MTech Additive Manufacturing Syllabus

8/20/2019 MTech Additive Manufacturing Syllabus

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NATIONAL INSTITUTE OF TECHNOLOGY WARANGAL

SCHEME OF INSTRUCTION AND SYLLABIFOR M.TECH. PROGRAMMES

Effective from 2014-15

DEPARTMENT OF MECHANICAL ENGINEERING


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NATIONAL INSTITUTE OF TECHNOLOGY WARANGAL

VISION

Towards a Global Knowledge Hub, striving continuously in pursuit of excellence inEducation, Research, Entrepreneurship and Technological services to the society

MISSION

Imparting total quality education to develop innovative, entrepreneurial and ethical futureprofessionals fit for globally competitive environment.

Allowing stake holders to share our reservoir of experience in education and knowledge formutual enrichment in the field of technical education.

Fostering product oriented research for establishing a self-sustaining and wealth creatingcentre to serve the societal needs.

DEPARTMENT OF MECHANICAL ENGINEERINGVISION

To be a global knowledge hub in mechanical engineering education, research, entrepreneurship

and industry outreach services.

MISSION

Impart quality education and training to nurture globally competitive mechanical engineers.

Provide vital state-of-the-art research facilities to create, interpret, apply and disseminateknowledge.

Develop linkages with world class educational institutions and R&D organizations forexcellence in teaching, research and consultancy services.


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GRADUATE ATTRIBUTESThe Graduate Attributes are the knowledge skills and attitudes, which the students have at the

time of graduation. These attributes are generic and are common to all engineering programs.

These Graduate Attributes are identified by National Board of Accreditation.

1. Scholarship of Knowledge: Acquire in-depth knowledge of various manufacturing processeson a wider and global perspective, with an ability to discriminate, evaluate, analyze and

synthesize existing and new knowledge, and integration of the same for enhancement of

knowledge.

2. Critical Thinking: Analyze complex engineering problems critically, apply independent

judgment for synthesizing information to make intellectual and/or creative advances for

conducting research in a wider theoretical, practical and policy context.

3. Problem Solving: Think laterally and originally, conceptualize and solve manufacturing

engineering problems, evaluate a wide range of potential solutions for those problems andarrive at feasible, optimal solutions after considering public health and safety, societal and

environmental factors in the core areas of expertise.

4. Research Skill: Extract information pertinent to unfamiliar problems through literature survey

and experiments, apply appropriate research methodologies, techniques and tools, design,

conduct experiments, analyze and interpret data, demonstrate higher order skill and view

things in a broader perspective, contribute individually/in group(s) to the development of

scientific/technological knowledge in one or more domains of engineering.

5. Usage of modern tools: Create, select, learn and apply appropriate techniques, resources,

and modern engineering and IT tools, including prediction and modeling, to complex

engineering activities with an understanding of the limitations.

6. Collaborative and Multidisciplinary work: Possess knowledge and understanding of group

dynamics, recognize opportunities and contribute positively to collaborative-multidisciplinary

scientific research, demonstrate a capacity for self-management and teamwork, decision-

making based on open-mindedness, objectivity and rational analysis in order to achieve

common goals and further the learning of themselves as well as others.

7. Project Management and Finance: Demonstrate knowledge and understanding of

engineering and management principles and apply the same to one’s own work, as a member

and leader in a team, manage projects efficiently in respective disciplines and multidisciplinary

environments after consideration of economic and financial factors.

8. Communication: Communicate with the engineering community, and with society at large,

regarding complex engineering activities confidently and effectively, such as, being able to


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comprehend and write effective reports and design documentation by adhering to appropriate

standards, make effective presentations, and give and receive clear instructions.

9. Life-long Learning: Recognize the need for, and have the preparation and ability to engage in

life-long learning independently, with a high level of enthusiasm and commitment to improve

knowledge and competence continuously.10. Ethical Practices and Social Responsibility: Acquire professional and intellectual integrity,

professional code of conduct, ethics of research and scholarship, consideration of the impact

of research outcomes on professional practices and an understanding of responsibility to

contribute to the community for sustainable development of society.

11. Independent and Reflective Learning: Observe and examine critically the outcomes of one’s

actions and make corrective measures subsequently, and learn from mistakes without

depending on external feedback.


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DEPARTMENT OF MECHANICAL ENGINEERING

M.TECH. IN ADDITIVE MANUFACTURING

PROGRAM EDUCATIONAL OBJECTIVES:

Program Educational Objectives (PEOs) are broad statements that describe the career andprofessional accomplishments that the program is preparing graduates to achieve. They mustbe consistent with the mission of the Institution and Department. Department faculty membersmust continuously work with stakeholders (local employers, industry and RD advisors, and thealumni) to review the PEOs and update them periodically. The number of PEOs should bemanageable and small in number, say 4+1, and should be achievable by the program.

PEO1 Analyze, design and evaluate engineering products using the knowledge ofmathematics, science, engineering and IT tools.

PEO2 Solve complex manufacturing problems for significant technological and societaldevelopment.

PEO3 Apply additive manufacturing concepts to all possible fields of human life.

PEO4 Engage in lifelong learning to adapt to changing needs for professional advancement.

MAPPING OF MISSION STATEMENTS WITH PROGRAM EDUCATIONAL OBJECTIVES:

Mission PEO1 PEO2 PEO3 PEO4

Impart quality education and training to nurture globallycompetitive mechanical engineers.

3 3 3 2

Provide vital state of the art research facilities to create,interpret, apply and disseminate knowledge.

2 3 3 2

Develop linkages with world-class educational institutionsand R&D organizations for excellence in teaching, research

and consultancy services.

2 2 2 2

1: Slightly 2: Moderately 3: Substantially

MAPPING OF PROGRAM EDUCATIONAL OBJECTIVES WITH GRADUATE ATTRIBUTES:

GA1 GA2 GA3 GA4 GA5 GA6 GA7 GA8 GA9 GA10 GA11

PEO1 3 3 3 3 3 1 1 1 1 - -

PEO2 3 3 3 3 2 2 1 1 - 2 -

PEO3 3 2 3 2 2 2 1 - - 2 -

PEO4 2 2 2 3 2 2 - 1 3 - 2


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PROGRAM OUTCOMES:

Program Outcomes, as per NBA, are narrower statements that describe what the students areexpected to know and be able to do upon the graduation. These relate to the knowledge, skillsand behavior the students acquire through the program. The Program Outcomes (PO) arespecific to the program and should be consistent with the Graduate Attributes and facilitate the

attainment of PEOs. At the end of the program the student shall be able to:

PO1 Apply engineering knowledge, techniques, skills and modern tools to analyzeproblems in AM.

PO2 Identify different industrial sectors, relevant AM processes and measurementtechniques to reduce cost and time from design to manufacture.

PO3 Develop advanced sensing and control algorithms for AM technologyPO4 Exploit AM technology to reduce tooling cost at low volume production environmentsPO5 Apply 3D printing technology for organ printing and other bio-medical applicationsPO6 Design and conduct experiments to understand process behavior for providing

optimal solutions.

PO7 Develop and validate models to solve complex manufacturing problems using modernengineering and IT tools.

PO8 Communicate effectively while leading and executing projects.PO9 Apply professional, ethical, legal, security and social issues in the design of AM

processes.PO10 Engage in life-long learning as a means of enhancing knowledge and skills for

professional advancement. PO11 Conceptualize and analyze new problems leading to research and development.

MAPPING OF PROGRAM OUTCOMES WITH PROGRAM EDUCATIONAL OBJECTIVES:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11

PEO1 3 2 3 2 2 2 3 2 1 2 2

PEO2 3 2 2 2 2 2 3 1 2 1 2

PEO3 3 3 2 2 2 1 1 1 2 - 1

PEO4 1 1 1 1 1 1 1 2 1 3 2


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SCHEME OF INSTRUCTION

M. TECH. (ADDITIVE MANUFACTURING) COURSE STRUCTURE

I – Year, I – Semester

S. No. CourseCode Course Title L T P Credits Cat.Code

1 ME5701 CAD for Additive Manufacturing 4 0 0 4 PCC2 ME5702 Additive Manufacturing Processes

and Applications4 0 0 4 PCC

3 MA5945 Numerical and OptimizationTechniques

4 0 0 4 PCC

4 ME5203 CNC Technology and Programming 4 0 0 4 PCC5 Elective – I 3 0 0 3 DEC6 Elective – II 3 0 0 3 DEC7 ME5703 CAD/CAM Laboratory 0 0 3 2 PCC8 ME5704 Rapid Prototyping Laboratory 0 0 3 2 PCC

Total 22 0 6 26

I – Year, II – Semester

S. No. CourseCode

Course Title L T P Credits Cat.Code

1 ME5751 Additive Manufacturing Machines andSystems

4 0 0 4 PCC

2 ME5752 Rapid Tooling and Industrial Applications

4 0 0 4 PCC

3 MM5151 Materials and CharacterizationTechniques

4 0 0 4 PCC

4 Elective – III 3 0 0 3 DEC5 Elective – IV 3 0 0 3 DEC6 Elective – V 3 0 0 3 DEC7 ME5753 Rapid Prototyping and Tooling

Laboratory0 0 3 2 PCC

8 ME5754 Materials and Part CharacterizationLaboratory

0 0 3 2 PCC

9 ME5791 Seminar 0 0 3 2 PCCTotal 21 0 9 27


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II – Year, I – Semester

S. No. Course Code Course Title Credits Cat. Code

1 ME6742 Comprehensive Viva-voce 4 PCC2 ME6749 Dissertation Part-A 8 PCC

Total 12

II – Year, II – Semester

S. No. Course Code Course Title Credits Cat. Code

1 ME6799 Dissertation Part-B 18 PCCTotal 18

LIST OF ELECTIVES:

