MIN-104 Session 2018-2019 14-01-2019

Manufacturing Technology – I
MIN-104

Instructors –
Dr. Varun Sharma and Dr. Akshay Dvivedi

Spring 2018-19
Indian Institute of Technology Roorkee
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Manufacturing Technology – I

MIN-104

Relative Weightage of Marks

Practical Sessional (PRS): 25%
Mid Term Examination (MTE): 25% 100%
End Term Examination (ETE): 50%

Objective: To familiarize students with the principles of sheet

metal forming, material removal and finishing operations.

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COURSE CONTENT

S. No. Contents Contact

Hours
1 Introduction: Classification of different manufacturing processes, 2
application areas and limitations, selection of a manufacturing
process

2 Sheet Metal Forming: Introduction to sheet metal forming 10

operations, Types of presses, drives, Operations: shearing bending,
spinning, embossing, blanking, coining and deep drawing. Die
materials, compound and progressive dies and punches.
Construction details of die set. Auxiliary equipments, safety
devices.
3 Material Removal Processes: Classification of machining processes 10
and machine tools. Tool’s materials, different types of cutting tools,
Nomenclature of single point and multi point cutting tool.
Concept of cutting speed, feed and depth of cut. Coolants. Drilling,
Boring and broaching machines. Indexing head, milling operations
using simple, differential and compound indexing.
Introduction to CNC Machines. 3
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COURSE CONTENT

S. Contents Contact
No Hours
4 Abrasive Finishing: Operations and applications of surface, cylindrical 6
and centreless grinding processes; dressing, truing and balancing of
grinding wheels; grading and selection of grinding wheels.

Total 28

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SUGGESTED BOOKS

S. No. Name of Authors /Books /Publisher Year of

Pub.
1. DeGarmo, E. P., Black, J.T., and Kohser, R.A., “Materials and 1997
Processes in Manufacturing”, Prentice-Hall of India
2. Kalpakjian, S., and Schmid, S.R., “Manufacturing Engineering 2000
and Technology”, Pearson Education
3. Groover, M.P., “Fundamentals of Modern Manufacturing”, John 2002
Wiley & Sons
4. Lindberg, R.A., “Processes and Materials of Manufacture”, 1990
Prentice-Hall of India
5. Rao, P.N., “Manufacturing Technology”, (Vol. 1 & 2), Tata 2009
McGraw-Hill

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INTRODUCTION

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Different Components… Different Aspects …

Simple
Small

23 feet,
6 tonnes ,
99.72% iron,
No rust since 5th
century AD

Big Complex

Iron pillar

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MANUFACTURING – NEED AND

CONCEPT
Manufacturing - Value addition processes by which raw materials
(low utility and value due to inadequate material properties and
poor or irregular size, shape and finish) are converted into valued
products (high utility due to definite dimensions and finish)
imparting functional ability.

Value addition by manufacturing. 8

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MANUFACTURING

Definition of manufacturing Definition of manufacturing

as a technological process as an economic process

CLASSIFICATION OF INDUSTRIES

1. Primary industries – Cultivate and exploit natural

resources.
– Examples: agriculture, mining

2. Secondary industries – Convert output of primary

industries into products.
– Examples: manufacturing, power generation, construction

3. Tertiary industries – Service sector.

– Examples: banking, education, government, legal services, retail trade,
transportation

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CLASSIFICATION OF INDUSTRIES

• Process industries, e.g., chemicals, petroleum, basic metals,

foods and beverages, power generation.
Continuous production
Batch production

• Discrete product (and part) industries, e.g., cars, aircraft,

appliances, machinery, and their component parts.
Continuous production
Batch production

PROCESS INDUSTRIES AND DISCRETE MANUFACTURING

INDUSTRIES

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MANUFACTURING OPERATIONS

There are certain basic activities that must be carried

out in a factory to convert raw materials into finished
products.
For discrete products:
1. Processing and assembly operations
2. Material handling
3. Inspection and testing
4. Coordination and control

CLASSIFICATION OF MANUFACTURING PROCESSES

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PRODUCTION SYSTEM FACILITY

• The facilities include the factory, production machines and toolings, material
handling equipments, inspection equipments, and computer systems that
control the manufacturing operations.

• It also includes plant layout.

• Plant layout : The way the equipment is physically arranged in the factory.

• Manufacturing systems : Logical groupings of equipment and workers in the

factory.
Production line
Stand-alone workstation and worker

MANUFACTURING SYSTEMS

Three categories in terms of the human participation in the processes

performed by the manufacturing system:

1. Manual work systems - a worker performing one or more tasks

without the aid of powered tools, but sometimes using hand tools.

2. Worker-machine systems - a worker operating powered equipment.

3. Automated systems - a process performed by a machine without direct

participation of a human.

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MANUAL WORK SYSTEM

WORKER-MACHINE SYSTEM

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AUTOMATED SYSTEM

8 Stages of Industrial Cycle

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MANUFACTURING SUPPORT SYSTEMS

It involves a cycle of information-processing activities that consists of four
functions:
1. Business functions - sales and marketing, order entry, cost accounting,
customer billing.
2. Product design - research and development, design engineering,
prototype shop.
3. Manufacturing planning - process planning, production planning, MRP,
capacity planning.
4. Manufacturing control - shop floor control, inventory control, quality
control.

