ME (Mechanical) TOOL DESIGN - University College Of Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

Scheme of Instruction and Syllabi

of

M.E. (Mechanical)

Specialization:

TOOL DESIGN

Full time / Part time

(2012-13)

UNIVERSITY COLLEGE OF ENGINEERING (Autonomous)

Osmania University Hyderabad – 500 007, A.P., INDIA

2

With effect from the academic year 2012- 2013

Scheme of Instruction & Examination

M.E. (Mechanical Engineering) 4 Semesters (Full Time)

Sl. No

Subject

Periods per week

Duration

(Hrs)

Max. Marks

L/T D/P Univ. Exam Sessional

Semester - I

1. Core 3 -- 3 80 20

2. Core 3 -- 3 80 20

3. Core / Elective 3 -- 3 80 20

4. Core / Elective 3 -- 3 80 20

5. Core / Elective 3 -- 3 80 20

6. Elective 3 -- 3 80 20

7. Laboratory - I -- 3 -- -- 50

8. Seminar - I -- 3 -- -- 50

Total 18 6 480 220

Semester - II

1. Core 3 -- 3 80 20

2. Core 3 -- 3 80 20

3. Core / Elective 3 -- 3 80 20

4. Core / Elective 3 -- 3 80 20

5. Core / Elective 3 -- 3 80 20

6. Elective 3 -- 3 80 20

7. Laboratary - II -- 3 -- -- 50

8. Seminar - II -- 3 -- -- 50

Total 18 6 480 220

Semester - III

1.

Project Seminar*

--

6 -- -- 100**

Semester - IV

1. Dissertation -- -- -- Viva - Voce (Grade ***)

--

Note: Six core subjects, Six elective subjects, Two Laboratory Courses and Two Seminars should normally be completed by the end of semester II. * Project seminar presentation on the topic of Dissertation only ** 50 marks awarded by the project guide and 50 marks by the internal committee. *** Excellent / Very Good / Good / Satisfactory / Unsatisfactory

3


Scheme of Instruction & Examination

M.E. (Mechanical Engineering) 6 Semesters (Part Time)

Sl. No

Subject

Periods per week

Duration

(Hrs)

Max. Marks

L/T D/P Univ. Exam Sessional

Semester - I

1. Core 3 -- 3 80 20

2. Core / Elective 3 -- 3 80 20

3. Elective 3 -- 3 80 20

4. Lab. I / Seminar - I

-- 3 -- -- 50

Total 9 3 240 110

Semester - II

1. Core 3 -- 3 80 20

2. Core / Elective 3 -- 3 80 20

3. Elective 3 -- 3 80 20

4. Lab. I / Seminar - I

-- 3 -- -- 50

Total 9 3 240 110

Semester - III

1. Core 3 -- 3 80 20

2. Core / Elective 3 -- 3 80 20

3. Elective 3 -- 3 80 20

4. Lab. II / Seminar - II

-- 3 -- -- 50

Total 9 3 240 110

Semester - IV

1. Core 3 -- 3 80 20

2. Core / Elective 3 -- 3 80 20

3. Elective 3 -- 3 80 20

4. Lab. II / Seminar - II

-- 3 -- -- 50

Total 9 3 240 110

Semester – V

1.

Project Seminar*

--

6 -- -- 100**

Semester - VI

1. Dissertation -- -- -- Viva - Voce (Grade ***)

--

Note : Six core subjects, Six elective subjects, Two Laboratory Courses and Two Seminars should normally be completed by the end of semester IV. * Project seminar presentation on the topic of Dissertation only ** 50 marks awarded by the project guide and 50 marks by the internal committee. *** Excellent / Very Good / Good / Satisfactory / Unsatisfactory

4


Scheme of Instruction & Examination of Post Graduate course in Mechanical Engineering with

specialization in Tool Design Course duration: 4 Semesters (Full – time), 6 semesters (Part – Time)

Sl. No

Syllabus Ref.No.

Subject

Scheme of Instruction

Scheme of Examination

Periods per week Duration

in Hours

Max. Marks

L/T D/P Univ.

Exam

Sessio

-nal

CORE SUBJECTS

1. ME 518 Advanced Metrology 3 -- 3 80 20 2. ME 563 Material Science & Technology 3 -- 3 80 20 3. ME 564 Metal Cutting & Forming 3 -- 3 80 20 4. ME 565 Design of Metal Cutting Tools and

Accessories

3 -- 3 80 20

5. ME 560 Design of Press Tools 3 -- 3 80 20 6. ME 561 Design of Dies 3 -- 3 80 20

ELECTIVES

1. ME 501 Automation 3 -- 3 80 20

2. ME 508 Finite Element Techniques 3 -- 3 80 20 3. ME 509 Programming Methodology and data

structures

3

--

3

80

20 4. ME 510 Computer Aided Modeling and

Design

5. ME 511 Optimization Techniques 3 -- 3 80 20

6. ME 512 Neural Networks and Fuzzy Logic 3 -- 3 80 20 7. ME 513 Artificial Intelligence and Expert

Systems

3

--

3

80

20 8. ME 505 Computer Integrated Manufacturing 3 -- 3 80 20 9. ME 566 Machine Tool Design 3 -- 3 80 20 10. ME 516 Theory of Elasticity and Plasticity 3 -- 3 80 20

11. ME 517 Experimental Techniques and Data Analysis

3

--

3

80

20

12. ME 519 Product Design and Process Planning

3

--

3

80

20

13. ME 521 Engineering Research Methodology 3 -- 3 80 20 14. ME 567 Industrial Tribology 3 -- 3 80 20

15. 16.

ME 520

ME 568

Rapid Prototyping Principles and Applications Non-Traditional Machining and Forming

3

3

--

--

3

3

80

80

20

20

DEPARTMENTAL REQUIREMENTS

1. ME 523 Production Engineering Lab (Lab – I) -- 3 -- -- 50 2. ME 524 Computation Lab (Lab –II) -- 3 -- -- 50 3. ME 525 Seminar – I -- 3 -- -- 50 4. ME 526 Seminar – II -- 3 -- -- 50 5. ME 527 Project Seminar -- 3 -- -- 100 6. ME 528 Dissertation -- 9 -- Viva-

Voce (*Grade)

*Excellent/Very Good/Good/Satisfactory/Unsatisfactory

5

With effect from the academic year 2012 - 2013

ME 518

ADVANCED METROLOGY

Instruction 3 Periods /Week Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks

UNIT-I End & line standards for length, Airy & Bessel points, desirable features of end standards, slip gauge manufacture, calibration of end standards by interferometry. NPL gauge interferometer, calibration of line standards by micrometer microscope – superposition, coincidence and symmetric straddling, photoelectric microscope and Moir fringe techniques, measurement of large displacements using lasers,

calibration of Tomlinson gauges by interferometry. Photoelectric Autocollimator, calibration of polygons & circular scales. Types of interchangeability, dimensional chains. UNIT-II Fixed & Indicating Gauges: Taylor’s principles of gauge design, limitations of ring & plug gauges, position and receiver gauges, types of indicating gauges.

Comparators: Multirange Sigma comparator, Back pressure and free flow type pneumatic comparators, Differential back pressure gauge, usage of different types of jets, contact & non contact tooling. Amplification selection. Air to electric transducer, Differential transducer, Variation transducer, Pre process, In-process & Post process gauging, computation & match gauging. Usage of LVDT & Capacitive type gauge heads, Automatic inspection.

