Bansilal Ramnath Agarwal Charitable Trust’s Vishwakarma ...3) Sheet metal formability: Concept of...

Vishwakarma Institute of Technology Issue 01 : Rev No. 1 : Dt. 01/07/18

Structure and Syllabus of T.Y. B. Tech. Production Engineering. Pattern C-19, A.Y. 2019-20 (P a g e | 1)

Bansilal Ramnath Agarwal Charitable Trust’s

Vishwakarma Institute of Technology (An Autonomous Institute affiliated to Savitribai Phule Pune University)

Structure & Syllabus of

B. Tech. (Production Engineering)

Pattern ‘C19’

Effective from Academic Year 2019-20

Prepared by: - Board of Studies in Industrial & Production Engineering



T.Y. B. Tech. Production Engineering AY 2019-20 (C19)

Subject No.

Subject Code

Subject Name Teaching Scheme (Hrs/Week)

Examination scheme Credits

Theory Lab CA MSE GD/ PPT

ESA Total HA LAB ESE VIVA

Semester-1 (Module-V)

S1 PR3001 Metal Forming Technologies

3 2 10 30 15 10 15 20 100 4 PR3002 Production Planning & Control

S2 PR3003 Production Metallurgy

3 2 10 30 15 10 15 20 100 4 PR3004 Quality & Reliability Engineering

S3 PR3005 Work Study & Human Factors Engineering

3 2 10 30 15 10 15 20 100 4 PR3006 CAD/CAM/CIM

S4 PR3009 Product Design & Modelling

3 2 10 30 15 10 15 20 100 4 PR3008 Design for Manufacturing & Assembly

S5 PR3171 Engineering Design & Innovation - 1 1 2 -- -- -- -- -- -- 100 4 Total 13 10 20

Semester-2 (Module-VI)

S1 PR3036 Additive Manufacturing

3 2 10 30 15 10 15 20 100 4 PR3037 Modern Manufacturing Processes

S2 PR3038 Metal Cutting & Tool Design

3 2 10 30 15 10 15 20 100 4 PR3039 Mechatronics & Industrial Robotics

S3 PR3040 Machine Tool Design

3 2 10 30 15 10 15 20 100 4 PR3041 Industrial Fluid Power

S4 PR3042 Statistical Methods for Data Analytics

3 2 10 30 15 10 15 20 100 4 PR3043 Project Management

S5 PR3186 Engineering Design & Innovation - 2 1 2 -- -- -- -- -- -- 100 4

S8 PR3089 **General Proficiency - 2 -- -- -- -- -- -- -- -- -- -- Total 13 10 20

(**) Audit Course evaluated in second semester



Module V



FF No. : 654

PR3001::METAL FORMING TECHNOLOGIES

Credits: 4 Teaching Scheme: Theory 3Hrs/Wk, Lab 3 Hrs/Wk

SECTION-1

1) Fundamentals of Metal Forming

Classification of forming processes, Materials and their structures, Mechanical behavior of

crystalline materials, tensile behavior work done in tensile test, types of stress and strains

Engineering stress-strain and true stress-strain, Compression behavior, Strain hardening,

temperature rise in plastic deformation.

2) Concept of flow stress determination, compression test Effect of temperature, strain rate,

Elasticity, Mohr’s circle for three dimensional state of stress, Elasticity, State of stress,

Principal stresses, Octahedral stress, Theory of plasticity- Yield criteria of Von Mises criteria

and Tresca criteria.

3) Sheet metal formability: Concept of sheet metal formability and forming diagram.

Sheet/plate forming techniques: Stretch Forming, Spinning, Incremental forming.

4) Forging Processes: Comparison of forging with other manufacturing processes.

Classification of forging processes-open die and closed die forging, Hot and cold forging,

Basic forging operations such as drawing, fullering, edging, blocking etc, Forging

equipment- Hammers and presses, construction working capacities and selection of

equipment.

5) Special forging techniques: Isothermal forging, Rotary swaging, Orbital forging, Liquid

forging and Powder forging.

6) Forgeability: Concept of forge ability and formability tests, Analysis of forging load

considering friction, Analysis of upset forging, Forging defects and remedies.

7) Advanced Forming techniques: HERF: Explosive forming- Confined and unconfined

techniques, High velocity forming- principles, comparison of high velocity and conventional

Forming processes. Magnetic pulse forming, Electro hydraulic forming: principal and

process

SECTION-2

1) Rolling of Metals Scope and importance of rolling. Cold rolling and Hot rolling Types of

Rolling Mills- Construction and working.

2) Analysis of Rolling load: Friction in rolling, Roll bite, reduction, elongation and spread.

Analysis of rolling load. Deformation in rolling and determination forces required.

3) Rolling Process variables: redundant deformation. Roll flattening, Roll camber - its effect

on rolling process, mill spring. Automatic gauge control- Lubrication in rolling, Defects in

rolling.

4) Rod, Wire and tube drawing Introduction rod and wire drawing machines - construction

and working. Preparation of stock for wire drawing. Wire drawing dies, material and design.



Variables in wire drawing, Maximum reduction in wire in one pass, forces analysis in wire

drawing and strip drawing Multiple drawing, work hardening, lubrication in wire drawing.

Tube drawing: Methods, stock preparation. Lubrication in tube drawing. Force analysis in

Tube drawing.

5) Extrusion of Metals Types of Extrusion process: direct, reverse, impact and hydrostatic

extrusion. Dies for extrusion, Extrusion ratio, Extrusion Force equipment (with and without

friction), types of metal flow in extrusion, Extrusion load analysis, Extrusion dies Extrusion

defects and remedies. Design of Extrusion Die set.

List of Practical (Any Six):

1. Estimation of amount total work done in tensile deformation of MS/Al/ Brass

2. Estimation of amount of total work done in compressive deformation of MS/Al/ Brass.

3. Design of edging die profile for lever forged component.

4. Rolls pass design for box pass.

5. Estimation of extrusion ratio, shape factor and circumscribing circle diameter for

structural section of aluminum.

6. Forgeability test of notched surface of low C steel.

7. Microstructural analysis of super plastically deformed sample.

8. Study of Industry practices in any metal forming industry.

9. Measurement of plastic strain ratio of sheet metal.

10. Study the effect of strain rate on flow stress of metal.

11. Cold Rolling of aluminum strip and optimization of rolling passes.

12. Hot Rolling of steel plates and to study its texture.

13. Severe plastic deformation for strengthening of metals.

List of Project areas:

1) To study effect of strain rate in tensile deformation at room temperature.

2) To study effect of strain rate in Compressive deformation at room temperature.

3) Estimation of flow stress at high temperature in tensile deformation.

4) Estimation of flow stress in compressive deformation.

5) Estimation of anisotropic behavior of sheet metals.

6) Severe plastic deformation and characterization of mechanical and microstructures.

7) Forgeability analysis of various metals.

8) Texture analysis of metals after mechanical working.

9) Design and manufacture mini wire drawing set up.

10) Design and manufacture mini extrusion set up.

11) To determine forming limit curves for single pass deep drawing.

12) To study effect of processing temperature on plastic deformation.

13) Simulation of forged components.

Text Books:

1) Dieter G.E., “Mechanical Metallurgy”, McGraw Hill, Co., S.I. Edition, 2001

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



Reference Books:

1. Dr. R. Narayanswamy, Metal Forming Technology, Ahuja Book Co.

2. Surender Kumar, Principles of Metal Working, Oxford & IBH Publishing Company, 1985,

Edition 2.

3. ASM Metal handbook, Metal working –Bulk Forming, Vol: 14A, ASM International

4. J. N. Harris, Mechanical working of metals

5. G. W. Rowe, Principles of industrial metal working process, Edward Arnold

6. Nagpal G.R., Metal forming processes, Khanna publishers, New Delhi, 2004

Course Outcomes:

Students will be able to

1. understand fundamentals of elastic and plastic deformation of metals.

2. select appropriate forging process, equipment, tools and analysis of forging load..

3. classify rolling processes, equipment and analysis of rolling forces and defects.

4. understand wire and tube drawing machines, tools and analyze wire and tube drawing

forces.

5. understand types of extrusion process and analysis of extrusion load and metal flow.

6. compare and apply nonconventional forming techniques.



