TA202 A Lecture 1

Tutor: Shantanu Bhattacharya

 Manufacturing Systems Approach
Definition of Manufacturing Technology:

Manufacturing technology provides the tools that enable production of all

manufactured goods. These master tools of industry magnify the effort of
individual workers and give an industrial nation the power to turn raw materials
into the affordable, quality goods essential to todays society.
Manufacturing technology provides the productive tools that power a growing,
stable economy and a rising standard of living. Thus manufacturing process really
represents adding value to a raw material and creation of wealth.
Replenish

Sales Production rate,

fluctuations quality and
Manufacturing delivery
Raw materials cost and
Manufacturing availability System
Business Profit
Facility Add environment
comprising of
Value Social Pressure manufacturing Reputation
Output Input processes
Resources and
plans

Wealth Manufacturing
Process is the key
to wealth
generation
 Casting Processes
These are the only processes where
liquid metal in used.
Casting is the oldest known
manufacturing process.
It requires preparation of a cavity usually
in a refractory material to resemble
closely to the object to be realized.
Molten metal is poured into this
refractory mould cavity and is allowed to
solidify.
The object after solidification is removed
from the mould.
 Forming Processes
These are solid state manufacturing processes involving minimum amount of
material wastage and faster production.
Metal is heated to a temperature which is slightly below the solidus temperature
and then a large force is applied such that the material flows and take the desired
shape.
The desired shape is controlled by means of certain tools called dies which may be
completely or partially closed during manufacture.
These processes are normally used for large scale production rates.

Extrusion
Drop forging

Rolling Process

Wire Drawing
 Fabrication processes
These are secondary manufacturing processes where the starting raw
materials are processed by any of the previous methods.
It essentially involves joining pieces either temporarily or permanently so
that they would perform the necessary function.
The joining can be achieved by both heat and pressure and / or a joining
material.
Gas Welding
Resistance Welding

Arc Welding
 Material Removal Processes
These are also secondary manufacturing processes where the additional unwanted
material is removed in the form of chips from the blank material by a harder tool
so that a final desired shape can be obtained.
Material removal is the most expensive manufacturing process because more
energy is consumed, and also a lot of waste material is generated in the process.

Turning Shaping
Grinding

Milling Drilling
Sawing
 Why Machining ?
1. Finishing Requirements of Parts:
Parts manufactured by casting, forming, and various shaping
processes require further finishing before they are ready for
use or assembly.
2. Interchangeability of parts:
Sometimes in many engineering applications
interchangeability of parts is needed for which specific
tolerances, dimensional accuracy and surface finish are vital.
3. Specific and complex geometries and accuracy in assembly:
Machining involves the removal of some material from the
work piece in order to produce a specific geometry at a
definite degree of accuracy and surface quality.
Classification of Machining
 Marks Distribution In the Course
Total Marks= (100), All blue text in brackets are actual marks out of which the scores will be provided

Theory: 50% or overall (50) Lab Activities: 50% or overall(50)

Attendance 10% (5)

LabTurns 20% Project 80%

Mid Semester 30% (15)

Final Exam 60% (30) Lab Exercise 10% (5) Project Drawing 10% (5)
(This would include the lab report
marks (2) and the rating of the
technical staff (3))
Project Workability and
Lab Quiz 10% (5) Innovation 50% (25)
Lab Quiz Dates:
26/08/2013~30/08/2013
Venue: TA202 Lab
(Quiz and solution would be
provided to TA by Instructor
I/C. Checking and grade Project presentation 20% (10)
submission by TA to instructor (Based on Individual
I/C latest by 02/09/2013) Performance)

Note: A minimum of 17 marks in each of theory and lab activities section is needed by students to pass
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the examination
 Topics To be Covered in Theory
1. Manufacturing Properties of Materials.(1 class) (A computer numeric
control of machines video will be demonstrated)
2. Fundamentals of Conventional Machining. (Mechanics of material
removal, Introductory processes Turning, Milling, Shaping and
Planning, Drilling and Grinding) (4 classes)
3. Computer Numeric Control of Machines (2 classes)
4. Fundamentals of non-conventional machining (Illustration of basic
processes, Process model of Ultrasonic machining and
Electrochemical machining) (5 classes)
5. A perspective to Modern miniaturized manufacturing (1 class)
6. A perspective to Metrology (Science of measurements) (1 class)

Material of class notes would be very important.

Text Book used is Manufacturing Science by Professors Amitabha
Ghosh and Ashok Kumar Mallick, Publisher Affiliated East West
press.
 Activity Roster for Lab-work
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)

I First turn : Project groups should be formed. (Emphasize in class)

II Second turn : Project groups name should be given to the tutor.
III Third turn : Project discussion with Technical Staff / Guide with Material List.
IV 4th to 5th turn : Everything should be finalized during the 4th to 5th lab turn. So
the work should start without any loss of time on the 6th lab turn.

Activity Schedule:

Lab Turns: 29/07/2013~ 30/08/2013

Project Turns : 02/09/2013 ~ 25/10/2013

Evaluation: 28/10/2013~01/11/2013 (Monday ~ Friday) as per schedule 2:00-5:00

pm in TA202 (a).

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 Activity Calender

Evaluation between 28/10/2013~01/11/2013

Total Make Up Labs: 05 normal (Green Highlighted)+ 01 due to Antaragini (Date to be announced)
All makeups should be preferentially on Saturday 9:00 am -12:00 noon 12