TA202A: Introduction to Manufacturing Processes
N. Sinha Department of Mechanical Engineering IIT Kanpur Email:
[email protected]
Information About the Course Lectures Schedule: Tuesday (8:00-9:00 AM) Venue: L-7
Labs Schedule: Monday-Friday (2:00-5:00 PM) Venue: TA202 ME Lab
TA202 Lab
Course updates and announcements http://home.iitk.ac.in/~nsinha/ta.html
Information About the Course TA202A: Introduction to Manufacturing Processes TA: Technical Arts. Introduction: Latin verb introducere, refers to a beginning. Manufacturing: something made from raw materials by hand or by machinery. Process: a series of actions that you take in order to achieve a result. Goal: The course aims to impart the basic knowledge about the fundamental manufacturing techniques employed to convert a raw material into final product.
Manufacturing - Technological • Application of physical and chemical processes to alter the geometry, properties, and/or appearance of a starting material to make parts or products
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Manufacturing – Economic • Transformation of materials into items of greater value by one or more processing and/or assembly operations
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Manufacturing Industries • Industry consists of enterprises and organizations that produce or supply goods and services • Industries can be classified as: 1. Primary industries - cultivate and exploit natural resources, e.g., agriculture, mining 2. Secondary industries - take the outputs of primary industries and convert them into consumer and capital goods 3. Tertiary industries - service sector
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Manufacturing Industries - Continued • Secondary industries include manufacturing, construction, and electric power generation • For our purposes, manufacturing means production of hardware – Nuts and bolts, forgings, cars, airplanes, digital computers, plastic parts, and ceramic products
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Manufactured Products • Final products divide into two major classes: 1. Consumer goods - products purchased directly by consumers • Cars, clothes, TVs, tennis rackets 2. Capital goods - those purchased by companies to produce goods and/or provide services • Aircraft, computers, communication equipment, medical apparatus, trucks, machine tools, construction equipment
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Manufacturing Processes Two basic types: 1. Processing operations - transform a work material from one state of completion to a more advanced state – Operations that change the geometry, properties, or appearance of the starting material 2. Assembly operations - join two or more components to create a new entity
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Question Why do I need this course? Why theory? Why lab exercises?
Question
Which Process to Select and Why?
www.wonkeedonkeetools.co.uk
Questions Need to machine newly developed metals and non-metals with special properties that make them difficult or impossible to machine by conventional methods Need for unusual and/or complex part geometries that cannot easily be accomplished by conventional machining Need to avoid surface damage that often accompanies conventional machining
Example Intricate shaped blind hole – e.g. square hole of 15 mm x 15 mm with a depth of 30 mm Difficult to machine material – e.g. same example as above in Inconel, Tialloys or carbides. Low Stress Grinding – Electrochemical Grinding is preferred as compared to conventional grinding Deep hole with small hole diameter – e.g. φ 1.5 mm hole with l/d = 20 Machining of composites.
Questions
Questions
http://www.me.iitb.ac.in/~ramesh/courses/ME338/non_trad.pdf
Microfabrication
Miniaturization: Information Storage
Data recording on a disc The information is transformed to strings of binary digits (0s and 1s, also called bits). Each bit is then laser “burned” into the disc, using a single beam of light, in the form of dots. The storage capacity of optical discs is mainly limited by the physical dimensions of the dots. Fgure Source: International Data Corporation (IDC)
Miniaturization: Information Storage How far can we reduce the size of the dots? Abbe’s Limit: If a light beam is focused through a lens, the diameter of the resulting spot of light can’t be smaller than half its wavelength. Way to get around the problem The first beam (red, in the figure) has a round shape, and is used to write data. Then, place a doughnut-shaped laser (purple, in the figure) around the initial laser in order to limit the abilities of the first beam. This effectively made the standard laser’s diameter smaller, and it could then write smaller bits. Source: http://theconversation.com/more-data-storage-heres-how-to-fit-1-000-terabytes-on-a-dvd-15306
Layered/Additive Manufacturing Additive Manufacturing (AM) refers to a process by which digital 3D design data is used to build up a component in layers by depositing material. (from the International Committee F42 for Additive Manufacturing Technologies, ASTM)..
What You See Is What You Build (WYSIWYB) Process
Additive vs Subtractive Manufacturing Part Complexity; Material; Speed; Part Quantity; Cost.
