MEEG 217
Basic Manufacturing Processes
3 Cr.
Course Objectives
To develop a basic theoretical foundation in concepts of mechanical behavior of materials and various manufacturing processes and equipment’s.
Chapter 1- General Introduction (2 hours)
Manufacturing, Product Design and Concurrent Engineering, Design for Manufacture, Assembly, Disassembly, and Service, Green Design and Manufacturing, Selection of Materials, Selection of Manufacturing Processes, Computer-integrated Manufacturing, Quality Assurance and Total Quality Management, Lean Production and Agile Manufacturing, Manufacturing Costs and Global Competition , General Trends in Manufacturing.
Chapter 2 - Fundamentals of the Mechanical Behavior of Materials (8 hours)
Introduction: Types of Test commonly used to determine the mechanical properties of materials- Tension, Compression, Torsion, Bending, Hardness, Fatigue, Creep, Impact, Residual Stresses, Triaxial Stresses, and Work of Deformation.
Stress-Strain Curves, their features, significance, and dependence on parameters such as temperature and deformation rate.
Characteristics and the roles of hardness, fatigue, creep, impact and residual stresses in materials processes. Yield Criteria and their applications in processing metals.
Chapter 3 – Material Removal Processes (10 hours)
Machining Processes and Machine Tools: Fundamentals of Machining - Introduction, various operations of machining, Material Removal Rate, Mechanics of Cutting, Cutting Forces and Power, Merchant Circle, Temperatures in Cutting, Tool Life: Wear and Failure, Surface Finish and Integrity, Machinability.
Cutting-Tool Materials and Cutting Fluids.
Machining Processes: Turning and Hole Making, the Turning Process, Lathes and Lathe Operations, Boring and Boring Machines, Drilling, Drills, and Drilling Machines, Reaming and Reamers, Tapping and Taps.
Milling and Milling Machines, Planing and Shaping, Broaching and Broaching Machines, Sawing, Filing, Gear Manufacturing by Machining.
Abrasives and Bonded Abrasives, Grinding Process, Grinding Operations and Machines.
Chapter 4 - Joining Processes and Equipment (8 hours)
Fusion-Welding Processes: Introduction, Oxyfuel-gas Welding, Arc-Welding Processes: Non- consumable Electrode, Arc-welding Processes: Consumable Electrode, Electrodes for Arc Welding, Electron-beam Welding, Laser-beam Welding, Cutting, The Weld joint, Quality and Testing.
Solid-State Welding Processes: Introduction, Cold Welding and Roll Bonding, Ultrasonic Welding, Friction Welding, Resistance Welding, Explosion Welding, Diffusion Bonding.
Brazing, Soldering, Adhesive-Bonding Processes.
Chapter 5 – Metal-Casting Processes and Equipment (8 hours)
Fundamentals of Metal Casting: Introduction, Solidification of Metals, Fluid Flow, Fluidity of Molten Metal, Heat Transfer, Defects.
Foundry Hand Tools, Foundry Sand and their Control Additives, Core and types of core, Pattern materials and types of patterns, Gating mechanism, Shrinkage allowances, Molding processes. Special Casting Methods.
Metal-Casting Processes and Equipment : Introduction, Expendable-mold, Permanent-pattern Casting Processes, Expendable-mold, Expendable-pattern Casting Processes, Permanent-mold Casting Processes, Rapid Solidification, Inspection of Castings, Melting Practice.
Chapter 6 – Bulk Deformations Processes in Metal Working (9 hours)
Overview of Metal Working, Formability, Homologous Temperature, Strain Hardening, Cold Working, Warm Working, Hot Working.
Metal-Rolling Processes and Equipment’s: Introduction, The Flat-rolling Process, Rolling Mills, Various Rolling Processes and Mills, Defects in Rolled Products.
Metal-Forging Processes and Equipment’s: Introduction, Open-die Forging, Impression-die and Closed-die Forging, Various Forging Operations, Forgeability of Metals; Forging Defects, Forging Machines.
Metal Extrusion and Drawing Processes and Equipment: Introduction, The Extrusion Process, Hot Extrusion, Cold Extrusion, Extrusion Defects, Extrusion Equipment, The Drawing Process, Drawing Practice, Drawing Defects and Residual Stresses, Drawing Equipment.
References:
1. Serope Kalpakjian and Steven R. Schmid, Manufacturing Processes for Engineering Materials, Prentice Hall, 5th Edition, 2008.
2. Rajendra Singh, Introduction to Basic Manufacturing Processes and Workshop Technology.
3. Mikell P. Groover, Fundamentals of Modern Manufacturing – Materials, Processes and Systems, Wiley, 2nd Edition, 2002.
4. E. Paul Degarmo, J.T. Black, Ronald A. Kohner, Materials and Processes in Manufacturing, 9th Edition, John Wiley & Sons.
5. J.S. Campbell, Principle of Manufacturing, TMH Publications & Co.
6. Begman & Amsteed, Manufacturing Processes, 8th Edition, John Wiley & Sons.