FF No. : 654

PR3002::PRODUCTION PLANNING & CONTROL

Credits: 04 Teaching Scheme: Theory 3 Hrs / Week &

Lab/Project 2 Hrs/Week

SECTION-1

Scope of Operations Management - Nature, Scope, Importance, Various Functions in

Operations, Types of Production Systems – Project type, Job shop, Batch Production, Flow /

Continuous Production, Mass Production - Characteristics and applicability of each type.

Operations Strategies: Process choice – Select the appropriate production system,

Competitiveness with Operations, Competing on cost, quality, flexibility, speed, reliability.

Order Winners & Order Qualifiers. Introduction to ETO, MTO, ATO & MTS, Operations

Planning & Control – PPC – Functions, Operations Planning & Control Framework,

Demand Forecasting -Components of Demand, Techniques of Demand Forecasting –

Qualitative (Survey & Judgmental – Delphi, Expert Opinion) & Quantitative (Causal

Methods – Input-Output Method, Leading Indicators Method & Time Series Analysis –

Moving Average, Exponential Smoothing, Regression Method). Holts Model, Winters

Model, Box-Jenkins Model. Measuring Errors in Forecasting – MAD, MFE, MSE & MAPE

Aggregate Planning (Sales & Operations Planning)

Introduction, Requirement of Aggregate Plan, Steps in Developing an Aggregate Plan,

Advantages of Aggregate Plan, Aggregate Planning Strategies, Planning Options. Selecting

the Method in Aggregate Planning, Aggregate Planning in Services Pure Strategies – Chase,

Level, Mixed Strategies, Numerical in Aggregate Planning.

SECTION-2

MRP II (Manufacturing Resource Planning) – Master Production Scheduling, Rough Cut

Capacity Planning, Operations Control – Gantt Charts, Planning & Scheduling Techniques:

Scheduling v/s Loading, Scheduling Types – Forward Scheduling & Backward Scheduling

Scheduling Techniques –Single machine scheduling- SPT, WSPT, Slack per operations,

Critical Ratio, EDD, etc. –Evaluate lateness, tardiness. Hogdson algorithm, Minimizing

tardiness heuristics. Detailed Capacity Requirement Planning

Material Requirement Planning (MRP I)

Material Requirement Planning (MRP I): Inputs to MRP – MPS, BOM –Types of BOM,

BOM Explosion, Inventory Transaction Files, MRP Processing (Logic) Time Phased

Operation Plan, Numerical on BOM Explosion Netting Requirements, Lot sizing methods.



Operations scheduling

LPT for multiprocessing machines, Flow shop Modeling-Johnson’s method – Johnson’s rule

for 2,3 and M machines problem, Assignment models, CDS Methods, Minimize machine

Idle Machine Method, Line Balancing, Oven processing problems ,Network scheduling of

jobs on parallel processing (similar Machines), Job shop scheduling-CLXspt method

List of Practicals:

1. Case study Assignment on Production Systems

2. Case study Assignment on Operations Strategy

3. Assignment on Demand Forecasting – Time Series Models

4. Assignment on Demand Forecasting – Errors in Forecasting

5. Assignment on Aggregate Planning – Pure & Mixed Strategies

6. Assignment on Aggregate Planning – Service Processes

7. Assignment on Master Production Schedule

8. Assignment on Rough Cut Capacity Planning & Capacity Requirement Planning

9. Assignment on MRP 1 – BOM Explosion & Netting Requirements

10. Case study Assignment on Materials Requirement Planning

11. Assignment on Operations Scheduling

12. Assignment on Line Balancing


1. Operations strategies Implementation

2. Demand Forecasting - Products

3. Demand Forecasting - Services

4. Aggregate Planning

5. Master Production Scheduling

6. Rough Cut Capacity Planning

7. Capacity Requirement Planning

8. Materials Requirement Planning

9. Line Balancing

10. Operations Scheduling

Text Books:

1. Paneerselvam, Production & Operations Management, 3rd Edition, McGraw Hill

Publications.

2. Chary, Production & Operations Management –McGraw Hill Publications

3. Chase, Aquilano, Jacobs, Operations Management for Competitive Advantage, Tata

McGraw Hill

4. S K Mukhopahyay, Operations Planning & Control, Jaico Publications

Reference Books:

1. Chary; Production & Operations Management; 1st Edition, McGraw Hill Publications

Course Outcomes:

The student will be able to –

1. Determine the appropriate production system based on the product attributes such as

variety, volumes, etc.

2. Understand need of various functions in production planning and control for better

management of manufacturing and/or service systems



3. Develop analytical mind for identifying and solving demand forecasting problems using

appropriate tools and techniques

4. Develop aggregate plans, master production schedule, capacity requirement plan, and

material requirements plans, as part of resource requirements planning systems

5. Develop analytical mind for planning material requirements in a manufacturing

environment

6. Understanding different scheduling techniques used in production systems



FF No. : 654

PR3003::PRODUCTION METALLURGY



SECTION-1

Introduction to Metallography: Micro and macro examination, Specimen preparation for

micro & macro examination. Optical metallurgical microscope, Etching technique. Iron-Iron

carbide equilibrium diagram, Critical temperatures, Allotropy, cooling curve and volume

changes of pure iron. Microstructure, non-equilibrium cooling of steel, widmanstatten

structure, structure property relationship. Classification and applications of plain carbon

steels, specifications of some commonly used steels like BIS, EN, AISI, SAE.

Introduction to heat treatment furnaces and Furnace atmospheres: Transformation

products of austenite, Time-temperature- transformation diagrams, Critical cooling rate,

Continuous cooling Transformation diagrams. Heat treatment of steels Quenching media,

Annealing, Normalizing, Hardening, Tempering. Retention of austenite. Effects of retained

austenite. Elimination of retained austenite, Tempering. Secondary hardening, Temper

embrittlement, Hardenability testing. Defects due to heat treatment, causes and remedial

measure.

Surface hardening and Isothermal treatments – Process details, applications

modifications in these treatments. Isothermal treatments like Austempering, Patenting, Iso

forming, Ausforming etc. procedures of these treatments, applications

SECTION-2

Alloy Steels and Tool steels - Effects of alloying elements on properties of plain carbon

steels, classification of alloying elements. Typical examples of alloy steels like HSLA, Duel

phase steels, Maraging steels, Stainless Steels, Sensitization of stainless steel, weld decay of

stainless steel. Tool steels and tool materials, Heat treatment of high-speed steel. Special

purpose steels with applications. Special cutting materials like Stellites, Ceramics, Cermets

etc.

Cast irons - Differences between steels and cast irons. Classification of cast irons, Gray cast

iron, White cast iron, Malleable cast iron, Ductile Iron, Chilled and alloy cast irons. Effects

of various parameters on structures and properties of cast irons, Heat treatments of cast iron.

Different alloy cast irons. Applications of cast irons for different components of machine

tool, automobiles, pumps etc.



Nonferrous alloys- Copper alloys like Brasses, Bronzes (Tin, Aluminium, Beryllium,

Silicon bronzes) Copper nickel alloys, Nickel - Silver, Aluminium and aluminium alloys.

Solders, Bearing materials and their properties and applications, Precipitation hardening

alloys. High Temperature materials such as Nimonics, Super alloys, Ti-alloys, Nickel alloys,

Bio materials etc. Properties of these alloys and typical applications.

List of Practicals:

1. Specimen preparation for micro examination.

2. Macro examination

3. Study and drawing microstructures of plain carbon steels.

4. Study and drawing microstructures of heat treated steels.

5. Study and drawing microstructures of Cast Irons.

6. Study and drawing microstructures of non ferrous alloys.

7. Hardenbility testing

8. Study and drawing microstructures of annealed & normalized steels.

9. Study the effect of carbon content on hardness of hardened steel.

10. Study the effect of tempering temperature on hardness of hardened steel.

11. Study the effect of allowing elements on hardness of hardened steel.

12. Comparison of Hardenability of plain carbon steel and alloy steel.


1. Effect of carbon percentage on hardness after hardening.

2. Effect of tempering temperature on hardness.

3. Use of macro examination in Metallography.

4. Hardenability testing of different steels and co relating results with composition of Steel.

5. Study the effect of tempering on hardness of steel.

6. Study Carburizing steel.

7. Study Carbonitriding of steel.

8. Measurement of case depths.

9. Study of the effect of Carburizing time on case depth.

10. Study of tempering of tool steel

11. Study & comparison of different bearing materials.

12. Sorting of plain carbon steels by observing their microstructures.

Text Books:

1. Dr. V. D. Kodgire, Material Science and Metallurgy for Engineers, Everest Publishing

House, Pune.

