Overview

ABOUT THE COURSE: Casting processes shape metal by pouring molten material into molds, addressing terminologies, patterns, gating design, risers, and defect remedies. Welding joins materials using various methods, considering joint types, weld metallurgy, mechanics, and defect remedies. Powder metallurgy forms parts from metal/ceramic powders, involving preparation, sintering, pressing, molding, and extrusion, with applications across various industries. Metal forming involves deformation techniques like forging, rolling, extrusion, and drawing, focusing on formability and defect analysis. Additive manufacturing is the advanced net shape manufacturing technology capable of yielding safety critical parts with dimensional accuracy and improved mechanical and physical properties. Machining is often the last step in manufacturing to meet the end goal of meeting dimensional requirements for the intended application of the developed part geometry. The present course will offer a comprehensive know how on process modelling of abovementioned manufacturing processes, in view of grabbing insight into the process physics as well as its optimisation and control.INTENDED AUDIENCE: Undergraduate/PostgraduatePREREQUISITES: Elementary Mathematics and MechanicsINDUSTRY SUPPORT: IndustriesAshok Leyland, Larsen & Toubro (L&T), Tata Steel, Mahindra & Mahindra, Maruti Suzuki India Ltd., Bajaj Auto Ltd., Hero MotoCorp Ltd., Siemens India, Bharat Heavy Electricals Limited (BHEL), Hindustan Aeronautics Limited (HAL), Tata motors, JSW Steel.Funding agenciesCSIR, DST, ISRO, DRDO, SERB

Syllabus

Week 1:Introduction to manufacturing science and different processes, Introduction to numerical methods (working principle, merits-demerits and applications): FDM, FVM,BEM, FEMWeek 2:Introduction to casting process, casting terminologies,pattern, gate, and riser design principlesWeek 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 propertiesWeek 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 generationWeek 5:Introduction to welding, welding terminologies, types of joints, classification of welding process, insight of weld metallurgy, weld mechanics, welding defects and their remediesWeek 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 weldingWeek 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.Week 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.Week 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 processesWeek 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 materialsWeek 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
Week 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