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    Fundamentals of Manufacturing Materials, Processes & Systems

    Posted By: BlackDove
    Fundamentals of Manufacturing Materials, Processes & Systems

    Fundamentals of Manufacturing Materials, Processes & Systems
    Genre: eLearning | MP4 | Video: h264, 1280x720 | Audio: AAC, 44.1 KHz
    Language: English | Size: 7.21 GB | Duration: 17h 58m


    18 Hours Course to Understand the Industrial Manufacturing Processes for Plastics and Metals and Joining of Metals 2022

    What you'll learn
    Discuss in detail the manufacturing processes of metallic and plastic parts.
    Compare between different types of metal forming processes and differentiate between their output product.
    Describe different types of joining process and introduce the concept of sustainable manufacturing.
    Recognize, understand and develop working knowledge of broad range of manufacturing processes that are used in the industry.
    To compare the existing technologies used in casting, shaping, forming, property enhancing, joining and assembly process.
    To learn how component can be manufactured in sustainable manner and learn about the environmental hazards of different manufacturing processes.
    Apply appropriate manufacturing processes for a product and determine its parameters.
    Analyze process dynamics and performance of different manufacturing processes.

    Description
    This course provides an introduction to the manufacturing processes that are used in industry to manufacture products that are widely used in daily life.

    Introduction to Manufacturing: Types of manufacturing industries, materials used in manufacturing and properties of materials, different processing operation.

    Sand Casting

    Introduction: Sand casting, molding, heating, pouring, solidification, and cooling. Pattern: making, material, types, construction, pattern allowances.

    Core: making, types, sand conditioning, testing of the sand, molding process, tools and equipment, molding machines, different types of casting, cleaning and finishing of castings, an inspection of castings.

    Permanent Mold Casting (PMC): Introduction, types of PMC, gravity die casting, and its types. Pressure die casting, Centrifugal casting, and their types. Furnaces used in PMC.

    Metal Forming
    Fundamentals, Types, hot, warm, and cold working.
    Bulk Deformation Processes

    Rolling; rolled products, rolling types: flat, shape, thread, gear, ring rolling, and rolling mill configurations.

    Forging; open die, impression die, press, upset, roll, net shape, isothermal forging and swaging.

    Extrusion; solid & hollow shapes, direct & indirect, hot & cold, continuous & discrete, impact extrusion, hydrostatic.

    Drawing; bar, wire, tube drawing and its types tike tube sinking, fixed mandrel, floating plug.
    Other metal forming processes; roll extrusion, riveting, staking, peening, coining, hubbing, burnishing.

    Sheet metal forming processes: Shearing operations: slitting, blanking, piercing, cutoff, parting, dinking, slotting, perforating, notching, semi-notching, lancing, nibbling, trimming, shaving, fine blanking. Bending operations: V bending, edge bending, flanging, curling, hemming, seaming. Drawing operations like deep and shallow drawing, embossing.

    Welding Processes: Classification, Fusion welding and its types such as oxyfuel gas welding and oxygen torch cutting, arc welding (shielded metal, flux-cored, gas metal, submerged, gas tungsten, plasma, stud welding, Arc cutting), resistance welding (spot, seam and projection. Heating, pressure, current control and power supply for resistance welding).
    Solid-state welding and its types include diffusion welding, friction welding, and ultrasonic welding.

    Other welding processes: Forge, Roll, Friction, Explosion, Thermic, Electron beam, Laser welding and cutting, Brazing and Soldering.

    Fabrication of Plastics: Casting, Blow molding and its types, Compression molding, Transfer molding, Cold molding, Injection molding: Injection molding machine, mold design, and construction, types of mold, cooling and ejection of mold, Reaction injection molding, Welding of plastics.

    In the end, there are videos that are videos related to the course for better understanding.