2. Raymond A. Higgins, Engineering Metallurgy, Part 1: Applied Physical Metallurgy, 5th

Edition, English Language Book Society.

3. K.G. Budinski, M. K. Budinski, Engineering Materials, Prentice –Hall India Pvt. Ltd.

4. Sidney H. Avner, An Introduction to Physical Metallurgy, Indian Edition

Reference Books:

1. E.C. Rollason, Metallurgy for Engineers, English Language Book Society



2. Donald Clark and Wilbur Varney, Physical Metallurgy for Engineers, East- West Press

Pvt. Ltd. New Delhi.

3. Donald. Askeland and P.P. Phule, The science and engineering of materials, 4th edition,

Thomson learning Inc.

4. A.S.M. Metals Hand book Volume 4, Heat Treatments.

Course Outcomes:


1. Interpret Fe-Fe3C equilibrium, microstructures & correlate structure-properties

relationship of steels & cast irons.

2. Use the concept of TTT, CCT diagrams & apply the heat treatment techniques to enhance

mechanical properties of steels.

3. Apply the surface hardening & isothermal heat treatment techniques to enhance

mechanical properties of steels.

4. Select appropriate alloy steel and tool steel for different engineering applications

5. Select appropriate cast iron nonferrous material for different engineering applications.

6. Select appropriate non ferrous material for different engineering applications.



FF No. : 654

PR3004::QUALITY & RELIABILITY ENGINEERING Credits: 04 Teaching Scheme: 3 TH + 2 Lab Hrs/Wk

SECTION-1

1. Concepts of Quality- Meaning of Quality, Modern concept of Quality- Quality loss

function, Quality Characteristics , Major aspects of Quality, Quality of Product versus

Quality of Service, Quality control, Quality Assurance, Quality and Reliability, Quality

Improvement, Cost of Quality, Value of Quality, Cost-Quality Trade-off, Quality and

Productivity, some philosophies and their impact on Quality

2. Acceptance Sampling: 100% Inspection versus Sampling Inspection, Concept of

Producer Risk and Consumers Risk, Operating Characteristics Curve, Some measures for

evaluating sampling plans- AOQ, ATI, ASN, Types of Sampling Plan – Single, multiple and

sequential sampling plans. Design of single sampling plans, Determining Sampling Plan on

the basis of MIL, ASQ Standards

3. Statistical Process Control: Variations – Concept, Causes – Special & Common,

Statistical basis for control chart, Errors in making inferences from control charts- Type I

and Type II errors, Difference – Process in Control versus Process is Capable, Control Charts

for variables and Attributes, Process capability Analysis, Process capability Indices, Six

Sigma Limits

SECTION-2

1. Introduction to TQM, Quality Circles, Quality function Deployment, Benchmarking,

Quality Improvement Tools- Check Sheet, Histogram, Pareto Chart, Fishbone Diagram, Run

Charts, Scatter Diagram, Process Flow Chart, QM Tools – Program Decision Process Chart,

Tree Diagram, Affinity Diagram, Prioritization Matrix, Matrix Diagram, Network diagram,

other Quality tools like why-why Analysis, Mistake Proofing

2. Importance and overview of ISO 9000, Standard clauses, Introduction to TS16949, ISO

9000 Certification: Certifying Bodies & Accreditation Agencies, Necessity for Certification

& Certification Process, Benefits of Certification

3. Introduction to Six Sigma: Definition, Concept, Six Sigma Approaches – Design for Six

Sigma (DFSS) Approach & DMAIC Approach, Six Sigma Tools, Methodology, Six Sigma

Organization

4. Reliability: Concept of probability, definition, Life-cycle curve and probability

distribution in modeling Reliability- exponential and weibull distributions, determination of

MTBF and MTTR, Active and Passive Redundancy, Evaluation of overall system reliability-

series, parallel and mixed configuration

Concept of Maintenance, Preventive maintenance, reliability centered maintenance, system

availability and maintainability



List of Practicals:

1. Assignment on Control Charts for Variables

2. Assignment on Control Charts for Attributes

3. Assignment on Process Capability Analysis

4. Assignment on Design of Acceptance Sampling plans

5. Assignment on Determination of AOQ, AOQL, ATI and ASN

6. Construction of control chart, Run Chart, Cause & Effect Diagram, Scatter plot, Pareto

chart using MINITAB/SPSS/R software

7. Construction of control Scatter plot, Pareto chart using MINITAB/SPSS/R software

8. Case study on application of 7 QC tools

9. Case study on application of & QM tools

10. Case study on implementation and impact of Six Sigma Projects.

11. Assignments on Reliability

12. Assignments on Availability, maintainability etc.

List of Project:

1. Project on quality cost analysis/Benchmarking

2. Project on Mistake proofing

3. Project on study and application of ISO 9000

4. Project on statistical process control

5. Project on Quality Control tools I

6. Project on Quality Control tools II

7. Project on Quality Management tools I

8. Project on Quality Management tools II

9. Project on Quality Function Deployment I – Constructing House of Quality: Products

10. Project on Quality Function Deployment II – Constructing House of Quality: Services

11. Project on Process Improvement through Six Sigma I (Define, Measure and Analyse

phase)

12. Project on Process Improvement through Six Sigma II (Define, Measure and Analyse

phase)

Text Books:

1. Amitava Mitra; Fundamentals of Quality Control & Improvement; 2nd

edition, Pearson

Education 2002

2. Phadke M. S.; Quality Engineering using Robust Design; Pearson Education 2008

3. A.V. Feigenbaum; Total Quality Control; McGraw Hill International Editions, USA.1987

4. Douglas. C. Montgomery; Introduction to Statistical quality control; 4th edition, John

Wiley 2001.

5. Charles E. Ebelin; Reliability and maintainability engineering; TMH (2000)

Reference Books:

1. J. M. Juran & F. M. Gryna; Quality Planning and Analysis; 5th

Edition, McGraw-Hill,

1993



2. Juran’s Quality Handbook; J. M. Juran, A. Blanton Godfrey; 5th

Edition, McGraw Hill

Professional, 1999

3. E.L. Grant & R.S. Leavenworth; Statistical Quality Control; 7th

Edition, Tata McGraw Hill

4. Kaoru Ishikawa; Guide to Quality Control; Asian Productivity Organisation, Tokyo,

1986.

5. ISO 9000 Quality Management System; International Trade Center, Geneva

6. Patrick D. T. O’Connor; Practical Reliability Engineering; 4th edition, John Wiley 1993

7. Green A. E., and Bourne A. J.; Reliability Technology; Wiley Inderscience, 1991

Course Outcomes:


1. Understand and apply principles of quality management

2. Interpret for process control, identify and analyze and eliminate/reduce causes of

variation and carry out process capability studies

3. Select and design an acceptance sampling plan for sampling inspection

4. Develop an ability of problem solving and decision making using quality improvement

tools

5. Understand and apply Six Sigma Methodology and QMS and its applications

6. Evaluate reliability, maintainability and availability of product/component systems



FF No.: 654

PR3005::WORK STUDY & HUMAN FACTORS ENGINEERING

Credits: 04 Teaching Scheme: Th-3 Hrs/Wk + Lab/Project-2 Hrs/Wk

SECTION-1

Methods Improvement

1. Productivity - Introduction to Industrial Engineering, Historical background,

Contribution of Taylor and Gilbreth, Productivity – Definition, Types, Improvement,

Work Content Analysis, Definition and Scope of Work Study, Productivity study,

productivity ratios, Numerical and Cases on Productivity

2. Methods Analysis - Definition, Steps in Method Study, Various Considerations to

select a job for Method Study, Recording – Significance, Need, Charting

Symbols, Recording Techniques - Charts and Diagrams, Examine – Questioning

Techniques – Primary & Secondary Questions, Methods improvement - cost benefit

analysis, Cases on Recording Techniques

3. Methods Improvement - Introduction to Principles of Motion Economy, Develop –

Alternate Methods of Doing Work, Evaluate – Criteria for Evaluating & Selecting Best

Method, Define – Develop Standard Operating Procedures, Work Instructions,

Implement – Practical Aspects in Implementing New Method, Overcoming Resistance to

Change, Maintain, Standard Operating Procedures – Developing SOPs, Standard Work

Instructions

SECTION-2

Work Measurement

1. Time Study – Definition, Steps, Concept of Observed Time, Basic/Normal Time,

Standard Time, Video Time Study – Elemental breakdown of tasks, types of elements,

Rating – Concept, Types, Allowances – Concept, Types, Application, Calculation of

Standard Time, Numerical on estimating standard time, Work Sampling – Steps

Involved, Applications, Advantages

2. Predetermined Motion Time Standards – Introduction, Methods Time Measurement –

Establishing Time Standards using MTM. Introduction to MOST - Basic, Mini and Maxi

MOST, General Move, Control Move, Tool Use Sequence, examples on MOST

3. Introduction to Human Factors Engineering - Definition and scope, objectives,

human-machine system, characteristics of human-machine system, need for application

of Human Factors Engineering in industry and society, Introduction to Anthropometry,

type of dimensions, use of anthropometry data, Principles in the application of

anthropometric data, work space envelopes, work place design, science of seating,.

