COURSE OBJECTIVES

This course provides an introduction to the manufacturing processes that are used in industry to manufacture products that are widely used in daily life. The course objectives are as follows:

1. Recognize, understand and develop working knowledge of broad range of manufacturing processes that are used in the industry.
2. To compare the existing technologies used in casting, shaping, forming, property enhancing, joining and assembly process.
3. To apply the limitations and advantages of different manufacturing processes with an economic point of view to the industry.
4. To learn how component can be manufactured in sustainable manner and learn about the environmental hazards of different manufacturing processes.

COURSE LEARNING OUTCOMES (CLO)

CLO-1: Relate processing operations (shaping, property enhancing and surface processing) with their process dynamics and performance. (C3)
CLO-2: Relate machining operations with their process dynamics and performance. (C3)
CLO-3: Relate joining operations with their process dynamics and performance. (C3)
CLO-4: Compare, organize and select appropriate manufacturing processes, equipment and process parameters. (C4)

COURSE CONTENTS

  1. Introduction to Manufacturing Processes – Two Lectures
  • Materials in manufacturing
  • Manufacturing Processes
  • Production Systems
  • Overview of Casting Technology

2. Fundamentals of Metal Casting – Two Lectures

  • Heating and Pouring
  • Solidification and Cooling

3. Metal Casting Processes – Three Lectures

  • Expendable and Permanent Mold Casting Processes
  • Foundry Practice
  • Casting Quality, Product Design Considerations

4. Shaping Processes for Plastics – Four Lectures

  • Properties of Polymer Melts
  • Extrusion, Injection Molding
  • Blow Molding and Rotational Molding
  • Polymer Foam Processing and Forming
  • Product Design Considerations

5. Powder Metallurgy – Two Lectures

  • Characterization and Production of Engineering Powders
  • Conventional Pressing and Sintering
  • Alternative Pressing and Sintering
  • Product Design Considerations

6. Sheet Metal Working – Four Lectures

  • Cutting, Bending and Drawing Operations
  • Dies and Presses for Sheet Metal Processes
  • Sheet-Metal Operations Not Performed on Presses

7. Theory of Metal Machining – Four Lectures

  • Machining Technology Overview
  • Theory of Chip Formation in Metal Forming
  • Force, Power and Energy Relationships in Machining
  • Effect of Cutting Temperature

8. Joining – Three Lectures

  • Brazing, soldering, sintering,
  • Adhesive bonding, fastening,
  • Press fitting processes

9. Welding Processes – Four Lectures

  • Overview of Welding Technology
  • The Weld Joint
  • Physics of Welding
  • Features of a Fusion Welded Joint
  • Arc Welding
  • Resistance Welding
  • Oxy-fuel Gas Welding
  • Other Fusion Welding Processes
  • Solid State Welding
  • Weld Quality
  • Weld ability
  • Design Considerations in Welding

10. Non-conventional machining processes – Two Lectures

  • Mechanical Energy Processes
  • Electrochemical Machining Processes
  • Thermal Energy Processes
  • Chemical Machining
  • Application Considerations

11. Additive manufacturing – Two Lectures

  • 3D printing