First Course Handout (FCH)

TA211
MANUFACTURING PROCESSES-I
2024-2025 Semester-I

Indian Institute of Technology, Kanpur

Department of Materials Science and Engineering

INSTRUCTOR LAB IN-CHARGE COURSE IN-CHARGE

Prof. Kantesh Balani Mr. Anil Kumar Verma Mr. I. P. Singh

Office: Lab for Biomaterials TA211 Lab: DJAC 101H, G TA211 Lab: DJAC 101H, G

Ph: 6194/kbalani@
Ph: 7978/akumarv@ Ph: 7865/indraps@
Laboratory Monday/Wednesday/Friday: 14:00 - 17:00
(As per assigned days of your section)

Venue: TA211, Diamond Jubilee Complex

(Engineering Metallurgy Laboratory)

Course website https://hello.iitk.ac.in/ta211sem12425/#/home

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 TA211: Introduction of Manufacturing Processes-I
Engineering Metallurgy Lab (Diamond jubilee Academic Complex)
2024-2025, Semester-I, Laboratory Schedule

Time: 02:00 pm to 05:00 pm

Experiment
6th
Turns 1st 2nd 3rd 4th 5th 7th 8th 9th 10th 11th 12th 13th
Lab Exam (LE6) +
Day E1 E2 E3 E4 D5 P1 P2 P3 P4 P5 P6 Project Evaluation
Drawing Submission
(PE)
Monday
5/8 12/8 19/8 24/8* 2/9 9/9 23/9 30/9 14/10 21/10 28/10 4/11 11/11
Wednesday
31/7 7/8 14/8 21/8 28/8 4/9 11/9 25/9 16/10 23/10 30/10 6/11 13/11
Friday
2/8 9/8 16/8 23/8 30/8 6/9 13/9 27/9 4/10 18/10 25/10 1/11** 8/11

Holiday/ Mid & End Sem Examination Date Saturday Make-up Lab

Janmashtami (Vaishnava) Aug 26, 2024 (Mon) August 24, 2024@10am to 1 pm*
Milad-un-Nabi or Id-e-Milad Sep 16, 2024 (Mon) 1/11 (2-5 pm)**
Mid Semester Examination Sep 17 – 22, 2024 (Tue-Sun)
Mahatma Gandhi's Birthday Oct 2, 2024 (Wed)
Mid Semester Recess (Dussehra) Oct 5 – 13, 2024 (Sat – Sun)
Guru Nanak's Birthday Oct 15, 2024 (Fri)
End Semester Examination Nov 17-26, 2024 (Sun-Tue)

Lab In-Charge: Course In-Charge: Course Instructor:

Mr. Anil Kumar Verma Mr. Indra Pal Singh Prof. Kantesh Balani
Contact:7978/akumarv@ Contact:7865/indraps@ Contact:6194/kbalani@

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Tutors, TAs & staff members contact:
Tutors:

Day Tutor Email Phone

Monday Prof. Kantesh Balani [email protected] 6194

Wednesday Prof. Sarang Ingole [email protected] 7089
Friday Prof. Kallol Mondal [email protected] 6156

TAs:

Day Tutor Email

Monday Mr. Poresh Kumar [email protected]

Monday Mr. Santosh K. Singh [email protected]
Wednesday Ms. Ruhi A.G. Syed [email protected]
Wednesday Mr. Praveen Kumar [email protected]
Friday Mr. Rahul Poddar [email protected]
Friday Ms. Bhavna [email protected]

Staff members:

S No. Staff Members Email Phone

1. Mr. Anil Kumar Verma [email protected] 7978

2. Mr. Indra Pal Singh [email protected] 7865
3. Mr. Rakesh Kumar [email protected] 7978/7375
4. Mr. Gaurav Mishra [email protected] 7978
5. Mr. Bharat Raj Singh [email protected] 7978
6. Mr. Gyanendra Singh [email protected] 7978
7. Mr. Surya P. Sonkar [email protected] 7949
8. Mr. Rajdipta Samadder [email protected] 7933
9. Mr. A. C. Saini -- 7978
10. Mr. Pappu -- 7978

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General Information

Grading policy:
• Laboratory (100%):
Weekly lab quiz and attendance (E1-E5): 15 %
Weekly job (E1 – E5): 15 %
Lab exam (LE6): 15 %,
Weekly Project Design Progress (E2-E5): 10%
Weekly Project Progress and attendance (P1 – P6): 15 %
Project report (6th turn): 10 %
Final Project Evaluation (PE) with weightage to attendance: 20 %
Minimum 40% required for passing the course.
• There will be a total of 12 labs starting from Aug. 5th 2024 (for Monday) Jul. 31st 2024 (for
Wednesday) and Aug. 2nd 2024 (for Friday). All the lab turns are mandatory. Only during medical
emergencies, which must be approved by SUGC, absence can be accepted. In such cases, no make-
up for attendance or quiz marks would be given. 13th Turn is reserved for Project Evaluation.
Absence in 3 or more labs will result in deregistration OR Fail grade
• Contribution to the group project is mandatory component of the course.

