Domain Track: Manufacturing (Conventional, CNC and Additive)

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Dillip Mohanta

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 Domain Track: Manufacturing (Conventional, CNC and Additive)

Code: CUTM2016

 

Total Credits ( T-P-P): 26 (2-14-10)

Course Divisions

 

1.    Manufacturing Requirements and Planning (Jigs & Fixtures; Process Planning & Cost Estimation)  (2-0-0)

2.    Conventional Machining for Cylindrical and Prismatic Shape Components  (0-4-2)

3.    CNC Machining  (0-6-2)

4.    Non-Traditional Machining and 3D Printing  (0-2-2)

5.    Wood Engineering  (0-2-0)

6.    Internship  (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

Domain Syllabus:

 

1. Manufacturing Requirements and Planning (Jigs & Fixtures; Process Planning & Cost Estimation) (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 (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 (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 (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 (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

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

https://www.youtube.com/watch?v=fTPluUa6be0

https://www.youtube.com/watch?v=jF4F8Zr2YO8

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

https://www.youtube.com/watch?v=B1A3aiEHIzk

https://www.youtube.com/watch?v=H5Hk_Hdo41Q

List of Projects/ Papers/Jobs/Products to be done in the Domain:

 

1. Materials and Process Characterisation, Process Optimization

2. CNC Precision Turned and Milled Components (Industrial, Automotive, Machinery)

3. Wooden Products (Interior Designs, Furniture, Structures)

 

Gate Process for Project

Gate 0:       Idea

Gate 1:       Scope

Gate 2:       Development 

Gate 3:       Testing

Gate 4:       Documentation

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