Introduction. TEQIP Course on Introduction to Manufacturing Processes. Introduction to Manufacturing Processes. June 11-22, 2018

Transcription

1 TEQIP Course on Introduction to Manufacturing Processes June 11-22, 2018 Introduction to Manufacturing Processes Introduction For a country like India, that has an enormous young manpower, technical education is an unbeatable tool to harness the capacity of its people and amplify its national growth. The rapidly growing Indian economy, spurred by the slogan to MAKE IN INDIA, requires massive technical manpower and large scale technological innovation. Manufacturing plays a massive role in economic strength of a country. The enormous technical workforce of India requires right tools and guidance to know about basic idea about processes involved in making a product. This 10-day course aimed to impart the basic knowledge about the fundamental manufacturing techniques employed to convert a raw material into final product. Each day started with one-hour lecture about various manufacturing processes followed by lab work. At the end of the course, the participants were divided into groups and they worked as a team to demonstrate a working prototype designed, fabricated and assembled by them.

2 77 Undergraduate students and 5 faculty members that have been appointed recently through TEQIP were the participants of this course. Organizer Prof. Neeraj Sinha Assistant Professor Department of Mechanical Indian Institute of Technology Kanpur nsinha@iitk.ac.in Web page: Topics Discussed 1. Introduction: Introduction to manufacturing, evolution of manufacturing, importance of design in manufacturing, engineering materials, mechanical properties important for manufacturing. 2. Conventional Material Removal Processes: Theory of chip formations, generation of surfaces, force and power relationships, cutting tool material and its geometry, tool wear, fundamentals of machine tools, types of machining operations. 3. Unconventional Material Removal Processes: Introduction, mechanical energy processes, thermal energy processes, electro chemical machining. 4. Computer Numerical Control and Programming: Basics of numerically controlled machines, programming for NC machines, motion and coordinate system, structure of a NC part program, examples of part programming. 5. Microfabrication Processes: Silicon processing, lithography, microfabrication processes. 6. Layered/Generative Manufacturing Processes: Fundamentals, steps in additive manufacturing, additive manufacturing technologies. 7. Metrology: Dimensions, tolerances, surfaces, structure and properties, surface texture and roughness, engineering metrology and instrumentation

3 Event Pictures Prototypes made by students at the end of the course Reports and videos on these projects are available at: workshop/2018/manufa cturing-process/

4 For more pictures click here

5 Schedule Time Day 9:00 10:00 10:00 10:15 10:15 13:00 13:00 14:00 14:00 17:00 Day 1 Day 2 Day 3 Course overview. Introduction to engineering materials, discussion on mechanical properties important for manufacturing Conventional Material Removal Processes Conventional Material Removal Processes Visit to TA202 lab. Formation of group. Assignment of guides. Discussing projects with assigned with the instructor and guides. Training and exercise on lathe, milling & drilling and fitting (in groups of 20) Day 4 Day 5 Day 6 Day 7 Day 8 Day 9 Day 10 Conventional Material Removal Processes CNC Programming Unconventional Material Removal Processes Unconventional Material Removal Processes Microfabrication Additive Manufacturing Metrology Tea Isometric drawing, drawings of individual parts, calculations and bill of materials. Visit to other labs Project making and assembly (self) Lunch Demonstrati on on CNC and metrology CNC practice with own program. Start making the project. Project making and assembly (with help of guides) Project demonstrati on and valedictory

6 Sr.N o. Participating Students Name Department Institute 1 Ved Prakash Mechanical 2 Bibek Karan Mechanical 3 Suraj Kumar Mechanical 4 Faisal Mechanical 5 Sanjeet Kumar Mechanical 6 Purnendu Kumar Mechanical 7 Vinay Kumar Mechanical 8 Varsha Rani Mechanical 9 Chandan Kumar Mechanical 10 Sandhya Kumari Mechanical 11 Vishajeet Kumar Mechanical 12 Ujjwal Kumar Mechanical DCE, Darbhanga DCE, Darbhanga DCE, Darbhanga DCE, Darbhanga DCE, Darbhanga DCE, Darbhanga DCE, Darbhanga DCE, Darbhanga DCE, Darbhanga DCE, Darbhanga DCE, Darbhanga DCE, Darbhanga

7 13 Manish Kumar Mechanical 14 Vidhyarthi Kumar Mechanical 15 Abhishek Kumar Mechanical 16 Suraj Kumar Jha Mechanical 17 Nitesh Anand Singh Mechanical 18 Isha Raj Murmu Mechanical 19 Amit Kumar Thakur Mechanical 20 Nitesh Kumar Mechanical 21 Pranaw Kumar Mechanical 22 Deepak Kumar Kewat Mechanical 23 Raj Sagar Mechanical 24 Gautam Kumar Yadav Mechanical 25 Sintu Kumar Mechanical 26 Rashmi Priya Mechanical 27 Khushboo Kumari Mechanical DCE, Darbhanga DCE, Darbhanga DCE, Darbhanga Dumka College Dumka College Dumka College Dumka College Dumka College Dumka College Dumka College Dumka College Dumka College Dumka College LNJPIT, Chapra LNJPIT, Chapra

8 28 Abhishek Kumar Alok Mechanical 29 Bipin Kumar Mechanical 30 Bibhash Kumar Mechanical 31 Chandan Kumar Mechanical 32 Nitish Kumar Mechanical 33 Anubhav Raj Mechanical 34 Nitish Kumar Mechanical 35 Rahul Kumar Sah Mechanical 36 Pratibha Singh Mechanical 37 Veer Bahadur Patel Mechanical 38 Ruchi Priyadarshi Mechanical 39 Richa D Verma Mechanical 40 Aman Kumar Gautam Mechanical 41 Manisha Mechanical 42 Prity Kushwaha Mechanical LNJPIT, Chapra LNJPIT, Chapra LNJPIT, Chapra LNJPIT, Chapra LNJPIT, Chapra LNJPIT, Chapra LNJPIT, Chapra LNJPIT, Chapra

9 43 Himanshu Pandey Mechanical 44 Pradum Singh Mechanical 45 Ashutosh Kumar Mechanical 46 Pratibha Singh Mechanical 47 Saurav Yadav Mechanical 48 Satyavik Singh Mechanical 49 Ashish Kumar Gaurav Mechanical 50 Pranjul Mani Mechanical 51 Prince Kasaudhan Mechanical 52 Rajan Kumar Mechanical 53 Neelam suman Mechanical 54 Ramu Verma Mechanical 55 Shubham Yadav Mechanical 56 Himanshu Sharma Mechanical 57 Neeraj Kumar Mechanical

10 58 Kuldeep Yadav Mechanical 59 Avinash Kumar Verma Mechanical 60 Asheesh Kumar Mechanical 61 Santhana Karthikeyan.RM Mechanical 62 Prithivi Raj.M Mechanical 63 Kevin Christopher.S Mechanical 64 Veera Manikandan.V Mechanical 65 Bharath Raj B K Mechanical 66 Kani Balan.T Mechanical 67 Rajesh.P Mechanical 68 Abdulazeez.R Mechanical 69 Prashanth Mariappan.M Mechanical 70 Logesh Karthick. M Mechanical 71 Karthik Raja.D Mechanical 72 Balakumaran.R Mechanical Thiagarajar college of, Thiagarajar college of, Thiagarajar college of, Thiagarajar college of, Thiagarajar college of, Thiagarajar college of, Thiagarajar college of, Thiagarajar college of, Thiagarajar college of, Thiagarajar college of, Thiagarajar college of, Thiagarajar college of,

11 73 Balaji M.P Mechanical 74 Sathis Kumar.R Mechanical 75 Pragadeesh Suhan B.H Mechanical 76 Neela Aravind. P Mechanical 77 Kumara Prasad.K Mechanical Thiagarajar college of, Thiagarajar college of, Thiagarajar college of, Thiagarajar college of, Thiagarajar college of, Institute D.C.E. Darbhanga Dumka College LNJPIT, Chapra Thiagarajar college of, Participating Faculty Faculty Name Mr. Rajat Gupta (Assistant Professor) Mr. Prasenjit Sarkhel Mr. Saurabh Priyadarshi Mr. Saurabhi Tripathi & Mr. Anshul Gupta Mr. C Vignesh Participation summary S. Institutes Participants No 1. Darbhanga College of, 16 Darbhanga 2. Dumka engineering college Lok Nayak Jay Prakash Institute of 11 Technology, Chapra, Bihar 4. REC Banda Thiagarajar College of 18 Total 83

12 STATEWISE PARTICIPATION UP 32% Bihar 46% Tamil Nadu 22%

13 Outcome This was one of the most successful summer program offered by KIT, IIT Kanpur. Students thoroughly enjoyed this course as it kept them fully engaged and introduced them to several aspects of manufacturing process. They were enthusiastic to work at labs of IIT Kanpur and it motivated the accompanying faculty to set up their own labs plan courses like this at their institutes. The course introduced important mechanical properties of materials, conventional and non-conventional material removal processes, CNC programming, metrology, microfabrication processes and layered manufacturing technique. At the end of the course students worked hard to prepare a model on what they learnt during the course. They were divided into groups and together they worked to prepare some prototypes. This helped them to build new contacts with students from other collages and learn how to work as a team. The course gave all the participants ideas on basic knowledge of transforming an idea into a useful product. It gave opportunity to the students to get a hands on experience that they usually lack due to absence of infrastructure in their institute. The faculty members were exposed to the pedagogy of IIT Kanpur and this course helped them in planning the course and setting up the lab in their parent institute in an efficient manner. Course Webpage Course pictures

14 Feedback Summary 1. Clarity of communication about workshop? 1% 40% 59% Excellent Good Ordinary 2. Organization of the sessions 28% 0% 72% Excellent Good Ordinary

15 3. Quality of lectures? 3% 59% 38% Excellent Good Ordinary 4. Effectiveness of discussions 6% 52% 42% Excellent Good Ordinary

16 5. Effectiveness of learning experience 0% 35% 65% Excellent Good Ordinary 6. Duration of course 0% 46% 54% Appropriate Short Long

17 7. Would you like to have more such sessions? 11% 0% Definitely Maybe No 89% 8. Would you like e-lectures by experts on special topics? 19% 1% Definitely Maybe No 80%

18 9. Suggest specific topic that you would like additional expert lectures on Design of machine element energy comer nation CNC Machine design & auto mobile Heat and mass transfer design of machine element Micro fabrication Welding, forging, plastic extension Pattern making & casting welding etc. Thermodynamics I.C. engine, A.C. refrigeration 10. Additional Suggestions These workshop has to be conducted regularly These communications could have been better We want to be attend all other course that is related to my branch. This course is only which sead and study in previous time Longer duration of course as it requires more time Projects should be given more time to computer Learning 1. Do you get enough class projects? 8% Yes No 92%

19 2. Is the learning adequate? 4% Yes No 96% 3. Do you have sufficient resources for laboratory courses? 23% Yes No 77%

20 4. Is the library/journal support/e-connection adequate? 24% Sufficient Inadequate 76% 5. Would you like to have common (TEQIP) repository of course material? 15% 0% Definietly Maybe 85%

21 6. Would you like to visit IITK to attend specialized courses? 5% 0% Definitely Maybe No 95% 7. Would you like MOOCS/e-resources based courses? 0% 42% 58% Definitely Maybe No

22 8. What is your area of specialization? Automobile Machine design & automobile Mechanical engg. Het & mass transfer and strength of material Kinematics of machinery thermodynamics fluid mechanics Thermal casting & welding 9. How can TEQIP help improve your learning? By conducting these events regularly By organize more of ever training sessions TEQIP improve our learning by arranging workshop on the course and lab To give opportunity to come here To organize this type of lab based course in the vacation First of all, we come IITK with the help of TEQIP. I am very thankful to TEQIP. TEQIP give me opportunity to learn the manufacturing It gives me practical knowledge about subjects We meet experienced teachers who tell many more things about machines and all things By giving / introducing more practical and theoretical based courses to underprivileged college like they did

23 Research 1. Would you like to visit an IIT for short visit/internship/post-doctoral stint, if offered (via TEQIP) 7% 1% Definitely Maybe No 92% 2. Would you like to share/use research infrastructure at IITK, if made available? 11% 0% Definitely Maybe No 89%

24 3. Would you like to conduct collaborative research with IITK faculty? 0% 14% Definitely Maybe No 86% 4. Would you like lectures by experts (Indian and international) on niche research areas/topics? 0% 14% Definitely Maybe No 86%

25 5. Do you want special-topic conferences? 0% 16% Definitely Maybe No 84% 6. How can TEQIP improve your research? Teqip can help improve my search provided them many idea and laboratory project and direction of additive name futurity By providing resources to our college By providing adequate resources and opportunity To practically do the workshop to do the job. TEQIP help to improve my interest in research by arranging such type of lab and new field of manufacturing process to do something The teqip cell should conduct some research programme at international level By giving visit at IIT s Organize such types of workshop internship in other IIT college with a sufficient period. I forced many which is learned more things By providing renowned professor and experience guide under whom we could carry our research

26 Additional Questions 7. Please suggest some topics for similar courses? Design of machine element CNC, Microfibrication machining The lecture class time is more required because this course time is not good Thermodynamics, material science & F.M, I.C. engine, A.C Refrigeration, automobile

27 Organizer s Report O Report on TEQIP Course on Introduction to Manufacturing Processes held between 11 th to 22 nd June 2018 at TA202 Lab, IIT Kanpur Course Co-ordinator: Dr. Niraj Sinha Department of Mechanical IIT Kanpur Background The economic strength of a country is usually judged by the growth of its manufacturing industries. Therefore, manufacturing has become part of the fabric of our country with emphasis on "Make in India" by the government. It is important that technical workforce from all disciplines have basic idea about processes involved in making a product. Against this backdrop, the course aimed to impart the basic knowledge about the fundamental manufacturing techniques employed to convert a raw material into final product. The course introduced important manufacturing techniques that was followed by working in the lab. At the end of the course, the participants were able to demonstrate a working prototype that were designed, fabricated and assembled by them. The workshop was spread over ten days. The details of the workshop have been presented in the latter part of the report. Objectives Objectives of the workshop were to: 1. Introduce fundamental concepts of manufacturing processes, 2. Introduce hands-on experimental sessions to demonstrate their use in making a working prototype from raw material, and 3. Optimal selection of a manufacturing process to fabricate a part based on engineering requirements.

28 Course Details The proposed course has covered the following topics: 1. Introduction: Introduction to manufacturing, evolution of manufacturing, importance of design in manufacturing, engineering materials, mechanical properties important for manufacturing. 2. Conventional Material Removal Processes: Theory of chip formations, generation of surfaces, force and power relationships, cutting tool material and its geometry, tool wear, fundamentals of machine tools, types of machining operations. 3. Unconventional Material Removal Processes: Introduction, mechanical energy processes, thermal energy processes, electro chemical machining. 4. Computer Numerical Control and Programming: Basics of numerically controlled machines, programming for NC machines, motion and coordinate system, structure of a NC part program, examples of part programming. 5. Microfabrication Processes: Silicon processing, lithography, microfabrication processes. 6. Layered/Generative Manufacturing Processes: Fundamentals, steps in additive manufacturing, additive manufacturing technologies, type of additive manufacturing processes. 7. Metrology: Dimensions, limits, fits, tolerances, surfaces, surface texture and roughness, engineering metrology and instrumentation Contribution This workshop was envisaged to introduce the fundamentals of manufacturing processes and to some extent the physics behind them. With this in mind, we drew a plan to utilize the facilities available within IITK to deliver a workshop that would enable participants to learn from one of the best infrastructures in the country. Since it was a primarily lab based course, we had a total of 10 hours of lectures and 30 hours of hands-on laboratory sessions. Additionally, students spent 30 hours on their own in the lab towards activities such as generating project ideas, preparing drawings and calculations for the same.

29 Feedback from the participants: Out of the 77 participants who registered, 76 of them were present for the workshop. The participants were B.Tech. students from TEQIP mentored colleges. The workshop was very well received and all sessions were very interactive. The participants were highly appreciative of how the workshop was structured from start to finish and of how the learnings in classroom teachings translated to hands-on experimental sessions. Most of the participants had never before done any such experiments (starting from idea to prototype development) as they did during the workshop. Overall, we believe that this was a very successful workshop and we hope that this motivated interest in the field of manufacturing engineering that can strengthen the manufacturing workforce in the country. Key take-away from the course for the participants Participating in the course, we hope has enabled participants to o appreciate the role of manufacturing in economy and development of a nation o gain knowledge about fundamentals of various manufacturing processes o gain hands on training on manufacturing processes and fabricate a working prototype by optimally selecting the manufacturing process from a set of available processes Acknowledgements In the end, we sincerely thank the TEQIP team. They made an impeccable arrangement for the program and also took care of all the necessary details (posters, dinners, tags, etc). This workshop would not have been successful without their constant support.

30 Course Schedule A Short Term Course on Introduction to Manufacturing Processes (June 11-22, 2018) Time Day Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7 Day 8 Day 9 Day 10 9:00 10:00 Course overview. Introduction to engineering materials, discussion on mechanical properties important for manufacturing Conventional Material Removal Processes Conventional Material Removal Processes Conventional Material Removal Processes CNC Programming Unconventional Material Removal Processes Unconventional Material Removal Processes Microfabrication Additive Manufacturing Metrology 10:00 10:15 Tea 10:15 13:00 Visit to TA202 lab. Formation of group. Assignment of guides. Discussing projects with assigned with the instructor and guides. Isometric drawing, drawings of individual parts, calculations and bill of materials. Project making and assembly (self) 13:00 14:00 Lunch 14:00 17:00 Training and exercise on lathe, milling & drilling and fitting (in groups of 25) Demonstration on CNC and metrology CNC practice with own program. Start making the project. Project making and assembly (with help of guides) Project demonstration and valedictory

31

32