Domain Track: Manufacturing (Conventional, CNC and Additive)
Teacher
Dillip Mohanta
Category
Domain Courses
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Code: CUTM2016
Total Credits ( T-P-P): 26 (2-14-10)
Course Divisions
1. Manufacturing Requirements and Planning (CUCM2150) (2-0-0)
2. Conventional Machining for Cylindrical and Prismatic Shape Components (CUCM2151) (0-4-2)
3. CNC Machining (CUCM2152) (0-6-2)
4. Non-Traditional Machining and 3D Printing (CUCM2153) (0-2-2)
5. Wood Engineering (CUCM2154) (0-2-0)
6. Internship (CUCM2155) (0-0-4)
Objective:
1. To provide in-depth technical training & knowledge of machining technologies and machinery which would strengthen product development and industrial-institutional partnership.
Learning Outcomes:
Students will able to
1. Operative machine tools effectively & efficiently
2. Produce components/products by executing various operations with desired accuracy & finish
| COs | Course Outcomes | Mapping COs with POs (High-3, Medium-2, Low-1) |
| CO1 | Knowledge to do machining effectively & efficiently. | PO1 ( 3) |
| CO2 | Able to identify and solve problems in product machining. | PO2(3) |
| CO3 | Use of advanced CAD & CAM software | PO4(3), PO5 (3) |
| CO4 | Research in advancement in machining | PO2 (3), PO3 (2) |
Domain Syllabus:
1. Manufacturing Requirements and Planning (CUCM2150) (2-0-0) (20 Hrs)
Theory
1.1 Introduction to Jigs & Fixtures- Fundamental Concept and Need of Jigs and Fixtures
1.2 Jigs and Fixtures Design Principles
1.3 Locators- Degrees of Freedom and Constraints; Foolproofing
1.4 Locating Principles & Methods, Types of Locators
1.5 Clamps & Indexing Devices - Principles of clamping
1.6 Types of clamps, Indexing
1.7 Jigs- Types of Drilling Jigs
1.8 Drilling Jig Component & Selection)
1.9 Fixtures- Milling & Turning Fixtures
1.10 Grinding and Modular Fixtures
1.11 Process Planning- Approaches to Process Planning, Process Planning Activities
1.12 Operating Sequences, Setup Documents for Process Planning, Process Sheet
1.13 Material Requirement- Bill of Material, Selection of Machinery
1.14 Process Time Calculation
1.15 Computer-Aided Process Planning- Retrieval Type & Generative Process Planning
1.16 Group Technology
1.17 Cost Estimation- Cost Estimation Procedure, Data Requirements and Sources of Information
1.18 Allowances in Production Cost Estimation Estimation
1.19 Cost Estimation in Machine Shop-Machined components
1.20 Overhead Cost & Expenses
2. Conventional Machining for Cylindrical and Prismatic Shape Components ( CUCM2151) (0-4-2) (75 Hrs)
Practice
2.1 Turning Operations (Internal and External), Knurling, Thread Cutting, Chamfering & Cut-off.
2.2 Drilling & related operations (Reaming, Boring, Counter Sinking, Counter Boring)
2.3 Surface Finishing Operations
2.4 Shaper Operations ( Horizontal & Vertical shaping, Shaping of Grooves, Slots)
2.5 Shaper Operations (Steps & Keyways, Angular Shaping, Cutting of Splines & Gear Teeth)
2.6 Milling & Related Operations (Slab Milling, Face Milling, Gear Cutting, etc.)
2.7 Slotter Operations (Internal Grooves or Keyways, Internal Gears, etc.)
2.8 Process Planning of Cylindrical & Prismatic Components, Logical Sequencing of Operations
2.9 Estimation of Machining Operations Time and Cost
3. CNC Machining (CUCM2152) (0-6-2) (100 Hrs)
Practice
3.1 Work Organization and Management (Safety; Simple Maintenance; Principles of Cutting; Machinery-handbooks, Datasheets, and tables; Computer Operating Systems)
3.2 Interpret Engineering Drawings (Drawing, Standards & Symbols)
3.3 Fundamentals, Numerical Control & Tools (Identification of Cutting Tools; Manual Cutting Operations; Off-setting and its Types; Fanuc & Siemens )
3.4 Programming ( Manual & CAM- Developing Program for Facing, Turning, Taper Turning, Drilling, Boring and Threading by following Process Plan)
3.5 Metrology (Range of Tools and Gauging Instruments and Their Applications-Callipers, Micrometers, Gauges)
3.6 Setting and Operating CNC Lathe and Milling Machine (Setup, Initialization, Manipulation and Stop)
3.7 Finalize and Deliver Workpiece (Procedures and Calculations Required for Scheduling Time with Software and Machinery)
