Course Details
Subject {L-T-P / C} : MM3203 : Manufacturing Processes { 3-0-0 / 3}
Subject Nature : Theory
Coordinator : Prof. Syed Nasimul Alam
Syllabus
Metal Joining:
Welding: Principle, theory and classification of welding process details for each type of welding welding metallurgy of carbon and alloy steels, cast irons, stainless steels, Al- and Cu-based alloys weldability and heat affected zones (HAZ) hardfacing: Basic concept and applications.
Soldering and brazing: Difference between both the processes, consumables used, methods of brazing, fluxes used, their purposes and flux residue treatment.
Joining of metals in vacuum: Vacuum brazing of similar or dissimilar materials different grade of brazing filler metals and alloys – their applications.
Casting:
Conventional and advanced casting processes: Brief mention about solidification techniques, significance and practical control of cast structure conventional casting process advanced casting processes such as investment casting, die casting, centrifugal casting, full mould casting, injection moulding and vacuum sealed casting.
Metal working:
Forging, rolling, wire drawing, extrusion – basic concepts and advancements.
Powder metallurgy:
Basic concept and applications in metallurgical field, advanced powder processing techniques.
Product Quality:
Possible defects and their detection, assessment and remedy.
Course Objectives
- To understand the principle of different manufacturing process including Metal joining, Casting, Metal Working, Powder Metallurgy
- To study the Possible defects in different manufacturing technology and their detection, assessment and remedy.
- Students will be able to understand different metal working techniques like forging, rolling, wire drawing, and corresponding parameters and process up-gradation.
- Comprehension of the principle of welding, soldering, brazing techniques, and different process attributes. Students will be able to understand conventional and advanced casting processes and their respective structure. Comprehension of powder metallurgy as manufacturing process, applications of powder metallurgically prepared products and advancement in the powder metallurgy field.
Course Outcomes
1. The student will be able to select or develop simplified manufacturing processes with the aim of cost reduction, reducing material wastage, machining time and manpower. The students will be able to combine and develop novel hybrid techniques from the available state of art techniques. <br />2. The student will be able to identify and select appropriate process parameters for a particular manufacturing process that affect the product quality. They will be able to rectify any possible defects in the process and remove them. <br />3. The objective of the course is to provide the students the knowledge of modern manufacturing processes and also introduce to them the advanced topics of manufacturing processes as knowledge of the various advanced machining of metals, non-metals, ceramics and composites is very essential. <br />4. The students will be able to categorize different material removal, and joining processes as per the requirements of the material being used to manufacture an end product. <br />5. Understanding the possibility of defects introduced during processing and remedial actions that need to be taken to avoid these defects. <br />6. The students will be able to perform process analysis taking into account the various responses considered in a process.
Essential Reading
- J. Beddoes, M. J. Bibby, Principles of Metal Manufacturing Processes, Elsevier, Butterworth-Heinemann, 1999
- R. W. Hein, C. R. Loper and P. C. Rosenthal, Principles of Metal casting, Mc Graw Hill, 1976
Supplementary Reading
- R. H. Todd, D. K. Allen, L. Alting, Fundamental Principles of Manufacturing Processes, Industrial Press, Inc.1994
- K. Weman, Welding Processes Handbook (2nd Edition), Woodhead Publishing, 2011