TA202A: Introduction to

Manufacturing Processes

N. Sinha
Department of Mechanical Engineering
IIT Kanpur
Email: nsinha@iitk.ac.in
 Information About the Course
Lectures
Schedule: Tuesday (8:00-9:00 AM)
Venue: L-7
Labs
Schedule: Monday-Friday (2:00-5:00 PM)
Venue: TA202 ME Lab

TA202 Lab

Course updates and announcements

http://home.iitk.ac.in/~nsinha/ta.html
 Information About the Course
TA202A: Introduction to Manufacturing Processes

TA: Technical Arts.

Introduction: Latin verb introducere, refers to a beginning.

Manufacturing: something made from raw materials by

hand or by machinery.

Process: a series of actions that you take in order to achieve

a result.

Goal: The course aims to impart the basic knowledge about

the fundamental manufacturing techniques employed to
convert a raw material into final product.
 Manufacturing - Technological
• Application of physical and chemical processes
to alter the geometry, properties, and/or
appearance of a starting material to make parts
or products

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 Manufacturing – Economic
• Transformation of materials into items of greater
value by one or more processing and/or assembly
operations

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 Manufacturing Industries
• Industry consists of enterprises and organizations
that produce or supply goods and services
• Industries can be classified as:
1. Primary industries - cultivate and exploit natural
resources, e.g., agriculture, mining
2. Secondary industries - take the outputs of primary
industries and convert them into consumer and capital
goods
3. Tertiary industries - service sector

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Manufacturing Industries - Continued
• Secondary industries include manufacturing,
construction, and electric power generation
• For our purposes, manufacturing means
production of hardware
– Nuts and bolts, forgings, cars, airplanes, digital
computers, plastic parts, and ceramic products

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 Manufactured Products
• Final products divide into two major classes:
1. Consumer goods - products purchased directly
by consumers
• Cars, clothes, TVs, tennis rackets
2. Capital goods - those purchased by companies to
produce goods and/or provide services
• Aircraft, computers, communication
equipment, medical apparatus, trucks, machine
tools, construction equipment

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 Manufacturing Processes

Two basic types:

1. Processing operations - transform a work material
from one state of completion to a more advanced
state
– Operations that change the geometry, properties,
or appearance of the starting material
2. Assembly operations - join two or more
components to create a new entity

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 Question

Why do I need this course?

Why theory?
Why lab exercises?
 Question

Which Process to Select and Why?

www.wonkeedonkeetools.co.uk
 Questions

Need to machine newly developed metals and non-metals with
special properties that make them difficult or impossible to
machine by conventional methods

Need for unusual and/or complex part geometries that cannot
easily be accomplished by conventional machining

Need to avoid surface damage that often accompanies
conventional machining
Example

Intricate shaped blind hole – e.g. square hole of 15 mm x 15 mm with a
depth of 30 mm

Difficult to machine material – e.g. same example as above in Inconel, Ti-
alloys or carbides.

Low Stress Grinding – Electrochemical Grinding is preferred as compared
to conventional grinding

Deep hole with small hole diameter – e.g. φ 1.5 mm hole with l/d = 20

Machining of composites.
Questions
 Questions

http://www.me.iitb.ac.in/~ramesh/courses/ME338/non_trad.pdf
Microfabrication
 Miniaturization: Information Storage

Data recording on a disc

 The information is transformed to strings of binary digits (0s and 1s,
also called bits).
 Each bit is then laser “burned” into the disc, using a single beam of
light, in the form of dots.
 The storage capacity of optical discs is mainly limited by the
physical dimensions of the dots.
Fgure Source: International Data Corporation (IDC)
 Miniaturization: Information Storage
How far can we reduce the size of the dots?
Abbe’s Limit:
If a light beam is focused through a
lens, the diameter of the resulting spot
of light can’t be smaller than half its
wavelength.

Way to get around the problem

The first beam (red, in the figure) has a round shape, and is used to
write data.

 Then, place a doughnut-shaped laser (purple, in the figure) around

the initial laser in order to limit the abilities of the first beam. This
effectively made the standard laser’s diameter smaller, and it could
then write smaller bits.
Source: http://theconversation.com/more-data-storage-heres-how-to-fit-1-000-terabytes-on-a-dvd-15306
 Layered/Additive Manufacturing
Additive Manufacturing (AM) refers to a process
by which digital 3D design data is used to build up
a component in layers by depositing material.
(from the International Committee F42 for Additive
Manufacturing Technologies, ASTM)..

What You See Is What You Build (WYSIWYB) Process

Additive vs Subtractive Manufacturing

Part Complexity;

Material;

Speed;

Part Quantity;

Cost.
 Additive vs Subtractive Manufacturing

Figure: Features that represent problems using CNC machining.

