Manufacturing Processes I

ME25402:

Manufacturing Processes – I

Course Objectives:

Appreciate and determine the appropriate manufacturing pathways for producing specific products.

Digital storage of geometrical shapes: Geometrical shape types (2. 5D – constant cross section, 2. 75D – offsetting a surface, and general 3D shapes) Storage of shape information in digital geometrical models; Wireframe model, surface models and solid models. File formats; STL file; slicing into layers.

Practical:

1. Create Wire frame model, surface model and solid model of a given geometrical shape in any CAD software

Subtractive Manufacturing

Mechanics of Cutting: Orthogonal and Oblique cutting, Chip formation, Type of chips, Nomenclature of single point cutting tool, Shear plane theory, Shear stress, Shear strain, Forces in machining, Merchant’s circle, cutting tool materials, Tool wear and mechanisms, cutting fluids, temperature in machining, surface roughness, tool life, machinability.

Turning, Drilling, Milling: Lathe Operations, Need for drilling, Geometry of twist drill, Types of drilling machines, Drilling and related operations, up milling and down milling, Types of Milling machines and cutters, milling operations, indexing, work holding and tool holding devices, machining time and power estimation

Abrasive Processes: Grinding – Specification of grinding wheel, mechanism of metal removal in grinding, grindability and its improvement, Dressing, truing, types of grinding machines– surface grinding, cylindrical grinding, centerless grinding, Honing, lapping, super finishing methods.

Practical:

1. Taper turning on a cylindrical workpiece using different methods (form tool method, compound rest method, and tailstock set-over method).

2. Evaluation of the machinability of two work materials based on tool wear and chip morphology and cutting force.

3. Evaluation of the grindability of two materials by determining the G-ratio and measuring the surface finish.

4. Drilling and Milling practicals

5. Use of any open source CAM software to simulate milling

Additive manufacturing: ISO nomenclature of AM processes; AM processes that add material in an empty space - directed energy deposition (DED), material extrusion (MEX), material jetting (MJT), AM processes that modify material already existing i - powder bed fusion (PBF), vat photopolymerization (VPP), Binder jetting (BJT)

Practical:

6. Simulation of 3D printing processes using any open source software

Programmable Positioning systems: Need for spatial positioning of cutting tools and Additive Manufacturing heads; tool paths as containing shape information; Coordinate systems, Motion control systems – point to point control, continuous path control, Coordinate systems, Interpolation methods, Absolute and incremental positioning, CNC software, DNC, Advantages of CNC.

Practical:

7. Manual part programming for CNC turning centre (facing, turning, threading).

8. Manual part programming for CNC machining centre (drilling, pocketing, contouring).

Pattern, Mold, and Mask making: Physical storage of surface information on molds, patterns and masks. Patterns and their types. Molds and their various features. Mold types: flow-through molds, open molds, closed molds; Making of masks for chemical machining, silicon electronics fabrication

Practical:

9. Make a 3D CAD model of any mold

Tasks:

T1. Design and manufacture a precision shaft component using lathe operations (turning, threading, knurling), ensuring dimensional accuracy and surface finish.

T2. Develop a machining process plan for producing a gear (spur/helical) using milling, shaping, or hobbing, including tool selection and machining parameters.

T3. Design and optimize a grinding process to achieve required surface finish and dimensional tolerance for a mechanical component (e.g., bearing shaft).

T4. Develop a CNC part program for a turning or machining center to manufacture a component (e.g., flange or bracket) using appropriate tool paths and cycles.

Weightage: Continuous Assessment: 50%, End Semester Examinations: 50%

Assessment Methodology:

Written Test (40%), Practical (30%), Activity (30%).

Practical: Lab Experiments (50%), Tasks (50%) (Each student must complete a minimum of two tasks).

Activity: Review of GATE/ESE Questions(10%), Mini Project/ Quiz/ Assignment Programs/ Flipped Class /Seminar Presentation (20%)

References:

1. SeropeKalpakjianandStevenSchmid,ManufacturingEngineeringand Technology, 9th edition, Pearson, 2025

2. Groover, Mikell P. Fundamentals of modern manufacturing: materials, processes, and systems. 7th Edition, John Wiley & Sons, 2019.

3. Knight, Winston A., and Geoffrey Boothroyd. Fundamentals of metal machining and machine tools. CRC Press, 2019.

4. A. B. Chattopadhyay, Machining and Machine Tools, 2nd Edition, Wiley, 2017.

5. Juneja, B. L. Fundamentals of metal cutting and machine tools. New Age

International, 2017.

6. P N Rao, Manufacturing Technology: Metal cutting and machine tools. Tata McGraw-Hill, 2013.