Manufacturing Processes (TA 201A)

6 credit course

Course Instructor

K.MondalDepartment of Materials Science and EngineeringDepartment of Materials Science and Engineering

kallol@iitk.ac.in6156 (office)

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Before starting……SAFETY

Follow safety instructions….

Don’t employ shortcuts…

Don’t panic

Please keep your ear OK….it is the most vital organ that can avoid accidentsPlease keep your ear OK….it is the most vital organ that can avoid accidents (my personal experience)

T k ti d ’t h thi ill b d It t k fTake time….don’t rush….things will be done…..It may take few more minutes….it is nothing…(Moreover, if you submit early….it will not carry any extra marks…submit in time and at the same time don’t rush)

HOWEVER, IF YOU CROSS DEADLINE….YOU WILL LOOSE MARKS.

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Course Content

1. Engineering materials

2. Microstructure Processing relationship

3. Solidification processes

4. Molding and casting

5. Joining processes (Welding, Brazing and Soldering)

6. Deformation Processes (hot and cold working)

7 Powder Metallurgy processing (Powder production Sintering)7. Powder Metallurgy processing (Powder production, Sintering)

8. Fe-C phase diagram and heat treatment

9. Surface modification (Carburization, CVD, PVD)

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Class Schedule

Lecture: Tuesday 9:00-9:50: L7

Laboratory: MTWThF 2-5 PM at MSE TA Lab

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Seating arrangement

2nd class onward….

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Reading materials

Mikell P. Groover; Fundamentals of ModernManufacturing(PRENTICE HALL),19961996

Kalpakjian Serope; Manufacturing Processes for Engineering Materials(ADDISON-WESLEY PUBLISHING COMPANY), Second Edition, 1992.

G.K.Lal and S.K.Chaudhury; Fundamentals of Manufacturing Processes(Narosa).

Dieter George E; Mechanical Metallurgy (MCGRAW HILL), 3rdEdition.

Merton C. Flemings; Solidification Processing ( McGraw-HILL SERIES), 1929.

Notes from your Instructor (may be useful throughout thesemester and questionswill come from your Instructor’s noteand class lectures only. )

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Objectives

We try to answer few questions and decide accordingly

1. How to manufacture Useful Engineering Product?

2. What are different materials?

3 What material to be used?3. What material to be used?

4. What are different Processes?

5 What process to be used?5. What process to be used?

6. What are the deciding factors for Q2-5?

We shall try to make some products too…

1. How good is Your Craftsmanship?

AWARD…..Certificates…..Good for future… 7

Marks distributionMarks distribution:

Mid Sem: 15 2 hrs (4 questions)

End Sem: 25 3 hrs (6 questions)Attendance: It can decide your grade

(Note: To pass: 12 marks you have to get out of WRITTEN exam marks of 40)

Attendance: It can decide your gradeLab: 60 Marks distribution

S bject Marks (MSE) Job responsibilit

>85% marks out of total 100 marks (lab + written exam marks): ‘A’ grade

Subject Marks (MSE) Job responsibility

Daily logbook + Attendance 5 TA

Experiments/job

During Training

10 Lab Incharge

During Training

Project Job

(Innovation, Finish and volume of

work)

30 Tutors+ Lab Incharge + Course

Instructor

work)

Project Viva 5 Tutors + Lab Incharge + Course

Instructor

Project Report and Drawing 10 Tutors and Lab Incharge

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Project Report and Drawing

(Neatness, sequence, timely

submission)

10 Tutors and Lab Incharge

Total 60

SAFETY INSTRUCTIONS: TA201N (MSE Lab)

Please follow these instructions

SAFETY INSTRUCTIONS: TA201N (MSE Lab)•Dress Code: Students must attend all laboratory sessions wearing (i) Trousers, (ii)half-sleeve tops/shirts and (iii) Leather shoes. Half pants, loosely hanging garmentsand slippers are strictly not allowedand slippers are strictly not allowed.

•To avoid injury, the student must take the permission of the concerned laboratorystaff before handling any machine. Careless handling of machines may result inserious injuryserious injury.

•Students must ensure that their work areas are clean and dry to avoid slipping.

•A leather apron will be issued to each student during Welding Exercise. Studentsp g gnot wearing the apron will not be permitted to work in the laboratory. Students arerequired to clear off all tools and materials from machine/work place.

•During Welding experiments, the students must wear UV glasses all the time.During Welding experiments, the students must wear UV glasses all the time.

•All the students must take extra precautions, while attending laboratory sessionson casting and welding.