    Course Outline

    Introduction to Manufacturing

    Lecture 1

    Introduction to Manufacturing Processes

    What is manufacturing

    Manufacturing Industries

    Manufacturing Products

    Production Quantity and Product variety

    Materials in Manufacturing

    Manufacturing Processes (Processing operations and Assembly operations)

    Sand Casting

    Lecture 2

    Overview of casting technologies

    Difference between casting and molding

    Advantages and Disadvantages of casting processes

    Casting Processes (Expendable mold casting and permanent mold casting)

    Lecture 3

    Sand casting and Engineering analysis of sand casting y sand

    Pouring and Engineering Analysis of Pouring

    Flow rate and time required to fill the mold

    Fluidity

    Solidification and Cooling

    Lecture 4

    Solidification of pure metals and alloys (Alloys and Eutectic Alloys)

    Solidification time and Shrinkage

    Directional Solidification

    Lecture 5

    Riser Design with Exercise Problems.

    Lecture 6

    Pattern for casting

    Materials used for pattern

    Types of pattern

    Mold making and Classification of sand molds

    What is foundry sand?

    Lecture 7

    Buoyancy Force

    Metal casting processes

    Shell molding

    Advantages and Disadvantages of Shell molding

    Vacuum molding

    Advantages and Disadvantages of Vacuum molding

    Expanded Polystyrene Casting

    Advantages and Disadvantages of Expanded Polystyrene Casting

    Investment casting

    Plaster and Ceramic Mold casting

    Permanent Mold Casting (PMC)

    Lecture 8

    Types of pattern allowance (Shrinkage and contraction allowance, Draft allowance, Machining allowance, and Distortion allowance)

    Permanent mold casting and its Applications.

    Slush casting

    Low-pressure casting

    Vacuum permanent mold casting

    Die casting (Hot and cold chamber die casting)

    Advantages and Limitations

    Centrifugal casting and Semi centrifugal casting

    Lecture 9

    Furnaces

    Cupolas Furnace

    Direct Fuel Fired Furnace

    Crucible Furnace

    Electric Arc Furnace

    Induction Furnace

    Metal Forming

    Lecture 10

    Fundamentals of metal forming

    Types of deformation processes of metal

    Bulk deformation (Rolling, Forging, Extrusion, Wire Drawing)

    Sheet metal working

    Stress-Strain Curve

    Derivation of the relation between stress and strain

    Flow stress and Average flow stress

    The temperature in metal forming (Cold working and Hot-working)

    Recrystallization

    Iso thermal forming (recovery and Grain growth)

    Strain rate Sensitivity

    Lecture 11

    Introduction of rolling

    Shapes used for rolling

    Types of rolling

    Working of the rolling process

    Analysis of the rolling

    Rolling mills

    No-Slip Point for rolling

    Flatness control and rolling defect

    Lecture 12

    Numerical Problems related to the rolling process

    Lecture 13

    Introduction to forging

    Classification of forging

    Types of forging

    Analysis of the forging

    Barreling effect in forging

    Open Die forging and its practices

    Impression Die forging and its practices

    Advantages and Limitations of Impression Die forging

    Fleshless forging

    Forging Press and Forging Hammers

    Lecture 14

    Numerical Problems related to the forging process

    Lecture 15

    Introduction to the extrusion process

    Classification of extrusion

    Direct and Indirect extrusion

    Hot and Cold extrusion

    Direct and Continuous extrusion

    Analysis of the extrusion process

    Effect of friction on extrusion

    Extrusion Dies and Orifice

    Extrusion press and other extrusion processes

    Lecture 16

    Numerical Problems related to the extrusion process

    Introduction to Drawing

    Difference between drawing and wire drawing

    Bar Drawing

    Wire Drawing

    Features of Draw Die

    Preparation of the work

    Analysis of the drawing process

    Sheet metal forming processes

    Lecture 17

    Introduction to sheet metal cutting process

    Characteristics of Edges

    Types of sheet metal cutting

    Shearing

    Blanking and Punching

    Clearance in Sheet metal cutting

    Analysis of sheet metal cutting processes

    Numerical Problems related to the sheet metal cutting process

    Lecture 18

    Introduction of sheet metal bending process

    Types of sheet metal bending

    Analysis of the sheet metal bending process

    Numerical Problems related to the sheet metal bending process

    Spring Back

    Lecture 19

    Introduction to the drawing process

    Mechanics of drawing

    Stages of deformation

    Analysis of the drawing process

    Tests of Drawing Feasibility

    Blank force and blank size determination

    Numerical Problems related to the drawing process

    Lecture 20

    Other drawing processes (Redrawing, Reverse Drawing and Drawing without Blank holder)

