ME361 |
Manufacturing Science and Technology |
Credits: |
3L-0T-1P-0A (10 Credits) |
Pre-requisite: |
TA201, TA202. |
Course Content:
Introduction to manufacturing processes and system concept and its evolution; Metal casting: Solidification Mechanism, Gating and Riser Design, Defects and Product Design; Metal Forming: Fundamentals of Plasticity, Force Equilibrium Method, Forging/upsetting, Drawing, Extrusion, Deep Drawing and Bending, Defects; Machining: Tool Specifications, Orthogonal and Oblique cutting, Tool wear and Tool Life, Economics of Machining; Shaping processes for Plastics and Tool Design; Joining Processes; Un-Conventional Material Removal Processes: ECM, EDM, LBM and Jet Machining; Rapid Prototyping and Tooling; Micro-fabrication technologies; Metrology and Selection of Manufacturing Processes.
Lecturewise Breakup
I. Introduction to manufacturing processes and system concept: (1 Lecture)
II. Metal Casting: (5 Lectures)
- Solidification of Alloys and its mechanism.
- Gating System Design and Estimation of Solidification time.
- Riser Design and Riser Placement.
- Defects and Product Design.
III. Metal Forming : (7 Lectures)
- Mechanism of plastic deformation, fundamentals of plasticity.
- Introduction to Force equilibrium method.
- State of Stress and boundary conditions in Upsetting/forging, Rolling, Wire and tube drawing, Extrusion and Deep Drawing, Defects.
- Load estimation for one plane strain and one axi-symmetric bulk deformation process.
- Analysis of Deep Drawing and Bending.
- Introduction to High velocity forming processes.
IV. Metal Cutting: (6 Lectures)
- Tool Geometry – single edge tools – reference plane, system.
- Tool Specifications – ASA, NRS.
- Mechanics of Orthogonal cutting – Force relationship, Shear angle relationship, determination of co-efficient of friction, determination of stress, strain and strain rate.
- Mechanics of Oblique cutting – Force relationship, shear relationship, co-efficient of friction, stress strain and strain rate.
- Tool Wear and Tool life – Tool wear mechanism, Progressive tool wear, variables affecting tool life.
- Economics of machining – Optimizing cutting parameters for minimum cost.
- Grinding of metals, Grinding forces and specific energy, wheel wear and grinding performance.
V. Unconvensional Machining Processes : (3 Lectures)
- Mechanics of Electrochemical machining; ultrasonic machining; electro-discharge machining; laser beam machining and Jet (Abrasive and Water) Machining.
VI. Shaping Process For Plastics: (2 Lectures)
- Properties of polymer melts and Visco-elasticity common shaping processes (Extrusion, Injection Molding, Compression Molding) and their tool design.
- Common defects; Product design considerations.
VII. Joining: (3 Lectures)
- Introduction to friction welding process and mechanism.
- Introduction to non metal joining processes.
- Weld quality, defect and inspection.
VIII. Rapid Prototyping and Rapid Tooling: (3 Lectures)
- Need for RP/RT; Common RP processes; steriolithography, fused deposition modelling(FDM), selective laser sintering.
- Introduction to rapid tooling techniques; various soft and hard tooling techniques. Applications of RP/RT.
IX. Micro-Manufacturing: (4 Lectures)
- Introduction and Scaling Laws for micro-manufacturing.
- Silicon Layer Processes.
- LIGA process Other Micro-fabrication Processes.
IX. Metrology: (5 Lectures)
- Principles of engineering metrology, Abbe’s principle of alignment, Measuring errors, application of least square principle.
- Interferometry – principles, flatness testing using optical flat, optical interferometers, Moire fringe system measurements.
- Measurement of Angle, taper and radius.
- Limits, fits and tolerances.
- Measurement and gauging of screw threads and gears.
- Acceptance tests for machine tool – CMM.
IX. Selection of Manufacturing Processes: (2 Lectures)
- Basic considerations.
- Process Information Maps (PRIMAs) and Real life examples.
Laboratory sessions:
I. Machining: Force measurement in turning.
II. Machining: Force measurement in Grinding.
III. Forming: Load prediction and measurement and their comparison for Extrusion and/or Deep Drawing.
IV. Electrical discharge machining .
V. Metrology: CMM and Other measuring Instruments.
VI. Micro-fabrication technologies.
References
- Ghosh, A., Mallik, A.K., Manufacturing Science (2nd edition), EastWest Press, 2010.
- Lal, G.K., Introduction to Machining Science (2nd edition), New Age International publishers, 2009.
- Groover, M.P, Fundamentals of Modern Manufacturing (2nd edition), John Wiley.
- Kalpakjian, S., Schmid, S.C., Manufacturing Engineering and Technology, Pearson Education.
- Galyer, J.F.W., Shotbolt, C.R., Metrology for Engineers, ELBS.