UNIT-III Measuring Machines: Floating carriage diameter measuring m/c. Universal measuring m/c. Matrix internal diameter measuring machine. Optical dividing head. Coordinate measuring machine, Optical projector-light beam systems, Work tables, measurement techniques, fixturing & accessories. Sources of error in measurement. Design principles of measuring machines Abbe’s rule, Kelvin coupling, flexible steel strip, advantages & limitations of hydrostatic & aerostatic bearings.

UNIT-IV Form Errors: Evaluation of straightness & flatness, usage of beam comparator, evaluation of roundness – intrinsic & extrinsic datums. Talyrond. PGC, RGC, MZC & LSC, methods, roundness evaluation for even & odd number of lobes. Surface Finish: stylus instrument (TALYSURF). M & E Systems, numerical assessment, vertical &

horizontal descriptors, profile as a random process, usage of interferograms. Plastic replica technique. UNIT-V Screw Threads: Measurement of thread elements for internal & external threads, progressive periodic, drunkenness and irregular pitch errors. NPL pitch measuring machine, virtual effective diameter, thread gauging.

Gears: measurement of tooth thickness, involute profile, pitch, concentricity and alignment, rolling gear test. Suggested Reading: 1. R.K.Jain, Engineering Metrology, Khanna Publishers

2. ASTME, Hand Book of Industrial Metrology, Prentice Hall of India Pvt Ltd. 3. I.C. Gupta, A Text Book of Engineering Metrology, Dhanpat Rai & Sons.

6

With effect from the academic year 2012 - 2013 ME 563

MATERIAL SCIENCE & TECHNOLOGY


UNIT-I Classification of Materials: Types and Crystal Structures. Imperfections. Strain hardening, Plastic range, Fracture, Fatigue, Creep and Creep properties. Recovery. Recrystallisation and Grain growth. Primary and secondary recrystallisation and sub-grain structure. Mechanism of strengthening in metals. Grain size and its relation to mechanical properties.

UNIT-II Testing of Materials: Review and brief discussion on stress strain diagram of steel and the parameters for ductility toughness, strain hardening, and tensile strength percentage of elongation etc. Fracture toughness and crack growth measurement. Failure analysis, Factor-graphy and scanning electronic Microscope. Fatigue and Creep testing, testing for Residual stresses.

UNIT-III Tool Materials: Selection and specification of carbon and alloy steels for general engineering purpose, Specification of materials as per various standards (IS, BS, AISI, APS etc.) Case hardening steels, Cold work tool steels, hot work tool steels, high speed tool steels. Types of modern Cutting Tool materials like Carbide, Coated carbides, Ceramics, CBN, Diamod, Sialons, Impregnated tools. Introduction to Plastics.

Properties of plastics-Thermo plastics-Thermo setting plastics. Methods of processing of plastics and plastic processing machines. UNIT-IV Ferrous and Non-ferrous materials: Specifications, Properties and applications of Carbon and alloy Steels, Specification of Grey iron casting IS: 210 SG Cast Iron IS: 865, Malleable iron castings IS: 2108

and IS: 2640. Selection and specification of die casting non-ferrous zinc and Aluminium (IS and LM Series). Powder Metallurgy and New Materials: Production of powders by various methods. Compacting, Sintering applications.

UNIT-V Heat treatment: Hardenability, its concepts and its role in steel specification. Hardening and annealing of tool steels. Case hardening and local hardening, methods, selection and specification of such steels study of Isothermal Transformation diagrams. Austempering, Martempering and Isothermal annealing for tool steels,. Tool failures due to improper heat treatment like Overheating, improper quenching and loading. ION Nitrating, Vacuum carburising, Chemical Vapour depositing. Heat treatment of non-ferrous

materials-Aluminium Alloys. Suggested Reading: 1. Richards C.W., Engineering Material Science-Prentice-Hall of India (P) Ltd., 1965.

2. Van Vlack, Elements of Materials Science, India book house pvt, ltd., Bombay, 1975. 3. Barret C.S., Structure of Metals, Eueania Pub., New Delhi, 1968. 4. William D Callister, Materials Science and Engineering an Introduction, John Wiley & Sons, 2003 5. Aviner, Physical Metallurgy, Mc Graw Hill Book Company, 1987. 6. Raghavan V., First Course in Material Science, Prentice Hall, New Delhi, 1974. 7. IS Standards, BIS, New Delhi.

7


METAL CUTTING & FORMING


UNIT-I Tool Materials: Tool material properties – HSS, Carbides, coated carbides, ceramic and CBN and diamonds, sialons, powder coatings – Relative advantages. Tool Geometry: Various methods of tool nomenclature and their inter relationship. Theoretical Determination of shear angle and cutting forces: Shear plane theory–Merchant’s models, Lee and

Shofer’s model. Velocity relations. Estimation of shear angle experimentally. Metal cutting friction. Real area of contact-Rules of dry sliding, stress distribution of tool face-variation of co-efficient of tool face friction with the rake angle. UNIT-II Dynamometry: Theoretical and empirical estimation of force and power in turning, drilling, milling and

grinding processes optimization in cutting forces – Dynamometer requirements – Force measurements – Electric transducers. Lathe, drilling and milling dynamometers. Cutting Temperatures: Shear Plane temperature – Average chip-tool interface temperature-interface temperature by dimensional analysis – Distribution of shear plane temperature-Measurement of temperature by radiation pyrometer – Moving thermo couple – Photo cell – Photographic method.

UNIT-III Tool Wear, Tool life and Machinability: Mechanism of tool wear – Adhesive, Abrasive, Diffusive and Chemical wear – Taylor’s tool life equation. Cutting Fluids – Carbon tetrachloride – Direction of fluid application – Chip curl-economics of machining – Comparison of machinability of different metals. Recent development in metal cutting: Hot machining. Rotary machining – High speed machining, rapid proto typing.

UNIT-IV Plastic Deformation: Mechanism of plastic deformation, Factors affecting plastic deformation, S train hardening behavior. Recovery, Recrystallization and grain growth. Variables affecting stress-strain curves, Ideal & Practical stress-strain curves. Cold working, warm working and hot working. Plasticity cycle. Tresca’s and Von Mises’s yield criter ia under complex states of stress, including Plane stress &

Plane strain condition.Rolling: Principle of rolling, process parameters. Estimation of rolling loads. Principles of roll pass design for various product shapes. Principles of ring rolling.

UNIT-V Unconventional Methods In Metal Forming: High energy rate forming. Merits and limitations of HERF Processes. Principle, merits, limitations and applications of pneumatic-mechanical systems. Explosive

forming, electro-magnetic forming, electro-hydraulic forming and water hammer forming. Forming with rubber pads – Guerin, Marform & Wheelon forming techniques. Suggested Reading: 1. M.C. Shaw. Metal cutting principles – CBS Publications, New Delhi, 1992.

2. BhattaCharya, Metal cutting – Central book publishers, Calcutta – 1996. 3. Heinrich Makelt, Mechanical presses, Edward Arnold (Pvt) Ltd., London, 1968. 4. Bary. Donald.F and Reads. Edward A., Techniques of press working sheet metal, Prentice Hall Publ.,

1974. 5. Kameschikov, Forming Practice, Mir Publishers, Moscow, 1970. 6. High Velocity Forming methods, ASTME, Michigan, 1968.

8


DESIGN OF METAL CUTTING TOOLS & ACCESSORIES


UNIT-I Cutting Tools: Development of cutting tool materials. Design of single point tools for turning, planning and slotting. Calculations of tool profile for flat tools, circular tools, inclined (skewing) tools and for tangential tools-Broaches – gears, calculation and design, holding, sharpening of reamers, drills, boring tools – Deep hole drilling.

