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TA (Technical Art)-201N Introduction to Manufacturing Processes Krishanu Biswas [email protected]

TA201N

Introduction to Manufacturing Processes Spring 2012

Instructor: Dr.Krishanu Biswas Assistant Professor, Materials Science and Engineering, WL – 210 Phone: 6184 Course website: www.iitk.ac.in/infocell/TA201N2010/

Course Objectives -To expose the students to the fundamentals of Casting – solidification -To Discuss basic metal working processes -To obtain fundamental understanding of Machining and tool wear -To expose the students to welding and heat treatment -To expose the students to various Powder metallurgical processing routes and to discuss the mechanisms of sintering metallic and ceramic solids

Introduction to Manufacturing Processes (2-0-2-5) Theory: Lecture, W : 10-11 AM , TH: 8-9 AM

Labs: MTWThF 2-5 PM at ME and MSE

Course Content 9 Introduction to Manufacturing, Historical perspective; 9Importance of manufacturing; Classification of manufacturing processes, Engineering materials 9Casting, Fundamentals of casting, Sand casting,Permanent mold casting including pressure die casting, Shell, investment & centrifugal casting processes, Continuous casting, Casting defects 9Metal Forming, Basic concepts of plastic deformation, Hot & cold working, Common bulk deformation processes (Rolling, Forging, Extrusion and Drawing), Common sheet metal forming processes 9Machining, Chip formation and generation of machined surfaces, Tool geometry, tool material, tool wear and practical machining operations (turning, milling and drilling), Grinding processes, Finishing processes, Introduction to unconventional machining processes 9 Fundamentals of welding & classification ofWelding processes, Gas and arc welding, Brazing and soldering, Adhesive bonding, Mechanical fastening 9Heat Treatment, Principles of heat treating; annealing, normalizing, hardening and tempering, 9Manufacturing of Polymer and Powder Products, Classification of polymers, Introduction to extrusion, injection molding, blow molding, compression and transfer molding 9Green compacts from powders including slip casting of ceramics, Sintering 9Modern Trends in Manufacturing 9Case Studies

TA 201 N: Suggested Reading 9Mikell P. Groover; Fundamentals of ModernManufacturing (PRENTICE HALL), 1996 - 30 copies 9Kalpakjian Serope; Manufacturing Processes for Engineering Materials (ADDISON-WESLEY PUBLISHING COMPANY), Second Edition, 1992 - 30 Copies ¾ G.K.Lal and S.K.Chaudhury; Fundamentals of Manufacturing Processes (Narosa): 10 Copies 9Merton C. Flemings; Solidification Processing ( McGraw-HILL SERIES), 1929 – 2 Copies 9Bruce Chalmers; Principles of Solidification (ROBERT E KRIEGER PUBLISHING COMPANY, New York) , 1964 – 2 Copies 9Dieter George E; Mechanical Metallurgy (MCGRAW HILL), 3rd Edition - 4 Copies

Course Goals ™ It is important to know the following: 9 How to manufacture Useful Engineering Product? 9 What kind of Technology you would like to use? 9 What Materials to be used? 9 What types of Processes to be used ? 9 What are the deciding factors for above question? We shall try to make some products too: Project How good is Your Craftsmanship? AWARD…..Certificates…..Good for future…

Credit Distribution Theory: 50 % Mid Semester Exam: 20 % ( 2 hours : 4 Questions) End Semester Exam : 25 % (3 hours: 6 Questions Class Attendance : 5%

Laboratory: 50% ME Lab

MSE Lab

Practice Jobs,- 10%

5.0 %

5.0 %

Practical Laboratory Exam

4.0 %

4.0 %

Lab quiz (combined quiz) Project

- 30 %

2.0% 15.0 %

15.0 %

PROJECT Separate projects in ME and MSE lab ¾Size of the project should not exceed 1.5 ft (max) in all dimensions and total weight for casting objects should not exceed 3 kg per project. ¾The project groups with each of 5-6 students will be decided by 1st turn. From 2nd turn, the tentative plan needs to be submitted. After discussion with tutors during 5th turns, the final project plan needs to be submitted on 6th turns. In case you do not submit the drawing on 6th turn, you will not get any marks on drawing. ¾At least three operations are to be incorporated in the project. One component in the ME project should be made in CNC. ¾External color can not be used. ¾Report is to be prepared on the same day (Template will be provided). It is sort of log book and it is important to ensure that the students learn the importance of filling the log book. The answers to the questions related to different operations are to be submitted at the end of experimental lab session to the respective Tutors. ¾You are required to bring your lab manual in lab. However, one set of each experiment is going to be displayed on the notice board to facilitate the students to do experiments.