Safety:
• SAFETY IS MUST
• Half pants, loosely hanging garments, and slippers are strictly prohibited for safety reasons.
Students must come to the laboratory wearing (i) Trousers, (ii) Preferably cotton cloths (especially
for welding/brazing) and (iii) Closed shoes.
• To avoid injury, the student must take the permission of the laboratory staff before handling any
machine. Careless handling of machines may result in serious injury.
• Students must ensure that their work areas are clean and dry to avoid slipping.
• A leather apron and leather hand gloves will be issued to each student during Welding and Brazing
exercises. Students not wearing the apron will not be permitted to work in the laboratory.
• At the end of each experiment, students must clear off all tools and materials from the work area.
• During Sheet Metal forming, wearing cotton hand gloves is compulsory.

General Information:
• Follow the lab timing (2:00 pm – 5:00 pm). There will be two attendances: Initial attendance will be based
on Weekly Quiz and final one consists of filling the job submission form. Those coming after 2.00 will
miss the quiz and those coming after 2:15 pm will be sent back.
• Mobile phones are prohibited during the lab.
• Students must take permission of the Tutor, if they have to leave the lab before time, for any emergency.
• Project report must be submitted on the 6th turn. Any group not submitting the project report by
this time will be appropriately penalized.
• There will be a Weekly lab quiz during first 5 experiments on questions related to the previous lab. On the
6th turn, there will be lab quiz first followed by lab exam.
• Every student should obtain a copy of the Manufacturing Processes Laboratory manual. You are required
to bring your lab manual every day. Lab manual will also be available on the course website.

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Suggested Reading Materials:
• Preferred: Fundamentals of Modern Manufacturing: Materials, Processes and Systems, Mikell P. Groover
• Fundamental of Manufacturing, G. K. Lal & S. K. Choudhury
• Manufacturing Engineering & Technology, S. Kalpakjian
• E. P. Degarmo: Materials & Processes in Manufacturing, Macmillan.

Material List:
The list of materials that students can assume to be available, is attached as Appendix-A. Parts must be
designed using only these materials. Outside material/parts should not exceed 5%.

Plagiarism:
Plagiarised reports or drawings will be dealt with severely. You are encouraged to get inspiration and ideas
from real things and also from internet. However, do not copy and present those things as your own.

Lab turns distribution:

Lab
S No. Experiments Staff members
Turn
Mr. G. Singh, Mr. S.P. Sonkar,
1 E1 Sand Moulding & Casting and Forging
Mr. R. Samadder, Mr. I. P. Singh
2 E2 Sheet Metal Forming Mr. R. Kumar
Welding Processes, Powder Metallurgy and
3 E3 Mr. G. Mishra
Plasma Cutting Process
Brazing Process, Drilling/Cutting/Grinding
4 E4 Mr. B. R. Singh
Operations, Object Fabrication
Demonstration of Rolling, Swaging,
5 E5 Mr. A. K. Verma
Injection Moulding and Tape Casting
6 LE6 Lab Exam and Project Report Submission Respective staff member
7 P1 Project Staff supervisor
8 P2 Project Staff supervisor
9 P3 Project Staff supervisor
10 P4 Project Staff supervisor
11 P5 Project Staff supervisor
12 P6 Project Staff supervisor
13 PE Project Evaluation Respective members

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Rotation of experimental turns:
Green sand
molding &
Casting
E1

Sheet metal
Demonstration
forming
D5
E2

MMAW,MAG
Brazing or
welding or
joining process
joining process
E4
E3

There will be 5 Experiment groups consisting of approximately 18-20 students each. Each group will
conduct different experiments on a given day (E1 – E5). In the next turn, they will be moved to the
next experiment as per the rotation policy shown above.

Project Information
Schedule: Stick to the project schedule to earn marks for project progress.

1st Turn Project group formation

2nd Turn Bring a minimum of three project ideas along with the rough sketch - Discussion

3rd Turn One project idea will be finalized.

Discussion on a finalized project with proper drawing as per engineering norms,
4th Turn
including parts drawing (with numbering and materials)

5th Turn A final discussion on drawing and process (bring draft of complete report)

6th Turn Final report submission (including drawings).

7th - 12th Turns Projects
13th Turn Project Evaluation

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Outline of project report: Keep a copy of the project report with you which you will use during
your project turns.