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Please follow these instructions

1. 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.

2. Class notes/PPT of the entire week will be put in Copy Point on Friday at 5pm. Solved problems and model questions will be placed in Copy point on Monday at 5pm. This will start after two lectures. Apart from that, some of the notes/PPTs/Videos related to Lab and Class will also be put online. The link will be provided after 1st week of Lab/Class.

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Lab schedule (MSE)

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Contact persons (MSE Lab)

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Contact persons (MSE Lab)

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Tutors and TAs for MSE section

Day TutorTAs (Responisible for record

keeping)

TAs (For assisting main TAs and Tutor)

Before Mid Sem After Mid Sem

Mr. Rahul Kumar Sharma,Mr. Alok Kumar, alokn@ Mr. Anup Kumar Mr. Suman Patra

Monday (C3,C4, C15)Mr. Rahul Kumar Sharma, ksrahul@ Mr. P Dhandapani, dhanda@

Tuesday (C8, C9, C13) Mr. Arjun Singh, arjunsin@

Mr. Suresh Chandra, schand@ Mr. Alok Kumar Mr. P Dhandapani

M Akhil h N i l @y j g j @

Mr. Akhileshwar N., anirala@

Wednesday (C5, C6, C7)Mr. Chinmoy Bhattacharya, chinmoy@

Ms. Alka Gupta, alkag@ Mr. Suresh Chandra Mr Akhileshwar N

Mr. S Ariharan, ariharan@

Thursday (C1, C2, C14) Mr. Sumanta Samal, sumanta@ Mr. Asit Prakash, asitp@ Mr Aditya Prakash Mr. S Ariharan

Mr. Aditya Prakash, aadi@

Mr. Soumitro Mahanti,Mr. Aunp K. Patel, akpatel@ Ms Alka Gupta Mr. Asit Prakash

Friday (C10, C11, C12)Mr. Soumitro Mahanti, soumitro@ Mr. Suman Patra, sumanp@

InstructorMr. Mohammad Faisal, faisal@

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Please see the final project reports made in previous semester at pCOPY POINT. This is for your guidance.

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Lets see some videos (experiments to be done in Laboratory)

Sand casting Videohttp://www.youtube.com/watch?v=rgL2Jn5mk1Agas weldinghttp://www.youtube.com/watch?v=R4LmsNZj9VgOxy‐acetyleneOxy acetylenehttp://www.youtube.com/watch?v=DWJQudCiUes&feature=relatedBrazing and weldinghttp://www.youtube.com/watch?v=TQP8EBQRvr0

ldi   fwelding safetyhttp://www.youtube.com/watch?v=MVrI2kuRKdA&playnext=1&list=PLC415ABDC4A196A9DOpen die forgingp g ghttp://www.youtube.com/watch?v=tLRkOupbARM

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What is Manufacturing?

Two Latin wordsmanus (hand) and

f t ( k )factus (make);the combination means “made by hand”

• “Made by hand” accurately described the fabrication methodsthat were used when the English word “manufacture” was firstcoined around 1567 A.D.coined around 1567 A.D.

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Art and Science of Transforming Materials into Value Added Products….What is Manufacturing?

ART:

Visual design, Computer aided designComputer aided design,

Aesthetic design (Overall engineering)SCIENCE:

USE of scientific laws to human purpose or product development,

TRANSFORMING MATERIALS:

Series of interrelated activities (example: Product design, development)Materials selection

Process planningInventory control and quality assuranceInventory control and quality assurance

Value added products:

To meet specific requirement

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To meet specific requirementDurability

Ease to degrade or decompose after serving purpose(Environment requirement)

Manufacturing of a Bicycle

19Acknowledgement: Taken from Prof. K.Biswas’s Note

Materials Tetrahedron

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How would you make Engine block?

Look at the complication and 

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Look at the complication and intricate design of engine block

Sand Casting Steps

Pattern making Sand blasting and 

Sent to supplier

Design section

S d  ki

(Pattern shop)

Shake out 

gMachining (finishing)

Design section

Sand making(Sand Plant)

Mold making

ki

raw casting out

Core making(core shop) Core assembling on mold Pouring

Metal making (Melting shop)

Transfer of metalsTo Pouring station

Pouring ladle

Quality control

Manufacturing system

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Manufacturing Operation

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Selection Criteria for Manufacturing Processes

Manufacturing cost

P d i l d d i Production volume and production rate

Characteristics and properties of work piece

Limitations on shape and size

Surface finish and tolerance requirements

Functional requirements of the products

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Let us enjoy TA 201A…..j y

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