Welcome to

TA (Technical Art)-201A
Introduction of Manufacturing
Processes
Krishanu Biswas
kbiswas@iitk.ac.in

TA201N

Introduction to Manufacturing
Processes
Spring 2012

Instructor: Dr.Krishanu Biswas

Associate Professor,
Materials Science and Engineering,
email : kbiswas@iitk.ac.in
WL 210
Phone: 6184
Course website:
http://lattice.mme.iitk.ac.in/~kbiswas/index.html

Course Objectives
-To expose the students to the fundamentals of Casting
solidification
-To Discuss basic metal working processes
-To expose the students to welding and heat treatment
-To expose the students to various Powder metallurgical
processing routes and to discuss the mechanisms of
sintering metallic and ceramic solids

Introduction to Manufacturing
Processes (2-0-2-5)
Theory: Lecture, T : 9-10 AM , L7

Labs: MTWThF 2-5 PM at Engg.

Metallurgy Lab

Course Content
Introduction to Manufacturing, Historical perspective;
Importance of manufacturing; Classification of manufacturing processes, Engineering materials
Casting, Fundamentals of casting, Sand casting, Permanent mold casting including pressure
die casting, Shell, investment & centrifugal casting processes, Continuous casting, Casting defects
Metal Forming, Basic concepts of plastic deformation, Hot & cold working, Common bulk
deformation processes (Rolling, Forging, Extrusion and Drawing), Common sheet metal
forming processes
Fundamentals of welding & classification of Welding processes, Gas and arc welding, Brazing and
soldering, Adhesive bonding, Mechanical fastening
Heat Treatment, Principles of heat treating; annealing, normalizing, hardening and tempering,
Manufacturing of Polymer and Powder Products, Classification of polymers, Introduction to extrusion,
injection molding, blow molding, compression and transfer molding
Green compacts from powders including slip casting of ceramics, Sintering
Modern Trends in Manufacturing
Case Studies

TA 201 N: Suggested Reading

Mikell P. Groover; Fundamentals of ModernManufacturing (PRENTICE
HALL), 1996 - 40 copies
Kalpakjian Serope; Manufacturing Processes for Engineering
Materials (ADDISON-WESLEY PUBLISHING COMPANY), Second Edition,
1992 - 30 Copies
G.K.Lal and S.K.Chaudhury; Fundamentals of Manufacturing Processes
(Narosa): 10 Copies
Merton C. Flemings; Solidification Processing ( McGraw-HILL
SERIES), 1929 2 Copies
Bruce Chalmers; Principles of Solidification (ROBERT E KRIEGER
PUBLISHING COMPANY, New York) , 1964 2 Copies
Dieter George E; Mechanical Metallurgy (MCGRAW HILL), 3rd Edition
- 4 Copies

Course Goals
To bring to the students an appreciation for breadth of manufacturing
processes
To provide students with an understanding of the importance of
manufacturing process

To provide students with an understanding of manufacturing

processes
Concepts
Examples
Applications in the real world

Course Goals
It is important to know the following:
How to manufacture Useful Engineering Product?
What are different materials?
What material to be used?
What are different Processes?
What process to be used?
What are the deciding factors for Q2-5?
We shall try to make some products too: Project
How good is Your Craftsmanship?
AWARD..Certificates..Good for future

Credit Distribution
Theory: 50 %
Mid Semester Exam: 20 % ( 2 hours : 4 Questions)
End Semester Exam : 25 % (3 hours: 6 Questions
Class Attendance :

5%

Laboratory: 50%
Practice Jobs (including lab report):

5%

Practical Laboratory Exam:

10 %

Project :

25 %

Project report:

10%

PROJECT
Size of the project should not exceed 1.5 ft (max) in all dimensions and total
weight for casting objects should not exceed 3 kg per project.
The project groups with each of 5-6 students will be decided by 1st turn. From
2nd turn, the tentative plan needs to be submitted. After discussion with tutors
during 5th turns, the final project plan needs to be submitted on 6th turns. In case
you do not submit the drawing on 6th turn, you will not get any marks on drawing.
External color can not be used.
Report is to be prepared on the same day (Template will be provided). It is sort of log
book and it is important to ensure that the students learn the importance of filling the log
book. The answers to the questions related to different operations are to be submitted at the
end of experimental lab session to the respective Tutors.
You are requested to bring your lab manual in everydays lab. However, one set of each
experiment is going to be displayed on the notice board to facilitate the students to do
experiments part.

