COURSES

BS course

UMT310: Introduction to Materials Manufacturing (Jan) 

Contents:

• Introduction to Casting Processes: Casting terminologies, type of patterns, pattern allowances, elements of gating design, choke area, gating ratio, type of risers and its design aspects, different type of castings, casting defects and remedies, mechanism of solidification.

• Introduction to Welding Processes: Welding terminologies, type of joints, classification of welding process, insight of weld metallurgy; weld mechanics, weld & HAZ microstructure, effect of process parameters on weld quality in welding processes, welding defects and remedies.

• Introduction to Powder Metallurgy Processes: Powder metallurgy process and its application, powder preparation, mechanics of solid-state sintering, hot isostatic pressing, injection moulding, powder forging, rolling and extrusion of metal/ceramic powders.

• Introduction to Metal Forming Processes: Fundamentals of metal forming, forging, rolling, extrusion, wire and tube drawing, hot and cold working, rolls and roll pass Design, Extrusion Processes, Extrusion Defects, Experimental methods to assess formability of sheet materials, Defects in sheet metal forming.

Reference books:

1. Rao, P.N., Manufacturing Technology Volume 1 (Foundry, Forming and Welding), McGraw Hill Education (India) Pvt. Ltd.

2. Rao, P.N., Manufacturing Technology Volume 2 (Metal Cutting and Machine Tools), McGraw Hill Education (India) Pvt. Ltd.

3. Ghosh, A., Malik, A.K., Manufacturing Science, East-West Press Pvt. Ltd. 

4. Khanna, O.P., Foundry Technology, Dhanpat Rai Publications.

5. Dieter, G.E., Mechanical Metallurgy, McGraw Hill Book Company.

Masters/PhD course

MT309: Introduction to Manufacturing Science (Jan) 

Contents:

• Introduction to Casting Processes: Mechanism of solidification, gravity die casting; pressure assisted casting processes: pressure die casting, squeeze casting etc.; compocasting; semi-solid casting processes: rheocasting, thixocasting, rheo and thixo-moulding etc.; centrifugal casting; vacuum assisted casting.

• Introduction to Welding Processes: Insight of weld metallurgy; weld mechanics, filler and base material interaction; quality control of weld; weld & HAZ microstructure; effects of process parameters on weld quality in welding processes.

• Introduction to Powder Metallurgy Processes: Insight of powder processing; powder preparation, mechanics of solid state sintering, hot isostatic pressing, injection moulding, powder forging, rolling and extrusion of metal/ceramic powders, quality control of PM parts, processing-microstructure correlation of PM parts.

• Introduction to Metal Forming Processes: Mechanics of metal working, friction, temperature and strain rate effects, processing maps. forging, rolling, extrusion, wire and tube drawing, hot and cold working, rolls and roll pass design, extrusion processes, extrusion defects, experimental methods to assess formability of sheet materials, defects in sheet metal forming.

Reference books:

1. Rao, P.N., Manufacturing Technology Volume 1 (Foundry, Forming and Welding), McGraw Hill Education (India) Pvt. Ltd.

2. Rao, P.N., Manufacturing Technology Volume 2 (Metal Cutting and Machine Tools), McGraw Hill Education (India) Pvt. Ltd.

3. Ghosh, A., Malik, A.K., Manufacturing Science, East-West Press Pvt. Ltd. 

4. Khanna, O.P., Foundry Technology, Dhanpat Rai Publications.

5. Dieter, G.E., Mechanical Metallurgy, McGraw Hill Book Company.

MT 310 : Manufacturing Process Modelling  (Jan) 

Contents:

Introduction to numerical methods (working principle, merits-demerits and applications): FDM, FVM, BEM, FEM, Die filling analysis (nature of flow, back pressure, porosity, air entrapment), Solidification (behavior and filling time), Transport phenomena during solidification: governing equations, phase change, Finite Volume based multiphase and multiscale model of solidification, Initial and boundary conditions, Phase field model of solidification microstructure formation and defect generation, Analytical method and Boundary Element Method to solve the heat conduction equation applied to welding processes, Finite Volume/ Finite Element based multiphase flow model of melt pool transport phenomena and solidification in fusion welding process, Thermo mechanical modeling of the residual stress in welding, Transport phenomena involved in Metal/Ceramic Injection Moulding processes: estimation of filling and cooling time, injection pressure, defect visualization etc., Finite element based continuum model of sintering densification and mechanical behaviour, Molecular dynamics based model of neck growth, microstructure evolution, Finite volume method for modeling additive manufacturing: - melting/ solidification and mass-transfer, Microstructure modelling of multi-layer and multi-track additive manufacturing processes, Forming limit diagrams, FE analysis of deformation behaviour of metals, Finite Element Analysis (FEA) for Metal Forming Processes (forging, rolling, drawing and shearing) and its comparison with the analytical techniques, Analytical and FE modelling of orthogonal machining, FE modelling of chip formation and prediction of cutting forces/machinability of Light alloys and composites 

