Fundamentals of Manufacturing Materials, Processes & Systems

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Course Outline

Introduction to Manufacturing:

Lecture 1

• Introduction to Manufacturing Processes
• What is manufacturing
• Manufacturing Industries
• Manufacturing Products
• Production Quantity and Product variety
• Materials in Manufacturing
• Manufacturing Processes (Processing operations and Assembly operations)

Sand Casting:

Lecture 2

• Overview of casting technologies
• Difference between casting and molding
• Advantages and Disadvantages of casting processes
• Casting Processes (Expendable mold casting and permanent mold casting)

Lecture 3

• Sand casting and Engineering analysis of sand casting y sand
• Pouring and Engineering Analysis of Pouring
• Flow rate and time required to fill the mold
• Fluidity
• Solidification and Cooling

Lecture 4

• Solidification of pure metals and alloys (Alloys and Eutectic Alloys)
• Solidification time and Shrinkage
• Directional Solidification

Lecture 5

• Riser Design with Exercise Problems.

Lecture 6

• Pattern for casting
• Materials used for pattern
• Types of pattern
• Mold making and Classification of sand molds
• What is foundry sand?

Lecture 7

• Buoyancy Force
• Metal casting processes
• Shell molding
• Advantages and Disadvantages of Shell molding
• Vacuum molding
• Advantages and Disadvantages of Vacuum molding
• Expanded Polystyrene Casting
• Advantages and Disadvantages of Expanded Polystyrene Casting
• Investment casting
• Plaster and Ceramic Mold casting

Permanent Mold Casting (PMC):

Lecture 8

• Types of pattern allowance (Shrinkage and contraction allowance, Draft allowance, Machining allowance, and Distortion allowance)
• Permanent mold casting and its Applications.
• Slush casting
• Low-pressure casting
• Vacuum permanent mold casting
• Die casting (Hot and cold chamber die casting)
• Advantages and Limitations
• Centrifugal casting and Semi centrifugal casting

Lecture 9

• Furnaces
• Cupolas Furnace
• Direct Fuel Fired Furnace
• Crucible Furnace
• Electric Arc Furnace
• Induction Furnace

Metal Forming:

Lecture 10

• Fundamentals of metal forming
• Types of deformation processes of metal
• Bulk deformation (Rolling, Forging, Extrusion, Wire Drawing)
• Sheet metal working
• Stress-Strain Curve
• Derivation of the relation between stress and strain
• Flow stress and Average flow stress
• The temperature in metal forming (Cold working and Hot-working)
• Recrystallization
• Iso thermal forming (recovery and Grain growth)
• Strain rate Sensitivity

Lecture 11

• Introduction of rolling
• Shapes used for rolling
• Types of rolling
• Working of the rolling process
• Analysis of the rolling
• Rolling mills
• No-Slip Point for rolling
• Flatness control and rolling defect

Lecture 12

• Numerical Problems related to the rolling process

Lecture 13

• Introduction to forging
• Classification of forging
• Types of forging
• Analysis of the forging
• Barreling effect in forging
• Open Die forging and its practices
• Impression Die forging and its practices
• Advantages and Limitations of Impression Die forging
• Fleshless forging
• Forging Press and Forging Hammers

Lecture 14

• Numerical Problems related to the forging process

Lecture 15

• Introduction to the extrusion process
• Classification of extrusion
• Direct and Indirect extrusion
• Hot and Cold extrusion
• Direct and Continuous extrusion
• Analysis of the extrusion process
• Effect of friction on extrusion
• Extrusion Dies and Orifice
• Extrusion press and other extrusion processes

Lecture 16

• Numerical Problems related to the extrusion process
• Introduction to Drawing
• Difference between drawing and wire drawing
• Bar Drawing
• Wire Drawing
• Features of Draw Die
• Preparation of the work
• Analysis of the drawing process

Sheet metal forming processes:

Lecture 17

• Introduction to sheet metal cutting process
• Characteristics of Edges
• Types of sheet metal cutting
• Shearing
• Blanking and Punching
• Clearance in Sheet metal cutting
• Analysis of sheet metal cutting processes
• Numerical Problems related to the sheet metal cutting process

Lecture 18

• Introduction of sheet metal bending process
• Types of sheet metal bending
• Analysis of the sheet metal bending process
• Numerical Problems related to the sheet metal bending process
• Spring Back

Lecture 19

• Introduction to the drawing process
• Mechanics of drawing
• Stages of deformation
• Analysis of the drawing process
• Tests of Drawing Feasibility
• Blank force and blank size determination
• Numerical Problems related to the drawing process

Lecture 20

• Other drawing processes (Redrawing, Reverse Drawing and Drawing without Blank holder)
• Defects in Drawing
• The operation performed with metal tooling
• Ironing
• Coining & Embossing
• Lancing & Twisting
• The operation performed with flexible Rubber tooling
• Guerin and Hydro forming process

Lecture 21

• Numerical Problems related to the other drawing processes

Welding Processes:

Lecture 22

• Fundamentals of welding
• Difference between joining and welding
• Advantages and Disadvantages of Welding
• History of welding
• Types of the welding process
• Components used for welding process (Filler material, Flux, and Electrolyte)
• Consumable and Non-consumable electrolyte
• Welding positions
• Welding Electrode Nomenclature
• Type of Weld Joints (Butt joint, Corner Joint, Lap joint, Tee Joint, Edge Joint)
• Types of Weld (Filler Weld, Groove Weld, Plug weld or slot weld, Spot and Seam weld, Flange and Surface Weld)
• Features of Fusion Welded Joints
• Physics of welding (Power Density and Numerical of Power Density)
• Heat Balance in Fusion Welding
• Welding as Commercial Operation
• Automation in Welding (Machine, Automatic and Robotic)
• Welding Safety

Lecture 23

• Welding Categories (Fusion Welding, Solid State Welding, Soldering and Brazing)
• Arc Welding
• Arc Shielding
• The power source in Arc welding
• Types of Arc Welding (Shielding metal arc welding, Gas Metal Arc Welding, Flux Cored Arc Welding, Submerged Arc Welding,
• Gas Tungsten welding
• Plasma arc welding

Lecture 24

• Oxyfuel arc welding
• Oxyacetylene welding
• Resistance welding
• Spot Welding
• Resistance seam welding
• Resistance projection welding
• Energy beam welding (Electron beam welding, Laser beam welding)
• Numerical Problems related to the welding processes

Lecture 25

• Numerical Problems Related to the welding processes

Lecture 26

• Solid-state welding
• Types of solid-state welding
• (Diffusion welding, Friction welding, and Ultrasonic welding)
• Welding Defects of Solid State Welding
• Brazing and Soldering

Fabrication of Plastics:

Lecture 27

• Plastics
• Type of Plastics
• Properties of polymer melt (Viscosity and Viscoelasticity)
• Extrusion process for Plastics in detail
• Extruder Screw
• Feed Section
• Compression Section
• Metering Section
• Process Parameters
• Solid and Hollow Profiles
• Wire and Tube coating
• Defects in the extrusion process

Lecture 28

• Injection molding for Plastics in detail
• Clamping
• Injection
• Cooling
• Ejection
• Application and Material
• Advantages and Disadvantages

Lecture 29

• Blow Molding
• Extrusion Blow Molding
• Injection Blow Molding
• Stretched Blow Molding
• Compression Molding
• Transfer Molding (A pot transfer molding and B plunger-type transfer molding)

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