SCHEME OF INSTRUCTION AND EVALUATION I - … · ES Computer Lab 3-0 2 100 50 2 1 50 ES ... Experiment/Design for ... Melting of steels and non-ferrous metals and alloys, solidification,

B.Tech (Production Engineering) Syllabus for Admission Batch 2015-16

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SCHEME OF INSTRUCTION AND EVALUATION I - VIII SEMESTER OF B.TECH. DEGREE PROGRAMME

Branch-Production Engineering/ Manufacturing Engineering

First Year Engineering

First Semester

Theory Practical

Code Course Name Hours/

Week L/T

Credit Theory

University Marks

Internal Evaluation

Hours/

Week L/T

Credit Practical

Marks

BS Applied Mathematics-I 3-1 4 100 50 - - -

BS Applied Chemistry/Applied Physics

3-0 3 100 50 2 1 50

ES Basics of Mechanical Engineering / Basics of Civil Engineering

3-0 3 100 50 2 1 50

MC & GS

Environmental Studies & Health Care Engineering/ Professional Ethics

3-0 3 100 50

HS English Communication Skill

3-0 3 100 50 2 2 50

ES Computer Lab 3-0 2 100 50 2 1 50

ES Engineering Workshop/ Engineering Graphics lab.

4 2 100

Total 16 18 600 300 18 7 300

Total Marks: 1200

Total Credits: 25


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Second Semester

Theory Practical

Code Course Name Hours/

week L/T

Credit Theory

University marks

Internal Evaluation

Hours/

Week L/T

Credit Practical

Marks

BS Applied Mathematics-II 3-1 4 100 50 - - -

BS Applied Physics/Applied Chemistry

3-0 3 100 50 2 1 50

ES Basics of Civil Engineering / Basics of Mechanical Engineering

3-0 3 100 50 2 1 50

MC & GS Environmental Studies & Health Care Engineering/ Professional Ethics

3-1 3 100 50

ES Electrical & Electronics Engineering

3-0 3 100 50 2 2 50

ES Computer Lab 3-0 2 100 50 2 1 50

ES Engineering Graphics lab./ Engineering Workshop

4 2 100

MC NSS/NCC/NSO/Yoga - - - -

Total 17 18 600 300 14 7 300

Total Marks: 1200

Total Credits: 25


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Second Year Engineering

Third Semester

Theory Practical Code Course Name Hours/

Week L/T

Credit Theory

University Marks

Internal Evaluation

Hours/Week L/T

Credit Practical

Marks

PC Manufacturing Technology I

3-0 3 100 50 2 1 50

PC Introduction to Physical Methodology & Engineering Material

3-0 3 100 50 2 1 50

PC Applied Thermodynamics

3-0 3 100 50 2 1 50

PC Theory of Machine 3-0 3 100 50 2 1 50 PC Strength of Material 3-1 4 100 50 HS Engineering Economics/

Organizational Behaviour

2-1 3 100 50

Total 19 19 600 300 8 4 200

Total Marks: 1100

Total Credits: 23

Honours

Composite Material/ Surface Engineering Principle and Practice

4 4 100 50

Minor Manufacturing Processes

Fourth Semester


Week L/T

Credit Theory

University Marks

Internal Evaluation

Hours/Week L/T

Credit Practical

Marks

HS Applied Mathematics f III

3-0 3 100 50

PC Manufacturing Science II

3-0 3 100 50 2 1 50

PC Design of Machine Elements

3-0 3 100 50 2 1 50

PC Metrology & Inspection 3-0 3 100 50 2 1 50 PC Robotics & FMS 3-0 3 100 50 2 1 50 HS Engineering Economics/

Organizational Behavior 2-1 3 100 50

*Skill Project and Hands on

6 3 100

Total 18 18 600 300 14 7 300

Total Marks: 1200

Total Credits: 25 Honours Fault

Diagnostics And Condition Monitoring

4 4 100 50

Minor Metrology, Quality Control & Reliability


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*College should conduct at least one NSDC program under this category.

Third Year Engineering

Fifth Semester


Week L/T

Credit Theory

University Marks

Internal Evaluation

Hours/Week L/T

Credit Practical

Marks

PC Production & Operation Management

3-0 3 100 50 2 1 50

PC Materials Deformation Processes

3-0 3 100 50 2 1 50

PC Tool Design 3-0 3 100 50 2 1 PE Statistical Quality Control

& Reliability/Fluid Mechanics & Fluid Power Engineering/Plastic Processing/Work Study & Ergonomics

3-1 4 100 50 50

OE Human Resources Management/C++ & Object Oriented Programming/Internet & Web Technology/Tribology/Non-Convention Energy Sources/Supply Chain Management

3-1 4 100 50

PC Advance Lab-I 8 4 200

Total 17 17 500 250 14 7 350

Total Marks: 1100

Total Credits: 24

Honours Advance Casting and Welding/Optimization in Manufacturing

4 4 100 50

Minor Production Design and Development


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Sixth Semester

Theory Practical Code Course Name Hours/week

L/T Credit Theory

University Marks

Internal Evaluation

Hours/week L/T

Credit Practical

Marks

PC Non-Traditional Machining

3-0 3 100 50 2 1 50

PC CAD/CAM 3-0 3 100 50 2 1 50 PE Computer

Integrated Manufacturing/Maintenance Engineering & Management/Precision Engineering

3-1 4 100 50

PE Rapid manufacturing Process/Machine Tool Design/Plastic Mold & Die Design

3-1 4 100 50

^SE 3-0 3 100 50 OE Industrial Lecture

# 3 1 50

HS Business Communication & Skill for Interview ##

2-0 1 50 4 2 100

Total 19 18 500 300 13 6 300

Total Marks: 1100

Total Credits: 24

Honours 4 4 100 50

Minor

^ Supervise Elective (SE) to taken up by the student by his/her choice of any topic which will be provided by the

University/College. Only one faculty will be assigned to act as guide. The examination shall be conducted by a panel of three

examiners out of which one shall be nominated by the University. There will be no common examination by the University.

*Project/ Case Study as assigned by the College/Supervisor

# To be conducted by the Training & Placement department by inviting experts from the industry. No academician to be

called. Record may be asked by the University for verification. Evaluation to be done by the TPO.

# # To be conducted by the Training & Placement department of the College.


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Final Year Engineering

Seventh Semester


Week L/T

Credit Theory

University Marks

Internal Evaluation

Hours/Week L/T

Credit Practical

Marks

GS Nano & Bioscience 3-1 4 100 50 PE Product Design &

Development/Industrial Hydraulics/Surface Engineering Instrumentation & Control Engineering

3-1 4 100 50

PE Design of Experiment/Design for Manufacturing &Assembly/Mechatronics & MEMS

3-1 4 100 50

OE Soft Computing* / Other Subjects

3-1 4 100 50

PC Advance Lab-II/ Project 8 4 200 Projects on Internet of

Things

Total 16 16 400 200 16 8 400

Total Marks: 1000

Total Credits: 24

Honours 4 4 100 50

Minor

*Student can choose from any department but subject must be running in that semester.

Eighth Semester

Training cum Project Evaluation Scheme Code Course Name Hours/week

L/T Credit Theory

Total Marks

Marks

Industrial Training cum Project/ Entrepreneurship Training cum Project / Stratup Training cum Project

30 20 1000 Evaluation by the Industry / Training Organisation

500

Evaluation by the Institute (Report & Institute Viva)

500

Total 30 20 1000 1000 Total Marks:1000 Total Credits:20

Note- Minimum Pass Mark from Industry Evaluation is 300 (i.e. 60%).


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Distribution of Credit Semester wise: Semester Credit

First 25

Second 25

Third 23

Fourth 25

Fifth 24

Sixth 24

Seventh 24

Eighth 20

-------------------------------------

Total 190

Internal Evaluation Scheme

Attendance & Class Interaction 05

Assignment 05

Surprise Test 05

Quiz 05

Class Test I & II 30

Total 50

Class Test Time(Hrs.): 1

Pass Mark in Internal is 50% of total marks i.e. 25

External Evaluation Scheme

University Semester Examination of 3 Hours duration.

Pass mark will be 35% which means students have to score 35 out of 100.

Practical/Sessional Evaluation Scheme

Pass mark will be 50% which means students have to score 25 out of 50.

Evaluation Scheme

Attendance & Daily Performance -10

Lab Record - 10

Lab Quiz - 05

Final Experiments & Viva – 25

-------------------------------------------------------

Total=50

All Lab examinations are to be completed one week before the end semester examination and

marks are to be displayed on the college notice board.


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III-V SEMESTER DETAILED SYLLABUS

OF

B.TECH. DEGREE PROGRAMME

FOR

ADMISSION BATCH 2015-16

BRANCH-PRODUCTION ENGINEERING

B.Tech (Production Engineering) Syllabus for Admission Batch 2015-163rd Semester

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Second Year Engineering

Third Semester

Theory Practical

Code Course Name Hours/week L/T

Credit Theory

University Marks

Internal Evaluation

Hours/Week L/T

Credit Practical

Marks

PC Manufacturing Technology I

3-0 3 100 50 2 1 50

PC Introduction to Physical Methodology &Engg. Material

3-0 3 100 50 2 1 50

PC Applied Thermodynamics 3-0 3 100 50 2 1 50

PC Theory of Machine 3-0 3 100 50 2 1 50 PC Strength of Material 3-1 4 100 50

HS Engineering Economics/ Organizational Behavior

2-1 3 100 50

Total 19 19 600 300 8 4 200

Total Marks: 1100

Total Credits: 23

Honours

Composite Material/ Surface Engineering Principle and Practice

4 4 100 50

Minor Manufacturing Processes


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MANUFACTURING TECHNOLOGY-I

Module-I (10 classes)

Manufacturing process: Definition, Manufacturing process vs. manufacturing system, Classification

of manufacturing process, selection of materials and processes.

Sand Casting : Pattern – materials, allowances, types, molding types, molding procedure, molding

and properties, testing of molding sand, cores, core materials, properties of core making. Melting

and founding of cast iron, degasification, design of casting and risering, pouring and feeding of

casting, casting defects and inspection.

Special casting: Melting of steels and non-ferrous metals and alloys, solidification, shell mould

casting, investment casting, Die casting, and centrifugal casting.

Module-II (10 classes)

Fusion welding processes: Introduction, oxy-fuel gas welding, arc welding processes-I (consumable

electrode): principle, equipment, power sources, principle of metal transfer, Electrodes, Submerged

arc welding, Gas Metal Arc Welding, arc welding processes-II (non-consumable electrode): Gas

Tungsten Arc Welding, Plasma Arc Welding, Defects in welding, Gas and arc cutting.

Brazing, Soldering, Adhesive Bonding, Mechanical fastening and joining plastics

Module-III ( 08 classes)

Solid state welding process: Introduction, Ultrasonic welding, Friction welding, Resistance welding,

Explosion welding.

Other welding processes: Thermit welding, Electron beam welding, Laser beam welding

Metallurgy of welding: Welding design and process selection: Introduction, welded joint, weld

quality, weldabilty, testing of welded joint

Module – IV (08 classes)

Hot and cold working of metals, Classification, Advantages, Limitations and applications of Extrusion,

Forging and Rolling , Wire Drawing, Classification, Advantages, Limitations and applications, Sheet

Metal Working: Deep drawing process.

Text:

1. Manufacturing Technology: Foundry, Forming and Welding by P.N. Rao, TMH. 2. Manufacturing Science by A. Ghosh and A.K. Mallick, Wiley Eastern

References

1. Principles of manufacturing Materials and processes, by James S. Campbell, TMH. 2. Welding Metallurgy by G.E. Linnert, AWS. 3. Production Engineering Sciences by P.C. Pandey and C.K. Singh, Standard Publishers Ltd. 4. Manufacturing Engineering and Technology, 4th Edition- S.Kalpakjian and S.R. Scsimid,

Pearson Education. 5. Manufacturing Process, J.P.Kaishish, PHI


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MANUFACTURING TECHNOLOGY-I

Practical L/T/P (Hours per week): 2, Credit: 1

Laboratory Experiments (Minimum 8 experiments)

1. Determination of grain size, clay content, permeability and green compressive strength of

Molding sand. (2 to 3 experiments)

2. Practice and preparation of job in Gas welding

3. Practice and preparation of job in Arc welding

4. Practice and preparation of job in TIG/MIG welding ( 2experiments)

5. Practice and preparation of job in sheet metal using processes like forming and deep drawing.

6. Demonstration of different rolling mills

7. Demonstration of Extrusion processes


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INTRODUCTION TO PHYSICAL METALLURGY AND ENGINEERING MATERIALS

Module-I(08 Lectures)

Classification of Engineering Materials, Engineering properties of materials. Characteristic property

of metals, bonding in solids, primary bonds like ionic, covalent and metallic bond, crystal systems,

common crystal structure of metals, representations of planes and directions in crystals, atomic

packing in crystals, calculation of packing density, voids in common crystal structures and

imperfections crystals.

Module-II(08 Lectures)

Concept of plastic deformation of metals, critical resolve shear stress, dislocation theory,

deformation by slip and twin, plastic deformation in polycrystalline metals, yield point phenomenon

and related effects, concept of cold working preferred orientation. Annealing ; recovery;

recrystalization and grain growth; hot working.

Concept of alloy formation, types of alloys, solid solutions, factors governing solids solubility viz. size

factor, valency factor, crystal structure factor and chemical affinity factor; order-disorder

transformation.

Module-III (10 Lectures)

Binary phase diagrams (a) Isomorphism system, (b) Eutectic system, (c) Peritectic system,

(d)Eutectoid system and (e) Peritectoid system. Allotropic transformation. Lever rule and its

application, Interpretation of solidification behaviors and microstructure of different alloys

belonging to those systems, Effect of non-equilibrium cooling, coring and homogenization.

Iron-cementite and iron-graphite phase diagrams, microstructure and properties of different alloys

(alloy steels; stainless steel, tool steel, HSS, high strength low alloy steel) types of cast iron, their

microstructures and typical uses. Specification of steel.

T.T.T. diagram: concept of heat treatment of steels i.e. annealing, normalizing, hardening and

tempering; microstructural effects brought about by these processes and their influences on

mechanical properties; factor affecting hardenability.

Module-IV (10 Lectures)

Optical properties of Materials: Scattering, Refraction, Theory of Refraction and absorption, Atomic

Theory of optical properties. Lasers, Optical fibres- Principle, structure, application of optical fibres.

Plastic-: Thermosetting and thermoplastics.

Ceramics: Types, structure, Mechanical properties, application

Composite Materials: Agglomerated Materials: Cermets .Reinforced Materials: Reinforced Concrete.