Additive vs Subtractive Manufacturing
Figure: Features that represent problems using CNC machining. Source: Gibson, Additive Manufacturing
Additive vs Forming Manufacturing
Advantages of Additive Manufacturing
Principle 1: Complexity is Free
Principle 2: Variety is Free
Principle 3: No Assembly Required
Principle 4: Zero Lead Time
Principle 5: Zero Constraints
Principle 6: Zero Skill Manufacturing
Principle 7: Compact & Portable Manufacturing
Principle 8: Less Waste By-product
Principle 9: Infinite Shades of Materials
Principle 10: Precise Replication
Source Google images
Current and Potential industries for Additive Manufacturing
Benefits
Source: SAVING project/Crucible Industrial Design Ltd.; Roland Berger
Benefits
Source: Roland Berger
Benefits
Source: Roland Berger
Future: Home Manufacturing
Old toothbrush
Customization: •Bristle hardness •Colour •Handle Style and shape •Etc.
Laser scanner to input personalized data Home 3D Printer
New toothbrush
Case Studies
Source: Royal Academy of Engineerin
Topics 1. Introduction: Introduction to manufacturing; evolution of manufacturing; importance of design in manufacturing. 2. Conventional Material Removal Processes: Theory of chip formations; generation of surfaces; force and power relationships; cutting tool material and its geometry; tool wear; fundamentals of machine tools; types of machining operations. 3. Unconventional Material Removal Processes: Introduction, mechanical energy processes, thermal energy processes, electro chemical machining.
Topics 4. Computer Numerical Control and Programming: Basics of numerically controlled machines; programming for NC machines; motion and coordinate system; structure of a NC part program; examples of part programming. 5. Microfabrication Processes: Silicon processing, lithography, micro and nanofabrication processes. 6. Layered/Generative Manufacturing Processes: Fundamentals of layered manufacturing; layered manufacturing technologies, modeling. 7. Engineering Metrology: Dimensions, tolerances, surfaces, structure and properties, surface texture and roughness, engineering metrology and instrumentation
Reference Books 1. Fundamental of Modern Manufacturing: Materials, Processes and Systems: M. P. Groover (John Wiley). 2. Manufacturing Processes for Engineering Materials: S. Kalpakliam and S. R. Schmid (Prentice Hall). 3. Manufacturing Science: A. Ghosh and A.K. Mallik (EastWest Press). 4. Fundamental of Manufacturing Processes: G. K. Lal and S. K. Choudhuary (Narosa). 5. Advanced Machining Processes: V. K. Jain (Allied Publishers). 6. Introduction to Micromachining: Ed. V. K. Jain (Narosa). 7. Micromanufacturing Processed: Ed.: V.K.Jain (CRC Press).
Lab
Themes 1. Agriculture, 2. Transportation, 3. Healthcare, 4. Educational toys to help school children, 5. Machines and Mechanisms. 45
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List of Tutors
Dr. J. Ramkumar
Dr. S. Bhattacharya
Dr. S.K. Choudhry
Mr. A. Kene
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List of Tutors and TAs Day
Tutor
TAs
Email
Monday
Dr. J. Ramkumar (
[email protected])
Gaganpreet Singh (14105274) Atinder Pal Singh (14105268)
gaganprt atinder
Tuesday
Dr. S. Bhattacharya (
[email protected])
Pankaj Singh Chauhan (14205263) Rupal Srivastava (14205265)
pankajs rupalsri
Wednesday
Dr. S.K. Choudhury (
[email protected])
Kashfull Orra (13205071) Navneet Singh (12807436)
Kashu navneets
Thursday
N. Sinha (
[email protected])
Kartikeya Dixit (14105279) Ashutosh Rai (14205002)
dkartik arai
Friday
Mr. A. Kene (
[email protected] )
Raghubeer Singh Bangari (13205076) Vivek Chawda (12807829)
raghusb vchawda
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Grading Criteria Lab (45%)
Theory (55%) Details
Details
Quizzes
7%
Project Drawings
2.5%
Mid Semester Exam
18%
Lab Exercises
2.5%
End Semester Exam
30%
Lab Reports
2.5%
Guide’s Evaluation
2.5%
Attendance
5%
Mid Semester Evaluation
7.5%
End Semester Evaluation
22.5%
To pass this course, one should score total marks ≥ 35 % and theory marks ≥ 30 % of the marks assigned for theory. Academic Dishonesty: ZERO Tolerance “F” Grade
