TA201

Manufacturing Processes

WEEK-1

J A N 1 0 TH 2 0 1 7
2016-2017 SEMESTER-II
 Course Info
2

Instructor In-Charge: Dr. Shashank Shekhar

Materials Science & Engineering
Office: Western Lab 304A Ph. 6528
Email: shashank@iitk.ac.in
Lecture: Tuesday 09:00 09:50 (venue L7)
Lab: Monday-Friday 14:00 16:50
(Venue- Engineering Metallurgy Lab)
Lab In-charge: Mr. Anil Kr. Verma
Materials Science & Engineering
Ph. 7978/7862; Email: akumarv@iitk.ac.in

http://lattice.mse.iitk.ac.in/~shashank/TA201
Dr. Shashank Shekhar 2016-17 Semester-II TA 201
 Tutors
3

Day Sections Tutor E-mail Phone

Monday D1, D2, D6 Prof. Shobit Omar somar@ 7427

Tuesday D3, D4, D5 Prof. Tanmoy Maiti tmaiti@ 6599

Wednesday D7, D8, D9 Prof. Gouthama gouthama@ 7450

Thursday D10, D11, D12 Prof. Shashank Shekhar shashank@ 6528

Friday D13, D14, D15 Mr. Amit Das dasamit@ 6750

Dr. Shashank Shekhar 2016-17 Semester-II TA 201

 Teaching Assistants
4
Day Sections TAs E-mail Phone
1) Mr. Payyavula Raju payyavul@iitk.ac.in 7318020850
Monday D1, D2, D6 2) Mr. Aditya Chaudhary adityac@iitk.ac.in 9532811500
3) Mr. Anil Kumar kranil@iitk.ac.in 9554890543
1) Ms. Saumita Gangopadhyay saumitag@iitk.ac.in 7318020288
Tuesday D3, D4, D5 2) Mr. Mizanur Rahaman mizanur@iitk.ac.in 9454012093
3) Mr. Gidla Mani Ratnam mani@iitk.ac.in 8172913828
1) Mr. Rohit Kumar Tiwari rtiwari@iitk.ac.in 7318019270
Wednesday D7, D8, D9 2) Mr. Kapil Kumaer Verma kpkapil@iitk.ac.in 8174893033
3) Ms. Nirma Kumari nirma@iitk.ac.in 8564888970
1) Mr. Aditya Patel adipatel@iitk.ac.in 7607784804
Thursday D10, D11, D12 2) Mr. Amit Bharadwaj amitbhar@iitk.ac.in 9793825111
3) Mr. Dinesh Kumar dineshku@iitk.ac.in 8290095917
1) Mr. Boina Sagar boina@iitk.ac.in 9963483612
Friday D13, D14, D15 2) Tuhin Dolui tuhindol@iitk.ac.in 9475972390
3) Mr. Ajay Kumar Soni ajaysoni@iitk.ac.in 8516064848

Instructor 1) Mr. Mukul Janbandhu mukuljan@iitk.ac.in 7755057934

Dr. Shashank Shekhar 2016-17 Semester-II TA 201

 Marks Distribution
5
For Theory:
Mid Semester 20 Tutors + Instructor
End Semester 30 Tutors + Instructor
Total 50
A bonus of 5% for attendance of 12-13 lectures. A bonus of 3% for attendance of 10-
11 lecture. Take seat according to seating plan.

For Lab:
Lab Quiz + Attendance in Lab 5+5 TAs
Experiments/job during lab 5 Lab In-charge
Lab Exam 5 Lab In-charge
Project Job 20 Tutors + Lab In-charge +
(Innovation, Finish and volume Course Instructor
of work)
Project Report and Engineering 10 Tutors + Lab In-charge +
Drawing Course Instructor
(Neatness, sequence, timely
submission)
Total 50

Dr. Shashank Shekhar 2016-17 Semester-II TA 201

 Grading
6

For passing the course:

Attendance in all labs (missing 2 lab turns or 1 practice turn
will lead to F grade or de-registration)
Minimum 40% in overall course

Other Grades: Relative grading

Examination Policy:
Academic dishonesty of any kind would not be tolerated and
would be dealt with severely (for the one who copies as well as
for the one who promotes). Any kind of copying or
cheating would draw an F-grade immediately.
Make-up for mid-sem and end-sem exams would be allowed
only on health grounds. (no make-up for participating in
cultural/ technical programs)
Dr. Shashank Shekhar 2016-17 Semester-II TA 201
 Lab safety policy
7

