Manufacturing Technology

First Lecture
Course Objectives and Learning outcomes
Objectives:
1. To impart knowledge and train students in area of metal casting and welding
processes, by making them familiar with the basic design principles and
metallurgical conceptsinvolvedandtheir application.
2. Toprovidefundamentalsof metal formingprocesses.
3. To impart the knowledge and train the students in the area of machiningscience
and make the students familiar with the various basic principles of machining
science, cutting tool materials and its wear mechanisms during the machining
operation.
Learning Outcomes:
1. Understanding of mechanism of chip formation in machining and grinding
processes.
2. Understanding of tool life, role and types of cutting fluids, machinabilityindex and
ability to measure tool life, tool wear and flank wear during machining.
3. Understanding of basic design principles involved in Metal casting and
understanding of fundamentals of arc welding.
4. Understanding of different non- conventional machining processes
Manufacturing Technology L T P D 3 0 0 1
Conventional Machining Processes: Metal cutting with single point and multi point cutting
tools, selection of machining parameters, Taylors tool life equation, Machinability, factors
affecting machinability, tool wear mechanisims, Factors influencing surface quality,
dimensional accuracy and material removal rate in machining, Calculation of economic cutting
speed, Types of chips, Cutting tool temperature measurement, cutting fluids, cutting forces and
power requirements in single point cutting tool merchant circle theory, shear angle
relationships, friction and thermal aspects in machining, Nature of cutting with multi-point
cutting tools, mechanism of chip formation in drilling and milling, grinding process and its
specific features. (Milling cutters and milling machines , Drilling tools and operations, Grinding
and other abrasive finishing processes, grinding wheel selection, surface grinding, centreless
grinding, Abrasive finishing processes)
Non-Conventional Machining Processes: Comparison of non-conventional and conventional
methods of machining, process parameters, material removal rate and application of electro-
discharge machining (EDM), electro-chemical machining (ECM), ultra-sonic machining (USM),
electron beam machining (EBM) & laser beam machining (LBM), Abrasive and water jet
machining (AJM/ AWJM), Chemical machining.
Phase Diagrams, Arc welding Basics and Fundamentals of metal forming processes :
Concept of phase, phase rule, eutectics, Iron-carbon phase diagram, Classification of steels.
Arc welding fundamentals, welding power sources and power source characteristics. Elementary
theory of plasticity, stress / strain / strain-rate characteristics of materials, yield criteria of
metals, formability, High energy rate forming processes.
Metal Casting Processes: Sand testing procedures, Machine moulding, cupola furnace, cupola
charge estimation, Design of casting: Sprue design, Riser and Gating system design. Nucleation
and grain growth, Segregation, Inspection of castings, casting defects; Shell moulding;
investment casting; Hot chamber and cold chamber die casting; centrifugal casting; Powder
metallurgy techniques.
Introduction to Computer aided Manufacturing (CAM): Programmable automation,.
Numerical control of machine tools. Adaptive control of machine tools CNC design features,
Introduction to Manual part programming and computer assisted part programming.