I Year, I Semester

PH5111 Lasers in Manufacturing Technology

CH5120 Polymer Engineering

ME5212 Micro and Nano Manufacturing

ME5314 Soft Computing Techniques

ME5451 Integrated Product Design and Development

ME5711 Modern Manufacturing Processes

ME5712 Mechatronics

I Year, II Semester

MM5170 Powder Metallurgy

ME5169 Computational Fluid Dynamics

ME5262 Product Design for Manufacturing and Assembly

ME5362 Design and Analysis of Experiments

ME5471 Finite Element Analysis

ME5761 Additive Manufacturing in Medical Applications

ME5762 Modeling and Simulation of Manufacturing Systems

ME5763 Reverse Engineering and Computer Aided Inspection

ME5764 Manufacturing Control and Automation


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DETAILED SYLLABUS

ME5701 CAD FOR ADDITIVE MANUFACTURING PCC 4 – 0 – 0 4 Credits

PRE-REQUISITES: None

COURSE OUTCOMES: At the end of the course, the student shall be able to:

CO1 Apply geometric transformation techniques in CAD. CO2 Develop mathematical models to represent curves, surfaces and solids. CO3 Identify STL file problems and apply repair algorithms. CO4 Determine part orientation, apply suitable slicing algorithm and generate tool path for

minimum build time, support material and part errors.CO5 Design and analyze engineering components.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 1 1CO2 2 2CO3 3 1 1 1 2 1 2CO4 2 2 1 2 3 3 2 1 2 2CO5 3 2 1 2 2 2 2 2 2 2 2

DETAILED SYLLABUS:

2D & 3D Transformations of geometry: Translations, Scaling, Reflection, Rotation,Homogeneous representation of transformation, Concatenation of transformations, Perspective,

Axonometric projections, Orthographic and Oblique projections.

Design of Curves: Analytic Curves, PC curve, Ferguson, Composite Ferguson, curve Trimming

and Blending, Bezier segments, de Casteljau's algorithm, Bernstein polynomials, Bezier-subdivision, Degree elevation, Composite Bezier, Splines, Polynomial Splines, B-spline basisfunctions, Properties of basic functions, Knot Vector generation, NURBS.

Design of Surfaces: Differential geometry, Parametric representation, Curves on surface,Classification of points, Curvatures, Developable surfaces, Surfaces of revolution, Intersectionof surfaces, Surface modeling, 16-point form, Coons patch, B-spline surfaces.

Design of Solids: Solid entities, Boolean operations, B-rep of Solid Modeling, CSG approach ofsolid modeling, Advanced modeling methods.

Data Exchange Formats and CAD Applications: Data exchange formats, Finite element

analysis, reverse engineering, modeling with point cloud data, Rapid prototyping.

3D Scanning and Digitizing Devices CAD Model Construction from Point Clouds, Data handling& Reduction Methods, AM Software (Magics, Mimics, 3Matic, Rhino)

Tessellated Models, STL File Problems, STL File Manipulation and Repair Algorithms

Part orientation and support generation, Slicing Algorithms, Tool path generation


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Multi-material representation in AM

READING:

1. Michael E. Mortenson, “Geometric Modeling”, Wiley, NY, 1997. 2. Anupam Saxena, Birendra Sahay, “Computer Aided Engineering Design”, Springer, 2005.

3. Ian Gibson, “Software Solutions for Rapid Prototyping”, Professional EngineeringPublishing Limited, UK, 2002.

4. Ali K. Kamrani and Emad Abouel Nasr, “Engineering Design and Rapid Prototyping”,Springer, 2010.

5. Ibrahim Zeid “CAD/CAM Theory and Practice” TMH.


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ME5702 ADDITIVE MANUFACTURING PROCESSESAND APPLICATIONS

PCC 4 – 0 – 0 4 Credits


COURSE OUTCOMES: At the end of the course, the student shall be acquainted with theknowledge of:CO1 Importance of AM in ManufacturingCO2 Different AM TechnologiesCO3 Select suitable materials for AMCO4 Different methods for Post-processing of AM partsCO5 “Design for manufacture” for AM C06 Process AnalysisC07 Applications of AM in Automobile, Aerospace, Bio-medical etc.C08 Future Directions of AM

CO-PO MAPPING:PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11

CO1 2 3 1 2 2 2 2 2 2 2 2CO2 2 3 2 2 2 2 3 3 3 3 2CO3 2 2 2 2 1 3 2 1 2 2 2CO4 2 3 1 1 1 2 2 2 1 2 2CO5 3 2 1 3 2 2 3 2 2 3 3CO6 3 2 3 3 2 3 3 2 3 3 3CO7 2 2 1 2 2 2 2 2 3 2 2CO8 2 3 2 2 2 2 2 2 3 3 3

DETAILED SYLLABUS:

Introduction to Additive Manufacturing: Introduction to AM, AM evolution, Distinctionbetween AM & CNC machining, Advantages of AM,

AM process chain: Conceptualization, CAD, conversion to STL, Transfer to AM, STL filemanipulation, Machine setup, build , removal and clean up, post processing.

Classification of AM processes: Liquid polymer system, discrete particle system, moltenmaterial systems, solid sheet system.

Design for AM: Motivation, DFMA concepts and objectives, AM unique capabilities, Exploringdesign freedoms, Design tools for AM, Part Orientation, Removal of Supports, Hollowing outparts, Inclusion of Undercuts and Other Manufacturing Constraining Features, InterlockingFeatures, Reduction of Part Count in an Assembly, Identification of markings/ numbers etc.

Guidelines for process selection: Introduction, selection methods for a part, challenges ofselection, example system for preliminary selection, production planning and control

AM Applications: Functional models, Pattern for investment and vacuum casting, Medicalmodels, art models, Engineering analysis models, Rapid tooling, new materials development,


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Bi-metallic parts, Re-manufacturing. Application examples for Aerospace, defense, automobile,Bio-medical and general engineering industries

Post processing of AM parts: Support material removal, surface texture improvement,accuracy improvement, aesthetic improvement, preparation for use as a pattern, propertyenhancements using non-thermal and thermal techniques.

Future Directions of AM: Introduction, new types of products and employment anddigiproneurship.

READING:

1. Chua Chee Kai, Leong Kah Fai, “Rapid Prototyping: Principles & Applications”, WorldScientific, 2003.

2. Ian Gibson, David W Rosen, Brent Stucker., “Additive Manufacturing Technologies:Rapid Prototyping to Direct Digital Manufacturing”, Springer, 2010

3. Ali K. Kamrani, Emand Abouel Nasr, “Rapid Prototyping: Theory & Practice”, Springer,2006.

4. D.T. Pham, S.S. Dimov, Rapid Manufacturing: The Technologies and Applications of RapidPrototyping and Rapid Tooling, Springer 2001


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MA5945 NUMERICAL AND OPTIMIZATIONTECHNIQUES




CO1 Construct hermite and spline interpolating polynomials. CO2 Construct finite difference methods.CO3 Solve differential equations by FDM. CO4 Solve unconstrained and constrained optimization problems using classical methods. CO5 Evaluate the special programming structures - linear, quadratic, geometric and

dynamic and derive the solutions of them

CO-PO MAPPING

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 2 1 1 1 1CO2 2 2 2 1 1 1 1 1CO3 2 2 2 1 2 1 1 1CO4 2 3 2 2 2 1 1 1CO5 2 2 3 1 1 1

DETAILED SYLLABUS:

Numerical Techniques: Hermite and Spline Interpolation; Gaussian Quadrature, FiniteDifference Methods for boundary value problems - Ordinary differential equations, Partialdifferential equation - Parabolic and Elliptic problems.

Optimization: Statement of an optimization problem, classification of optimization problems,classical optimization techniques – unconstrained and constrained optimization. Onedimensional minimization methods, Gradient Methods-Newton’s method, Powell’s method,Flecher Reeves method.

Linear Programming: Brief treatment of linear programming-simplex method, Dual simplexmethod-introduction of an additional constraint, Integer programming-Cutting Plane method.Introduction to non-linear programming – Quadratic programming, Dynamic programming,Geometric programming

READING:

1. MK Jain, SRK Iyengar and RK Jain, Numerical Methods for Scientific and EngineeringComputation, New Age Int. Pub., 2010

2. Rao S.S., Optimization Theory and Applications, Wiley Eastern Ltd., 2nd Edition, 2004.3. Fox R.L., Optimization Methods for Engineering Design, Addison Wesley, 2001.4. Rao V. Dukkipati; Applied Numerical Methods using Matlab; Newage International

Publications, 2012


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ME5203 CNC TECHNOLOGY AND PROGRAMMING PCC 4 – 0 – 0 4 Credits



CO1 Classify and distinguish NC, CNC and DNC systems.CO2 Develop manual and APT part programs for 2D complex profiles and test the programs

through simulation.CO3 Explain CNC machine structures and system drives.CO4 Develop interpolation algorithms for control loops.CO5 Explain latest developments in CNC system.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 1 1 2 1 1 1 1

CO2 2 2 1 2 2 1 1CO3 1 2 1 3 1 2 1 1CO4 2 1 1 3 2 1 1 1CO5 1 1 1 1 1

DETAILED SYLLABUS:

CNC technology - An overview: Introduction to NC/CNC/DNC machine tools, Classification ofNC /CNC machine tools, Advantage, disadvantages of NC /CNC machine tools, Application ofNC/CNC

DNC systems: Classifications, Merits, Demerits and application

Design of CNC: Constructional features of NC/CNC machine tools, CNC tooling and fixturingsystem, Designation of axis in CNC systems

Part programming: CNC programming and introduction, Manual part programming: Basic(Drilling, milling, turning etc.), Special part programming, Advanced part programming,Computer aided part programming (APT)

System Drives and devices: Hydraulic and pneumatic motors and their features, Electricalmotors AC/DC and their features

Interpolators: Hardware Interpolators, Software Interpolators, NC/CNC controllers

Adaptive control systems: Adaptive control with optimizations (ACO), Adaptive control withconstraints (ACC)

Latest developments: Machining centre, Turing centre, Communication networking, Recentdevelopments of CNC systems, Virtual NC systems


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READING:

1. Yoram Koren, Computer Control of Manufacturing Systems, McGraw Hill International,Singapore, 2006

2. John Stenerson and Kelly Curran, Computer Numerical Control: Operation andProgramming , PHI, New Delhi, 2009

3. TC Chang, RA Wysk and HP Wang, Computer Aided Manufacturing , PHI, New Delhi, 2009.


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PH5111 LASERS IN MANUFACTURINGTECHNOLOGY

DEC 3 – 0 – 0 3 Credits



CO1 Understand the essential characteristics of lasing materials and principles of lasers.CO2 Understand the properties of lasers and identify their suitability for various

applications.CO3 Identify the lasers based on their functionality for different applications.CO4 Determine the requirement of laser components in different configurations.CO5 Differentiate the lasers required for various material processes and manufacturing.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 1 1 1 1CO2 2 1 1 1 1 1CO3 1 2 1 2 2 2 1 2 1 1CO4 2 1 1 1 1 1 1CO5 2 1 1 2 1 1 1 1

DETAILED SYLLABUS:

Electromagnetic Radiation, Energy Levels, Interaction of Radiation and Matter, Spontaneousand stimulated emission, Population Inversion, Resonant Cavity.

