Doe IST-F-32/04 Institute of Space Technology 2016 Date of Issue LP No: | MECI-MP-LP-00/01 Lesson Plan —— 1of8 DEPART & PROGRAM: BS. Mechanical Engineering COURSE CODE. COURSE NAME: 3/4514 Manufacturing Processes CR: 3-0 COURSE DESCRIPTION This course is specially des igned t0 introduce the students to manufacturing processes and techniques employed in curren and next generation manufacturing industry. The students are introduced with Jandamentals of manufacturing, Material properties, casting processes, metal cutting process, shaping Processes, sheet metal forming, rolling and extrusion, gear manufacturing, jigs and fixtures design, non- conventional machining process like electrochemical and electrical discharge machining and advanced mamufacturing concepts of Computer Aided Engineering with focus on rapid prototyping, imegrated manufacturing, and smart factory concepts. PREREQUISITE: 114503 Workshop Technology CO-REQUISITE: Nil TEXT AND MATERIAL ‘Textbook: J. Fundamentals of Modern Manuficturing-4" edition by Mikell P_ Groover Material and Processes in Manufacturing 10!"-edition hy DeGarmo, John Wiley & Sons Manufacturing Processes for advanced composites by F.C. Campbell, Elsevier Reférence Material: 2 Manufacturing Engineering & Technology b 2. Principles of engineering manufacture, 1" RELEVANT PROGRAM LEARNING OUTCOMES: Thie designed course will target upon the following PLOs 1 PLO In ability 10 idenvify, formulate, research literature, and analyze complex engineering problems reaching substantiated conclusions using first principles of 3» Serope Kalpakjian dition by SC. Black and S.J, Martin Problem Anal ‘mathematics, natural sciences and engineering sciences 2 PLO-O3: Design/Development of Solutions: An ability to design soluions for complex engineering problems and design systems, components, ar processes that meet specified needs with appropriate consideration for public health and safety, cultura, societal, and environmental considerationsDoe # Date of Issue | O8-May LP No: | MECH-MP-LP-00/01 Institute of Space Technology Lesson Plan Page| 20f8 3 ironment and Sustainability: An ability to understand the impact of professional ¢ solutions in societal and environmental contexts and demonstrate knowledge and need for sustainable development. enginee Course Objectives: ful completion of the course, the student will demonstrate competency by being able to: 1. Describedemtify the process capabilites of major manufacturing processes 2. Determine/Catcutate the process requirements for the manufacturing of desired product 3. Recommend/Propose solutions for the real time industrial issues in the light of ecofriendly and sustainable manufacturing proc Upon succes 4. Share/Report the technical know-how of the common manufacturing processes used in industry. PRACTICAL APPLICATION: This course teaches the applications and design of manufacturing setups for product development 1als as well as plastics are a few of the topics covert Casting, forging, extrusion, and drawing of n this subject. These in turn helps the students to prepare for the challenges the industry is facing today. In short, as far as the industry is concerned, this course is of primal importance. LECTURE PLAN: Instruction Diseussion Exercises/Tutorial Module Topic Reference Week/ Lecture Introduction and overview of Manufacturing Processes Ld What is Manufacturing 1.2, Manufacturing Industries and Products 1.3 Manufacturing Capability I 14 Materials in Manufacturing Textbook 1 1} : ’ Chapter I 15 Processing Operations 1.6 Assembly Operations 17 Production Machines and Tooling 18 Production Systems 1.9 Manufacturing Support Systems Fundamentals of Metal Casting and Casting Design Textbook 1 