Fibre reinforced plastics, Properties of composites, Metal matrix composites, manufacturing

procedure for fiber reinforced composite.


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Text Books:

1. Introduction to Physical Metallurgy by Avner, Tata McGraw Hill

2. Materials Science and Engineering by W.D.Callister, Wiley and Sons Inc.

3. Physical Metallurgy: Principles and Practice by Ragahvan, PHI

Reference Books

1. Engineering Physical Metallurgy and Heat Treatment by Y.Lakhtin, Mir Publisher, Moscow.

2. Elements of Material Science and Engineering, L.H.Van Vlack, Addison Wesley

3. Materials Science and Engineering by V.Raghavan, Prentice Hall of India Pvt.Ltd.

4. Elements of Materials Science & Engineering by Van Vlack, Pearson

5. Mechanical Metallurgy by Dieter, Tata MacGraw Hill

6. Composite Material science and Engineering by K. K. Chawla, Springer

7. Material Science and Metallurgy, by U. C. Jindal, Pearson


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APPLIED THERMODYNAMICS

Module-I ( 6 Lectures)

Review of First and Second laws:

First law analysis of unsteady flow control volumes, Entropy generation ,Entropy balance for closed

systems and steady flow systems, Available energy, Quality of energy, Availability for non flow and

flow process, Irreversibility, Energy balance, Second law efficiency.

Module – II (8 Lectures)

1. Air Standard Cycle & Introduction to I.C. Engine: Otto, diesel and dual cycles, description and

operation of four and two stroke cycle engine, comparison of SI and CI engines, valve timing

diagram, power output and efficiency calculation.

2. Reciprocating Air Compressors: Introduction (Uses of compressed air), The reciprocating

cycle neglecting and considering clearance volume, Volumetric efficiency and its effect on

compressor performance, Limitations of single stage compression, Multistage compression

and intercooling, Optimum intercooler pressure, Performance and design calculations of

reciprocating compressors, Air motors

Module – III (10 Lectures)

8. Steam And Steam Generator :- Properties of steam, measurement of dryness fraction, use of

steam table. T-S and H-S diagrams for representing thermodynamic processes. Boiler,

Classification of boiler, comparison between water tube boiler and fire tube boiler. Boiler

mountings and accessories. Description of Cochran & Babcock -Wilcox boiler.

9. Steam Nozzles :- Types of nozzles, isentropic flow through nozzles, effect of friction on nozzle

efficiency. Critical pressure ratio and maximum discharge, throat and exit area.

Module – IV (12 Lectures)

10. Steam Turbines & Condensers:- Turbine type and applications. Impulse turbine, pressure and

velocity compounding, velocity diagram, work output, losses and efficiency. Impulse reaction

turbine, velocity diagram, degree of reaction, work output, losses and efficiency. Jet and

surface condensers. Condenser vacuum and vacuum efficiency.

11. Heat Transfer : Basic modes of heat transfer, one dimensional steady state, conduction

through slab, cylinder and sphere ; basic theory of radiant heat transfer, black body & mono

chromatic radiation, total emissive power.

12. Refrigeration system: Reversed Carnot cycle, Reversed Brayton cycle (Gas refrigeration

system), The vapor compression cycle, The vapor absorption cycle.


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Text Books

1. Engineering Thermodynamics by P. K. Nag, Publisher:TMH

2. Engineering Thermodynamics by P. Chattopadhyay, OXFORD

3. Fundamentals of Thermodynamics by Sonntag, Borgnakke, Van Wylen, John Wiley & Sons

4. Fundamentals of Engineering Thermodynamics by E. Rathakrishnan, PHI

References

1. Engineering Thermodynamics by M.Achyuthan, PHI

2. Engineering Thermodynamics by Y.V.C. Rao, University Press

3. Thermodynamics and Thermal Engineering by Kothandaraman & Domkundwar, Dhanpat Rai

4. Applied Thermodynamics by P.L.Ballaney, Khanna Publishers

5. Steam Tables in SI Units by Ramalingam, Scitech

6. Steam Tables by C.P.Kothandaraman, New Age International


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Practical (Hours per week): 2, Credit: 1

Laboratory Experiments: (Minimum 8 experiments)

1. Study of Cut-Sections of 2 stroke and 4 stroke Diesel Engine.

2. Study of Cut-Sections of 2 stroke and 4 stroke Petrol Engine.

3. Study of steam power plant.

4. Study of refrigeration system.

5. Study of gas turbine power plant.

6. Performance analysis of reciprocating air-compressor.

7. Performance analysis of Centrifugal / Axial Flow compressor.

8. Determination of performance characteristics of gear pump.

9. Measurement of steam quality using calorimeter

10. Verification of Joule-Thomson coefficient.


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THEORY OF MACHINE

Module-I(10 classes)

Mechanism: Basic Kinematic concepts and definitions, mechanism, link, kinematic pair, classification

of kinematic pairs, degree of freedom, kinematic chain, binary ternary and quaternary joints and

links, degrees of freedom for plane mechanism, grubler’s equation, inversion of mechanism, four bar

chains and their inversions, single slider crank chain, double slider crank chain and their inversion

Module-II (10 classes)

Friction of a screw and nut, square threaded crew, V-threaded screw, pivot and collar, friction circle,

friction axis, friction clutches, transmission of power by single plate, multiplate and cone clutches.

Gear trains: simple train, compound train, reverted train, epicyclic train and their application.

Module-III(08 classes)

Toothed gears: Theory of shape and action of tooth properties methods of generation of standard

Tooth profiles, Standard proportions, Interference and Under-cutting, methods of Eliminating

Interference, Minimum numbers of teeth to avoid interference.

Module-IV(08 classes)

Governors: Centrifugal Governors-watt and Porter Governors, Spring loaded Governor-Hartnell

Governor ,sensitiveness, stability, Isochronisms ,Hunting, Governor effort and power, curves of

controlling force.

TEXT BOOK(S):

1. Theory of machines – S.S Ratan, Tata McGraw Hill.

2. A Textbook of theory of machines (in S.I units) – R.K.Bansal, Laxmi Publication.

REFERENCE(S):

1. Mechanism and machine Theory- Rao and Dukkipati, Wiley Eastern Ltd.

2. Theory of Machines –Thomas Beven.


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PRACTICAL (HOURS PER WEEK): 2, CREDIT: 1

Laboratory Experiments: (Minimum 8 experiments)

1. Determination of gyroscopic couple.

2. Performance characteristics of spring loaded governor.

3. Determination of critical speed of rotating shaft.

4. Experiment on static and dynamic balancing apparatus. (2 experiments)

5. Determination of natural frequency under damped and un-damped vibration.(2

experiments)

6. Study of interference and undercutting for gear.

7. Radius of gyration of compound pendulum

8. Radius of gyration of connecting rodExperiment on Screw Jack

9. Experiment on Journal Bearing Apparatus

10. Experiment on Epicyclic Gear Train

11. Experiments on Simple/Compound/Reverted Gear trains

12. Experiment on Dynamometer


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STRENGTH OF MATERIAL

Module-I(10 classes)

Analysis of axially loaded members: Composite bars in tension and compression-temperature

stresses in composite rods-statically indeterminate problem. 2D Stress system, Principal Planes,

Principal stress, Mohr’s stress circle, Members in biaxial state of stress: Stresses in thin cylinders,

thin spherical shells under internal pressure-wire winding of thin cylinders. Strain &

deformation: Two dimensional state of strain, Principal Strains, Calculation of principal stresses from

principal strains, Strain measurement.

Module-II(10 classes)

Shear force and bending moment diagrams for simple beams: Support reactions for statically

determinate beams, relationship between bending moment and shear force, shear force and

bending moment diagrams.

Simple bending of beams: Theory of simple bending of initially straight beams, distribution of normal

and shear stress, composite beams.

Module-III(12 classes)

Torsion in solid and hollow circular shafts, Twisting moment, strength of solid and hollow circular

shafts, Strength of shafts in combined bending and twisting, Close-coiled helical springs.

Deflection of Beams: Slope and deflection of beams by integration method and area-moment

method.

Module-IV(10 classes)

Buckling of columns: Euler’s theory for initially straight columns with various end conditions.

Theories of failure: maximum principal stress theory, maximum shear stress theory, maximum

principal strain theory, Maximum strain energy theory and maximum distortion energy theory.

TEXT BOOK(S):

1. Strength of Materials- G.H.Ryder, Macmillan India.

2. Mechanics of Materials- J.M.Gere and S.Timoshenko.

3. Strength of Materials by R.Subramaniam, Oxford University Press

REFERENCE(S):

1. Mechanics of Materials-I- E.J. Hern; Paragaman.

2. Introduction to Mechanics of Solids- Crandell, Dahl and Lardner, McGraw Hill.

3. Mechanics of Materials by Beer and Johnston, Tata McGraw Hill

4. Mechanics of Materials by R.C.Hibbeler, Pearson Education


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PRACTICAL (HOURS PER WEEK): 2, CREDIT: 1

Laboratory Experiments (Minimum 8 experiments)

1. Determination of tensile strength of materials by Universal Testing Machine

2. Determination of compressive strength of materials by Universal Testing Machine

3. Determination of bending strength of materials by Universal Testing Machine

4. Double shear test in Universal Testing Machine

5. Determination of Impact strength of material (Charpy and Izod)

6. Determination of Hardness strength of materials (Brinnel, Rockwell and Vickers)

7. Determination of Rigidity modulus of material

8. Determination of Fatigue strength of material

9. Estimation of Spring Constant under Tension and Compression.

10. Load measurement using Load indicator, Load Cells.

11. Strain measurement using Strain Gauge.

12. Stress measurement using strain rosette.


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HONOURS ELECTIVE

COMPOSITE MATERIALS

Module – I (10 hours)

Introduction and characteristics of composite materials, mechanical behaviour of composites,

constituents, Reinforcements, Matrices, Fillers, Additives, Applications and advantages of

composites.

Classification of composites – Matrix-Polymer matrix composites (PMC), Metal matrix

composites(MMC), Ceramic matrix composites (CMC) – Reinforcement – Particle reinforced

composites, Fibre reinforced composites. Applications of various types of composites.

Module – II (12 hours)

Characteristics of Polymer matrix composites – Characteristics of resins, Thermosetting resins,

thermoplastic resins – Reinforcement fibres – Rovings – Woven fabrics – Non woven random mats –

various types of fibres. PMC processes - Hand lay up processes – Spray up processes – Compression

moulding – Reinforced reaction injection moulding - Resin transfer moulding – Pultrusion – Filament

winding – Injection moulding. Fibre reinforced plastics (FRP), Glass fibre reinforced plastics (GRP).

Characteristics of Metal Matrix Composites , Various types of Metal matrix composites Alloy vs.

MMC, Advantages of MMC, Limitations of MMC, Metal Matrix, Reinforcements – particles – fibres.

Effect of reinforcement - Volume fraction – Rule of mixtures. Processing of MMC – Powder

metallurgy process - diffusion bonding – stir casting – squeeze casting.

Module – III (10 hours)

Engineering ceramic materials – properties – advantages – limitations – Monolithic ceramics - Need

for CMC – Ceramic matrix - Various types of Ceramic Matrix composites- oxide ceramics – non oxide

ceramics – aluminium oxide – silicon nitride – reinforcements – particles- fibres- whiskers. Sintering -

Hot pressing – Cold isostatic pressing (CIPing) – Hot isostatic pressing (HIPing).

Module – IV(10 hours)

Advances in composites:

Carbon / carbon composites – Advantages of carbon matrix – limitations of carbon matrix Carbon

fibre – chemical vapour deposition of carbon on carbon fibre perform. Sol gel technique. Composites

for aerospace applications.

Text Book

1. Chawla K.K., Composite materials, Springer – Verlag, 1987

2. Mathews F.L. and Rawlings R.D., Composite materials: Engineering and Science, Chapman and

Hall, London, England, 1st edition, 1994.

3. Mechanics of Composite Materials, R.M. Jones, Mc. Graw Hill Book Co.


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Reference Book :

1. Fibre - Reinforced composites :- Materials, manufacturing and Design by P.K. Mallick, CRC Press.

2. Composite materials, Broutman & Crock,

3. Principles of Composite Material Mechanics, R.F.Gibson, CRC Press


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SURFACE ENGINEERING PRINCIPLE AND PRACTICE

Module-I (10 classes)

Mechanisms of Wear and Metal Cleaning: Basic Mechanisms of wear-abrasive, adhesive wear,

contact fatigue, Fretting corrosion, Testing of wear resistance, practical diagnosis of wear, general

cleaning process for ferrous and non ferrous metals and alloys selection of cleaning processes,

alkaline cleaning, emulsion cleaning, ultrasonic cleaning, pickling salt bath descaling, abrasive bath

cleaning, polishing and buffing shot peening.

Module-II(10 classes)

Thermal Spraying Processes and Electrodeposited Coatings: Thermal spraying materials,

characteristics of thermal spray processes, Design for thermally sprayed coatings coating production,

spray fused coatings, Principles of electroplating, Technology and control-electroplating systems,

Properties and applications of electrodeposits, Non aqueous and electroless deposition, plasma

coating.

Module-III (12 classes)

Hot Dip Coating and Diffusion Coating: Principles, Surface preparation, Batchcoating and continuous

coating process, Coating properties and application, Principles of cementation, Cladding-vacuum

deposition, Sprayed metal coating, Structure of diffusion coatings, Chemical vapour deposition

(CVD), Physical vapour deposition (PVD).

Non-Metallic Coating Oxide and Conversion Coatings: Plating coating, lacquers, rubbers and

elastomers, viterous enamels, anodizing Chromating, application to aluminium, magnesium, tin, zinc,

cadmium copper and silver, phosphating primers.

Module-IV (10 classes)

Quality Assurance, Testing and Selection af Coatings: The quality plan, design, testing and inspection,

thickness and porosity measurement, selection of coatings, industrial applications of engineering

coatings.

Text Book(s):

1. Electroplating and other Surface Treatments; C.D.Varghese; TMH, 1993.

2. Engineering Coatings-design and application- S. Grainger, Jaico Publishing House.

Reference(S):

1. Electroplating Handbooks- N.V.Parathasarathy, Prentice Hall.

2. Advances in surface treatment- Niku-Lavi, Pergamon.

3. Metal Pretreatment; N.D.Banik; TMH, 1992

4. Principles of Metals surface treatment and protection- D. R. Gabe, Pergamon.


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MINOR SPECIALIZATION

MANUFACTURING PROCESS

Module I (10 classes)

Manufacturing Processes:

Introduction to manufacturing processes, Classification and Selection of Manufacturing Processes.

Metal Casting Processes:

Patterns, Types of patterns, allowances and material used , moulding materials, , Metal casting:

Types of casting processes, advantages, disadvantages and applications of casting processes; Green

sand moulding and permanent moulding , casting defects.

