Lecture 1-Introduction.pdf

202TA 202A Introduction to Manufacturing Processes

2015‐16 (I Semester)

Instructor‐in‐Charge: Prof. Arvind Kumar

Li id M t l GLiquid Metals GroupManufacturing Science Lab Building

Department of Mechanical Engineering

E‐mail: [email protected] Telephone: 7484

Webpage: http://home.iitk.ac.in/~arvindkr

ScheduleTheory: T 8 00 9 00 am Venue: L7Theory: T 8.00‐9.00 am Venue: L7Theory TAs: Sanjay Kumar (sanjaykr@), S. Patel (psushil@), Priya Gupta (priyag

Labs: M‐F 2.00‐5.00 pm Venue: TA 202 lab

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

Course content: Introduction to manufacturing; Conventional material removal processes: chip formation, tool dynamics, practical machining and finishing operations; CNC machining; Unconventional machining; Introduction to microfabrication, layered manufacturing and metrology

S N Ti l S d f b f l

Lecture-wise break-upS. No. Titles Suggested of number of lectures

1 Introduction to manufacturing and its evolution

1

2 Computer numerical control and programming 2

3 Conventional material removal processes 44 Un‐conventional material removal processes 4

5 Micro fabrication processes 15 Micro‐fabrication processes 16 Layered / generative manufacturing processes 1

7 Engineering metrology 1Total number of lectures 14


Suggested text and reference material• Fundamental of Modern Manufacturing: Materials, Processes and Systems: M.P. Groover (John Wiley)

• Manufacturing Processes for Engineering Materials: S. Kalpakliam and S. R. Schmid (Prentice Hall)

• Fundamental of Manufacturing Processes: G.K. Lal and S.K. Choudhuary (Narosa)• Advanced Machining Processes: V.K. Jain (Allied Publishers)• Introduction to Micromachining: Ed. V. K. Jain (Narosa)g ( )• Micromanufacturing Processed: Ed.: V.K. Jain (CRC Press)


Grading Policy

Theory: 55 % Project: 45 %Mid Sem Exam = 17.5 % Project drawings = 2.5 %

Total = 55 %

End Sem Exam = 30 %Two Quizzes = 7.5 %

Lab exercises = 2.5 %, Lab reports = 2.5 %, Guide’s evaluation = 2.5 %, Lab Attendance = 5 %

Total= 45 %Final project = 30 % (includes

Prototype, Presentation, and Answers to the questions asked by theto the questions asked by the committee = 25 %. Project report and load sheet = 5 %)

• 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

PLEASE NOTE IT CAREFULLYTHEORY 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


Laboratory Session

Session Name of ExperimentSession Name of Experiment1 Turning 2 Milling + CNC demonstration3 Drilling and fitting

4 & 5 CNC class room training system usage and exercise6 – 13 Project

Project evaluation


Project involves• Conceptual design soft copy• Conceptual design – soft copy • Rough Detailed design – soft copy• Manufacturing drawing – hard copy• Fabrication

You are required to bring your lab manual for every exercise lab turn.Project group – 7 members (1st turn).Size of the project should not exceed 1 5 ft (max) in all dimensions or 450*450*450 mmSize of the project should not exceed 1.5 ft (max) in all dimensions or 450*450*450 mm

From 2nd to 4th turn following are to schedule

Turn 2 – Discuss your idea with staffTurn 2 – Discuss your idea with staff‐ Come with minimum 3 ideas for discussion‐ Simple working idea is more appreciated than complex incomplete project

Turn 3 – Finalizing rough drawingg g g

Turn 4 ‐Make individual component drawing

Turn 5 – Submit hard copy of part drawing including the load sheet. This sheet you will fill from 5thturn onwards


turn onwards

Turn 6 – Start project

Lab Report Template


Three major concerns to be followed in labThree major concerns to be followed in lab

• Safety‐ You must not wear loose clothes or clothing with loose long sleeves and not come with loose long hair.

‐ You must wear shoes (chappals /sandals are prohibited) and full pant ‐ Safety accessories (apron goggles gloves etc ) provided in the lab must be usedSafety accessories (apron, goggles, gloves etc.) provided in the lab must be used

• No shortcut• No mobile phones


Staff members of TA202 Lab



Content

• What is manufacturingg• Materials in manufacturing• Manufacturing processes


What is Manufacturing?• The word manufacture is derived from two Latin words manus (hand) and factus (make); the combination means “made by hand”

• Most modern manufacturing operations are accomplished by mechanizedMost modern manufacturing operations are accomplished by mechanized and automated equipment that is supervised by human workers

Manufacturing Defined ‐ Technological Definitiong g• Application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products

• Manufacturing also includes the joining of multiple parts to make assembled productsp p p

• Accomplished by a combination of machinery, tools, power, and manual labour


• Almost always carried out as a sequence of operations

Manufacturing Defined ‐Economic Definition

• Transformation of materials into items of greater value by means of one or more processing and/or assembly operations

• Manufacturing adds value to the material. Examples:Converting iron ore to steel adds value

Transforming sand into glass adds value R fi i t l i t l dd l Refining petroleum into plas c adds value


Product Creation Cycle

Design → Material Selec on → Process Selec on →Manufacture → Inspec on → Feedback

Production Quantity and Product Variety

• Soft product variety ‐ small diff b t d t C d ldifferences between products. Car models made on the same production line

• Hard product variety ‐ products differ p y psubstantially. The difference between a car and a truck


Materials in Manufacturing


Materials

• Ferrous metals: carbon‐, alloy‐, stainless‐, tool‐and‐die steels• Non‐ferrous metals: aluminum, magnesium, copper, nickel, titanium,Non ferrous metals: aluminum, magnesium, copper, nickel, titanium, superalloys, refractory metals, beryllium, zirconium, low‐melting alloys, gold, silver, platinum, …

• Plastics:• Plastics: thermoplastics (acrylic, nylon, polyethylene, ABS,…)thermosets (epoxies, Polymides, Phenolics, …)elastomers (rubbers, silicones, polyurethanes, …)

• Ceramics, Glasses, Graphite, Diamond, Cubic Boron Nitride• Composites: reinforced plastics metal‐ ceramic matrix compositesComposites: reinforced plastics, metal , ceramic matrix composites• Nanomaterials, shape‐memory alloys, superconductors, …


Properties of MaterialsProperties of Materials

Mechanical properties of materialsMechanical properties of materialsStrength, Toughness, Hardness, Ductility, Elasticity, Fatigue and Creep

Chemical propertiesChemical propertiesOxidation, Corrosion, Flammability, Toxicity, …

Physical propertiesy p pDensity, Specific heat, Melting and boiling point, Thermal expansion and conductivity,

Electrical and magnetic properties


Classification of Manufacturing Processes


Documents

Lecture 1-Introduction.pdf