Principles of seat design, design of work surfaces

List of Practical:

1. Numerical on Productivity

2. Case Study on Productivity



3. Assignment on Recording Tools & Techniques – Charts

4. Assignment on Recording Tools & Techniques – Charts using WorkPro Software

5. Assignment on Recording Tools & Techniques - Diagrams

6. Methods Analysis (Record, Examine) using WorkPro Software

7. Methods Improvement (Record, Examine) using WorkPro Software

8. Training in Rating - Dealing Cards

9. Setting Time Standards using Time Study–Video Analysis using WorkPro Software

10. Work System Analysis for reducing standard time using WorkPro Software

11. Work System Improvement for improving resource utilization using WorkPro Software

12. Work Sampling exercise


1. Productivity improvement

2. Work content analysis using WorkPro Software

3. Work Content Reduction using WorkPro Software

4. Methods Analysis using WorkPro Software

5. Methods improvement in manufacturing sector using WorkPro Software

6. Methods improvement using in service sector industry WorkPro Software

7. Work place design

8. Work Sampling in service sector

9. Work Sampling in manufacturing sector

10. Work Measurement -Time Study in manufacturing sector using WorkPro Software

11. Work Measurement – Time Study in service sector industry using WorkPro Software

12. Establishing standard time using predetermined time standards

Text Books

1. George Kanawaty, Introduction to Work Study, Fourth revised edition, Universal Book

Corporation, Bombay. International Labour Office, Geneva

Reference Books

1. Kjell B. Zandin, Most Work Measurement Systems, Second revised edition, Marcel

Dekker, Inc, New York

2. M. S. Sanders and Ernest J. McCormick, Human Factors Engineering and Design, Seventh

edition, McGraw-Hill Inc

Course Outcomes:


1. Understand and apply productivity concepts and principles and analyze work content

2. Systematically record; critically examine methods of doing work to effect improvements

3. Design the workplace using principles of motion economy and develop improved methods

4. Establish standard time to carry out a specified job using stop watch time study

5. Establish standard time to carry out a specified job using video watch time study

6. Establish standard time to carry out a specified job using predetermined time standards



FF No.: 654

PR3006::CAD/CAM/CIM

Credits: 4 Teaching Scheme: Th-3 Hrs/Wk + Lab/Project-2 Hrs/Wk

SECTION-1

Review of CAD/CAM systems - 3 hours

Product life cycle, CAD/CAM systems and applications, 3D modeling concepts, PLM and

associated databases

Computer Graphics - 4 hours

Transformations – 2D & 3D, Homogenous representation, concatenated transformations,

Visualisation – Hidden line, surface and solid algorithms, shading, colors

Geometric modeling – Curves - 6 hours

Curve entities and representation, analytic curves – line, circle, ellipse, parabola, synthetic

curves – Hermite cubic spline, Bezier curve, B-spline curve, NURBs, Curve manipulations

Geometric modeling – Solids - 4 hours

Geometry and topology, solid entities and representation, Boundary representation,

Constructive solid geometry, Features

SECTION-2

Computer Aided Manufacturing-

Scope-Manufacturing Planning and Manufacturing Control, CAD/CAM, Process definition

and manufacturing planning – Structures of a process plan – CAD based process planning –

Coding systems – Methods of CAPP – Process planning systems., Nature of the CIM system

– Types of manufacturing systems – Evolution of CIM – Computers in CIM. Background –

Role of MRP – II in CIM systems,

NC & CNC Machine tools Basics

1)INTRODUCTION TO CNC MACHINE TOOLS Evolution of CNC Technology,

principles, features, advantages, applications, CNC and DNC concept, classification of CNC

Machines – turning centre, machining centre, grinding machine, EDM, types of control

systems, CNC controllers, characteristics, interpolators– Computer Aided Inspection

2)STRUCTURE OF CNC MACHINE TOOL CNC Machine building, structural details,

configuration and design, guide ways – Friction, Anti friction and other types of guide ways,

elements used to convert the rotary motion to a linear motion – Screw and nut, recirculating

ball screw, planetary roller screw, recirculating roller screw, rack and pinion, spindle

assembly, torque transmission elements – gears, timing belts, flexible couplings, Bearings.



3) DRIVES AND CONTROLS Spindle drives – DC shunt motor, 3 phase AC induction

motor, feed drives –stepper motor, servo principle, DC and AC servomotors, Open loop and

closed loop control, Axis measuring system – synchro, synchro-resolver, gratings, moiré

fringe gratings, encoders, inductosysn, laser interferometer.

4)CNC PROGRAMMING 11 Coordinate system, structure of a part program, G & M Codes,

tool length compensation, cutter radius and tool nose radius compensation, do loops,

subroutines, canned cycles, mirror image, parametric programming, machining cycles,

programming for machining centre and turning centre for well known controllers such as

Fanuc, Heidenhain, Sinumerik etc., generation of CNC codes from CAM packages.

5) TOOLING AND WORK HOLDING DEVICES -Introduction to cutting tool materials –

Carbides, Ceramics, CBN, PCD–inserts classification- PMK, NSH, qualified, semi qualified

and preset tooling, tooling system for Machining centre and Turning centre, work holding

devices for rotating and fixed work parts, economics of CNC, maintenance of CNC

machines. CAM software – Integration of computers in CIM environment

List of Practicals-

1. 2D transformations of geometric entities

2. 3D transformations of geometric entities

3. Enumeration and illustration of synthetic curves

4. Toolpath optimization and simulation for milling operations

5. Toolpath optimization and simulation for turning operations

6. CNC Lathe programming – Basics G and M codes

7. Example of programming-liner interpolation.

8. Example of programming-circular interpolation clockwise

9. Example of programming-circular interpolation anti clockwise

10. Example of programming-Automatic canned cycle-turning

11. Example of programming- Automatic canned cycle-facing, threading, grooving

12. Example of programming-Cutter diameter, tool nose radius compensation, tool length

offsets.

13. Simulation of tool path using CNC simulation pro software

Project Areas:

1. Survey of various softwares in CAD/CAM/.CIM

2. Survey of Conversion of CAD software data to CAM protocols

3. Modeling of part using CAD

4. Survey of various softwares in FEA

5. Manufacturing of Part on CNC lathe

6. Manufacturing of Part on Vertical machining centre

7. Manufacturing of Part on Horizontal machining centre

8. Manufacturing of Part on turning centre

9. Optimization of tool path (to reduce machining time) using any CAM software

10. Generation of G and M code using CAM software for turned component

11. Generation of G and M code using CAM software for milled component

12. Survey of various process planning softwares



Text Books:

1. Groover, Zimmer-CAD/CAM: Computer-aided Design & Manufacturing 7th

Edition

Pearson Education 2010

2. Ibrahim Zeid, CAD/CAM - Theory &Practice Tata McGraw Hill

Reference Books:

1. Rao P N Introduction to CAD/CAM Tata McGraw Hill Publishing Co.2011

Course Outcomes-

1. Understand and appreciate use of computer in product development.

2. Apply algorithms of graphical entity generation.

3. Understand mathematical aspects of geometrical modelling

4. Understand and use finite element methods for analysis of simple components.

5. Understand hard and soft automation and CAM

6. Describe construction and working of CNC machines.

7. Understand concepts of CAM,CIM and FMS



FF No.: 654

PR3008::DESIGN FOR MANUFACTURING & ASSEMBLY

Credits: 04 Teaching Scheme: Th-3Hrs + Lab-2Hrs/Wk

SECTION-1

Product Design Process

Importance, design process, steps, concept, design, product life cycle, technology,

development cycle, sequential vs. concurrent design approach. Economics of Process

selection – General design principles of manufacturability, Material selection – Strength and

Mechanical factors- Application of form design, Selection of Shapes

Design for Manufacture

Review of Manufacturing Processes, Selection of manufacturing Processes, Design for

Casting, Design for Bulk Deformation Processes, Design for Sheet Metal Forming Processes,

Design for Machining, Design for plastic processing, injection molding etc.