Module 2 (12 classes)

Metal Joining Processes:

Principle of welding,. Classification of welding. Capabilities and applications; Gas welding and gas

cutting, Arc welding, Power sources and consumables, Resistance welding: Spot, Projection and

seam welding process, Defects in welding, Introduction to Soldering and Brazing.

Metal Shaping and Forming:

Hot and cold working of metals, Classification, Advantages, Limitations and applications of Extrusion,

Forging and Rolling , Wire Drawing, Classification, Advantages, Limitations and applications, Sheet

Metal Working: Deep drawing process.


Metal Cutting Principles:

Machine tools classification, working and auxiliary motions in machine tools, Primary cutting

motions in machines tools, Cutting tool geometry and tool signature, cutting forces and power

requirement in machining


Advanced Manufacturing Processes

Introduction, equipment, process variables , advantages, disadvantages and applications of Abrasive

Jet Machining, Ultrasonic Machining, Chemical Machining Electrochemical Machining, Laser Beam

Machining

TEXT BOOK(S):

1. Manufacturing Technology (Foundation Forming & Welding)- P.N. Rao, Tata McGraw Hill.

2. Manufacturing Science, Ghosh and Mallik, East West Press.

3. Principles of manufacturing materials and processes- J.S.Campbell, Tata McGraw Hill.


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REFERENCE(S):

1. Manufacturing Engineering and Technology, 4th Edition- S.Kalpakjian and S.R. Scsimid,

Pearson Education.

2. Robotics Technology and Flexible Automation- S.R.Deb, TMH.

3. Principle of Metal Casting- Heine, Loper and Rosenthal, Tata McGraw Hill.


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GEOLOGY LAB

The student will have to go for four weekends for geological tour besides sessional / practical classes

in 3rd

semester.

1) Study of Physical properties of minerals.

2) Study of important igneous sedimentary and metamorphic rocks.

3) Interpretation of folds and faults from maps.

B.Tech(Production Engineering) Syllabus for Admission Batch 2015-164th Semester

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Fourth Semester


week L/T

Credit Theory

University Marks

Internal Evaluation

Hours/Week L/T

Credit Practical

Marks

HS Applied Mathematics - III

3-0 3 100 50

PC Manufacturing Science II

3-0 3 100 50 2 1 50

PC Design of Machine Elements

3-0 3 100 50 2 1 50

PC Metrology & Inspection 3-0 3 100 50 2 1 50 PC Robotics & FMS 3-0 3 100 50 2 1 50 HS Engineering Economics/

Organizational Behavior 2-1 3 100 50

*Skill Project and Hands on

6 3 100

Total 18 18 600 300 14 7 300

Total Marks: 1200

Total Credits: 25

Honours Fault Diagnostics And Condition Monitoring

4 4 100 50

Minor Metrology, Quality Control & Reliability


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APPLIED MATHEMATICS - III

Module-I

Complex Analysis:

Analytic function, Cauchy-Riemann equations, Complex integration: Line integral in the

complex plane, Cauchy’s integral theorem, Cauchy’s integral formula, Derivatives of analytic

functions, Taylor’s series, Maclaurin’s series, Laurent’s series, Singularities and zeros.

Module-II

Complex Analysis:

Residue integration method, evaluation of real integrals

Numerical Methods: Errors of numerical results, error propagation,., Lagrange Interpolation, Newton divided

difference interpolation, Newton’s forward and backward interpolation, Spline interpolation.

Module-III

Numerical Methods:

Numerical integration: The trapezoidal rule, The Simpson’s rules, Gauss Integration formulas.

Solution of ordinary differential equation: Euler’s method, Improvement of Euler’s method,

Runge-Kutta methods, multi step methods, Methods for system and higher order ordinary

differential equations.

Module-IV

Probability Theory and Its Applications: Probability, Random variables, Probability

distributions, Mean and variance; Features of Probability Distribution: Binomial, Poisson,

Uniform and Normal distribution, Distribution of several random variables.

Statistical Techniques and Its Applications: Scope of Statistics, Random sampling, Sampling

Distribution,Correlation analysis, Regression Analysis,Fitting Straight Lines, Estimation of

Parameters, Statistical Hypothesis.

Text books: 1. E. Kreyszig,” Advanced Engineering Mathematics:,Tenth Edition, Wiley India

2. S.Pal and S.C. Bhunia, “Engineering Mathematics” Oxford University Press

3.Jay L. Devore, “Probability and Statistics for Engineering and Sciences”, Seventh Edition,

Thomson/CENGAGE Learning India Pvt. Ltd

Reference books:

1. E.B. Saff, A.D.Snider, “Fundamental of Complex Analysis”, Third Edition, Pearson

Education, New Delhi

2. P. V. O’Neil, “Advanced Engineering Mathematics”, CENGAGE Learning, New Delhi


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MANUFACTURING SCIENCE-II

Module – I (13 hours) Geometry of cutting tools in ASA and ORS, Effect of Geometrical parameters on cutting force

and surface finish, Mechanics of chip formation, Merchant’s theory, Force relationship and

velocity relationship, Types of Tool Wear: Flank wear, Crater wear, Wear measurement, Effect

of variables on tool life and surface finish, Measurement of cutting force, Lathe tool

dynamometer, Drill tool dynamometer. Economics of machining.

Module – II (13 hours) Conventional machining process and machine tools – Turning, Drilling, Shaping, Planning,

Milling, Grinding. Machine tools used for these processes, their specifications and various

techniques used.

Principles of machine tools : Kinematics of machine tools, speed transmission from motor to

spindle , speed reversal mechanism, mechanism for feed motion, Tool holding and job holding

methods in different Machine tools, Types of surface generated, Indexing mechanism and thread

cutting mechanism, Quick return mechanism,.

Production Machine tools – Capstan and turret lathes, single spindle and multi spindle

semiautomatics, Gear shaper and Gear hobbing machines, Copying lathe and transfer machine.

Module – III (10 hours) Cutting Tool Materials & Cutting Fluids: Characteristics of tool materials, various types of

cutting tool materials, coated tools, cutting tool selection, Purpose and types of cutting fluids,

basic actions of cutting fluids, effect of cutting fluid on tool life, selections of cutting fluid,

Cutting fluid and its effect; Machinability Criteria, Tool life and Taylor's equation.

Module – IV (10 hours) Non-traditional Machining processes:

Ultrasonic Machining, Laser Beam Machining, Plasma Arc Machining, Electro Chemical

Machining, Electro Discharge Machining, Wire EDM , Abrasive Jet Machining.

Text Books :

1.Metal Cutting Principles, M.C.Shaw, Oxford University Press

2. Fundamentals of Machining and Machine Tools, G.Boothroyd and W.A.Knight, CRC Press

3. Metal Cutting Theory and Practice, A.Bhattacharya, Central Book Publishers

Reference Books : 1. Manufacturing Technology – by P.N.Rao, Tata McGraw Hill publication.

2. Modern Manufacturing Processes, P.C.Pandey, H.S.Shan, Tata McGraw Hill

3. Manufacturing Science, Ghosh and Mallik, East West Press.

4. Metal Cutting Theory and Practice, D.A.Stephenson and J.S.Agapiou, CRC Press

5. Machining Technology; Machine Tools and Operation, H.A.Youssef and H. El-Hofy, CRC

Press

6. Machine Tools and Manufacturing Technology, Krar, Rapisarda and Check, Cengage

Learning

7. Technology of Machine Tools, Krar, Gill and Smidt, Tata McGraw Hill


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8. Principles of Metal Cutting, G.Kuppuswamy, Universities Press

9. Metal Cutting and Machne Tools, G.T.Reddy, Scitech

10. Fundamentals of tool Engineering Design, S.K.Basu, S.K.Mukherjee, R. Mishra , Oxford &

IBH Pub Co.

11. Machine Tools, R.N.Datta, New Central Book Agency

PRACTICALS

Manufacturing Science-II

1.Study of non-traditional machining process (ultrasonic machining/ abrasive jet machining/

electro-discharge machining)

2.Determination of cutting forces in turning using lathe tool dynamometer

3.Determination of cutting forces in drilling using drilling tool dynamometer

4.Study on C. N.C. Machines

5.Study of single point cutting tools

6.Study of multi point cutting tools

7.Job on lathe with tapper turning, thread cutting, knurling and groove cutting (3 experiments).

8.Gear cutting (with index head) on milling machine

9.Working with shaper, Planner and slotting machine.

10.Working with surface and cylindrical grinding.


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DESIGN OF MACHINE ELEMENTS

[Only specified data book as mentioned in the syllabus is permitted during examination]

Module-I (8 hours)

1. Mechanical engineering design: Introduction to design procedure, Stages in design, Code

and Standardization, Interchangeability, Preferred numbers, Fits and Tolerances, Engineering

materials: Ferrous, Non-ferrous, Non-metals, design requirements – properties of materials,

Material selection, Use of Data books.

2.Fundamentals of Machine Design: Types of load, Modes of failure, factor of safety concepts,

Theories of Failure, concept and mitigation of stress concentration, Fatigue failure and curve,

endurance limit and factors affecting it, Notch sensitivity, Goodman, Gerber and Soderberg

criteria.

Module-II (8 hours)

3. Machine Element Design: Design of Joints: Rivets, welds and threaded fasteners based on

different types of loading, Boiler joints, cotter joints and knuckle joints.

Module-III (10 hours)

4. Design of Keys, Shaft and Couplings: Classification of keys and pins, Design of keys and

pins, Theories of failure, Design of shafts: based on strength, torsional rigidity and fluctuating

load, ASME code for shaft design, Design of couplings: Rigid coupling, Flexible coupling.

5. Design of Mechanical Springs: Types of helical springs, Design of Helical springs, bulking

of spring, spring surge, end condition of springs, Design of leaf springs: nipping.

Module-IV (6 hours)

6. Bearings: Types and selection of ball and roller bearings, Dynamic and static load ratings,

Bearing life, Design of sliding contact bearings, Journal bearing, foot step bearing.

TEXT BOOKS:

1. Design of Machine Elements, V.B. Bhandari, Tata McGraw Hill

2. Mechanical Engineering Design, J.E.Shigley, C.R.Mischke, R.G.Budynas and K.J.Nisbett,

TMH

REFERENCE BOOKS:

1. Machine Design, P.Kanaiah, Scietech Publications

2. Fundamentals of Machine Component Design by R.C.Juvinall and K.M.Marshek, John

Wiley & Sons

3. Machine Drawing by N.Sidheswar, McGraw-Hill

4. Machine Design, P.C.Sharma and D.K.Agrawal, S.K.Kataria & Sons

5. Machine Design, Pandya and Shah, Charotar Book Stall

6. Machine Design, Robert L. Norton, Pearson Education Asia.

7. Design of Machine Elements by C. S. Sharma and K. Purohit, PHI


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DESIGN DATA HAND BOOKS:

1. P.S.G. Design Data Hand Book, PSG College of Tech Coimbature

2. Design Data Hand Book, K. Lingaiah, McGraw Hill, 2nd Ed. 2003.

3. Design Hand Book by S.M.Jalaluddin ; Anuradha Agencies Publications

4 .Design Data Hand Book by K.Mahadevan and B.Reddy,CBS Publisher

PRACTICAL

MACHINE DESIGN PROJECT – I

1. Assembly drawing of tail-stock of lathe with bill of materials

2. Assembly drawing of screw jack with bill of materials

3. Design & drawing of Riveted joint

4. Design and drawing of Cotter joint

5. Design and drawing of Knuckle joint

6. Design of shafts subjected to combined loading

7. Design and drawing of Flange coupling

8. Design of lever

9. Design and drawing of belt and pulley

Total number of Design : Minimum 6 nos. Total No. of Drawing : 5 sheets (Two sheets for

assembly drawing as per Sl no. 1 and 2 and three sheets for design, under Sl. No. 3, 4, 5, 7 and 9)


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METROLOGY AND INSPECTION

Module I :CONCEPTS OF METROLOGY:

Principles of Measurements, Line and End & optical Standards, Calibration, accuracy and

Precision, Random error and systemic error, Measurement of Surface Roughness, Screw Thread

and Gears, Limits, Fits and Gauges, Assembly by full, partial and group interchangeability,

geometric tolerances, Measurement of straightness, Flatness and circularity.

Terminologies – Standards of measurement - Line and End & optical Standards – Errors in

measurement – Interchangeability and Selective assembly – Accuracy and Precision –

Calibration of instruments – Basics of Dimensional metrology and Form metrology

Module II :MEASUREMENT OF SURFACE ROUGHNESS:

Definitions – Types of Surface Texture: Surface Roughness Measurement Methods-

Comparison, Contact and Non Contact type roughness measuring devices, 3D Surface

Roughness Measurement, Nano Level Surface Roughness Measurement – Instruments.

Module III :INTERFEROMETRY:

Introduction, Principles of light interference – Interferometers – Measurement and Calibration –

Laser Interferometry.

Module IV :COMPUTER AIDED AND LASER METROLOGY:

Tool Makers Microscope –Coordinate Measuring Machines – Applications – Laser Micrometer,

Laser Scanning gauge, Computer Aided Inspection techniques - In-process inspection, Machine

Vision system-Applications.

Text Books

1. Engineering Metrology,R.K. Jain, Khanna Publisher, Delhi

2. Quality control and Application ,B.L. Hansen and P.M. Ghare, Prentice Hall of India.

3. Reliability Engg. And Terotechnology , A.K. Gupta, Macmillan India.

4. Taguchi methods Explained Practical steps to Robust design T.P. Bagchi, PHI

Reference Books

1. A text book of Engineering Metrology I.C. Gupta, Dhanpat Rai & sons, Delhi.

2. Whitehouse,D.J., "Surface and their measurement", Hermes Penton Ltd, 2004


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PRACTICAL (METROLOGY & INSPECTION)

(Minimum 08 Experiments/Studies)

List of Experiments:

1. Measurement of straightness and flatness

2. Measurement of roughness of the surface

3. Experiment on slip gauges and sine bar

4. Calibration of Dial gauge, Micrometer, Vernier and Height gauge

5. Use of Sine bar for measuring angles

6. Study and use of Profile Projector

7. Measurement of thread parameters using Floating Carriage Micrometer

8. Surface roughness measurement

9. Use of Mechanical and Pneumatic comparator

10. Measurement of gear tooth thickness

11. Measurement of Internal, External angles and Bores using standard Balls, and Height

gauge.