n 2.1 Overview of Casting Technology Chapter 10 rm] 2.2 Casting Processesm. W. v. Metal Cutting 7 5. Metal Cutting Technology Institute of Space Technology Lesson Plan 2.3 Sand-Casting Molds 24 Heating and. Pouring 2.5 Engi ing Analysis of Pouring 2.6 Solidification and Cooling 2.7 Solidification Time 2.8 Shrinkages 2.9 Directional Solidi 210 cation Riser Design Casting Quality Metals for Casting Product Design Considerations Sand Casting and other Casting Processes 2.15 Permanent mold casting processes Metal Forming and Sheet Metal forming 3.1 Overview of Metal Forming 3.2 Material Behavior in Metal Forming 3.3 Temperature in Metal Forming 3.4 Friction and Lubrication 3.5 Sheet Metal Processes Butk-Deformation processes 3.6 Introduction 3.7 Importance and benefits 3.8 Rolling and Related Operations 3.9 Forging and Related Operations 3.10 3a Extrusion and Related Operations Wire and Bar Drawing Composites Manufacturing Process 4.1 Introduction 1.2 Manufacturing processes for thermoset composites [__ Doe y | IST-F-32/04 [Date of tssue_| 0! LPNo: |M [sors Paget Textbook 1, Chapter 18-20 Textbook 3, Chapter 1, 9, 4.3 Manufacturing processes for thermoplastic composites jeory and Machining Operations 2 Overview of Machining Technology 5.3. Theory of Chip Formation in Metal Cutting 5.4 The Orthogonal and Oblique Cutting Modet Textbook 1, Chapter 21, 22 -May-2016 H-MP-LP-00/01 78 9-10 | —Is 1-F-32/04 "08-May-2016 ute of Space Technology Lesson PI | MECHEMP-LP-00001 | : ” on Plan 4of8 - 3.3 Force Relationship and the Merchant Equation ' 3.6 Power and Energy Relationship in Machining 5.7 Cutting Temperature During Machining 3. Factors affecting Machinability 5.9 Turning and related Operations 5.10. Drilling and related Operations 5.11 Milling and retated Operations 5.12 _ Engineering Analysis of Machining Processes Now-teaditional(NT) Machining Processes 6. Introduction 6.2 Need of NT Machining 6.3 Advantages and benefits and NT machining 6.4 Ultrasonic Machining Textbook |. Mel? VR 6.5 Processes using Water and Abrasive Jets Chapter 26 ° 6.6 Electrochemical Milling 6.7 Electrical Discharge Machining (EDM) 6.8 Wire EDM 6.9 Thermal and Chemical Energy Based! Processes Jigs ami Fixtures 7.1 Introduetion 2 Difference between Jigs and Fixtures Textbook I, vib. 7.3 Funetion of Jigs and Fixtures Chaprer23 13 7-4 Main componenas of Jigs and Fistures 7.5 Types of digs and Fixtures 76 Design consideration for Jigs and Fixtures Moitern trends in manufacturing 81 Computer Aided Manufacturing (CAM) and Computer tided Engineering (CAE 8.2. Computer Aided Quality Control (CAQC) coe 83 Significance and Basie Concepts of Computer Cte ee . vi. Invegrated Manufacturing (CIM ee ates : Reference Book I. 8.4 Rapid Protonsping and Additive Manufacturing cee Technigues 8.5 Environment and Sustainability 8.6 Industry 4.0 and Smart Factory Concept IX. Presentations/Report Submission Discussions 16Institute of §; 1 [Doce | ISt-F-32/04 ° Space Teel , — _ — - pace Technology Hae of oe [eae MECH-MP-LP-00/01 — Lesson Plan "7 Module | CLO. Learning | PLOsto No. | No. Assessment Methodology: Domain target with Level Lv | 1 | Lectures /Diseussions | Quiz/OMTs/Assignmemts/ Final | PLO-3 aan ei | | 1 | 2 ; , (na, mn 2 | Lectures / Discussions | Quiz/OHTs/Assignments/ Final C3 PLO-3 MA Frnay | 4 | Hectares / Discussions | Assignment/ Presentations AB PLO-2 Assessment through Complex Engineering Problems/Activities will be judged as follows | | Targeted | Teaching | Assessment | Learning ] | assessment | CLO® Attribute | Methodology | Methodology | Domain Comers | © | cording to PEC with Level | | | target | Accr. Manual | | (Bloom | | - 2019 | Taxonomy) | i | [2 Range of 1 | resources | | | Complex 