Course Objective

1. To Understand the Importance of Materials, Manufacturing Processes, Process Planning &  Design in Product Manufacturing

Learning Outcomes

Students will able to

1. Select Engineering Material for a Required Purpose

2. Identify Various Manufacturing Processes

3. Implement Modern Approaches to Process Planning, Product Design & Development

Course Syllabus

Module I: Classification of Materials (5 hrs)

Common Engineering Materials; Crystal Geometry ( Crystal Types, Crystal Structures, Crystal Defects, Recrystallization, Crystal Growth, Methods of Determining Crystal Structure, Scanning Electron Microscope).

Practice

1. Tensile, Hardness and Impact Testing of Materials

Module II: Tool Materials (4 hrs)

Engineering Alloys (Selection and Specification of Carbon and Alloy Steels for General Engineering Purpose, Specification of Materials as per Various Standards- IS, BS, AISI, APS, etc.); Steels (Case Hardening Steels, Cold Work Tool Steels, Hot Work Tool Steels, High-Speed Tool Steels; Modern Cutting Tool Materials (Carbide, Coated carbides, Ceramics, CBN, Diamond, Sialons, Impregnated tools); Introduction to Plastics (Properties of Plastics, Thermo Plastics-Thermo Setting Plastics, Methods of Processing of Plastics); Cast Iron (Grey Iron Casting IS: 210 SG Cast Iron IS: 865, Malleable Iron Castings IS: 2108 and IS: 2640); Non-Ferrous Alloys ( Zn & Al Alloys); Powder Metallurgy (Methods for Production of Powders, Powder Metallurgy Steps).

Module III: Heat Treatment (4 hrs)

Heat Treatment of Steel (Annealing, Hardening, Tempering, Surface hardening); Heat Treatment Defects.

Module IV: Manufacturing Processes (8 hrs) 

Forming Processes (Cold & Hot Working, Rolling, Forging, Drawing, Bending & Extrusion); Joining Processes (Arc Welding, Gas Welding, Resistance Welding, Thermit Welding, TIG & MIG Welding, LBW, EBW, Adhesive Bonding, Soldering & Brazing,); Casting Process (Sand Casting, Die Casting, Investment Casting, Centrifugal Casting, Vacuum Casting, Plaster Mould Casting, Lost Foam Method, Continuous Casting).

Practice

2. Pattern & Mold Making in Sand Casting.

3. Butt Joint by using Oxy Acetylene Gas Welding.

4. Joining of Metal Sheets using Spot Welding.

5. Soldering & Brazing Practice.

6. TIG Welding of Stainless Steel

7. MIG Welding Technique and Applications

Module V: Machining Processes (6 hrs)                                                                                                         

Conventional Machining Processes: Turning, Milling, Drilling, Shaping, Grinding & Finishing; Unconventional Machining Processes: EDM, AJM, LBM, etc); Rapid Prototyping 

Practice

8. EDM Working Principle and Process Parameters

9. 3D Printing

Module VI: Process Planning  (5 hrs)           

Process Planning (Concept, Manufacturing Planning, Process Design, Process Sheet, Process Selection Parameters, Computer Aided Process Planning)

Practice

10. Process Planning & Simulation in DELMIA

Module VII: Computer Aided Production Management (8 hrs)

Role of Computer in Product Design and Management(Computer in Manufacturing & Design Process, Creation of Manufacturing Data Base, Computer Integrated Manufacturing, Communication Network, Production Flow Analysis, Group Technology)

Process & Product Design (Degree of Accuracy, Finish and Tolerance, Capability Studies, Basic Product Design Rules for Casting, Forging, Machining, Sheet Metal and Welding. Physical Properties of Engineering Materials and their Importance on Products, Selection of Plastics, Rubber, Composites and Ceramics for Product Design)

Practice

11. Casting Design & Analysis using CATIA

12. Forging Design & Analysis using CATIA

Session Plan

Module I: Classification of Materials (5 hrs)

Session 1:  Common Engineering Materials

https://www.youtube.com/watch?v=HuACRHhuy24

https://www.youtube.com/watch?v=OG4G8gaOTMw

Session 2: Crystal Geometry

https://www.youtube.com/watch?v=BjVTdZ_htu8

https://www.youtube.com/watch?v=61Lgo56bBbg

https://www.youtube.com/watch?v=_4OJKPoZn5o

Session 3: Methods of Determining Crystal Structure

https://www.youtube.com/watch?v=GY9lfO-tVfE

https://www.youtube.com/watch?v=fv1l-EIc4sM

https://www.youtube.com/watch?v=pUJtSPICn0w

Session 4: Defects  in Solids

https://www.youtube.com/watch?v=ie-KfQionjY

https://www.youtube.com/watch?v=Z0Ks3wjFnrk

Session 5: Mechanical Properties, Mechanical Tests and Deformation of Materials

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

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

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

Assignment 1

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Assignment-1.pdf

Course Material

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Module-1-Manufacturing-Process.pdf

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Module-1-1-1.pdf

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Module-1-3.pdf

Module II: Tool Materials (4 hrs)

Session 6: Engineering Alloys 

https://www.youtube.com/watch?v=TILs8w6myoU

https://www.youtube.com/watch?v=JTu-Zz5jalc

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

Session 7: Modern Cutting Tool Materials

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

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

Session 8: Powder Metallurgy

https://www.youtube.com/watch?v=azGg68B-Glk

https://www.youtube.com/watch?v=I39m28NZ7_s

https://www.youtube.com/watch?v=MgukjCT9o80

Assignment 2

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Assignment-2.pdf

Course Material

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Module-2.pdf

Module III: Heat Treatment (4 hrs)

