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Fundamentals of manufacturing processes

By Prof. D K Dwivedi   |   IIT Roorkee
Learners enrolled: 590
It is proposed to include fundamental of following aspects of manufacturing technology 
A) Understanding Manufacturing: concept of manufacturing, need, scope, advantages, limitation, application, materials and manufacturing, classification of manufacturing, process capabilities, selection, break even analysis of manufacturing processes 
B) Casting: approach, steps, pattern, molding, gate and riser, melt treatment, solidification, casting processes: sand mould, shell mould, permanent mould casting, casting defect and their remedy 
C) Forming: approach, hot and cold forming, rolling, forging, extrusion, drawing, sheet metal forming, press, dies, types of dies and die set sheet metal operations punching, blanking, notching, nibbling 
D) Joining: approach, need, principle of fusion welding, gas welding, thermit welding, arc welding  common arc welding processes, resistance welding, weldability of metals, solidification of weld, weld discontinuities and their remedy 
E) Machining: approach, mechanism, classification, cutting tool, tool material, heat generation, cutting fluid, grinding, internal and external surface grinding, centerless grinding designation and selection of grinding wheel, trueing and balancing, honing, reaming, lapping, polishing etc. 
F) Improving properties: heat treatment of steel and aluminum alloys, Fe-C diagram, TTT diagram, and CCT diagram, heat treatment processes annealing, normalizing, quenching tempering, surface modification methods namely without change chemistry, changing chemical composition and development of coating and cladding.


INTENDED AUDIENCE : Any interested learners
PRE-REQUISITES : NIL
Summary
Course Status : Upcoming
Course Type : Core
Duration : 12 weeks
Start Date : 26 Jul 2021
End Date : 15 Oct 2021
Exam Date : 24 Oct 2021
Enrollment Ends : 02 Aug 2021
Category :
  • Mechanical Engineering
Credit Points : 3
Level : Undergraduate/Postgraduate



Course layout

Week 1 : Understanding Manufacturing
Fundamental approaches of manufacturing
Manufacturing process specific advantages and limitation
Materials and manufacturing processes
Classification of manufacturing processes

Week 2 : Selection of manufacturing processes 
Application of manufacturing processes 
Effect of manufacturing processes on properties of metals
Break-even point analysis in manufacturing processes
Metal Casting: Introduction & Suitability

Week 3 : Metal Casting: Steps of casting processes
Metal Casting: Terminology
Metal Casting: Pattern allowances I
Metal Casting: Pattern allowances II
Metal Casting: Sand Moulding I

Week 4 : Metal Casting: Sand Moulding II
Metal Casting: Core & Core Prints 
Metal Casting: Gating System 
Metal Casting: Yield 
Metal Casting: Riser Design

Week 5 : Metal Casting: Cleaning of casting
Metal Casting: Casting defects & their prevention
Metal Casting: Shell molding  
Metal Casting: Investment and permanent mould casting
Metal working processes: Hot and cold working 

Week 6 : Metal working processes: Rolling
Metal working processes: Forging 
Metal working processes: Extrusion
Metal working processes: Wire Drawing
Metal working processes: Press

Week 7 : Metal working processing: Sheet metal operations (Shearing)
Metal working processing: Sheet metal operations II
Metal working processing: Sheet metal operations III
Metal working processing: Dies and die set
Material removal processes: Machining

Week 8 : Material removal processes: Mechanism of the metal cutting
Material removal processes: Chip Formation
Material removal processes: Types of chips and power consumption
Material removal processes: Heat generation
Material removal processes: Tool failure and tool life

Week 9 : Material removal processes: Tool materials
Material removal processes: Cutting fluids
Material removal processes: Grinding I
Material removal processes: Grinding II
Material removal processes: Grinding III

Week 10 :Material removal processes: Grinding operations
Joining of metals: Fundamentals I
Joining of metals: Fundamentals II
Joining of metals: Welding processes I
Joining of metals: Brazing, soldering and weldability

Week 11 :Joining of metals: Weldability and welding defects
Heat treatment: Fundamentals   
Heat treatment: Fundamentals II
Heat treatment: Fundamentals III
Heat treatment: Normalizing and hardening

Week 12 :Heat treatment: Tempering
Improving surface properties: Introduction
Improving surface properties: Surface modification processes I
Improving surface properties: Changing chemical composition
Improving surface properties: Coating

Books and references

M P Grover, Modern Manufacturing Processes, John Wiley (2002). 
S Kalpakkajian, S R Schmid, Manufacturing Engineering and Technology, Pearson (2000)DeGarmo et al. Materials and Processes in Manufacturing, Prentice Hall of India, (1997).
R S Parmar, Welding process and technology, Khanna Publisher, New Delhi (2004).
P N Rao, Manufacturing Technology Vol. I & II, Tata McGraw Hill (2009).

Instructor bio

Prof. D K Dwivedi

IIT Roorkee
D K Dwivedi obtained BE (mechanical engineering), in 1993 from GEC Rewa, ME (welding engineering) from Univ. of Roorkee in 1997 and PhD in Met. Engineering from MNIT, Jaipur in 2003. He has about 9 years teaching experience at NIT Hamirpur and 14 years at IIT Roorkee in subjects related with manufacturing at UG level and welding engineering related subjects at PG level. He has published more than 120 research papers in SCI/SCIE indexed journals and undertaken 20 sponsored research and 50 industrial consultancy projects. He has authored two books entitled Production and Properties of Cast Al-Si Alloys with New Age International, New Delhi (2013) and Surface Engineering with Springer, New Delhi (2018).

Course certificate

The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.
The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).
Date and Time of Exams: 24 October 2021 Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.
Registration url: Announcements will be made when the registration form is open for registrations.
The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.
Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.

CRITERIA TO GET A CERTIFICATE

Average assignment score = 25% of average of best 8 assignments out of the total 12 assignments given in the course.
Exam score = 75% of the proctored certification exam score out of 100

Final score = Average assignment score + Exam score

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75. If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.

Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Roorkee.It will be e-verifiable at nptel.ac.in/noc.

Only the e-certificate will be made available. Hard copies will not be dispatched.

Once again, thanks for your interest in our online courses and certification. Happy learning.

- NPTEL team


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