Text Books
1. Metal cuttingprinciples, Shaw. M. C. , OUP USA, 2004,
2NDedition
2. Fundamentals of machining processes: conventional and
nonconventional processes, CRC/ TAYLOR AND FRANCIS ,
Volume978, Issues0-7289, 2006, HassanEl Hofy
3. Introductionto Non-traditional MachiningProcesses, ASM
International, GaryF. Benedict
4. Principles of metal casting ,Heinz RW, Loper CR Jr ,
Rosenthal P.C., 2nded. NewYork: McGraw-Hilll, 1967
5. CAD/CAM:computer-aided design and manufacturing
Prentice-Hall, 1984, Mikell PGroover,EmoryW. Zimmers
6. Mechanical Metallurgy , George E. Dieter, Mcgraw
hill,1986
Course Evaluation Scheme
Assessment Type Weightage
End Semester Exam 40
Mid Semester Exam 1 20
Mid Semester Exam 2 20
Quizes+Assignments 10
Term Paper 10
History of Foundry Practice
Date Development Location
9000 B.C. Earliest metal objects of wrought native copper Near East
6500 B.C. Earliest life-size statues, of plaster Jordan
5000-3000 B.C. Chalcolithicperiod: melting of copper; experimentation with smelting Near East
3000-1500 B.C. Bronze Age: arsenical copper and tin bronze alloys Near East
3000-2500 B.C. Lost wax casting of small objects Near East
2500 B.C. Granulation of gold and silver and their alloys Near East
2400-2200 B.C. Copper statue of PharoahPepi I Egypt
2000 B.C. Bronze Age Far East
1500 B.C. Iron Age (wrought iron) Near East
700-600 B.C. Etruscan dust granulation Italy
600 B.C. Cast iron China
224 B.C. Colossus of Rhodes destroyed Greece
200-300 A.D. Use of mercury in gilding (amalgam gilding) Roman world
1200-1450 A.D. Introduction of cast iron (exact date and place unknown) Europe
Circa 1122 A.D. Theophilus'sOn Divers Arts, the first monograph on metalworking
written by a craftsman Germany
1252 A.D. Diabutsu(Great Buddha) cast at Kamakura Japan
Circa 1400 A.D. Great Bell of Beijing cast China
16th century Sand introduced as moldmaterial France
1709 Cast iron produced with coke as fuel, Coal brookdaleEngland
1715 Boring mill or cannon developed Switzerland
1735 Great Bell of the Kremlin cast Russia
1740 Cast steel developed by Benjamin Huntsman England
1779 Cast iron used as architectural material, IronbridgeGorge England
1826 Zinc statuary France
1838 Electrodepositionof copper Russia, England
1884 Electrolytic refining of aluminum United States, France
(Reference source ASM Handbook volume 15 (2002))
BRONZE Age
Top and side view (a) of arsenical copper axes from Oxfordshire, England, (b) Detail of one of the
arsenical copper axes showing the joint of the bivalve (permanent two-part) mold, placed so
that no core was necessary. (Reference source ASM Handbook volume 15 (2002))
Foundry Practice
The Bronze Age
Bronze Age began before 3000 B.C. The first
bronze that could be called a standard alloy
was arsenical copper, usually containing up to
4% As, although a few objects contain 12% or
more.
This alloy was in widespread use and occurs in
objects from Europe and the British Isles.
Cast Iron
The Iron Bridge (a) across the Severn River at IronbridgeGorge. The structure was cast
from iron smelted by Abraham Darby at Coalbrookdale. (b) Detail of the Iron Bridge
showing the date, 1779. This was the first important use of cast iron as a structural
material. (Reference source ASM Handbook volume 15 (2002))
Cast Iron
Cast Iron
Cast iron appeared in China in about 600 B.C.
Most Chinese cast irons were unusually high in
phosphorus, and because coal was often used in
smelting, high in sulfur as well.
Colossal Statues
Cellini, in 1568, defined a colossal statue as one at least three
times life size. The Colossus of Rhodes was a bronze statue that
stoodmorethan30m(100ft) tall.
Japan boasts several Diabutsu, or Great Buddhas, in bronze. The
Great Buddha at Nara, begun in theeighth century, is gilded and
wasthereforecast inalow-tinalloy.
Overall view (a) of the Great Buddha at Kamakura, J apan, cast in high-lead tin bronze in 1252. (b)
View of the face of the Kamakura Buddha showing metal losses at the joints between separate casts.
(Reference source ASM Handbook volume 15 (2002))
Modern Statuary
With the Renaissance came a revival in bronze casting. Large
single castings were attempted in lost wax. Cellini also claimed a
"secret" moldmaterial of rottedragsinclay, althoughit isknown
that in the previous century pieces of cloth were added to the
clayusedfor guncores.
Sandfor moldingwasnewlyintroducedfromasourcenear Paris,
and"Frenchsand" continuedtobehighlyrecommendedintothe
20thcentury.
The 19th century saw many technical innovations, includingthe
electroplating of copper statues and architectural elements as
large as domes. Aluminumwas moreexpensive, costingabout as
much as silver until the Hall-Heroult refining process was
invented. An aluminumcasting, rather than stone, was used to
capthetipof theWashingtonMonument in1884, andaluminum
hasbeenoccasionallyusedsinceasastatuarymaterial.