Properties of Laser Light: Linewidth, Beam Divergence Angle, Spatial Profiles of Laser

Beams, Temporal Behavior of Laser Output, Coherence, Radiance, Focusing Properties ofLaser Radiation, Power.

Practical Lasers: Gas Lasers – He-Ne lasers, Noble Gas Ion-lasers, CO2 Lasers, Excimerlasers; Solid state lasers. Semi-conductor diode lasers; Beam conditioning; High power diodelasers, Optically pumped lasers, Diode-Pumped Solid State Tunable Lasers.

Light beam deflectors, Q-switches, Optical isolators, Beam profilers, Beam homogenizers, Lasercare and safety

Interaction of High-Power Laser Radiation with Materials, Laser Applications in MaterialProfessing: welding, Hardening, Laser Alloying, cladding, Laser induced material removal:drilling, cutting, marking

READING:

1. K. Thyagarajan, Ajoy Ghatak, Lasers: Fundamentals and applications, 2nd Ed., Springer,2010

2. Ready, J.F, Industrial applications of Lasers, Academic Press, 2nd Ed., 19973. Willium T Selfvast, Laser Fundamentals, Cambridge Univ. Press, 2008


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CH5120 POLYMER ENGINEERING DEC 3 – 0 – 0 3 Credits

PRE-REQUISITES: NoneCOURSE OUTCOMES: At the end of the course, the student shall be able to:

CO1 Explain the relationship between polymer properties (thermal, rheological, mechanical),and polymer microstructure and molecular weight.CO2 Relate polymer properties to their processing and uses for additive manufacturing.CO3 Explain methods for determining the microstructure and molecular weight of polymers.CO4 Describe different types of polymerization process, polymer processing and the

significance for AM.CO5 Understand the applications and design concepts for use of polymer in device

manufacturing.

CO-PO MAPPING:


CO1 1 1 1 1 1 1 1CO2 1 2 2 2 1 1 1CO3 2 1 2 1 1 1CO4 1 1 2 1 1 1 1CO5 1 1 1 1 1 1 1 1

DETAILED SYLLABUS:

Basic Concepts: Classification of polymers, Concept of functionality, Polydispersity andMolecular weight [MW], Molecular Weight Distribution [MWD], various methods of determinationof MWD.

Kinetics and Mechanism: Polymerization Kinetics Free radical polymerization, Mechanism ofPolycondensation

Techniques of Polymerization and nanocomposites: Techniques of polymerization, bulk,emulsion, suspension, Polymer composites and nano-composites

Polymer ProcessingMethods of spinning for additive manufacturing: Wet spinning, Dry spinning. Biopolymers,Compatibility issues with polymers. Moulding and casting of polymers, Polymer processingtechniques and the effect of these processing techniques on polymer structure,

Designing of polymeric devices and polymers used for Additive: Aspects of designing

polymeric devices and polymer additives, Polymers used for additive manufacturing :polyamide, PF resin, polyesters etc

READING:1. G Odian Principles of Polymerization, Wiley Inerscience John Wiley and Sons, 4th edition,

20052. V.R. Gowarikar Polymer Science, , New Age Int., 20023. F.W. Billmeyer Jr Text book of Polymer Science, Inter science Publisher John Wiley and

Sons, 3rd edition 1999.


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ME5212 MICRO AND NANO MANUFACTURING DEC 3 – 0 – 0 3 Credits



CO1 Explain different techniques for the synthesis and characterization of nano-materials

CO2 Design and analyze methods and tools for micro and nano-manufacturing.

CO3 Select a micro and nano-manufacturing method and identify key variables to improvequality of MEMS.

CO4 Select appropriate industrially viable process, equipment and tools for a specific product.

CO-PO MAPPING:


CO1 1 2 1 2 1 1CO2 1 2 2 2 1 1 2CO3 1 1 1 2 2CO4 2 2 2 2 1

DETAILED SYLLABUS:

Introduction: Importance of Nano-technology, Emergence of Nanotechnology, Bottom-up andTop-down approaches, challenges in Nanotechnology

Nano-materials Synthesis and Processing: Methods for creating Nanostructures; Processesfor producing ultrafine powders- Mechanical grinding; Wet Chemical Synthesis of nano-

materials- sol-gel process, Liquid solid reactions; Gas Phase synthesis of nano-materials-Furnace, Flame assisted ultrasonic spray pyrolysis; Gas Condensation Processing (GPC),Chemical Vapour Condensation(CVC)- Cold Plasma Methods, Laser ablation, Vapour – liquid –solid growth, particle precipitation aided CVD, summary of Gas CondensationProcessing(GPC).

Structural Characterization: X-ray diffraction, Small angle X-ray Scattering, OpticalMicroscope and their description, Scanning Electron Microscopy (SEM), Scanning ProbeMicroscopy (SPM), TEM and EDAX analysis, Scanning Tunneling Microscopy (STM), Atomicforce Microscopy (AFM).

Spectroscopic characterizations: Basic concepts of spectroscopy, operational principle and

application for analysis of nano-materials, UV-VIS-IR Spectrophotometers, Principle ofoperation and application for band gap measurement, Raman spectroscopy.

Surface Characterization: X-ray Photoelectron Spectroscopy (XPS), Auger electronspectroscopy, Low Energy Ion Scattering Spectroscopy (LEISS), Secondary Ion MassSpectroscopy (SIMS), Rutherford Backscattering Spectroscopy (RBS).

Thermal Characterization of Nano-materials: DTA, TGA, DSC (Principle and Applications),Determination of thermo physical parameters.


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Micro fabrication Techniques: Lithography, Thin Film Deposition and Doping, Etching andSubstrate Removal, Substrate Bonding, MEMS Fabrication Techniques, Bulk Micromachining,Surface Micromachining, High- Aspect-Ratio Micromachining

Nanofabrication Techniques: E-Beam and Nano-Imprint Fabrication, Epitaxy and Strain

Engineering, Scanned Probe Techniques, Self-Assembly and Template Manufacturing.

MEMS devices and applications: Pressure sensor, Inertial sensor, Optical MEMS and RF-MEMS, Micro-actuators for dual-stage servo systems.

READING

1. Mark James Jackson, Microfabrication and Nanomanufacturing, CRC Press, 2005.2. Gabor L. Hornyak, H.F Tibbals, Joydeep Dutta & John J Moore, Introduction to Nanoscience

and Nanotechnology, CRC Press, 2009.3. Ray F. Egerton , Physical Principles of Electron Microscopy: An Introduction to TEM, SEM,

and AEM , Springer, 2005.

4. Robert F Speyer, Thermal Analysis of Materials, Marcel Dekker Inc , New York, 1994.5. B.D. Cullity - Elements of X-Ray Diffraction, 3rd edition, Prentice Hall , 2002.6. Tai-Ran Hsu, “MEMS and Microsystems: Design and Manufacture,” McGraw- Hill, 2008.


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ME5314 SOFT COMPUTING TECHNIQUES DEC 3 – 0 – 0 3 Credits



CO1 Differentiate and classify traditional and non-traditional optimization methods.CO2 Formulate an optimization problem to solve complex manufacturing engineering

problems.CO3 Apply A*, AO*, Branch and Bound search techniques for problem solving.CO4 Apply GA, PSO and ACO algorithms for problems in scheduling, process planning and

layout design.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 3 2 1 2 1 1CO2 3 2 1 1 2 1 1

CO3 3 2 2 1 2 1 1CO4 3 2 2 1 2 1 1

DETAILED SYLLABUS:

Problem Solving Methods and Tools: Problem Space, Problem solving, State space, Algorithm’s performance and complexity, Search Algorithms, Depth first search method,Breadth first search methods their comparison, A*, AO*, Branch and Bound search techniques,p type, Np complete and Np Hard problems.

Evolutionary Computing Methods: Principles of Evolutionary Processes and genetics, Ahistory of Evolutionary computation and introduction to evolutionary algorithms, Genetic

algorithms, Evolutionary strategy, Evolutionary programming, Genetic programming.

Genetic Algorithm and Genetic Programming: Basic concepts, working principle, proceduresof GA, flow chart of GA, Genetic representations, (encoding) Initialization and selection, Geneticoperators, Mutation, Generational Cycle, applications.

Swarm Optimization: Introduction to Swarm intelligence, Ant colony optimization (ACO),Particle swarm optimization (PSO), Artificial Bee colony algorithm (ABC), Other variants ofswarm intelligence algorithms.

Advances in Soft Computing Tools: Fuzzy Logic, Theory and applications, Fuzzy Neuralnetworks, Pattern Recognition, Differential Evolution, Data Mining Concepts, Applications of

above algorithms in manufacturing engineering problems.

Artificial Neural Networks: Neuron, Nerve structure and synapse, Artificial Neuron and itsmodel, activation functions, Neural network architecture: single layer and multilayer feed forwardnetworks, recurrent networks. Back propagation algorithm, factors affecting back propagationtraining, applications.


