TA202A: Introduction to

Manufacturing Processes
(2017-18, 1st semester)
Instructor-in-Charge
Dr. J. Ramkumar
Department of Mechanical Engineering
IIT Kanpur
Email:jrkumar@iitk.ac.in
 Course Schedule

 Lectures:
Schedule :Tuesday (8:00-9:00 AM)
Venue: L-20

 Labs:
Schedule: Monday-Friday (2:00-5:00 PM)
Venue: TA202 ME Lab
Goal: The course aims to impart the basic knowledge about the
fundamental manufacturing techniques employed to convert a
raw material into final product.
 Course Contents

1.Introduction: Introduction to manufacturing, evolution of

manufacturing, classification of manufacturing, Materials in
Manufacturing.[2]
2.Conventional Material Removal Processes: Theory of chip
formations, generation of surfaces, force and power relationships,
cutting tool material and its geometry, tool wear and tool life,
fundamentals of machine tools, types of machining operations. [3]
3.Unconventional Material Removal Processes: Introduction, need for
advanced machining processes, classifications: mechanical energy
processes, thermal energy processes, electro chemical machining
etc. [3]
 Course Contents

4.Layered/Generative Manufacturing Processes: Fundamentals of

layered manufacturing, layered manufacturing technologies,
classifications of additive manufacturing processes.[2]
5.Computer Numerical Control and Programming: Basics of numerically
controlled machines, programming for NC machines. Programming
examples including turning, drilling, milling etc.[1]

7. Engineering Metrology: Dimensions, limit, fit and tolerances,

surfaces, structure and properties, surface texture and roughness,
engineering metrology and instrumentation.[2]
 Reference Books

1. Fundamental of Modern Manufacturing: Materials, Processes and

Systems: M. P. Groover (John Wiley).
2. Manufacturing Science: A. Ghosh and A.K. Mallik (East- West Press).
3. Advanced Machining Processes: V. K. Jain (Allied Publishers).
4. Fundamental of Manufacturing Processes: G. K. Lal and S. K.
Choudhuary (Narosa).
5. Introduction to Micromachining: Ed. V. K. Jain (Narosa).
6. Micro manufacturing Processed: Ed.: V. K. Jain (CRC Press).
7. Manufacturing Processes for Engineering Materials: S. Kalpakliam and
S. R. Schmid (Prentice Hall).
 Tutors
Name Photograph Day Email

Dr. Arvind Kumar Monday arvindkr@iitk.ac.in

Dr. J. Ramkumar Tuesday jrkumar@iitk.ac.in

Dr. S.K. Chaudhury Wednesday choudhary@iitk.ac.in

Dr. Niraj Sinha Thursday nsinha@iitk.ac.in

Dr. Shantanu Bhattacharya Friday bhattacs@iitk.ac.in

 Lab (TA202)
Lab Training first five turns:
Turning (1 Turn), Milling and Shaper (1 Turn), Drilling Fitting (1 Turn), CNC
demonstration and job design (1 Turn), CNC practice (1 Turn)

 1st Turn: Project groups should be formed. (Emphasize in class)

 2nd Turn : Project groups name should be given to the tutor.
 3rd Turn : Project discussion with Technical Staff / Guide with Material List.
 4th Turn : Prototyping submission
 5th Turn : Manufacturing drawing submission
 6th Turn : The work should start without any loss of time

1. Agriculture,
Topics: 2. Healthcare,
3. Energy,
4. Machines and Mechanisms for play toys
 Staff Members: TA202 Lab
Ph. No. 7984

P C GOND H P SHARMA ANIL KUMAR JHA

G SREENIVASULU
pcgond@iitk.ac.in hpsharma@iitk.ac.in anilkjha@iitk.ac.in
gaddam@iitk.ac.in
LAB INCHARGE

AMAN SINGH RAKESH THAPLIYAL NAFE SINGH NAMDEO B MURKHE

amans@iitk.ac.in trakesh@iitk.ac.in nafes@iitk.ac.in nbmurkhe@iitk.ac.in
 Staff Members :TA202 Lab

KULDEEP VISHWAKARMA ARUN KUMAR DUBEY DHEERAJ KUMAR SONI

RABINDRA NATH TUDU
kvish@iitk.ac.in arunkd@iitk.ac.in dheerajk@iitk.ac.in
rntudu@iitk.ac.in

