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What you’ll learn:
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Discuss in detail the manufacturing processes of metallic and plastic parts.
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Compare between different types of metal forming processes and differentiate between their output product.
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Describe different types of joining process and introduce the concept of sustainable manufacturing.
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Recognize, understand and develop working knowledge of broad range of manufacturing processes that are used in the industry.
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To compare the existing technologies used in casting, shaping, forming, property enhancing, joining and assembly process.
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To learn how component can be manufactured in sustainable manner and learn about the environmental hazards of different manufacturing processes.
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Apply appropriate manufacturing processes for a product and determine its parameters.
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Analyze process dynamics and performance of different manufacturing processes.
Description:
This course provides an introduction to the manufacturing processes that are used in industry to manufacture products that are widely used in daily life.
Introduction to Manufacturing: Types of manufacturing industries, materials used in manufacturing and properties of materials, different processing operation.
Sand Casting:
- Introduction: Sand casting, molding, heating, pouring, solidification, and cooling. Pattern: making, material, types, construction, pattern allowances.
- Core: making, types, sand conditioning, testing of the sand, molding process, tools and equipment, molding machines, different types of casting, cleaning and finishing of castings, an inspection of castings.
Permanent Mold Casting (PMC): Introduction, types of PMC, gravity die casting, and its types. Pressure die casting, Centrifugal casting, and their types. Furnaces used in PMC.
Metal Forming:
Fundamentals, Types, hot, warm, and cold working.
Bulk Deformation Processes:
- Rolling; rolled products, rolling types: flat, shape, thread, gear, ring rolling, and rolling mill configurations.
- Forging; open die, impression die, press, upset, roll, net shape, isothermal forging and swaging.
- Extrusion; solid & hollow shapes, direct & indirect, hot & cold, continuous & discrete, impact extrusion, hydrostatic.
- Drawing; bar, wire, tube drawing and its types tike tube sinking, fixed mandrel, floating plug.
Other metal forming processes; roll extrusion, riveting, staking, peening, coining, hubbing, burnishing.
Sheet metal forming processes: Shearing operations: slitting, blanking, piercing, cutoff, parting, dinking, slotting, perforating, notching, semi-notching, lancing, nibbling, trimming, shaving, fine blanking. Bending operations: V bending, edge bending, flanging, curling, hemming, seaming. Drawing operations like deep and shallow drawing, embossing.
Welding Processes: Classification, Fusion welding and its types such as oxyfuel gas welding and oxygen torch cutting, arc welding (shielded metal, flux-cored, gas metal, submerged, gas tungsten, plasma, stud welding, Arc cutting), resistance welding (spot, seam and projection. Heating, pressure, current control and power supply for resistance welding).
Solid-state welding and its types include diffusion welding, friction welding, and ultrasonic welding.
- Other welding processes: Forge, Roll, Friction, Explosion, Thermic, Electron beam, Laser welding and cutting, Brazing and Soldering.
Fabrication of Plastics: Casting, Blow molding and its types, Compression molding, Transfer molding, Cold molding, Injection molding: Injection molding machine, mold design, and construction, types of mold, cooling and ejection of mold, Reaction injection molding, Welding of plastics.
In the end, there are videos that are videos related to the course for better understanding.
Course Outline
Introduction to Manufacturing:
Lecture 1
- Introduction to Manufacturing Processes
- What is manufacturing
- Manufacturing Industries
- Manufacturing Products
- Production Quantity and Product variety
- Materials in Manufacturing
Fabrication of Plastics: Casting, Blow molding and its types, Compression molding, Transfer molding, Cold molding, Injection molding: Injection molding machine, mold design, and construction, types of mold, cooling and ejection of mold, Reaction injection molding, Welding of plastics.
In the end, there are videos that are videos related to the course for better understanding.
Course Outline
Introduction to Manufacturing:
Lecture 1
- Introduction to Manufacturing Processes
- What is manufacturing
- Manufacturing Industries
- Manufacturing Products
- Production Quantity and Product variety
- Materials in Manufacturing
- Manufacturing Processes (Processing operations and Assembly operations)
Sand Casting:
Lecture 2
- Overview of casting technologies
- Difference between casting and molding
- Advantages and Disadvantages of casting processes
- Casting Processes (Expendable mold casting and permanent mold casting)
Lecture 3
- Sand casting and Engineering analysis of sand casting y sand
- Pouring and Engineering Analysis of Pouring
- Flow rate and time required to fill the mold
- Fluidity
- Solidification and Cooling
Lecture 4
- Solidification of pure metals and alloys (Alloys and Eutectic Alloys)
- Solidification time and Shrinkage
- Directional Solidification
Lecture 5
- Riser Design with Exercise Problems.
Lecture 6
- Pattern for casting
- Materials used for pattern
- Types of pattern
- Mold making and Classification of sand molds
- What is foundry sand?
Lecture 7
- Buoyancy Force
- Metal casting processes
- Shell molding
- Advantages and Disadvantages of Shell molding
- Vacuum molding
- Advantages and Disadvantages of Vacuum molding
- Expanded Polystyrene Casting
- Advantages and Disadvantages of Expanded Polystyrene Casting
- Investment casting
- Plaster and Ceramic Mold casting
Permanent Mold Casting (PMC):
Lecture 8
- Types of pattern allowance (Shrinkage and contraction allowance, Draft allowance, Machining allowance, and Distortion allowance)
Who this course is for:
- ll concepts are introduced slowly and gradually, but comfort with thinking analytically will be helpful.
- Engineering students and professionals who want to level up their skills.
- Engineers in Mechanical, Manufacturing, Industrial, Electrical and other related fields looking for a way out of traditional processes for their projects and products.
- Anyone starting their career in the manufacturing and production world.
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