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Application of Soft Computing to Mechanical Engineering/Production EngineeringProblems: Application to Inventory control, Scheduling problems, Production Distribution,Routing, Transportation, Assignment problems.

READING:

1. Tettamanzi Andrea, Tomassini and Marco, Soft Computing Integrating Evolutionary, Neuraland Fuzzy Systems, Springer, 2001.

2. Elaine Rich, Artificial Intelligence, McGraw Hill, 2/e, 1990.3. Kalyanmoy Deb, Multi-objective Optimization using Evolutionary Algorithms, John Wiley and

Sons, 2001.


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ME5451 INTEGRATED PRODUCT DESIGN ANDDEVELOPMENT




CO1 Understand the Reverse Engineering and redesign methodology, and modern designTheories for effective development of present day engineering products.

CO2 Describe the social, environmental and ethical concerns to be addressed duringProduct development.

CO3 Understand the modeling and embodiment Principles used in product developmentprocess.

CO4 Identify the significance of analytical and numerical techniques in Productdevelopment engineering.

CO5 Understand the concepts of Robust design, and develop physical models using

product design theory.CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 1 2 2 1 1 1 2CO2 1 3 1CO3 2 2 1 1 1 2CO4 3 2 3 1 1 1CO5 2 2 1 1 1 1 1 2

DETAILED SYLLABUS:

Modern Product development and design theories: Understanding the opportunity, Developa concept, Implement a concept, Reverse engineering and redesign methodology.

Product development process tools: Product development teams, Planning Process,Planning and scheduling tools.

Understanding customer needs: Kano diagram of customer satisfaction, Prioritising Customerneeds

Establishing product function: Function analysis system technique, Function structure.

Product tear down and experimentation: Tear down process, methods, applications, Post

teardown reporting.

Benchmarking and establishing engineering specifications:

Product Portfolios and portfolio Architecture: Portfolio architecture types and choice,Product modularity, Clustering.


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Generating concepts and concept selection: Information gathering, Brainstorming, TRIZ,Morphological Evaluation, Concept selection Process, Numerical Concept scoring.

Concept embodiment: System modeling and embodiment principles.

Modelling of Product metrics: Modelling approaches and case studies.

Design for the environment: DFE methods, Life cycle assessment, Techniques to reduceenvironmental impact.

Analytical and Numerical model solutions: Simulation and optimization techniques.

Design for robustness: Robust Design model construction, methods.

READING:

1. Kevin N. Otto, Kristin L. Wood, Product Design, Pearson Education, 2004.2. Gahl, W Beitz J Feldhusun, K. G. Grote, Engineering Design, 3rd Edition, Springer 2007.

3. W. Ernest Eder, S. Hosendl., Design Engineering, CRC Press, 2008.4. Ali K. Kamrani and Emad Abouel Nasr, “Engineering Design and Rapid Prototyping”,

Springer, 2010.


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ME5711 MODERN MANUFACTURING PROCESSES DEC 3 – 0 – 0 3 Credits

PRE-REQUISITES: Manufacturing Technology, Machining Science


CO1 Identify the characteristics and need for modern manufacturing processes.CO2 Describe the basic mechanism of material removal and working principle of processes.CO3 Identify the process parameters and manufacturing characteristics of processes.CO4 Analyse the effect of process input parameters on process output parameters.CO5 Develop mathematical model relate process input and output parameters.CO6 Apply this knowledge to identify the suitable manufacturing process for specific product

fabrication.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 1 1 1 1

CO2 1 1 1CO3 2 2 1CO4 1 3 2CO5 2 2 2CO6 1 2 2 1

DETAILED SYLLABUS:

Introduction to modern manufacturing processes, need, characteristics and development ofprocesses

Introduction to casting: Stir casting, Slip casting, Combo casting and Sol-gel casting, Metal

injection moulding, Full mould casting, Plaster moulding, Ceramic moulding, Vacuum moulding,and VRH process : Working principle, Identification of process parameters, Analyse the effect ofprocess parameters on output parameters, Mathematical modelling relating process input andoutput parameters, Advantages, Disadvantages and Applications.

Introduction to welding: Laser beam Welding, Electron beam welding, Friction stir welding,Hybrid welding process: Laser arc welding, and Laser MAG welding: Working principle,Identification of process parameters, Analyse the effect of process parameters on outputparameters, Mathematical modelling relating process input and output parameters, Advantages,Disadvantages and Applications.

Introduction to Forming: Hydro forming, Tape forming, High velocity forming, Explosive

forming, Electromagnetic forming, Vacuum forming and Hydro forming: Working principle,Identification of process parameters, Analyze the effect of process parameters on outputparameters, Mathematical modeling relating process input and output parameters, Advantages,Disadvantages and Applications.

Introduction to modern machining: Electric discharge grinding (EDG), Electric dischargediamond grinding (EDDG), Electro chemical grinding (ECG), Electro stream drilling (ESD),Electro chemical deburring (ECD), Laser assisted machining (LAM) and Shaped tubeelectrolytic machining (STEM): Working principle, Material removal mechanism, Identification of


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process parameters, Analyse the effect of process parameters on output parameters,Mathematical modelling relating process input and output parameters, Advantages,Disadvantages and Applications.

READING:

1. P.L. Jain, “Principles of Foundry Technology,” TMH, New Delhi, 2011 2. RS Mishra, Friction Stir Welding and Processing, ASM International, 2007.3. GR Nagpal, Metal Forming Processes, Khanna Pub, New Delhi, 2000.4. V.K. Jain, Advanced Machining Processes, Allied Publishers, Mumbai, 2002.


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ME5712 MECHATRONICS DEC 3 – 0 – 0 3 Credits



CO1 Model, analyze and control engineering systems.CO2 Select appropriate sensors, transducers and actuators to monitor and control the

behavior of a process or product.CO3 Develop PLC programs for a given task.CO4 Evaluate the performance of mechatronic systems.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 3 3 3 1 2 2 2CO2 3 3 3 2 2 2 2

CO3 2 3 3 2 2 2 2 1CO4 3 2 2 2 3 1 2 1

DETAILED SYLLABUS:

Overview of Mechatronics: Historical perspective, Definition, Applications, Block diagram ofMechatronic system, Functions of Mechatronic Systems, Systems Engineering, Verification VsValidation, Benefits of mechatronics in manufacturing.

Electrical and Electronic Systems: Electrical circuits and Kirchhoff’s laws, Network Theoremsand AC circuit Analysis, Transformers, Analog Devices, Signal Conditioning, Digital Electronics,Data Acquisition systems.

Modeling, Analysis and Control of Physical Systems: Basics of System Modeling: LTI andLTV systems, Need for modeling, Types of modeling, Steps in modeling, Building blocks ofmodels, Modeling of one and two degrees of freedom systems, Modeling of Electro-mechanicalsystems, Mechanical Systems, Fluid systems, Thermal systems; Dynamic Responses, SystemTransfer Functions, State Space Analysis and System Properties, Stability Analysis using RootLocus Method, Stability Analysis using Bode Plots, PID Controllers (with and without TimeDelay)

Sensors and Actuators: Static characteristics of sensors and actuators, Position,Displacement and Proximity Sensors, Force and torque sensors, Pressure sensors, Flowsensors, Temperature sensors, Acceleration sensors, Level sensors, Light sensors, Smartmaterial sensors, Micro and Nano sensors, Selection criteria for sensors, Actuators: Electrical

Actuators (Solenoids, Relays, Diodes, Thyristors, Triacs, BJT, FET, DC motor, Servo motor,BLDC motor, AC motor, Stepper motors), Hydraulic and Pneumatic actuators, Design ofHydraulic and Pneumatic circuits, Piezoelectric actuators, Shape memory alloys.

Microprocessors, Microcontrollers and Programmable Logic Controllers: Logic Conceptsand Design, System Interfaces, Communication and Computer Networks, Fault Analysis inMechatronic Systems, Synchronous and Asynchronous Sequential Systems, Architecture,Microcontrollers, Programmable Logic Controllers (PLCs): Architecture, Number Systems


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Basics of PLC Programming, Logics, Timers and Counters, Application on real time industrialautomation systems.

Case Studies: Design of pick and place robot, Car engine management system, Automatedmanufacturing system, Automatic camera, Automatic parking system, Safety devices andsystems.

READING:

1. W. Bolton, Mechatronics, Electronic control systems in mechanical and electricalengineering , Pearson Education, 5/e, 2011.

2. James J Allen, Micro Electro Mechanical Systems Design, CRC Press Taylor & Francisgroup.

3. David G. Alcaiatore and Michel B. Histand, Introduction to Mechatronics and MeasuringSystems, Mc. Graw Hill Int. Edition, 3/e, 2006.

4. Craig K. C. and Stolfi, F. R., Introduction to Mechatronic System Design with Applications,IEEE Educational Activities Department, 1994.

5. Robert H. Bishop, The Mechatronics Handbook , CRC Press, 2/e, 2007.


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ME5703 CAD/CAM LABORATORY PCC 0 – 0 – 3 2 Credits


CO1 Draw complex geometries of parts in sketcher mode. CO2 Generate freeform shapes in part mode to visualize parts. CO3 Create complex engineering assemblies using appropriate assembly constraints.CO4 Identify and correct the problems in STL files during modeling.CO5 Generate error-free model and fabricate a given part.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 3 1 2 1 3 1 1CO2 3 1 2 1 2 1 1 1CO3 3 1 2 1 3 1 1 1

CO4 3 1 2 1 1 1 1CO5 3 1 2 1 3 1 1 1

DETAILED SYLLABUS:

1. Introduction to Solid Modeling & Pro/E Package2. Working with sketch mode of Pro/E3. Working with creating features (Extrude & Revolve)4. Working with the tools like Hole, Round, Chamfer and Rib5. Working with the tools like Pattern, Copy, Rotate, Move and Mirror6. Working with advanced modeling tools (Sweep, Blend & Swept Blend)7. Assembly modeling in Pro/E

8. Generating, editing and modifying drawings in Pro/E9. Working with CAD Data Exchange formats: IGES, ACIS, DXF and STL10. Identification of STL file problems using MAGICS s/w11. Application of repair algorithms to make the model error-free using MAGICS s/w


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ME5704 RAPID PROTOTYPING LABORATORY PCC 0 – 0 – 3 2 Credits



CO1 Optimize the process parameters of FDM machine to improve the quality of the partsproduced.

