Fundamentals of Manufacturing Materials, Processes & Systems
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.
- The only requirement for this course is your interest to learn the manufacturing process.
CMfgE ( Certified Manufacturing Engineer) is an advanced credential for experienced manufacturing engineers. CMfgEs demonstrate knowledge in such areas as mathematics and engineering sciences and materials, manufacturing processes, design and development, quality control, and management.
This course covers the topics of engineering sciences and materials, manufacturing processes, design and development, and quality control of materials in manufacturing that are required for passing the certification Exam of CMfgE.
The course is also enough for Engineering Students who want to cover these topics for their studies or want to revise the topics for their Interviews.
Introduction to Manufacturing: Types of manufacturing industries, materials used in manufacturing and properties of materials, different processing operation.
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.
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 IN DETAILS
INTRODUCTION TO MANUFACTURING PROCESSES:
Introduction to Manufacturing Processes
What is manufacturing
Production Quantity and Product variety
Materials in Manufacturing
Manufacturing Processes (Processing operations and Assembly operations)
Overview of casting technologies
Difference between casting and molding
Advantages and Disadvantages of casting processes
Casting Processes (Expendable mold casting and permanent mold casting)
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
Solidification and Cooling
Solidification of pure metals and alloys (Alloys and Eutectic Alloys)
Solidification time and Shrinkage
Riser Design with Exercise Problems.
Pattern for casting
Materials used for pattern
Types of pattern
Mold making and Classification of sand molds
What is foundry sand?
Metal casting processes
Advantages and Disadvantages of Shell molding
Advantages and Disadvantages of Vacuum molding
Expanded Polystyrene Casting
Advantages and Disadvantages of Expanded Polystyrene Casting
Plaster and Ceramic Mold casting
PERMANENT MOLD CASTING (PMC):
Types of pattern allowance (Shrinkage and contraction allowance, Draft allowance, Machining allowance, and Distortion allowance)
Permanent mold casting and its Applications.
Vacuum permanent mold casting
Die casting (Hot and cold chamber die casting)
Advantages and Limitations
Centrifugal casting and Semi centrifugal casting
Direct Fuel Fired Furnace
Electric Arc Furnace
METAL FORMING PROCESSES:
Fundamentals of metal forming
Types of deformation processes of metal
Bulk deformation (Rolling, Forging, Extrusion, Wire Drawing)
Sheet metal working
Derivation of the relation between stress and strain
Flow stress and Average flow stress
The temperature in metal forming (Cold working and Hot-working)
Iso thermal forming (recovery and Grain growth)
Strain rate Sensitivity
Introduction of rolling
Shapes used for rolling
Types of rolling
Working on the rolling process
Analysis of the rolling
No-Slip Point for rolling
Flatness control and rolling defect
Numerical Problems related to the rolling process
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
Forging Press and Forging Hammers
Numerical Problems related to the forging process
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
Numerical Problems related to the extrusion process
Introduction to Drawing
Difference between drawing and wire drawing
Features of Draw Die
Preparation of the work
Analysis of the drawing process
SHEET METAL FORMING PROCESSES:
Introduction to sheet metal cutting process
Characteristics of Edges
Types of sheet metal cutting
Blanking and Punching
Clearance in Sheet metal cutting
Analysis of sheet metal cutting processes
Numerical Problems related to the sheet metal cutting process
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
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
Other drawing processes (Redrawing, Reverse Drawing and Drawing without Blank holder)
Defects in Drawing
The operation performed with metal tooling
Coining & Embossing
Lancing & Twisting
The operation performed with flexible Rubber tooling
Guerin and Hydroforming process
Numerical Problems related to the other drawing processes
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 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 Categories (Fusion Welding, Solid State Welding, Soldering and Brazing)
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
Oxyfuel arc welding
Resistance seam welding
Resistance projection welding
Energy beam welding (Electron beam welding, Laser beam welding)
Numerical Problems related to the welding processes
Numerical Problems Related to the welding processes
Types of solid-state welding
(Diffusion welding, Friction welding, and Ultrasonic welding)
Welding Defects of Solid State Welding
Brazing and Soldering
FABRICATION OF PLASTICS:
Type of Plastics
Properties of polymer melt (Viscosity and Viscoelasticity)
Extrusion process for Plastics in detail
Solid and Hollow Profiles
Wire and Tube coating
Defects in the extrusion process
Injection molding for Plastics in detail
Application and Material
Advantages and Disadvantages
Extrusion Blow Molding
Injection Blow Molding
Stretched Blow Molding
Transfer Molding (A pot transfer molding and B plunger-type transfer molding)
Our team worked very hard on this course hope you get the desired knowledge that you are expecting.
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.
OZIS Academy is the platform for struggling university or high school students and professionals who want to improve their skills in the work field as we provide 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 the most qualitative education by the way of systematic methodical and scientific approaches.