TA202 a Lecture 1

TA202 A Lecture 1 Tutor: Shantanu Bhattacharya

Manufacturing Systems Approach Definition of Manufacturing Technology: •Manufacturing technology provides the tools that enable production of all manufactured goods. These master tools of industry magnify the effort of individual workers and give an industrial nation the power to turn raw materials into the affordable, quality goods essential to today’s society. •Manufacturing technology provides the productive tools that power a growing, stable economy and a rising standard of living. Thus manufacturing process really represents adding value to a raw material and creation of wealth. Replenish Sales fluctuations

Output

Manufacturing Facility Add Value

Raw materials cost and availability Business environment

Input

Social Pressure

Manufacturing System comprising of manufacturing processes

Production rate, quality and delivery Profit Reputation

Resources and plans

Wealth

Manufacturing Process is the key to wealth generation

Casting Processes • • •

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These are the only processes where liquid metal in used. Casting is the oldest known manufacturing process. It requires preparation of a cavity usually in a refractory material to resemble closely to the object to be realized. Molten metal is poured into this refractory mould cavity and is allowed to solidify. The object after solidification is removed from the mould.

Forming Processes • •

• •

These are solid state manufacturing processes involving minimum amount of material wastage and faster production. Metal is heated to a temperature which is slightly below the solidus temperature and then a large force is applied such that the material flows and take the desired shape. The desired shape is controlled by means of certain tools called dies which may be completely or partially closed during manufacture. These processes are normally used for large scale production rates.

Extrusion Drop forging

Rolling Process Wire Drawing

Fabrication processes • These are secondary manufacturing processes where the starting raw materials are processed by any of the previous methods. •It essentially involves joining pieces either temporarily or permanently so that they would perform the necessary function. •The joining can be achieved by both heat and pressure and / or a joining material. Gas Welding Resistance Welding

Arc Welding

Material Removal Processes •

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These are also secondary manufacturing processes where the additional unwanted material is removed in the form of chips from the blank material by a harder tool so that a final desired shape can be obtained. Material removal is the most expensive manufacturing process because more energy is consumed, and also a lot of waste material is generated in the process.

Turning

Milling

Shaping

Grinding

Drilling Sawing

Why Machining ? 1. Finishing Requirements of Parts: • Parts manufactured by casting, forming, and various shaping processes require further finishing before they are ready for use or assembly. 2. Interchangeability of parts: • Sometimes in many engineering applications interchangeability of parts is needed for which specific tolerances, dimensional accuracy and surface finish are vital. 3. Specific and complex geometries and accuracy in assembly: • Machining involves the removal of some material from the work piece in order to produce a specific geometry at a definite degree of accuracy and surface quality.

Classification of Machining

Marks Distribution In the Course Total Marks= (100), All blue text in brackets are actual marks out of which the scores will be provided Lab Activities: 50% or overall(50)

Theory: 50% or overall (50)

Attendance 10% (5) Mid Semester 30% (15) Final Exam 60% (30)

LabTurns 20%

Lab Exercise 10% (5)

Project 80%

Project Drawing 10% (5)

(This would include the lab report marks (2) and the rating of the technical staff (3))

Lab Quiz 10% (5) Lab Quiz Dates: 26/08/2013~30/08/2013 Venue: TA202 Lab (Quiz and solution would be provided to TA by Instructor I/C. Checking and grade submission by TA to instructor I/C latest by 02/09/2013)

Project Workability and Innovation 50% (25)

Project presentation 20% (10) (Based on Individual Performance)

Note: A minimum of 17 marks in each of theory and lab activities section is needed by students to pass 9 the examination

Topics To be Covered in Theory 1. Manufacturing Properties of Materials.(1 class) (A computer numeric control of machines video will be demonstrated) 2. Fundamentals of Conventional Machining. (Mechanics of material removal, Introductory processes Turning, Milling, Shaping and Planning, Drilling and Grinding) (4 classes) 3. Computer Numeric Control of Machines (2 classes) 4. Fundamentals of non-conventional machining (Illustration of basic processes, Process model of Ultrasonic machining and Electrochemical machining) (5 classes) 5. A perspective to Modern miniaturized manufacturing (1 class) 6. A perspective to Metrology (Science of measurements) (1 class) •Material of class notes would be very important. •Text Book used is Manufacturing Science by Professors Amitabha Ghosh and Ashok Kumar Mallick, Publisher Affiliated East West press.

Activity Roster for Lab-work Lab Training first five turns: #Turning (1 Turn), #Milling and Shaper (1 Turn), #Drilling Fitting (1 Turn), #CNC demonstration and job design (1 Turn), #CNC practice (1 Turn) I First turn II Second turn III Third turn IV 4th to 5th turn

: Project groups should be formed. (Emphasize in class) : Project groups name should be given to the tutor. : Project discussion with Technical Staff / Guide with Material List. : Everything should be finalized during the 4th to 5th lab turn. So the work should start without any loss of time on the 6th lab turn.

Activity Schedule: Lab Turns: 29/07/2013~ 30/08/2013 Project Turns : 02/09/2013 ~ 25/10/2013 Evaluation: 28/10/2013~01/11/2013 (Monday ~ Friday) as per schedule 2:00-5:00 pm in TA202 (a). 11

Activity Calender

Evaluation between 28/10/2013~01/11/2013

Total Make Up Labs: 05 normal (Green Highlighted)+ 01 due to Antaragini (Date to be announced) All makeup’s should be preferentially on Saturday 9:00 am -12:00 noon

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