Reference books:

1. Anderson J.D., Computational Fluid Dynamics: The Basics with Applications.

2. Goldak, J. A., Akhlaghi, M. Computational welding mechanics. Germany: Springer.

3. Jones W.D., Fundamentals of Powder Metallurgy.

4. Kalpakjian S. and Schmid S., Manufacturing Engineering and Technology.

5. Hosford W. F. and Caddell R. M., Metal Forming: Mechanics and Metallurgy.

Contents:

Module 1:: Introduction to manufacturing science and different processes, Introduction to numerical methods (working principle, merits-demerits and applications): FDM, FVM, BEM, FEM.

Module 2: Introduction to casting process, casting terminologies, pattern, gate, and riser design principles.

Module 3: Die filling analysis (nature of flow, back pressure, porosity, air entrapment), Solidification (behavior and filling time). Solidification of metals and alloys: principles, control of grain structure, effect of cooling rate on microstructure and properties.

Module 4: Transport phenomena during solidification: governing equations, phase change, Finite Volume based multiphase and multiscale model of solidification, Initial and boundary conditions, Phase field model of solidification microstructure formation and defect generation.

Module 5: Introduction to welding, welding terminologies, types of joints, classification of welding process, insight of weld metallurgy, weld mechanics, welding defects and their remedies.

Module 6: Analytical method and Boundary Element Method to solve the heat conduction equation applied to welding processes, Finite Volume/ Finite Element based multiphase flow model of melt pool transport phenomena and solidification in fusion welding process, Thermo mechanical modeling of the residual stress in welding.

Module 7: Introduction to powder metallurgy process and its application, powder preparation, mechanics of solid-state sintering, Hot isostatic pressing, injection moulding, powder forging, rolling and extrusion of metal/ceramic powders. 

Module 8: Transport phenomena involved in Metal/Ceramic Injection Moulding processes: estimation of filling and cooling time, injection pressure, defect visualization etc., Finite element based continuum model of sintering densification and mechanical behaviour, Molecular dynamics based model of neck growth, microstructure evolution. 

Module 9: Introduction to additive manufacturing processes, finite volume method for modeling additive manufacturing: - melting/ solidification and mass-transfer, Microstructure modelling of multi-layer and multi-track additive manufacturing processes. 

Module 10: Introduction to metal forming, forging, rolling, extrusion, wire and tube drawing, hot and cold working, Different analysis techniques of metal forming processes: slab analysis of rolling process, slip line analysis of punching, experimental methods to assess formability of sheet materials.

Module 11: Forming limit diagrams, FE analysis of deformation behaviour of metals, Finite Element Analysis (FEA) for Metal Forming Processes (forging, rolling, drawing and shearing) and its comparison with the analytical techniques.

Module 12: Introduction to machining processes, analytical and FE modelling of orthogonal machining, FE modelling of chip formation and prediction of cutting forces/machinability of Light alloys and composites 

Reference books:​

1. Rao, P.N., Manufacturing Technology Volume 1 (Foundry, Forming and Welding), McGraw Hill Education (India) Pvt. Ltd.​

2. Rao, P.N., Manufacturing Technology Volume 2 (Metal Cutting and Machine Tools), McGraw Hill Education (India) Pvt. Ltd.​

3. Ghosh, A., Malik, A.K., Manufacturing Science, East-West Press Pvt. Ltd. ​

4. Kou S., Welding metallurgy.​

5. Khanna, O.P., Foundry Technology, Dhanpat Rai Publications.​

6. Dieter, G.E., Mechanical Metallurgy, McGraw Hill Book Company.​

7. German. R.M., Powder Metallurgy Science.​

8. Thuummler F. and Oberacker R., Introduction to Powder Metallurgy Science.​

9. Reddy, J. N., An Introduction to the Finite Element Method, McGraw Hill Education India.​

10. Versteeg H. K. and Malalasekera W., An Introduction to Computational Fluid Dynamics: The Finite Volume Method.

Short term courses