12. Measurement of Straightness and Flatness using precision level.

13. Study and use of Toolmaker's microscope

14. Study of Digital measuring instruments


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ROBOTICS AND FMS

Module – I

Fundamentals of Robotics: Evolution of robots and robotics, Definition of industrial robot, Laws

of Robotics, Classification, Robot Anatomy, Work volume and work envelope, Human arm

characteristics, Design and control issues, Manipulation and control, Resolution; accuracy and

repeatability, Robot configuration, Economic and social issues, Present and future application.

Mathematical modeling of a robot: Mapping between frames, Description of objects in space,

Transformation of vectors.

Direct Kinematic model: Mechanical Structure and notations, Description of links and joints,

Kinematic modeling of the manipulator, Denavit-Hartenberg Notation, Kinematic relationship

between adjacent links, Manipulator Transformation matrix.

Module – II

Inverse Kinematics: Manipulator workspace, Solvable of inverse kinematic model, Manipulator

Jacobian, Jacobian inverse, Jacobian singularity, Static analysis.

Dynamic modeling: Lagrangian mechanics, 2D- Dynamic model, Lagrange-Euler formulation,

Newton-Euler formulation.

Robot Sensors: Internal and external sensors, force sensors, Thermocouples, Performance

characteristic of a robot.

Module – III

Robot Actuators: Hydraulic and pneumatic actuators, Electrical actuators, Brushless permanent

magnet DC motor, Servomotor, Stepper motor, Micro actuator, Micro gripper, Micro motor,

Drive selection.

Trajectory Planning: Definition and planning tasks, Joint space planning, Cartesian space

planning.

Applications of Robotics: Capabilities of robots, Material handling, Machine loading and

unloading, Robot assembly, Inspection, Welding, Obstacle avoidance.

Module – IV

Introduction and Description, limitations with conventional manufacturing, Need for FMS

Introduction, Definition, Basic Component of FMS, Significance of FMS, General layout and

configuration of FMS, Principle Objectives of FMS, Benefits and limitations of FMS, Area of

Application of a FMS in Industry, Various Hardware and Software required for an FMS, CIM

Technology, Hierarchy of CIM, FMS Justification.

Text Books: 1. Robotics Technology and Flexible Automation, S.R.Deb and S. Deb, TMH

2. Robotics and Control, R.K. Mittal and I.J. Nagrath, Tata McGraw Hill

3. Introduction to Robotics: Mechanics and control, John J Craig, PHI


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Reference Books: 1. Introduction to Robotics, S. K. Saha, Tata McGraw Hill

2. Robotics: Control, Sensing, Vision and Intelligence, K.S.Fu, R.C.Gonzalez and C.S.G.Lee,

McGraw Hill

3. Robotics, Appuu Kuttan K.K., I.K. international

4. Robot Dynamics and Control, M.W.Spong and M. Vidyasagar , Wiley India.

5. Industrial Robotics Technology, programming and application, M.P.Groover, TMH.

6. Introduction to Robotics: Analysis, Systems, Applications, S.B.Niku, PHI

7. Robotics: Fundamental Concepts and Analysis, A. Ghosal, Oxford University Press

8. Fundamentals of Robotics: Analysis and Control, R. J. Schilling, PHI

9. Robotic Engineering: An Integrated Approach, R.D. KLAFTER, T. A. Chmielewski, and

M. Negin, PHI

10. Robot Technology: Fundamentals: J. G. Keramas, Cengage Learning

PRACTICAL

List of Experiments (Robotics and FMS)

1. Study of different types of robots based on configuration and application.

2. Study of different type of links and joints used in robots

3. Study of components of robots with drive system and end effectors.

4. Determination of maximum and minimum position of links.

5. Verification of transformation (Position and orientation) with respect to gripper and

world coordinate system

6. Estimation of accuracy, repeatability and resolution.

7. Robot programming exercises

8. Study of mobile robot with all types of controllers


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HONOUR ELECTIVE

FAULT DIAGNOSTICS AND CONDITION MONITORING Module – I (10 hours)

Principles of Maintenance, Fault analysis planning and system availability: Failure modes, effects and

criticality analysis (FMECA), Failure effects assessment (FEA), Critical areas assessment, Fault tree

method, Availability concepts, Failure prediction/reliability assessment Data Processing and Signal

Analysis: Computer-Aided Data Acquisition.

Module – II (12 hours)

Time Domain Analysis, Frequency Domain Analysis - Fast Fourier Transform Performance trend

monitoring: Primary monitoring – performance, Primary and secondary performance parameters,

Performance trend analysis. Vibration Analysis: Vibration monitoring equipment, System monitors and

vibration limit detectors, vibration monitoring experience Discrete frequencies: Introduction, Simple

vibrations, Gear excitation, Rolling element bearings, Blade vibration, Fans and Pumps and Case Studies

on Vibration Monitoring Contaminant analysis.

Module – II (08 hours )

Contaminants in used lubricating oils, Carrier fluid degradation, Contaminant monitoring techniques

(Wear processes), Oil degradation analysis, Abrasive particles in lubrication oil, Abrasive particle in

bearings, Abrasive particle in hydraulic systems, Dissolved gas fault monitoring.

Module – IV (10 hours)

Electric Motor Current and Signature Analysis Non-Destructive Test and Evaluation technology:

Overview: Radiography, Ultrasonics: Principle, transducers, equipments and testing Liquid Penetrant

Test, Magnetic Particle Test, Eddy Current Test. Other Topics: Thermal Infrared Imaging, Acoustic

Emission, Leak Testing Industrial Applications of NDE

Text Books

1. Mechanical Fault Diagnosis and Condition Monitoring by Ralph Albert Collacott, Wiley (or Chapman

and Hall, 1977)

Reference Books

1. Condition Based Maintenance and Machine Diagnostics, John W Williams, Alan Davies, Paul R

Drake, Springer, 2006

2. Rotating Machinery Vibration; From Analysis to Troubleshooting, Maurice L. Adams, Jr., CRC Press

3. Lubrication and Maintenance of Industrial Machinery; Best Practices and Reliability, R.M.Gresam and

G.E.Totten, CRC Press

4. Vibration, Monitoring and Diagnosis: Techniques for Cost-effective Plant Maintenance by Ralph

Albert Collacott, 1979, Wiley

5. Handbook on Condition Monitoring, B.K.N. Rao, Elsevier Science 1998

6. Handbook of Condition Monitoring Techniques and Methodology, M.Davies, Springer 2006

7. Vibratory Condition Monitoring of Machines”, J.S.Rao, CRC Press, 2000

8. Vibration Monitoring, Testing, and Instrumentation, Editor(s): Clarence W. de Silva, University of

British Columbia, Vancouver, Canada, Series: Mechanical Engineering Series, CRC Press (Taylor &

Francis)

9. Non-destructive Test and Evaluation of Materials, J.Prasad and C.G.K.Nair, TataMcGraw-Hill 10.

Machinery Condition Monitoring and Trouble Shooting, John S. Mitchell


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MINOR SUBJECT

METROLOGY, QUALITY CONTROL & REALIABILITY

Module I (12 hours) Principles of Measurements, Line and End & optical Standards, Calibration, accuracy and Precision, Random error and systemic error. Measurement of Surface Roughness, Screw Thread and Gears. Limits, Fits and Gauges, Assembly by full, partial and group interchangeability, geometric tolerances. Measurement of straightness, Flatness and circularity.

Module II (10 hours) Some useful Probability Distribution, Testing of hypothesis, type I and type II errors, control limit theorem. Causes of Variation, standard error of mean, process capability, PCR, RPI, Natural tolerance Limits, Specification Limits, Trial and Revised control Limits, Rational subgroups, Control charts for variable (X,R,S, CUSUM, EWMA), Control charts for fraction, nonconforming control charts for non-conformation.

Module III(08 hours) Design of single sampling plan. Double, multiple and sequential sampling plans, O.C. curve, AOQ, AOQL, Taguchi’s Loss function, Orthogonal Arrays, Linear Graphs, parametric design, signal-to noise Ratio, ANOVA, TQM, Taguchi, ISO 9000, ZIT, Quality circle.

Module-IV(10hours) Definition, bath-tub-curve, system reliability, reliability improvement, maintainability and availability, Availability of single repairable system using Markov model, Life tests, acceptance sampling plan based on life tests, Sequential acceptance sampling plan based on MTTF & MTBF.

Test Books 1. Engineering Metrology,R.K. Jain, Khanna Publisher, Delhi 2. Quality control and Application ,B.L. Hansen and P.M. Ghare, Prentice Hall of India. 3. Reliability Engg. And Terotechnology , A.K. Gupta, Macmillan India. 4. Taguchi methods Explained Practical steps to Robust design T.P. Bagchi, PHI Reference

Books 1. A text book of Engineering Metrology I.C. Gupta, Dhanpat Rai & sons, Delhi. 2. E.L. Grant and R.S. Leveaworth, Statistical quality Control”, 7e, mc-Graw Hill. 3. Introduction to Statistical Quality control, D.C.Montgonery, John Wiley & sons. 4. Introduction to /reliability and MaitainabilityEngg E. Ebeling, MC-Graw Hill. 5. Statistical Quality Control, M. Mahajan, Dhanpat Rai & Sons. 6. Statistical Process Control and Improvement, A.Mitra, Pearson.

B.Tech (Production Engineering) Syllabus for Admission Batch 2015-16 5th Semester

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Fifth Semester


L/T Credit Theory

University Marks

Internal Evaluation

Hours/week L/T

Credit Practical

Marks

PC Production & Operation Management

3-0 3 100 50 2 1 50

PC Materials Deformation Processes

3-0 3 100 50 2 1 50

PC Tool Design 3-0 3 100 50 2 1 PE Statistical Quality Control &

Reliability/Fluid Mechanics & Fluid Power Engg./Plastic Processing/Work Study & Ergonomics

3-1 4 100 50 50

OE Human Resources Management/C++ & Object Oriented Programming/Internet & Web Technology/Tribology/Non-Convention Energy Sources/Supply Chain Management

3-1 4 100 50

PC Advance Lab-I 8 4 200

Total 17 17 500 250 14 7 350

Total Marks: 1100

Total Credits: 24

Honours Advance Casting and Welding/Optimization in Manufacturing

4 4 100 50

Minor Production Design and Development


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PRODUCTION AND OPERATION MANAGEMENT

Module I (10 Hours)

Operations Function in an Organization, Manufacturing Vrs Service Operations, System view

of Operations, Strategic Role of Operations, Operations Strategies for Competitive

Advantage, Operations Quality and Productivity Focus, Meeting Global Challenges of

Production and Operations Imperatives.

Designing Products, Services and Processes: New Product Design- Product Life Cycle,

Product Development Process, Process Technology : Project, Jobshop, Batch, Assembly

Line, Continuous Manufacturing; Process Technology Life Cycle, Process Technology

Trends, FMS, CIM, CAD, CAM; Design for Services, Services Process Technology.

Module II (10 Hours)

Work Study: Methods Study- Techniques of Analysis, recording, improvement and

standardization; Work Measurement : Work Measurement Principles using Stopwatch Time

Study, Predetermined Motion Time Standards and Work Sampling, Standard Time

Estimation.

Module III (10 Hours)

Location and Layout Planning: Factor Influencing Plant and Warehouse Locations, Impact of

Location on cost and revenues. Facility Location Procedure and Models: Qualitative Models,

Breakeven Analysis, location Model, centroid method. Layout Planning: Layout Types :

Process Layout, Product Layout, Fixed Position Layout Planning, block diagramming, line

balancing, computerized layout planning- overview. Group Technology

Forecasting : Principles and Method, Moving Average, weighted Moving Average,

Exponential Smoothing, Winter’s Method for Seasonal Demand, Forecasting Error.

Manufacturing Planning and Control : The Framework and Components : Aggregate

Planning, Master Production Scheduling, Rough-cut-Capacity Planning, Material

Requirements Planning, Capacity Requirements Planning.

Module IV (10 Hours)

Sequencing and Scheduling : Single Machine Sequencing : Basics and Performance

Evaluation Criteria, Methods for Minimizing Mean Flow Time, Parallel Machines :

Minimization of Makespan, Flowshop sequencing : 2 and 3 machines cases : Johnson’s Rule

and Jobshop Scheduling : Priority dispatching Rules.

Inventory Control : Relevant Costs, Basic EOQ Model, Model with Quantity discount,

Economic Batch Quantity, Periodic and Continuous Review Systems, Safety Stock, Reorder

Point and Order Quantity Calculations. ABC Analysis.

Modern Trends in Manufacturing : Just in Time (JIT) System : Shop Floor Control By

Kanbans, Total Quality Management, Total Productive Maintenance, ISO 9000, Quality

Circle, Kaizen, Poka Yoke, Supply Chain Management.

Reference Book: 1. S.N.Chary, “Production and Operations Management”, Tata McGraw Hill.

2. R. Paneerselvam, “Production and Operations Management, Prentice Hall of India.

3. Aswathappa& Bhatt – Production & Operations Management, HPH.

4. Gaither & Frazier - Operations Management, Cengage Publication

5. Russell & Taylor - Operations Management, PHI Publication

6. Chase, Aquilanno, Jacob & Agarwal - Operations Management, TMH Publication.

7. E.E. Adam and R.J. Ebert “Production and Operations Management”, Prentice Hall of India.


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PRACTICAL (PRODUCTION AND OPERATION

MANAGEMENT)

1. Solving LPP, Transportation and Assignment Problem and other Optimization problem

with the help of Excel Add-In: Solver or with the Software LINDO/LINGO.

2. Problem Formulation, and Solution & Sensitivity Analysis Using LINGO

3. Writing simple codes for GA optimization problem.

4. Design of process layout for the given problem.

5. Preparation of Assembly Chart and Product Structure, and MRP planning

6. Construction of X-bar and R Chart.

MATERIALS DEFORMATION PROCESSES

Module I (10 Hours)

Introduction: Scope of the subject, elastic, plastic, and anelastic deformation. Constitutive

equations in elasticity for isotropic and anisotropic materials, strain energy, elastic stiffness

and compliance tensor, crystal structure and elastic constants. Plastic response of materials -

different types of uniaxial stress-strain curves. Equivalent stress and strain.

Module II (10 Hours)

Levy-Mises and Prandlt-Reuss equations. Deformation theory of plasticity. Yield surface,

Isotropic and kinematic hardening - Bauschinger effect. Elements of dislocation theory -

crystallography, elastic properties, dislocations and their interactions in different crystal

structures, origin and multiplication of dislocations, thermally activated dislocation motion.

Critical resolved shear stress in single crystals.

Module III (10 Hours)

Work hardening in single and polycrystals. Strengthening mechanisms in polycrystals –role

of grain boundaries, solid solution, precipitates and dispersoids, orderdisorder transformation,

Mechanical properties of composites. Elevated termperature deformation mechanisms - cross

slip, climb and grain boundary sliding. Deformation mechanism maps.

