Fundamentals of Manufacturing Processes

It is proposed to include fundamental of following aspects of manufacturing technology: Understanding Manufacturing: the concept of manufacturing, need, scope, advantages, limitation, application, materials and manufacturing, classification of manufacturing, process capabilities, selection, break even analysis of manufacturing processes. 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. 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. Joining: approach, need, the 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. 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. 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.

Understanding Manufacturing.
Fundamental Approaches of Manufacturing.
Manufacturing process Specific advantages and limitations.
Material and Manufacturing Processes.
Classification of Manufacturing Processes.
Selection of Manufacturing Processes.
Applications of Manufacturing Processes.
Effect of Manufacturing Process on Mechanical properties.
Break Even Analysis in Manufacturing Processes.
Casting: Introduction and Suitability.
Steps of Casting Processes.
Casting: Terminology.
The Pattern Allowances I.
The Pattern Allowances II.
Casting: Sand Moulding l.
Sand Moulding II.
Casting: Core and Core Prints.
Casting: Gating System.
Casting: Yield and Riser Design.
Casting: Riser Design.
Casting: Cleaning of Castings.
Casting Casting Defects and their Preventions.
Casting: Shell Mould Casting.
Casting: Investment and Permanent Mould Casting.
Metal Working Processes: Hot & Cold Working.
Metal Working Processes: Rolling.
Metal Working Processes: Forging.
Metal Working Processes: Extrusion.
Metal Working Processes: Wire Drawing.
Metal Working Processes: Press.
Sheet Metal Operations: Shearing.
Metal Working Processes: Sheet Metal Operations II.
Metal Working Processes: Sheet Metal Operations III.
Metal Working Processes: Dies and Die sets.
Material Removal Processes: Machining.
Material Removal Processes: Mechanism of 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.
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.
Material removal processes: Grinding operations.
Joining of metals: Fundamentals I.
Joining of metals: Fundamentals II.
Joining of metals: Welding processes.
Brazing, soldering and weldability.
Weldability and welding defects.
Heat treatment: Fundamentals I.
Heat treatment: Fundamentals II.
Heat treatment: Fundamentals III.
Heat treatment: Normalizing and hardening.
Heat treatment: Tempering.
Improving surface properties: Introduction.
Improving surface properties: Surface modification processes.
Improving surface properties: Changing chemical composition.
Improving surface properties: Coating.