Fundamentals of Manufacturing Materials, Processes & Systems
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 OutlineIntroduction to Manufacturing: Lecture 1Introduction to Manufacturing ProcessesWhat is manufacturingManufacturing IndustriesManufacturing ProductsProduction Quantity and Product varietyMaterials in ManufacturingManufacturing Processes (Processing operations and Assembly operations)Sand Casting:Lecture 2Overview of casting technologiesDifference between casting and moldingAdvantages and Disadvantages of casting processesCasting Processes (Expendable mold casting and permanent mold casting)Lecture 3Sand casting and Engineering analysis of sand casting y sandPouring and Engineering Analysis of PouringFlow rate and time required to fill the moldFluiditySolidification and CoolingLecture 4Solidification of pure metals and alloys (Alloys and Eutectic Alloys)Solidification time and ShrinkageDirectional SolidificationLecture 5Riser Design with Exercise Problems.Lecture 6Pattern for castingMaterials used for patternTypes of patternMold making and Classification of sand moldsWhat is foundry sand?Lecture 7Buoyancy ForceMetal casting processesShell moldingAdvantages and Disadvantages of Shell moldingVacuum moldingAdvantages and Disadvantages of Vacuum moldingExpanded Polystyrene CastingAdvantages and Disadvantages of Expanded Polystyrene CastingInvestment castingPlaster and Ceramic Mold castingPermanent Mold Casting (PMC): Lecture 8Types of pattern allowance (Shrinkage and contraction allowance, Draft allowance, Machining allowance, and Distortion allowance)Permanent mold casting and its Applications.Slush castingLow-pressure castingVacuum permanent mold castingDie casting (Hot and cold chamber die casting)Advantages and LimitationsCentrifugal casting and Semi centrifugal castingLecture 9FurnacesCupolas FurnaceDirect Fuel Fired FurnaceCrucible FurnaceElectric Arc FurnaceInduction FurnaceMetal Forming:Lecture 10Fundamentals of metal formingTypes of deformation processes of metalBulk deformation (Rolling, Forging, Extrusion, Wire Drawing)Sheet metal workingStress-Strain CurveDerivation of the relation between stress and strainFlow stress and Average flow stressThe temperature in metal forming (Cold working and Hot-working)RecrystallizationIso thermal forming (recovery and Grain growth)Strain rate SensitivityLecture 11Introduction of rollingShapes used for rollingTypes of rollingWorking of the rolling processAnalysis of the rollingRolling millsNo-Slip Point for rollingFlatness control and rolling defectLecture 12Numerical Problems related to the rolling processLecture 13Introduction to forgingClassification of forgingTypes of forgingAnalysis of the forgingBarreling effect in forgingOpen Die forging and its practicesImpression Die forging and its practicesAdvantages and Limitations of Impression Die forgingFleshless forgingForging Press and Forging HammersLecture 14Numerical Problems related to the forging processLecture 15Introduction to the extrusion processClassification of extrusionDirect and Indirect extrusionHot and Cold extrusionDirect and Continuous extrusionAnalysis of the extrusion processEffect of friction on extrusionExtrusion Dies and OrificeExtrusion press and other extrusion processesLecture 16Numerical Problems related to the extrusion processIntroduction to DrawingDifference between drawing and wire drawingBar DrawingWire DrawingFeatures of Draw DiePreparation of the workAnalysis of the drawing processSheet metal forming processes: Lecture 17Introduction to sheet metal cutting processCharacteristics of EdgesTypes of sheet metal cuttingShearingBlanking and PunchingClearance in Sheet metal cuttingAnalysis of sheet metal cutting processesNumerical Problems related to the sheet metal cutting processLecture 18Introduction of sheet metal bending processTypes of sheet metal bendingAnalysis of the sheet metal bending processNumerical Problems related to the sheet metal bending processSpring BackLecture 19Introduction to the drawing processMechanics of drawingStages of deformationAnalysis of the drawing processTests of Drawing FeasibilityBlank force and blank size determinationNumerical Problems related to the drawing processLecture 20Other drawing processes (Redrawing, Reverse Drawing and Drawing without Blank holder)Defects in DrawingThe operation performed with metal toolingIroningCoining & EmbossingLancing & TwistingThe operation performed with flexible Rubber toolingGuerin and Hydro forming processLecture 21Numerical Problems related to the other drawing processesWelding Processes:Lecture 22Fundamentals of weldingDifference between joining and weldingAdvantages and Disadvantages of WeldingHistory of weldingTypes of the welding processComponents used for welding process (Filler material, Flux, and Electrolyte)Consumable and Non-consumable electrolyteWelding positionsWelding Electrode NomenclatureType of Weld Joints (Butt joint, Corner Joint, Lap joint, Tee Joint, Edge Joint)Types of Weld (Filler Weld, Groove Weld, Plug weld or slot weld, Spot and Seam weld, Flange and Surface Weld)Features of Fusion Welded JointsPhysics of welding (Power Density and Numerical of Power Density)Heat Balance in Fusion WeldingWelding as Commercial OperationAutomation in Welding (Machine, Automatic and Robotic)Welding SafetyLecture 23Welding Categories (Fusion Welding, Solid State Welding, Soldering and Brazing)Arc WeldingArc ShieldingThe power source in Arc weldingTypes of Arc Welding (Shielding metal arc welding, Gas Metal Arc Welding, Flux Cored Arc Welding, Submerged Arc Welding,Gas Tungsten weldingPlasma arc weldingLecture 24Oxyfuel arc weldingOxyacetylene weldingResistance weldingSpot WeldingResistance seam weldingResistance projection weldingEnergy beam welding (Electron beam welding, Laser beam welding)Numerical Problems related to the welding processesLecture 25Numerical Problems Related to the welding processesLecture 26Solid-state weldingTypes of solid-state welding(Diffusion welding, Friction welding, and Ultrasonic welding)Welding Defects of Solid State WeldingBrazing and SolderingFabrication of Plastics:Lecture 27PlasticsType of PlasticsProperties of polymer melt (Viscosity and Viscoelasticity)Extrusion process for Plastics in detailExtruder ScrewFeed SectionCompression SectionMetering SectionProcess ParametersSolid and Hollow ProfilesWire and Tube coatingDefects in the extrusion processLecture 28Injection molding for Plastics in detailClampingInjectionCoolingEjectionApplication and MaterialAdvantages and DisadvantagesLecture 29Blow MoldingExtrusion Blow MoldingInjection Blow MoldingStretched Blow MoldingCompression MoldingTransfer Molding (A pot transfer molding and B plunger-type transfer molding)OZIS Academy is the best platform for struggling students and professionals who want to improve their skills for the workfield as it provides a large no of quality and detailed courses. 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