Session 9: Heat Treatment of Steel

https://www.youtube.com/watch?v=sKq3but88Qw

https://www.youtube.com/watch?v=wVZkdWEZv80

https://www.youtube.com/watch?v=skQRLfU3plM

Session 11: Major Defects  due to Faulty Heat Treatment

https://www.youtube.com/watch?v=-Wuhaw2IWLM

Assignment 3

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Assignment-3.pdf

Course Material

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Module-3-1.pdf

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Module-3-2.pdf

Module IV: Manufacturing Processes (6 hrs) 

Session 12: Forming Processes

https://www.youtube.com/watch?v=743fHkOvOkA

https://www.youtube.com/watch?v=cIkqYA8LLSA

https://www.youtube.com/watch?v=ZD8gW_OzkCQ

Session 13: Gas Welding & Arc Welding

https://www.youtube.com/watch?v=o8BGko__DlA

https://www.youtube.com/watch?v=mibENu9te20

https://www.youtube.com/watch?v=QZdY3ZRY9RA

Session 14:  MIG & TIG Welding

https://www.youtube.com/watch?v=twUAa5LWUvk

https://www.youtube.com/watch?v=uO5pVLOAmD4

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

Session 15: Other Joining Processes

https://www.youtube.com/watch?v=AwL1CAg43PU

https://www.youtube.com/watch?v=U8o3pOuE_f8

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

Session 16: Casting Process

https://www.youtube.com/watch?v=YUp8vH5YUPo

https://www.youtube.com/watch?v=43XSwFTlKt4

https://www.youtube.com/watch?v=YUp8vH5YUPo&t=33s

 Session 17: Special Casting Process

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

https://www.youtube.com/watch?v=TVsJlWEzZY8

https://www.youtube.com/watch?v=Xeg575g_Cgs

Assignment 4

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Assignment-4.pdf

Course Material

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Module-4-1.pdf

Module V: Manufacturing Processes (6 hrs)

Session 18: Machining Process

https://www.youtube.com/watch?v=Y0EWrg0FuhY

https://www.youtube.com/watch?v=MwC2Tma7mus

https://www.youtube.com/watch?v=8EsAxOnzEms

Session 19: Rapid Prototyping

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

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

https://www.youtube.com/watch?v=KJj8CfnC0Ek

Assignment 5

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Assignment-5.pdf

Course Material

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Module-5-2.pptx

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Module-5-2.pdf

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Module-5-3.pptx

Module VI: Process Planning (5 hrs)

Session 20: Process Planning

https://www.youtube.com/watch?v=Ieek7XgKfxM

https://www.youtube.com/watch?v=GvFA0hHqC6E

https://www.youtube.com/watch?v=hfQGHh5NIXI

 Session 21: Process Planning & Simulation in DELMIA

https://www.youtube.com/watch?v=2EB-LyDF5fQ

https://www.youtube.com/watch?v=z5dA2m6TFvM

https://www.youtube.com/watch?v=ux9_5sLJWd0

Assignment 6

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Assignment-6.pdf

Course Material

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Process-Planning-2.pptx

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Process-Planning-3.pdf

Module VII: Computer-Aided Production Management   (8 hrs)  

Session 22: Computer in Manufacturing & Design Process

https://www.youtube.com/watch?v=K-SWNbC63HI

https://www.youtube.com/watch?v=kesidO8c9XM

https://www.youtube.com/watch?v=Sx_j50K5qZo

Session 23: Forging Design & Analysis using CATIA

https://www.youtube.com/watch?v=rLq0XghhYxM

https://www.youtube.com/watch?v=TiG2jhWPeJE

https://www.youtube.com/watch?v=uGiehJadc6U

Session 24: Production Flow Analysis, Group Technology

https://www.youtube.com/watch?v=WyM9gBwb5BU

Session 25: Casting Design & Analysis using CATIA

https://www.youtube.com/watch?v=LxtJKLjEDK0

https://www.youtube.com/watch?v=xe7fPMMgsWE

Session 26: Ergonomic Considerations in Product Design

https://www.youtube.com/watch?v=vSwH8-MFkKc

Session 27: Just-in-Time and Kanban System

https://www.youtube.com/watch?v=AH5Bn8iguNM

https://www.youtube.com/watch?v=cAUXHJBB5CM

https://www.youtube.com/watch?v=-2huDogfXS8

Session 28: Modern Approaches to Product Design

https://www.youtube.com/watch?v=xNqs_S-zEBY

https://www.youtube.com/watch?v=FwvLkmdV9QA

https://www.youtube.com/watch?v=PYg7Qeo5-QY

Assignment 7

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Assignment-6.pdf

Course Material

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Process-Planning-1.pptx

Lesson Plan

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Format_-Lesson-Plan.xlsx

Text Books:

1. Balasubramaniam R., "Callister's Materials Science and Engineering”, 2^nd Edition, Wiley.

2. Rao P.N., “Manufacturing Technology”, Volume 1, Mc-Graw Hill.

3. Chitale A.K., Gupta R.C., "Product Design & Manufacturing”, 6^th Edition, PHI Learning.

Reference Books:

1. Campbell F., “Elements of Metallurgy and Engineering Alloys”, ASM International.

2. Kesavan R., Elanchezhian C., Vijaya Ramnath B., “Process Planning & Cost Estimation”, New Age International.

Course Outline Prepared by Dr. P S Rao & Prof. D Mohanta                   

Source of Reference: NCrF, Level 5

Assignment

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Assignment.pdf

Question Bank

http://courseware.cutm.ac.in/wp-content/uploads/2023/07/Question-Bank.pdf