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.
Important For Certification/Credit Transfer:
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Final Exam (in-person, invigilated, currently conducted in India) is mandatory for Certification and has INR Rs. 1100 as exam fee.
INTENDED AUDIENCE
UG/PG Student, practicing engineers It is a core course for UG students.
PRE-REQUISITES
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INDUSTRIES THAT WILL RECOGNIZE THIS COURSE
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6477 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
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).
CERTIFICATION EXAM :
The exam is optional for a fee.
Date of Exams : October 28 (Sunday)
Time of Exams : Morning session 9am to 12 noon; Afternoon session: 2pm to 5pm
Exam for this course will be available in both morning & afternoon sessions.
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.
CERTIFICATION:
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.
