ME 338 — Manufacturing Processes II

Description:
The course takes us through the fundamentals of different machining processes, and optimization of a chain of processes through which a part undergoes.
Basics of fixturing and metrology are also covered in this course.
As contrasted to the additive/joining processes covered in the course Manufacturing Processes 1(viz. casting, forming, welding), this course covers subtractive processes of material removal (machining/ milling) . In addition, non traditional manufacturing processes, like Electro-Discharge Machining (EDM), laser beam machining, plasma cutting etc are also a part of this course.
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:

  • Material Removal Processes: Mechanics of Machining, tool geometry and materials, chip formation, tool temperature, tool wear, tool life, surface finish, machinability.
  • Optimization of machining processes.
  • Machine Tools: Generation of surfaces by machining, basic operations on shaping, slotting and planning machines, lathe, drilling and boring machines and grinding machines.
  • Process Parameters and setups.
  • Production Machines: Capstan and turret lathes, automats, broaching machines, centre-less grinding machines.
  • Special purpose machines for thread cutting and gear cutting (hobbing and shaping).
  • Finishing processes honing, laping burnishing and deburring.
  • Introduction to modern machining processes: EDM, ECM, LASER.
  • Jigs and fixtures: principles of location and clamping, synthesis of simple jigs and fixtures. Principles of assembly engineering, theory of dimensional chains, fully interchangeable and selective assembly.
  • Introduction to Numerical Control.

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

Recources:

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:

  • G.Boothroyd and W.A.Knight, Fundamentals of Machining and Machine Tools, Marcel Dekker, 1989. (Can be used as a course text book)
  • Introduction to Manufacturing Processes, J.A. Schey, 3nd edition. McGraw Hill Co., 2000.
  • Manufacturing Processes for Engineering Materials, S. Kalpakjian and S. R. Schmid, 5th  edition; Prentice Hall, 2003.
  • Metrology for Engineers, J. F. W.Galyer, and C. R. Shotbolt, ELBS
  • A.Ghosh and A.K.Mallik, Manufacturing Science, Affiliated East West Press, 1985.HMT, Production Technology, Tata McGraw Hill, 1980.

Internet Resources

Interesting Links:

Traditional Processes:

  • Basic Turning:
  • Basic Milling/Machining Centers:
  • Machining a spur gear:
  • Machining a cube inside a cube:
  • 5 axis machining of a concept car:
  • CNC carving of a Harley Davidson Logo:
  • 5 axis machining of an engine block:
  • Machining impeller blades:
  • Honing (of an engine cylinder):
  • Broaching:
  • Rotary broaching
  • Reaming:

Non traditional Processes:

  • Waterjet cutting:
  • 3D Laser cutting:
  • Plasma Cutting:
  • EDM basics:
  • EDM:
  • Wire EDM:
  • Ultrasonic Machining:
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