Design for Assembly

Review of Assembly Processes, Design for Welding, Design for Brazing and Soldering,

Design for Adhesive Bonding. Types of assembly, DFA, evaluation of assembly, assembly

cost reduction , Case studies for design for manufacture and design of assembly.

SECTION-2

Design for Reliability and Quality

Design for Quality, House of quality for QFD process, Human Engineering Considerations in

Product Design, Identification of controls, Design for Optimization, Design for Reliability,

Approach to Robust Design, Failure Mode and Effect Analysis. Failure Mode and Effect

Analysis

Design for Maintainability and Safety

Maintenance, Need of Maintenance Management, Maintenance practices on production

machines- Lathe, Drilling, Milling, Welding, Shaper, CNCs. Rules for Design for

Maintainability, Safety aspects in Manufacturing Environment, Design for Safety

application for products and Equipments

Design for Specific Purpose

Design for Additive Manufacturing, Design for Logistics, Design for Delayed differentiation,

Design for ergonomics, Design for Environment, Design for recycling, Case studies based on

above DFX concepts

List of Practical’s:

Case studies & Problem solving and sketching figures for any 06 of following :

1. Product Design and Product Life Cycle

2. New Product Development

3. Selection of material

4. Selection of shapes



5. Human factors in Engineering design

6. Quality Function Deployment

7. Basic principles of DFM

8. Design for casting

9. Design for machining

10. Design for material forming

11. Design for plastic processing

12. Design for Assembly: Welding/ Brazing

13. Design for Assembly

14. Design for quality

15. Optimization of design

16. Design for reliability

17. Failure Mode Effect Analysis –FEMA ( FMEA software)


1. Product Design

2. New Product Development - NPD

3. Product Life Cycle Management

4. Technology Development

5. Design for Manufacturing (Boothroyd Dewhurst DFMA Software)

6. Design for Assembly(Boothroyd Dewhurst DFMA Software)

7. Design for Quality and Reliability

8. Design for Maintainability

9. Design for Specific Purpose (DFx) viz. Recycling, Reverse Logistics etc.

10. Failure Mode Effect Analysis( FMEA software)

11. Quality Function Deployment

12. Design for Safety and Environment

Text Books:

1. Dieter George E, Engineering Design, 3rd

Edition Mc Graw Hills Publications 2000.

2. G Boothroyd, P Dewhurst and W Knight, Product design for manufacture and assembly,

John Wiley, NY: Marcel Dekkar, 1994.

Reference Books:

1. K G Swift and J D Booker, Process selection: from design to manufacture, London:

Arnold, 1997.

2. J G Bralla, Handbook for Product Design for Manufacture, McGraw Hill, NY, 1998.

3. ASTM Design handbook.

4. M Fashby and K Johnson, Materials and Design - the art and science of material selection

in product design, Butterworth-Heinemann, 2003.

Course Outcomes:


1. Define technical considerations of design and manufacturing.

2. Utilize DFMA and Concurrent Engineering Principles on a "real life" project.



3. Apply the concept of DFMA for casting, welding, forming and assembly

4. Understand the quality aspects of design for manufacture and assembly.

5. Apply the concept of FMEA and reliability for design and manufacturing

6. Apply the concept of DFMA for specific purpose such as recycling, delayed

differentiation



FF No. : 654

PR3009::PRODUCT DESIGN & MODELLING

Credits: 04 Teaching Scheme: Theory 3 Hrs/Wk & Lab 2 Hrs/Wk

SECTION-1

Introduction to product design and development process - Key concepts, processes and

methods, including product classification / specifications, Generic product development

process, Product life cycle. Product mix. Proof of concept, Value Engineering / Value

Analysis. Ergonomics / Aesthetics, Intro. To TRIZ- axiomatic design, Concurrent Engg.,

Rapid prototyping,

Conceptual Design - Innovative / Creative thinking. Concept generation, selection &

embodiment of concept, Design morphology. Engineering drawings, Design for prototyping,

and manufacturing. Product architecture. Designing to codes and standards, DFX. Product

costing. Legal, ethical and social issues in design.

Sketching and Engg. Drawing techniques, standards and Conventions : Freehand

drawing, perspective, sketching and editing. Dimensioning technique for machine

components, Conventional representation of machine components as per IS code: SP-46 such

as screw threads, springs, gears, bearing, tapped holes, knurling, splined shafts, tapers,

chamfers, countersunk and counter bores, keys, & welded joints,

Standard Machine components and Fasteners - Rivets - forms & proportions of rivet heads,

types of riveted joints. Thread terminology, thread forms, designations, single and multi-start

threads, right and left hand threads, types of screws , bolts and nuts, nut locking

arrangements using pins, washers & screws. Std. components - Bearings, Seals, retaining

rings, etc.

SECTION-2

Surface Roughness - Introduction, terminology, machining symbol with all parameters,

roughness values (Ra) and roughness grade numbers, indicating surface roughness on

drawing.

Tolerances, Fits, GD&T - Definitions applied to tolerances, types of tolerance, types of fits,

fit system. Geometrical tolerances – Nomenclature, tolerance frame, types of geometrical

tolerances & their symbols, indicating geometric tolerances on drawing,

Assembly & Details of Machine Parts - Introduction to assembly & part drawing ,

examples-Revolving Centers, Machine Vice, Tool post, Screw Jack, jigs & fixtures, tailstock,

Cotter Joint, Knuckle Joint, Flange Joint, Rigid and Flexible Coupling, Drawing reading. –

Title block, part list / bill of material, revision block etc.

Basics of computer graphics & CAD - Software configurations, functions of CAD package,

constructing the geometry, various graphics elements such as line, circle, rectangle, ellipse,

arc, spline etc. Geometric transformations, translations, rotation, mirror, concatenations, etc.

Examples in Typical CAD software like AutoCAD,



Fundaments of solid modeling - Geometry and topology use of primitives in solid

modeling, Basics of Boolean operations, and representations schemes of solids, B-rep and

CSG, Examples in Typical 3D CAD software like Catia,

Advanced Solid, surface and Assembly modeling - Assembly design and drawing,

Advanced solid modeling and surface modeling in 3D-CAD. Simulation of mechanical

movement, animation, photo rendering, top-down-design and generating drawings.

List of Lab. Practicals:

1. On Full Imperial Sheets - Conventional representation of machine components as per IS

Code: SP 46

2. On Full Imperial Sheets - Types of screws, Bolts and nuts, Nut locking arrangement.

3, 4, 5. On Full Imperial Sheets - Assembly and details of any 3 of machine Assembly :

Cotter joint, Knuckle joint, Flange joint, Rigid and flexible coupling, Stop valve, Non return

valve, Revolving centers, Machine vice, Tool holder.

6. 2D / 3D CAD modeling assignments on min. 6 drawings / parts

7,8,9. on 2D CAD - Assembly and details of any 3 of machine Assembly : Cotter joint,

Knuckle joint, Flange joint, Rigid and flexible coupling, Stop valve, Non return

valve, Revolving centers, Machine vice, Tool holder.

10,11,12 - on 3D CAD - Assembly and details of any 3 of machine Assembly : Cotter joint,

Knuckle joint, Flange joint, Rigid and flexible coupling, Stop valve, Non return

valve, Revolving centers, Machine vice, Tool holder. (Using Solid, surface and assembly

modeling)


1. Blueprint reading and comprehension

2. Assembly modeling and animation

3. Programs on parametric programming involving: Programming for standard machine

components, Programming involving decision making and looping.

4. Use of Standard part libraries

5. Use of script files and CAD customization

6. Special CAD modeling assignments

Text Books:

1. Gill P. S., A Text book of Machine Drawing, Revised Edition K. Kataria and Sons, New

Delhi, 2008,

2. Farazdak Haideri, Machine Drawing and Computer Graphics, Nirali Prakashan, Pune,

1998.