You must attend the lab as per schedule for your

section only (Section change request has to be made to UG office)
Students must come to the laboratory wearing (i)
Trousers, and (ii) Leather shoes. (Half pants, loosely
hanging garments and slippers are ABSOLUTELY not
allowed)
Wear safety gears when your are conducting
experiments
Do not bring mobile phones inside the lab. Absolutely
no photography etc. is allowed. Be courteous to staff
and other peers
Dr. Shashank Shekhar 2016-17 Semester-II TA 201
 Lab policy
8

Strictly adhere to lab timings: There will be two

attendances Initial attendance (at sharp 2 PM) to be
taken by TAs at the beginning of lab session and final one
before you leave the lab
Remember there is a short-quiz at the start of the lab and
you have 10 minutes to submit it. Your experiments start
by 2:10pm. Go through lab-manual and videos on the
website for preparation.
Attendance in lab is compulsory. Missing practice turn
will lead to F-grade or de-registration from the course
Every student should obtain a copy of Manufacturing
Processes Laboratory Manual. You must bring your copy
of lab manual in everydays lab. You can also purchase the
manual in the lab.
Dr. Shashank Shekhar 2016-17 Semester-II TA 201
 General Information
9

In this laboratory you will be exposed to the common manufacturing

processes such as casting, metal forming, and joining processes.
Laboratory experiments will consist of hands-on experience and
demonstration of the various manufacturing processes. This laboratory is
divided into four parts:

A. Practice turns: Hand-on-experience and demonstration of the

various manufacturing processes (5 turns)
1. Practice and Demonstration of green sand mold making and Casting (Demo: Lost
form casting)
2. Sheet Metal Practice and Demonstration (Demo: sheet cutting, sheet bending)
3. GMA Welding Practice and Demonstration (Demo: Resistance welding, Plasma
Cutting)
4. Brazing Practice and Demonstration (Demo: Gas Welding)
5. Demonstration of Rolling, Powder Metallurgy & Plastic Injection Molding
B. Practical laboratory examination & Drawing submission (1 turn)
C. Project turns (6 turns)
D. Project Evaluation (1 turn)

Dr. Shashank Shekhar 2016-17 Semester-II TA 201

 Lab/ Project Turns
10

Lab Practice: First to Fifth Turn

five subgroups for exercises and
demonstrations
Rotation of groups after first turn onwards:
123451

Ex. No. Description 1st Turn 2nd Turn 3rd Turn 4th Turn 5th Turn

1 Molding and Casting A E D C B

2 Sheet Metal Working B A E D C
3 Welding C B A E D
4 Brazing D C B A E
5 Demo of Rolling, PM and Forging E D C B A

Dr. Shashank Shekhar 2016-17 Semester-II TA 201

 Project framing schedule
11
Practice Turn What is expected
1st and 2nd Turn Project group formation and projects to be
discussed with Tutor
3rd Turn Bring minimum of 3 project ideas along with
rough sketch. One project idea will be finalized
in this turn.
4th Turn Discussion on finalized project with proper
drawing as per engineering norms, including
parts drawing
5th Turn Discussion with final drawing and process plan
(Bring complete report)
6th Turn Final drawing submission
7th to 12th Turn Making project
13th Turn Project evaluation
Dr. Shashank Shekhar 2016-17 Semester-II TA 201
 Course Lab Schedule
12

Lab starts 10th Jan (Tuesday) in Engineering

Metallurgy Lab
Lecture Make-up:
14th Jan at 10.30am in L7
1st April at 9.00am in L7
Lab Make-up:
21st Jan at 2pm for Friday group
4th Feb at 10.00am for Thursday group
1st April at 2pm for Tuesday group
8th April at 10.00am for Monday group

Dr. Shashank Shekhar 2016-17 Semester-II TA 201

 About the Project
13

Number of student in each group will be Four.

Project should be a mix (almost equal) of the different
processes that you will practice in the lab. At least
three operations are to be incorporated in the project.
Size of the project: 1 x 1 x 1 ft3 (strictly to be followed)
and total weight for casting objects should not exceed
1.5 kg per project. Oversized and over weighted project
will be credited negative marking. Moving parts in the
project will be given extra credit during evaluation.
External color/paint can NOT be used. Dont
polish/grind cast component used in your project.

