Fundamentals of Manufacturing Materials, Processes & Systems

This course provides an introduction to the manufacturing processes that are used in industry to manufacture products that are widely used in daily life.

Introduction to Manufacturing: Types of manufacturing industries, materials used in manufacturing and properties of materials, different processing operation.

Sand Casting:

• Introduction: Sand casting, molding, heating, pouring, solidification, and cooling. Pattern: making, material, types, construction, pattern allowances.
• Core: making, types, sand conditioning, testing of the sand, molding process, tools and equipment, molding machines, different types of casting, cleaning and finishing of castings, an inspection of castings.

Permanent Mold Casting (PMC): Introduction, types of PMC, gravity die casting, and its types. Pressure die casting, Centrifugal casting, and their types. Furnaces used in PMC.

Metal Forming:
Fundamentals, Types, hot, warm, and cold working.
Bulk Deformation Processes:

• Rolling; rolled products, rolling types: flat, shape, thread, gear, ring rolling, and rolling mill configurations.
• Forging; open die, impression die, press, upset, roll, net shape, isothermal forging and swaging.
• Extrusion; solid & hollow shapes, direct & indirect, hot & cold, continuous & discrete, impact extrusion, hydrostatic.
• Drawing; bar, wire, tube drawing and its types tike tube sinking, fixed mandrel, floating plug.
  Other metal forming processes; roll extrusion, riveting, staking, peening, coining, hubbing, burnishing.

Sheet metal forming processes: Shearing operations: slitting, blanking, piercing, cutoff, parting, dinking, slotting, perforating, notching, semi-notching, lancing, nibbling, trimming, shaving, fine blanking. Bending operations: V bending, edge bending, flanging, curling, hemming, seaming. Drawing operations like deep and shallow drawing, embossing.

Welding Processes: Classification, Fusion welding and its types such as oxyfuel gas welding and oxygen torch cutting, arc welding (shielded metal, flux-cored, gas metal, submerged, gas tungsten, plasma, stud welding, Arc cutting), resistance welding (spot, seam and projection. Heating, pressure, current control and power supply for resistance welding).
Solid-state welding and its types include diffusion welding, friction welding, and ultrasonic welding.

• Other welding processes: Forge, Roll, Friction, Explosion, Thermic, Electron beam, Laser welding and cutting, Brazing and Soldering.

Fabrication of Plastics: Casting, Blow molding and its types, Compression molding, Transfer molding, Cold molding, Injection molding: Injection molding machine, mold design, and construction, types of mold, cooling and ejection of mold, Reaction injection molding, Welding of plastics.

In the end, there are videos that are videos related to the course for better understanding.

Course Outline

Introduction to Manufacturing:

Lecture 1

• Introduction to Manufacturing Processes
• What is manufacturing
• Manufacturing Industries
• Manufacturing Products
• Production Quantity and Product variety
• Materials in Manufacturing
• Manufacturing Processes (Processing operations and Assembly operations)

Sand Casting:

Lecture 2

• Overview of casting technologies
• Difference between casting and molding
• Advantages and Disadvantages of casting processes
• Casting Processes (Expendable mold casting and permanent mold casting)

Lecture 3

• Sand casting and Engineering analysis of sand casting y sand
• Pouring and Engineering Analysis of Pouring
• Flow rate and time required to fill the mold
• Fluidity
• Solidification and Cooling

Lecture 4

• Solidification of pure metals and alloys (Alloys and Eutectic Alloys)
• Solidification time and Shrinkage
• Directional Solidification

Lecture 5

• Riser Design with Exercise Problems.

Lecture 6

• Pattern for casting
• Materials used for pattern
• Types of pattern
• Mold making and Classification of sand molds
• What is foundry sand?

Lecture 7

• Buoyancy Force
• Metal casting processes
• Shell molding
• Advantages and Disadvantages of Shell molding
• Vacuum molding
• Advantages and Disadvantages of Vacuum molding
• Expanded Polystyrene Casting
• Advantages and Disadvantages of Expanded Polystyrene Casting
• Investment casting
• Plaster and Ceramic Mold casting

Permanent Mold Casting (PMC):

Lecture 8

• Types of pattern allowance (Shrinkage and contraction allowance, Draft allowance, Machining allowance, and Distortion allowance)
• Permanent mold casting and its Applications.
• Slush casting
• Low-pressure casting
• Vacuum permanent mold casting
• Die casting (Hot and cold chamber die casting)
• Advantages and Limitations
• Centrifugal casting and Semi centrifugal casting

Lecture 9

• Furnaces
• Cupolas Furnace
• Direct Fuel Fired Furnace
• Crucible Furnace
• Electric Arc Furnace
• Induction Furnace

Metal Forming:

Lecture 10

• Fundamentals of metal forming
• Types of deformation processes of metal
• Bulk deformation (Rolling, Forging, Extrusion, Wire Drawing)
• Sheet metal working
• Stress-Strain Curve
• Derivation of the relation between stress and strain
• Flow stress and Average flow stress
• The temperature in metal forming (Cold working and Hot-working)
• Recrystallization
• Iso thermal forming (recovery and Grain growth)
• Strain rate Sensitivity