3. George Omura, ABC’s of Autolisp, BPB Publications, 2002.

4. Zeid Ibrahim, Mastering CAD/CAM, Tata McGraw Hill.

5. Xiang Z. & Roy P., Computer Graphics, 2nd Edition, McGraw-Hill International Edition,

2001,

6. Sham Tickoo, Catia V5-6r15 for Designers, 13th Edition, Dreamtech Press, 2016



Reference Books:

1. Narayana K. L., Kannaiah P., Venkata Reddy K., Machine Drawing, 2nd

Edition, New

Age International Publishers, Delhi, 2008, ISBN 81-224-1917-8.

2. Bhat N. D., Panchal, Machine Drawing, Charotar Pub. House, 2000.ISBN: 9380358466

3. John Hood D., Using AutoCAD with Auto LISP, McGraw Hill Book Company

1990. ISBN: 00702974872.

Course Outcomes:


1. Describe the product development process and account for its conditions and terms, and

use the most common methods of managing teams and concept development,

2. Use standard machine drawing techniques to communicate ideas, make design and

manufacturing drawings of parts and assemblies.

3. Plan, implement and present a design project using a 2D / 3D CAD-software to design

products, create advanced solid, surface and assembly models, produce realistic images and

simple animations of a product,

4. Use of GD & T standards to design and understand various designs on shopfloor.



Module VI



FF No. : 654

PR3036::ADDITIVE MANUFACTURING TECHNIQUES


SECTION-1

INTRODUCTION

Overview – History – Need-Classification -Additive Manufacturing Technology in product

development - Materials for Additive Manufacturing Technology – Tooling – Applications

CAD & REVERSE ENGINEERING

Basic Concept – Digitization techniques – Model Reconstruction – Data Processing for

Additive Manufacturing Technology: CAD model preparation – Part Orientation and support

generation – Model Slicing –Tool path Generation – Softwares for Additive Manufacturing

Technology: MIMICS, MAGICS

LIQUID BASED AND SOLID BASED ADDITIVE MANUFACTURING SYSTEMS

Classification – Liquid based system – Stereolithography Apparatus (SLA) - Principle,

process, advantages and applications – Solid based system –Fused Deposition Modeling –

Principle, process, advantages and applications, Laminated Object Manufacturing

SECTION-2

POWDER BASED ADDITIVE MANUFACTURING SYSTEMS

Selective Laser Sintering – Principles of SLS process – Process, advantages and applications,

Three Dimensional Printing – Principle, process, advantages and applications- Laser

Engineered Net Shaping (LENS), Electron Beam Melting

MEDICAL AND BIO-ADDITIVE MANUFACTURING

Customized implants and prosthesis: Design and production, Bio-Additive Manufacturing -

Computer Aided Tissue Engineering (CATE) – Case studies

DESIGN FOR ADDITIVE MANUFACTURING PROCESSES

Motivation, DFMA concepts and objectives, AM unique capabilities, Exploring design

freedoms, Design tools for AM, Part Orientation, Removal of Supports, Hollowing out parts,

Inclusion of Undercuts and Other Manufacturing Constraining Features, Interlocking

Features, Reduction of Part Count in an Assembly, Identification of markings/ numbers etc.

List of Practicals:

1. Comparison of properties of 3D Printing Materials

2. Study of fill patterns

3. Logic behind “stl” file generation

4. 3D Modeling using “123D Catch”

5. Experimental Investigation on 3D Printing parameters

6. G-Code file generation of Object

7. Study of slicing software



8. Methodology of 3D printed objects

9. Comparative assessment of FDM and DLP Techniques

10. Shape optimization using DFAM approach

11. Seminar topic on novel AM technique

12. Study of Research Paper on Additive Manufacturing

List of Project Areas:

1. Creation of input files for 3D Model and logic behind it

2. Analysis and modeling of different slicing strategies

3. Blending and G Code generation

4. 3D Printing of objects

5. 3D printing defects and methods to avoid/overcome them

6. Shape optimization

7. Printing of assemblies

8. Assessment of different fill patterns

9. Cost estimation of 3D Printed parts

10. Parametric assessment on VAT Photopolymerisation

11. Parametric assessment on Fused Deposition Modeling

Text Books:

1. Chua C.K., Leong

K.F. and Lim C.S.

Rapid prototyping:

Principles and

applications

Third

Edition

World Scientific

Publishers

2010

2. Gebhardt A. Rapid prototyping Hanser Gardener

Publications

2003

Reference Books:

1. Liou L.W. and Liou

F.W

Rapid Prototyping and Engineering

applications: A tool box for

prototype development

CRC Press 2007

2. Kamrani A.K. and

Nasr E.A.

Rapid Prototyping: Theory and

practice

Springer 2006

3. Hilton P.D. and

Jacobs P F

1. Rapid Tooling: Technologies

and Industrial Applications

CRC press 2000

Course Outcomes:

Students will be able to:

1. Understand various additive manufacturing processes for different applications

2. Use correct CAD file formats in 3D printed parts manufacturing

3. Select appropriate 3D printing parameters considering shape features, part quality and

printer specifications

4. Apply AM concepts for Bio medical and medical fields

5. Perform reverse engineering steps to prepare virtual model

6. Operate 3D printer machine to manufacture desired 3D objects



FF No. : 654

PR3037::MODERN MANUFACTURING PROCESSES


SECTION-1

Introduction to nontraditional machining methods - Need for non - traditional machining -

Sources of metal removal - Classification on the basis of energy sources - Parameters

influencing selection of process

Mechanical Processes

Abrasive Jet Machining – Water Jet Machining – Abrasive Water Jet Machining. (AJM,

WJM and AWJM). Operating principles -Equipment -Parameters influencing metal removal

- Applications -Advantages and Limitations. Ultrasonic Machining, Operating Principle and

Process characteristics

Thermo Electrical Energy Techniques Electrical Discharge Machining (EDM)

Fundamental principle of EDM, Equipment’s required for EDM process parameters, process

capabilities. Application example trouble shooting, Introduction to wire EDM, Process

principle and parameters, process capacities and its applications.EDM tool design, Machine

tool selection, EDM accessories / applications, electrical discharge grinding.

SECTION-2

Thermal Energy Techniques

Operating principles - Equipment and sub systems - Parameters influencing metal removal-

Benefits - Applications - Advantages and limitations of Electron beam machining (EBM),

Plasma ARC Machining (PAM) and laser beam machining (LBM). Electron Beam

Machining, EBM Principle and process characteristics

Electro Chemical Machining (ECM)

Background of ECM process, Classification of ECM processes. Electrochemistry of ECM,

Equipment required in ECM. Process capabilities and processes parameters. Evaluation of

MRR. Parameters influencing metal removal- Applications - Advantages and limitations.

Electro Chemical Grinding: Process principles, process parameters, Applications

Chemical Machining (CHM)

Introduction, Elements of process Chemical blanking process:-Preparation of workpiece.

Preparation of masters, masking with photo resists, etching for blanking, applications of

chemical blanking, chemical milling (Contour machining):- Process steps – masking,

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

Advantages & application of CHM. Electro-chemical Drilling and De-burring operations.

List of Practicals:

1. Student will do experiment and process modeling of following processes in order to

predict MRR, Surface roughness etc. and also they will study parametric correlations of

the process.



• Laser Beam Machining

• Electro Discharge Machining

• Electro Chemical machining

• Wire Electro discharge Machining

• Abrasive Water Jet Machining

2. Experiment on Ultrasonic machining (USM), Abrasive Jet Machining (AJM) and

Abrasive water jet machining (AWJM)

3. Experiment on MRR and surface roughness modeling of EDM process and wire-EDM

process.

4. Experiment on Laser Beam Machining (LBM), Plasma Arc Machining (PAM) and

Electron Beam Machining (EBM)

5. Experiment on Electro Chemical Machining (ECM) and Chemical Metal removal process

6. Case study on Hybrid material Removal process (ECDM, ECG, EDG etc.)

7. Exercise on Ultrasonic machining (USM)

8. Exercise on ABRASIVE JET MACHINING (AJM)

9. Case study: Mechanical Material Removal process (USM, AJM)

10. Case study: Thermal material Removal process (EDM, WEDM)

11. Exercise/Case study on chemical metal removal process and Electro Chemical Machining

12. Case study: Micro machining and its applications


Students will perform projects of following processes (Any One) for experimental

investigation of the process, modeling of the process and process optimization.

1. Abrasive water jet Machining

2. Abrasive Jet Machining

3. Ultrasonic Machining

4. Electro Discharge Machining

5. Wire- Electro discharge Machining

6. Laser Beam Machining

7. Plasma Arc Machining

8. Electron Beam Machining

9. Chemical Machining

10. Electro-chemical Machining

11. Hybrid Machining

12. Micro Machining

Text Books:

1. V. K. Jain Advanced Machining

Processes

Edition

No.,

Allied Publishers Pvt.