UNIT-II Milling Cutters – types calculation, sharpening, design details – Tools for threads – Design of threading taps for metric and trapezoidal threads and design of circular threading dies for metric threads. Design of tangential and radial threading chasers – Gears – involute geometry for gears, geometrical and analytical method of determining conjugate profile – Design of hobs, rag tools, fellow cutters, fly cutters, etc., to

spline shafts, gears, worm wheels, etc. Design of tools for CNC machines. Exercise on Form tools, Broaches, Drilling Cutter for the given job. Threading tools. UNIT-III Jigs & Fixtures: Tolerance analysis and procedure of designing. The economic calculations, location of the work piece, degree of freedom, references surfaces, resting components, fixture elements for surface

concentric and radial locations – Clamping of the workpiece, review of cutting forces, principles and methods of clamping. Quick clamping devices, standards. Guiding elements for tools, guage for cutter, jig bushes, standards – indexing methods – standards design of Jigs/Fixtures/Accessories for Drilling, Milling, Turning, Broaching, Grinding, Welding Assembly, etc., standardization of elements computer software & standard libraries for Jigs & Fixture design.

UNIT-IV Gauges: Plain limit gauges: Review of systems of tolerances, fits and tolerance analysis (IS: 919, 170) Taylors principles and its applications. Calculation of dimensions and design details of plain gauges: Study of standard tapers and methods of dimensioning. Thread Gauges: Review of thread tolerance as per IS: 4218 and IS: 7008. Design calculations – Spline Gauges: Details of different splines. Different types and design calculations of spline gauges – Functional Gauges – CNC Gauging.

UNIT-V Design of plain Gauges, Taper Gauges, Thread Ring Gauges, Turning mandrel. Calculation of clamping force to resist the turning force. Lathe fixtures on the face plate. Studying the possibility of making fixtures selection of the location surface. Plate drill jig, Calculating the force of drilli ng, selection of the locating surface. Selection of standard clamping, tolerance analysis taking errors of locating, surface

guide bushed tools – drill jig – Milling – broaching fixtures, study of process sheet – Fixture for horizontal boring – selection of locating surface, tolerance analysis – Design of tool holder, selection of shank, calculation of cutting force clamping of tool to the holder, Welding fixture. Suggested Readings:

1. Henrickson, Manual of Jigs and Fixtures Design, Industrial Press Inc., New York, 1973. 2. Joshi, Jigs and Fixtures, Tata Mc Graw Hill, New Delhi, 1996. 3. Fundamentals of the Tool Design, ASTME, Prentice-Hall of India Private Ltd., New Delhi, 1976. 4. Shaw Mc, Metal Cutting Principles, Oxford, IBH Publ., Calcutta 1957. 5. Juneja, Theory and Application of Metal Cutting, Wiley Eastern Ltd., New Delhi, 1987.

9


DESIGN OF PRESS TOOLS


UNIT-I Classification of Mechanical, Hydraulic, and pneumatic presses Press Characteristics, safety devices in presses. Principles of stretch forming machines, principles of feeding and unloading equipment. Design principles of presses.

UNIT-II Design of Dies: Introduction terminology shearing dies- types of dies – analysis process shearing clearance – size and tolerances of die opening and punch – force, power, energy in shearing – loading center, shearing with inclined edges – strip layouts, economical stock – Utilization. UNIT-III

Elements of shearing dies – die plates – split dies, rules of development for split dies, inserts, types of punches, punch holders, punches – strippers – calculation of springs and rubber ejector, shedders, stops – pilots – stock guides – alignment system design for press tools. UNIT-IV Compound dies, progressive dies, stock feeding devices – cam actuated die, horn dies (type, sub-press

dies) – precision shearing dies, shaving dies, lamination dies – Bending dies, theory of bending development of blank, spring back, curling, flanging and press brake dies, bending on press brake. UNIT-V Drawing and forming Dies: Theory of drawing, blank development, strain factor, calculation of force, construction of drawing and drawing dies – Drawing of rectangular components (development, stages

draw beeds) – Ironing (application of rubber and hydraulic system) – Defects in deep drawing – Modern Metal forming techniques – Discussion of various computer software for sheet metal design. Suggested Reading: 1. Fundamentals of tool Design – ASTME, Prentice Hall, New Delhi, 1987

2. Die design Hand book – AISME, Mc Graw Hills, New York, 1965 3. Geoffrey Rowe W., An Introduction to the Principles of Metal Working, Edward Arnold, 1977. 4. Serope Kalpakjain, Mechanical Processing in Materials, 1967. 5. Heinrich Makelt, Mechanical Presses, Edward Arnold, London, 1968. 6. Javoronkov V.A and Chaturvedi. R.C. Rolling of Metals. 7. Eary and Redds, Shear Working of Metals, Prentice Hall, New Delhi, 1969.

8. Honeyeeme R.W.K., The plastic Deformation of metals, Edward Arnold, London, 1968. 9. Kamenschikov, Forging Practice, Mir. Pub., Moscow, 1968. 10. High Velocity Forming of metals, ASME, Michigan, 1968. 11. Bhattacharya.A, New Technology, Institute of Engineers, Calcutta, 1973.

10


DESIGN OF DIES


UNIT-I Design principles for dies of thermo-plastic and thermo-setting components. Impression core cavities, strength of cavities, guide pillars and bushes, ejection systems, cooling methods, bolster types. Split moulds, methods of actuating the splits, moulds of threaded components, internal & external under cuts, moulds with under – feed systems. Design principles and standards for Transfer and compression

moulding dies. Design of Tools: Mould for a spindle component with sleeve, pin ejection. Mould with splits Multi -cavity mould with stripper plate, inserts, ejectors. UNIT-II Design of Dies for metal mould Castings, Die casting, Shell moulding.

Design of casting cavity, sprue, slug, fixed and movable cores, finger cam, core, pin, draft, ejector pins, ejector plate, gate, goose-neck, nozzle, over-flow, platen plunger, runner, slot, slide, vent, water line. Design of hot chamber, cold chamber machines, vertical, horizontal,, die locking machines, toggle and hydraulic systems, injection systems, rack and pinion, knockout pins and plates, hydraulic ejection, Other parts of die casting machines.

UNIT-III Design of various types of dies – Single cavity, multi cavity, combination, unit dies. Alignment of dies with sprue. Design approach for die elements. Selection of materials and heat treatment for die casting dies and elements – die casting alloys – types of die casting alloys, Case studies on executed dies and design details. Finishing, Trimming, and inspection. Gravity die casting – Die design with cores and inserts – Bulk forming tools.

UNIT-IV Open die forging, Advantages of open die forging over closed die forging. Calculation of allowances and tolerances. Methods of open die forging. Design of dies. Closed die forging. Preparation of material for forging. Calculation of raw-stock, cutting off, heating in furnaces. Allowances and tolerances for closed die forging as per IS: 3469 1974.

UNIT-V Die blocks for forging operations. Design of fuller impression, Roller impression, Bender impression, Blocker impression, Finisher impression. Swaging tools. Planning layout of multi impression dies. Flash and cutter calculations – additional operations on forging, piercing, and trimming dies, coining dies. Horizontal forging machines. Design of upsetting dies. Calculations on upsetting dies – Press forging

reducer rollers. Forging equipment. Layout of forge shop. Roll forming, wire drawing forward & backward extrusion. Suggested Reading: 1. Rusinoff S.E., Forging & Forming Metals, Taraporewala, Bombay, 1952.

