MP II Lecture NO 1

7/31/2019 MP II Lecture NO 1

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Course OutlineMaterial Removal. Machine of chips formation, types of chips produced,forces and pressure involved, surface finishing and integrity, machinability.Calculation of material removal rate.

Cutting Tools. Single point tool geometry, mill cutters, factors which effecttool life, tool life relationship, tool materials, types and properties of cuttingfluids.

Machine Processes for producing various shape. Milling operation,milling machine, planning and shape, broaching and broaching machine,

gear manufacturing by machining.Abrasive Machining and Finishing Operations. Abrasive, bondedabrasives(grinding wheels) grinding process, grinding fluids, designconsideration for grinding, ultrasonic machining.

Non Conventional Machining Process. Machining, electrochemical,electrical discharge machine, wire EDM.

Control of Machine Tools. Machine tools control, numercial controlsystem, sequence control, PLC, servo copying, Computerized NumercialControl (CNC), adaptive control, programming for numercial control,

Jigs and Fixture. General design principle, elements for jigs, locationdevice and clamping devices.


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Course Outline

Computer Integrated Manufacturing System. Manufacturing

system, Computer Integrated Manufacturing (CIM), ComputerAided Manufacturing (CAM), computer simulation of Manufacturingprocess and system, group techonolgy, Flexible ManufacturingSystem (FMS), Artifical Intelligence, Cellular Manufacturing.

Metrology. Specification and standardization, limits and fits

tolerances and allowances. Precision measurements. Standards, sources of errors, angular

measurements, measure microscope, optical projectionstraightness and flatness testing, surface finish measurements.

Introduction to process planning.


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Grading

The course will be graded as under:-

Assignment ----------------- 10%

Quiz------------------------------10%

Projects------------------------- 10% 75%

Mid-Term Exam---------------- 20% Final Exam---------------------- 50%

Practical+ Practical note book-------- 15%

viva------------------------------ ------- 10%

Total --------------------------------------100


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Manufacturing

Manufacturing is a process of convertion of rawmaterial into useful product. It refers to thefollowing: - 1. Production of components/parts in large quantity.

2. Use of power operated machines.

3 The machines are dedicated.

4. The components are intrchangeable

5. The process is normally automatic.

6. The quality of product is same.

Production of component/parts in small quantityis called making and not manufacturing.Makingnormally refers to products made manually.

Things made by Almighty is creation, neither

making nor manufacturing.


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Workshop

A workshop is a room or buildingwhich provides area, machinery,men, materials, tools, equipment,

resources, facilities that may berequired for the manufacturing orrepair of manufactured goods and

safety of persons working there in.


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Basic manufacturing processes

Machining

Deformation processes

Casting Joining(fastening, welding and

adhesive)

Finishing


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Machine

Any device which reduces mans

efforts and save time is calledMachine.


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Machine tool

A machine tool is a non-portable poweroperated and reasonably valued device orsystem of devices in which energy is

expended to produce jobs of desired size,shape and surface finish by removingexcess material from the preformedblanks in the form of chips with the help

of cutting tools moved past the worksurface(s).


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Machining

Machining is a process of precise removalof material. It is gradually removing theexcess material from the preformed blank

in the form of chips with the help ofcutting . The net result of cutting is twoproducts, the waste or excess material,and the finished part. In this process

power-driven machine tools, such aslathes, milling machines, and drill presses,

are used.


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Machinability

The term machinability refers to the ease withwhich a metal can be machined to an acceptablesurface finish. Machinability has no concern withthe machine itself.

The characteristics of good machinabilityMaterials with good machinability

i) can be cut quickly so save timeii) easily obtain a good finishiii) do not wear the tooling much

iv) requires less power duringmachining.


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Conventional machining

Turning Drilling

Boring

Grinding

Honning

Slotting etc.

Milling

Shaping Planing

Broaching

Hobbing(grear forming)


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Non-traditional Machining

Chemical machining(CM)Electro-chemical machining (ECM)Electrical discharge machining (EDM)

Wire cut machining (WCM)Electro-beam machinig (EBM)Plasma arc machining(PAM)Laser Beam machining (LBM)Water jet machining (WJM)Abrasive jet machining (AJM)Ultra sonic machining (USM) etc


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Deformation processes

Deformation processes exploit a remarkableproperty of metals, which is their ability to flowplastically in the solid state without deteriorationof their properties.

Deformation processes are:- Rolling

Forging

Extrusion

Swaging Deep drawing

Tube and wiring

Bending


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Manufacturing ProcessesExamples- Forming

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C


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Casting Casting is a process which produces solid metallic object or part by pouring liquid

metal into mould cavity and allowing the molten metal to solidify. The term casting is used both for the process of casting and the product itself.

There are more than 40 casting processes. Sand mould casting.

Permanent mould casting.

Die casting.

Hot and cold chamber.

Centrifugal casting.

Slush casting.

Vacuum casting.

Compression casting.

Transfer casting

Injection casting. Blow casting.

Rotational moulding.

Thermo forming.

Shell mould casting.

Precision investment casting

Continuous casting


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Manufacturing ProcessesExamples- Casting

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Welding

Welding is a process of joining two ormore pieces of like metals by heatingthe material to a temperature high

enough to cause softening or meltingthereby joining by either fusion orforging .Approximately 100 welding

and allied welding processes.

Cl ifi ti f W ldi P


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Classification of Welding Processes

A Fusion Welding

1 Arc Welding

(Consumable electrodes )

Shielded metal arc welding

Gas metal arc welding

Submerged arc welding

(Non-consumable electrode)

Gas tungsten arc welding Plasma arc welding

Carbon arc welding

2 Resistance Welding

Resistance spot welding

Resistance seam welding Projection welding

Upset welding

Percussion welding

High frequency welding

3 Oxy fuel gas Welding

Oxy-acetylene welding

Oxy-hydrogen welding

4 Thermal or Unique

Processes

Thermit welding

Laser beam welding

Electroslag welding

Induction welding

Electron beam welding

B Solid-State Welding

Forge welding

Cold welding

Diffusion welding

Friction welding

Ultrasonic welding

Explosion welding

Roll welding

MP II Lecture NO 1

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