KNOWLEDGE INCUBATION FOR TEQIP

IIT KANPUR

Glimpse of the Program

A BOUT

Importance of materials for manufacturing industries cannot beundermined. The development of new materials and/orrefinement of the exiting material composition /processingtechniques are expected to broaden the diversity of theapplication of materials in the coming year. Developmentof new and advanced materials demand innovation inexisting manufacturing processes to obtain the desiredproperties in the materials without compromising on theproduction front. In the above context, this TEQIP three-daylab based short term course was planned to provide anunderstanding of the fundamentals of materials processingtechniques and their use in a range of sectors likeautomotive, defense and aerospace. The course introducedimportant aspects of casting/ solidification, different joiningprocesses, powder metallurgy, micro fabrication processesand various deformation techniques like forging, rolling,swaging etc. In the above broad prospective, the coursehad three major objectives to serve:

The fundamental concept of materialmanufacturing processes.

To provide the fundamental as well as theapplication-oriented knowledge for understandingimportant concepts in materials engineeringrelated to the manufacturing of materials.

Exposure of the laboratory experiments onmanufacturing and materials property evaluation

TOPICS DISCUSSED

1. Introduction: Introduction to manufacturing Process,Engineering material-classification Structure of materials,Types of materials, Properties of materials, Microstructureproperty interrelationship.

2. Casting/Solidification: Classifications of casting processesPatterns, Core making, Gating system, Solidification of puremetals and alloys, shrinkage,gas solubility, Riser design Investment casting, Castingdefects.

3. Joining Processes: Fusion welding: Arc (MMAW, SAW,SMAW), Gas welding and resistance welding, Fusion zone,Heat-affected zone (HAZ), Brazing and Soldering, Solidstate welding processes.

4. Deformation Processes: Stress strain curve, Effect of temperature on the workability, Extrusion (direct and indirect); Rolling– Hot and Cold, Forging (open and closed die) Swaging

5. Powder Metallurgy: Introduction, Powder production, Compaction and Sintering

6. Micro Fabrication Processes: Silicon processing, Lithography, Micro fabrication technique

O RGANIZERS

1. Dr. Anish Upadhyaya ProfessorDepartment of Material Science and EngineeringIndian Institute of Technology Kanpur Email: anishu@iitk.ac.inWeb-page: https://www.iitk.ac.in/new/anish-upadhyaya#

2. Dr. Asit Prakash Bajpayee (Co-coordinator)Research Establishment OfficerDepartment of Material Science and EngineeringIndian Institute of Technology Kanpur Email: asitp@iitk.ac.in

L IST OF S PEAKERS

1. Dr. Anish Upadhyaya ProfessorDepartment of Material Science and EngineeringIndian Institute of Technology Kanpur Email: anishu@iitk.ac.inWeb-page: https://www.iitk.ac.in/new/anish-upadhyaya#

2. Dr. Monika Katiyar ProfessorDepartment of Materials and Metallurgical EngineeringIndian Institute of Technology Kanpur Email: mk@iitk.ac.inWeb-page: http://home.iitk.ac.in/%7Emk/

3. Dr. Asit Prakash BajpayeeResearch Establishment OfficerDepartment of Material Science and EngineeringIndian Institute of Technology Kanpur Email: asitp@iitk.ac.in

S TATEWISE P ARTICIPATION

67%

25%

8%

Uttar Padesh Jharkhand Bihar

S. No State Institute Name Registeredcandidates

1.2.

3.

Uttar Pradesh UPTTI Kanpur 5IET, Bundelkhand University Jhansi

7

Rajkiya Engineering College Banda

4

4.

5.