2. Dochlar H.H., Die Casting Dies, Mc Grawhill, 1951. 3. I.S. Standards, BSI., New Delhi. 4. Pye R.G.W., Injection Mould Design, Longman scientific & Technical Publishers, London, 1989.

11


AUTOMATION

Instructions 3 periods/week

Duration of university Examination 3 hours University Examination 80 Marks Sessional 20 Marks UNIT – I Introduction: Definition of automation, Types of production, Functions of Manufacturing, Organization and

Information Processing in Manufacturing, Production concepts and Mathematical Models, Automation Strategies, Production Economics: Methods of Evaluating Investment Alternatives, Costs in Manufacturing, Break-Even Analysis, Unit cost of production, Cost of Manufacturing Lead time and Work-in-process. UNIT – II

Detroit-Type Automation: Automated Flow lines, Methods of Workpart Transport, Transfer Mechanism, Buffer Storage, Control Functions, Automation for Machining Operations, Design and Fabrication Considerations. Analysis of Automated Flow Lines: General Terminology and Analysis, Analysis of Transfer Lines Without Storage, Partial Automation, Automated Flow Lines with Storage Buffers, Computer Simulation of Automated Flow Lines.

UNIT – III Assembly Systems and Line Balancing: The Assembly Process, Assembly Systems, Manual Assembly Lines, The Line Balancing Problem, Methods of Line Balancing, Computerized Line Balancing Methods, Other ways to improve the Line Balancing, Flexible Manual Assembly Lines. Automated Assembly Systems: Design for Automated Assembly, Types of Automated Assembly Systems, Part Feeding Devices, Analysis of Multi-station Assembly Machines, Analysis of a Single Station Assembly Machine.

UNIT –IV Automated Materials Handling: The material handling function, Types of Material Handling Equipment, Analysis for Material Handling Systems, Design of the System, Conveyor Systems, Automated Guided Vehicle Systems. Automated Storage Systems: Storage System Performance, Automated Storage/Retrieval Systems, Carousel Storage Systems, Work-in-process Storage, Interfacing Handling

and Storage with Manufacturing. UNIT – V Automated Inspection and Testing: Inspection and testing, Statistical Quality Control, Automated Inspection Principles and Methods, Sensor Technologies for Automated Inspection, Coordinate Measuring Machines, Other Contact Inspection Methods, Machine Vision, Other optical Inspection

Methods. Modeling Automated Manufacturing Systems: Role of Performance Modeling, Performance Measures, Performance Modeling Tools: Simulation Models, Analytical Models. The Future Automated Factory: Trends in Manufacturing, The Future Automated Factory, Human Workers in the Future Automated Factory, The social impact.

Suggested Reading:

1. Mikell P.Grover, Automation, Production Systems and Computer Integrated Manufacturing, Pearson Education Asia.

2. C.Ray Asfahl, Robots and manufacturing Sutomation, John Wiley and Sons New York. 3. N.Viswanadham and Y.Narahari, Performance Modeling of Automated Manufacturing Syetms,

Printice Hall India Pvt. Ltd. 4. Stephen J. Derby, Design of Automatic Machinary, Special Indian Edition, Marcel Decker, New

York, Yesdee publishing Pvt. Ltd, Chennai

12


FINITE ELEMENT TECHNIQUES

Instruction 3 Periods /Week Duration of University Examination 3 Hrs University Examination 80 Marks

Sessional 20 Marks UNIT-I Introduction to Finite Element Method of solving field problems. Stress and Equilibrium. Boundary conditions. Strain-Displacement relations. Stress-strain relations. One Dimensional Problem: Finite element modeling. Local, natural and global coordinates and shape

functions. Potential Energy approach : Assembly of Global stiffness matrix and load vector. Finite element equations, treatment of boundary conditions. Quadratic shape functions. UNIT-II Analysis of trusses and frames: Analysis of plane truss with number of unknowns not exceeding two at each node. Analysis of frames with two translations and a rotational degree of freedom at each node.

Analysis of Beams: Element stiffness matrix for two noded, two degrees of freedom per node for beam element. UNIT-III Finite element modeling of two dimensional stress analysis problems with constant strain triangles and treatment of boundary conditions. Two dimensional four noded isoparametric elements and numerical

integration. Finite element modeling of Axisymmentric solids subjected of axisymmetric loading with triangular elements. Convergence requirements and geometric isotropy. UNIT-IV Steady state heat transfer analysis: One dimensional analysis of a fin and two dimensional conduction

analysis of thin plate. Time dependent field problems: Application to one dimensional heat flow in a rod. Dynamic analysis: Formulation of finite element modeling of Eigen value problem for a stepped bar and beam. Evaluation of Eigen values and Eigen vectors. Analysis of a uniform shaft subjected to torsion using Finite Element Analysis.

UNIT-V Finite element formulation of three dimensional problems in stress analysis. Finite Element formulation of an incompressible fluid. Potential flow problems Bending of elastic plates. Introduction to non-linear problems and Finite Element analysis software. Suggested Reading:

1. Tirupathi R Chandraputla and Ashok. D. Belegundu, Introduction of Finite Element in Engineering,

Prentice Hall of India, 1997. 2. Rao S.S., The Finite Element Methods in Engineering, Pergamon Press, 1989. 3. Segerland. L.J., Applied Finite Element Analysis, Wiley Publication, 1984. 4. Reddy J.N., An Introduction to Finite Element Methods, Mc Graw Hill Company, 1984.

13


PROGRAMMING METHODOLOGY AND DATA STRUCTURES

Instruction 3 periods / week Duration of University Examination 3 hrs University Examination 80 Marks

Sessional 20 Marks UNIT - I Programming Methodology: Introduction, Algorithm, Data Flow Diagrams, Decision Tree, Decision Table and Life Cycles of Project Development.

UNIT - II Programming in ‘C’: Data types & Memory size, Expressions, Statements, Operators, Control flows, Arrays, Pointers, Structures, Functions, Dynamic Memory Allocation and Simple programs in Mechanical Engineering.

UNIT - III Sorting and Searching Techniques: Selection sort, Quick sort, Radix sort, Heap sort. Linear search, Binary search trees and Applications in Mechanical Engineering. UNIT - IV Data Structures: Classification of Data Structures, Definitions of Linked Lists, Double Linked Lists,

Stacks and Queues. Operations and Implementations of Stack, Queues and Linked List. General and Mechanical Engineering Applications UNIT - V Advanced Data Structures: Tree, Basic Terminology, Binary Trees, Operations on Binary tree, Tree traversals, Graph, Graph representation Adjacency matrix, Adjacency Lists and Applications.

Suggested Reading:

1. G.Michael Schneider, Steven C.Bruell, “Concepts in Data Structures and Software Development”, Jaico Publishing House,2002

2. Kernighan B.W, Ritchie D.M, “The C Programming Language”, 2nd

Edition, Prentice-Hall of India,

2003 3. Ellis Horowitz, Sartaj Sahni, “Fundamentls of Data Structures”, Galgotia, 1999 4. Kruse RL, Bruce RL, Cloris Lt, “Data Structures and Program Design in C”, PHI, 1991. 5. Trembly and Sorenson, “An Introduction to Data Structures with application”, McGraw Hill, 1984.

