TA202A

Manufacturing Processes II

Overview of the plan for the course

Mohit Law
Mechanical Engineering
mlaw@iitk.ac.in

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TA202A - Manufacturing Processes II

• This course is not about primary manufacturing processes, but secondary

– that is why the course is titled: ‘Manufacturing Processes II’

• Primary manufacturing processes include processes like casting, forging,

forming, joining, etc. These are covered in ‘TA201A:Manufacturing
Processes I’

• In this course, we will only deal with machining – which is a secondary

manufacturing process. We will also discuss machines used for machining.

• The main aim of the course is learning through hands-on-experience of

manufacturing a product – project work!

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What is the objective of the course?

• To celebrate manufacturing

• To learn through making – lab component

• To introduce concepts and working principles of machines that will be

used to make things – class and lab component

• Developing a bottom-up thinking approach to engineering

• To appreciate how manufacturing adds value to material

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UGARC student survey suggests …

“… something like TA202a, which, face it, lost

it’s relevance 30 years back.”

“Theory exam essentially boils down to rote

learning …”

“The theory section of the TA 201 and 202

courses seems irrelevant …”

“Requires CAD knowledge, which is never

explicitly taught to students …”

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I almost feel like …

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New things that were introduced last semester

• Weightage of lab was 75%, and 25% for exams

• Class was designed to supplement labs and to relate theory with practice

• Restructured lab exercises

– Labs on CAD and CAM

– 3D printing

– Arduino board based motor programming

– Use of printed parts and programmable motors in all projects

– Use of a CNC machined part

– Groups were formed randomly

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Selective feedback from last semester

“I am doing this course for the 3rd time and this is the only time I
was able to relate practical with theory. Also, as this course
requires more physical labor, I was able to work in the lab with
enthusiasm as it carries more percentage this time …”

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Example of a project idea: wire bending machine

https://www.youtube.com/watch?v=HPQbKTJPsU4&t=21s
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What your colleagues made last semester

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Project examples: mini conveyor

https://www.youtube.com/watch?time_continue=1&v=GHWAhXgC2Zs

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What your colleagues made last semester

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Excellent resources for project ideas

• https://howtomechatronics.com/

• https://nevonprojects.com/mechanical-engineering-projects/

• Your guides

• The world around you

Project ideas can include solutions for: agriculture, food processing,

health care, energy, machines, mechanisms, toys, and whatever else
catches your fancy

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Class and lab schedule

• Class: 8 am on Tuesdays in L20, or maybe L7

• Labs: 2 – 5 pm, Monday – Friday in the TA202A labs near Gate 4

Attendance policy

• Attendance is mandatory for laboratory sessions, and highly

encouraged for class.

• If you do decide to grace the classroom, please come on time.

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Structure of the course (indicative only)
Lecture Contents Lab Activity
1 Overview 1 Intro. to machines (turning +
2 Why mfg. matters? drilling/fitting exercise)

3-4 Mechanisms 2 Intro. to machines (turning +

drilling/fitting exercise)
4-5 Sizing projects and motors
3 Assemble + Disassemble 3D printers.
6 Machines and machining processes Assign groups & guides
7-9 CNC machines + NC programming 4 CAD exercise + project discussions
9 - 11 Mechanics of machining 5 CAM exercise + Arduino exercise +
12 Non-traditional machining project discussions
13 Additive manufacturing 6 Submission of project files
6 - 12 Project work
13 Evaluation
Reference texts:
1. Manufacturing Engineering and Technology by Kalpakjian and Schmid
2. Fundamental of Modern Manuf. Materials, Processes and Systems by Groover
3. Several other books. You might benefit more by coming to class