Module IV(10 Hours)

Fracture – mechanisms of ductile and brittle fracture; fracture in creep and stress corrosion

conditions; fractograohy. Griffith theory of brittle fracture. Concepts of stress concentrations

and stress intensity factors, rack tip plastic zone. J and CTOD parameters. Ductile to brittle

transition behavior.

PRACTICAL (Materials Deformation Processes)

1. Determination of equilibrium of coplanar forces.

2. Determination of Moment of Inertia of Flywheel

3. Determination of tensile strength of materials by Universal Testing Machine.

4. Determining Stress Distributions over Deforming Polycrystals.

5. Impact strength

6. Hardness strength

7. Rigidity modulus

8. Compression / Bending strength

9. Fatigue strength


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TOOL DESIGN Module I (10 hours)

Product design considerations, product planning, product development, value analysis,

product specification. Role of computer in product design. Product design for sand casting:

design of gating system and risering, Design of single point cutting tools, tool strength and

rigidity calculation, selection of tool angles, chip breakers, carbide tipped tools, High

production cutting tools.

Module II (12 hours)

Cutting process in broaching, Geometric elements of broach teeth, Design of internal &

external surface broach, Calculation of no. of teeth, Rigidity, Cutting force, Power.

Forging design: allowances, die design for drop forging, design of flash and gutter, upset

forging die design.

Module III (12 hours)

Sheet metal working: Design consideration for shearing, blanking piercing, deep drawing

operation, Die design for sheet metal operations, progressive and compound die, strippers ,

stops, strip layout.

Module IV (12 hours)

Design of jigs and fixtures, principle of location and clamping, clamping methods, locating

methods, Drill Jig bushing, Indexing type drilling Jig. Design of single point cutting tool,

broach and form tool. Design of limit gauges.

Process Planning – selection of processes, machines and tools. Design of sequence of

operations, Time & cost estimation, Tooling design for turret lathe and automats.

Text Books:

1. Fundamentals of Tool Engineering design, S.K. Basu, S.N. Mukherjee, R. Mishra, Oxford

& IBH Publishing co.

2. Manufacturing Technology, P.N. Rao , Tata McGraw Hill

3. A Textbook of Production Engineering, P.C. Sharma, S. Chand & Co

Reference Books:

1. Product Design & Manufacturing, A K Chitale, R C Gupta, Eastern Economy Edition,

PHI.

2. Product Design & Development, Karl T Ulrich, Steven D Eppinger, Anita Goyal, Mc

Graw Hill

3. Technology of Machine Tools, Krar, Gill, Smid, Tata Mc Graw Hill

4. Jigs & Fixture Design, Edwrd G Hoffman, Cengae Learning.

PRACTICAL (Tool Design)

1. To observe the variation of horizontal and vertical forces with variation in cutting

speed, depth of cut and feed using a lathe tool dynamometer.

2. Study of chip formation in different speed and feeds.

3. Determination of cutting forces in drilling in drill tool dynamometer.

4. Study of vibration and tool chatter during cutting.

5. Design of a single point cutting tool.

6. Design of a multi point cutting tool


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STATISTICAL QUALITY CONTROL AND RELIABILITY

Module-I (10 hours)

Quality Control: Causes of variation, standard errors of mean, Process capability analysis,

Natural tolerance limits, Specification Limits, Trial and Revised Control limits, Rational

Subgroups, Methods and Philosophy of Statistical Process Control , Control Charts for

variables (X, R, S, CUSUM, EWMA), Control Charts for attributes.(P, np)

Sampling Plans: Design of single sampling plan, double, multiple and sequential sampling

plans, O.C. curve, AOQ, AOQL, ATI, AFI, ASN.

Module-II (10 hours)

Quality Engineering: Taguchi’s quadratic loss function, Off line & online quality control,

importance of parameter selection design, experimental design principle for product and

process design, two-level experimental for full factorial and fractional factorial design, S/N

ratio, Inner and outer arrays.


Total Quality Control: Components of TQM, TQM Implementation, Quality function

deployment, PDCA cycle, Quality Circle: Implementation, Training for QC, Kaizen and Poke

Yoke Systems, Quality Cost, Concept of Zero defect, Quality assurance systems- ISO 9000,

14000, 18000.

Module-IV (10 hours)

Reliability: System effectiveness, Mission reliability, Design adequacy, Operational

readiness, serviceability, performance indices, their evaluation, uses and limitation, reliability

models of maintained systems, relationship between reliability and maintainability, system

with components in series, parallel and standby, Maintainability prediction.

TEXT BOOK(S):

1. Fundamentals Of Quality Control & Improvement- A.Mitra, PHI

2. Introduction to Statistical Quality Control- D.C.Montogomery, John Wiley & Sons.

3. Total Quality Control- A.V.Feigenbaum, TMH.

REFERENCE(S):

1. Statistical Quality Control- E.L. Grant and R.S. Leavenworth, McGraw Hill.

2. Taguchi techniques for Quality Engineering- P.J.Ross, McGrawHill.

3. Quality Assurance through ISO 9000- H.D. Gupta, South Asia publication.


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FLUID MECHANICS AND FLUID POWER ENGINEERING

Module I (13 Lectures)

Introduction : Scope of fluid mechanics and its development as a science

Physical property of Fluid: Density, specific gravity, specific weight, specific volume,

surface tension and capillarity, viscosity, compressibility and bulk modulus, Fluid

classification.

Fluid statics: Pressure, Pascal’s Law, Pressure variation for incompressible fluid, atmospheric

pressure, absolute pressure, gauge pressure and vacuum pressure, manometer.

Hydrostatic process on submerged surface, force on a horizontal submerged plane surface,

force on a vertical submerged plane surface.

Buoyancy and floatation, Archimedes’ principle, stability of immersed and floating bodies,

determination of metacentric height.

Module II (07 Lectures)

Fluid kinematics : Introduction, description of fluid flow, classification of fluid flow.

Reynold’s number, Acceleration of fluid particles, flow rate and continuity equation,

differential equation of continuity,

Mathematical definitions of irrotational and rotational motion. Circulation, potential function

and stream function. Flow net

Module III (12 Lectures)

Fluid dynamics : Introduction, Euler’s equation along a streamline, energy equation,

Bernoulli’s equation and its application to siphon, venturimeter, orificemeter, pitot tube.

Flow in pipes and ducts: Loss due to friction, Minor energy losses in pipes Hydraulic

Gradient Line (HGL), Total Energy Line (TEL), Power transmission in the fluid flow in

pipes, fluid flow in pipes in series and parallel. Flow through nozzles.

Module IV (10 Lectures)

Hydraulic turbine: Classification, Impulse and Reaction turbine; Tangential, Radial and axial

turbine.

Impulse turbine, Pelton wheel, bucket dimensions, number of buckets in pelton wheel,

efficiency and performance curves.

Reaction Turbines: Francis turbine and Kaplan turbine, velocity triangle and efficiencies,

performance curve. Function of draft tube and casing cavitation

Centrifugal Pump: constructional features, vane shape, velocity triangles, Efficiencies, Multi

stage centrifugal pumps, Pump Characteristic, NPSH and Cavitation.

Positive displacement pumps: Reciprocating Pump, Working principle, Discharge, work done

and power requirement, Slip, Indicator diagram

Text Books

1. Fluid Mechanics and Hydraulic Machines, Modi & Seth

1. Introduction to Fluid Mechanics and Fluid Machines by S.K. Som and G. Biswas,

TMH

2. Fluid Mechanics, A.K.Jain, Khanna Publishers

Reference Books:

1. Fluid Mechanics by A.K. Mohanty, PHI

2. Introduction to Fluid Mechanics by Fox, McDonald, Willey Publications

3. Fluid Mechanics by Kundu, Elsevier

4. An Introduction to Fluid Dynamics by G.K.Batchelor, Cambridge University Press

5. Engineering Fluid Mechanics by Gardeet. al., Scitech

6. First course in Fluid Mechanics by Narasimhan, University press

7. Fluid Mechanics by J.F.Douglas, J.M.Gasiorek, J.A.Swaffield and L.B.Jack, Pearson

Education.


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PLASTIC PROCESSING

Module– I (10 Lectures)

Natural Polymer , Nomenclature of Polymers – Sources of Raw Materials – Methods of

Manufacture – General Characters & Properties, processing behaviour and applications of

natural polymers such as Shellac Resin – Natural Rubber – Casein.

Module – II (10 Lectures)

Commodity Plastics - Olefinic&Styrenic Plastics ,Sources of Raw Materials – Method of

Manufacture – General Characteristics & Properties – Processing Behaviour and applications

of Low Density Polyethylene, Linear Low Density Polyethylene, High Density Polyethylene,

High Molecular weight High Density Polyethylene, Polypropylene (Homo & Copolymer),

Polystyrene, High Impact Polystyrene, Acrylonitrile Butadiene Styrene , Styrene

Acrylonitrile Expanded Polystyrene

Module – III(10 Lectures)

Commodity Plastics - Vinyl & Cellulosic Plastics , Sources of Raw Materials – Method of

Manufacture – General Characteristics & Properties – Processing Behaviour and applications

of Polyvinyl chloride & Chlorinated Polyvinyl chloride, Polyvinylidene Chloride, Polyvinyl

Acetate, Polyvinyl Alcohol, Cellulose Nitrate, Cellulose Acetate, Cellulose Acetate Butyrate,

Regenerated Cellulose. Polymethyl Methacrylate, Polyacrylonitrile, Thermoplastic

Elastomers.

Module – IV (10 Lectures)

Thermoset Plastics , Source of Raw Materials – Methods of Manufacture – General

Characters & Properties – Processing Behaviour and Applications of Phenol Formaldehyde –

Urea Formaldehyde – Melamine Formaldehyde – Unsaturated Polyesters – Alkyd Resins –

Epoxy Resin – Polyurethane – Silicones.

Text / Reference Books

1. Plastic Materials – J.A. Brydson.

2. Plastic Materials Hand Book – A.S. Athalye.


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WORK STUDY AND ERGONOMICS

Module –I(10 Lectures)

Method study: purpose of work study,its objectives, procedure & applications;method study

definition & basic procedure,selection of job, various recording techniques like outline

process charts, flow process charts, man machine charts, two handed process charts, string

diagram,flow diagram, multiple activity chart, simo,cyclo-graphs and chrono-cyclographs;

critical examination, development, installation and maintenance of improved method;

principles of motion economy and their application in work design; micro motion study,

memo motion study and their use in methods study.

Module-II(10 Lectures)

Work measurement:Introduction& definition, objectives and basic procedure of work

measurement;application of work measurement in industries;time study: basic procedure,

equipments needed, methods of measuring time, selection of jobs, breaking a job into

elements; numbers of cycles to be timed; rating and methods of rating,

allowances,calculation of standard time.Work sampling: Basic procedure,design of work

sampling study conducting work sampling study and establishment of standard-time.

Module -III (10 Lectures)

Job evaluation and incentive schemes:Starlightline,Tailor,Merrick and Gantt incentive plans

Standard data system;elemental & non-elemental predetermined motion system,work factors

system;Methods Time Measurement (MTM), MOST.

Module –IV(10 Lectures)

Human factor engineering:Definition and history of development of human factors

engineering, types &characteristics of man-machine-system, relative capabilities of human

being and machines; development and use of human factor data; information input and

processing: Introduction to information theory; factors effecting information reception and

processing; coding and selecting of sensory inputs.

Display systems and anthropometric data:Display- types of visual display,visual indicators

and warning signals; factorial and graphic display; general principles of auditory and tactral

display, characteristics and selection.

TEXT BOOKS:

1. ILO; work-study; International Labour Organization

2. Khan MI; Industrial Ergonomics; PHI Learning

3. Barrnes RM; Motion and Time Study; Wiley pub

4. Megaw ED; Contemprory ergonomics; Taylor &francis

5. Sandera M and Mc Cormick E; Human Factors in Engg and design; MGHill

6. Currie RM; Work study; BIM publications


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OTHER ELECTIVE

HUMAN RESOURCE MANAGEMENT

Module I (12 hrs)

Concept scope and objectives of HRM. Relationship between HRM and HRD. The

challenges for HRM – Environmental, organizational and Individual. Role and functions of

HR managers in the changing business scenario. Human Resources Planning – overview,

Recruitment – concept, objectives, legal framework regulating recruitment in India, Selection

– Objectives and methods, Test and interviews, Induction and orientation, validity and

reliability of Tests and interviews.

Module II (12 hrs)

Career Planning – concept, objectives. Different stages of career and its implications,

Methods of career planning and development, Promotion – types and process, Transfer –

types. Separations including lay off and retrenchment. Performance Management – concept

and objectives. Performance Appraisal – concept objectives and methods – management by

objectives (MBO), Assessment centre, 360 degree feedback. Appraisal errors. Competency

mapping – concept, objectives and the process.

Module III (12 hrs)

Compensation Management – objectives and principles. wage & salary. Wage concept –

minimum wage, Fair wage, living wage. nominal wage and real wage. Components of wages,

methods of wage determination, job evaluation – methods wage differentials and its

functions.

Module IV (06 hrs)

Training and Development – Training need Assessment, Types of Training Programs – on the

job and off the job training programs, Evaluation of effectiveness of training programs.

Text Books

1. Personnel & HRM – P. subha Rao, Himalaya Publishing House.

2. HRM - Text and cases – Aswathappa, THM

3. Managing Human Resources – Gomez, Belkin & Cardy, PHI. HRM – Snell,

Bohlander, Vohra – Cengage Publication


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C++ & OBJECT ORIENTED PROGRAMMING

Module I (08 hrs)

Introduction to object oriented programming, user defined types, structures, unions,

polymorphism, encapsulation. Getting started with C++ syntax, data-type, variables, strings,

functions, default values in functions, recursion, namespaces, operators, flow control, arrays

and pointers.

Module II (16 hrs)

Abstraction mechanism: Classes, private, public, constructors, destructors, member data,

member functions, inline function, friend functions, static members, and references.

Inheritance: Class hierarchy, derived classes, single inheritance, multiple, multilevel, hybrid

inheritance, role of virtual base class, constructor and destructor execution, base initialization

using derived class constructors.

Module III (12 hrs)

Polymorphism: Binding, Static binding, Dynamic binding, Static polymorphism: Function

Overloading, Ambiguity in function overloading, Dynamic polymorphism: Base class

pointer, object slicing, late binding, method overriding with virtual functions, pure virtual

functions, abstract classes. Operator Overloading: This pointer, applications of this pointer,

Operator function, member and non member operator function, operator overloading, I/O

operators. Exception handling: Try, throw, and catch, exceptions and derived classes,

function exception declaration.