CO2 Build complex engineering assemblies in plastic material with less process planning. CO3 Improve surface finish of fabricated plastic components for the engineering applications. CO4 Design and fabricate working models for the conceptual testing applications.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 1 2 1 3 3 3 2 2 1 1 3CO2 1 3 1 3 1 1 1 2 1 1 2

CO3 1 3 1 3 2 1 2 1 1 1 2CO4 1 2 2 2 2 1 1 3 1 1 2

DETAILED SYLLABUS:

1. Review of CAD Modeling Techniques and Introduction to RP2. Forming Groups & Assigning Creative Idea3. Generating STL files from the CAD Models & Working on STL files4. Modeling Creative Designs in CAD Software5. Assembling Creative Designs in CAD Software6. Processing the CAD data in Catalyst software (Selection of Orientation, Supports

generation, Slicing, Tool path generation)

7. Simulation in Catalyst Software8. Sending the tool path data to FDM RP machine9. Fabricating the physical part on FDM RP machine10. Removing the supports & post processing (cleaning the surfaces)11. Demonstrating Creative Working Models12. Converting CT/MRI scan data into STL file using MIMICS software (Demo)

READING:

1. Chua Chee Kai., Leong Kah Fai., Chu Sing Lim, Rapid Prototyping: Principles and Applications in Manufacturing, World Scientific, 2010.

2. FDM Dimension 768 RP Machine Manual, Stratasys INC., USA, 2006.3. Mojo 3D Printer Manual, Stratasys INC., USA, 2013.


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ME5751 ADDITIVE MANUFACTURING MACHINESAND SYSTEMS



COURSE OUTCOMES: At the end of the course, the student shall be acquainted with theknowledge of:CO1 Construction of basic AM machinesCO2 Energy delivery, Material delivery, Nozzle and Heating SystemsCO3 Optical & Optoelectronic components in AMCO4 CNC Controller & Process ControllerCO5 Environmental control systemsC06 Pre-processing in AMC07 Post-processing in AMC08 Rapid Tooling equipment

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 3 2 3 3 2 3 3 3 3 3 3CO2 3 2 3 2 2 3 3 3 2 3 3CO3 3 2 3 2 2 3 2 3 2 3 3CO4 3 2 3 2 2 2 3 3 3 3 3CO5 3 2 3 1 2 3 3 3 3 3 3CO6 3 2 2 2 2 3 3 2 2 3 3CO7 3 3 2 3 2 3 3 3 3 3 3CO8 2 3 2 3 2 3 2 3 2 3 3

DETAILED SYLLABUS:

Construction of basic AM machines: Construction of CNC Machine - Axes, Linear motionguide ways, Ball screws, Motors, Bearings, Encoders/ Glass scales, Process Chamber, Safetyinterlocks, Sensors

Energy delivery, Material delivery, Nozzle and Heating Systems: Lasers & electron beam,Laser scanning system and Fibre Delivery Systems, Powder feeding and Wire feeding systems,Multi-material processing, Co-axial & Lateral Nozzles.

Optical & Optoelectronic components in AM: Laser, basic laser optics, collimators, beamexpanders, optic fibres, metal optics etc.

CNC Controller & Process Controller: CNC Controller, Process Controller – Processparameters, Scanning strategies – Raster scan, Patterned Vector Scanning and HatchingPatterns.

Environmental control systems: Environmental controller for temperature, oxygen level,humidity etc.


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Pre-processing in AM: Pre-processing of CAD model – STL Conversion, STL errordiagnostics, Support generation, Transformations, Slicing, Surface preparation of materials,Pre-heating of powders.

Post-processing in AM: Post-processing equipments - Support material removal, surfacetexture improvement, accuracy improvement, aesthetic improvement, preparation for use as a

pattern, property enhancements using non-thermal and thermal techniques.

Rapid Tooling equipment: Introduction, Classification of Rapid Tooling, Direct and IndirectMethods, Applications

READING:

1. Chee Kai Chua, Kah Fai Leong, 3D Printing and Additive Manufacturing: Principles and Applications: Fourth Edition of Rapid Prototyping

2. Andreas Gebhardt, Understanding Additive Manufacturing: Rapid Prototyping, RapidTooling, Rapid Manufacturing

3. Rapid Tooling: Technologies And Industrial Applications by Jacobs, Paul F

4. D.T. Pham, S.S. Dimov, Rapid Manufacturing: The Technologies and Applications of RapidPrototyping and Rapid Tooling


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ME5752 RAPID TOOLING AND INDUSTRIALAPPLICATIONS




CO1 Identify suitable rapid tooling technique for rapid product development.CO2 Model the suitable tooling method for the given industrial application.CO3 Identify the errors during development of tool and minimize them.CO4 Design and fabricate the tool for the given medical applicationCO5 Design and fabricate the tool for the given automobile application

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 2 1 3 2 1 1 1 2 1 2

CO2 2 3 2 2 2 2 2 1 2 1 2CO3 3 3 2 2 2 2 2 1 1 1 3CO4 1 3 1 2 3 2 1 1 1 1 3CO5 1 3 1 2 2 2 1 1 1 1 3

DETAILED SYLLABUS:

Introduction: Convectional Tooling Vs. Rapid Tooling, Classification of Rapid Tooling, Directand Indirect Tooling methods, Soft and Hard Tooling methods.

Rapid Tooling Process Modeling: Introduction to modeling, Concurrent Rapid Product andProcess Development, Finite Element Modeling and Simulation, Injection-moulding, Die-casting,

Blow-moulding, Theroforming Processes modeling

Indirect Methods for Rapid Tool Production and Rapid Bridge Tooling: Role of Rapid SoftTooling methods in tool production, Introduction to Bridge tooling, CAFÉ Bridge tooling,DirectAIM Rapid Bridge tooling, RapidTool Rapid Bridge tooling, Shrinkage Variation, Random-noise Srinkage, Metal deposition tools, RTV tools, Epoxy tools, Ceramic tools, Cast Metal tools,Investment-cast Rapid Production tooling, Fusible metallic cores, Rapid Production tooling forPrecision Sand Casting, Keltool process.

Direct Method for Rapid Tool Production: Role of direct methods in tool production, Direct ACES Injection moulds, Laminated Object Manufactured (LOM) tools, DTM RapidTool,RapidSteel 1.0, RapidSteel 2.0, Copper Polymide tools, SandForm tools, EOS DirectTool

Process, Direct Metal Tooling using 3DP, Topographic Shape Formation (TSF) tools. The Express Tool Process: Introduction, High-Thermal-Conductivity Materials, ConformalCooling Channels, The ExpressTool Process, Finite-Element Analysis of ExpressTools,ExpressTool Process Characteristics, Case studies of Express Tools.

The Role of Rapid Tooling in Investment-Casting Applications: Introduction, Rapid ToolMaking for investment Casting, Rapid Tooling for developing Casting Applications, BELLHelicopter 427 Program


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The Role of Rapid Tooling in Sand-Casting Applications: Sand casting Process, ToolDesign and Construction for Sand Casting, Sand Casting Dimensional Control, Tooling

Alternative Selection Case Studies.

Rapid Tooling in the Medical Device Industry: Introduction, Investment Casting andConventional Wax Pattern Tooling, Conventional Tooling Manufacture Vs. Rapid Tooling

Manufacture, Medical Case studies like Hip Stem and Knee implants. Rapid Tooling in the

Automotive Industry: Approaching Niche Vehicle Markets, Accelerating ProductDevelopments, Utilizing Rapid Prototyping and Manufacturing, Machining Laminates, RapidPrototype Stages, Subsequent Casting Operations, Rapid Tooling Developments, CaseStudies.

The Future of Rapid Tooling and Rapid Manufacturing: Factors influencing Accuracy oftools, Data Preparation Errors, Part Building Errors, Selection of Part Build Orientation, Post-processing methods.

READING:

1. D.T. Pham and S.S Dimov, Rapid Manufacturing: The Technogies and Applications of RapidPrototyping & Rapid Tooling , Springer, 2001.

2. Peter Hilton and Paul F Jacobs, Rapid Tooling Technologies and Industrial Applications,Marcel Dekker Inc, New York, 2001

3. Wanlong Wang, Henry W. Stoll and James G. Conley, Rapid Tooling Guidelines for SandCasting, Springer, 2010.

4. Andreas Gebhardt, Understanding Additive Manufacture: Rapid Prototyping, Rapid Toolingand Rapid Manufacture, Hanser Publishers, 2013.


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MM5151 MATERIALS AND CHARACTERIZATIONTECHNIQUES


Pre-requisites: None

Course Outcomes: At the end of the course the student will be able to:CO1 Interpret various materials characterization techniques.

CO2 Understand the principle and operation of characterization equipment and theadjustment of operation variables to obtain good images / results

CO3 Select the characterization tool for specific application

CO4 Compare the principle and operation of different characterization tools such as opticalmicroscope, Scanning electron microscopes and transmission electron microscope

CO5 Analyze the characterization results by various equipment

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 1 1 1 1 1 1CO2 1 2 1 2 1 1 1 1CO3 1 2 1 2 1CO4 1 1 1 1 1 1CO5 1 1 1 2 1 2 1

DETAILED SYLLABUS:

Optical Microscopy - Introduction, Optical principles, Instrumentation, Specimen preparation-metallographic principles, Imaging Modes, Applications, Limitations.

Scanning Electron Microscopy (SEM) - Introduction, Instrumentation, Contrast formation,Operational variables, Specimen preparation, imaging modes, Applications, Limitations.

Transmission Electron Microscopy (TEM) - Introduction, Instrumentation, Specimenpreparation-pre thinning, final thinning, Image modes- mass density contrast, diffractioncontrast, phase contrast, Applications, Limitations.

