Manufacturing Process-Process Planning and Heat Treatment

Teacher

Dillip Mohanta

Category

Core Courses

Course Attendees

Still no participant

Course Reviews

Still no reviews

Course Name: Manufacturing Process-Process Planning and Heat Treatment

Course Code: CUTM1079

 

Course Credits : 2-1-0

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); Mechanical Properties, Mechanical Tests and Deformation of Materials (Mechanism of Strengthening in Metals. Grain Size and its relation to Mechanical Properties, Review and Brief Discussion on Stress-Strain Diagram of Steel and the Parameters for Ductility, Percentage of Elongation, Toughness, Strain Hardening, and Tensile Strength,  etc., Fracture Toughness and Crack Growth Measurement, Failure Analysis), Fatigue and Creep Testing, Testing for Residual Stresses.

 

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 (Hardenability Concepts and its Role in Steel Specification, Hardening and Annealing of Tool Steels, Case Hardening and Local Hardening,  Isothermal Transformation Diagrams, Austempering, Martempering and Isothermal Annealing for Tool Steels, Major Defects in Metals or Alloys due to Faulty Heat Treatment, ION Nitrating, Vacuum Carburizing, Chemical Vapour Depositing); Heat Treatment of Non-ferrous Materials (Classification of Heat Treatment Processes for Aluminium Alloys, Heat Treatment of Wrought & Cast Aluminium Alloys).

 

Module IV: Manufacturing Processes (7 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); Machining Processes ( Traditional-Turning, Milling, Drilling, Shaping, Grinding & Finishing, Non-Traditional- EDM. AJM, LBM etc.)

Practice

1. Pattern & Mold Making in Sand Casting.

2. Butt Joint by using Oxy Acetylene Gas Welding.

3. Joining of Metal Sheets using Spot Welding.

4. Soldering & Brazing Practice.

5. TIG Welding of Stainless Steel

6. MIG Welding Technique and Applications

7. EDM working Principle and Process Parameters

 

Module V: Process Planning (5 hrs)                                                                                                         

Process Planning (Concept, Manufacturing Planning, Process Design, Process Planning Activities, Process Sheet, Process Selection Parameters, Steps in Process Planning, Computer-Aided Process Planning) 

Practice

1. Process Planning & Simulation in DELMIA

 

Module VI: Computer-Aided Production Management   (7 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)

1. Casting Design & Analysis using CATIA

2. Forging Design & Analysis using CATIA

 

Module VII: Industrial Ergonomics (3 Hrs)                                                                                                          

Man/Machine Considerations, Ease of Maintenance. Ergonomic Considerations in Product Design, Anthropometry, Design of Controls & Displays, Man/Machine Information Exchange, Process Sheet Detail and Their Importance, Advanced Techniques for Higher Productivity, Just-in-Time and Kanban System, Modern Approaches to Product Design (Concurrent Design, Quality Function Development, Rapid Prototyping)

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

 

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: Plastics & Nonferrous Alloys

https://www.youtube.com/watch?v=jQdBag_p6kE

https://www.youtube.com/watch?v=8lhbU6aO_FA

https://www.youtube.com/watch?v=nyDG7Wt3lmE

Session 9: 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

 

Module III: Heat Treatment (4 hrs)

Session 10: 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

Session 12: ION Nitrating & Chemical Vapour Depositing

https://www.youtube.com/watch?v=CH3IsHP7llM

https://www.youtube.com/watch?v=TWZFpsJ9tq4

https://www.youtube.com/watch?v=9XKGVHPXXho

Session 13: Heat Treatment of Non-ferrous Materials

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

https://www.youtube.com/watch?v=uUw8XDhX8zY

 

Module IV: Manufacturing Processes (7 hrs) 

Session 14: 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 15: 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 16:  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 17: 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 18: 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 19: 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

Session 20: Machining Process

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

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

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

 

Module V: Process Planning (5 hrs)

Session 21: Process Planning

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

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

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

 Session 22: 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

Session 23: 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 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

 

Module VI: Computer-Aided Production Management   (7 hrs)  

Session 26: 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

 

Module VII: Industrial Ergonomics (3 Hrs)

Session 27: Industrial Ergonomics

https://www.youtube.com/watch?v=KESCiJskGo8

https://www.youtube.com/watch?v=JW3gGVwCGUk

https://www.youtube.com/watch?v=05ChaWGJ0-A

Session 28: Ergonomic Considerations in Product Design

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

Session 29: 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 30: Rapid Prototyping

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

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

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

Session 31: 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

 

Text Books:

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

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

3. Chitale A.K., Gupta R.C., "Product Design & Manufacturing”, 6th 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: NSQF, Level 8, Capital Goods & Manufacturing-Sector

Case Studies

Case Studies

Recent Comments

    Our Main Teachers