Module IV (10 hrs)

Dynamic memory management, new and delete operators, object copying, copy constructor,

assignment operator, virtual destructor. Template: template classes, template functions.

Namespaces: user defined namespaces, namespaces provided by library.

Text Books:

1. Object Oriented Programming with C++ - E. Balagurusamy, McGraw-Hill Education

(India)

2. ANSI and Turbo C++ - Ashoke N. Kamthane, Pearson Education

Reference Books:

1. C++: The Complete Reference- Schildt, McGraw-Hill Education (India)

2. “C++ and Object Oriented Programming” – Jana, PHI Learning.

3. “Object Oriented Programming with C++ “- Rajiv Sahay, Oxford

4. Mastering C++ - Venugopal, McGraw-Hill Education (India) “Object Oriented

Programming with C++”, David Parsons, Cengage Learning.


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INTERNET AND WEB TECHNOLOGY (PME5H005)

Module –I (Lecture Hour 12)

The Internet and WWW

Understanding the WWW and the Internet, Emergence of Web, Web Servers, Web Browsers,

Protocols, Building Web Sites

HTML

Planning for designing Web pages, Model and structure for a Website, Developing Websites,

Basic HTML using images links, Lists, Tables and Forms, Frames for designing a good

interactive website

Module –II (Lecture Hour 12)

JAVA Script

Programming Fundamentals, Statements, Expressions, Operators, Popup Boxes, Control

Statements, Try…. Catch Statement, Throw Statement, Objects of Javascript: Date object,

array object, Boolean object, math object

CSS

External Style Sheets, Internal Style Sheets, Inline Style, The class selector, div & span tag

DOM

HTML DOM, inner HTML, Dynamic HTML (DHTML), DHTML form, XML DOM

Module –III (Lecture Hour 11)

CGI/PERL

Introduction to CGI, Testing & Debugging Perl CGI Script, Using Scalar variables and

operators in Perl

Java Applet

Introduction to Java, Writing Java Applets, Life cycle of applet

Textbooks

1. Web Warrior Guide to Web Design Technologies, Don Gosselin, Joel Sklar& others,

Cengage Learning

Reference Books 1. Web Programming: Building Internet Applications, Chris Bates, Wiley Dreamtech

2. Programming the World Wide Web, Robert W Sebesta, Pearson

3. Web Technologies, Uttam K Roy, Oxford

4. Web Technology: A developer perspective, Gopalan&Akilandeswari, PHI


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HONOUR ELECTIVE

ADVANCED CASTING & WELDING

MODULE- I (12 hours) MELTING AND POURING: Principles of melting practice-fluxing- Degasification and

inoculation- types of furnaces- Crucibles, Cupola, Oil fired furnaces – Electric arc and

induction furnaces –Melting practice of cast iron, SG iron, steel, aluminium and copper

alloys.

CASTING DESIGN: Solidification of pure metals and alloys-shrinkage in cast metals-design

of sprue, runner, gate and risers-problems in design and manufacture of thin and unequal

sections designing for directional solidification, minimum distortion and for overall economy

- design problems of L, T, V, X and Y junctions.

Module II (08 hours) WELD DESIGN AND WELDING METALLURGY: Design of welded components-

symbolic representation of welds on drawings- welding classes-residual stresses in welds-

weld distortions-design consideration-strength consideration of welded joints-analysis of

statistically loaded welded joints-welded structures subjected to fatigue loads.

MODULE III (08 hours) SPECIAL CASTING AND WELDING PROCESSES: Evaporative pattern casting-ceramic

mould casting –electro magnetic moulding-squeeze casting –investment casting-shell

moulding- PAW-electron beam welding-laser beam welding- friction welding-ultrasonic

welding – diffusion welding-high velocity oxy fuel processes

MODULE IV (08 hours) QUALITY CONTROL AND AUTOMATION : Cleaning and inspection of castings –

Casting defect and remedies – foundry automations-moulding machines-Automation of sand

plant, moulding and fettling sections of foundry-Dust and fume control-Welding defects –

causes and remedies – Non Destructive tests – arc welding using robots-weld positioner and

manipulators –weld seam tracking-vision system-arc sensing welding

TEXT BOOKS 1. PARMAR, R.S., Welding Processes and Technology, Khanna Publishers, 1997.

2. JAIN, P.L., Principles of Foundry Technology, Tata McGraw Hill, 2003.

REFERENCES 1. A.S.M Hand book, vol 15, casting, ASM international, 1988

2. KLAS WEMAN, welding processes hand book, CRC press, 2003

3. CARY and HOWARD,B., Modern Welding Technology, Prentice-Hall, 1989.

4. HEINE, R.W., LOPER.L.R., and ROSENTHAL,C, Principles of Metal Casting, TMH

5. MINKOFF,J., solidification and cast structure,wiley.1986

6. DAVIES, A.C., Welding (10th Edition), Cambridge University Press, 1996.


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HONOUR ELECTIVE

OPTIMIZATION IN MANUFACTURING

MODULE-I (11 hours)

INTRODUCTION

Optimization – Historical Development – Engineering applications of optimization –

Statement of an Optimization problem – classification of optimization problems.

CLASSIC OPTIMIZATION TECHNIQUES

Linear programming - Graphical method – simplex method – dual simplex method – revised

simplex method – duality in LP – Parametric Linear programming – Goal Programming.

MODULE-II (09 hours)

NON-LINEAR PROGRAMMING

Introduction – Lagrangeon Method – Kuhn-Tucker conditions – Quadratic programming –

Separable programming – Stochastic programming – Geometric programming 9

MODULE-III (11 hours)

INTEGER PROGRAMMING AND DYNAMIC PROGRAMMING AND NETWORK

TECHNIQUES

Integer programming - Cutting plane algorithm, Branch and bound technique, Zero-one

implicit enumeration – Dynamic Programming – Formulation, Various applications using

Dynamic Programming. Network Techniques – Shortest Path Model – Minimum Spanning

Tree Problem – Maximal flow problem.

MODULE-IV (09 hours)

ADVANCES IN SIMULATION

Genetic algorithms – simulated annealing – Neural Network and Fuzzy systems

REFERENCES: 1. R. Panneerselvam, ―Operations Research‖, Prentice Hall of India Private Limited,

New Delhi 1 – 2005

2. J.K.Sharma, Operations Research – Theory and Applications – Macmillan India Ltd.,

1997

3. Hamdy A. Taha, Operations Research – An Introduction, Prentice Hall of India, 1997

4. P.K. Guptha and Man-Mohan, Problems in Operations Research – Sultan chand &

Sons, 1994

5. Ravindran, Philips and Solberg, Operations Research Principles and Practice, John

Wiley & Sons, Singapore, 1992


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MINOR SUBJECT

PRODUCT DESIGN AND DEVELOPMENT

Module I (10 hours)

Introduction: Design theory, design materials, human factors in design, man-machine system,

applied ergonomics, characteristics of successful product development, challenges to product

development.

Development process and product planning: Generic development process, Concept

development, product development process flows, product planning process, identifies

customer needs.


Product specifications and concept generation: Product specification, steps to establish the

target specifications, Concept generation, five step concept generation method, concept

selection, concept screening, concept testing, product architecture

Product design methods: Creative and rational, clarifying objectives - the objective tree

method, establishing functions- the function analysis method, setting requirements – the

performance specification method, determining characteristics – the QFD method, generating

alternatives – morphological chart method, evaluating alternatives – the weighted objective

method, improving details – the value engineering method and design strategies.


Design for manufacture: Estimating manufacturing cost, reducing component, assembly and

support costs, design for assembly, design for disassembly, design for environment, design

for graphics and packaging, effective prototyping – principle and planning


Industrial design: Its need, impact and quality, industrial design process and its management,

legal issues in product design, design resources, economics and management of product

development projects.

Prototyping: Basics and principles of prototyping, prototyping technologies, planning for

prototypes

Text Books:

1. K.T. Ulrich and S.D. Eppinger, “Product design and development”, Tata McGraw

Hill

2. Chitale & Gupta, “Product Development”, Tata McGraw Hill

3. Monks, J. G., “Operations Management”, McGraw Hill, 1997.

4. George Dietor, A material and Processing approach, McGraw Hill


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ADVANCE LAB I

(Using Solid Modelling software eg. AUTOCAD/SolidWorks/CATIA etc)

LIST OF EXPERIMENTS

1. Learning the Basics of Solid Modeling Software.

2. Describe and apply the CONE, SPHERE and TORUS command to draw solid primitives.

3. To create a 2D view of the given diagram using Auto CAD

4. Describe and apply the EXTRUDE and REVOLVE command to draw solid models.

5. Draw the sketch for the 3D modelling of solid work given dimension

6. Development of solid models by AUTO CAD

7. Development of solid models by CATIA / Solid works.

8. Draw the sketch of the solid model of any machine components by AUTO CAD.

9. Draw the sketch of the solid model of any machine components by CATIA.

10. Draw the sketch of the solid model of any machine components by SOLID WORKS.


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Sixth Semester


L/T Credit Theory

University Marks

Internal Evaluation

Hours/week L/T

Credit Practical

Marks

PC Non-Traditional Machining

3-0 3 100 50 2 1 50

PC CAD/CAM 3-0 3 100 50 2 1 50 PE Computer

Integrated Manufacturing/ Maintenance Engg. & Management/ Precision Engg.

3-1 4 100 50

PE Rapid manufacturing Process/Machine Tool Design/Plastic Mold & Die Design

3-1 4 100 50

^SE 3-0 3 100 50 OE Industrial Lecture

# 3 1 50

HS Business Communication & Skill for Interview ##

2-0 1 50 4 2 100

Total 19 18 500 300 13 6 300

Total Marks: 1100

Total Credits: 24

Honours 4 4 100 50

Minor


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NON –TRADITIONAL MACHINING

Module I (10 hours)

ULTRASONIC MACHINING (USM): Introduction, equipment, tool materials & tool size,

abrasive slurry, cutting tool system design:- Effect of parameters on Material removal rate,

tool wear, Accuracy, surface finish, applications, advantages & Disadvantages of USM.

ABRASIVE JET MACHINING (AJM): Introduction, Equipment, Variables in AJM: Carrier

Gas, Type of abrasive work material, stand off distance (SOD), nozzle design, shape of cut.

Process characteristics-Material removal rate, Nozzle wear, Accuracy & surface finish.

Applications, advantages & Disadvantages of AJM.


Water Jet Machining: Principle, Equipment, Operation, Application, Advantages and

limitations of Water Jet machining.

ELECTROCHEMICAL MACHINING (ECM): Introduction, study of ECM machine,

elements of ECM process: ECM Process characteristics – Material removal rate, Accuracy,

surface finish, Applications, Electrochemical turning, Grinding, Honing, deburring,

Advantages, Limitations.

CHEMICAL MACHINING (CHM): Introduction, elements of process, chemical blanking

process, process characteristics of CHM: material removal rate, accuracy, surface finish,

Hydrogen embrittlement, advantages & application of CHM.

Module III (10Lectures)

ELECTRICAL DISCHARGE MACHINING (EDM): Introduction, mechanism of metal

removal, dielectric fluid, spark generator, EDM tools (electrodes) Electrode feed control,

EDM process characteristics: metal removal rate, accuracy, surface finish, Heat Affected

Zone. Machine tool selection, Application, electrical discharge grinding, wire EDM.

PLASMA ARC MACHINING (PAM): Introduction, equipment, non-thermal generation of

plasma, selection of gas, Mechanism of metal removal, PAM parameters, process

characteristics. Applications, Advantages and limitations.

LASER BEAM MACHINING (LBM): Introduction, equipment of LBM mechanism of metal

removal, LBM parameters, Process characteristics, Applications, Advantages & limitations.

ELECTRON BEAM MACHINING (EBM): Principles, equipment, operations, applications,

advantages and limitation of EBM.

Module IV (10 Lectures)

Introduction to Surface engineering, High speed machining and grinding: Application of

advanced coatings in high performance modern cutting tools and high performance super-

abrasive grinding wheels, Micro and nano machining of glasses and ceramics. Theory and

application of chemical processing: Chemical Machining, Aching of semi conductors,

Coating and Electroless forming, PVD and CVD; Introduction to Reverse Engineering,

Concurrent Engineering and Rapid prototyping:

Text Books: 1. Modern machining process, Pandey and Shan, Tata McGraw Hill 2000

2. Manufacturing Engg. & Technology, Kalpakjian , Pearson Education

3. Manufacturing Science, A.Ghosh & A.K. Mallik, EWP


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Reference Books 1. Metals Handbook: Machining Volume 16, Joseph R. Davis (Editor), American

Society of Metals.

2. Surface Wear Analysis, Treatment & Prevention - ASM International, Materials Park,

OH, U.S.A., 1st Ed. 1995

3. Production Technology, HMT, Tata McGraw Hill. 2001

4. Modern Machining Process, Aditya. 2002

5. Non-Conventional Machining, P.K.Mishra, The Institution of Engineers (India) Test

book series, Narosa Publishing House – 2005.

6. Introduction to Rapid Prototyping, A Ghosh, North West Publication

NON –TRADITIONAL MACHINING

PRACTICAL

List of Experiments:

1. An Experimental study of working principle and applications of Electrochemical

Machining.

2. An Experimental study of working principle and applications of Chemical

Machining.

3. An Experimental study of working principle and applications of various finishing

processes.

4. A study of working principle and applications of Ultrasonic Machining.

5. A study of working principle and applications of Abrasive Jet Machining.

6. A study of working principle and applications of ELECTRICAL DISCHARGE

MACHINING.

7. A study of working principle and applications of ELECTRON BEAM

MACHINING.

8. Evaluation effects process parameters in Metal forming processes.

9. A comparative study of working principle and applications of various Micro-

Machining processes, and study effects of process parameters of them.

10. Study of process parameters of Laser processing


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COMPUTER AIDED DESIGN AND COMPUTER AIDED MANUFACTURING (3-0)

Module I (10 hour)

Fundamentals of CAD: Design process, Applications of computer for design, Creating the

Manufacturing Database, The Design workstation, Graphical Terminal, Operator input

Devices, Plotters and other devices, Central Processing Unit, Memory types.

Module II (10 hour)

Computer graphics Software and Database: Configuration, Graphics Packages, Constructing

the Geometry, Transformations of geometry, Database structure and content, Wire frame

versus solid modeling, Constraint– Based modeling, Geometric commands, Display control

commands, Editing.

