Objectives Of The Course:
•  Basic Knowledge to Expert Knowledge
•  Outside - In Method
•  Learning through Actions
•  Basic to Futuristic
•  Concept Evolution based on Material and
•  Manufacturing Constraints
•  Forecasting

Course Structure:
The course was a blend of lectures, studio work and industry visits. It was structured as follows:
1. Class Lectures ID 647
2. Case Study Presentations
3. Studio Assignments
4. Central Library Assignment
5. Design of Products for Materials
6. Industrial Visits

1. Class Lectures ID 647

• Study of Plastic and Plastic Processes
  • Thermosets
    According to IUPAC recommendation: A thermosetting polymer is a prepolymer in a soft solid or viscous state that changes irreversibly into an infusible, insoluble polymer network by curing. Curing can be induced by the action of heat or suitable radiation, or both. A cured thermosetting polymer is called a thermoset.
  
  
  • Thermoplastics
    A Thermoplastic, also known as a thermosoftening plastic, is a polymer that becomes pliable or moldable above a specific temperature, and returns to a solid state upon cooling. Most thermoplastics have a high molecular weight, whose chains associate through intermolecular forces; this property allows thermoplastics to be remolded because the intermolecular interactions spontaneously reform upon cooling. In this way, thermoplastics differ from thermosetting polymers, which form irreversible chemical bonds during the curing process; thermoset bonds break down upon melting and do not reform upon cooling.
     
  • Classification of Thermoplastics andThermosets
    • Acrylics
    • Cellulosics
    • Polyamides
    • Polyolefins
    • Styrenes
    • Vinyls
      
      
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  • Molding Processes
    • Blow molding
      
      Blow molding (also known as blow moulding or blow forming) is a manufacturing process by which hollow plastic parts are formed. In general, there are three main types of blow molding: extrusion blow molding, injection blow molding, and stretch blow molding. The blow molding process begins with melting down the plastic and forming it into a parison or preform. The parison is a tube-like piece of plastic with a hole in one end in which compressed air can pass through. The parison is then clamped into a mold.and air is pumped into it. The air pressure then pushes the plastic out to match the mold. Once the plastic has cooled and hardened the mold opens up and the part is ejected.
       
    • Compaction plus sintering
       
    • Compression molding
      
      Compression molding is a method of molding in which the molding material, generally preheated, is first placed in an open, heated mold cavity. The mold is closed with a top force or plug member, pressure is applied to force the material into contact with all mold areas, while heat and pressure are maintained until the molding material has cured.
      The process employs thermosetting resins in a partially cured stage, either in the form of granules, putty-like masses, or preforms. Compression molding is a high-volume, high-pressure method suitable for molding complex, high-strength fiberglass reinforcements.
      
      Advanced composite thermoplastics can also be compression molded with unidirectional tapes, woven fabrics, randomly oriented fiber mat or chopped strand. The advantage of compression molding is its ability to mold large, fairly intricate parts. Also, it is one of the lowest cost molding methods compared with other methods such as transfer molding and injection molding; moreover it wastes relatively little material, giving it an advantage when working with expensive compounds.
      
      However, compression molding often provides poor product consistency and difficulty in controlling flashing, and it is not suitable for some types of parts. Fewer knit lines are produced and a smaller amount of fiber-length degradation is noticeable when compared to injection molding. Compression-molding is also suitable for ultra-large basic shape production in sizes beyond the capacity of extrusion techniques. Materials that are typically manufactured through compression molding include: Polyester fiberglass resin systems (SMC/BMC), Torlon, Vespel, Poly(p-phenylene sulfide) (PPS), and many grades of PEEK.
       