X- Ray Diffraction (XRD) - Introduction, Basic principles of diffraction, X - ray generation,Instrumentation, Types of analysis, Data collection for analysis, Applications, Limitations

Thermal Analysis - Introduction, Basics of thermodynamics and heat transfer, Commoncharacteristics- Instrumentation, experimental parameters, Different types used for analysis,Differential thermal analysis, Differential Scanning Calorimetry, Thermogravimetry, Dilatometry,Dynamic mechanical analysis- Basic principles, Instrumentation, working principles,

Applications, Limitations.

Scanning Probe Microscopy (SPM) & Atomic Force Microscopy (AFM)-Introduction,Instrumentation, Scanning Tunneling Microscopy-Basics, probe tips, working environment,operational modes, Applications, Limitations.


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Atomic Force Microscopy (AFM) - basic principles, instrumentation, operational modes, Applications, Limitations

Electron Probe Micro Analyzer (EPMA) - Introduction, Sample preparation, Workingprocedure, Applications, Limitations

X- Ray Spectroscopy for Elemental Analysis - Introduction, Characteristics of X-rays, X- rayFluorescence Spectrometry, Wavelength Dispersive Spectroscopy-Instrumentation, Workingprocedure, Applications, Limitations, Energy Dispersive Spectroscopy - Instrumentation,Working procedure, Applications, Limitations.

READING:

1. ASM Handbook: Materials Characterization, ASM International, 2008.2. Yang Leng: Materials Characterization-Introduction to Microscopic and Spectroscopic

Methods, John Wiley & Sons (Asia) Pte Ltd., 2008.3. Robert F. Speyer: Thermal Analysis of Materials, Marcel Dekker Inc., New York, 1994.

4. V. T. Cherapin and A. K. Mallik: Experimental Techniques in Physical Metallurgy, AsiaPublishing House, 1967.

5. S.J.B. Reed: Electron Microprobe Analysis, Cambridge University Press, London, 1975.


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MM5170 POWDER METALLURGY DEC 3 – 0 – 0 3 Credits



CO1 Classify powder preparation techniquesCO2 Identify the characterization techniques for powderCO3 Differentiate between conventional powder compaction and modern compaction

techniquesCO4 Explain the mechanism of sintering theoryCO5 Explain importance of modern sintering techniquesCO6 Apply powder metallurgical techniques for mechanical components

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 1 1 1 1 1 1CO2 2 2 2 1 1 1 1CO3 1 2 1 1 1 1CO4 1 1 1 1 1 1 1CO5 1 1 1 1 1 1CO6 2 3 1 2 1 1

DETAILED SYLLABUS:

General Concepts: Introduction and History of Powder Metallurgy (PM), Present and FutureTrends of PM

Powder Production Techniques: Different Mechanical and Chemical methods, Atomisation ofPowder, other emerging processes, Performance Evaluation of different Processes, Design &Selection of Process.

Characterization Techniques: Particle Size & Shape Distribution, Electron Microscopy ofPowder, Interparticle Friction, Compressionability, Powder Structure, Chemical Characterization

Microstructure Control in Powder: Importance of Microstructure Study, Microstructures ofPowder by Different techniques

Powder Shaping: Particle Packing Modifications, Lubricants & Binders, Powder Compaction &Process Variables, Pressure & Density Distribution during Compaction, Isostatic Pressing,

Injection Molding, Powder Extrusion, Slip Casting, Tape Casting, Analysis of Defects of PowderCompact, Laser Engineering Net Shaping (LENS), 3D Printers for Ceramics

Sintering: Theory of Sintering, Sintering of Single & Mixed Phase Powder, Liquid PhaseSintering, Sintering Variables, Modern Sintering Techniques, Physical & Mechanical PropertiesEvaluation, Structure-Property Correlation Study, Modern Sintering techniques, Defects

Analysis of Sintered Components


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Application of Powder Metallurgy: Filters, Tungsten Filaments, Self-Lubricating Bearings,Porous Materials, Biomaterials etc.

READING:

1. Powder Metallurgy Technology, Cambridge International Science Publishing, 2002.

2. J. S. Hirschhorn: Introduction to Powder Metallurgy, American Powder Metallurgy Institute,Princeton, NJ, 1976.

3. P. C. Angelo and R. Subramanian: Powder Metallurgy- Science, Technology and Applications, PHI, New Delhi, 2008.

4. ASM Hand Book, vol. 7: Powder Metallurgy, ASM International.


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ME5169 COMPUTATIONAL FLUID DYNAMICS DEC 3 – 0 – 0 3 Credits



CO1 Explain the differential equations for flow phenomena and numerical methods for theirsolution

CO2 Analyze mathematical models and computational methods for fluid flow and heattransfer simulations

CO3 Solve computational problems related to fluid flow and heat transferCO4 Analyze the accuracy of a numerical solution by comparison to known solutions of

simple test problems and by mesh refinement studiesCO5 Evaluate forces in both internal and external flowsCO6 Use flow simulation software and develop code for the most important classes of flows

in engineering and science

CO-PO MAPPING: PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11

CO1 2 1CO2 3 1 1 1 1CO3 3 3 3 2 1 2CO4 2 1CO5 2 1CO6 2 2 2 1 3 1 2

DETAILED SYLLABUS:

INTRODUCTION: History and Philosophy of computational fluid dynamics, CFD as a designand research tool, Applications of CFD in engineering, Programming fundamentals, MATLABprogramming, Numerical Methods

GOVERNING EQUATIONS OF FLUID DYNAMICS: Models of the flow, The substantialderivative, Physical meaning of the divergence of velocity, The continuity equation, Themomentum equation, The energy equation, Navier-Stokes equations for viscous flow, Eulerequations for inviscid flow, Physical boundary conditions, Forms of the governing equationssuited for CFD, Conservation form of the equations, shock fitting and shock capturing, Timemarching and space marching.

MATHEMATICAL BEHAVIOR OF PARTIAL DIFFERENTIAL EQUATIONS: Classification of

quasi-linear partial differential equations, Methods of determining the classification, Generalbehavior of Hyperbolic, Parabolic and Elliptic equations.

BASIC ASPECTS OF DISCRETIZATION: Introduction to finite differences, Finite differenceequations using Taylor series expansion and polynomials, Explicit and implicit approaches,Uniform and unequally spaced grid points.


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GRIDS WITH APPROPRIATE TRANSFORMATION: General transformation of the equations,Metrics and Jacobians, The transformed governing equations of the CFD, Boundary fittedcoordinate systems, Algebraic and elliptic grid generation techniques, Adaptive grids.

PARABOLIC PARTIAL DIFFERENTIAL EQUATIONS: Finite difference formulations, Explicitmethods – FTCS, Richardson and DuFort-Frankel methods, Implicit methods – Laasonen,

Crank-Nicolson and Beta formulation methods, Approximate factorization, Fractional stepmethods, Consistency analysis, Linearization.

STABILITY ANALYSIS: Discrete Perturbation Stability analysis, von Neumann Stabilityanalysis, Error analysis, Modified equations, Artificial dissipation and dispersion

ELLIPTIC EQUATIONS: Finite difference formulation, solution algorithms: Jacobi-iterationmethod, Gauss-Siedel iteration method, point- and line-successive over-relaxation methods,alternative direction implicit methods.

HYPERBOLIC EQUATIONS: Explicit and implicit finite difference formulations, splittingmethods, multi-step methods, applications to linear and nonlinear problems, linear damping, flux

corrected transport, monotone and total variation diminishing schemes, tvd formulations,entropy condition, first-order and second-order tvd schemes.

SCALAR REPRESENTATION OF NAVIER-STOKES EQUATIONS: Equations of fluid motion,numerical algorithms: ftcs explicit, ftbcs explicit, Dufort-Frankel explicit, Maccormack explicit andimplicit, btcs and btbcs implicit algorithms, applications.

GRID GENERATION: Algebraic Grid Generation, Elliptic Grid Generation, Hyperbolic GridGeneration, Parabolic Grid Generation

FINITE VOLUME METHOD FOR UNSTRUCTURED GRIDS: Advantages, Cell Centered andNodal point Approaches, Solution of Generic Equation with tetra hedral Elements, 2-D Heat

conduction with Triangular Elements

NUMERICAL SOLUTION OF QUASI ONE-DIMENSIONAL NOZZLE FLOW: Subsonic-Supersonic isentropic flow, Governing equations for Quasi 1-D flow, Non-dimensionalizing theequations, MacCormack technique of discretization, Stability condition, Boundary conditions,Solution for shock flows.

Text Books:1. Anderson, J.D.(Jr), Computational Fluid Dynamics, McGraw-Hill Book Company, 1995.2. Hoffman, K.A., and Chiang, S.T., Computational Fluid Dynamics, Vol. I, II and III,

Engineering Education System, Kansas, USA, 2000.3. Chung, T.J., Computational Fluid Dynamics, Cambridge University Press, 2003.

4. Anderson, D.A., Tannehill, J.C., and Pletcher, R.H., Computational Fluid Mechanics andHeat Transfer , McGraw Hill Book Company, 2002.


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ME5262 PRODUCT DESIGN FOR MANUFACTURINGAND ASSEMBLY




CO1 Understand the quality aspects of design for manufacture and assembly.CO2 Apply Boothroyd method of DFM for product design and assembly.CO3 Apply the concept of DFM for casting, welding, forming and assembly.CO4 Identify the design factors and processes as per customer specifications.CO5 Apply the DFM method for a given product.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 1 1 1 1 1 1 1 1CO2 2 1 2 3 1CO3 2 3 2 1 1CO4 2 1 1 1 2 2 1 1 2CO5 2 3 1 2 2 1 1 2 1 1

DETAILED SYLLABUS:

Introduction to DFM, DFMA: How Does DFMA Work?, Reasons for Not Implementing DFMA,What Are the Advantages of Applying DFMA During Product Design?, Typical DFMA CaseStudies, Overall Impact of DFMA on Industry.