Jharkhand

Dumka Engineering College 3

UCET, Vinoba Bhave University, Hazaribag, Jharkhand

3

6. Bihar Gaya College Of Engineering, Gaya

2

TOTAL 24

S CHEDULE

Day 1: 12 September, Thursday

Time Event

8:00-9:00 Registration

9:00-9:15 Inauguration

9:15-9:45Tea & Refreshments

9:45-10:45 Lecture 1: Introduction to Engineering Materials and theirproperties

Prof. A.Upadhyaya

(Venue: Outreach Room 102)

10:45-11:45Lecture 2: Structure-Processing Interrelationship

Prof. A.Upadhyaya

(Venue: Outreach Room 102)

11:45-1:00 PMLecture 3 + Q&A Session

Classification of Manufacturing Processes

Prof. A.Upadhyaya

(Venue: Outreach Room 102)

1:00-2:00 PM Lunch break

2:00-3:00 PM Lecture 4: Fundamentals of Solidification Processes

Prof. A.Upadhyaya

(Venue: Outreach Room 102)

3:00-5:00 PM

Lab module 1Material Characterization: XRD, SEM and Mechanical Testing

Venue: ACMS lab

5:00-5:15 PM Tea break

5:15-6:15 PM Lab Module IIPowder Metallurgical Processing of Metallic and Ceramics

Venue: PM Lab

Day 2 September 13, Friday

Time Event9:00-10:00 Lecture 5: Materials Joining Processes

Prof. A.Upadhyaya

(Venue: Outreach Room 102)10:00-11:00 Lecture 6: Deformation Processing

Prof. A.Upadhyaya

(Venue: Outreach Room 102)11:00-11:15 Tea break

11:15-12:15 Lecture 7: Heat-Treatment of Ferrous and Non-Ferrous Alloys

Prof. A.Upadhyaya

(Venue: Outreach Room 102)12:15-1:15 Lecture 8: Metallography and Microscopy

Dr. A.P. Bajpai

(Venue: Outreach Room 102)1:15-2:00 Lunch Break

2:00-4:00 Lab Module III

Metallography Practices; Heat-Treatment of Ferrous and Non-Ferrous Metals and their Alloys

Venue: Physical Metallurgy Lab4:00-4:15 Tea Break

4:15-5:15 Lecture 9: Surface Modification Techniques

Prof. A.Upadhyaya

(Venue: Outreach Room 102)5:15-6:15 Lecture 10: Additive Manufacturing: Rapid Prototyping and

Rapid Tooling

Prof. A.Upadhyaya

(Venue: Outreach Room 102)

7:30 PM Onwards Special Dinner

Venue: New Dinning Hall

Day 3 September 14, Saturday

Time Event9:00-11:00 Lab Module IV

Solidification Processing Techniques Deformation Processing(Rolling, Forging and Swaging)

Venue: Engineering Metallurgy Lab

11:00-11:15 Tea Break

11:15-12:15 PM Lecture 11: Micro-Fabrication and Processes

Dr. A.P. Bajpai

Venue: Engineering Metallurgy Lab12:15-1:15 PM Lecture 12: Flexible Electronics

Prof. M. Katiyar

1:15-2:00 PM Lunch

2:00-4:00 PM Lab Module VSheet Metal Working Joining Processes (Brazing; Welding:

OAW, MIG and TIG), HAZVenue: Engineering Metallurgy Lab

4:00-5:00 PM Valedictory Session(certificate distribution and group photograph

Venue: Engineering Metallurgy Lab5:00 PM High Tea

O UTCOME

A series of lectures were delivered by the specialist, on thefundamentals and manufacturing processes. This course gavean opportunity to participants to get hands on experience indifferent manufacturing equipment’s housed in EngineeringMetallurgy Lab (TA 201) as well as it exposed them to thepedagogy of IIT Kanpur. At the end of the course, theparticipants had the basic idea on how to tailor themanufacturing process for a given material. They gotintroduced to the laboratory experiments on manufacturingand materials property evaluation The course introducedparticipants to the fundamental as well as the application-oriented knowledge for understanding important concepts inmaterials engineering related to the manufacturing ofmaterials. Participants requested an extended version of thiscourse so that they can learn more about the subject withmore time dedicated to hands on training.

