TA 202A

202
Introduction to Manufacturing Processes
2018‐19 (I Semester)

Instructor‐in‐Charge: Prof. Arvind Kumar

Department of Mechanical Engineering

E‐mail: arvindkr@iitk.ac.in
Phone: 7484
Webpage: http://home.iitk.ac.in/~arvindkr
Schedule
Theory: T 8.00‐9.00
8.00 9.00 am Venue: L20
Theory TAs: Alok Kumar (alokkr@), Amal B Soman (amal@), Sateesh K Yadav (sateeshk@)
Labs: M‐F 2.00‐5.00 pm Venue: TA202 Lab
TA‐202
TA 202 Introduction of Manufacturing Processes (2018 19 1st Semester)
(2018‐19
TA Details
Day Tutor Name
Name Email‐ID
Prof. S. Bhattacharya Gaganpreet Singh gaganprt@iitk.ac.in
Monday
bhattacs@iitk.ac.in Sunny Singhania sunnys@iitk.ac.in
Prof. Arvind Kumar Amit Kumar Smarty aksmarty@iitk.ac.in
Tuesday
arvindkr@iitk.ac.in Sanjay Kumar sanjaykr@iitk.ac.in
Prof S.K.
Prof. S K Choudhary Pankaj Singh Chauhan pankajs@iitk ac in
pankajs@iitk.ac.in
Wednesday
Choudhry@iitk.ac.in Bibeka Nanda Padhi bibeka@iitk.ac.in
Prof. Niraj Sinha Yashwant Kumar Nama yashnama@iitk.ac.in
Thursday
nsinha@iitk.ac.in Vijay Mandal vijaym@iitk.ac.in
Prof. J. Ramkumar Divyansh Patel divy@iitk.ac.in
Friday
jrkumar@iitk.ac.in Shashank Singh kshashan@iitk.ac.in
Alok Kumar alokkr@iitk.ac.in
TAs for theory under Prof. Arvind Kumar
Amal B Soman amal@iitk.ac.in
@
(
(Tue: 8‐9
8 9 AM))
Sateesh Kumar Yadav sateeshk@iitk.ac.in

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

 Day Tutor Name Photograph Email

Monday Prof. S. Bhattacharya bhattacs@iitk.ac.in

Tuesday Prof. Arvind Kumar arvindkr@iitk.ac.in

Wednesday Prof. S.K. Choudhary choudhry@iitk.ac.in

Thursday Prof. Niraj Sinha nsinha@iitk.ac.in

Friday Prof J.
Prof. J Ramkumar jrkumar@iitk ac in
jrkumar@iitk.ac.in

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

Course content: Introduction to manufacturing; Conventional material removal
p
processes: chip
p formation, tool dynamics,
y practical machiningg and finishingg operations;
p p
CNC machining; Unconventional machining and introduction to microfabrication;
Layered manufacturing; Metrology

Lecture‐wise break‐up
S. No. Titles Suggested of number of lectures

1. Introduction to manufacturing and its evolution 2

2. Conventional material removal processes 3
3
3. U
Unconventional
ti l material
t i l removall processes 4
4. Layered / generative manufacturing processes 2
5. Computer numerical control and programming 1
6
6. Engineering metrology 1
Total number of lectures 13

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

Suggested text and reference material
• Fundamental of Modern Manufacturing: Materials, Processes and Systems: M.P.
Groover (John Wiley)
• Manufacturing Science: A. Ghosh and A.K. Malik (East‐West Press)
• Manufacturing Processes for Engineering Materials: S. Kalpakliam and S.R. Schmid
(Prentice Hall)
• Fundamental of Manufacturing Processes: G.K. Lal and S.K. Choudhuary (Narosa)
• Advanced Machining Processes: V.K. Jain (Allied Publishers)
• Introduction to Micromachining: Ed. V.K. Jain (Narosa)
• Micromanufacturing Processes: Ed. V.K. Jain (CRC Press)

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

 Grading Policy
Out of total marks 100
Theory: 40 % (40 marks) Project: 60 % (60 marks)
Mid Sem Exam = 15 Lab quiz = 10
Project drawings = 5

End Sem Exam = 25 Lab reports = 2.5

Lab attendance = 2.5
Guide’s overall evaluation + load sheet = 5 (2.5 each)
with individual weightage. This Individual weightage
will be multiplied in Final Project evaluation marks

Project mid evaluation = 7.5 (in 5th project turn)

Final project = 22.5
Project report = 5

• To pass this course, one should score total marks ≥ 40 % (40/100). Additionally,
the theory marks ≥ 25 % of the marks assigned for theory (10/40). Note that
b th should
both h ld beb fulfilled.
f lfill d

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

Please note it carefully
Theory class attendance has no marks but lab attendance has certain weightage. please note that
there is always a good, positive and almost linear correlation between alphabetic
grade and attendance.

No make‐up will be considered unless the student has authorized leave really for unavoidable
situations A student seeking a make
situations. make‐up
up is usually at disadvantage.
disadvantage
Note: No make‐up for mid sem and quiz.