    Defects in Drawing

    The operation performed with metal tooling

    Ironing

    Coining & Embossing

    Lancing & Twisting

    The operation performed with flexible Rubber tooling

    Guerin and Hydro forming process

    Lecture 21

    Numerical Problems related to the other drawing processes

    Welding Processes

    Lecture 22

    Fundamentals of welding

    Difference between joining and welding

    Advantages and Disadvantages of Welding

    History of welding

    Types of the welding process

    Components used for welding process (Filler material, Flux, and Electrolyte)

    Consumable and Non-consumable electrolyte

    Welding positions

    Welding Electrode Nomenclature

    Type of Weld Joints (Butt joint, Corner Joint, Lap joint, Tee Joint, Edge Joint)

    Types of Weld (Filler Weld, Groove Weld, Plug weld or slot weld, Spot and Seam weld, Flange and Surface Weld)

    Features of Fusion Welded Joints

    Physics of welding (Power Density and Numerical of Power Density)

    Heat Balance in Fusion Welding

    Welding as Commercial Operation

    Automation in Welding (Machine, Automatic and Robotic)

    Welding Safety

    Lecture 23

    Welding Categories (Fusion Welding, Solid State Welding, Soldering and Brazing)

    Arc Welding

    Arc Shielding

    The power source in Arc welding

    Types of Arc Welding (Shielding metal arc welding, Gas Metal Arc Welding, Flux Cored Arc Welding, Submerged Arc Welding,

    Gas Tungsten welding

    Plasma arc welding

    Lecture 24

    Oxyfuel arc welding

    Oxyacetylene welding

    Resistance welding

    Spot Welding

    Resistance seam welding

    Resistance projection welding

    Energy beam welding (Electron beam welding, Laser beam welding)

    Numerical Problems related to the welding processes

    Lecture 25

    Numerical Problems Related to the welding processes

    Lecture 26

    Solid-state welding

    Types of solid-state welding

    (Diffusion welding, Friction welding, and Ultrasonic welding)

    Welding Defects of Solid State Welding

    Brazing and Soldering

    Fabrication of Plastics

    Lecture 27

    Plastics

    Type of Plastics

    Properties of polymer melt (Viscosity and Viscoelasticity)

    Extrusion process for Plastics in detail

    Extruder Screw

    Feed Section

    Compression Section

    Metering Section

    Process Parameters

    Solid and Hollow Profiles

    Wire and Tube coating

    Defects in the extrusion process

    Lecture 28

    Injection molding for Plastics in detail

    Clamping

    Injection

    Cooling

    Ejection

    Application and Material

    Advantages and Disadvantages

    Lecture 29

    Blow Molding

    Extrusion Blow Molding

    Injection Blow Molding

    Stretched Blow Molding

    Compression Molding

    Transfer Molding (A pot transfer molding and B plunger-type transfer molding)

    OZIS Academy is the best platform for struggling students and professionals who want to improve their skills for the workfield as it provides a large no of quality and detailed courses. We offer courses from brilliant Ph.D. Professors from prestigious Universities who are experts in their relative fields. We have a team of well-experienced, full-time faculty and dedicated staff including talented retired and working University professors. Our mission is to impart most qualitative education by the way of systematic methodical and scientific approaches.

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    Who this course is for
    ll concepts are introduced slowly and gradually, but comfort with thinking analytically will be helpful.
    Engineering students and professionals who want to level up their skills.
    Engineers in Mechanical, Manufacturing, Industrial, Electrical and other related fields looking for a way out of traditional processes for their projects and products.
    Anyone starting their career in the manufacturing and production world.