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TA202A: Introduction to Manufacturing Processes(2017-18, 2nd 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 a rawmaterial into final product.
Course Contents
1.Introduction: Introduction to manufacturing, evolution ofmanufacturing, classification of manufacturing, Materials inManufacturing.[2]
2.Conventional Material Removal Processes: Theory of chipformations, 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 foradvanced machining processes, classifications: mechanical energyprocesses, thermal energy processes, electro chemical machiningetc. [3]
Course Contents
4.Layered/Generative Manufacturing Processes: Fundamentals oflayered manufacturing, layered manufacturing technologies,classifications of additive manufacturing processes.[2]
5.Computer Numerical Control and Programming: Basics of numericallycontrolled machines, programming for NC machines. Programmingexamples including turning, drilling, milling etc.[1]
6. 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).
Tutors
Name Photograph Day EmailDr. Niraj Sinha Monday [email protected]
Dr. J. Ramkumar Tuesday [email protected]
Mr. Amarjit P. Kene Wednesday [email protected]
Dr. Mohit Law Thursday [email protected]
Dr. Arvind Kumar Friday [email protected]
Lab (TA202)
Lab Training first five turns:
1st & 2nd Turn: Project group formation
2nd Turn: Discussion with project ideas (Each group members come with an ideacompulsory
3rdTurn: Bring rough sketches (Isometric) of finalized project
4th Turn: CNC Demonstration
5th Turn: Drawings Submission
Topics: 1. Agriculture,
2. Healthcare,
3. Energy,
4. Machines and Mechanisms for play toys
Turning (1st Lab), Milling (2nd Lab), Drilling & Fitting (3rd Lab), CNC demonstration (4th
Lab), Project final submission (5th Lab)
Staff Members: TA202 Lab Ph. No. 7984
P C GOND
LAB INCHARGE
G SREENIVASULU
H P SHARMA
ANIL KUMAR JHA
AMAN SINGH
RAKESH THAPLIYAL
NAFE SINGH
[email protected] B MURKHE
Staff Members :TA202 Lab
KULDEEP VISHWAKARMA
ARUN KUMAR DUBEY
[email protected] NATH TUDU
DHEERAJ KUMAR SONI
RAHUL
[email protected] KUMAR
[email protected] BABU PRAJAPATI
GREESH PRATAP
CHATURVEDI
Sample Lab Report Template
Grading policy
Theory
(50Marks)
Marks
Mid Semester Exam
End Semester Exam
Quiz
20
25
05
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 raw material byvarious processes, machinery, & operations following a well organizedplan 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 tent Fingers engraved water glass
Prism glass
Pouring 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 of different countries
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 moreprocessing and/or assembly operations.
Manufacturing Industries
Industry consists of enterprises and organizations that produce orsupply goods 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 andconvert them into consumer and capital goods
3. Tertiary industries - service sector
Note: Secondary industries include manufacturing, construction, andelectric power generation.
For our purposes, manufacturing means production of hardware –Nuts and bolts, forgings, cars, airplanes, digital computers, plasticparts, and ceramic products.
Classification of Manufacturing processes
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.
Mechanical properties
Tensile strength – Measures the force required to pull something such as rope,wire or a structuralbeam 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 withoutbreaking
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. externalforces) that made it deform or distort is removed
Plasticity - The deformation of a material undergoing non-reversible changes of shape in response toapplied 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)
Ashby Curve
Metals
Usually alloys, which are composed of two or more elements, at least one ofwhich is metallic. Two basic groups:
1. Ferrous metals - Based on iron, comprises about 75% of metal tonnagein 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
CeramicsCompounds 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 shareelectrons to form very large molecules
Polymer usually consists of carbon plus one or more elements such as hydrogen andnitrogen
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.
CompositesMaterial consisting of two or more phases that are processed separately and then bondedtogether to achieve properties superior to its constituents
Phase - homogeneous mass of material, such as grains of identical unit cell structure in asolid 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 arecombined 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 to theiroriginal 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
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 ofsubstances synthetic or natural in origin, which can be used for any period of time, asa whole or as a part of a system which treats, augments, or replaces any tissue, organor function of the body.
Theoretically, any material can be a biomaterial as long as it serves the stated medicaland surgical purposes.
Example of Biomaterial
Titanium Biomaterials
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 jointreplacements.
Polymers such as ultra high molecular weight polyethylene are used as articulatingsurfaces 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 of the lecture
Overview of the course
Manufacturing: Introduction
Classification of Manufacturing
Materials in Manufacturing
Different Materials in Manufacturing