Academic Dishonesty
For cheating in the examination hall: zero tolerance  “F” grade

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

 Laboratory Session

Monday D9,10,11 Session Name of Experiment

1 Turning
Tuesday D1,2,3
2 Milling + CNC demonstration
Wednesday D12,13,14 3 Drilling and fitting
4&5 CNC class room training system usage and exercise
Thursday D4,5,6
6 – 12 Project
Friday D7,8,15 Project evaluation

1st & 2nd Turn Project group formation

2nd Turn Discussion with p
project
j ideas ((come with three ideas and finalize one))
3rd Turn Bring rough sketches (Isometric) of finalized project
4th Turn CNC Demo & Final Drawings Discussion
5th Turn CNC Lab Exercise & Drawing Submission
6th ‐12
12th Turn
T F b i t your project
Fabricate j t

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

Project involves
• Conceptual design – soft copy
• Rough detailed design – soft copy
• Manufacturing drawing – hard copy
• Fabrication

You are required to bring your lab manual for every exercise lab turn.
Project group – 7 members (1st turn).
Size of the project should not exceed 1.5
1 5 ft (max) in all dimensions or 450×450×450 mm

From 2nd to 4th turn following are to schedule

Turn 2 – Discuss your idea with staff
– Come with minimum 3 ideas for discussion
– Simple working idea is more appreciated than complex incomplete project

Turn 3 – Finalizingg rough

g drawingg
Turn 4 – Make individual component drawing
Turn 5 – Submit hard copy of part drawing including the load sheet. This sheet you will fill from 5th
turn onwards

Turn 6 – Start project

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

 Lab Report Template

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur
Guidelines:
• Each student is expected to be in the theory class by 7.55 AM. Anybody coming after
8:03 PM will not be allowed in the class.
• Each student is expected to be in the Lab class latest by 1.55 PM. If anybody comes
after
ft 2 2.05
05 PM
PM, the
th Tutor/TA
T t /TA h has th
the right
i ht tto d
deny th
the entry
t in
i the
th TA202 LLab.
b
Accordingly attendance for that day will not be considered. Since the lab attendance
has a significant weightage, the students should come to the lab well in time as
mentioned above and a zero tolerance p policyy will be followed.

Three major concerns to be followed in lab

• Safety
‐ You must not wear loose clothes or clothing with loose long sleeves and not
come with loose long hair.
‐ You must wear shoes (slippers / chappals /sandals are prohibited) and full pant
‐ Safety accessories (apron, goggles, gloves etc.) provided in the lab must be used
• No shortcut
• No mobile phones

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur
 Staff Members of TA202 Lab
P. C. GOND
pcgond@iitk.ac.in AMAN SINGH KULDEEP VISHWAKARMA
LAB INCHARGE amans@iitk.ac.in kvish@iitk.ac.in
Ph: 8043

G. SREENIVASULU RAKESH THAPLIYAL ARUN KUMAR DUBEY

gaddam@iitk ac in
gaddam@iitk.ac.in trakesh@iitk ac in
trakesh@iitk.ac.in arunkd@iitk ac in
arunkd@iitk.ac.in

H. P. SHARMA NAFE SINGH RABINDRA NATH TUDU

hpsharma@iitk.ac.in nafes@iitk.ac.in rntudu@iitk.ac.in

ANIL KUMAR JHA NAMDEO B. MURKHE DHEERAJ KUMAR SONI

anilkjha@iitk.ac.in nbmurkhe@iitk.ac.in dheerajk@iitk.ac.in

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

 Staff Members of TA202 Lab

RAHUL
rahul@iitk.ac.in

GREESH CHATURVEDI VIPIN KUMAR

gpratap@iitk.ac.in

MAHESH KUMAR
mahesh@iitk.ac.in
PANKAJ KUMAR
pankajkm@iitk.ac.in NEERAJ AWASTHI

KISHAN BABU PRAJAPATI

dheerajk@iitk.ac.in

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

 Content
• What is manufacturing
• Materials in manufacturing
• Manufacturing processes
 TA202A: Introduction to Manufacturing Processes

TA: Technical Arts.

Arts

Introduction: Latin verb introducere, refers to a beginning.

Manufacturing: Something made from raw materials by hand or by machinery.

Process: A series of actions that yyou take in order to achieve a result.

Goal: The course aims to impart the basic knowledge about the fundamental
manufacturing techniques employed to convert a raw material into final
product.

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

 Manufacturing?

• The word manufacture is derived from two Latin words manus (hand) and
factus (make); the combination means “made
made by hand”
hand
• Most modern manufacturing operations are accomplished by mechanized
and automated equipment that is supervised by human workers

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

 Manufacturing & Employment Relations

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

Contribution of manufacturing to GDP of different countries

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

 Manufacturing Defined ‐ Technological Definition
• Application of physical and chemical processes
to alter the geometry, properties, and/or
appearance of a given starting material to make
parts or products

• Manufacturing also includes the joining of

multiple parts to make assembled products

• Accomplished by a combination of machinery,

tools, power, and manual labour

• Almost always carried out as a sequence of

operations

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur

 Manufacturing Defined ‐ Economic Definition

• Transformation of materials into items of greater value by means of

one or more processing and/or assembly operations

• Manufacturing adds value to the material. Examples:

Converting iron ore to steel adds value
Transforming sand into glass adds value
R fi i petroleum
Refining t l iinto
t plastic
l ti adds
dd value
l

Dr. Arvind Kumar Liquid Metals Group IIT Kanpur