INFORMATION PROCESSING CYCLE IN

MANUFACTURING SUPPORT SYSTEMS

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MANUFACTURING – IN A NUTSHELL
Production Engineering covers two domains:
– Production or Manufacturing Processes
– Production Management
• Manufacturing Processes - science and technology of
manufacturing products effectively, efficiently, economically
and environment-friendly through:
– Application of any existing manufacturing process and
system
– Proper selection of input materials, tools, machines and
environments.
– Improvement of the existing materials and processes
– Development of new materials, systems, processes and
techniques
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Manufacturing – Need and concept

Material flow is of three main types:

• Through flow, corresponding to mass-conserving processes
(change in material properties without change in geometry)
• Diverging flow, corresponding to mass-reducing processes
• Converging flow, corresponding to assembly or joining
processes

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MANUFACTURING – NEED AND CONCEPT

A manufacturing process normally consists of a series of basic processes, which
constitute the structure of the material flow.
• Basic processes can be divided into three typical phases:
– Phase 1 (material into a suitable state/geometry like heating, melting,
sawing etc.)
– Phase 2 (desired geometry and/or change in properties)
– Phase 3 (component into the specified end state (solidification, cooling,
deburring etc.)

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CLASSIGICATION OF
MANUFACTURING PROCESSES
(a) Shaping or forming: Manufacturing a solid product of
definite size and shape from a given material taken in
three possible states:
– Solid state – e.g., forging, rolling, extrusion, drawing etc.
– Liquid/semi-liquid state – e.g., casting, injection molding etc.
– Powder form – e.g., powder metallurgical process
(b) Joining process
– Welding, brazing, soldering etc.
(c) Removal process
– Machining (Traditional or Non-traditional), Grinding etc.

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CLASSIGICATION OF
MANUFACTURING PROCESSES
(d) Regenerative manufacturing
• Production of solid products in layer by layer from raw
materials in different form:
– Liquid – e.g., stereo lithography
– Powder – e.g., selective sintering
– Sheet – e.g., LOM (laminated object manufacturing)
– Wire – e.g., FDM. (Fused Deposition Modeling)

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ENGINEERING MANUFACTURING PROCESSES

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SELECTION OF MANUFACTURING
PROCESSES

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SELECTION OF MANUFACTURING
PROCESSES
Factors affecting the selection of manufacturing processes
• Cost (material, manufacturing, operating and replacement
cost)
• Material (specified by design)
• Quantity (determines economics of manufacturing process)
• Machine or equipment availability (Machines and operators)
• Quality Surface finish, Accuracy (geometrical, dimensional)
• Geometry (Cylindrical, conical, threads – Lathe)
(Plane surface, slots – shaping, planning, milling)
(Complex Shapes – Casting, Forging)
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SOLIDIFICATION PROCESSES

• Starting material is sufficiently heated to transform into liquid or highly

plastic state.
• E.g.: casting of metals, molding of plastics.

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STEPS IN SAND CASTING

1. Pour the molten metal into sand mold
2. Allow time for metal to solidify
3. Break up the mold to remove casting
4. Clean and inspect casting
– Separate gating and riser system
5. Heat treatment of casting is sometimes required to improve metallurgical
properties

Figure is from
www.themetalcasting.com 32

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DEFORMATION PROCESSES
• Work part is shaped by the application of forces that exceed the yield
strength of the material.
• Example: forging and extrusion.

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MATERIAL REMOVAL PROCESSES

• Turning, drilling, milling, grinding, non-conventional machining processes.

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POWDER METALLURGY
• Powder metallurgy is the process of blending fine powdered materials,
compacting the same into a desired shape or form inside a mould
followed by heating of the compacted powder in a controlled atmosphere,
referred to as sintering to facilitate the formation of bonding of the
powder particles to form the final part.

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SELECTING MATERIALS FOR

MANUFACTURING
• Mechanical properties of materials
– Strength, toughness, ductility, hardness, elasticity, fatigues,
creep, …
• Physical properties of materials
– density, specific heat, thermal expansion and conductivity,
melting point, and electrical and magnetic properties, ……
• Chemical properties, environmental resistance and wear
– corrosion, toxicity, flammability, ……

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• Strength : ability to bear load before fracture

• Toughness: ability of a metal to deform plastically and to absorb
energy in the process before fracture is termed toughness.
• Ductility: extent of permanent or plastic deformation that a material
undergoes before fracture (% elongation, % reduction in area
• Hardness: resistance to plastic deformation which includes
indentation, scratching, or marking
• Elasticity: ability to restore to original shape and size after removal of
external deforming loads
• Fatigue : permanent deformation and/or failure of a component
when subjected to fluctuating (both in magnitude and direction)
loads
• Creep : permanent deformation and/or failure of a component when
subjected to high stresses at high temperature
• Stiffness: resistance to elastic deformation
• Fracture : splitting of a component into at least two halves 39

Material-Based Selection of
Manufacturing Processes
Forming Deforming Removing Joining Modifying

Metals XX XX XX XX XX
Materials

Ceramics XX -- X -- --

Polymers XX X X X --

Composites XX -- X X --

XX - Widely Used
X - Seldom Used
-- - Not Used .
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Thank You….

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