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Courses » Fundamentals of manufacturing processes

Fundamentals of manufacturing processes

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.


INTENDED AUDIENCE

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



PRE-REQUISITES

NIL


INDUSTRIES THAT WILL RECOGNIZE THIS COURSE

NIL

8253 students have enrolled already!!

INSTRUCTOR DETAILS



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).


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

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 6

Metal working processes: Rolling
Metal working processes: Forging 
Metal working processes: Extrusion
Metal working processes: Wire Drawing
Metal working processes: Press

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).


MORE DETAILS ABOUT THE COURSE

Certification Exam

The exam is optional for a fee. Exams will be on October 22, 2017.
Time:
Shift 1: 9am-12 noon
Shift 2: 2pm-5pm
Any one shift can be chosen to write the exam for a course.
Registration url: Announcements will be made when the registration form is open for registrations.
The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published.

Certificate

Final score will be calculated as : 25% assignment score + 75% final exam score
25% assignment score is calculated as 25% of average of  Best 8 out of 12 assignments
E-Certificate will be given to those who register and write the exam and score greater than or equal to 40% final score. Certificate will have your name, photograph and the score in the final exam with the breakup. It will have the logos of NPTEL and IIT Roorkee. It will be e-verifiable at nptel.ac.in/noc