard, but brittle

Polymers

Compound formed of repeating structural units called mers, whose atoms share

electrons to form very large molecules

Polymer usually consists of carbon plus one or more elements such as hydrogen and

nitrogen

Polyethylene: (the mer unit is C2H4) Polypropylene: (the mer unit is C3H6)

Composed primarily of C and H (hydrocarbons).

Low melting temperature.

Most are poor conductors of electricity and heat.

Many have high plasticity.

A few have good elasticity.

Some are transparent, some are opaque.

Composites

Material consisting of two or more phases that are processed separately and then bonded

together to achieve properties superior to its constituents

Phase - homogeneous mass of material, such as grains of identical unit cell structure in

a solid metal

Usual structure consists of particles or fibers of one phase mixed in a second phase

Properties depend on components, physical shapes of components, and the way they

are combined to form the final material.

In two material system, there are two phases : Primary phase & Secondary phase.

The primary phase forms the matrix within which the secondary phase imbedded

The imbedded phase is also known as dispersed phase or reinforcing phase

Shape Memory Materials

Definition:

Shape Memory Materials (SMM) are those materials which, after being deformedplastically (i.e., permanently) at the room temperature into various shapes, return totheir original shapes upon heating.

Examples:

Typical Shape Memory Alloys are

55% Ni-45%Ti

Copper-Aluminum-Nickel

Copper-Zinc-Aluminum

Iron-Manganese-Silicon

Characteristics:

SMM have good ductility, good corrosion resistance, high electrical conductivity

Behavior of SMM can also be reversible, i.e., shape can switch back and forth uponheating

Applications:

Can be used To generate motion and/or force in temperature sensitive actuators

Eyeglass frames, connectors, clamps and fasteners

Shape Memory Materials

Sell Shape Memory spring Jacket with Shape memory fabric

Shape Memory alloy

Piezoelectric Materials

Piezoelectric materials are materials that produce an electric current when they are

placed under mechanical stress. The piezoelectric process is also reversible, so if you

apply an electric current to these materials, they will actually change shape slightly (a

maximum of 4%).

There are several materials that we have known for some time

that posses piezoelectric properties, including bone, proteins,

crystals (e.g. Quartz) and ceramics (e.g. Lead Zirconate

Titanate).

Biomaterial

A biomaterial can be defined as any substance (other than a drug) or combination of

substances synthetic or natural in origin, which can be used for any period of time, as

a whole or as a part of a system which treats, augments, or replaces any tissue, organ

or function of the body.

Theoretically, any material can be a biomaterial as long as it serves the stated medical

and surgical purposes.

Example of Biomaterial

Ti biomaterial

Biomaterial applications

Orthopedic Applications:

Metallic materials are normally used for load bearing members such as pins and

plates and femoral stems etc.

Ceramics such as alumina and zirconia are used for wear applications in joint

replacements.

Polymers such as ultra high molecular weight polyethylene are used as articulating

surfaces against ceramic components in joint replacements.

Dental Applications:

Metallic biomaterials have been used as pins for anchoring tooth implants and as

parts of orthodontic devices.

Ceramics have found uses as tooth implants including alumina and dental porcelains.

Polymers, are also orthodontic devices such as plates and dentures.

Recap

Overview of the course

Manufacturing: Introduction

Classification of Manufacturing

Materials in Manufacturing

Different Materials in Manufacturing