Credit Distribution: PROJECT

Project involves: Conceptual Design, Detailed Design and
Drawings, Working Model and Report

Project Grading:
Innovative Idea: 15%
Final Product: 70%
Report with Engg. Drawing: 15%

PROJECT
Project groups: 5-6 students/group in 1st Lab turn
Group members should preferably be from different branches
2nd 5th Turns : Interaction Hour from 4 -6 PM to discuss about
the design of the project.
YOU MUST COME UP WITH ATLEAST 3 DIFFERENT
PRODUCT CONCEPTS FOR DISCUSSION. SIMPLE,
INNOVATIVE, FINISHED PROJECTS WILL BE GIVEN MORE
CREDIT THAN COMPLICATED, UNFINISHED PROJECTS
Project duration: 6 lab turns in MSE
Prizes will be given to Best projects from each lab day, Overall
Best projects
The project grading will be done by all tutors.

Laboratory Schedule
LAB
Mon

D1

Tue

D2

Wed

D3

Thurs

D4

Fri

D5

Safety:
You must not wear loose clothes or clothing with loose long sleeves and not come
with loose long hair. You must wear shoes (bathroom slippers/sandals are prohibited).
Safety accessories (apron, goggles, gloves etc.) provided in the lab must be used.

Contact details of Tutors

Name
Prof. S.S. Singh
,sudhanss@

Office/Locati
on

Phone No.

Day

Lab

TAs

Old SAC
206A

6908 (O)

MON

MSE

Mr. Miral Verma

Mr. Anil Kumar Chauhan

WLE114

7176 (O)

TUE

MSE

WL210A

7353(O)

WED

MSE

Mr. Telmasre Tusar

Khemraj
Mr. Venkatesh V
Mr. Vikrant Kumar Beura
Mr. Vipin Nanda

Biomaterial
s lab

6194 (O)

THUR

MSE

Mr. Paidpilli Mahesh

Kumar Ms. Rubia Hassan

FB407

6449 (O)

FRI

MSE

Mr. Ram Pyar Singh

Mr. Nitin Tandekar

WL-210

6184 (O)

----

MSE

Mr. Rajesh Kumar (V

Prashad)

D1
Prof S. Sangal

sangals@
D2
Prof. D. Gupta

saboo@
D3
Prof. K. Balani

kbalani@
D4
Prof. R. Mukherjee

rajdipm@
D5

Prof. K. Biswas
Instructor-in-charge

Contact details of Lab-in-charges

Name
Mr. A.K.Verma
akumarv@

Office/Loca
tion
MME, WL204

Phone No
7978, 7974

Contact details of Teaching Assistants : MSE lab

Lab Day

Name

Email address

Home/Hostel

MON

Mr. Miral Verma

miralv@

HALL4, H-108

MON

Mr. Anil Kumar Chauhan

anilkc@

HALL9, C-312

TUE

Mr. Telmasre Tushar Khemraj

telmasre@

HALLXI, A-401

TUE

Mr. Venkatesh V

venkatv@

HALL4, D-307

WED

Mr. Vikrant Kumar Beura

vkbeura@

HALL4, A-217

WED

Mr. Vipin Nanda

vipinn@

HALL4, F-110

THUR

Mr. Paidpilli Mahesh Kumar

paidpill@

HALL4, F-213

THUR

Ms. Rubia Hassan

rubia@

HALL6, B-203

Mr. Ram Pyar Singh

singhrp@

HALL4, E-211

FRI
Mr. Nitin Tandekar
With INSTRUCTOR Mr. Rajesh Kumar *

nitintnd@
rajeshkr@

HALL9, B-306
HALL9, B-318

FRI

*: Attendance in the class

Before startingSAFETY
Follow safety instructions.
Dont employ shortcuts
Dont panic
Take time.dont rush
It may take few more minutes.

Moreover, if you submit early.it will not carry any extra marks
submit in time and at the same time dont rush

Important Announcements

If someone is absent consecutively in three lectures without any suitable reason, he/she will
get no credit for attendance.

If someone misses Mid Sem, marks will be prorated on the basis of End Sem. No make up
for mid sem. There will be no mixing between lab marks and written exam marks. These
two things will be considered separately.

Class notes of the entire week will be put in Copy Point on Friday at 5pm. Solved
problems and model questions will be placed in Copy point on Monday at 5pm. This will
start after two lectures. Apart from that, PPTs/Videos related to Lab and Class will also be
available online.

INTRODUCTION AND
OVERVIEW OF
MANUFACTURING
What is Manufacturing?
Materials in Manufacturing
Manufacturing Processes

What is Manufacturing?
The word manufacture is derived from two Latin
words manus (hand) and factus (make); the
combination means made by hand
Made by hand accurately described the
fabrication methods that were used when the
English word manufacture was first coined
around 1567 A.D.
Most modern manufacturing operations are
accomplished by mechanized and automated
equipment that is supervised by human workers

Can Cooler

www.made-in-china.com

Chilled Cold-drinks on a road trip?