Dr. Shashank Shekhar 2016-17 Semester-II TA 201

 Project Guidelines
14

The final project report must include:

assembly drawing with important components marked
table of contents
drawing with dimensions for important components
exploded view of complex parts
materials being used for each component
processes being used for each component
turn wise work distribution
member wise work distribution

After completing the project, you must also include

cost estimate of your project

Dr. Shashank Shekhar 2016-17 Semester-II TA 201

 Recommended Readings
15

Fundamentals of Modern Manufacturing: Materials,

Processes and Systems, Mikell P. Groover
Fundamentals of Manufacturing Processes, G.K. Lal and
S.K. Choudhury
Materials & Processes in Manufacturing, E. P. DeGarmo,
J.T. Black and R. Kohser
Manufacturing Engineering and Technology, S.
Kalpakjian
E.P. DeGarmo: Materials and Processes in
Manufacturing, Macmillan
(Apart from these, there are several videos that have been
made available and an NPTEL course, link to which is
available on course website)

Dr. Shashank Shekhar 2016-17 Semester-II TA 201

 Web References
16

Web Resources:
There are several courses at NPTEL website
(http://nptel.iitm.ac.in/courses.php?disciplineId=113) related to
Manufacturing and can be used as reference for this course.
Manufacturing Processes:
http://www.nptel.iitm.ac.in/courses/Webcourse-contents/IIT-
ROORKEE/MANUFACTURING-PROCESSES/index.htm
http://nptel.iitm.ac.in/video.php?subjectId=112107145
Advanced Manufacturing Processes:
http://nptel.iitm.ac.in/courses/Webcourse-
contents/IIT%20Kharagpur/Manuf%20Proc%20II/New_index1.html
http://nptel.iitm.ac.in/video.php?subjectId=112105126
http://nptel.iitm.ac.in/courses/112107077
http://nptel.iitm.ac.in/courses/112107078/
Design for Manufacturing:
http://nptel.iitm.ac.in/courses/112101005
Materials Selection and Design:
http://nptel.iitm.ac.in/courses/Webcourse-contents/IIT-
KANPUR/material_selection/ui/Course_Objective.html

Dr. Shashank Shekhar 2016-17 Semester-II TA 201

Some earlier projects

2016-17 Semester-II
2016-17 Semester-II
 19

Dr. Shashank Shekhar 2016-17 Semester-II MSE 370

 Objectives of the course
20

To discuss and demonstrate fundamental

manufacturing process:
casting/ solidification

metal working processes

welding and heat treatment

various Powder metallurgical processing routes

and to discuss the mechanisms of sintering
metallic and ceramic solids
plastic injection moulding

Dr. Shashank Shekhar 2016-17 Semester-II TA 201

 Objectives of the course
21

At the end of this course, whenever you look at a

component, you should start asking questions like:
How to manufacture this Engineering Product?
What material was used for this product?
What are other materials that can be used ?
What process was used?
What are other Processes that can be used?
What are the deciding factors for Q2-5?
Hands-on experience: Project

Project will test Your Craftsmanship

Dr. Shashank Shekhar 2016-17 Semester-II TA 201

 Course contents
22

Lecture No. Topic

1 Introduction to manufacturing:
Engineering Materials:
Engineering materials classification
Structure of materials
2/3/4
Types of materials
Properties of materials
Microstructure-property interrelationship
Casting/ Solidification:
Classifications of casting processes
Patterns, Core making, Gating system
5/6 Solidificationof pure metals and alloys, shrinkage, gas solubility
Riser design
Investment casting
Casting defects

Dr. Shashank Shekhar 2016-17 Semester-II TA 201

 Course contents
23

Lecture No. Topic

Joining processes:
Fusion welding: Arc (MMAW, SAW, SMAW), Gas welding and resistance welding
Fusion zone, Heat affected zone (HAZ)
6/7
Brazing and Soldering
Solid state welding processes
Thermit welding
Deformation processes:
Engineering stress-strain curve
Effect of temperature on the workability
Extrusion (direct and indirect)
8/9/10 Rolling classification, roll camber, defects
Forging (open and closed-die)
Wire drawing
Defects
Sheet-metal forming
Dr. Shashank Shekhar 2016-17 Semester-II TA 201
 Course contents
24

Lecture No. Topic

Powder metallurgy:
Introduction
10/11 Powder production
Compaction and Sintering
Engineering stress-strain curve
Plastic injection moulding:
11/12
Flow forming of plastic components
Heat Treatment
12/13
Special techniques (Non-conventional techniques)

Dr. Shashank Shekhar 2016-17 Semester-II TA 201