ME 206- Manufacturing Processes 1

Course Code/Name: ME 206- Man Pro 1

Description:

The course is meant as an introduction towards primary manufacturing processes such as casting, forming and welding. These processes are additive in nature, i.e. the manufacture of the object takes place by combining or building from scratch (Contrast this with subtractive manufacturing processes of material removal like turning/milling where the manufacture is made from by reducing an existing chunk of material).

Given an object geometry to be manufactured, this course teaches one how to choose required casting/forging die design parameters. Some time is also devoted to how multi-physics simulations can be carried out for casting processes. Additionally, different kinds of joining processes (welding) and their process parameters are discussed.

The course is aimed at teaching the pros and cons of different processes, so that one can apply this knowledge to the selection of a process for making a part to the required level of accuracy and in required time.

Course Contents:

• Manufacturing Introduction: Materials, processes
• Metal Casting: Types, tooling design, solidification, feeder design, mold filling, gating design, simulation, defects
• Welding and Brazing: Types, analysis and defects
• Metal Forming Processes: Rolling, forging, bending, drawing, extrusion
• Miscellaneous: Powder metallurgy, plastic injection molding, free form fabrication (rapid prototyping)

Motivation:
Designing is fun. But its completely pointless if we cant make something real out of the design. Thus, its design for manufacturing, which is important and not just designing. For this, its extremely essential to have an idea of all the manufacturing processes so that, the time, cost and the feasibility of our design being manufactured can be evaluated. The course is, thus, extremely essential and has vast applications.

Any future courses which need this course as an official or unofficial pre-requisite
Most courses in manufacturing have this course as a basic requisite. More importantly, the following courses will require a strong base in manufacturing:

• • ME 649 : Advanced Manufacturing Processes
  • ME 669: Design for Manufacturing
  • ME 750: Sheet Metal Engineering
  • ME 677: Laser Material Processing
  • ME 730: Ultra Precision Machining

Useful resources:
While it is a good practice to refer to textbooks or video lectures besides your class notes, it is also important to remember that these sources may not be flawless. Reference material should only be used as a tool to strengthen concepts and not as a substitute for your class notes.

Books:

• Manufacturing Science, A.Ghosh and A.K.Mallik, Affiliated East West Press, 1985.HMT, Production Technology, Tata McGraw Hill, 1980.
• Metal Casting: Computer Aided Design and Analysis, B. Ravi, Prentice-Hall India, ISBN-81-203-2726-8, 2005-2007, Third Reprint.
• Introduction to Manufacturing Processes, J.A. Schey, 3nd edition. McGraw Hill Co., 2000

Internet Resources:

• Georgia Tech Web Resources: http://www.me.gatech.edu/jonathan.colton/me4210/me6222index.html
• NPTEL Courses:
  • Web course: http://nptel.iitm.ac.in/courses/Webcourse-contents/IIT-ROORKEE/MANUFACTURING-PROCESSES/index.htm
  • Video Lectures: http://nptel.iitm.ac.in/video.php?subjectId=112107145
• Hong Kong University of Science and Technolgy Lectures Notes: http://www.ielm.ust.hk/dfaculty/ajay/courses/ieem215/lec_toc.html
• Eastern Mediterranean University Lecure Notes: http://me.emu.edu.tr/me364/lecnotes.html

Interesting Trivia:

• Microwave Melting: http://home.c2i.net/metaphor/mvpage.html?
• Step-by-step Sand Casting Instructions: http://www.foundry101.com/new_page_7.htm
• Casting Defects: http://www.foundry101.com/new_page_3.htm
• Practical aspects of casting and some learning resources: http://www.foundry101.com/archive.htm
• Some basics of metal forming: http://www.metalformingfacts.com/forming-basics/
• Welding Trivia: http://www.careersinwelding.com/welding_fun_facts.php

Videos:

• Step by step Sand Casting
• Casting of a Ferrari V12 engine:
• Pressure Die Casting Simulation:
• Investment Casting:
• Lost Wax Casting:
• Centrifugal Casting:
• Making Coins:
• Deep Drawing:
• Sheet Metal Bending:
• Punching:
• Hydraulic Punch Press:
• Forging:
• Thermoforming:
• Arc Welding:
• Submerged Arc Welding:
• Spot Welding:
• Ultrasonic Welding: