BASIC MANUFACTURING PROCESSES - iMechanica

1 BasicManufacturing PROCESSES (NME-101/201). Please submit your suggestions and detected errors toJeetender Singh 07 July2013 BASIC MANUFACTURINGPROCESSESQ uestions and answersJeetender Singh Kushawaha07/July/2013 BASIC MANUFACTURING PROCESSES (NME-101/201)NOCopyright 2013byJeetenderSingh KushawahaNorights of thiscollectionmay be reproduced or transmittedin any formorby any means without written permissionfromthe in India by Jeetender Singh Kushawaha and can be printed by PROCESSES (NME-101/201). Please submit your suggestions and detected errors toJeetender Singh 07 July2013 DedicatedtoBasicManufacturing PROCESSES (NME-101/201). Please submit your suggestions and detected errors toJeetender Singh 07 July2013 PrefaceThis collection is an effort in the direction to helpand support the students of UPTU to have verygood understanding of the BASIC MANUFACTURING PROCESSES as per the new syllabus and to pass theexamination with very important feature of this collection is that the questions asked in previous examinations havebeen included as they were asked in the question papers.

2 Thisshall help students to know thepattern of questions before hand. The answers have beenarranged and elaborated in such a waythatall the related aspects of the topic are covered together, without leaving any the criticism and suggestions are welcome and also requested to improve the collection forfulfilling the objective so that students are able to pass with verygoodmarks. Your contributionsshall be appreciated in future is of utmost importance that I must acknowledge and accept that lot of illustrative material hasbeen procured from works of various authors and web sites. I am obliged to all such sources fromwhere the contents have been collected yet it is not possible for me to acknowledge Singh KushawahaMobilePhone: PROCESSES (NME-101/201).

3 Please submit your suggestions and detected errors toJeetender Singh 07 July2013 NEWSYLLABUS[Effective from Session 2013-14] (1stYear)Further reading and reference booksin addition toprescribedreference books(1)Materials and MANUFACTURING PROCESSES by E Paul DeGarmo, JT Black, Ronald A Kohser(2)Workshop technology by SK Garg(3) MANUFACTURING PROCESSES by V Narula(4) MANUFACTURING PROCESSES byBS RaghuvanshiNME-101/201: BASIC MANUFACTURING PROCESSESUnit-I Engineering MaterialsL T P [2 0 0]Materials and Civilization,Materials and Engineering, Classification of Engineering of common engineering materials and their socio economic & Alloys: Properties and ApplicationsMechanical Properties of Materials:Strength, elasticity, plasticity, stiffness, malleability, ductility, brittleness,malleability, toughness, hardness, resilience, hardness, machine ability, formability, weld ability.

4 Elementaryideas of fracture fatigue & and CastIrons:Carbon steels, their classification based on percentage of carbon as low, mild, medium& high carbon steel, their properties & applications. Wrought steels: stainless steel, tool Treatment PROCESSES : Introductionto Heat-treatment of carbon steels: annealing, normalizing, quenching,tempering and of Non Ferrous metals:Common uses of various non-ferrous metals (Copper, Zink, Tin, Magnesium,Lead, Aluminum etc.) & alloys and its composition such as Cu-alloys: Brass, Bronze, BASIC Metal Forming & Casting PROCESSES : BASIC metal forming operations & uses of such as: Forging, Rolling, Wire&Tubedrawing/making and Extrusion, and their : Die & Punch assembly, cutting and forming,its versus :Pattern: Materials, types and allowances.

5 Type and composition of Molding sands and theirdesirableproperties. Mould making with the use of a core. Gating defects & and its Machining and Welding operations and their applicationsMachining: BASIC principles of Lathe-machine and operations performed on it. BASIC description ofmachinesand operations of Shaper-Planer, Drilling, Milling & :Introduction, classification of welding PROCESSES . Gas-welding, types of flames and welding. Soldering &Brazing PROCESSES and their Misc. TopicsQuality:Introduction, BASIC concept about quality of a Establishment: Plant layout its of Materials:Common types & uses of Wood, Cement-concrete, Ceramics, Rubber, PROCESSES :Powder-metallurgy process & its applications, Plastic-products MANUFACTURING , Books:1.

