202 TA 202A Introduction To Manufacturing Processes

TA202A
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
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)
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
IITKanpur
PLEASE NOTE IT CAREFULLY

THEORY CLASS ATTENDANCE HAS NO MARKS BUT LAB. ATTENDANCE HAS CERTAIN WEIGHTAGE ALREADY
INFORMED THROUGH E-MAIL. PLEASE NOTE THAT THERE IS ALWAYS A
GOOD, POSITIVE AND
ALMOST LINEAR CORRELATION BETWEEN ALPHABETIC GRADE AND ATTENDANCE
NO MAKE-UP
WILL BE CONSIDERED UNLESS THE STUDENT HAS AUTHORIZED LEAVE REALLY FOR
UNAVOIDABLE SITUATIONS. A STUDENT SEEKING A MAKE-UP IS USUALLY AT DISADVANTAGE.

No Make-up for mid sem and quiz
ACADEMIC DISHONESTY
FOR CHEATING IN THE EXAMINATION HALL: ZERO TOLERANCE
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
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
IITKanpur
Lab Report Template
IITKanpur
Three major concerns to be followed in lab

Threemajorconcernstobefollowedinlab
Safety
Youmustnotwearlooseclothesorclothingwithlooselongsleevesandnot
comewithlooselonghair.
Youmustwearshoes(chappals /sandalsareprohibited)andfullpant
Safetyaccessories(apron,goggles,glovesetc.)providedinthelabmustbeused
Safety accessories (apron goggles gloves etc ) provided in the lab must be used
Noshortcut
Nomobilephones
IITKanpur
Staff members of TA202 Lab
IITKanpur
IITKanpur
Content
Whatismanufacturingg
Materialsinmanufacturing
Manufacturingprocesses
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
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
IITKanpur
MaterialsinManufacturing
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,
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
IITKanpur
ClassificationofManufacturingProcesses
IITKanpur

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TA202A

PLEASE NOTE IT CAREFULLY

GOOD, POSITIVE AND

ALMOST LINEAR CORRELATION BETWEEN ALPHABETIC GRADE AND ATTENDANCE

UNAVOIDABLE SITUATIONS. A STUDENT SEEKING A MAKE-UP IS USUALLY AT DISADVANTAGE.

Lab Report Template

Three major concerns to be followed in lab

Staff members of TA202 Lab

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