14


COMPUTER AIDED MODELLING & DESIGN


UNIT-I Introduction to CAD, Criteria for selection of CAD workstations, Shigle Design Process, Design criteria, Geometric modeling, entities, 2D & 3D Primitives. 2D & 3D Geometric Transformations: Translation, Scaling, Rotation, Reflection and Shearing, conlatenation. Graphics standards: GKS IGES, PDES.

UNIT-II Wire frame modeling: Curves: Curve representation. Analytic curves – lines, Circles, Ellipse, Conis. Synthetic curves – Cubic, Bezier, B-Spline, NURBS. UNIT-III

Surface Modeling: Surface entities, Surface Representation. Analytic Surface – Plane Surface, Ruled Surface, Surface of Revolution, Tabulated Cyliner. Synthetic Surface-Cubic, Bezier, B-spline, Coons. UNIT-IV Solid Modeling Techniques: Graph Based Model, Boolean Models, Instances, Cell Decomposition &

Spatial – Occupancy Enumeration, Boundary Representation (B-rep) & Constructive Solid Geometry (CSG). UNIT-V Advanced Modeling Concepts: Feature Based Modeling, Assembling Modeling, Behavioural Modeling, Conceptual Design & Top Down Design.

Capabilities of Modeling & Analysis Packages such as solid works, Unigraghics, Ansys, Hypermesh. Computer Aided Design of mechanical parts and Interference Detection by Motion analysis. Suggested Reading: 1. Ibrahim Zeid, CAD/CAM, Theory and Practice, Mc Graw Hill, 1998.

2. Foley, Van Dam, Feiner and Hughes, Computer Graphics Principles and Practice, 2nd

Ed., Addison – Wesley, 2000.

3. Martenson, E. Micheal, Geometric Modelling, John Wiley & Sons, 1995. 4. Hill Jr, F.S., Computer Graphics using open GL, Pearson Education, 2003.

15


OPTIMISATION TECHNIQUES

Instruction 3 Periods/week Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks

UNIT – I Simulation: Introduction, Types of Simulation, Simulation Models, Monte Carlo Simulation, Random Number, Pseudo Random Number, Mid-Square Method of generating Random Numbers, Application & Limitation, Application of Simulation to Inventory Control and Queuing Problem UNIT – II

Decision Theory: Introduction, Decision, Decision Making & Decision Theory, Types of Decisions, decision making process, Types of Decision making Environment: Decision making under certainty –Expected Monetary Value (EMV), Expected Opportunity Loss (EOL) Criterion & Expected Value of Perfect Information (EVPI) Criterion Decision making under risk- Criterion of Pessimism or Manimax, Criterion of Optimism or Maximin, Minimax Regret Criterion, Criterion of Realism & Criterion of Rationality

Decision making under uncertainty and Decision tree analysis: Introduction, Procedure of Constructing Decision Trees & Solution through Decision Tree Analysis. UNIT – III Integer Programming: Introduction, Types of Integer Programming Problems, Gomory’s Cutting Plane method. Branch and Bound method for all Integer Programming Problems & Mixed Integer Programming

Problems UNIT – IV Dynamic Programming: Introduction- Bellman’s principle of optimality-Application of dynamic programming-Linear programming problem-Capital budgeting problem

UNIT – V Classical Optimization: Introduction; Unconstrained problems of maxima and minima, constrained problems of maxima and minima; Constraints in the form of equations – Lagrangian method; Constraints in the form of inequalities -Kuhn-tucker conditions.

Suggested Reading:

1. S.S.Rao, Optimization Theory and Applications, NAI Publishers, Hyderabad, 1995. 2. S.D.Sharma, Operations Research, Kedarnath and Co. Publishers, Meerut, 2004.

3. V. K. Kapoor, Operations Research, S. Chand, New Delhi, 2004. 4. Hamdy A.Taha, Operations Research, Pearson Education, New York, 2001.

5. Bronson-Schaum Series, Operations Research, McGraw Hill, Singapore, 1983.

6. David Goldberg, Genetic Algorithms, S Chand Publications, 2006.

16


NEURAL NETWORKS AND FUZZY LOGIC


UNIT-I Concepts of fuzzy sets: Introduction – Crisps sets, notation of fuzzy sets, basic concepts of fuzzy sets, operation, fuzzy compliment, union, intersection, Binary relation, Equivalence and similarity relations, belief and plausibility measures, probabili ty measures, computability, relations, ordering morphisms, possibility and necessary measures.

Uncertainty and information: Types of uncertainty, measures of dissonance, measures of confusion, measures of nonspecificity, uncertainty and information. Complexity, Principle of uncertainity. UNIT-II Adaptive fuzzy systems: Neural and Fuzzy intelligence, Fuzziness as multivalent, fuzziness in probabilistic world, randomness verses ambiguity.

UNIT-III Fuzzy association memories: Fuzzy and neural function estimates, FAN mapping, neural verses fuzzy representation of structural knowledge, FAM as mapping, Fuzzy hebb FAM’s Bidirectional FAM theorem, Super imposition FAM Rules, FA System architecture.

UNIT-IV Introduction to Neural networks: Knowledge base information processing, general view of knowledge based algorithm, neural information processing, Hybrid intelligence, and artificial neurons. UNIT-V Characteristics of artificial Neural Networks: Single Neural Networks, Multi Layer Neural Networks,

Training of ANN – objective, supervise training, unsupervised training, overview of training. Neural networks Paradigms: Perception meculloch and Pitts Model, back propagation algorithm and deviation, stopping criterion, Hopfield nets, Boldman’s machine algorithm, Neural networks applications. Suggested Reading:

1. Bart, Kosko, Neural Networks and Fuzzy Systems, Prentice Hall of India, 1994. 2. Limin Fu, Neural Networks in Computer Intelligence, McGraw Hill, 1995. 3. George J Klir and Tina A. Folger, Fuzzy Sets Uncertainity an Information, Prentice Hall of India,

New Delhi, 2000. 4. James A Freeman, Simulating Neural Networks, Adison Publication, 1995.

17


ARTIFICIAL INTELLIGENCE AND EXPERT SYSTEMS

Instruction 3 Periods /Week Duration of University Examination 80 Marks Sessional 20 Marks

UNIT-I Artificial Intelligence: Definition, Study of AI techniques, problems and Problems space, AI characteristics, Heuristics. Problem solving Methods: Forward and backward reasoning, problem trees, problem graph, hill climbing, search method, problem reduction, constraint satisfaction, means and analysis, game playing, mini max algorithms, alphabetic heuristics.

UNIT-II Computer Vision: Perception, early processing, representation and recognition of scenes, Guzman’s algorithms of spurting objects in a scene, Waltz algorithm. UNIT-III

Neural Language understanding problems, syntactic analysis, semantic analysis, augmented transition networks. UNIT-IV Knowledge representation (Logic): Representing facts in logic predicate logic, resolution, unification, question answering, mathematical theorem proving.

Knowledge representation (Structured): Declarative representation, Semantic nets, procedural representation. UNIT-V Learning: Learning as induction, failure drive learning, learning by teaching, learning through examples (Winston’s program) skill acquisition.

Suggested Reading: 1. Elaine Rich, Artificial Intelligence, Mc Graw Hill, 1985. 2. Nilson, Principles of Artificial Intelligence. 3. Winston, The Psychology of Computer.