Module III (10 hour)

Geometric Modeling: Types of Curves and Curve Manipulations, Types of Surfaces and

Surface Manipulations, Solids: Introduction, Geometry and Topology, Solid Entities,

Fundamentals of Solid Modeling, Boundary Representation (B-rep), Constructive Solid

Geometry (CSG) – examples, Sweeps and Solid Manipulations Feature based Modeling:

Introduction, Feature Entities, Parametrics, Feature Manipulations Rapid Proto Typing:

Introduction, RP activities, RP applications, RP techniques: Stereolithography, Selective

Laser Sintering, 3 – D Printing, Fused Deposition Modeling and Laminated Object

Manufacturing.

Module IV (10 hour)

CAM - Numerical Control and NC Part Programming: Numerical Control, Numerical

Control elements, NC Cordinate system, NC motion control system, Manual and Computer

Aided programming, the APT language, Miscellaneous Functions, M, Advanced part-

programming methods.

Problems with conventional NC, NC technology: CNC, DNC, Combined DNC/ CNC system,

Adaptive control manufacturing systems, Computer Integrated Manufacturing system,

Machine Tools and related equipment, Materials Handling system: AGV, Robots, Lean

manufacturing.

COMPUTER AIDED DESIGN AND COMPUTER AIDED

MANUFACTURING

PRACTICAL

1. Introduction to Modeling software :

i. 2D drawing and drafting using sketcher workbench – 2 drawings

ii. 3D modeling and drafting using 3D features

iii. 5 models - Assembling and drafting of 2 assemblies with interference checking.

Surface modeling – 4 exercises

2. Computer aided manufacturing:

i. CNC Lathe – 4 exercises

ii. CNC Machining Center – 4 exercises

iii. Generation of tool path, generation of NC code, Optimization of tool path

(to reduce machining time) using any CAM software


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COMPUTER INTEGRATED MANUFACTURING (3-1)

Module I (10 hours) Fundamentals of Manufacturing and Automation: Production systems, automation principles

and its strategies; Manufacturing industries; Types of production function in manufacturing;

Automation principles and strategies, elements of automated system, automation functions

and level of automation; product/production relationship, Production concept and

mathematical models for production rate, capacity, utilization and availability; Cost-benefit

analysis.

Computer Integrated Manufacturing: Basics of product design, CAD/CAM, Concurrent

engineering, CAPP and CIM.


Industrial Robotics: Robot anatomy, control systems, end effectors, sensors and actuators;

fundamentals of NC technology, CNC, DNC, NC part programming; Robotic programming,

Robotic languages, work cell control, Robot cleft design, types of robot application,

Processing operations, Programmable Logic controllers: Parts of PLC, Operation and

application of PLC, Fundamentals of Net workings; Material Handling and automated storage

and retrieval systems, automatic data capture, identification methods, bar code and other

technologies.


Introduction to manufacturing systems: Group Technology and cellular manufacturing, Part

families, Part classification and coding, Production flow analysis, Machine cell design,

Applications and Benefits of Group Technology.


Flexible Manufacturing system: Basics of FMS, components of FMS, FMS planning and

implementation, flexibility, quantitative analysis of flexibility, application and benefits of

FMS.

Computer Aided Quality Control: objectives of CAQC, QC and CIM, CMM and Flexible

Inspection systems.

Text Books: 1. Automation, Production Systems and Computer Integrated Manufacturing: M.P. Groover,

Pearson Publication.

2. Automation, Production systems & Computer Integrated Manufacturing, M.P Groover,

PHI.

3. CAD/CAM/CIM, P.Radhakrishnan, S.Subramanyam and V.Raju, New Age International

4. Flexible Manufacturing Systems in Practice, J Talavage and R.G. Hannam, Marcell Decker

Reference Books: 1. CAD/CAM Theory and Practice, Zeid and Subramanian, TMH Publication

2. CAD/CAM Theory and Concepts, K. Sareen and C. Grewal, S Chand publication

3. Computer Aided Design and Manufacturing, L. Narayan, M. Rao and S. Sarkar, PHI.

4. Principles of Computer Integrated Manufacturing, S.K.Vajpayee, PHI

5. Computer Integrated Manufacturing, J.A.Rehg and H.W.Kraebber, Prentice Hall


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MAINTENANCE ENGINEERING AND MANAGEMENT

Module I (10 hours)

INTRODUCTION

Maintenance definition – Maintenance objectives and Scope – Challenges and functions of

Maintenance management – Maintenance costs.

Maintenance – Key to reliability & productivity. Basic elements of maintenance system –

inspection, planning & scheduling, job execution, record keeping, data analysis, learning &

improvement. Preventive, operating and shutdown maintenance; Condition based

maintenance and Application of preventive maintenance for system of equipment.

Module II (10 hours) MAINTENANCE MODELS AND TESTINGS

Maintenance policies – Imperfect maintenance – Preventive & break down maintenance –

PM schedule and product characteristics – Inspection decisions: Maximizing profit –

Minimizing downtime – Replacement models.

Non-destructive testing – Visual examination – optical aids, liquid penetrate testing, magnetic

particle testing, eddy current testing, radiography, ultrasonic testing, acoustic emission

testing, thermography, leak testing, corrosion monitoring, standards for NDT.

Module III (10 hours) MAINTENANCE LOGISTICS

Maintenance Crew size – Human factors –Resource requirements: Optimal size of service

facility – Optimal repair effort – Maintenance planning and scheduling – Spares control.


MAINTENANCE QUALITY

Five Zero concept –FMECA – Maintainability prediction– Design for maintainability –

Reliability Centered Maintenance.

TOTAL PRODUCTIVE MAINTENANCE

TPM fundamentals – Chronic and sporadic losses – Six big losses – OEE as a measure –

TPM pillars– Autonomous maintenance –TPM implementation.

Maintenance Management

Maintenance planning, maintenance scheduling, work orders, work measurement,

maintenance cost budgeting, store and spare control, maintenance planning and control

techniques, Incentives for maintenance work.

REFERENCES:

1. Andrew K.S.Jardine & Albert H.C.Tsang, “Maintenance, Replacement and Reliability”,

Taylor and Francis, 2006.

2. Bikas Badhury & S.K.Basu, “Tero Technology: Reliability Engineering and Maintenance

Management”, Asian Books, 2003.

3. Seichi Nakajima, “Total Productive Maintenance”, Productivity Press, 1993.


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PRECISION ENGINERRING

Module I (10 hours) PRECISION ENGINEERING

Introduction - Accuracy & precision – Need – application precision machining –Tool

based Micro & Ultra precision Machining grinding – Thermal effects – Materials for tools

and machine elements – carbides – ceramic, CBN & diamond.

Module II (10 hours) TOLERANCE AND FITS

Tolerance – Zone – fits – Variation – Hole & shaft system – limits – expected Accuracy of

machining processes – Selective assembly – gauges acceptance tests for machine tools.

Module III (10 hours) ULTRA PRECISION MACHINE ELEMENTS

Introduction – Guide ways – Drive systems – Spindle drive – preferred numbers – Rolling

elements – hydrodynamic & hydrostatic bearings – pneumatic bearings.

Module IV (10 hours) MEMS

Introduction – MEMS – principle – Elements – Characteristics – Design – Application:

automobile defence, aerospace etc.,

ERROR CONTROL

Error – Sources – Static stiffness – Variation of the cutting force – total compliance –

Different machining methods – Thermal effects – heat source – heat dissipation –

Stabilization – decreasing thermal effects – forced vibration on accuracy – clamping &

setting errors – Control – errors due to locations – principle of constant location surfaces.

TEXT BOOKS

1. Nakazawa, H. Principles of Precision Engineering, Oxford University Press, 1994.

2. Precision Engineering – R.L. Murthy


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RAPID MANUFACTURING PROCESS

MODULE -I (12 hours)

INTRODUCTION: History - Development of RP systems - Applications in Product Development,

Reverse Engineering, Rapid Tooling, Rapid Manufacturing- Principle - Fundamental - File

formatOther translators - medical applications of RP - On demand manufacturing - Direct material

deposition - Shape Deposition Manufacturing. LIQUID BASED AND SOLID BASED RAPID

PROTOTYPING SYSTEMS: Classification - Liquid based system - Stereo lithography Apparatus

(SLA), details of SL process, products, Advantages, Limitations, Applications and Uses. Solid based

system- Fused Deposition Modeling, principle, process, products, advantages, applications and uses -

Laminated Object Manufacturing

MODULE -II (08 hours)

POWDER BASED RAPID PROTOTYPING SYSTEMS: Selective Laser Sintering - principles of

SLS process, principle of sinter bonding process, Laser sintering materials, products, advantages,

limitations, applications and uses. Three Dimensional Printing - process, major applications, research

and development. Direct shell production casting -key strengths, process, applications and uses, case

studies, research and development. Laser Sintering System, e-manufacturing using Laser sintering,

customized plastic parts, customized metal parts, e-manufacturing - Laser Engineered Net Shaping

(LENS).

MODULE -III (10hours)

MATERIALS FOR RAPID PROTOTYPING SYSTEMS: Nature of material - type of material -

polymers, metals, ceramics and composites liquid based materials, photo polymer development -solid

based materials, powder based materials - case study.

REVERSEENGINEERING AND NEW TECHNOLOGIES :Introduction, measuring device- contact

type and non-contact type, CAD model creation from point clouds-pre-processing, point clouds to

surface model creation, medical data processing - types of medical imaging, software for making

medical models, medical materials, other applications - Case study.

MODULE -IV (10hours)

Software for RP: STL files, Overview of Solid view, magics, mimics, magic communicator, etc.

Internet based software, Collaboration tools, Rapid Manufacturing Process Optimization: factors

influencing accuracy, data preparation errors, Part building errors, Error in finishing, influence of

build orientation. Surface digitizing, surface generation from point cloud, surface modification- data

transfer to solid models.

TEXT BOOKS

1. Rafiq I. Noorani, Rapid Prototyping - Principles and Applications, Wiley & Sons, 2006.

2. Chua C.K, Leong K.F and Lim C.S, Rapid Prototyping: Principles and Applications, second

edition, World Scientific, 2003.

REFERENCES

1. N.HOPKINSON, R.J.M, HAUGE, P M, DICKENS, “Rapid Manufacturing - An Industrial

revolution for the digital age”, Wiley, 2006

2. IAN GIBSON, “Advanced Manufacturing Technology for Medical applications: Reverse

Engineering, Software conversion and Rapid Prototyping”, Wiley, 2006

3. Paul F.Jacobs, Rapid Prototyping and Manufacturing, “Fundamentals of Stereo lithography”,

McGraw Hill 1993.

4. D.T.Pham and S.S.Dimov, “Rapid Manufacturing”, Springer Verlog 2001.

5. Rapid Prototyping: Principles and Applications in Manufacturing- C.C. Kai and L.K.Fai, World

Scientific Co.

6. Rapid Prototyping & Manufacturing- Paul F. Jacobs, McGraw-Hill.


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MACHINE TOOL DESIGN

MODULE –I (10 hours)

Principles Of Machine Tool Design

General requirements of machine tool design - design process machine tool layout general

requirements of machine tool design – design process machine tool layout.

Machine Tool Drives and Mechanisms

Working and auxiliary motion. Drives- Electric drives, Hydraulic transmission, Kinmatic

structure, Regulation of speed and feeds, stepped regulation, standardization of speed and

feed, stepless regulation of speeds and feeds.

MODULE –II (10 hours)

Cutting Force Analysis and Power Requirement

In Turning, Milling, Drilling, Shaping and Broaching operation with simple problems.

General requirements of machine tools - Centre lathe, Milling machine.

Design Of Machine Tool Structures

Functions-Requirements-Design criteria Material used – static and dynamic stiffness – Profile

and basic design procedure for machine tool structures. Design of beds, columns, housing,

bases, tables, cross-rails, arms saddle, carriages.

MODULE –III (10 hours)

Design Of Guide Ways And Power Screws

Function and types of guide ways – Design and lubrication of slide ways - aerostatic slide

ways - antifriction guide ways, combination guide ways - protecting devices, design of power

screws.

Design of Spindle And Spindle Bearings

Functions-Requirements and materials for spindle compliance and machining accuracy.

Design of spindles, antifriction bearing, Hydrodynamic and Hydrostatic bearing, Air

lubricated bearing.

MODULE –IV. (10 hours)

Dynamics of Machine Tools

Concept of dynamic cutting process, Physical causes of chatter and vibrations, Types of

Chatter. Stability chart, chatter vibration in Lathe, Drilling machine, Grinding machine and

Milling machine. Different methods for avoiding machine tool chatter and vibration.

Control Systems In Machine Tools

Functions, requirements and classification. Control system for speed and feeds centralized

control pre selective control, control system for forming and auxiliary motions – Mechanical

control– Ergonomic consideration and compatibility – Automatic control system – Electric

Hydraulic and pneumatic systems.

Text Books:

1 Machine tool design and numerical control by N.K.Mehta

2 Mechanical Vibration by Grover

3 Mechanical vibration by V.P.Singh

4 Design of Machine Tools by S.K.Basu.

5 Principals of machine Tools by Sen. and Bhattacharya

6 Principals of machine Tools by Koenigs-Berger


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PLASTIC MOLD AND DIE DESIGN

Module I:

Ejection and Cooling System (12 hrs)

Ejection system: Constructional features of ejector grid, ejector grid layout, types of ejector elements

– pin ejectors, sleeve ejectors, valve ejectors, D-pin ejectors; stripper plate ejection technique; types of

sprue pullers, calculation for ejector force. Cooling system: Bolster cooling systems, insert cooling

systems, baffle, bubbler cooling systems, heat rod and heat pipe systems, cooling time calculation,

cooling channel layout.

Two Plate and Underfed Mould

Design and constructional features of two plate molds, design and constructional underfed molds.

Module II:

Die Design (8 hrs)

Extrusion die design: Basic considerations in die design, constructional features of rod die,

constructional features of in-line pipe die, cross-head pipe die, offset pipe die, constructional features

of centre-fed blown film die, side-fed blown film die, spiral mandrel blown film die.

Module III:

Heat Treatment and Finishing Operations (10 hrs)

Basic tools and die materials, BIS and other major coding systems, materials and heat treatments,

effect of alloying elements on steel, various heat treatments like annealing, normalizing, hardening,

tempering, surface hardening like carburizing, nitriding, cyaniding, carbo-nitriding etc., cutting tool

geometry, mold fabrication techniques like spark erosion, milling, finishing operations like grinding,

polishing, honing, buffing, lapping, super finishing, depth of cut and power required for machining,

costing of molds and mold maintenance.

Module IV:

Fabrication and Manufacturing (10 hrs)

Constructional features of basic mold components – types of locating rings, types of guide pillars,

guide bush- standard guide pillars and guide bush, spigotted guide pillars and guide bush; Design

features of standard mold components, materials used for mold bolsters, inserts, standard mold parts,

manifold, gears, splits, wear plate, heel block, lead screw, chemical compositions of materials,

understanding injection molding machine specifications, clamping tonnage and shot weight

estimation, calculations for number of cavities based on clamping tonnage, shot weight, machine

platen size, Calculations for cavity pressure. Feed system: Constructional features and types of sprue

bush, types of runners, runner layout, calculation of runner efficiency, runner design; types of gates,

gate design calculations, runner and gate fabrication techniques, runner balancing calculations.