GREESH PRATAP
RAHUL
MAHESH KUMAR KISHAN BABU PRAJAPATI CHATURVEDI
rahul@iitk.ac.in
mahesh@iitk.ac.in kishan@iitk.ac.in gpratap@iitk.ac.in
 Staff Members :TA202 Lab

PANKAJ KUMAR NEERAJ AWASTHI VIPIN KUMAR

pankajkm@iitk.ac.in
Lab Report Template
 Grading policy

Theory Marks Lab (50Marks) Marks

(50Marks) Lab Quiz 10.0
Mid Semester 20 Lab Exercises 02.5
Exam Lab Reports 02.5
Guide’s Evaluation 05.0(Weightage)
End Semester 30 Mid Semester Evaluation 10.0
Exam End Semester Project 20.0
End Semester report 05.0

To pass this course, one should score

Minimum theory marks ≥ 20% (10/50)
Total marks ≥ 40 %
 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.

Manufacturing (Latin word) : Manus (Made) + factus (Hands) :

Made by hands.

 Present perspective: Involves making products from raw

material by various processes, machinery, & operations
following a well organized plan for each activity required.
 Really fascinating products

LASER Keyboard Self stirring mug Mug with its own biscuit pocket

Fingers engraved water

A pocket-sized washing machine A solar-powered camping tent
glass
 Pouring made E-z pan attachment
Prism glass

Dots that let you find

things with your phone
How products have transformed over the years
Changes in life style with product development
 Cost fall of components

Tablet average global selling price Microprocessor cost per transistor cycle
 Manufacturing sector in India

Make in India, structural reforms will enable

manufacturing sector to drive growth
Contribution of Manufacturing to GDP
Manufacturing & Employment Relation
 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
 Manufacturing – Economic

Transformation of materials into items of greater value by one or

more processing and/or assembly operations
 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

Note: 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
 Classification of various Manufacturing Processes

 Primary forming processes (additive or accretion)

 Casting and moulding processes
 Powder metallurgy, rapid prototyping
 Deforming processes (formatives): (Forging, Rolling, Wire drawing,
etc.)
 Secondary (Subtractive) process : Machining processes
 Conventional (turning, milling, etc.)
 Advanced machining processes (ECM,EDM,LBM etc.)
 Joining and fabrication processes (assembly)
Welding, Revetting, Brazing, Soldering, etc.
 Cont’d
 Finishing and surface treatment processes
 Burr removal (de-burring)
 Mechanical cleaning and finishing
 Chemical cleaning
 Coating
 Vaporized metal coating
 Heat treatment or bulk property enhancing processes
 Hardening
 Ductility, toughness and Machinability
 Strengthening
Classification of Manufacturing processes
 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
 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.
Select the suitable manufacturing processes for the following products.
Materials in Manufacturing

Their chemistries are different, and their

mechanical and physical properties are
different. These differences affect the
manufacturing processes that can be used
to produce products from them.
Ashby Curve
 Mechanical properties

Tensile strength – Measures the force required to pull something such as rope,wire or a
structural beam to the point where it breaks
Ductility – A measure of how much strain a material can take before rupturing.
Malleability – The pproperty of a material that can be worked or hammered or shaped
without breaking

Brittleness –Breaking or shattering of a material when subjected to stress (when force is

applied to it).
Elasticity – The property of a material that returns to its original shape after stress (e.g.
external forces) that made it deform or distort is removed

Plasticity - The deformation of a material undergoing non-reversible changes of shape in

response to applied forces
 Mechanical properties

Toughness – The ability of a material to absorb energy and plastically deform without
fracturing

Hardness – The property of being rigid and resistant to pressure; not easily scratched
Machinability – The property of a material that can be shaped by hammering, pressing,
rolling
 Physical properties