Source: Gibson, Additive Manufacturing

Additive vs Forming Manufacturing
Advantages of Additive Manufacturing
Principle 1: Complexity is Free
Principle 2: Variety is Free
Principle 3: No Assembly Required
Principle 4: Zero Lead Time
Principle 5: Zero Constraints
Principle 6: Zero Skill Manufacturing
Principle 7: Compact & Portable Manufacturing
Principle 8: Less Waste By-product
Principle 9: Infinite Shades of Materials
Principle 10: Precise Replication
Source
Google images

Current and Potential industries for Additive Manufacturing

 Benefits

Source: SAVING project/Crucible Industrial Design Ltd.; Roland Berger

Benefits

Source: Roland Berger

Benefits

Source: Roland Berger

 Future: Home Manufacturing
Customization:
•Bristle hardness
•Colour
Old •Handle Style and
toothbrush shape
•Etc.
New
toothbrush

Laser scanner to
input personalized
data

Home 3D Printer
Case Studies

Source: Royal Academy of Engineerin

 Topics
1. Introduction: Introduction to manufacturing; evolution
of manufacturing; importance of design in manufacturing.

2. Conventional Material Removal Processes: Theory of

chip formations; generation of surfaces; force and power
relationships; cutting tool material and its geometry; tool
wear; fundamentals of machine tools; types of machining
operations.

3. Unconventional Material Removal Processes:

Introduction, mechanical energy processes, thermal energy
processes, electro chemical machining.
 Topics
4. Computer Numerical Control and Programming: Basics
of numerically controlled machines; programming for NC
machines; motion and coordinate system; structure of a
NC part program; examples of part programming.

5. Microfabrication Processes: Silicon processing,

lithography, micro and nanofabrication processes.

6. Layered/Generative Manufacturing Processes:

Fundamentals of layered manufacturing; layered
manufacturing technologies, modeling.

7. Engineering Metrology: Dimensions, tolerances,

surfaces, structure and properties, surface texture and
roughness, engineering metrology and instrumentation
 Reference Books
1. Fundamental of Modern Manufacturing: Materials,
Processes and Systems: M. P. Groover (John Wiley).
2. Manufacturing Processes for Engineering Materials: S.
Kalpakliam and S. R. Schmid (Prentice Hall).
3. Manufacturing Science: A. Ghosh and A.K. Mallik (East-
West Press).
4. Fundamental of Manufacturing Processes: G. K. Lal and
S. K. Choudhuary (Narosa).
5. Advanced Machining Processes: V. K. Jain (Allied
Publishers).
6. Introduction to Micromachining: Ed. V. K. Jain
(Narosa).
7. Micromanufacturing Processed: Ed.: V.K.Jain (CRC
Press).
 Lab

Themes
1. Agriculture,
2. Transportation,
3. Healthcare,
4. Educational toys to help school children,
5. Machines and Mechanisms.
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 List of Tutors

Dr. J. Ramkumar Dr. S. Bhattacharya Dr. S.K. Choudhry Mr. A. Kene

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 List of Tutors and TAs
Day Tutor TAs Email
Monday Dr. J. Ramkumar Gaganpreet Singh (14105274) gaganprt
(jrkumar@iitk.ac.in) Atinder Pal Singh (14105268) atinder
Tuesday Dr. S. Bhattacharya Pankaj Singh Chauhan (14205263) pankajs
(bhattacs@iitk.ac.in) Rupal Srivastava (14205265) rupalsri
Wednesday Dr. S.K. Choudhury Kashfull Orra (13205071) Kashu
(choudhry@iitk.ac.in) Navneet Singh (12807436) navneets
Thursday N. Sinha Kartikeya Dixit (14105279) dkartik
(nsinha@iitk.ac.in) Ashutosh Rai (14205002) arai
Friday Mr. A. Kene Raghubeer Singh Bangari (13205076) raghusb
(amarjitk@iitk.ac.in ) Vivek Chawda (12807829) vchawda
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 Grading Criteria
Theory (55%) Lab (45%)
Details Details

Quizzes 7% Project Drawings 2.5%

Mid Semester Exam 18% Lab Exercises 2.5%
End Semester Exam 30% Lab Reports 2.5%
Guide’s Evaluation 2.5%
Attendance 5%
Mid Semester Evaluation 7.5%
End Semester Evaluation 22.5%

To pass this course, one should score total marks ≥ 35 % and

theory marks ≥ 30 % of the marks assigned for theory.

Academic Dishonesty: ZERO Tolerance  “F” Grade