18


COMPUTER INTEGRATED MANUFACTURING

Instruction 3 periods/week Duration of university Examination 3 hours University Examination 80 Marks Sessional 20 Marks

UNIT – I Introduction to CIM The meaning of Manufacturing, Types of Manufacturing; Basic Concepts of CIM: CIM Definition, Elements of CIM, CIM wheel, concept or technology, Evolution of CIM, Benefits of CIM, Needs of CIM: Hardware and software. Fundamentals of Communication: Communications Matrix. Product Development Cycle, Concurrent Engineering: Definition, Sequential Engineering Versus Concurrent Engineering, Benefits of Concurrent Engineering, Characteristics of concurrent Engineering, Framework

for integration of Life-cycle phases in CE, Concurrent Engineering Techniques, Integrated Product Development(IPD), Product Life-Cycle Management (PLM), Collaborative Product Development. UNIT – II CIM database and database management systems Introduction, Manufacturing Data: Types, sources; Database Terminology, Database requirements, Database models, Database Management System, DBMS Architecture, Query Language, Structural

Query Language (SQL): Basic structure, Data definition Language (Create, Alter, Drop, Truncate, View), Data Manipulation Language (store, retrieve, update, delete). Illustration of Creating and Manipulating a Manufacturing Database. SQL as a Knowledge Base Query Language. Features of commercial DBMS: Oracle, MySQL, SQL Access, Sybase, DB2. Product Data Management (PDM), Advantages of PDM. UNIT – III CIM Technology and Systems

Product Design: Needs of the market, Design and Engineering, The design Process, Design for Manufacturability (DFM): Component Design, Design for Assembly. Computer-Aided Process Planning: Basic Steps in developing a process plan, Variant and Generative Process Planning, Feature Recognition in Computer-Aided Process Planning. Material Requirements Planning (MRP), Manufacturing Resource Planning (MRP –II), Cellular Manufacturing: Design of Cellular Manufacturing Systems, Cell Formation Approaches: Machine–Component Group Analysis, Similarity Coefficients-

Based Approaches. Evaluation of Cell Design. Shop-floor Control: Data Logging and Acquisition, Automated Data Collection, Programmable Logic Controllers, Sensor Technology. Flexible Manufacturing Systems: Physical Components of an FMS. Types of Flexibility, Layout Considerations: Linear Single Machine Layout, Circular Machine Layout, Cluster Machine Layout, Loop Layout; Operational Problems of FMS. FMS benefits.

UNIT – IV Enterprise Wide Integration in CIM and CIM Models Introduction to Networking, Principles of Networking, Network Terminology, Types of Networks: LAN, MAN, WAN; Selection of Network Technology: Communication medium, Network Topology, Medium access control Methods, Signaling methods; Network Architectures and Protocols: OSI Model, MAP & TOP, TCP/IP, Network Interconnection and Devices, Network Performance. Framework for Enterprise-

wide Integration. CIM Models: ESPRIT-CIM OSA Model, NIST-AMRF Model, Siemens Model of CIM, Digital Equipment Corporation Model, IBM Concept of CIM. UNIT – V Future Trends in Manufacturing Systems

Lean Manufacturing: Definition, Principles of Lean Manufacturing, Characteristics of Lean Manufacturing, Value of Product, Continuous Improvement, Focus on Waste, Relationship of Waste to Profit, Four Functions of Lean Production, Performance Measures, The Supply Chain, Benefits of Lean Manufacturing. Introduction to Agile and Web Based Manufacturing systems. Suggested Reading:

1. S.Kant Vajpayee: Principles of Computer Integrated Manufacturing, Printice-Hall India. 2. Nanua Singh: Systems Approach to Computer Integrated Design and Manufacturing- John Wiley. 3. P.Radhakrishnan, S.Subramanyam: CAD/CAM/CIM, New Age International 4. Alavudeen, Venkateshwaran: Computer Integrated Manufacturing, Printice-Hall India

19


MACHINE TOOL DESIGN


UNIT-I Classification of Machine Tools: General purpose, Special purpose, Automatic, Semi-Automatic machine tools, Transfer lines. Kinematics of Machine Tools: Shaping of geometrical and real surfaces, Developing and designing of

kinematics schemes of machine tools, Kinematic structures of lathe, drilling, milling, relieving lathe, grinding, gear shaping and gear hobbing machining. Kinematic design and speed and feed boxes. Productivity loss. Stepped and stepless regulation. UNIT-II Strength and Rigidity of Machine Tool Structures: Basic principles of design for strength. Different types

of structures. General design procedures. Effect of materials and shape factors on the rigidity of structure, overall compliance of machine tool. Design of beds, bases columns, tables, cross rails for various machines. Effect of wear of guide ways on the performance. Various types of guide ways, their relative advantages. Materials for machine tool components including plastic guide ways (PTFE). UNIT-III

Analysis of Spindles, Bearing and Power Screws: Design of spindles subjected to combined bending and torsion. Layout of bearings. Pre-loading. Anti-friction slide ways. Rolling contact, hydrodynamic, hydrostatic, aerostatics and magnetic bearings, their relative performance. Power Screws, Recirculating ball screws. Hydrodynamic design of journal bearings. UNIT-IV

Machine Tool Vibrations: Effect of vibration on machine tool; Forced vibrations. Machine tool chatter. Self excited vibration and dynamic stability single and two degree freedom analysis. Comply coefficient. Elimination of vibration. Vibration analysis of machine tool structures. UNIT-V Hydraulic Systems: General principles, hydraulic fluid power lines. Properties of hydraulic fluid. Various

positive displacement pumps, their characteristics and operation. Design of hydraulic tanks and other systems. Various valves used in hydraulic systems. Design and application of various hydraulic circuits. One position and multi-position scheme. Single and multi pump screws. Electrical analogy. Pneumatic circuits. Hydro copying system. Evaluation of machine tools with regard to accuracies, sound and vibration. Machine tool testing.

Suggested Reading: 1. Sen and Bhattacharya, Principles of Machine Tools, New Central Book Agency, Calcutta, 1975. 2. S.K. Basu, Design of Machine Tools, Allied Publishers, India, 1961. 3. Acharkan, Machine Tool Design (vol. 1,2 & 3), MIR Publishers, Moscow, 1973.

20


THEORY OF ELASTICITY AND PLASTICITY

Instruction 3 Periods/week Duration of University Examination 3 Hrs. University Examination 80 Marks Sessional 20 Marks

UNIT-I Basic Concepts of Stress : Definition, State of Stress at a point, Stress tensor, invariants of stress tensor, principle stresses, stress ellipsoid, derivation for maximum shear stress and planes of maximum shear stress, octahedral shear stress, Deviatoric and Hydrostatic components of stress, Invariance of Deviatoric stress tensor, plane stress.

UNIT-II Basic concepts of Strain : Deformation tensor, Strain tensor and rotation tensor; invariants of strain tensor, principle strains, derivation for maximum shear strain and planes of maximum shear strain, octahedral shear strain, Deviatoric and Hydrostatic components of strain tensor, Invariance of Deviatoric strain tensor, plane strain.

UNIT-III Generalized Hooke’s Law : Stress-strain relationships for an isotropic body for three dimensional stress space, for plane stress and plane strain conditions, differential equations of equilibrium, compatibility equations, Material (D) matrix for Orthotropic Materials.

UNIT-IV True stress and true strain, von-Mise’s and Tresca yield criteria, Haigh–Westergard stress space representation of von - Mise’s and Tresca yield criteria, effective stress and effective strain, St. Venants theory of plastic flow, Prandtle–Reuss and Levy–Mise’s constitutive equations of plastic flow, Strain hardening and work hardening theories, work of plastic deformation.