Books:

1. Injection Mold Design - R.C.W. Pye , fourth edition, East-west press pvt.ltd publication,

2. How to make Injection Molds – Menges and Mohren, Hanser publication Munich Vienna New

York, second edition, 1986.

3. Dies for Plastics Extrusion - M.V. Joshi, Macmillan India Ltd., first published in 1984.

4. Plastic Molds and Dies by Sors, Bardocz, Radnoti, Publisher : Von Nostrand Reinhold Company

and Akademiai Kiado,1981

5. Mold engineering by Herbert Rees, Hanser Publishers, Munich Vienna N.Y.,1995 6. Plastics Mold

Engineering Handbook by J. Harry DuBOIS and Wayne I. Pribble, publisher: Von Nostrand Reinhold

N.Y., 1987.

7. Molding machine and Mold for plastic processing by Negri Bossi, second edition, publisher : Negri

Bossi Spa., 1987

8. Machine tool engineering, G. R Nagpal, Khanna Publishers, 2004

9. Engineering Metrology, R. K. Jain, Khanna Publishers, 2007

B.Tech (Production Engineering) Syllabus for Admission Batch 2015-167th Semester

Pag

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Seventh Semester


L/T Credit Theory

University Marks

Internal Evaluation

Hours/week L/T

Credit Practical

Marks

GS Nano & Bioscience

3-1 4 100 50

PE Product Design & Development/Industrial Hydraulics/Surface Engg./Instrumentation & Control Engg.

3-1 4 100 50

PE Design of Experiment/Design for Manufacturing &Assembly/Mechatronics & MEMS

3-1 4 100 50

OE Soft Computing* / Other Subjects

3-1 4 100 50

PC Advance Lab-II/ Project

8 4 200

Projects on Internet of Things

Total 16 16 400 200 16 8 400

Total Marks: 1000

Total Credits: 24

Honours 4 4 100 50

Minor


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PRODUCT DESIGN AND DEVELOPMENT

Module I (10 hours)

Introduction: Design theory, design materials, human factors in design, man-machine system,

applied ergonomics, characteristics of successful product development, challenges to product

development.

Development process and product planning: Generic development process, Concept

development, product development process flows, product planning process, identify

customer needs.


Product specifications and concept generation: Product specification, steps to establish the

target specifications, Concept generation, five step concept generation method, concept

selection, concept screening, concept testing, product architecture

Product design methods: Creative and rational, clarifying objectives - the objective tree

method, establishing functions- the function analysis method, setting requirements – the

performance specification method, determining characteristics – the QFD method, generating

alternatives – morphological chart method, evaluating alternatives – the weighted objective

method, improving details – the value engineering method and design strategies.


Design for manufacture: Estimating manufacturing cost, reducing component, assembly and

support costs, design for assembly, design for disassembly, design for environment, design

for graphics and packaging, effective prototyping – principle and planning


Industrial design: Its need, impact and quality, industrial design process and its management,

legal issues in product design, design resources, economics and management of product

development.

Prototyping: Basics and principles of prototyping, prototyping technologies, planning for

prototypes

Text Books:

1. K.T. Ulrich and S.D. Eppinger, “Product design and development”, Tata McGraw Hill

2. Chitale & Gupta, “Product Development”, Tata McGraw Hill

3. Monks, J. G., “Operations Management”, McGraw Hill, 1997.

4. George Dietor, A material and Processing approach, McGraw Hill


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INDUSTRIAL HYDRAULICS

Module-I (10 hours)

Introduction - Pascal’s law - Advantages and Disadvantages of hydraulic systems -

Requirements of hydraulic oil - Maintenance of hydraulic oils: Heat exchanges, Filters and

Strainers etc. - Reservoir design criteria - Principle hydraulic jack - Pipes, Packing and Seals.


Various types of pumps and motors like Gear type, Piston type ,(radial &axial),Vane type

(intra vane etc.) - Selection criteria for a specific application like Injection molding machines,

Extrusion, Blow molding etc. - Working principles and Performance.


Types - Classification - Details of pressure control - Flow control; Methods of flow control,

Meter in, Meter out, Bleed off, Flow control valves like pressure compensated and non

pressure compensated in detail with applications. Directional control valves; One way (check

valves) of various types inline, right angle, restriction, pilot operated etc., two way valves

rotary type, spool type, operating controls, spool central conditions, deceleration valves.

Pressure controls - relief valves of types simple and compound, venting and relief valves,

unloading valves, sequence valves and its applications, counter balance valve, brake valve,

pressure reducing valves like direct acting and pilot operated etc. Principles of operation -

Application in molding machines


Types like weight loaded, spring loaded, gas charge with and without separator, piston type -

with advantages and limitations and applications - intensifiers - its purpose, type like single

acting and double acting, applications with various circuits. Introduction - Construction and

its mechanism –Various types of valves like Mechanical , Electrohydraulic, single stage/two

stage spool type, High performance servo valves with torque motors , Its application in

industries

Books:

1. Industrial Hydraulics Manual 5th Ed. 2nd Printing Eaton Hydraulics Training Services

(Vickers)

2. Industrial hydraulics John J. Pippenger, Tyler Gregory Hicks Gregg Division, McGraw-

Hill, 1979


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SURFACE ENGINEERING

Module-I (10 hours)

Mechanisms of Wear and Metal Cleaning: Basic Mechanisms of wear-abrasive, adhesive

wear, contact fatigue, Fretting corrosion, Testing of wear resistance, practical diagnosis of

wear, general cleaning process for ferrous and non ferrous metals and alloys selection of

cleaning processes, alkaline cleaning, emulsion cleaning, ultrasonic cleaning, pickling salt

bath descaling, abrasive bath cleaning, polishing and buffing shot peening. [10]


Thermal Spraying Processes and Electrodeposited Coatings: Thermal spraying materials,

characteristics of thermal spray processes, Design for thermally sprayed coatings coating

production, spray fused coatings, Principles of electroplating, Technology and control-

electroplating systems, Properties and applications of electrodeposits, Non aqueous and

electroless deposition, plasma coating. [10]


Hot Dip Coating and Diffusion Coating: Principles, Surface preparation, Batchcoating and

continuous coating process, Coating properties and application, Principles of cementation,

Cladding-vacuum deposition, Sprayed metal coating, Structure of diffusion coatings,

Chemical vapour deposition (CVD), Physical vapour deposition (PVD). [06] Non-Metallic

Coating Oxide and Conversion Coatings: Plating coating, lacquers, rubbers and elastomers,

viterous enamels, anodizing Chromating, application to aluminium, magnesium, tin, zinc,

cadmium copper and silver, phosphating primers. [06]


Quality Assurance, Testing and Selection af Coatings: The quality plan, design, testing and

inspection, thickness and porosity measurement, selection of coatings, industrial applications

of engineering coatings. [08]

TEXT BOOK(S):

1. Engineering Coatings-design and application- S. Grainger, Jaico Publishing House.

2. Principles of Metals surface treatment and protection- D. R. Gabe, Pergamon.

3. REFERENCE(S):

1. Electroplating Handbooks- N.V.Parathasarathy, Prentice Hall.

2. Advances in surface treatment- Niku-Lavi, Pergamon.


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INSTRUMENTATION AND CONTROL ENGINEERING

Module-I (10 hours)

Introduction to Instruments and their Representation:

Typical Applications of Instrument Systems, Functional Elements of a Measurement System,

Brief Description of the Functional Elements of the Instruments, Classification of

Instruments, Microprocessor -Based Instrumentation, Standards and Calibration.

Static and Dynamic Characteristics of Instruments:

Static Performance Parameters, Impedance Loading and Matching, Selection and

Specifications of Instruments, Dynamic Response, Compensation.

Transducer Elements:

Analog Transducers, Digital Transducers,

Basic detector transducer elements : Electrical transducer, Sliding Contract devices, Variable-

inductance transducer elements, the differential transformer, Variable-reluctance transducers,

Capacitive transducers. The piezoelectric effect, photo-electric transducer, electronic

transducer element.

Intermediate Elements:

The simple current sensitive circuit, the ballast circuit, The voltage-dividing potentiometer

circuit, The voltage balancing potentiometer circuit, Resistance bridges.

Indicating, Recording and Display Elements:

Meter Indicators. The vacuum tube voltmeter, CRO, Electronic Switch, CRO recording

techniques, Oscillographs. Digital Recorders


Strain Measurement

The electrical resistance strain gauge. The metallic resistance strain gauge, Selection and

Installation factors for metallic strain gauge, Circuitry, metallic strain gauge. The strain gauge

ballast circuit, the staring gauge bridge circuit, Temperature compensation.

Measurement of Pressure

Pressure measurement systems, Pressure measurement transducers, Elastic diaphragms, strain

gauge pressure cells, measurement of high pressure, Measurement of low pressures, dynamic

characteristics of pressure measuring systems.

Measurement of Fluid Flow

Flow characteristics obstruction meters, Obstruction meter for compressible fluids- Orifice,

Venturi meter and Pitot tube, The variable-area meter, Turbine Flow meters.


Temperature Measurement

Use of bimetals pressure thermometers, Thermocouples, Pyrometry, Calibration of

temperature measuring devices.

Force, Power, Speed and Torque Measurement :

Load Cell, Dynamometers, Tachometer and Tacho-generator, Stroboscope, The seismic

instrument.- Vibrometers and accelerometers


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Description of open and closed loop control systems and their block diagrams. Use of block

diagram and signal flow graph to find overall transfer function.

1st and 2nd order systems and their response to step and sinusoidal input, error analysis,

static and dynamic error coefficients.

Routh’s stability criterion. The Root-Locus method, Bode Plot and Nyquist plot, Gain margin

and phase margin.

TEXT BOOK(S):

1. Instrumentation Measurement and Analysis, B.C.Nakra and KK.Chaudhry, Tata Mc

Graw Hill, Third Edition.

2. Mechanical Measurements- T.G. Beckwith & N.Lewis Buck, Oxford and IBH.

3. Modern Control Engineering- K.K. Ogata, PHI.

REFERENCE(S):

1. Control Systems Emgineering- I.J.nagrath and M.Gopal, New Age international.


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DESIGN OF EXPERIMENTS

Module I (10 hours)

Simple Comparative Experiments

Basic Statistical Concepts, Hypothesis Testing, Choice of Sample Size, the Paired

Comparison Problem, Hypothesis testing, confidence intervals, choice of sample size ,

Interferences about the differences in means, randomized designs.

Experiments with a Single Factor: The Analysis of Variance

The analysis of variance, Analysis of the fixed effects model, Model Adequacy Checking,

Single Factor Experiment, Application of a Designed Experiment, Discovering Dispersion

Effects , practical interpretation of results. Sample computer output, Determining sample

size.


Randomized Blocks, Latin Squares, and Related Designs

The randomized complete block design, The latin square design, The graeco – Latin square

design, Balanced incomplete block designs, statistical analysis of the BIBD, Least squares of

estimation of the parameters


Introduction to Factorial Designs

Basic definitions and principle, The advantage of factorials , The two factor factorial design,

The general factorial design, Fitting response curves and surfaces, Blocking in a factorial

design, The

2k Factorial Design

The 22 design, The 2

3 Design, The general 2

k Design, A Single Replicate of the 2

k Design,

Data Transformation in a Factorial Design, Duplicate Measurements on the Response, Credit

Card Marketing.


Two-Level Fractional Factorial Designs

The One–Half Fraction of the 2k Design, The one quarter fraction of the 2

k design, The

general

2 k-p

fractional factorial design, Resolution III designs, Resolution IV and V Designs.

Three-Level and Mixed-Level Factorial and Fractional Factorial Designs

The 3k Design, Confounding in the 3

k factorial design , The Spin Coating Experiment, An

Experiment with Unusual Blocking Requirements

Text BOOKS

1. Design & Analysis of Experiments- D.C. Montgomery, John Wiley & Sons.

2. Design and Analysis of Experiments- J.Antony, Butterworth-Heinemann.


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MECHATRONICS Module 1 (10 hours)

Evolution of Mechatronics, components of mechatronic system, types of mechatronic

products, Signal theory, signal analysis and processing, Laplace transformation, Z-

transformation modulation and de-modulation.

Electrical components and Electronic device –Resister, inductor and capacitor, reactance and

impedance. Basic electronics devices junction diodes, Bipolar transistors


Basic Digital Technology : Digital number system, Binary number system, Hexadecimal

number system, Binary addition, Boolean Algebra, Logic function, Universal GATES, FLIP-

FLOP, Registers counters.

System modeling : Frequency response, Mechanical system, electrical system, Thermal

system, Fluid system.


Actuators- Electric motors; D.C. Motors, Stepper motor, , Hydraulic actuators, Pneumatic

actuators

Transducer and Sensors : Principles, difference between transducer and sensors, transducer

types – photo emissive, photo conductive, photovoltaic, thermistors, Thermocouple,

Inductive, capacitive, Peizoelectric, Hall effect transducers, Ionization transducer, Encoders-

Incremental encoder, Optical encoder, Bimetallic strip, Strain gauge, load cell.

Programmable Logic controller : Basic Structure - Programming : Ladder diagram Timers,

Internal Relays and Counters - Shift Registers - Master and Jump Controls, data handling ,

Analog input / output , PLC Selection &Application.

Microprocessor ad Microcontroller : Microprocessor based Digital control, registers, Program

counter, Intel -8085 microprocessor


Precision Engineering – Concepts and significance – Micro fabrication – Types - Top down –

Bottom up approaches – LIGA process – Lithography steps – X ray Lithography – Masks –

Mask materials Micromachining –

Theory of micromachining – Types – Concepts – Tools used in micromachining – Micro

EDM – Micro wire cut EDM – Abrasive Jet Micromachining - Ion beam milling

Text Books

1. Mechatronics, A.Smaili & F Mrad, Oxford University Press

A Text Books of Mechatronics, R.K.Rajput, S.Chand & company

2. Mechatronics, N.G. P.C Mahalik, Tata McGraw Hill

3. Mechatronics, D.G. Alciator, M.B. Histand, Tata McGraw Hill

4. M. J. Madou, “Fundamentals of Micro Fabrication”, CRC Press.

Reference Books :

1. Mechatronics, K.P.ramchandran, G,K Vijay Raghavan, M. S Balachandran

2. Mechatronics An Intigrated approach, Clarence W de Sliva, CRC Press

Documents

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