Design for Manual Assembly: General Design Guidelines for Manual Assembly, Development

of the Systematic DFA Methodology, Assembly Efficiency, Effect of Part Symmetry, Thickness,Weight on Handling Time, Effects of Combinations of Factors, Application of the DFAMethodology.

High speed Automatic Assembly & Robot Assembly: Design of Parts for High-SpeedFeeding and Orienting, Additional Feeding Difficulties, High-Speed Automatic Insertion, GeneralRules for Product Design for Automation, Design of Parts for Feeding and Orienting, ProductDesign for Robot Assembly.

Design for Machining and Injection Molding: Machining Using Single-Point & Multi pointcutting tools, Choice of Work Material, Shape of Work Material, Machining Basic ComponentShapes, Cost Estimating for Machined Components, Injection Molding Materials, The MoldingCycle, Injection Molding Systems, Molding Machine Size, Molding Cycle Time, Estimation of theOptimum Number of Cavities, Design Guidelines.

Design for Sheet Metal working & Die Casting: Dedicated Dies and Press-working, PressSelection, Turret Press working, Press Brake Operations, Design Rules, The Die Casting Cycle,

Auxiliary Equipment for Automation, Determination of the Optimum Number of Cavities,Determination of Appropriate Machine Size, Die Casting Cycle Time Estimation, Die CostEstimation, Design Principles.


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Design for Assembly Automation: Fundamentals of automated assembly systems, Systemconfigurations, parts delivery system at workstations, various escapement and placementdevices used in automated assembly systems, Quantitative analysis of Assembly systems, Multistation assembly systems, single station assembly lines.

READING

1. Geoffrey Boothroyd, Assembly Automation and Product Design, Marcel Dekker Inc., NY, 3rdEdition,2010.

2. Geoffrey Boothroyd, Hand Book of Product Design, Marcel Dekker Inc., NY, 1992.


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ME5362 DESIGN AND ANALYSIS OF EXPERIMENTS DEC 3 – 0 – 0 3 Credits



CO1 Formulate objective(s) and identify key factors in designing experiments for a givenproblem.

CO2 Develop appropriate experimental design to conduct experiments for a given problem.CO3 Analyze experimental data to derive valid conclusions.CO4 Optimize process conditions by developing empirical models using experimental data.CO5 Design robust products and processes using parameter design approach.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 3 3 2 3 1 1 2 2 2CO2 2 2 1 3 1 1 2 2CO3 1 2 1 3 2 1 2 2CO4 2 2 1 2 3 1 2 2CO5 2 2 1 2 2 1 1 2 2

DETAILED SYLLABUS

Fundamentals of Experimentation: Role of experimentation in rapid scientific progress,Historical perspective of experimental approaches, Steps in experimentation, Principles ofexperimentation;

Simple Comparative Experiments: Basic concepts of probability and statistics, Comparison of

two means and two variances, Comparison of multiple (more than two) means & ANOVA;Experimental Designs: Factorial designs, fractional factorial designs, orthogonal arrays,standard orthogonal arrays & interaction tables, modifying the orthogonal arrays, selection ofsuitable orthogonal array design, analysis of experimental data;

Response Surface Methodology: Concept, linear model, steepest ascent, second ordermodel, regression;

Taguchi’s Parameter Design: Concept of robustness, noise factors, objective function & S/Nratios, inner-array and outer-array design, data analysis

READING

1. Montgomery DC, Design and Analysis of Experiments, 7th Edition, John Wiley & Sons, NY,2008.

2. Ross PJ, Taguchi Techniques for Quality Engineering, McGraw-Hill Book Company, NY,2008.


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ME5471 FINITE ELEMENT ANALYSIS DEC 3 – 0 – 0 3 Credits



CO1 Understand the Finite Element Formulation procedure for structural Problems.CO2 Understand the representation and assembly considerations for Beam and Frame

elements.CO3 Analyze plane stress, plane strain, axi-symmetric problems.CO4 Formulate and solve simple heat transfer and fluid mechanics problemsCO5 Identify significant applications of FEM in Manufacturing.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 1 1 3 1 2 2CO2 2 1 1 3 1 2 2CO3 2 1 1 3 1 2 2CO4 1 1 1 1 2 2CO5 3 1 2 2 3 1 1 2 2

DETAILED SYLLABUS:

Introduction: Historical Perspective of FEM and applicability to mechanical engineeringproblems

Mathematical Models and Approximations: Review of elasticity, mathematical models forstructural problems, Equilibrium of continuum-Differential formulation, Energy Approach-Integral

formulation, Principle of Virtual work - Variational formulation. Overview of approximatemethods for the solution of the mathematical models; Ritz, Rayleigh-Ritz and Ge larkin’smethods, Philosophy and general process of Finite Element method

Finite Element Formulation: Concept of discretisation, Interpolation, Formulation of Finiteelement characteristic matrices and vectors, Compatibility, Assembly and boundaryconsiderations

Finite element Method in One Dimensional Structural problems: Structural problems withone dimensional geometry. Formulation of stiffness matrix , consistent and lumped load vectors.Boundary conditions and their incorporation: Elimination method, Penalty Method, Introductionto higher order elements and their advantages and disadvantages. Formulation for Trusselements, Case studies with emphasis on boundary conditions and introduction to contactproblems.

Beams and Frames: Review of bending of beams, higher order continuity, interpolation forbeam elements and formulation of FE characteristics, Plane and space frames and examplesproblems involving hand calculations.

Two dimensional Problems: Interpolation in two dimensions, natural coordinates,Isoparametric representation, Concept of Jacobian. Finite element formulation for plane stress


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plane strain and axi-symmetric problems; Triangular and Quadrilateral elements, higher orderelements, subparametric, Isoparametric and superparametric elements. General considerationsin finite element analysis of two dimension problems, Introduction plate bending elements andshell elements

Three Dimensional Problems: Finite element formulation for 3-D problems, mesh preparation,

tetrahedral and hexahedral elements, case studies.

Dynamic Analysis: FE formulation in dynamic problems in structures using Lagragian Method,Consistent and lumped mass models, Formulation of dynamic equations of motion andintroduction to the solution procedures.

FEM in Heat Transfer and Fluid Mechanics problems : Finite element solution for onedimensional heat conduction with convective boundaries. Formulation of element characteristicsand simple numerical problems, Finite element applications in one dimensional potential flows;Formulation based on Potential function and stream function.

Algorithmic Approach for problem solving: Algorithmic approach for Finite element

formulation of element characteristics, Assembly and incorporation of boundary conditions,Guidelines for code development, Introduction to commercial FE packages

READING

1. Seshu P, Textbook of Finite Element Analysis, PHI. 20042. Reddy, J.N., Finite Element Method in Engineering, Tata McGraw Hill, 2007.3. Singiresu S.Rao, Finite element Method in Engineering, 5ed, Elsevier, 20124. Zeincowicz, The Finite Element Method for Solid and Structural Mechanics, 4th Edition,

Elsevier 2007.


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ME5761 ADDITIVE MANUFACTURING IN MEDICALAPPLICATIONS




CO1 Apply the concepts of medical imaging, 3D scanning and digitizing for accurate 3Dmodel construction.

CO2 Identify the errors during processing of medical image data and minimize them.CO3 Select the suitable material for the given medical application.CO4 Analyze and select an additive manufacturing technology for a given medical

application.CO5 Analyze and design the virtual models of the patient for planning the surgery. CO6 Design and fabricate bio-models for the given medical application.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 2 3 1 3 2 2 1 2 1 2CO2 2 2 2 1 3 2 2 1 2 1 2CO3 1 1 1 1 3 2 1 1 2 1 2CO4 2 3 2 3 3 3 2 1 2 1 2CO5 2 2 2 2 3 1 2 1 2 1 3CO6 2 2 2 2 3 1 2 1 2 1 3

DETAILED SYLLABUS:

3 Dimensional Data Capture and Processing: Introduction to medical imaging, X-Ray

technology, Computed Tomography (CT), Magnetic Resonance Imaging (MRI), Ultrasoundimaging, 3-D laser scanners, Industrial CT Scanners, 3D reconstruction and ReverseEngineering (RE)

Medical Image Processing Software: Processing of medical data from CT/MRI scan to 3Dmodel in MIMICS, 3D-Doctor, Velocity2Pro, VoXim, SurgiGuide, SimPlant Software

Bio-modelling and Virtual Models in Medicine: Surgical applications of virtual models inCranio-maxillofacial biomodelling, Oral and Maxillofacial surgery, customized cranio-maxillofacial prosthetics, Biomodel-guided stereotaxy, Vascular biomodelling, Skull-base tumoursurgery, Spinal surgery and Orthopaedic biomodelling.

MIMICS Software: MIMICS software modules, Importing data, thresholding, segmentation,Editing, region growing, volume reduction, 3D Visualization, surgical simulation, Meshing,Measurement tools, Smoothing tools, STL conversion , Morphological operations, Labelling,volume, RP file generation.

Biomaterials: Introduction to biomaterials, metallic biomaterials, ceramic biomaterials,polymeric biomaterials, composite biomaterials, biodegradable polymeric biomaterials, tissue-derived biomaterials


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Planning and Simulation of Complex Surgeries: Cranioplasty of large cranial defect,Congential malformation of facial bones, Cosmetic facial reconstruction, Separation of conjoinedtwins, Tumor in the jaw, Cancerous brain, Dental precision planning and Spinal instrumentation.

Design and Fabrication of Customized Implants and Prosthesis: Cranium implants, Hipimplants, Knee implants, Intervertebral spacers, Buccopharyngeal stent, Tracheobronchial

stents, Obturator prosthesis and Tissue engineering scaffolds.

Design and Production of Medical Devices: Biopsy needle housing, Drug delivery devices,Masks for burnt victims, Functional prototypes help prove design value.

