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202 TA 202A Introduction To Manufacturing Processes
202 TA 202A Introduction To Manufacturing Processes
202
IntroductiontoManufacturingProcesses
201516(ISemester)
InstructorinCharge:Prof.ArvindKumar
LiquidMetalsGroup
Li
id M t l G
ManufacturingScienceLabBuilding
DepartmentofMechanicalEngineering
Email:[email protected]
Telephone:7484
Webpage:http://home.iitk.ac.in/~arvindkr
Schedule
Theory:T8.009.00amVenue:L7
Theory:
T 8 00 9 00 am Venue: L7
TheoryTAs:Sanjay Kumar(sanjaykr@),S.Patel (psushil@),Priya Gupta (priyag
Labs:MF2.005.00pmVenue:TA202lab
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
Coursecontent: Introductiontomanufacturing;Conventionalmaterialremoval
processes:chipformation,tooldynamics,practicalmachiningandfinishingoperations;
CNCmachining;Unconventionalmachining;Introductiontomicrofabrication,layered
manufacturingandmetrology
Lecture-wise break-up
S N
S.No.
Ti l
Titles
S
Suggestedofnumberoflectures
d f
b
fl
Introductiontomanufacturingandits
evolution
Computernumericalcontrolandprogramming
3
4
Conventionalmaterialremovalprocesses
Unconventionalmaterialremovalprocesses
4
4
5
6
Microfabricationprocesses
Micro
fabrication processes
Layered/generativemanufacturingprocesses
1
1
Engineeringmetrology
Totalnumberoflectures
1
14
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
Suggestedtextandreferencematerial
FundamentalofModernManufacturing:Materials,ProcessesandSystems:M.P.
Groover (JohnWiley)
ManufacturingProcessesforEngineeringMaterials:S.Kalpakliam andS.
R.Schmid (PrenticeHall)
FundamentalofManufacturingProcesses:G.K.Lal andS.K.Choudhuary (Narosa)
AdvancedMachiningProcesses:V.K.Jain(AlliedPublishers)
IntroductiontoMicromachining:Ed.V.K.Jain(Narosa)
g
(
)
Micromanufacturing Processed:Ed.:V.K.Jain(CRCPress)
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
GradingPolicy
Theory:55%
MidSem Exam=17.5%
EndSem Exam=30%
TwoQuizzes=7.5%
Project:45%
Project drawings = 2.5 %
Labexercises=2.5%,Labreports=
2.5%,Guidesevaluation=2.5%,Lab
Total=55% Attendance=5%
Finalproject=30%(includes
Prototype,Presentation,andAnswers
to the questions asked by the
tothequestionsaskedbythe
committee=25%.Projectreportand
loadsheet=5%)
Total
=45%
To pass this course, one should score total marks 35 % and theory marks 35 %
of the marks assigned for theory
UNANNOUNCED TWO Quizzes will be held in the course
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
NO MAKE-UP
WILL BE CONSIDERED UNLESS THE STUDENT HAS AUTHORIZED LEAVE REALLY FOR
ACADEMIC DISHONESTY
FOR CHEATING IN THE EXAMINATION HALL: ZERO TOLERANCE
Dr.ArvindKumarLiquidMetalsGroup
F GRADE
IITKanpur
Laboratory Session
Session
Name of Experiment
1
Turning
2
Milling + CNC demonstration
3
Drilling and fitting
4 & 5 CNC class room training system usage and exercise
6 13
Project
Project evaluation
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
Projectinvolves
Conceptualdesign
Conceptual design softcopy
soft copy
RoughDetaileddesign softcopy
Manufacturingdrawing hardcopy
Fabrication
Youarerequiredtobringyourlabmanualforeveryexerciselabturn.
Projectgroup 7members(1st turn).
Size of the project should not exceed 1 5 ft (max) in all dimensions or 450*450*450 mm
Sizeoftheprojectshouldnotexceed1.5ft(max)inalldimensionsor450*450*450mm
From2nd to4th turnfollowingaretoschedule
Turn2
Turn
2 Discussyourideawithstaff
Discuss your idea with staff
Comewithminimum3ideasfordiscussion
Simpleworkingideaismoreappreciatedthancomplexincompleteproject
g
g
g
Turn3 Finalizingroughdrawing
Turn4 Makeindividualcomponentdrawing
Turn5 Submithardcopyofpartdrawingincludingtheloadsheet.Thissheetyouwillfillfrom5th
turn onwards
turnonwards
Turn6 Startproject
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
Content
Whatismanufacturingg
Materialsinmanufacturing
Manufacturingprocesses
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
WhatisManufacturing?
ThewordmanufactureisderivedfromtwoLatinwordsmanus (hand)and
factus (make);thecombinationmeansmadebyhand
Most
Mostmodernmanufacturingoperationsareaccomplishedbymechanized
modern manufacturing operations are accomplished by mechanized
andautomatedequipmentthatissupervisedbyhumanworkers
ManufacturingDefined
g
TechnologicalDefinition
g
Applicationofphysicalandchemicalprocesses
toalterthegeometry,properties,and/or
appearanceofagivenstartingmaterialtomake
partsorproducts
Manufacturingalsoincludesthejoiningof
multiplepartstomakeassembledproducts
p p
p
Accomplishedbyacombinationofmachinery,
tools,power,andmanuallabour
Almostalwayscarriedoutasasequenceof
operations
Dr.Arvind KumarLiquidMetalsGroupIITKanpur
ManufacturingDefinedEconomicDefinition
Transformationofmaterialsintoitemsofgreatervaluebymeansof
oneormoreprocessingand/orassemblyoperations
Manufacturingaddsvaluetothematerial.Examples:
Convertingironoretosteeladdsvalue
Transformingsandintoglassaddsvalue
Refiningpetroleumintoplas
R fi i
t l
i t l caddsvalue
dd
l
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
ProductCreationCycle
DesignMaterialSelec onProcessSelec on
ManufactureInspec onFeedback
ProductionQuantityandProductVariety
Softproductvariety small
diff
differencesbetweenproducts.Carmodels
b t
d t C
d l
madeonthesameproductionline
Hardproductvariety
p
y p
productsdiffer
substantially.Thedifferencebetweena
carandatruck
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
MaterialsinManufacturing
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
Materials
Ferrousmetals:carbon,alloy,stainless,toolanddiesteels
Non
Nonferrous
ferrousmetals:aluminum,magnesium,copper,nickel,titanium,
metals: aluminum, magnesium, copper, nickel, titanium,
superalloys,refractorymetals,beryllium,zirconium,lowmeltingalloys,
gold,silver,platinum,
Plastics:
Plastics:
thermoplastics(acrylic,nylon,polyethylene,ABS,)
thermosets (epoxies,Polymides,Phenolics,)
elastomers (rubbers,silicones,polyurethanes,)
Ceramics,Glasses,Graphite,Diamond,CubicBoronNitride
Composites: reinforcedplastics,metal
reinforced plastics metal,ceramicmatrixcomposites
ceramic matrix composites
Nanomaterials,shapememoryalloys,superconductors,
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
Properties of Materials
PropertiesofMaterials
Mechanicalpropertiesofmaterials
Mechanical
properties of materials
Strength,Toughness,Hardness,Ductility,Elasticity,FatigueandCreep
Chemicalproperties
Chemical
properties
Oxidation,Corrosion,Flammability,Toxicity,
Physicalproperties
y
p p
Density,Specificheat,Meltingandboilingpoint,Thermalexpansion
andconductivity,
Electricalandmagneticproperties
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur
ClassificationofManufacturingProcesses
Dr.ArvindKumarLiquidMetalsGroup
IITKanpur