Objectives

The main objective of this course is to acquaint students with secondary manufacturing processes. In addition to their classification, this course includes physics of various secondary manufacturing processes. Further, the students will be introduced to working and control of manual and CNC machines besides measurement techniques used in manufacturing.

Course content

Introduction to manufacturing processes and system concept and its evolution; Metal casting: Solidification Mechanism, Gating and Riser Design, Defects and Product Design; Metal Forming: Fundamentals of Plasticity, Force Equilibrium Method, Forging/upsetting, Drawing, Extrusion, Deep Drawing and Bending, Defects; Machining: Tool Specifications, Orthogonal and Oblique cutting, Tool wear and Tool Life, Economics of Machining; Shaping processes for Plastics and Tool Design; Joining Processes; Un-Conventional Material Removal Processes: ECM, EDM, LBM and Jet Machining; Rapid Prototyping and Tooling; Micro-fabrication technologies; Metrology and Selection of Manufacturing Processes.

Total number of lectures: 28

Lecturewise breakup

1. Introduction to and outlining the course:1 Lecture

2. Conventional machining processes: 8-10 Lectures

• Orthogonal cutting mechanics; thermal aspects of machining; tool wear and life analysis; oblique cutting; turning with a nose radius; milling; drilling; grinding 

3. Non-traditional machining processes: 6-10 Lectures

• Mechanical, thermal, electrochemical and chemical processes such as abrasive jet machining, ultrasonic machining, electric discharge machining, electrochemical machining, and laser beam machining

4. Machines and their operations: 2-3 Lectures

• Overview of working of manual and CNC machines and their control

Recommended books

1. Ghosh, A., Mallik, A.K., Manufacturing Science (2nd edition), EastWest Press

2. Groover, M.P., Fundamentals of Modern Manufacturing (2nd edition), John Wiley

3. Kalpakjian, S., Schmid, S.C., Manufacturing Engineering and Technology, Pearson Education

4. Boothroyd, G., Knight, W.A., Fundamentals of Machining and Machine Tools, Taylor & Francis

5. Galyer, J.F.W., Shotbolt, C.R., Metrology for Engineers, ELBS

Any other remarks

Two laboratory exercises on conventional machining; A laboratory exercise on non-traditional machining; A laboratory exercise on metrology.

Proposing instructors: Dr. V. Kumar, Dr. S. Mishra, Dr. K. Ramani, Dr. U. Roy, Dr. S. Mukhopadhyay, Dr. M. Law, Dr. A. Kumar, Dr. N. Sinha, Dr. S. Bhattacharya