S. No. Description Page no.

1 Project name
2 Tutor name
3 Course In-charge and Lab In-charge names 1

4 Section:
5 S No. Roll no. Name Signatures
6 Contents 2
7 Certificate about plagiarism 3
8 Acknowledgements 4
9 Introduction 5
10 Motivation 6
11 Group member work distribution 7
12 Materials List 8
13 Isometric Drawing with numbering 9
14 Part Drawing (mm, page no.) 10 - xyz

Points to be used in the project report:

• The manufacturing process involve in each component to be mentioned.

• Proper drawing should be made and submitted in consultation with tutor and lab staff.
• The part drawing should be made with appropriate dimensions.
• You must make isometric and part drawing with appropriate dimensions on A-4 sheet.

Project Constraints:

• Maximum size of the project: 40 cm x 40 cm x 40 cm (to be followed strictly) and total weight
for casting objects should not exceed 1 kg of aluminium per project. Oversize/overweight projects
will invite penalty in the project evaluation.

• Do not grind the aluminium parts of the project.

• Total project weight should not exceed 5 Kg.

• External colour /paint should not be used.

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About the project

1. Plan your project carefully. Do not make it unnecessarily complicated. The project has to be entirely
your work. Laboratory staff will be available only to guide you.

2. Your tutor, course In-charge and the technical staffs will advise on the projects.

3. There will be no extra lab turn for project.

4. The project groups will be formed and informed to you by the end of the first lab turn.

5. You should come with at least three ideas with the rough sketch on the second lab turn for the
discussion. On the third lab turn, one idea will be frozen.

6. On the fourth and fifth lab turns, you should come with all necessary information, such as drawing,
manufacturing process for each part etc. The drawing should be as per the engineering norms.

7. The copy of the final project drawing with material list and process plan (complete report) must be
submitted on the sixth lab turn. You should select materials from the list only. (The list will be
displayed on lab notice board).

8. The exact responsibilities of each group member should be specified.

9. Maximum size of the project: 40 cm x 40 cm x 40 cm (to be followed strictly) and total weight for
casting objects should not exceed 1 kg of aluminium per project. Oversize/overweight projects will
invite penalty in the project evaluation.

10. Do not grind the aluminium parts of the project.

11. Moving parts in your project will result in extra credit during evaluation.

12. External colour/paint cannot be used.

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 Appendix-A: Materials List
(Materials made available to students for project)
Sr. No. Items Size Cost
1 Mild Steel Flat 25x3 mm Rs.65/kg
2 Mild Steel Flat 25x5 mm Rs.63/kg
3 Mild Steel Round Rod 25 mm dia Rs.65/kg
4 Mild Steel Round Rod 10 mm dia Rs.68/kg
5 Mild Steel Round Rod 8 mm dia Rs.68/kg
6 Mild Steel Round Rod 6 mm dia Rs.70/kg
7 Mild Steel Round Rod 5 mm dia Rs.70/kg
8 Mild Steel Round Rod 4 mm dia Rs.70/kg
9 Mild Steel Round Rod 3 mm dia Rs.80/kg
10 Mild Steel Square Rod 10x10 mm Rs.63/kg
11 Mild Steel Square Rod 6x6 mm Rs.65/kg
12 Mild Steel Round Pipe 25 mm dia (1" dia) Rs 450/20 ft length pipe
13 Mild Steel Round Pipe 18 mm dia (3/4" dia) Rs 425/20 ft length pipe
14 Mild Steel Round Pipe 10 mm dia Rs 300/20 ft length pipe
15 Mild Steel Square Pipe 25x25 mm Rs 450/20 ft length pipe
16 Mild Steel Square Pipe 15x15 mm Rs 300/20 ft length pipe
17 Mild Steel Angle 25x25 mm Rs 450/20 ft length pipe
20,30,40,50,60,70mm dia
18 Mild Steel Disks x8-10mm Thick Avg ~ Rs 20-25/disc
19 Galvanized Iron Sheet 0.35 mm Rs 756/sheet
20 Galvanized Iron Sheet 0.5 mm Rs 820/sheet
21 Mild Steel Sheet 0.5 mm Rs 945/sheet
22 Mild Steel Sheet 0.7 mm Rs 1058/sheet
23 Mild Steel Sheet 1.0 mm Rs 1278/sheet
24 Mild Steel Sheet 2.0 mm Rs 3090/sheet
25 Thermocol 1/2 inch Rs 30/sheet
26 Thermocol 1 inch Rs 65/sheet
27 Thermocol 1.5 inch Rs 110/sheet
28 Thermocol 2 inch Rs 160/sheet
29 Thermocol 3 inch Rs 220/sheet
30 Fevicol small size tube Rs 5/tube
31 Sandpaper for thermocol No. 80 Rs 7/sheet
Small Nut-Bolt with Mild steel
--------
32 Washer Avg ~ Rs 10/piece
33 Thin Galvanized Wire 1 mm and 2 mm dia Rs 20/ meter
34 Aluminium & Cast iron For casting Rs 380/kg
35 Cast Iron for melting Ingots Rs. 75/ kg