UNIT-V Analysis methods: Slab method, Slip line field method, uniform deformation energy method, upper and lower bound solutions. Application of Slab method to forging, wire drawing, extrusion and rolling processes.

Suggested Reading: 1. Timoshenko and Goodieer, Theory of Elasticity, Mcgraw Hill Publications 3

rd Edition,

2. Madleson, Theory of Plasticity, 3. J. Chakrabarty, Theory of Plasticity, 2

nd edition, McGraw Hill Publications 1998

4. George E Dieter, Mechanical Metallurgy, McGraw Hill Publications 1988

21


EXPERIMENTAL TECHNIQUES AND DATA ANALYSIS


UNIT-I Measurement of Cutting Forces: Strain gauge and piezoelectric transducers and their characteristics. Dynamometer construction, Bridge circuits. Instrumentation and calibration. Displacement and strain measurements by photoelasticity. Holography, interferometer, Moir techniques, strain gauge rosettes.

UNIT-II Temperature Measurement: Circuits and instrumentation for different transducers viz, bimetallic, expanding fluid, electrical resistance, thermister, thermocouples, pyrometers. Flow Measurement : Transducers for flow measurements of Non-compressible and compressible fluids. Obstruction and drag methods. Vortex shredding flow meters. Ultrasonic, Laser Dopler and Hotwire anemometer. Flow visualization techniques, Shadow graphs, Schlieren photography. Interferometer.

UNIT-III Metallurgical Studies: Optical and electron microscopy, X-Ray diffraction, Bragg’s Law and its application for studying crystal structure and residual stresses. Electron spectroscopy, electron microprobe. Surface Measurements: Micro hardness, roughness, accuracy of dimensions and forms. 3-D co-ordinate measuring machines.

UNIT-IV Experiment design & data analysis: Statistical methods, Randomised block design, Latin and orthogonal squares, factorial design. Replication and randomization. Data Analysis: Deterministic and random data, uncertainty analysis, tests for significance: Chi-square, student’s ‘t’ test. Regression modeling, direct and interaction effects. ANOVA, F-test. Time Series

analysis, Autocorrelation and autoregressive modeling. UNIT-V Taguchi Methods: Experiment design and planning with Orthogonal arrays and linear graphs. Additive cause effect model. Optimization of response level. Identification of Design and noise factors. Performance evaluation and Optimization by signal to noise ratios. Concept of loss function and its

application. Suggested Reading: 1. Holman, J.P.: Experimental Methods for Engineers, McGraw Hill Int., New York. 2. Venkatesh, V.C., and Chandrasekharan, Experimental Methods in Metal Cutting, Prentice Hall of

India, Delhi. 3. Davis, O.V.; The Design and Analysis of Industrial Experiments, Longman, London. 4. Box and Jenkins; Time Series analysis, Forecasting and control, Holden Day, Sanfrancisco. 5. Dove and Adams, Experimental stress analysis and motion measurement, Prentice Hall of India,

Delhi. 6. Tapan P. Bagchi, Taguchi Methods Explained, Prentice Hall of India, Delhi.

22


PRODUCT DESIGN AND PROCESS PLANNING


UNIT-I Product design and process design functions, selection of a right product, essential factors of product design, Morphology of design, sources of new ideas for products, evaluation of new product ideas. Product innovation procedure-Flow chart. Qualifications of product design Engineer. Criteria for success/failure of a product. Value of appearance, colours and Laws of appearance.

UNIT-II Product reliability, Mortality Curve, Reliability systems, Manufacturing reliability and quality control. Patents: Definitions, classes of patents, applying for patents. Trademarks and copyrights. Cost and quality sensitivity of products, Elements of cost of a product, costing methods, cost reduction and cost control activities. Economic analysis, Break even analysis Charts. Value engineering in product design,

creativity aspects and techniques. Procedures of value analysis – cost reduction, material and process selection. UNIT-III Various manufacturing processes, degree of accuracy and finish obtainable, process capability studies. Methods of improving tolerances. Basic product design rules for Casting, Forging, Machining, Sheet

metal and Welding. Physical properties of engineering materials and their importance on products. Selection of plastics, rubber and ceramics for product design. UNIT-IV Industrial ergonomics: Man-machine considerations, ease of maintenance. Ergonomic considerations in product design-Anthropometry, Design of controls, man-machine information exchange. Process sheet

detail and their importance, Advanced techniques for higher productivity. Just-in-time and Kanban System. Modern approaches to product design; quality function development, Rapid prototyping. UNIT-V Role of computer in product design and management of manufacturing, creation of manufacturing data base, Computer Integrated Manufacturing, communication network, production flow analysis, Group

Technology, Computer Aided product design and process Planning. Integrating product design, manufacture and production control. Suggested Reading: 1. Niebel, B.W., and Draper, A.B., Product design and process Engineering, Mc Graw Hill – Kogalkusha

Ltd., Tokyo, 1974. 2. Chitale, A.K, and Gupta, R.C., Product Design and Manufacturing, Prentice Hall of India Pvt. Ltd.,

New Delhi, 2004. 3. Mahajan, M. Industrial Engineering and Production Management, Dhanpath Rai & Co., 2000.

23

With effect from the academic year 2012 - 2013 ME/Ph.D 521

ENGINEERING RESEARCH METHODOLOGY Instruction 3 Periods/week Duration of University Examination 3 Hrs. University Examination 80 Marks Sessional 20 Marks

UNIT-I Research Methodology: Objectives and Motivation of Research, Types of Research, Research Approaches, Significance of Research, Research Methods verses Methodology, Research and Scientific

Method, Important of Research Methodology, Research Process, Criteria of Good Research, Problems Encountered by Researchers in India, Benefits to the society in general. Defining the Research Problem: Definition of Research Problem, Problem Formulation, Necessity of Defining the Problem, Technique involved in Defining a Problem. UNIT-II

Literature Survey: Importance of Literature Survey, Sources of Information, Assessment of Quality of Journals and Articles, Information through Internet. Literature Review: Need of Review, Guidelines for Review, Record of Research Review. UNIT-III Research Design: Meaning of Research Design, Need of Research Design, Feature of a Good Design,

Important Concepts Related to Research Design, Different Research Designs, Basic Principles of Experimental Design, Developing a Research Plan, Design of Experimental Set-up, Use of Standards and Codes. UNIT-IV Data Collection: Exploring the data, Description and Analysis of Data, Sample Design and Sampling,

Role of Statistics for Data Analysis, Functions of Statistics, Estimates of Population, Parameters, Parametric V/s Non Parametric methods, Descriptive Statistics, Points of Central tendency, Measures of Variability, Measures of relationship, Inferential Statistics-Estimation, Hypothesis Testing, Use of Statistical software. Data Analysis: Deterministic and random data, Uncertainty analysis, Tests for significance: Chi-square, student’s‘t’ test, Regression modeling, Direct and Interaction effects, ANOVA, F-test, Time Series

analysis, Autocorrelation and Autoregressive modeling. UNIT-V Research Report Writing: Format of the Research report, Style of writing report, References/Bibliography/Webliography, Technical paper writing/Journal report writing. Research Proposal Preparation: Writing a Research Proposal and Research Report, Writing Research

Grant Proposal. Suggested Reading: 1. C.R Kothari, Research Methodology, Methods & Technique; New Age International Publishers, 2004 2. R. Ganesan, Research Methodology for Engineers, MJP Publishers, 2011

3. Y.P. Agarwal, Statistical Methods: Concepts, Application and Computation, Sterling Publs., Pvt., Ltd., New Delhi, 2004 4. Vijay Upagade and Aravind Shende, Research Methodology, S. Chand & Company Ltd., New Delhi, 2009 5. P. Ramdass and A. Wilson Aruni, Research and Writing across the Disciplines, MJP Publishers, Chennai, 2009

24


INDUSTRIAL TRIBOLOGY


UNIT-I Introduction to Tribology. Surface Topography: Texture measurement, profilometry, cartography, photogrammetry, Texture depth, out flow meter, surface prints, statistical features, mathematical representation, parameter selection, model and Ideal surface.