Credit Distribution: PROJECT Project involves: Conceptual Design, Detailed Design and Drawings, Working Model and Report

Project Grading: 9Innovative Idea: 15% 9Final Product: 70% 9Report with Engg. Drawing: 15%

PROJECT Project groups: 5-6 students/group in 1st Lab turn Group members should preferably be from different branches 2nd – 5th Turns : Interaction Hour from 4 -6 PM to discuss about the design of the project. YOU MUST COME UP WITH ATLEAST 3 DIFFERENT PRODUCT CONCEPTS FOR DISCUSSION. SIMPLE, INNOVATIVE, FINISHED PROJECTS WILL BE GIVEN MORE CREDIT THAN COMPLICATED, UNFINISHED PROJECTS Project duration: 6 lab turns in MSE and 7 lab turns in ME lab Prizes will be given to Best projects from each lab day, Overall Best projects The project grading will be done by all tutors.

Laboratory Schedule ME LAB

MSE LAB

Mon

M1 M2

M6 M10

Tue

M3 M5

M1 M2

Wed

M7 M8

M4 M9

Thurs

M4 M9

M7 M8

Fri

M6 M10

M3 M5

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). Safety accessories (apron, goggles, gloves etc.) provided in the lab must be used.

Contact details of Tutors Name Prof. A.Upadhyay anishu@, (M1 &M2)

Office/Location

Phone No.

Day

Lab

TAs

FB 419

7672 (O)

TUE

MSE

Mr. Abhinav Varshnay, abhinavv@ Ms. Nayantikakumari, nayantik@

Prof. S. Bhattacharya NL 115 bhattacs@ (M1 & M2)

6050 (O)

MON

ME

Mr.Karandeep Singh, skaran@ Mr.Satish Kumar, satishkr@

Prof. R.K Dube rkd@, (M4 &M9) Prof. K.K Kar kamalkk@ (M6, M10) Prof. J.Ramkumar jrkumar@, (M4 & M9) Prof. P.Ghoshdostidar psg@ , (M3 & M5)

WL 210B

7769 (O)

WED

MSE

ACMS 203

7687 (O)

FRI

ME

Mr. Arjun Singh, arjunsin@ Ms. Shilpi Jain, shilpi@ Mr.Mithun Sarkar, mithuns@ Mr.Vaibhav, vrai@

NLX 115

7546 (O)

THURS

ME

Mr.Sunit Kumar Gupta, sunitgpt@ Mr.Sateesh Kumar Yadav, sateeshk@

FB 358

7019(O)

TUE

ME

Mr.Ashish Agarwal, ashisagl@ Mr.Ritukant Raj, ritukant@

Prof. Sarang Ingole somar@, (M3 & M5)

WL204

6688(O)

FRI

MSE

Mr. Koushik Sikdar, koushik@ Ms. Monalisa Mondal, monalisa@

Swati Sharma swati@, (M7 & M8)

WLE 116

7950(O)

THURS

MSE

Mr. Ravi Prakash, raviiitk@ Mr. Rahul K.Sharma, ksrahul@

S.S.Chinchanikarsatis Manu Sc.Lab,NLE h@, (M7 & M8)

7607454900

WED

ME

Mr.Avinash Kumar, avikr@ Mr.Prashant K. Jaiswara, jaiswara@

Amit S.Sharma amitsidd@, (M6 & M10)

7710 (O)

MON

MSE

Mr. Kandala Ramakrishna, ksrama @ Mr. Ishan Choudhary, ishanc@

WL 210

Contact details of Lab-in-charges Name Mr. Phool Chand Gond pcgond@ Mr. Gyan Prakash Bajpai gpbajpai@