    • Compaction plus sintering
    • Extrusion molding
    • Foam molding
    • Injection molding
    • Laminating
    • Reaction injection molding
    • Matched mold
    • Matrix molding
    • Plastic moulding
    • Pressure plug assist molding
    • Rotational molding (or Rotomolding)
    • Transfer molding
    • Thermoforming
    • Vacuum forming, a simplified version of thermoforming
    • Vacuum plug assist molding

• • Mold Design and Processing
     
  • Holes and Undercuts

    In manufacturing, an undercut is a special type of recessed surface. In turning it refers to a recess in a diameter. In machining it refers to a recess in a corner. In molding it refers to a feature that cannot be molded using only a single pull mold. In printed circuit board construction it refers to the portion of the wafer that is etched away under the photoresist.

  • Inserts

    Inserts are pins, bolts, screws, joints and other structures that are used to transfer localized loads to a composite panel or to join two composite panels together. 

  • Fastening and Joining

    The Fastening and Joining section features information about welding, adhesives, soldering, brazing, nuts, bolts, and rivets.

  • Composites

    Composite materials, often shortened to composites or called composition materials, are engineered or naturally occurring materials made from two or more constituent materials with significantly different physical or chemical properties which remain separate and distinct within the finished structure. A common example of a composite would be disc brake pads, which consist of hard ceramic particles embedded in soft metal matrix. Another example is found in shower stalls and bathtubs, which are made of fiberglass. Imitation granite and cultured marble sinks and countertops are also widely used. The most advanced examples perform routinely on spacecraft in demanding environments.

  • Design in Plastics
     
  • Understanding the design requirements in plastic
     
• Study of Ferrous and Non-Ferrous Metals
  • Casting, Core Making, Curing

    Casting is a manufacturing process by which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting materials are usually metals or various cold setting materials that cure after mixing two or more components together; examples are epoxy, concrete, plaster and clay. Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods.

  • Bending

    Bending is a manufacturing process that produces a V-shape, U-shape, or channel shape along a straight axis in ductile materials, most commonly sheet metal. [1] Commonly used equipment include box and pan brakes, brake presses, and other specialized machine presses. Typical products that are made like this are boxes such as electrical enclosures and rectangular ductwork.

  • Deep Drawing

    Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. [1] It is thus a shape transformation process with material retention. The process is considered "deep" drawing when the depth of the drawn part exceeds its diameter. This is achieved by redrawing the part through a series of dies. The flange region (sheet metal in the die shoulder area) experiences a radial drawing stress and a tangential compressive stress due to the material retention property. These compressive stresses (hoop stresses) result in flange wrinkles (wrinkles of the first order). Wrinkles can be prevented by using a blank holder, the function of which is to facilitate controlled material flow into the die radius.

  • Forging

    Forging is a manufacturing process involving the shaping of metal using localized compressive forces. Forging is often classified according to the temperature at which it is performed: "cold", "warm", or "hot" forging. Forged parts can range in weight from less than a kilogram to 580 metric tons. Forged parts usually require further processing to achieve a finished part.

  • Machining

    Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools, such as saws, lathes, milling machines, and drill presses, are used with a sharp cutting tool to physically remove material to achieve a desired geometry. Machining is a part of the manufacture of many metal products, but it can also be used on materials such as wood, plastic, ceramic, and composites.

• Study of Mechanisms and Linkages
  • Basic Engineering Concepts
  • Mechanical Concepts
  • Concepts of Basic Physics
  • Fixers
  • Cams
     
• Design in Plastic
• Basics of Design and Technology

2. Case Study Presentations

• Z-line Petrol Pump
• Post Box Design
• Samsonite Suitcase
• Back Hoe Loader

3. Studio Assignments

• Low Cost Toy Analysis: Focus on Economic Considerations
• Vehicle Disassembly:
• Comparison of materials across different vehicles
• Study of various elements like chassis, seat and fixing details
• Application Development in stainless steel

4. Central Library Assignment

• Use of futuristic materials in new products
• Scanning all journals and online journals

5. Design of Products for Materials

• Redesign of an existing product in five different materials with focus on change in design due to change of material.

6. Industrial Visits

• Plywood Industry
• Rubber Industry
• Plastic Industry
• Godrej
• Mahindra and Mahindra
• Midco