|
ME361
|
Manufacturing Science and Technology
|
Credits:
|
|
3L-0T-1P-0A (10 Credits)
|
|
|
|
Pre-requisite:
TA201, TA202.
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.
Lecturewise Breakup:
I. Introduction to manufacturing processes and system concept: (1 Lecture)
II. Metal Casting: (5 Lectures)
-
Solidification of Alloys and its mechanism.
-
Gating System Design and Estimation of Solidification time.
-
Riser Design and Riser Placement.
-
Defects and Product Design.
III. Metal Forming : (7 Lectures)
-
Mechanism of plastic deformation, fundamentals of plasticity.
-
Introduction to Force equilibrium method.
-
State of Stress and boundary conditions in Upsetting/forging, Rolling, Wire and tube drawing, Extrusion and Deep Drawing, Defects.
-
Load estimation for one plane strain and one axi-symmetric bulk deformation process.
-
Analysis of Deep Drawing and Bending.
-
Introduction to High velocity forming processes.
IV. Metal Cutting: (6 Lectures)
-
Tool Geometry – single edge tools – reference plane, system.
-
Tool Specifications – ASA, NRS.
-
Mechanics of Orthogonal cutting – Force relationship, Shear angle relationship, determination of co-efficient of friction, determination of stress, strain and strain rate.
-
Mechanics of Oblique cutting – Force relationship, shear relationship, co-efficient of friction, stress strain and strain rate.
-
Tool Wear and Tool life – Tool wear mechanism, Progressive tool wear, variables affecting tool life.
-
Economics of machining – Optimizing cutting parameters for minimum cost.
-
Grinding of metals, Grinding forces and specific energy, wheel wear and grinding performance.
V. Unconvensional Machining Processes : (3 Lectures)
VI. Shaping Process For Plastics: (2 Lectures)
-
Properties of polymer melts and Visco-elasticity common shaping processes (Extrusion, Injection Molding, Compression Molding) and their tool design.
-
Common defects; Product design considerations.
VII. Joining: (3 Lectures)
-
Introduction to friction welding process and mechanism.
-
Introduction to non metal joining processes.
-
Weld quality, defect and inspection.
VIII. Rapid Prototyping and Rapid Tooling: (3 Lectures)
-
Need for RP/RT; Common RP processes; steriolithography, fused deposition modelling(FDM), selective laser sintering.
-
Introduction to rapid tooling techniques; various soft and hard tooling techniques. Applications of RP/RT.
IX. Micro-Manufacturing: (4 Lectures)
IX. Metrology: (5 Lectures)
-
Principles of engineering metrology, Abbe’s principle of alignment, Measuring errors, application of least square principle.
-
Interferometry – principles, flatness testing using optical flat, optical interferometers, Moire fringe system measurements.
-
Measurement of Angle, taper and radius.
-
Limits, fits and tolerances.
-
Measurement and gauging of screw threads and gears.
-
Acceptance tests for machine tool – CMM.
IX. Selection of Manufacturing Processes: (2 Lectures)
Laboratory sessions:
I. Machining: Force measurement in turning.
II. Machining: Force measurement in Grinding.
III. Forming: Load prediction and measurement and their comparison for Extrusion and/or Deep Drawing.
IV. Electrical discharge machining .
V. Metrology: CMM and Other measuring Instruments.
VI. Micro-fabrication technologies.
References:
-
Ghosh, A., Mallik, A.K., Manufacturing Science (2nd edition), EastWest Press, 2010.
-
Lal, G.K., Introduction to Machining Science (2nd edition), New Age International publishers, 2009.
-
Groover, M.P, Fundamentals of Modern Manufacturing (2nd edition), John Wiley.
-
Kalpakjian, S., Schmid, S.C., Manufacturing Engineering and Technology, Pearson Education.
-
Galyer, J.F.W., Shotbolt, C.R., Metrology for Engineers, ELBS.
|