TA202A

Manufacturing Processes II

Overview of the plan for the course

Mohit Law
Mechanical Engineering
mlaw@iitk.ac.in

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 What is the purpose of this course?

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UGARC student survey suggests …

“… something like TA202a, which, face it, lost

it’s relevance 30 years back.”

“Theory exam essentially boils down to rote

learning …”

“The theory section of the TA 201 and 202

courses seems irrelevant …”

“Requires CAD knowledge, which is never

explicitly taught to students …”

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I almost feel like …

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What is the objective of the course?

• To celebrate manufacturing

• To learn through making – lab component

• To introduce concepts and working principles of machines that will be

used to make things – class and lab component

• To appreciate how manufacturing adds value to material

• Developing a bottom-up thinking approach to engineering

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TA202A - Manufacturing Processes II

• This course is not about primary manufacturing processes, but secondary

– that is why the course is titled: ‘Manufacturing Processes II’

• Primary manufacturing processes include processes like casting, forging,

forming, joining, etc. These are covered in ‘TA201A:Manufacturing
Processes I’

• In this course, we will only deal with machining – which is a secondary

manufacturing process. We will also discuss machines used for machining.

• The main aim of the course is learning through hands-on-experience of

manufacturing a product – project work!

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Example of a project idea: wire bending machine

https://www.youtube.com/watch?v=HPQbKTJPsU4&t=21s
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Project examples: mini conveyor

https://www.youtube.com/watch?time_continue=1&v=GHWAhXgC2Zs

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Project examples: quick return mechanism

https://www.youtube.com/watch?v=zA0owiHQgpc

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Project examples: double hack saw

https://www.youtube.com/watch?time_continue=1&v=o1d5dp1Lc6Q

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Project examples: mixer

https://www.youtube.com/watch?v=35kl6GeS9N4&list=PLZO_dTWSnBCqcQ7xaQvG7QmJIVyE0l8cB&index=3

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Excellent resources for project ideas

• https://howtomechatronics.com/

• https://nevonprojects.com/mechanical-engineering-projects/

• Your guides

• The world around you

Project ideas can include solutions for: agriculture, food processing,

health care, energy, machines, mechanisms, toys, and whatever else
catches your fancy

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Additional requirements for all projects

• 3D printing

– At least one component of the project must be printed

• Arduino board based motor programming

– A kit will be given to all groups. Each kit will have one Arduino board +
motor driver + battery back + geared DC motor. All groups to
compulsorily use the kit to do whatever they would like to

• CNC based part manufacturing

– At least one component of the project must be made on the CNC

machine

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Class and lab schedule

• Class: 8 am on Tuesdays in L20

• Labs: 2 – 5 pm, Monday – Friday in the TA202A labs near Gate 4

Attendance policy

• Attendance is mandatory for laboratory sessions, and highly

encouraged for class.

• If you do decide to grace the classroom, please come on time.

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Structure of the course (indicative only)

Lecture Contents Lab Activity

1 Overview 1 Intro. to machines
2 Why mfg. matters? 2 Assemble + Disassemble 3D printers.
3 Mechanisms Assign groups & guides

4 3 CAD exercise + project discussions

Materials
4 CAM exercise + project discussions
5 Machining
5 Arduino exercise + project discussions
6 Machining
6 Submission of project files
7 Machines
6 - 12 Project work
8 CNC machines
13 Evaluation
9 CNC programming
10 Non-traditional machining Reference texts:
1. Manufacturing Engineering and Technology by
11 Additive manufacturing Kalpakjian and Schmid
12 Micro-fabrication 2. Fundamental of Modern Manuf. Materials,
Processes and Systems by Groover
13 Metrology *You might benefit more by coming to class

