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ME 230
Mechanical Processing of Materials Outline

 About the course

Introduction  What is Manufacturing - Overview
 Challenges in Product Development
Prof. S. S. Pande  Manufacturing Automation - Approaches

Mechanical Engineering Department  Digital Product Development

Indian Institute of technology Bombay

Course Plan Course Plan

Scheme of Assessment
Syllabus
• Overview of Manufacturing Processes • Mid semester Exam and Tests : 45 marks
• Materials and their behavior under load • Project Assignments : 15 marks
• Fundamental of Deformation Theory • End-semester Exam : 40 marks
• Analysis of Bulk Deformation Metal Forming Processes
• Rolling, Forging, Extrusion and Wire Drawing
Text and Reference Books.
• Sheet Metal forming – Processes and tools
• Basics of Machining, Orthogonal and Oblique machining • Fundamentals of Machining and Machine Tools, G. Boothroyd and W.A.
• Mechanics of Machining- Knight. 2nd edition, Marcel Dekker, Inc., 1989.
• Merchant’s analysis - Cutting Force, Power, Energy
• Tool Temperatures, Tool wear, Taylor’s Tool Life Equation • Manufacturing Science, A. Ghosh and A. Mallick, East West, 2010
• Optimization of machining processes- Productivity , Cost • Manufacturing Processes for Engineering Materials, S. Kalpakjian and
• Non-conventional machining Processes- USN,AJM,WJT S. R. Schmid, 4th edition; Prentice Hall, 2003
• Simulation of Manufacturing processes
• Lorraine F. Francis, Materials Processing, Academic Press, 2016
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What is Manufacturing ? Industrial Revolutions

Process of converting Materials into Functional products From Artisanship to World class Manufacturing

Materials Functional Products Period Production Techniques

Wood Aerospace 18 th Century Manual, One off, Prototype

Rubber, Plastic, Glass Automobiles
Metals – Ferrous, Non ferrous Ships 19th Century Workshops, Machine Tools
Special Hard , Resistant alloys Domestic goods
Composite materials Electronic products
20th Century Automation, Transfer Lines,
Semiconductor materials Health care
CAD/CAM, CNC

21 st Century Intelligent Manufacturing,

Cyber-Physical, Industry
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Product Development Cycle Manufacturing Objectives

• To improve Productivity, Product Quality and

Reliability
Design Analysis • To reduce Product Cost and Time to market
• To reduce manual effort (drudgery), Operator fatigue
Approach
Marketing Planning
• Reduce Product Development Cycle Time
• Manufacturing Automation
Assembly Production

Challenges in Product Development Manufacturing Automation

Hard Automation
 Shorter Product Life Cycles
 Frequent Design Revisions • Process Layout vs Transfer Lines

 Need for high Product Quality, Productivity and Soft Automation

Low product cost
• Computer Numerical Control (CNC )
 Miniaturization – High Precision
• Flexible Manufacturing Cell / System
 Shortest Time to Market • Computer Integrated Manufacturing system (CIM)
 Distributed Global Product Development • Intelligent Manufacturing systems – Industry 4.0

Transfer Line

Mechanical Concept introduced by Henry Ford

• Cams, Templates, Mechanisms • Processing Units arranged Sequentially as per the

Process Route
Hydraulic/Pneumatic • Process Times are Balanced and Optimized
• No waiting of In-Process Inventory of parts
• Valves, Actuators, Tracer Templates • High Productivity

Electric
Suitable for Large Volume Standard Part Production
• Relays, Plugboard controlled Logic circuits • Automobile, Consumer part, Electrical / Electronics

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Digital Product Development Activities

Transfer Line Layout
 Conceptual Design
C
 Detailed Design A
 Engineering Analysis D
 Modeling/ Drafting C
I
 Production Planning
M
C
 Factory Automation
A
 Assembly, Testing
M
 Business Data
Management
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CIM Wheel
Digital Product Development
Marketing Product
Design

Advantages
Purchase Analysis

 Seamless Integration of Product Cycle Functions

Business Design

Finance
CIM
Simulation
 Quick Turn-around for Product change
Manufacturing  High Product Quality and Productivity
Information
Management
Manufacturing
Planning
 Global Product Development
Factory Production  Internet based distributed Virtual Team
Automation Control

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Integrated Manufacturing System

Integrated Manufacturing System