Ltd.

2007

2. P. K. Mishra Non-Conventional

Machining

Edition

No.,

The Institution of

Engineers (India)

1997

3. P. C. Pandey

and H. S. Shan

Modern Machining

Processes

Edition

No.,

Tata McGraw-Hill 2007



Reference Books:

1. G. F. Benedict, Unconventional

Machining Process,

Edition

No.,

Marcel Dekker

Publication, New York,

1987

2. McGeough, Advanced Methods

of Machining,

Edition

No.,

Chapman and Hall,

London,

1998

3. P. C. Sharma, A Text book of

Production Engg

Edition

No.

New Delhi, 1995

4. P. DeGarmo, J.

T. Black, and

R. A. Kohser,

Material & Processes

in Manufacturing

Edition

No. 8

Prentice Hall of India

Pvt. Ltd., New Delhi

2001

Course Outcomes:


1. Understand need of advanced machining processes and select process for any industrial

job based on its complexity, cost and specifications required.

2. Apply the working principles and processing characteristics of mechanical type advanced

machining processes such as USM, AJM, WJM and Develop experimental, regression

based, mathematical and physics based models for the advanced machining processes and

predict MRR and surface roughness.

3. Apply the working principles and processing characteristics of electro-thermal type

advanced machining processes such as EDM, wire-EDM and Develop experimental,

regression based, mathematical and physics based models for the advanced machining

processes and predict MRR and surface roughness.

4. Apply the working principles and processing characteristics of thermal type advanced

machining processes such as PAM, LBM, EBM machining to the production of precision

components.

5. Apply the working principles and processing characteristics of chemical type advanced

machining processes such as Electrochemical Machining to the production of precision

micro and macro components.

6. Apply the working principles and processing characteristics of chemical type advanced

machining process for production of precision components.



FF No. : 654

PR3038:: METAL CUTTING & TOOL DESIGN

Credits: 04 Teaching Scheme: 3Hrs/Wk

SECTION-1

Tool Nomenclature

Milling cutter, broach, Single point cutting tool, various tool elements, Designation of cutting

tools in ORS & ASA Systems, Importance of tool angles, Method of machining- orthogonal,

oblique cutting, Nomenclature of drill

Theory of Metal Cutting

Mechanics of chips formation, types of chips, determination of shear angle, chip reduction

factor, velocity relationship, merchant force circle, estimation of cutting forces, Tool

dynamometer. Heat generation & tool life

Heat generation in cutting, functions of cutting fluid, characteristics of cutting fluid, types of

cutting fluid, Tool wear, Tool life, modified Taylor’s equation, Tool dynamometers.

SECTION-2

Fundamentals of Jig & Fixtures

Introduction to jig & fixture, difference between jig & fixtures. Classification of jig &

fixtures. Principle of location, types of locators. Principle of guiding elements Types of

guiding elements, Principle of clamping elements, Types of clamps. Types of Jigs & Fixtures

Design of Jig & Fixtures

Concept of modular fixtures. General guide lines & procedures for design of jig & fixtures,

Bodies, bases & frame, Design of locators, Design of guiding elements, Analysis of number

of clamping forces required & their magnitude

Design of Cutting Tools

Tool materials, design of single point cutting tool, form tool, drill, reamer, Design of broach

& plain milling cutter

List of Practicals:

1. Experiment on chip formation.

2. Measurement of shear angle using chip thickness ratio criteria.

3. Study of influence of cutting parameters on surface roughness in turning.

4. Measurement of cutting forces in turning using lathe tool dynamometer.

5. Verification of metal cutting theories.

6. Tool life study on a single point turning tool.

7. Design & working drawing of one drilling jig.

8. Design & working drawing of one Fixture.

9. Design & working drawing of one Form tool.

10. Design & working drawing of any two of following cutting tools.

11. SPCT, Reamer, Broach, Plain milling cutter

12. Industrial visit report.



13. Research paper study & presentation on metal cutting processes

List of Course Project Areas:

1. Mechanics of Chip Formation

2. Preparation of Cutting Tool Models

3. Design of Drilling Jigs

4. Design of Milling Fixtures

5. Measurement of Cutting Forces using Multi Axis Tool Dynamometers

6. Machinability study of difficult-to-cut materials

7. Machining performance under different machining environments

8. Parametric study of cutting parameters on response parameters

9. Challenges in machining of composites

10. Variation in cutting forces during machining of Composites using Tool Dynamometer

11. Design and Manufacturing of Cutting Tools

Text Books:

1 P C Sharma Production Engg. Khanna publishers

2 M.H.A.

Kempster

Introduction to Jigs and fixtures

design

Reference Books:

1 Nagpal Tool Engg 2007

2 Dolalson, Lecain

and Gold

Tool design Tata McGraw

hill

2011

3 Hoffman Introduction to Jigs and fixtures

4 A.S.T.M.E. Tool Engineering Handbook

5 Basu, Mukherjee

and Mishra

Fundamentals of tool

engineering and design

6 R. K. Jain Production Technology Khanna

Publishers

7 Milton Shaw Metal cutting principle

Course Outcomes:


1. Understand and represent cutting tools using designation systems

2. Apply metal cutting theories to estimate and represent cutting forces

3. Analyze cutting environment and cutting parameters

4. Understand design principles of location, clamping for jigs and fixtures

5. Design and draw jigs and fixtures by following design principles

6. Design and draw single and multi-point cutting tools



FF No.: 654

PR3039::MECHATRONICS & INDUSTRIAL ROBOTICS Credits: 04 Teaching Scheme: 3 Hrs/Wk

SECTION-1

1 Mechatronics

Definition of mechatronics. Mechatronics in manufacturing, products and design. Review of

fundamentals of electronics. Data conversion devices, sensors, microsensors, transducers,

signal processing devices, relays, contactors and timers. Microprocessors controllers and

PLCs. Description of PID controllers. Drives: stepper motors, servo drives. Ball screws,

linear motion bearings, cams, systems controlled by camshafts, electronic cams, indexing

mechanisms, tool magazines, transfer systems. Hydraulic systems: flow, pressure and

direction control valves, actuators, and supporting elements, hydraulic power packs, pumps.

Design of hydraulic circuits. Pneumatics: production, distribution and conditioning of

compressed air, system components and graphic representations, design of systems. CNC

machines and part programming.

2 Basic Concepts in Robotics

Automation and robotics, robot anatomy, robot specifications, Development of industrial

Robots and manipulators, basic structure of robots, resolution, accuracy and repeatability.

Classification, Configuration of robots, arm and body motions, wrist motions, Mechanical,

hydraulic and pneumatic Manipulators

3 Robot Arm Kinematics

Orientations and frames, Mappings: Changing descriptions from frame to frame, Operators:

Translations, Rotations and Transformations - Transformation Arithmetic - D-H

Representation - Forward and inverse Kinematics Of Six Degree of Freedom Robot Arm –

Robot Arm dynamics

4 Static and dynamic analysis of manipulator arm

Statics of planer arm robot, Mass and inertia of links, Lagrangian formulation for equations

of motion for serial manipulators.

SECTION-2

1 Robot Grippers

Classification, types, Design consideration, Materials for hostile operation. Cylindrical Cam

type; Grippers using pneumatic, Vacuum Grippers, ultrasonic grippers

2 Sensors in Robotics

Sensors - functioning, types, analysis and fields of applications – position, velocity and

acceleration sensors, Tactile sensors, temperature sensors, Variable Pressure Light

Converting Sensor, High Resolution Compliance, Range & Proximity Sensors, Electro-

optical Sensors. Pneumatic tactile Sensor, Slip type Sensors

Vision system: Median filtering, thresholding, discretization, smoothening of binary image.

Recognition Procedure. CCD Camera.

3 Robot Drives, Control and Robot Programming



DC servo motors, basic control systems concepts and models, control system analysis, robot

activation and feed back components. Positional and velocity actuators. Methods of

Programming the robot, Languages, Robographics, Introduction to Artificial Intelligence,

Hydraulic systems, Power transmission systems, robot joint control design

List of Practicals:

1) problems on accuracy, precision and repeatability, resolution

2) Problem on axis rotation by matrix transformation

3) problem on forward kinematics-Cartesion

4) problem on forward kinematics-cylindrical

5) problem on forward kinematics-polar

6) problem on forward kinematics-jointed arm.


