Manufacturing and Production Processes

Syllabus

1. Overview of Manufacturing (6 hours)
   1. Introduction
   2. Product cycle
   3. Role of manufacturing in economic development
   4. Role of engineers in manufacturing
   5. Evolution of organization for manufacturing
   6. Product design and concurrent engineering
   7. Design for manufacture, assembly, disassembly and service
   8. Green design and manufacturing
   9. Selection of materials
   10. Selection of manufacturing processes
   11. Quality assurance and total quality management
   12. Lean production and agile manufacturing
   13. Manufacturing costs and global competition
   14. Trends in manufacturing
2. Solidification Process and Powder Metallurgy (5 hours)
   1. General characteristics of casting process and products
   2. Solidification phenomena and associated problems
   3. Sand casting process
   4. Investment casting process
   5. Permanent mould and pressure die casting
   6. Continuous casting characteristics and capabilities
   7. Powder metal processes and equipment
   8. Manufacturing process for plastic and composite materials
3. Bulk Deformation Process (5 hours)
   1. General characteristics of bulk deformation process and products
   2. Force, energy and deformation: sensitivity to frictions, geometry, temperature and deformation rate
   3. Forging practice and technology; press and hammers, tooling design, manufacture wear
   4. Design of forgings; characteristics and defects in forgings
   5. Flat rolling; characteristics and defects
   6. Shape rolling: process and products
   7. Extrusion
   8. Wires, bar and tube drawing
4. Sheet Metal Product Manufacturing Process (3 hours)
   1. Shearing and punching operations
   2. Sheet metal and tube bending: technology and practices
   3. Deep drawing and hydro forming
   4. Spinning operations and capabilities
   5. Formability assessment
5. Material Removal Processes: Chip-forming (6 hours)
   1. Modeling the cutting process
   2. Force, power and productivity relationship
   3. Cutting tools materials: characteristics and economics
   4. General purpose machine tool types: operation of lathes, milling, shapers and drilling machines; application of shaping, planning and slotting machines
   5. Methods of mounting of jobs and cutting tools in machine tools
   6. Uses of various attachments in machine tools
   7. Control of machine tools and product properties
   8. Cutting off process: saws, flame cutting, arc cutting
   9. Tribology in machining process
6. Material Removal Processes: Abrasive and Advanced (6 hours)
   1. Abrasive based tooling
   2. Grinding technology and practice
   3. Advanced machining processes
   4. Electrical discharge machining
   5. Electrochemical machining
   6. Laser-beam machining
   7. Electron-beam machining
   8. Water-jet and abrasive-jet machining processes
   9. Hybrid machining
   10. Economics of abrasive and advanced machining processes
7. Automation of Manufacturing Process (5 hours)
   1. Need for flexible automation and numerical controls
   2. CNC machine tool description; technology and practices
   3. Computer-integrated manufacturing
   4. Computer-aided design, engineering and process planning
   5. Industrial robots
   6. Group technology
   7. Economic consideration
8. Rapid Prototyping Process and Applications (4 hours)
   1. Need for rapid prototyping
   2. Subtractive and additive processes, virtual prototyping, self-replicating machines
   3. Direct manufacturing and rapid tooling
   4. Applications of rapid prototyping process
9. Material Joining Processes (5 hours)
   1. Principle of material joining process, types
   2. Fusion-welding processes
   3. Solid-state welding processes
   4. Brazing, soldering, adhesive-bonding processes
   5. Mechanical fastening processes
   6. Design considerations, defects analysis and testing of joints
   7. Economics of joining processes

Practicals

1. Solidification and bulk deformation processes
2. Sheet metal working
3. Engine lathe operations
4. Shaper operations
5. Milling machine operations
6. Drilling machine operation
7. Grinding machine operation
8. Arc welding
9. Gas welding

Evaluation

Final exam questions cover all chapters. Approximate marks distribution (total 60 marks over 45 hours):

1. Overview of Manufacturing: 8 marks
2. Solidification Process and Powder Metallurgy and Bulk Deformation Process: 14 marks
3. Material Removal Processes (Chip-forming and Abrasive and Advanced): 14 marks
4. Sheet Metal Product Manufacturing Process and Automation of Manufacturing Process: 12 marks
5. Rapid Prototyping Process and Applications and Material Joining Processes: 12 marks