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Assessment and Grading (indicative only)
Assessment: Grading:
• 25% class exams
Grade Cumulative
– 10% mid-sem exam
total
– 15% end-sem exam
• 75% lab A* ≥ 95
– 5% 3D printer assembly + disassembly
– 5% CAD exercise A ≥ 80
– 5% Arduino exercise
– 5% CAM exercise B ≥ 65
– 5% timely submission of complete CAD model
C ≥ 50
– 15% mid-project evaluation
– 10% Guide’s evaluation (based on your log sheets)
D ≥ 40
– 22.5% final project evaluation (including the report)
– 2.5% attendance F < 40
Notes:
1. Make up exams only with the Instructor’s and the DoAA’s approval
2. Any form of academic dishonesty will be rewarded with a F grade I usually prefer absolute grading
3. Missing more than 3 labs might result in forced de-registration

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Lab exercise 1: Introduction to machines

• This exercise will introduce students to the machines and machining processes on
those machines
Activity
Time
Turning Milling Drilling
2 pm – 3 pm A B C
3 pm – 4 pm B C A
4 pm – 5 pm C A B

Turning machine (Lathe) Milling machine Drilling machine

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Lab exercise 2: assemble + disassemble 3D printer

At the beginning After 50 min

After 20 min
• We have bought 10 machines
• Each group will get one machine to assemble +
disassemble (~50+ groups with 8-10 members in
each groups)
• Penalty for not finishing in time, or if parts are
misplaced
• Exercise is worth 5% of your grade
• Lab manual has further detailed instructions

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Lab exercise 3: CAD

• CAD exercise will include things like sketching, extruding, revolving, making gears,
assembling, making part drawings, etc.
• Students will work on their own laptops. Each group to bring at least two laptops
• Exercise is worth 5% of your grade – to be started and completed in the lab hours
• Lab manual has further detailed instructions

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Lab exercise 4: CAM for CNC and for 3D printing
CAM for CNC machine (subtractive) CAM for 3D printing

• CAM exercise will include generating a part program (G code) to load onto the CNC
machine to make a part, and to make a G code for slicing for the 3D printed part
• Students will work on their own laptops. Each group to bring at least two laptops
• Exercise is worth 5% of your grade – to be started and completed in the lab hours
• Lab manual has further detailed instructions

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Lab exercise 5: Arduino based driving of a motor

• Arduino based exercise will include driving a motor to in turn drive a Geneva
indexing mechanism. A kit with an Uno board, a motor driver, a battery back, a
geared DC motor and a Geneva mechanism will be given to each group.
• Exercise is worth 5% of your grade – to be started and completed in the lab hours
• Lab manual has further detailed instructions

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Tutors for the course
Monday Tuesday Wednesday

Dr. Ram Upadhyay Mr. Govind Sahu

Dr. Mohit Law
SERB Postdoc PhD student
Thursday Friday

Dr. Arvind Kumar Dr. Niraj Sinha

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TAs for the course

Monday Tuesday Wednesday Thursday Friday

Tutor Ram Upadhyay Mohit Law Govind Sahu Arvind Kumar Niraj Sinha

TAs Pulkit Gupta Devang Talaviya Ajay Kumar Mahendra Gohil Pulkit Jain
Mayank Patel Anutosh Nimesh Aman Singhal Akash Gupta Sunny
Sulav Kafle Pritam Bari Asheesh Kumar Kapil Manoharan Singhania
Abhishek Ram Singh Meraj Ahmad Praveen Kumar Geeta Bhat
Shrivastav

Technical Mr. Srijan Bharti, Mr. Karthik R, Mr. Arijit Roy, Mr. Anurag Singh, and Mr. Pankaj Deora
Consultants

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Technical consultants for the course

?
Srijan Bharati (Y14) Karthik R, Engineer, MadLab Arijt Roy, Engineer, MadLab

Pankaj Deora (Y16) Anurag Singh (Y16)

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TA202A: lab technical staff (1/2)

Jeebanbandhu
Mahanta

Dharmvir
Kumar

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TA202A: lab technical staff (2/2)

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All resources for the course:

• Website: http://home.iitk.ac.in/~mlaw/ta202.php

• Lecture notes: will be uploaded here after every class

• Lab manual: already uploaded on the website

• Additional resources: will be linked on the website

• If you need to contact me for anything course related, please

email: mlaw@iitk.ac.in or call: 6897

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