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ME-918: MATERIALS AND MANUFACTURING TECHNOLOGY Scope and classification of Engineering Materials and Manufacturing Techniques. Types, properties and uses of Metals and Alloys, Manufacturing processes for shaping casting, deforming, sheet metal forming, particulate processing, machining, and finishing and joining. , Advanced methods of manufacturing: Abrasive jet cutting, Ultrasonic machining, Laser beam machining, Electron beam and electrochemical machining., Superalloys: Types, properties, uses and their processing techniques. Nickel-base, Cobalt- base and iron-base superalloys, remelting, Particulate processing, casting, machining, rolling, forging and welding of superalloys, Polymers: Classifications Plastics: Types, properties, uses and manufacturing processing techniques. Thermoplastics, Thermosets, and Elastomers, Composites: Types, properties, uses and manufacturing processing techniques. Metal matrix composites, polymer matrix composites, ceramic matrix composites, FGM., Glass: Types, properties, uses and shaping processes, Ceramics: Types, properties, uses and shaping processes, Property enhancing and surface processing operations: cleaning and surface treatments., Surface coating technology: Scope and classification of coating techniques. Electroplating (metal or composite coatings), Electroless plating (metal or composite coatings), Weld overlays (metal or ceramic coatings), Thermal spraying (metal, plastic, ceramic, or composite coatings), Cladding (thick metal coatings), Chemical vapor deposition (metals, graphite, diamond, diamond like carbon, and ceramics), Physical vapor deposition (metals, ceramics, or solid lubricants), Thermoreactive deposition/diffusion process (carbides, nitrides, or carbonitrides)., Recent development in materials and manufacturing technology., REFERENCES 1.Groover, M.P., Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Wiley Student Edition, John Wiley and Sons, 2005. 2.Budinski, K. G., (1998), Engineering Materials, Properties and Selection, Pub. Prentice-Hall of India, New Delhi, India. 3.Batchelor, A.W., Lam, L.N. and Chandrasekaran, M, Materials Degradation and its Control by Surface Engineering, 2nd Edition, Imperial College Press, 2003. 4.Bunshah, R. F., Handbook of Hard Coatings: Deposition Technologies, Properties and Applications, Noyes Pub. Park Ridge, New Jersey, U. S. A./William Andrew Publishing, LLC, Norwich, New York, U.S.A., 2001. 5.Sims, C. T., Stoloff, N. S., and Hagel, W.C., Superalloys II, John Wiley and Sons, 1987. 6.Callister W. D., Jr., Material Science and Engineering An Introduction, John Wiley & Sons, Inc., 6th Ed., 2003. 7.Patton, W.J., Plastic Technology, Theory, Design and Manufacture; Lenton Publishing Company. 8.Ashby, M.F., Materials Selection in Mechanical Design: Pergamon press, 1992.
METAL CASTING: Appraisal of various casting processes, selection of casting process, - general design considerations for casting casting tolerances use of solidification simulation in casting design product design rules for sand casting. METAL JOINING: Appraisal of various welding processes, Factors in design of weidments general design guidelines pre and post treatment of welds effects of thermal stresses in weld joints design of brazed joints. Forging Design factors for Forging Closed die forging design parting lines of die5 drop forging die design general design recommendations. Extrusion & Sheet Metal Work: Design guidelines for extruded sections - design principles for Punching, Blanking, Bending, Deep Drawing Keeler Goodman Forming Line Diagram Component Design for Blanking. ASSEMBLE ADVANTAGES: Development of the assemble process, choice of assemble method assemble advantages social effects of automation. AUTOMATIC ASSEMBLY TRANSFER SYSTEMS : Continuous transfer, intermittent transfer, indexing mechanisms, and operator - paced free transfer machine. DESIGN OF MANUAL ASSEMBLY: Design for assembly fits in the design process, general design guidelines for manual assembly, development of the systematic DFA methodology, assembly efficiency, classification system for manual handling, classification system for manual insertion and fastening, effect of part symmetry on handling time, effect of part thickness and size on handling time, effect of weight on handling time, parts requiring two hands for manipulation, effects of combinations of factors, effect of symmetry effect of chamfer design on insertion operations, estimation of insertion time. REFERENCE BOOKS: 1. Geoffrey Boothroyd, "Assembly Automation and Product Design", Marcel Dekker Inc., NY, 1992. 2. Engineering Design Material & Processing Approach George E. Deiter, McGraw Hill Intl. 2nd Ed. 2000. 3. Geoffrey Boothroyd, "Hand Book of Product Design" Marcel and Dekken, N.Y. 1990. 4. A Delbainbre "Computer Aided Assembly London, 1992.
Physiology of touch, haptic interface, force-feedback technologies, interaction of touch and vision. Visual Interface Human eye, preattentive processing, detection, estimating magnitude, multiple attributes, design principles. Displays and Controls: Visual displays: display technologies, information coding, physical characteristics. Controls: control selection, identification. Combining displays and controls. Human Information Processing Human information processing model, information coding, improving performance. Graphic-user Interface Screen design and layout, user action and control, appropriate appearance. Hand Tool Design Ergonomically oriented hand tool design, safe design for hand tool. References : 1. Bailey, R. W., Human Performance Engineering: A guide for system designers, Prentie Hall. 2. Sanders, S. M. and McCormick, E. J., Human Factors in Engineering and Design, McGraw Hill. 3. Bridger, R. S., Introduction to Ergonomics, McGraw Hill. 4. Kroemer, K., Kroemer, H., and Kroemer-Elbert, K. E., Ergonomics - How to design for ease and efficiency, Prentice Hall. 5. Dix, A., Finlay, J., Abowd, G. D. and Beale, R., Human Computer Interaction, Pearson Education. ME 930: COMPUTER AIDED PRODUCT DESIGN Introduction: World Class manufacturing, Product definition, Engineering Design Process, Prototype Design and Innovation, Impact of Cost, Quality and time, Key Process Requirements for Rapid Prototyping. Product Prototyping, Prototype planning and management, Prototype cost estimation, Prototype Design Methods and tools. Materials Selection and Product Prototyping. Phases of Prototyping. Fundamentals of R.P. Classification of R.P. Processes. Rapid Prototyping Process: - Automated Processes, Difference between Additive and Subtractive Processes, Process Chain, steps in involved in R.P. Types of R.P. systems: - Liquid Based, Solid Based, & Powder Based. Application of R.P. in Manufacturing and Rapid Tooling. Rapid Prototyping and Manufacturing Benchmarking Modeling practice on softwares such as IDEAS, UNIGRAPHICS, ProE, etc.