4. Non-Traditional Machining and 3D Printing (CUCM2153) (0-2-2) (50 Hrs)
Practice
4.1 Electric Discharge Machining- Machining Parameters & Characteristics
4.2 Electric Discharge Machining- Machining of Different Materials & Analysis
4.3 Wire-EDM- Machine Control Panel, and Performance Characteristics by varying input parameters.
4.4 Additive Manufacturing- Rapid Prototyping Process, Various Rapid Prototyping Technologies: SLA, LOM, SLS and FDM.
5. Wood Engineering (CUCM2154) (0-2-0) (25 Hrs)
Practice
5.1 Work Organization and Management (Safety & Serviceability)
5.2 Reading and Interpreting Drawings; Setting Out and Measuring
5.3 Advanced Machine Tools, Carpentry Hand Tools (Basic Working Principles and Operations)
5.4 Wood Joints and Structural Assemblies (Forming Joints and Preparing Members for Assembly, Assembling, Fastening, and Finishing)
Session Plan:
1. Manufacturing Requirements and Planning (Jigs & Fixtures; Process Planning & Cost Estimation) (2-0-0) (20 Hrs)
Session 1: Introduction to Jigs & Fixtures
https://www.youtube.com/watch?v=CA3GnfImGmw
https://www.youtube.com/watch?v=inDMgs7RkH0
Session 2: Jigs and Fixtures Design Principles
https://www.youtube.com/watch?v=6BFTe1avMyE
https://www.youtube.com/watch?v=vOo2MCYPsm4
Session 3: Locators- Degrees of Freedom
https://www.youtube.com/watch?v=cMZln14wIAQ
Session 4: Locating Principles, Types of Locators
https://www.youtube.com/watch?v=knd4-p_lQNU
https://www.youtube.com/watch?v=ofx2rbBciyg
https://www.youtube.com/watch?v=_7T_wHRqECg
https://www.youtube.com/watch?v=7yzvno4AvKw
Session 5: Clamps & Indexing Devices
https://www.youtube.com/watch?v=cS_KkHOe8dc
https://www.youtube.com/watch?v=0LtWaDMGdDU
Session 6: Types of Clamps & Indexing
https://www.youtube.com/watch?v=aB4CE00FYXM
Session 7: Fixtures- Milling & Turning
https://www.youtube.com/watch?v=wKGC5xj-ZDQ
https://www.youtube.com/watch?v=7eSVIX8SEv4
https://www.youtube.com/watch?v=b28cfsZu-LU
https://www.youtube.com/watch?v=SaAvWLtXxYQ
https://www.youtube.com/watch?v=DXOR4YeMn-8
Session 8: Grinding Fixtures
https://www.youtube.com/watch?v=gcCw2F_Bpo0
Session 9: Drilling Jigs
https://www.youtube.com/watch?v=i1AhziW7WDs
https://www.youtube.com/watch?v=Qj0A7FFyP8U
Session 10: Drilling Jigs Component
https://www.youtube.com/watch?v=nI44BHz5Wls
Session 11: Approaches to Process Planning
https://www.youtube.com/watch?v=Ieek7XgKfxM&t=60s
Session 12: Operating Sequences, Process Sheet
https://www.youtube.com/watch?v=FmeWbgRkSu0
https://www.youtube.com/watch?v=1rcbW6c_1G0
Session 13: Material Requirement
https://www.youtube.com/watch?v=_RPBHEDgeAo
https://www.youtube.com/watch?v=Bj6vdGL9b8M
Session 14: Process Time Calculation
https://www.youtube.com/watch?v=Qwr_1852aDA
Session 15: Computer-Aided Process Planning
https://www.youtube.com/watch?v=2EB-LyDF5fQ
https://www.youtube.com/watch?v=hEkNV7WifpQ
https://www.youtube.com/watch?v=l26qHi48MKs
https://www.youtube.com/watch?v=S5lhPGL9TIk
Session 16: Group Technology
https://www.youtube.com/watch?v=48szrhv-DzM
Session 17: Cost Estimation
https://www.youtube.com/watch?v=A1EtpfwyOfA
Session 18: Production Cost Estimation
https://www.youtube.com/watch?v=POMI_peFx04
https://www.youtube.com/watch?v=XqXgGpsIYvs
Session 19: Cost estimation in Machine Shop
https://www.youtube.com/watch?v=gW3dnyBRas8
Session 20: Overhead Cost & Expenses
https://www.youtube.com/watch?v=_P1U6daB5W0
https://www.youtube.com/watch?v=NAVCHoHDbgs
Assignment 1
http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Assignment-1-1.pdf
Course Material
http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Class-note-1.pdf
http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Class-note-1.pdf
http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Process-Planning-3-1.pdf
2. Conventional Machining for Cylindrical and Prismatic Shape Components (0-4-2) (75 Hrs)
Session 1: Turning Operations (Internal and External), Knurling, Thread Cutting, Chamfering & Cut-off.
