Fundamentals of manufacturing processes

Start Date
24/07/2017

End Date
13/10/2017

Enrollment End Date
13/10/2017

No. of
Enrollments
827 students

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Created by

Dwivedi D K
IIT Roorkee
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Course Language
English
Course Type
Scheduled
Video transcripts
Course Category
Engineering
Learning Path
Undergraduate
Course Length
0 Hours
Weekly time commitments
0 Hours
Course Completion
Exam Date
To be announced
Credits
0

102

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Weekly Reading list

Overview

ABOUT THE COURSE

It is proposed to include fundamental of following aspects of manufacturing technology 
A) Understanding Manufacturing: concept of manufacturing, need, scope, advantages, limitation, application, materials and manufacturing, classification of manufacturing, process capabilities, selection, break even analysis of manufacturing processes 
B) Casting: approach, steps, pattern, molding, gate and riser, melt treatment, solidification, casting processes: sand mould, shell mould, permanent mould casting, casting defect and their remedy 
C) Forming: approach, hot and cold forming, rolling, forging, extrusion, drawing, sheet metal forming, press, dies, types of dies and die set sheet metal operations punching, blanking, notching, nibbling 
D) Joining: approach, need, principle of fusion welding, gas welding, thermit welding, arc welding  common arc welding processes, resistance welding, weldability of metals, solidification of weld, weld discontinuities and their remedy 
E) Machining: approach, mechanism, classification, cutting tool, tool material, heat generation, cutting fluid, grinding, internal and external surface grinding, centerless grinding designation and selection of grinding wheel, trueing and balancing, honing, reaming, lapping, polishing etc. 
F) Improving properties: heat treatment of steel and aluminum alloys, Fe-C diagram, TTT diagram, and CCT diagram, heat treatment processes annealing, normalizing, quenching tempering, surface modification methods namely without change chemistry, changing chemical composition and development of coating and cladding.

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INTENDED AUDIENCE

UG/PG Student, practicing engineers
It is a core course for UG students.

COURSE PLAN

Week 1

Understanding Manufacturing
Fundamental approaches of manufacturing
Manufacturing process specific advantages and limitation
Materials and manufacturing processes
Classification of manufacturing processes


Week 2

Selection of manufacturing processes 
Application of manufacturing processes 
Effect of manufacturing processes on properties of metals
Break-even point analysis in manufacturing processes
Metal Casting: Introduction & Suitability

Week 3

Metal Casting: Steps of casting processes
Metal Casting: Terminology
Metal Casting: Pattern allowances I
Metal Casting: Pattern allowances II
Metal Casting: Sand Moulding I

Week 4

Metal Casting: Sand Moulding II
Metal Casting: Core & Core Prints 
Metal Casting: Gating System 
Metal Casting: Yield 
Metal Casting: Riser Design

Week 5

Casting defects I: gas and shrinkage porosity, hard spot, hot tears
Casting defects II: Cracking, cold shut, mis-run, inclusion, swell, drop
Principle of deformation based manufacturing processes 
Hot, warm and cold forming 
Forming processes: rolling and forging

Week 6

Metal Casting: Cleaning of casting 
Metal Casting: Casting defects & their prevention 
Metal Casting: Shell molding  
Metal Casting: Investment and permanent mould casting 
Metal working processes: Hot and cold working

Week 7

Metal working processing: Sheet metal operations (Shearing)
Metal working processing: Sheet metal operations II
Metal working processing: Sheet metal operations III
Metal working processing: Dies and die set
Material removal processes: Machining

Week 8

Material removal processes: Mechanism of the metal cutting
Material removal processes: Chip Formation
Material removal processes: Types of chips and power consumption
Material removal processes: Heat generation
Material removal processes: Tool failure and tool life

Week 9

Material removal processes: Tool materials
Material removal processes: Cutting fluids
Material removal processes: Grinding I
Material removal processes: Grinding II
Material removal processes: Grinding III

Week 10

Material removal processes: Grinding operations
Joining of metals: Fundamentals I
Joining of metals: Fundamentals II
Joining of metals: Welding processes I
Joining of metals: Brazing, soldering and weldability

Week 11

Joining of metals: Weldability and welding defects
Heat treatment: Fundamentals   
Heat treatment: Fundamentals II
Heat treatment: Fundamentals III
Heat treatment: Normalizing and hardening

Week 12

Heat treatment: Tempering
Improving surface properties: Introduction
Improving surface properties: Surface modification processes I
Improving surface properties: Changing chemical composition
Improving surface properties: Coating



SUGGESTED READING

M P Grover, Modern Manufacturing Processes, John Wiley (2002). 
S Kalpakkajian, S R Schmid, Manufacturing Engineering and Technology, Pearson (2000)DeGarmo et al. Materials and Processes in Manufacturing, Prentice Hall of India, (1997).
R S Parmar, Welding process and technology, Khanna Publisher, New Delhi (2004).
P N Rao, Manufacturing Technology Vol. I & II, Tata McGraw Hill (2009).

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Faculty

Dwivedi D K


Prof. D K Dwivedi obtained BE (mechanical engineering) , in 1993 from GEC Rewa, ME (welding engineering) from Univ. of Roorkee in 1997 and PhD in Met. Engineering from MNIT, Jaipur in 2003. He has about 9 years teaching experience at NIT Hamirpur and 12 years at IIT Roorkee of subjects related with manufacturing at UG level and welding engineering related subjects at PG level. He has published more than 100 research papers in SCI/SCIE indexed journals and undertaken 16 sponsored research and 48 industrial consultancy projects. Instructor has authored two books entitled “Production and Properties of Cast Al-Si Alloys with New Age International, New Delhi (2013) and Surface Engineering with Springer, New Delhi (2017).

 

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