Lecture 11

• Introduction of rolling
• Shapes used for rolling
• Types of rolling
• Working of the rolling process
• Analysis of the rolling
• Rolling mills
• No-Slip Point for rolling
• Flatness control and rolling defect

Lecture 12

• Numerical Problems related to the rolling process

Lecture 13

• Introduction to forging
• Classification of forging
• Types of forging
• Analysis of the forging
• Barreling effect in forging
• Open Die forging and its practices
• Impression Die forging and its practices
• Advantages and Limitations of Impression Die forging
• Fleshless forging
• Forging Press and Forging Hammers

Lecture 14

• Numerical Problems related to the forging process

Lecture 15

• Introduction to the extrusion process
• Classification of extrusion
• Direct and Indirect extrusion
• Hot and Cold extrusion
• Direct and Continuous extrusion
• Analysis of the extrusion process
• Effect of friction on extrusion
• Extrusion Dies and Orifice
• Extrusion press and other extrusion processes

Lecture 16

• Numerical Problems related to the extrusion process
• Introduction to Drawing
• Difference between drawing and wire drawing
• Bar Drawing
• Wire Drawing
• Features of Draw Die
• Preparation of the work
• Analysis of the drawing process

Sheet metal forming processes:

Lecture 17

• Introduction to sheet metal cutting process
• Characteristics of Edges
• Types of sheet metal cutting
• Shearing
• Blanking and Punching
• Clearance in Sheet metal cutting
• Analysis of sheet metal cutting processes
• Numerical Problems related to the sheet metal cutting process

Lecture 18

• Introduction of sheet metal bending process
• Types of sheet metal bending
• Analysis of the sheet metal bending process
• Numerical Problems related to the sheet metal bending process
• Spring Back

Lecture 19

• Introduction to the drawing process
• Mechanics of drawing
• Stages of deformation
• Analysis of the drawing process
• Tests of Drawing Feasibility
• Blank force and blank size determination
• Numerical Problems related to the drawing process

Lecture 20

• Other drawing processes (Redrawing, Reverse Drawing and Drawing without Blank holder)
• Defects in Drawing
• The operation performed with metal tooling
• Ironing
• Coining & Embossing
• Lancing & Twisting
• The operation performed with flexible Rubber tooling
• Guerin and Hydro forming process

Lecture 21

• Numerical Problems related to the other drawing processes

Welding Processes:

Lecture 22

• Fundamentals of welding
• Difference between joining and welding
• Advantages and Disadvantages of Welding
• History of welding
• Types of the welding process
• Components used for welding process (Filler material, Flux, and Electrolyte)
• Consumable and Non-consumable electrolyte
• Welding positions
• Welding Electrode Nomenclature
• Type of Weld Joints (Butt joint, Corner Joint, Lap joint, Tee Joint, Edge Joint)
• Types of Weld (Filler Weld, Groove Weld, Plug weld or slot weld, Spot and Seam weld, Flange and Surface Weld)
• Features of Fusion Welded Joints
• Physics of welding (Power Density and Numerical of Power Density)
• Heat Balance in Fusion Welding
• Welding as Commercial Operation
• Automation in Welding (Machine, Automatic and Robotic)
• Welding Safety

Lecture 23

• Welding Categories (Fusion Welding, Solid State Welding, Soldering and Brazing)
• Arc Welding
• Arc Shielding
• The power source in Arc welding
• Types of Arc Welding (Shielding metal arc welding, Gas Metal Arc Welding, Flux Cored Arc Welding, Submerged Arc Welding,
• Gas Tungsten welding
• Plasma arc welding

Lecture 24

• Oxyfuel arc welding
• Oxyacetylene welding
• Resistance welding
• Spot Welding
• Resistance seam welding
• Resistance projection welding
• Energy beam welding (Electron beam welding, Laser beam welding)
• Numerical Problems related to the welding processes

Lecture 25

• Numerical Problems Related to the welding processes

Lecture 26

• Solid-state welding
• Types of solid-state welding
• (Diffusion welding, Friction welding, and Ultrasonic welding)
• Welding Defects of Solid State Welding
• Brazing and Soldering

Fabrication of Plastics:

Lecture 27

• Plastics
• Type of Plastics
• Properties of polymer melt (Viscosity and Viscoelasticity)
• Extrusion process for Plastics in detail
• Extruder Screw
• Feed Section
• Compression Section
• Metering Section
• Process Parameters
• Solid and Hollow Profiles
• Wire and Tube coating
• Defects in the extrusion process

Lecture 28

• Injection molding for Plastics in detail
• Clamping
• Injection
• Cooling
• Ejection
• Application and Material
• Advantages and Disadvantages

Lecture 29

• Blow Molding
• Extrusion Blow Molding
• Injection Blow Molding
• Stretched Blow Molding
• Compression Molding
• Transfer Molding (A pot transfer molding and B plunger-type transfer molding)

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