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Assessment and Grading (indicative only)
Assessment:
• 25% class exams
Grading:
– 12.5% mid-sem exam Grade Cumulative
– 12.5% end-sem exam total
• 75% lab
– 5% 3D printer assembly + disassembly A* ≥ 95
– 5% CAD exercise
– 5% Arduino exercise A ≥ 80
– 5% CAM exercise
– 5% demonstrable progress in conception of project and detailing B ≥ 65
of assemblies, sub-assemblies, and parts
– 5% timely submission of complete CAD model C ≥ 50
– 10% mid-project evaluation
– 10% Guide’s evaluation (based on log sheets) D ≥ 40
– 22.5% final project evaluation (including the report)
– 2.5% attendance F < 40
Notes:
1. Make up exams only with the Instructor’s and the DoAA’s approval I usually prefer absolute grading
2. Any form of academic dishonesty will be rewarded with a F grade
3. Missing more than 3 labs might result in forced de-registration

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Lab exercise 1 and 2: Making gears and support brackets

• This exercise will introduce students to the machines and machining processes on
those machines to specifically make a bevel/spur gear and a support bracket.
• These parts and examples of what the students will use in their projects

Activity
Week
Bevel gear making Support bracket making
1 A B
2 B A

Bevel gear Support bracket

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Lab exercise 3: assemble + disassemble 3D printer

At the beginning After 50 min

After 20 min
• We have bought 15 machines
• Each group will get one machine to assemble +
disassemble (~50+ groups with 8-10 members in
each groups)
• Penalty for not finishing in time, or if parts are
misplaced
• Exercise is worth 5% of your grade
• Lab manual has further detailed instructions

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Lab exercise 4: CAD

• CAD exercise will include things like sketching, extruding, revolving, making gears,
assembling, making part drawings, etc.
• Students will work on their own laptops. Each group to bring at least three laptops
• Exercise is worth 5% of your grade – to be started and completed in the lab hours
• Lab manual has further detailed instructions

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Lab exercise 5: CAM for CNC and for 3D printing
CAM for CNC machine (subtractive) CAM for 3D printing

• CAM exercise will include generating a part program (G code) to load onto the CNC
machine to make a part, and to make a G code for slicing for the 3D printed part
• Students will work on their own laptops. Each group to bring at least three laptops
• Exercise is worth 5% of your grade – to be started and completed in the lab hours
• Lab manual has further detailed instructions

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Lab exercise 5: Arduino based driving of a motor

• Arduino based exercise will include driving a motor to in turn drive a Geneva
indexing mechanism. A kit with an Uno board, a motor driver, a battery back, a
geared DC motor and a Geneva mechanism will be given to each group.
• Exercise is worth 5% of your grade – to be started and completed in the lab hours
• Lab manual has further detailed instructions

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Tutors for the course
Monday Tuesday Wednesday

Dr. Mahavir Singh Dr. Sounak Choudhury Mr. Pritam Bari

PhD student PhD student
Thursday Friday

Dr. Mohit Law Dr. Niraj Sinha

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TAs for the course

Monday Tuesday Wednesday Thursday Friday

Tutor Mahavir Singh Sounak Pritam Bari Mohit Law Niraj Sinha
Choudhury
TAs Pulkit Gupta, Devang, Ajay Kumar, Akash Gupta, Pulkit Jain,
Mayank Patel, Anutosh, Aman Singhal, Arjun Patel, Sunny,
Manish Kumar, Vyom Sharma Mohammad, Arpit Ghalot Saurabh,
Prashant Verma Govind Sahu Vishal

Technical Mr. Srijan Bharti, Mr. Karthik R, Mr. Arijit Roy, Mr. Anurag Singh, Mr. Subhash N
Consultants and Mr. Pankaj Deora

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Technical consultants for the course

Srijan Bharati, (Y14) Karthik R, Engineer, MadLab Arijt Roy, Engineer, MadLab

Subhash, Engineer, MadLab Pankaj Deora (Y16) Anurag Singh (Y16)

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TA202A: lab technical staff (1/2)

Jeebanbandhu
Mahanta

Dharmvir
Kumar

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TA202A: lab technical staff (2/2)

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All resources for the course:

• Website: http://home.iitk.ac.in/~mlaw/ta202.php

• Lecture notes: will be uploaded here after every class

• Lab manual: already uploaded on the website

• Additional resources: will be linked on the website

• If you need to contact me for anything course related, please

email: mlaw@iitk.ac.in or call: 6897

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