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MEPC16_Introduction_PPT

The document outlines the syllabus for a Manufacturing Technology course at the National Institute of Technology Tiruchirappalli, covering key topics such as manufacturing processes, materials, casting, welding, forming, machining, and CNC systems. It emphasizes the importance of selecting appropriate manufacturing processes based on material properties, geometry, tolerances, and cost. Additionally, it provides definitions and classifications of manufacturing, highlighting the transformation of materials into valuable products.

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Challa Yachendra
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4 views

MEPC16_Introduction_PPT

The document outlines the syllabus for a Manufacturing Technology course at the National Institute of Technology Tiruchirappalli, covering key topics such as manufacturing processes, materials, casting, welding, forming, machining, and CNC systems. It emphasizes the importance of selecting appropriate manufacturing processes based on material properties, geometry, tolerances, and cost. Additionally, it provides definitions and classifications of manufacturing, highlighting the transformation of materials into valuable products.

Uploaded by

Challa Yachendra
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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NATIONAL INSTITUTE OF TECHNOLOGY TIRUCHIRAPPALLI

Manufacturing Technology (MEPC16)

Dr. Vineet Kumar Yadav


Assistant Professor, Department of Production Engineering,
National Institute of Technology Tiruchirappalli,
Tiruchirappalli- 620015, Tamil Nadu, India.
Email: [email protected]
Syllabus
Unit 1: Introduction to manufacturing process - Selecting manufacturing process – global
competitiveness of manufacturing costs – Fundamentals of materials – their behavior and
manufacturing properties– Ferrous metals and alloys – Non-Ferrous metals and alloys.
Unit 2: Casting: Solidification of Alloys and its mechanism – Gating system design and
estimation of solidification time – Riser Design and Riser placement – Defects and Product
Design.
Welding: Physics of Arc sources – Welding equipment's - Types of welding processes –
Electrode designation and fluxes – Principle and application of Special welding processes.
Brazing and Soldering.
Unit 3: Forming process: Forging, Rolling, Drawing, Extrusion – Classification, Defects
and Inspection.
Sheet metal forming process: Shaping process for plastics – Extrusion, Injection and
Compression Molding.
Unit 4: Machining process: Various machining process and its working principles – Metal
Cutting: Tool geometry – single edge tools – reference plane – Tool specifications –ASA,
NRS – Mechanics of Orthogonal cutting and Oblique cutting – Tool wear and Tool life –
Economics of Machining.
Unit 5: NC & CNC machine tools and manual part programming Machining centre. NC part
programming – Computer aided part programming - Rapid Prototyping processes:
Stereolithography, Fused Deposition modelling, 3D Printing, Selective laser sintering –
Rapid Tooling techniques.
Outline

• Introduction
• Manufacturing Processes
• Casting
• Welding
• Forming
• Machining
• NC and CNC Systems
Acknowledgements:
• M. P. Groover, Fundamental of modern manufacturing Materials, Processes and systems
• J. T. Black and R. A. Kohser, Materials and processes in manufacturing
• P N Rao, Manufacturing Technology (Vol. I and II)
• S. Kalpakjian and S. R. Schmid, Manufacturing Engineering & Technology
Casting Welding

Forging (one of the forming process) Machining


Manufacturing

These products are produced by a combination of various processes.


Products & No. of Parts

Single material products Multi material (parts) products 12,000 parts

> 5,000 parts > 6 million parts


What is Manufacturing?

• The word manufacturing is centuries old and derived from two Latin words
manus (hand)
factus (make)
Hence, manufacturing literally means made by hand.
• Although modern manufacturing is accomplished by automated and computer-
controlled machinery, the word manufacturing is still in use.
Manufacturing is the economic term for making goods and services available to
satisfy human wants.
Manufacturing Process
Process- often implies a sequence of steps
A manufacturing process converts unfinished materials to finished products, often
using machines or machine tools.
What is Manufacturing?

Manufacturing can be defined in two ways; technologically and economically.


• Technologically: Manufacturing is the application of physical and chemical
processes to alter the geometry, properties, and/or appearance of a starting material
to make products. Manufacturing also includes assembly of multiple parts to make
products.
What is Manufacturing?

• Economically: Manufacturing is the transformation of materials into items of greater


value by means of one or more processing and/or assembly operations.
Manufacturing adds value to the material either by changing its shape or properties or
by combining it with other materials that have been similarly altered.

• Conversion of iron ore into steel


• Conversion of sand ore into glass
• Conversion of petroleum into plastic
• Conversion of plastics ore into chair
Engineering Materials
Materials in Manufacturing
Metals in Manufacturing
Metals used in manufacturing are usually alloys, which are composed of two or more
elements, with at least one being a metallic element.
Metals and alloys can be divided into two basic groups:
1. Ferrous- Based on iron
• Steel
• Cast Iron
2. Non-Ferrous- other metallic elements and their alloys
• Aluminum, Copper, Gold, Magnesium, Nickel, Silver, Tin, Titanium, Zinc, etc.
Ceramics in Manufacturing
A compound containing metallic (or semi-metallic) and nonmetallic elements.
• Traditional ceramics: Clay, Silica (used to make glass products), Alumina, Silicon carbide
• Newer Ceramics: Carbides, Nitrides
Polymers in Manufacturing
polymer is a compound formed of repeating structural units called ‘mers’
• Thermoplastic polymers: Polyethylene, Polystyrene, Polyvinylchloride, Nylon
• Thermosetting polymers: Phenolics, Amino resins, Epoxies
• Elastomers: Natural rubber, Neoprene, Silicone, Polyurethane
Composites in Manufacturing
Composites do not really constitute a separate category of materials; they are mixtures
of the other three types (metals, ceramics, and polymers).
A composite is a material consisting of two or more phases that are processed
separately and then bonded together to achieve properties superior to those of its
constituents.
e.g.
• Wood (Natural composite)
• Fiber-reinforced plastic (glass fibers in a polymer matrix)
• Epoxy-Kevlar composite (polymer fibers of one type in a matrix of a second
polymer)
• Cemented carbide cutting tool (tungsten carbide in a cobalt binder)
Classification of manufacturing processes
Casting

Forming
Machining

Welding

M.P. Groover, Fundamental of modern manufacturing Materials, Processes and systems, 4ed
Selection of manufacturing processes
• Required materials
• Required geometry Identify

• Number of parts
• Required tolerances Evaluate
• Cost (including tools and materials cost)
• Required level of automation Select

e.g.
Material choice will instantly rule out a vast number of unsuitable processes. Many processes work
exclusively with certain materials.
e.g. injection moulding can only be used with polymers, whilst die casting can only be used with
metals.

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