https://www.youtube.com/watch?v=mXaJQxbC7OM
https://www.youtube.com/watch?v=SvlZHHDXCZs
https://www.youtube.com/watch?v=_0o8vd6UUeY
Session 2: Drilling & related operations (Reaming, Boring, Counter Sinking, Counter Boring)
https://www.youtube.com/watch?v=HqNRlDsqWho
https://www.youtube.com/watch?v=f5HfRpeT7Fg
Session 3: Surface Finishing Operations
https://www.youtube.com/watch?v=npybvhWYklc
https://www.youtube.com/watch?v=FfjA5ZEUhi0
https://www.youtube.com/watch?v=gcWj4OcteTk
Session 4: Shaper Operations ( Horizontal & Vertical shaping, Shaping of Grooves, Slots)
https://www.youtube.com/watch?v=6jNFrRJMFGk
https://www.youtube.com/watch?v=so4O_yxUfCE
Session 5: Milling & Related Operations (Slab Milling, Face Milling, Gear Cutting, etc.)
https://www.youtube.com/watch?v=LDxq9AkxYfk
https://www.youtube.com/watch?v=YOSwl08-Yeg
https://www.youtube.com/watch?v=9OsNUi_o6C4
Session 6: Slotter Operations
https://www.youtube.com/watch?v=JBQKh7nYuds
Session 7: Estimation of Machining Operations Time and Cost
https://www.youtube.com/watch?v=VeS1Yxl7_sQ
3. CNC Machining (0-6-2) (100 Hrs)
Session 1: Work Organization and Management
https://www.youtube.com/watch?v=TiOWQW8DQjo
https://www.youtube.com/watch?v=9sjAuUdldyo
https://www.youtube.com/watch?v=pTdSs8kQqSA
Session 2: Interpret Engineering Drawings (Drawing, Standards & Symbols)
https://www.youtube.com/watch?v=a2TolF5wRj4
https://www.youtube.com/watch?v=R_ioIyghXak
Session 3: Fundamentals, Numerical Control & Tools
https://www.youtube.com/watch?v=VKvISyYRjIY
https://www.youtube.com/watch?v=FNYEXjRmDtI
https://www.youtube.com/watch?v=bUrp8JMRwx4
https://www.youtube.com/watch?v=YSdho8y4EoA
Session 4: Programming
https://www.youtube.com/watch?v=5XihF05K4yM
https://www.youtube.com/watch?v=xQygszvqXm4
https://www.youtube.com/watch?v=3oBJbvTLEck
Session 5: Metrology
https://www.youtube.com/watch?v=vkPlzmalvN4
https://www.youtube.com/watch?v=MOivxqXYCZk
https://www.youtube.com/watch?v=AUn-X-Bv9Uk
Session 6: Setting and Operating CNC Lathe and Milling Machine
https://www.youtube.com/watch?v=TecC9_nwpUw
4. Non-Traditional Machining and 3D Printing (0-2-2) (50 Hrs)
Session 1: Electric Discharge Machining- Machining Parameters & Characteristics
https://www.youtube.com/watch?v=L1D5DLWWMp8
https://www.youtube.com/watch?v=Y0EWrg0FuhY&t=54s
https://www.youtube.com/watch?v=vnmdrROssZM
Session 2: Electric Discharge Machining- Machining of Different Materials & Analysis
https://www.youtube.com/watch?v=2W4xZYRkWGo
Session 3: Wire-EDM- Machine Control Panel, and Performance Characteristics by varying input parameters.