Yes! No longer need to stop for that!

Specification:
1. Cooling system: Thermoelectric Peltier cooling system, CFC-free.
2. Capacity: For 355ml/500ml diameter 66mm beverage can.
3. Direct evaporator aluminum liner: Cool to 14 degree room temperature.
4. Heat dissipation by long life brushless DC fan.
5. Indicator: Green LED indicates cooling is ON.
6. DC Plug: Convenient 12V cigarete lighter plug into car
with locking mechanism.
7. Operating Voltage: 10-15V DC for connecting to cigarette lighter.
8. Power consumption: 30W.
9. Operation temperature: - 50C to 40 0C

Commercial airplane
Boeing 777

Air Bus 380

Assembly
operations on the
Boeing 777
(photo courtesy
of Boeing
Commercial
Airplane Co.).

Metal chips fly in a

high speed turning
operation performed
on a computer
numerical control
turning center
(photo courtesy of
Cincinnati Milacron).

A batch of silicon wafers enters a furnace

heated to 1000C (1800F) during
fabrication of integrated circuits under
clean room conditions (photo courtesy of
Intel Corporation).

Two welders perform

arc welding on a
large steel pipe
section (photo
courtesy of Lincoln
Electric Company).

Automated
dispensing of
adhesive onto
component parts
prior to assembly
(photo courtesy of
EFD, Inc.).

A robotic arm
performs
unloading and
loading operation
in a turning center
using a dual
gripper (photo
courtesy of
Cincinnati
Milacron).

Charging of a basic oxygen furnace, in

which molten pig iron produced in a blast
furnace is poured at temperatures

Assembly workers on an
engine assembly line
(photo courtesy of Ford
Motor Company).

Manufacturing of a Bicycle

AISI 1010 welded tubing,

assembly resistance welded
and electrostatically
painted

Manufacturing
of a bicycle

Aluminum alloy forging,

polished and buffed

Forged aluminum
tubing(alloy similar to
6063), polished and buffed

AISI 1010,swaged
and cadmium plated

AISI 1008,press formed

resistance welded and
painted

AISI 1020,forging
and chromium plated

AISI 1010, luster finished AISI 1008, press

coil stock,profile
formed,welded and plated
milled,resistance welded
and chromium plated
formed,welded and plated
Cold drawn medium
carbon steel,( similar to
AISI 1035) bright zinc
plated

AISI 1020 tubing, machine

threaded and painted

AISI 1010,stamped and

coined and chromium
plated
AISI 1010, stamped and
chromium plated

Seamless AISI 1020 tubing

swaged tube sections
brazed into fork
crown,painted

Headed brass,nickel plated

Aluminum permanent mold
casting,machined , polished
Hardened high-carbon
and buffed
steel,thread rolled and
chromium plated

AISI 1010,stamped and

chromium plated

AISI 1040
forging,carburized and
chromium plated
Case hardened forging
quality steel parts, black
oxide coating

Osteo-arhitries

Manufacturing is Important
Technologically
Economically
Historically

Manufacturing Technologically Important

Technology - the application of science to
provide society and its members with those
things that are needed or desired
Technology provides the products that help
our society and its members live better
What do these products have in common?
They are all manufactured

Manufacturing is the essential factor that

makes technology possible

Manufacturing - Technologically
Application of physical and chemical processes to alter the
geometry, properties, and/or appearance of a starting
material to make parts or products
Manufacturing also includes assembly
Almost always carried out as a sequence of operations

Manufacturing - Economically
Important
Indian economy:

Manufacturing is
one way by
which nations
create material
wealth

www. commerce. nic. in

Sector
Manufacturing
Agriculture, minerals, etc.
Construction & utilities
Service sector retail,
transportation, banking,
communication, education,
and government

% of
GDP
20%
19%
3%
58%

Manufacturing - Historically
Important
Throughout history, human cultures that were better at
making things were more successful
Making better tools meant better crafts & weapons
Better crafts allowed people to live better
Better weapons allowed them to conquer other cultures in
times of conflict
To a significant degree, the history of civilization is the
history of humans' ability to make things

Materials in Manufacturing
Most engineering materials can be classified into one of
three basic categories:
1. Metals
2. Ceramics
3. Polymers
Their chemistries are different
Their mechanical and physical properties are dissimilar
These differences affect the manufacturing processes that
can be used to produce products from them

Thanks, and Ill see you next Tuesday AT 9 AM.