 Specific heat – The heat required to raise the temperature of one gram of a
substance by one degree centigrade (J/kg K)
 Density – Mass per unit volume expressed in such units as kg/cm 3
 Thermal conductivity –Rate at which heat flows through a given material (W/m
K).
 Melting point – A temperature at which a solid begins to liquify
 Electrical conductivity – A measure of how strongly a material opposes the
flow of electric current (Ω⋅m)
 Coefficient of thermal expansion – Degree of expansion divided by the change
in temperature (m/°C)
 Metals
Usually alloys, which are composed of two or more elements, at least one of
which is metallic. Two basic groups:
1. Ferrous metals - Based on iron, comprises about 75% of metal tonnage
in the world:
Steel and cast iron
2. Nonferrous metals - All other metallic elements and their alloys:
Aluminum, copper, nickel, silver, tin, etc.
Metal properties:
Good conductors of electricity and heat
Lustrous appearance
Susceptible to corrosion
Strong, but deformable
 Ceramics
Compounds containing metallic (or semi-metallic) and nonmetallic elements.
Typical nonmetallic elements are oxygen, nitrogen, and carbon
For processing, ceramics divide into:
1. Crystalline ceramics – includes:
Traditional ceramics, such as clay, and modern ceramics, such as alumina (Al2O3)
2. Amorphous :Glasses – mostly based on silica (SiO2)
Properties:
Thermally and electrically insulating
Resistant to high temperatures and harsh environments
Hard, but brittle
 Polymers
 Compound formed of repeating structural units called mers, whose atoms share
electrons to form very large molecules
 Polymer usually consists of carbon plus one or more elements such as hydrogen and
nitrogen

Polyethylene: (the mer unit is C2H4) Polypropylene: (the mer unit is C3H6)

Composed primarily of C and H (hydrocarbons).

Low melting temperature.
Most are poor conductors of electricity and heat.
Many have high plasticity.
A few have good elasticity.
Some are transparent, some are opaque.
 Composites
Material consisting of two or more phases that are processed separately and then bonded
together to achieve properties superior to its constituents
 Phase - homogeneous mass of material, such as grains of identical unit cell structure in
a solid metal
 Usual structure consists of particles or fibers of one phase mixed in a second phase
 Properties depend on components, physical shapes of components, and the way they
are combined to form the final material.
In two material system, there are two phases : Primary phase & Secondary phase.
 The primary phase forms the matrix within which the secondary phase imbedded
 The imbedded phase is also known as dispersed phase or reinforcing phase
 Shape Memory Materials
Definition:
Shape Memory Materials (SMM) are those materials which, after being deformed
plastically (i.e., permanently) at the room temperature into various shapes, return to
their original shapes upon heating.
Examples:
Typical Shape Memory Alloys are
 55% Ni-45%Ti
 Copper-Aluminum-Nickel
 Copper-Zinc-Aluminum
 Iron-Manganese-Silicon
Characteristics:
 SMM have good ductility, good corrosion resistance, high electrical conductivity
 Behavior of SMM can also be reversible, i.e., shape can switch back and forth upon
heating
Applications:
 Can be used To generate motion and/or force in temperature sensitive actuators
 Eyeglass frames, connectors, clamps and fasteners
 Shape Memory Materials

Sell Shape Memory spring Jacket with Shape memory fabric

Shape Memory alloy

 Piezoelectric Materials
Piezoelectric materials are materials that produce an electric current when they are
placed under mechanical stress. The piezoelectric process is also reversible, so if you
apply an electric current to these materials, they will actually change shape slightly (a
maximum of 4%).
There are several materials that we have known for some time
that posses piezoelectric properties, including bone, proteins,
crystals (e.g. Quartz) and ceramics (e.g. Lead Zirconate
Titanate).
 Biomaterial
 A biomaterial can be defined as any substance (other than a drug) or combination of
substances synthetic or natural in origin, which can be used for any period of time, as
a whole or as a part of a system which treats, augments, or replaces any tissue, organ
or function of the body.
 Theoretically, any material can be a biomaterial as long as it serves the stated medical
and surgical purposes.
Example of Biomaterial

Ti biomaterial
 Biomaterial applications
Orthopedic Applications:
 Metallic materials are normally used for load bearing members such as pins and
plates and femoral stems etc.
 Ceramics such as alumina and zirconia are used for wear applications in joint
replacements.
 Polymers such as ultra high molecular weight polyethylene are used as articulating
surfaces against ceramic components in joint replacements.
Dental Applications:
 Metallic biomaterials have been used as pins for anchoring tooth implants and as
parts of orthodontic devices.
 Ceramics have found uses as tooth implants including alumina and dental porcelains.
 Polymers, are also orthodontic devices such as plates and dentures.
 Recap

 Overview of the course

 Manufacturing: Introduction
 Classification of Manufacturing
 Materials in Manufacturing
 Different Materials in Manufacturing