https://www.youtube.com/watch?v=pBueWfzb7P0
https://www.youtube.com/watch?v=XxBpUOSDX9Q
Session 4: Additive Manufacturing
https://www.youtube.com/watch?v=NYDzsPvywPc
https://www.youtube.com/watch?v=kKQ5KwFwW_s
Session 5: Rapid Prototyping
https://www.youtube.com/watch?v=OhNnKTaciVI&t=46s
5. Wood Engineering (0-2-0) (25 Hrs)
Session 1: Work Organization and Management (Safety & Serviceability)
https://www.youtube.com/watch?v=GQkUbdE3VS8
https://www.youtube.com/watch?v=ZeF6kfm4nIA
Session 2: Reading and Interpreting Drawings; Setting Out and Measuring
https://www.youtube.com/watch?v=0Gc4VBQ26Yc
https://www.youtube.com/watch?v=eDqgH7Zcmqs
https://www.youtube.com/watch?v=cDcrs0btn6
Session 3: Advanced Machine Tools, Carpentry Hand Tools (Basic Working Principles and Operations)
https://www.youtube.com/watch?v=m6a-I4y8CG4
https://www.youtube.com/watch?v=o4ijHIRaGXc
https://www.youtube.com/watch?v=LwxpSIIme6E
Session 4: Wood Joints and Structural Assemblies
https://www.youtube.com/watch?v=Pzx6cLTpAtY
Internship
Software Exposure
List of Projects/ Papers/Jobs/Products to be done in the Domain/2022:
Conventional Machining for Cylindrical and Prismatic Shape Components
|
Products |
Research Papers
|
||
|
Name |
Qty |
Purpose/ Client |
|
|
EDM Copper Electrode |
10 | Institutional |
1. Process Characterization 2. Process Optimization 3. Advances in Machining & Machine Tools |
|
Center Punch |
10 |
Institutional |
|
|
Chuck Kee |
06 |
Institutional |
|
|
EDM Vice |
03 |
Institutional |
|
|
Surface Gauge |
05 |
Institutional |
|
|
V-Block |
03 |
Institutional |
|
| 3D Printer Graphite Crucible |
02 |
Institutional |
|
CNC Machining; Non-Traditional Machining and 3D Printing
|
Products |
Research Papers |
||
|
Name |
Qty |
Purpose/ Client |
|
|
Bottom Cutter |
01 | Tata Motors |
1. Machine Tool Integration 2. Process Optimization 3. 3D Printing with different Materials 4. Machine Learning in Additive Manufacturing |
| Temperature Sensors Fixtures | 01 |
ISRO |
|
|
Forging Dies |
01 | RSB Transmission | |
|
Latch |
01 |
SMS India |
|
| Mild Steel Cannon | 01 |
Institutional |
|
|
Knurling Tool |
05 |
Institutional |
|
|
Bottom Cutter |
02 |
Institutional |
|
|
CNC Precision Turned and Milled Components |
05 |
Institutional |
|
|
Decorative & Useful Items |
20 |
Institutional |
|
Wood Engineering
|
Products/Jobs |
Research Papers |
||
|
Name |
Qty |
Purpose/ Client |
|
|
Interior Design; EV Unit |
01 |
Institutional |
1. Innovation & New Product Development 2. Joint Analysis 3. Wood Composites 4. Multifunctional Engineered Products |
|
Interior Design; Physiotherapy lab |
01 |
Institutional |
|
|
Interior Design; pharmacy lab |
01 |
Institutional |
|
1. Materials and Process Characterisation, Process Optimization
2. CNC Precision Turned and Milled Components (Industrial, Automotive, Machinery)
3. Wooden Products (Interior Designs, Furniture, Structures)
Text Book & Reference
Text Books:
1. Rao P.N., “Manufacturing Technology”, Volume II, Mc-Graw Hill.
2. Smid P., "CNC Programming Techniques'', 1st Edition, Industrial Press Inc.
Reference Books:
1. Groover P. M., “Fundamentals of Modern Manufacturing”, 4th Edition, John Wiley & Sons.
2. Kesavan R., Elanchezhian C., Vijaya Ramnath B., “Process Planning & Cost Estimation”, New Age International.
3. Bandyopadhyay A., "Additive Manufacturing" 1st Edition, CRC Press.
Others:
National Programme on Technology Enhanced Learning (NPTEL)
Source of Reference: NCrF, Levels 5
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