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TA202A: Introduction to
Manufacturing ProcessesManufacturing Processes
N. Sinha
Department of Mechanical Engineering
IIT Kanpur
Email: [email protected]
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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
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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.
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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
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Manufacturing – Economic
• Transformation of materials into items of greater
value by one or more processing and/or assembly
operations
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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
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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
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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
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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
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Question
Why do I need this course?
Why theory?
Why lab exercises?
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Question
Which Process to Select and Why?
www.wonkeedonkeetools.co.uk
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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
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Questions
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Questions
http://www.me.iitb.ac.in/~ramesh/courses/ME338/non_trad.pdf
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Microfabrication
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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.
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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.
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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
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Additive vs Subtractive Manufacturing
� Part Complexity;
� Material;
� Speed;
� Part Quantity;
� Cost.
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Additive vs Subtractive Manufacturing
Figure: Features that represent problems using CNC machining.
Source: Gibson, Additive Manufacturing
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Additive vs Forming Manufacturing
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Advantages of Additive Manufacturing
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Principle 1: Complexity is Free
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Principle 2: Variety is Free
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Principle 3: No Assembly Required
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Principle 4: Zero Lead Time
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Principle 5: Zero Constraints
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Principle 6: Zero Skill Manufacturing
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Principle 7: Compact & Portable Manufacturing
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Principle 8: Less Waste By-product
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Principle 9: Infinite Shades of Materials
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Principle 10: Precise Replication
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SourceGoogle images
Current and Potential industries for Additive Manufacturing
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Benefits
Source: SAVING project/Crucible Industrial Design Ltd.; Roland Berger
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Benefits
Source: Roland Berger
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Benefits
Source: Roland Berger
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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
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Case Studies
Source: Royal Academy of Engineering
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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.
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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
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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).
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Lab
45
Themes
1. Agriculture,
2. Transportation,
3. Healthcare,
4. Educational toys to help school children,
5. Machines and Mechanisms.
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List of Tutors
47
Dr. J. Ramkumar Dr. S. Bhattacharya Dr. S.K. Choudhry Mr. A. Kene
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List of Tutors and TAs
Day Tutor TAs Email
Monday Dr. J. Ramkumar
Gaganpreet Singh (14105274)
Atinder Pal Singh (14105268)
gaganprt
atinder
Tuesday Dr. S. Bhattacharya
Pankaj Singh Chauhan (14205263)
Rupal Srivastava (14205265)
pankajs
rupalsri
Wednesday Dr. S.K. Choudhury
Kashfull Orra (13205071)
Navneet Singh (12807436)
Kashu
navneets([email protected]) Navneet Singh (12807436) navneets
Thursday N. Sinha
Kartikeya Dixit (14105279)
Ashutosh Rai (14205002)
dkartik
arai
Friday Mr. A. Kene
Raghubeer Singh Bangari (13205076)
Vivek Chawda (12807829)
raghusb
vchawda
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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.