Additive Manufacturing in Forensic Science and Anthropology, Visualization ofbiomolecules and Organ Printing

READING:

1. Ian Gibson, Advanced Manufacturing Technology for Medical Applications, John Wiley,2005.

2. Paulo Bartolo and Bopaya Bidanda, Bio-materials and Prototyping Applications in Medicine,Springer, 2008.

3. Joseph D. Bronzino, The Biomedical Engineering Hand Book , 3rd Edition, CRC Press, 2006.


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ME5762 MODELING AND SIMULATION OFMANUFACTURING SYSTEMS




CO1 Classify simulation and analytical models used in manufacturing system environmentCO2 Review of probability and simulation languagesCO3 Design and evaluate a given manufacturing system using simulationCO4 Generate random numbers and variants to execute a simulation modelCO5 Evaluate queuing networks and markov chains in the context of manufacturing

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 2 2 1 1 1CO2 2 2 2 2 1 1CO3 2 2 2 3 1 1CO4 1 1 2 2 1 1CO5 1 1 1 1 1 1

DETAILED SYLLABUS:

Introduction to System and simulation: Concept of system and elements of system, Discreteand continuous system, Models of system and Principles of modeling and simulation, Montecarlo simulation, Types of simulation, Steps in simulation model, Advantages, limitations andapplications of simulation, Applications of simulation in manufacturing system

Review of statistics and probability: Types of discrete and continuous probability distributionssuch as Geometric, Poisson, Uniform, Geometric distribution with examples, Normal,Exponential distribution with examples

Random numbers: Need for RNs, Technique for Random number generation such as Midproduct method, Mid square method, and Linear congruential method with examples

Test for Random numbers: Uniformity - Chi square test or Kolmogorov Smirnov test,Independency- Auto correlation test

Random Variate generation: Technique for Random variate generation such as Inversetransforms technique or Rejection method

Analysis of simulation data: Input data analysis, Verification and validation of simulationmodels, Output data analysis

Simulation languages: History of simulation languages, Comparison and selection ofsimulation languages

Design and evaluation of simulation experiments: Development and analysis of simulationmodels using simulation language with different manufacturing systems


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Queueing models: An introduction, M/M/1 and M/M/m Models with examples, Open Queueingand Closed queueing network with examples

Markov chain models and others: Discrete time markov chain with examples, Continues timemarkov chain with examples, stochastic process in manufacturing, Game theory

READING:

1. Jerry Banks, John S. Carson, Barry L. Nelson, David M. Nicol, and P. Shahabudeen,Discrete Event System Simulation, PHI, New Delhi, 2008.

2. Averill M. Law and W. David Kelton, Simulation Modeling and Analysis, Tata McGraw Hill,New Delhi, 2006.

3. N. Viswanadham and Y. Narahari, "Performance Modeling of Automated ManufacturingSystems", PHI, New Delhi, 2007.


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ME5763 REVERSE ENGINEERING AND COMPUTER

AIDED INSPECTION DEC 3 – 0 – 0 3 Credits



CO1 Identify and explain the steps involved in reverse engineering of a given component.CO2 Develop design changes satisfying client’s requirements and fabricate a given

component bypassing the regular design and manufacturing steps.CO3 Apply the concepts of calibration, traceability and uncertainty for accurate and reliable

measurements.CO4 Identify and estimate measurement errors and suggest suitable techniques to minimize

them.CO5 Describe the methods and devices for dimensional metrology.CO6 Assess surface roughness and form errors.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 2 1 2 1 1CO2 2 2 1 2 2 1 2CO3 2 2 2 1 1 1CO4 2 3 1 1 1 1CO5 2 3 2 2 1 1 1CO6 2 3 2 2 1 1

DETAILED SYLLABUS:

Introduction to reverse engineering, Reverse Engineering –The Generic ProcessMethodologies and Techniques for Reverse Engineering – The Potential for Automationwith 3-D Laser Scanners, What Is Not Reverse Engineering, What is Computer-aided (Forward)Engineering, What Is Computer-aided Reverse Engineering, Computer Vision and ReverseEngineering

Reverse Engineering –Hardware and Software: Contact Methods Noncontact Methods,Destructive Method

Selecting a Reverse Engineering System: The Selection Process, Some AdditionalComplexities, Point Capture Devices, Triangulation Approaches, “Time-of-flight” or Ranging

Systems, Structured-light and Stereoscopic Imaging Systems, issues with Light-based Approaches, Tracking Systems, Internal Measurement Systems, X-ray Tomography,Destructive Systems, Some Comments on Accuracy, Positioning the Probe, Post processingthe Captured Data, Handling Data Points, Curve and Surface Creation, Inspection Applications,Manufacturing Approaches

Integration Between Reverse Engineering and Additive manufacturing: Modeling CloudData in Reverse Engineering, Data Processing for Rapid Prototyping, Integration of RE and RPfor Layer-based Model Generation, he Adaptive Slicing Approach for Cloud Data Modeling,


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Planar Polygon Curve Construction for a Layer, Determination of Adaptive Layer Thickness

Reverse Engineering in Automotive, Aerospace, Medical sectors: Legal Aspects ofReverse Engineering: Copyright Law, Reverse Engineering, Recent Case LawBarriers to Adopting Reverse Engineering

General Concepts: Generalized measurement system, Basic terminology, Errors inmeasurement, Calibration, Uncertainty.

Amplifying Devices: Tool Maker’s microscope, Profile projector, Comparators: Mechanical,Pneumatic, optical, electric and electronic.

Gear and Screw Thread Measurements: Gear measurement: Classification of gears, Forms ofgear teeth, Gear tooth terminology, Methods of measuring tooth thickness, tooth profile & pitch,Gear Errors. Screw Thread Measurement: Terminology, Forms of thread, Errors in threads,Measurement of major, minor and effective diameters

Laser Metrology - Applications of Lasers in precision measurements - Laser interferometer,

Laser scanners.

Surface Roughness Measurement: Components of surface texture, Need for surfaceroughness measurement, Measurement of surface roughness, Roughness characterization,Roughness grades

Geometric Form Measurement: Importance, Indication, Intrinsic and Extrinsic methods,Roundness, Straightness, Flatness, Cylindricity, Squareness, Parallelism, Run out andconcentricity

Coordinate Measuring Machine - Types of CMM - Probes used – Applications - dimensionalmetrology – Non-contact sensors for surface finish measurements.

Other Computer Aided Inspection Techniques/Instruments: In-process Inspection and On-line Sensing, Automated Inspection Techniques, Image processing and its application inMetrology.

READING:

1. K. Otto and K. Wood, Product Design: Techniques in Reverse Engineering and New ProductDevelopment , Prentice Hall, 2001.

2. Reverse Engineering: An Industrial Perspective by Raja and Fernandes, Springer-Verlag2008.

3. Thomas. G. G., Engineering Metrology, Butterworth Pub.1974.

4. R. K. Jain, Engineering Metrology, Khanna Publishers, 19/e, 2005.


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ME5764 MANUFACTURING CONTROL ANDAUTOMATION




CO1 Understand the fundamentals of automation, when and where to apply them.CO2 Identify various material handling systems and automation systems.CO3 Apply various control systems in manufacturing and evaluate automatic productionCO4 Design an optimal circuit for automation.CO5 Use modeling and simulation for manufacturing automation.

CO-PO MAPPING:

CO PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 1 1 1 1 1 2CO2 2 1 1 1CO3 2 2 1 2CO4 2 1 2 1CO5 3 2 2 2 2 3 2 2

1. Introduction: Automation in production system principles and strategies of automation,basic Elements of a automated system. Advanced Automation functions. Levels of

Automations, introduction to automation productivity.

2. Material Handling System: Over view of Handling system-Rotary feeders, oscillating forcefeeder, vibratory feeder, elevator type and Transport system storage system.

3. Automated Manufacturing Systems: Components of automation, line balancing,

manufacturing cells & transfer mechanism. Fundamentals and analysis of transfer linesproduct design for automatic assembly.

4. Control Technologies in Automation: Industrial control system. Process industry vsDiscrete manufacturing industries. Continuous vs discrete control. Continuous process andits forms, Sensors and Actuators. Other control system components. Supervisory ProductionControl and Management Systems

5. Evaluation of Automatic Production: Product manufacturability. Orientation devices-active and passive devices, Parts orientation and Escapement.

6. Pneumatic and Hydraulic Components and Circuits: Pneumatic sensors and amplifiers.Jet destruction devices, Logic devices, Schmit triggering devices, developing pneumaticcircuits for automatic die casting machine.

7. Modeling and Simulation for Manufacturing Plant Automation: Introduction. Need forsystem modeling. Building mathematical model of a manufacturing plant. Modern tools inmanufacturing automation, Robots and Application of Robots for Automation.


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READING:1. Mikell P Groover, Automation, Production Systems and Computer Integrated Manufacturing,

3rd Edition, Prentice Hall Inc., New Delhi, 2007.2. Tiess Chiu Chang and Richard A.W., An Introduction to Automated Process Planning

Systems, TMH, New Delhi, 2000.3. Nanua Singh, System Approach to Computer Integrated Manufacturing, Wiley & Sons Inc.,

1996.4. Andrew Kusiak, Intelligent Manufacturing System, Prentice Hall Inc., New Jersey, 1992.


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ME5753 RAPID PROTOTYPING AND TOOLINGLABORATORY




CO1 Model complex geometry of the engineering components. CO2 Identify and correct the problems in STL files during modelling. CO3 Optimize the process parameters of DMLS and DMD metal RP machines to improve the

quality of the parts produced. CO4 Build complex engineering assemblies in metal with less process planning. CO5CO6

Improve surface finish of fabricated components in metal for the Tooling applications.Design and fabricate micro-sized models for the functional testing applications.

CO-PO MAPPING:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11CO1 2 2 2 1 1 1 3 2 1 1 2CO2 3 2 3 2 2 1 2 1 1 1 3CO3 1 3 1 3 3 3 2 2 1 1 3CO4 1 3 1 3 2 2 1 2 1 1 2CO5 1 3 1 3 2 1 2 1 1 1 2CO6 1 2 2 2 3 1 1 3 1 1 2

DETAILED SYLLABUS:1.

Documents

MTech Additive Manufacturing Syllabus