ta202a: introduction to manufacturing processeshome.iitk.ac.in/~nsinha/introduction.pdf ·...

TA202A: Introduction to

Manufacturing ProcessesManufacturing Processes

N. Sinha

Department of Mechanical Engineering

IIT Kanpur

Email: nsinha@iitk.ac.in

Information About the Course

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

Venue: L-7

Lectures

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

Venue: TA202 ME Lab

http://home.iitk.ac.in/~nsinha/ta.html

Course updates and announcements

TA202 Lab

Information About the Course

TA202A: Introduction to Manufacturing Processes

Introduction: Latin verb introducere, refers to a beginning.

Manufacturing: something made from raw materials by

hand or by machinery.

TA: Technical Arts.

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

a result.

hand or by machinery.

Goal: The course aims to impart the basic knowledge about

the fundamental manufacturing techniques employed to

convert a raw material into final product.

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

5

Manufacturing – Economic

• Transformation of materials into items of greater

value by one or more processing and/or assembly

operations

6

Manufacturing Industries

• Industry consists of enterprises and organizations that produce or supply goods and services

• Industries can be classified as:1. Primary industries - cultivate and exploit natural

resources, e.g., agriculture, miningresources, e.g., agriculture, mining

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

3. Tertiary industries - service sector

7

Manufacturing Industries - Continued

• Secondary industries include manufacturing,

construction, and electric power generation

• For our purposes, manufacturing means

production of hardware

–Nuts and bolts, forgings, cars, airplanes, digital –Nuts and bolts, forgings, cars, airplanes, digital

computers, plastic parts, and ceramic products

8

Manufactured Products

• Final products divide into two major classes:

1. Consumer goods - products purchased directly by consumers

• Cars, clothes, TVs, tennis rackets

2. Capital goods - those purchased by companies to produce goods and/or provide servicesproduce goods and/or provide services

• Aircraft, computers, communication equipment, medical apparatus, trucks, machine tools, construction equipment

9

Manufacturing Processes

Two basic types:

1. Processing operations - transform a work material from one state of completion to a more advanced state

– Operations that change the geometry, properties, – Operations that change the geometry, properties, or appearance of the starting material

2. Assembly operations - join two or more components to create a new entity

10

11

Question

Why do I need this course?

Why theory?

Why lab exercises?

Question

Which Process to Select and Why?

www.wonkeedonkeetools.co.uk

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 machiningconventional 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.

Example

Questions

Questions

http://www.me.iitb.ac.in/~ramesh/courses/ME338/non_trad.pdf

Microfabrication

Miniaturization: Information StorageMiniaturization: Information StorageMiniaturization: Information StorageMiniaturization: Information Storage

Fgure Source: International Data Corporation (IDC)

Data recording on a disc

� The information is transformed to strings of binary digits (0s and 1s,

also called bits).

� Each bit is then laser “burned” into the disc, using a single beam of

light, in the form of dots.

� The storage capacity of optical discs is mainly limited by the

physical dimensions of the dots.

Miniaturization: Information StorageMiniaturization: Information StorageMiniaturization: Information StorageMiniaturization: Information StorageHow far can we reduce the size of the dots?

Abbe’s Limit:

If a light beam is focused through a

lens, the diameter of the resulting spot

of light can’t be smaller than half its

wavelength.

Source: http://theconversation.com/more-data-storage-heres-how-to-fit-1-000-terabytes-on-a-dvd-15306

Way to get around the problem

�The first beam (red, in the figure) has a round shape, and is used to

write data.

� Then, place a doughnut-shaped laser (purple, in the figure) around

the initial laser in order to limit the abilities of the first beam. This

effectively made the standard laser’s diameter smaller, and it could

then write smaller bits.

Layered/Additive Manufacturing

Additive Manufacturing (AM) refers to a processby which digital 3D design data is used to build upa component in layers by depositing material.(from the International Committee F42 for Additive

Manufacturing Technologies, ASTM)..

What You See Is What You Build (WYSIWYB) Process

Additive vs Subtractive Manufacturing

� Part Complexity;

� Material;

� Speed;

� Part Quantity;

� Cost.

Additive vs Subtractive Manufacturing

Figure: Features that represent problems using CNC machining.