6 PROCESSES and Materials of Manufacture , Lindberg, PHI2. MANUFACTURING Engineering And Technology , Kalpakjian and Schmid, Pearson3. MANUFACTURING PROCESSES , Kalpakjian and Schmid, Pearson4. MANUFACTURING PROCESSES , H. N .Gupta, R. C. Gupta, ArunMital, New AgeBasicManufacturing PROCESSES (NME-101/201). Please submit your suggestions and detected errors toJeetender Singh 07 July2013 UNIT-IMaterials:Material is any matter from which a thing is or can be made. It can be constituted of oneor more substances. Wood, cement, hydrogen, air, water and any othermatter are all examplesof materials. Sometimes the term "material" is used more narrowly to refer to substances orcomponents with certain physical properties that are used as inputs to production ormanufacturing.

7 In this sense, materials are the parts required to make something else, frombuildings,parts,to airplanes and :Discuss the importance of Materials on us makea general survey of the development of history of human society. Thedevelopmentandapplication of materialsisalways the milestone for the civilization andeconomicprogress. The introduction and application of a new type of materials has alwayscaused theimportant change for human societyand reason is obvioussince everything is either made ordepends on materials. Not tomention the food eaten, clothes worn, things utilized, all of thedevices, all of the tools, andvarious weapons which all cannot be manufactured withoutmaterials.

8 Even the so-called spiritualfood such as books, films, radio, television, internet,etc also cannot work without materials, butmust rely on are the bases of allthings including people s life, human progress and thebasiccivilizationof human of the typical materials to designate the stages of thecivilizationof humansociety just reflects the BASIC role of materials in the process of development forhumansociety, because any name of devices, articles and things, or some kind of abstractnamecannot replaceit. We know that a lot of great devices, buildings and other things werecreatedby our human, such as The Great Wall, The Pyramids, various skyscrapers, variousgreatbridges, automobiles, trains, planes, spacecrafts, satellites, internet etc.

9 They are allimportantsymbols for the civilization of human society, and we are proud of them. However,whocan imagine that such great things can be created without materials? Or from the otherpoint ofview, can we have The Great Wall Age, The Pyramid Age, or automobile, train andplane age? Ofcourse, we cannot do so though sometime some people havereferred to theworld as to theautomobile age or plane civilizationof human societymay be classified asshown below:BasicManufacturing PROCESSES (NME-101/201). Please submit your suggestions and detected errors toJeetender Singh 07 July2013 Materials and engineering:Thecreative application of scientific principles to design or develop structures, machines,apparatus, or MANUFACTURING PROCESSES , or works utilizing them singly or in combination; or toconstruct or operate the same with full cognizance(awareness)of theirdesign; or to forecasttheir behavior under specific operating conditions.

10 Inall respectsofan intended function,economics of operation or safety to life and relating the materials with the engineering we can say that materials engineeringisthe designing or engineering the structure of a material to produce the predetermined set ofproperties in the of engineering the engineering the different types of plain carbon steelswith theirproperties and , SEM-I, Spl-CarryThe engineering materials are those materials which are used for engineering and structuralpurpose, such as to make bridge, road, machine, building, etc. these can be classified as:Industrial application of engineering MaterialApplication1 MetalsSteelUsed for making of buildings, automobiles, trains, machineand their for making of ornaments, computers, in the making of pipelines, cable insulations, , windows, bridges, oxideUsed in the grinding wheels, abrasivesSilicon carbideUsed in the cutting in the making of bulletproof for aerospace and sports , Bio-Materials, SmartMaterials, Shapememory alloyUsed in the making of electronic equipments,Used in the replacement of damaged body parts,Used in the sensors and and alloysFerrous Metals(containing Iron asbase material)Non-Ferrous Metals(Not having Iron asbase material)BasicManufacturing PROCESSES (NME-101/201).