TA202 a Lecture 1

TA202 A Lecture 1

Manufacturing Systems Approach

•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.

Manufacturing Facility Add Value Input Output Replenish Wealth Manufacturing System comprising of manufacturing processes Sales fluctuations

Raw materials cost and availability Business environment Social Pressure Resources and plans Production rate, quality and delivery Profit Reputation Manufacturing Process is the key to wealth

Casting Processes

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.

Rolling Process

Drop forging

Extrusion

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

Arc Welding

Material Removal Processes

• 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 Drilling Grinding 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.

Marks Distribution In the Course

Total Marks= (100), All blue text in brackets are actual marks out of which the scores will be provided

Theory: 50% or overall (50) Lab Activities: 50% or overall(50)

LabTurns 20% Project 80%

Lab Exercise 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 Drawing 10% (5)

Project Workability and Innovation 50% (25) Project presentation 20% (10) (Based on Individual Performance) Mid Semester 30% (15) Final Exam 60% (30) Attendance 10% (5)

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

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)

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).

I First turn : Project groups should be formed. (Emphasize in class)

II Second turn : Project groups name should be given to the tutor.

III Third turn : Project discussion with Technical Staff / Guide with Material List.

IV 4th to 5th turn : 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 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)