Mr. Phool Chand Gond

Office/Loca tion ME, TA Lab

Phone No

MME, WL103E

7978

7984

Mr. Gyan Prakash Bajpai

Contact details of Teaching Assistants : MSE lab Lab Day

Name

Email address

Mobile No

Location/Offi Home/Hoste ce l

TUE

Abhinav Varshney

abhinavv@

9559690524

WL-225

H10, A-217

WED

ARJUN SINGH*

arjunsin@

9559754425

WL-108

H4, H313

THURS

RAVI P SRIVASTAVA

raviiitk@

9721672700

WL-204

H4, B-316

WED

SHILPEE JAIN

shilpee@

9005788397

Biomaterials Lab

GH2, A-221

THURS

RAHUL KUMAR SHARMA*

ksrahul@

9005018024

WL-108

H7,J-312

MON

Kandala Ramakrishna

ksrama@

8960485950

WL-208

----

MON

ISHAN CHOUDHARY*

ishanc@

9005660454

WL-108

H4, D-103

TUE

NAYANTIKAKUMARI PRAVINBHAI CHAUDHARI

nayantik@

9670705621

---

SBRA, Y2

FRI

MONALISA MANDAL

monalisa@

8765696507

---

Type 5, 501

FRI

KAUSHIK SIKDAR

koushik@

8090772325

---

H10, C-426

With Instructor

RAJA ANNAMALAI A.*

araja@

9956712333

WL-208

H8, B-118

*: Attendance in the class

Contact details of Teaching Assistants: ME lab Lab Day

Name

Email address

Mobile No

Location/Office

Home/Hostel

WED

Avinash Kumar

avikr@

8960485964

Micro Fab Lab (ME)

Hall-7, D-205

THURS

Sunit Kumar Gupta

sunitgpt@

8400677911

FB368

Hall-7, A-204

TUE

Ashish Agarwal

ashisagl@

8400951705

FB354

Hall-4, B-301

MON

Karandeep Singh

karans@

8765696403

NL115

Hall-4, E-305

FRI

Mithun Sarkar

mithuns@

8960386054

ACMS 203

Hall-4, E -111

THURS

Sateesh Kumar Yadav

sateeshk@

7546 (O) 9457670149

NLX115

Hall-4, B-309

MON

Satish Kumar

satishkr@

9044942899

NL115

Hall-4, D-316

FRI

Vaibhav

vrai@

WED

Prashant Kumar Jaiswara

jaiswara@

7987(O) 9839422830

HT Trans Lab(SL)

Hall-7, G-303

TUE

Ritukant Raj

ritukant@

9559772710

-----

Hall-7, H-304

Before starting……SAFETY Follow safety instructions…. Don’t employ shortcuts… Don’t panic Take time….don’t rush It may take few more minutes to complete

Moreover, if you submit job early….it will not carry any extra Marks. Submit jobs in time and at the same time don’t rush

Some Important Facts ¾ If someone is absent consecutively in three lectures without any suitable reason, he/she will get no credit for attendance. ¾ If someone misses Mid Sem, marks will be prorated on the basis of End Sem. No make up for mid sem. There will be no mixing between lab marks and written exam marks. These two things will be considered separately. ¾ Class notes of a topic will be kept in the Copy Point on weekends . Solved problems and model questions will be uploaded in course website. Apart from that, PPTs/Videos related to Lab and Class will also be available online.

INTRODUCTION AND OVERVIEW OF MANUFACTURING 9 What is Manufacturing? 9 Materials in Manufacturing 9 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” • “Made by hand” accurately described the fabrication methods that were used when the English word “manufacture” was first coined around 1567 A.D. • Most modern manufacturing operations are accomplished by mechanized and automated equipment that is supervised by human workers

Can Cooler

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Specification: 1. Cooling system: Thermoelectric Peltier cooling system, CFC-free. 2. Capacity: For 355ml/500ml diameter 66mm beverage can. 3. Direct evaporator aluminum liner: Cool to 14 degree below room temperature. 4. Heat dissipation by long life brushless DC fan. 5. Indicator: Green LED indicates cooling is ON. 6. DC Plug: Convenient 12V cigarete lighter plug into car with locking mechanism. 7. Operating Voltage: 10-15V DC for connecting to cigarette lighter. 8. Power consumption: 30W. 9. Operation temperature: - 50C to 40 0C

Commercial airplane Boeing 777

Air Bus 380

Photo Courtesy: Boeing Commercial Airplane Inc. and Airbus Inc.

Assembly operations on the Boeing 777 (photo courtesy of Boeing Commercial Airplane Co.).

Metal chips fly in a high speed turning operation performed on a computer numerical control turning center (photo courtesy of Cincinnati Milacron).

A batch of silicon wafers enters a furnace heated to 1000°C (1800°F) during fabrication of integrated circuits under clean room conditions (photo courtesy of Intel Corporation).

Two welders perform arc welding on a large steel pipe section (photo courtesy of Lincoln Electric Company).

Automated dispensing of adhesive onto component parts prior to assembly (photo courtesy of EFD Inc.).

A robotic arm performs unloading and loading operation in a turning center using a dual gripper (photo courtesy of Cincinnati Milacron).

Charging of a basic oxygen furnace, in which molten pig iron produced in a blast furnace is poured at temperatures

Assembly workers on an engine assembly line (photo courtesy of Ford Motor Company).