Source: Gibson, Additive Manufacturing

Additive vs Forming Manufacturing

Advantages of Additive Manufacturing

Principle 1: Complexity is Free

Principle 2: Variety is Free

Principle 3: No Assembly Required

Principle 4: Zero Lead Time

Principle 5: Zero Constraints

Principle 6: Zero Skill Manufacturing

Principle 7: Compact & Portable Manufacturing

Principle 8: Less Waste By-product

Principle 9: Infinite Shades of Materials

Principle 10: Precise Replication

SourceGoogle images

Current and Potential industries for Additive Manufacturing

Benefits

Source: SAVING project/Crucible Industrial Design Ltd.; Roland Berger

Benefits

Source: Roland Berger

Benefits

Source: Roland Berger

Future: Home Manufacturing

Old toothbrush

New toothbrush

Customization:•Bristle hardness•Colour•Handle Style and shape•Etc.

Home 3D Printer

Laser scanner to input personalized data

Case Studies

Source: Royal Academy of Engineering

Topics

1. Introduction: Introduction to manufacturing; evolution

of manufacturing; importance of design in manufacturing.

2. Conventional Material Removal Processes: Theory of

chip formations; generation of surfaces; force and power

relationships; cutting tool material and its geometry; tool

wear; fundamentals of machine tools; types of machining wear; fundamentals of machine tools; types of machining

operations.

3. Unconventional Material Removal Processes:

Introduction, mechanical energy processes, thermal energy

processes, electro chemical machining.

Topics

4. Computer Numerical Control and Programming: Basics

of numerically controlled machines; programming for NC

machines; motion and coordinate system; structure of a

NC part program; examples of part programming.

5. Microfabrication Processes: Silicon processing,

lithography, micro and nanofabrication processes. lithography, micro and nanofabrication processes.

6. Layered/Generative Manufacturing Processes:

Fundamentals of layered manufacturing; layered

manufacturing technologies, modeling.

7. Engineering Metrology: Dimensions, tolerances,

surfaces, structure and properties, surface texture and

roughness, engineering metrology and instrumentation

1. Fundamental of Modern Manufacturing: Materials,

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

2. Manufacturing Processes for Engineering Materials: S.

Kalpakliam and S. R. Schmid (Prentice Hall).

3. Manufacturing Science: A. Ghosh and A.K. Mallik (East-

West Press).

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

Reference Books

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

S. K. Choudhuary (Narosa).

5. Advanced Machining Processes: V. K. Jain (Allied

Publishers).

6. Introduction to Micromachining: Ed. V. K. Jain

(Narosa).

7. Micromanufacturing Processed: Ed.: V.K.Jain (CRC

Press).

Lab

45

Themes

1. Agriculture,

2. Transportation,

3. Healthcare,

4. Educational toys to help school children,

5. Machines and Mechanisms.

46

List of Tutors

47

Dr. J. Ramkumar Dr. S. Bhattacharya Dr. S.K. Choudhry Mr. A. Kene

List of Tutors and TAs

Day Tutor TAs Email

Monday Dr. J. Ramkumar

(jrkumar@iitk.ac.in)

Gaganpreet Singh (14105274)

Atinder Pal Singh (14105268)

gaganprt

atinder

Tuesday Dr. S. Bhattacharya

(bhattacs@iitk.ac.in)

Pankaj Singh Chauhan (14205263)

Rupal Srivastava (14205265)

pankajs

rupalsri

Wednesday Dr. S.K. Choudhury

(choudhry@iitk.ac.in)

Kashfull Orra (13205071)

Navneet Singh (12807436)

Kashu

navneets(choudhry@iitk.ac.in) Navneet Singh (12807436) navneets

Thursday N. Sinha

(nsinha@iitk.ac.in)

Kartikeya Dixit (14105279)

Ashutosh Rai (14205002)

dkartik

arai

Friday Mr. A. Kene

(amarjitk@iitk.ac.in )

Raghubeer Singh Bangari (13205076)

Vivek Chawda (12807829)

raghusb

vchawda

49

50

Grading Criteria

Details

Quizzes 7%

Mid Semester Exam 18%

End Semester Exam 30%

Details

Project Drawings 2.5%

Lab Exercises 2.5%

Lab Reports 2.5%

Guide’s Evaluation 2.5%

Theory (55%) Lab (45%)

Academic Dishonesty: ZERO Tolerance ���� “F” Grade

Guide’s Evaluation 2.5%

Attendance 5%

Mid Semester Evaluation 7.5%

End Semester Evaluation 22.5%

To pass this course, one should score total marks ≥ 35 % and

theory marks ≥ 30 % of the marks assigned for theory.