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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:[email protected]
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 [email protected]
Dr. J. Ramkumar Tuesday [email protected]
Dr. S.K. Chaudhury Wednesday [email protected]
Dr. Niraj Sinha Thursday [email protected]
Dr. Shantanu Bhattacharya Friday [email protected]
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
LAB INCHARGE
G SREENIVASULU
H P SHARMA
ANIL KUMAR JHA
AMAN SINGH
[email protected] THAPLIYAL
NAFE SINGH
[email protected] B MURKHE
Staff Members :TA202 Lab
KULDEEP VISHWAKARMA
[email protected] KUMAR DUBEY
[email protected] NATH TUDU
DHEERAJ KUMAR SONI
RAHUL
[email protected] KUMAR
[email protected] BABU PRAJAPATI
GREESH PRATAP
CHATURVEDI
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