5 1 Projects/Assig Fonsequences rojects/Assi . Engineering 3 sequences | Discussions | HE) Cs PLO? to society and inments Acsivity | environment ASSESSMENT: sand assignments at end of each module The course will include at least two hour tests, in addition qi muy be set A comprehensive final examination covering all the topies, of at least 3 hour's durations will be set at the end of the course, Evaluation will be done on following eriteria: Assignments/Presentations — 5-15% Quizzes 510% om 0% Final Exam 45-50% Project ___— 115%Doct | IST-F-32/04 Date of log | OR-May-2016, | LpNo: | MECHEMP-LP-00/01 \ - panies [Paget | 6ofR Tonal 100% ' inca a Learn | Categories | Assessment Criteria ht) Marking Seale | & | Lost PLOsto | age % | (10) orm | “Target | Target Level | Adequate knowledge = Excellent 6-10) | | ‘and background of the + Goal 68) | problem 10 | * Average (1-6) | | selected assigned + Fairy | | Poor 0-2) | | ability to relate + Excellent ®-10) | knowledge of + Good (6-8) | manyfacturing 1p | Average (6) | engineering 10 the Fair 2-9) | | proposed problem Pow (0-2) | | | 7 Excellent 8-10) | | An ability to understand + Good (68) | | iterated approach | 10 |* Average 6) towards mannfacturing + Fair | | - © Poor 2) [see ito set ad Freetown 21) | 4.3 | clot | Poor resentation | propose solution based! + Good (68) | Jon te sss related 10} yg |* Average 6) | | heath safer and| 7) | * Fair environment + Poor (02) | Propose alternative | | solutions to reduce the Excellent (8-10) | production cost Goud (6-8) | material mitization and | — 20 Average (4-6) | | the wwe of optimal Fair 9) energy in [5 Poor (0-2) | | manufacturing setup | | rr Frcellent | | | Reports are well writen | + Gol 6 dand in a presemable | 30° * dverage (+6) | | | format : + Poor (0Lesson Plan Rubric for essing PLO-2 through project/assignment: categories | Criteria Excellent od Average | Fair Poor li Clear and | Cone | Concise PH) sngceurte it) pocteround | | Knowtedge limited doesn't onse ta it | CRE ; concise asense thal inoysledge doesn't | and Inontedee | Roledge provide | vaguely sblem hackeround of | Mevledte | abou the | clear asics aioe on anne | the problem ne | hackground of | backgroud Of| pio | rman | \? the problem | the problem | | Detailed | Key concepts | Key concepts | Unelear and | x.y derstanding Knowledge of | knowledge of | are covered but | are covered | difficulty | 9r manufacturing | | manufacturing | the Aimed focus on | bu na focus on | derstand | ig inaccurate | engineering | manufacturin | the in depth | the in depth | g the related | sr, ftiowedl gprocesses | knowledge Inowledge | processes Accurately Accurately Described the | Fairly procedure of | described the described the Failed 0 described the ue | Fail procedure of . | product | procedire of (e maely Assignments procedure Of | teciay product product 7 esigh |? describe the | Presemation | Integrated | 1%" product design, | soos | design, | approach | sia process design, |" vce procedure of towards aoe implementation ie omttig | desta product — design. design, vy | implementa | design recess desig manafactrns | pfememati |” n, cand | implementati jmpleme management | mec | ements | implementation, tl end) with fewer | manase | and management. management. | tes but lacks | management. | lori | Proposed | Proposed | Propose | Multiple Proposed solution based | solution does | ee | solution based | solutions | solution based | oy ie issues | not-describe | CaM" Provi | on the issues | based on the | on the issues | rorenedt ie solutions to the | | | relared —t0| the issues | ee, relaed — to isswes related | reared 10 poatth safene| retred to M08. 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