SUMMARY of FEEDBACK

Questions Excellent Good OrdinaryClarity of communication about workshop

18Organization of the sessions 15 03Quality of lectures 18Quality of posters/Labs 18Effectiveness of discussions 15 3Effectiveness of learning experience 15 3

Appropriate Short LongDuration of workshop 01 14 03

Definitely Maybe NoWould you like to have more such sessions?

18

Would you like e-lectures by experts on special topics?

15 03

Suggest specific topic that you would like additional expert lectures on

Different type 7 materials and its matching operations with accuracy and its defects.

Manufacturing process. Analysis, CFD software FEA, thermal engineering and

the time duration should be more. Powder metallurgical process how to read SEM, TEM and

XRD images and interpret them. 3-D and 4-D printing technique of manufacturing. Metal cutting joining and forming, Numerical modelling

& simulation. Hybrid machining advance machining process composite

Materials. Ultra high temperature ceramics. M/S moulding and easting citing and measurement. Recent trends in welding moulding /CNC.

Additional Suggestions Report this type of training programs one by one. Arrange workshop for manufacturing processor for at lost

7 days. And a training program for mechanical faculties toperform experiments related to their research.

Short term course should be to longer duration, (5-7days)(i). Participation of the members from different institutions should be made mandatory(iii)A quiz session must be organised among the participate in the course so that a sense of competition must be included.

A debate at the end of the session should be organised at the last day so that all can arrive at the consensus which may be beneficial to all the stakeholders of the TEQIP.

Add practical sessions for participants. give them opportunity to make own models.

There can be more laboratory based sessions for different subjects for mechanical engineering.

There can be more laboratory based sessions for different subjects for mechanical engineering.

Add the practical based course as participates. Number of days of workshop can be little bit related.

1. Clarity of communication about workshop?

100%

Excellent Good Ordinary

2. Organization of the sessions?

83%

17%

Excellent Good Ordinary

Workshop

3. Quality of Lectures

100%

Excellent Good Ordinary

4. Quality of Labs

100%

Excellent Good Ordinary

5. Effectiveness of discussions

83%

17%

Excellent Good Ordinary

6. Effectiveness of learning experience

83%

17%

Excellent Good Ordinary

7. Duration of workshop

6%

78%

17%

Appropriate Short Long

8. Would you like to have more such sessions?

86%

14%

Definetly Maybe No

9. Would you like e-lectures by experts on special topics?

83%

17%

Definetly Maybe No

10. Suggestion specific topic that you would like additional expert lectures on

Different type 7 materials and its matching operations with accuracy and its defects. Manufacturing process. Analysis, CFD software FEA, thermal engineering and the time duration should be more. Powder metallurgical process how to read SEM, TEM and XRD images and interpret them. 3-D and 4-D printing technique of manufacturing. Metal cutting joining and forming, Numerical modelling & simulation. Hybrid machining advance machining process composite Materials. Ultra high temperature ceramics. M/S moulding and easting citing and measurement. Recent trends in welding moulding /CNC.

11.Additional Suggestions Report this type of training programs one by one. Arrange workshop for manufacturing processor for at lost 7 days. And a training program for mechanical faculties to

perform experiments related to their research. Short term course should be to longer duration, (5-7days) (i). Participation of the members from different institutions

should be made mandatory(iii)A quiz session must be organised among the participate in the course so that a sense of competition must be included.

A debate at the end of the session should be organised at the last day so that all can arrive at the consensus which may be beneficial to all the stakeholders of the TEQIP.

Add practical sessions for participants. give them opportunity to make own models. There can be more laboratory based sessions for different subjects for mechanical engineering. There can be more laboratory based sessions for different subjects for mechanical engineering. Add the practical based course as participates. Number of days of workshop can be little bit related.

12.Which Subjects do you teach? Electronics & Instrument Engineering workshop models and its operations Mechanics of m/c workshop Workshop and materials testing. Manufacturing science II manufacturing process. Engineering drawing workshop technology. IC engine advance manufacturing CNC. RAC, thermodynamics engineering drawing. Engineering physics, material science. Engineering drawing workshop technology and metrology. Manufacturing technology and thermodynamics. Engg. drawing manufacturing process and machine design. Material engineering manufacturing technology engineering mechanics. Materials engineering manufacturing technology engineering mechanics. Computer aided manufacturing machine design advance welding technology. Workshop technology options research theory of machines. Molding and casting. Mech. subj./ graphic.