UNIT-II Friction of Metals: Classic laws of Friction, General friction theories. Elastic and Elastic -Plastic contact. WSP theory, Junction growth and work Hardening. Surface contaminants. Friction of Elastomers: Fundamentals friction mechanism. Adhesion and Hysteris theories. UNIT-III

Wear: Wear mechanisms in metals, wear of clean metals, wear measurement, intrinsic and pattern Abrasion, Wear by Roll Formation, effects of speed and temperature. Experimental Methods: Rotating disc, External and internal Drum Equipment, Flat belt apparatus, wear and abrasion machine, squeeze-Film apparatus, impact of dynamic testers, cross-cylinder apparatus, Four ball Rolling machine, interferometer equipment, electron Diffraction and Microscopy.

UNIT-IV Lubrication: Basic Principles of lubrication, choice of lubrication type, selection of lubricating oils, oil-feed system, hydrodynamic, boundary and electrodynamics, lubrication. Oil changing and oil conservation, lubricant testing and specification, lubricant monitoring and Health & Safety aspects. UNIT-V

Applications of Tribology: Manufacturing processes, automotive applications, Transportation and Locomotion, Design of bearing – Slider bearings, Journal Bearings, Foil bearings, rolling contact bearings. Layered damping in beams, Friction damping. Suggested Reading:

1. Desmond F. Moore, Principles and applications of Tribology, Pergamon Press, USA, 1975. 2. Schey, Tribology in Metalworking: Friction, Lubricant and wear, American Society for Metals (ASM),

USA, 1983. 3. Lansdown, A.R., Lubrication, Pergamon Press, USA, 1982. 4. Camaron Alastair, Basic Lubrication theory, UK., 1976. 5. Neale M.J., Tribology Hand Book, Newnes – Butter worth, London.

25


RAPID PROTOTYPING PRINCIPLES AND APPLICATIONS

Instruction 3 Periods/Week Duration of University Examination 3 hours University Examination 80 Marks Sessional 20 Mraks

UNIT – I Introduction: Prototyping fundamentals, Historical development, Fundamentals of Rapid Prototyping, Advantages and Limitations of Rapid Prototyping, Commonly used Terms, Classification of RP process, Rapid Prototyping Process Chain: Fundamental Automated Processes, Process Chain. UNIT – II

Liquid-based Rapid Prototyping Systems: Stereo lithography Apparatus (SLA): Models and specifications, Process, working principle, photopolymers, photo polymerization, Layering technology, laser and laser scanning, Applications, Advantages and Disadvantages, Case studies. Solid ground curing (SGC): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies

Solid-based Rapid Prototyping Systems: Laminated Object Manufacturing (LOM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Fused Deposition Modeling (FDM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. UNIT – III

Powder Based Rapid Prototyping Systems: Selective laser sintering (SLS): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Three dimensional Printing (3DP): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Rapid Tooling: Introduction to Rapid Tooling (RT), Conventional Tooling Vs RT, Need for RT. Rapid

Tooling Classification: Indirect Rapid Tooling Methods: Spray Metal Deposition, RTV Epoxy Tools, Ceramic tools, Investment Casting, Spin Casting, Die casting, Sand Casting, 3D Keltool process. Direct Rapid Tooling: Direct AIM, LOM Tools, DTM Rapid Tool Process, EOS Direct Tool Process and Direct Metal Tooling using 3DP. UNIT – IV

Rapid Prototyping Data Formats: STL Format, STL File Problems, Consequence of Building Valid and Invalid Tessellated Models, STL file Repairs: Generic Solution, Other Translators, Newly Proposed Formats. Rapid Prototyping Software’s: Features of various RP software’s like Magics, Mimics, Solid View, View Expert, 3 D View, Velocity 2, Rhino, STL View 3 Data Expert and 3 D doctor.

UNIT –V RP Applications: Application – Material Relationship, Application in Design, Application in Engineering, Analysis and Planning, Aerospace Industry, Automotive Industry, Jewelry Industry, Coin Industry, GIS application, Arts and Architecture. RP Medical and Bioengineering Applications: Planning and simulation of complex surgery, Customised Implants & Prosthesis, Design and Production of Medical Devices, Forensic Science and Anthropology, Visulization of Biomolecules.

Suggested Reading: 1. Rapid prototyping: Principles and Applications - Chua C.K., Leong K.F. and LIM C.S, World Scientific publications , Third Edition, 2010.

2. Rapid Manufacturing – D.T. Pham and S.S. Dimov, Springer , 2001 3. Wholers Report 2000 – Terry Wohlers, Wohlers Associates, 2000 4. Rapid Prototyping & Manufacturing – Paul F.Jacobs, ASME Press, 1996.

26


PRODUCTION ENGINEERING LAB

Instruction 3 Periods/week Sessional 50 Marks List of Experiments:

1. Study of the morphology of chips produced from different materials and machining processes.

2. Effect of tool geometry on chip flow direction in simulated orthogonal cutting conditions.

3. Study of cutting ratio/chip thickness ratio in simulated orthogonal cutting with different materials

and tool geometry.

4. Evaluation of cutting forces using 3-D dynamometer in simple turning process.

5. Estimation of torque and thrust on a twist drill and effect of tool geometry and axial feed rate.

6. Evaluation of tool face temperature with thermocouple method.

7. Roughness of machined surface. Influence of tool geometry and feed rate.

8. Electro chemical machining. Effect of flow rate of electrolyte and material structure on machining

characteristics.

9. Study of the ultrasonic machining setup and simple experiments on machinability of glass and

other typical materials.

10. Study and operation of abrasive jet machining with simple experiments on M.R. with flow rate

and stand off distance.

11. Study of the construction and operating parameters of metal spinning Lathe.

12. Study of the water hammer equipment and hydrostatic extrusion setup.

13. Extrusion of cylindrical billets through dies of different included angles and exit diameters and

their effect on extrusion pressure.

14. Practice and study of blanking and punching process and their characteristic features on

mechanical press with existing dies.

27


COMPUTATION LABORATORY

Instruction 3 Periods/week Sessional 50 Marks List of Experiments:

1. Introduction to Finite Element Analysis Software.

2. Static Analysis of a corner bracket.

3. Statically indeterminate reaction force analysis.

4. Determination of Beam stresses and Deflection.

5. Bending analysis of a Tee-shaped beam.

6. Analysis of cylindrical shell under pressure.

7. Bending of a circular plate using axisymmetric shell element.

8. Stress analysis in a long cylinder.

9. Solidification of a casting.

10. Transient Heat transfer in an infinite slab.

11. Transient Thermal stress in a cylinder.

12. Vibration analysis of a Simply supported beam.

13. Natural frequency of a motor-generator.

14. Thermal-Structural contact of two bodies.

15. Drop test of a container (Explicit Dynamics).

Documents

ME (Mechanical) TOOL DESIGN - University College Of Engineering