Introduction to Manufacturing
ME 338: Manufacturing Processes II 1
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Outline
• Contact details
• Course objectives
• Introductory remarks
• Grading policy
• Intro to manufacturing
ME 338: Manufacturing Processes II 2
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Contact Details
• Prof. Ramesh Singh/Prof. S. S. Pande/Prof. S.
S. Joshi
– Room: Machine Tools Lab (Prof. Ramesh Singh)
– E-mail:
•
[email protected] – Tel: 7507
– Off. Hrs.: Fridays 4-5 p.m.
– Also by appointment
– Class website:
http://www.me.iitb.ac.in/~ramesh/ME338/
ME 338: Manufacturing Processes II 3
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Focus and Objectives of Course
• Learn the fundamentals of machining, optimization, non
conventional machining, fixturing and metrology
• Develop first order mathematical descriptions for select
processes to analyze and calculate important quantities for the
unit processes e.g., forces, power, time, final shape, etc.
• Develop an understanding of the capabilities and limitations of
the unit processes in terms of quality and productivity
• Emphasis on understanding the physical principles underlying
these processes
• Apply this knowledge to manufacturing process selection, part
design for manufacture and quality control.
• Encourage teamwork and group activity via group assignments
and Project.
ME 338: Manufacturing Processes II 4
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Introductory Remarks
• See second page of syllabus
– Homework
– Exams
– Honor code
– No cellphones on the desk !!!!
• In silent mode in your bag/pocket
ME 338: Manufacturing Processes II 5
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Grading Policy
• Group Assignments in self-selected
groups of 4 or less 10%
• Quizzes 10%
• Midterm 25%
• Term Project 15%
• End semester exam 40%
• Total 100%
ME 338: Manufacturing Processes II 6
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Definition
• What is Manufacturing?
– derived from the Latin word manufactus
– manus = hand, factus = made
– practical definition: process of converting or
processing raw materials into usable products.
Raw Materials Mfg. Proc. Usable Products
Metals, polymers, ceramics, Pins, vessels, cars, ...
composites Adds value to raw
material --> Changes in
Shape (Geometry) and
Properties
ME 338: Manufacturing Processes II 7
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
What is Materials Processing?
• Imparting changes in material :
– Geometry
– Material properties:
• Strength
• Hardness
• Toughness
• Etc.
ME 338: Manufacturing Processes II 8
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Systems-Oriented Definition
• Manufacturing as a system or enterprise
– “A series of interrelated activities and operations
involving design, materials selection, planning,
production, quality assurance, management, and
marketing of discrete consumer and durable
goods” (CAM-I)
– a highly complex, interdependent activity that is
dynamic in nature.
ME 338: Manufacturing Processes II 9
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
ME 338: Manufacturing Processes II 10
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Design - Materials - Process Relationship
• Product design, materials selection, and
materials processing are highly interrelated.
• For example:
– weight reduction --> thin cross-sections --> mfg.
problems
– tight tolerance specs. --> specialized/high
precision processes required --> increased cost
– aluminum vs. steel beverage cans --> different
metal forming needs.
ME 338: Manufacturing Processes II 11
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Coke Cans over the Years
0.66 oz. (18.8 g) in 60’s, 0.48 oz (13.5 g) in 90’s
ME 338: Manufacturing Processes II
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Classification of Unit Manufacturing
Processes
• Based on:
– process type e.g., shaping vs. non-shaping
– state of workpiece material e.g., solid or liquid
– processing energy e.g., mechanical, electrical,…
Ei
Mi Mo
Mfg.
Si Process So
Eo
ME 338: Manufacturing Processes II 13
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Classification of Unit Manufacturing
Processes
• Shaping process classification
– Mass conserving, dM ~ 0
• examples: casting, bulk forming, powder processing
– Mass reducing, dM < 0
• examples: conventional and unconventional machining
– Mass adding, dM > 0
• examples: joining processes
Further sub-classification is possible based on processing
energy and workpiece state considerations
ME 338: Manufacturing Processes II 14
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Cutting (dM < 0)
Casting (dM ~ 0)
Forging (dM ~ 0)
Welding (dM > 0)
ME 338: Manufacturing Processes II 15
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
Summary
• Focus on:
– Physical principles and analysis of process
– Process Capabilities
• Teamwork will be encouraged
– Homework
– Term Paper
ME 338: Manufacturing Processes II 16
Instructor: Ramesh Singh; Notes: Profs.
Singh/Melkote/Colton