13.What is the average student to teacher ratio in your institute?

20:1 8:1 24:1 25:1 25:1 15:6 26:1

Teaching

14.Do you have additional support for teaching (tutors, graders, teaching Assistants,etc)?

47%

53%

Yes No

15.Do you give class projects for UG classes?

60%

40%

Yes No

16.Do you give class projects for PG classes?

50%50%

Yes No

17.Do you have sufficient resources for laboratory courses?

31%

69%

Yes No

18.Is the Library / journal/e-connection support adequate?

33%

67%

Sufficient Inadequate

8. Would you like to have common (TEQIP) repository of course material?

67%

22%

11%

Definetly Maybe No

19.Would you like to visit IITK to participate in and develop course material (existing or new)?

81%

19%

Definetly Maybe No

20.Would you like to participate in creation of the repository material (course files/ lab. Manuals/question bank/ etc)

93%

7%

Definetly Maybe No

21.How can IITK effectively help you prepare for teaching?

19%

42%

35%

3%

E-courses Workshops Content None

22.How can TEQIP help improve your teaching?

Through learning by conducting w/s & seminars. Give separate funds according to lab &appoint separate

coordinator for TEQIP III. By conducting similar workshop. Arranging some this type of program. Proving opportunity to attend subject related workshop. It gives experience to high quality teaching and laboratory

facilities at IITK It trains for improved teaching ability. It gives exposure to high quality teaching and laboratory

facilities at IITK, It trains for improved teaching ability. Workshop short terms course FDP and conference. By short terms course for facility, laboratory staff and

students. Theory learning. Through workshop/conference short term course.

1. Would you like to visit for a visiting- faculty/post-doctoral fellow, if offered (via TEQIP)?

94%

6%

Definetly Maybe No

2. Would you like to share/ use research infrastructure at IITK, if made available?

83%

17%

Definetly Maybe No

Research

3. Would you like to conduct collaborative research with IIT Kanpur?

82%

18%

Definetly Maybe No

4. Would you like lectures by experts (Indian and international) on niche researchareas/topics?

88%

13%

Definetly Maybe No

5. Do you want special-topic conference?

94%

6%

Definetly Maybe No

6. How can TEQIP help improve your research?

By conducting more course programs. Its very helpful to teach and participating with our

Collage students. Through effective learning by TEQIP workshop. By providing research funds to faculties separately. And arrange program in IITK to perform experiment

related to research. It has given in the platform to share Ones ideas, discuss

with specialized individuals and related. The challenges and overcame their knowledge from the lab visit was extremely beneficial and

the research platform could be stop well. By making joint collaboration projects and funding to various national level funding agencies. By doing some collaborative research on innovative

ideas with colleges. By providing lab/equipment facilities. Guidance by

experts. Giving more opportunity to conduct tests Laboratory use at IITK, more intensive training on

regular basis. Subjects/topic based Training for knowledge enhancement. Facility providing research labs.

7. Key take-aways from this event. Practical lesson were very effective. materials structure and properties. practical session very effective. unorthodox teaching methods which can be beneficial and the ways can be introduced to motivate our

students and keep them alert in the class was highlyappreciated. (i) observation on small things which wasvery impotent and cannot be neglected. (ii)proverbsand quotes used during lecture seminar and the linkingof them with subject matter was interesting.come to know how interesting we can teach students

various chapter of physics and materials science thankspecially prof. Anish Upadhyay for same.

None. there are many but would like to mention for attend

few. (i.) laboratory exposure (ii). Quality of Teaching.(iii). Connect of course.

Advance material of testing fasciitis like sem. very wellestablished metallurgy lab. Effecting way for encamping student in class.

Practical succession

Organizer Report click here