Fundamentals of Manufacturing Processes

It is proposed to include fundamental of following aspects of manufacturing technologyA) Understanding Manufacturing: concept of manufacturing, need, scope, advantages, limitation, application, materials and manufacturing, classification of manufacturing, process capabilities, selection, break even analysis of manufacturing processesB) Casting: approach, steps, pattern, molding, gate and riser, melt treatment, solidification, casting processes: sand mould, shell mould, permanent mould casting, casting defect and their remedyC) 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, nibblingD) 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 remedyE) 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 : Any interested learnersPRE-REQUISITES : NIL

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