1. Robotic Work Cell Design

Text Books:

1. Deb S.R., Robotics, Tata McGraw Hill Publications, New Delhi.

2. Yoram Koren, Robotics for Engineers, McGraw Hill Book Co.

3. Groover M.P., Weiss M., Nagel R.N., Odrey N.G., Industrial Robotics Technology -

Programming and Applications, McGraw Hill Book Co.

4. Fu K.S., Gonzalex R.C., Lee C.S.G., Robotics Control Sensing, Vision and intelligence,

McGraw Hill Book Co

Reference Books:

1. Hartenberg and Denavit, Kinematics and Synthesis of Linkages, McGraw Hill Book Co.

2. Hall A.S., Kinematics and Linkage Design, Prentice Hall.

3. Hirchhorn J., Kinematics and Dynamics of Machinery, McGraw Hill Book Co.

4. Todd D.J., Fundamentals of Robot Technology, Wiley Publications

5. Paul R., Robots - Manipulators, Mathematics, Programming and Control, MIT Press.

6. Janakiraman P.A., Robotics and Image Processing, Tata McGraw Hill 1995.

Course Outcomes:


1. Understand robot system and Select type of robot for industrial applications

2. Solve direct and inverse kinematic problem for Cartesian, polar, cylindrical and articulated

arm robot.

3. Understand concept of static and dynamics of manipulator arm

4. Understand various types of end effectors used in industrial robots.

5. Understand concepts and applications of sensors used in industrial robots.

6. Study and Select appropriate drives and robot programming method for industrial robots



FF No.: 654

PR3040::MACHINE TOOL DESIGN Credits: 04 Teaching Scheme: Lecture 3 Hours/Week

Lab 2 Hours/Week

SECTION-1

Design of Machine Tool Drives

Stepped Regulation of Speed, Laws of Stepped Regulation, Why Geometric Progression is

used against Arithmetic, Harmonic & Logarithmic despite shortcomings, Relation between

Range ratio, Geometric Progression Ratio and No. of Speed Steps, 3)Design of Stepped

Drives: Break up of Speed Steps, Structural Formulae, Structural Diagram, Selection of Best

Structural Diagram, Ray Diagram, Speed Chart, General recommendations for Developing

the Gearing Diagram, Determining the number of teeth of Gears. 4) Speed/ Feed Gear box :

Limiting Transmission Ratio of Speed / Feed Gear Box.

Design of Spindle

Function & Requirements of Spindle Units, their Materials, Effect of Machine Tool

Compliance on Machining accuracy Design of Spindle for Bending Stiffness: Deflection of

Spindle Axis due to a) Bending, b) - due to Compliance of Spindle Supports, c) - due to

Compliance of the Tapered Joint. Optimum Spacing between Spindle Supports, Permissible

Deflection & Design for stiffness: Additional Check for Strength like Additional Supports,

Location of Bearings and Drive elements

Design of Spindle Supports

Requirements of Spindle Supports, Features of Anti-friction Bearings, Load bearing abilities

of Ball & Roller Bearings. Parameters which assess the viability of combination of roller &

Ball & Roller Bearings in Spindle Units. Preloading of Anti Friction Bearing & its method

Design of Sliding Bearings: Sleeve, Hydrodynamic Journal, Hydrostatic Journal, Air-

Lubricated (Aerodynamic, Aerostatic).

SECTION-2

Design of Machine Tool Structure

Function & Requirement of Machine Tool Structure, Design Criteria from Strength &

Stiffness considerations, Concept of Unit Rigidity, Unit Strength under Tension, Unit

Strength under Torsion & Unit Strength under Bending for Material of Machine Tool

Structures, Compare Steel & Cast Iron on the basis of Material Properties, Manufacturing

Problems and Economy, Role of Static & Dynamic Stiffness in the design of elements of

machine tools, Profiles of Machine Tool Structures, Factors affecting stiffness of machine

tool structures & methods of improving it, Basic Design procedure of machine tool structures

Design of Guide-ways

Design Criteria (Wear Resistance & Stiffness) and Calculations for Slide-ways operating

under semi liquid friction condition, ‘Stick Slip’ phenomena affects accuracy of setting &

working motions. Comparison of Design & stiffness of Hydrodynamic, Hydrostatic &

Aerostatic Slide-ways, Design of Antifriction Guide-way, Concept of Combination Guide-



ways. Function & Types of Guide-ways, Types of Slide-ways & Antifriction Ways,

Functional features of Slide-ways, its Shapes & Materials, Methods of adjusting Clearance

Design of Power Screws

Design of Sliding friction Power Screw for Wear Resistance, Strength, Stiffness, &

Buckling Stability. Design of Rolling friction Power Screw for Strength under static loading,

Strength under cyclic loading, & Stiffness

List of Practicals:

1. Design and Working Drawing of Speed Gear Box for Lathe

2. Design and Working Drawing of Feed Gear Box for Drilling Machine

3. Design and Working Drawing of Spindle for Lathe

4. Design and Working Drawing of Spindle-Support for Lathe

5. Design and Working Drawing of Sliding Friction Power Screw

6. Design and Working Drawing of Rolling Friction Power Screw


1. Design Case Studies of Bed of Lathe Column & Base of Milling Machine

2. Design Case Studies of Column of Milling Machine

3. Design Case Studies of Base of Milling Machine

4. Analyze and Design Lathe machine stepped gearbox

Text Books:

1. N. K. Mehta, Machine Tool

Design, 2

nd Edition, Tata McGraw

Hill, 2011.

2. D. K Pal, S. K. Basu, Design of

Machine Tool, 4

th Edition, Oxford, 2005.

3. G. C. Sen, A.

Bhattacharya Principles of

Machine Tool 2

nd Edition New central

book agency

Calcutta

1967

Reference Books: 1. N. S. Acherkan, V.

Vermakov

Machine Tool

Design Vol 2, 1

st Edition, MIR

publication, 2000.

2. F. Koenigsberger, Design Principles

of Metal Cutting

Machine Tools,

1st Edition., The

Macmillan

Company,

1964.

Course Outcomes: The student will be able to –

1. Design stepped speed gear boxes.

2. Design spindles using minimum deflection criterion

3. Design suitable bearings for spindle supports.

4. Analyze and design various machine tool structure using principle of free body diagram

and using minimum deflection design criterion

5. Design sliding and rolling friction guideways

6. Design sliding and rolling friction power screws



FF No.: 654

PR3041::INDUSTRIAL FLUID POWER Credits: 04 Teaching Scheme: 3 Hrs/Wk

SECTION-1

1 Introduction to Fluid Power-Basics (…7.. Hours)

Pascal’s Law, properties of fluid, laminar and turbulent flow, Pressure drop in hoses/pipes,

Power units and accessories, Types of hydraulic fluids - petroleum based, synthetic and water

based, selection of fluids, additives, effect of temperature and pressure on hydraulic fluid.

Seals, sealing materials, compatibility of seal with fluids, Types of pipes, hoses, material,

quick acting couplings, Fluid conditioning through filters, strainers, sources of contamination

and contamination control.

2 Hudraulic Pumps (…8.. Hours)

Pumps: Types, classification, principle of working and constructional details of vane pumps,

gear pumps, radial and axial plunger pumps, screw pumps, power and efficiency calculations,

characteristics curves, selection of pumps for hydraulic power transmission

3 Actuators (…7.. Hours)

Actuators: (i) Linear and Rotary. (ii) Hydraulic motors- Types- Vane, gear, piston types,

radial piston. (iii) Methods of control of acceleration, deceleration. (iv) Types of cylinders

and mountings. (v) Calculation of piston velocity, thrust under static and dynamic

applications, considering friction, inertia loads. (vi) Design considerations for cylinders

SECTION-2

1 Control of Fluid Power

Symbols for hydraulic and pneumatic circuits, Control of fluid power: (i) Necessity of fluid

control through pressure control, directional control, flow control valves. (ii) Principle of

pressure control valves, direct operated and pilot operated relief valves, pressure reducing

valve, sequence valve. (iii) Principle of flow control valves, pressure compensated,

temperature compensated flow control valves, meter in circuit, meter out circuits, flow

through restrictor. (iv) Types of directional control valves: two way two position, four way

three position, four way two positions valves. Open centre, close centre, tandem centre

valves. Introduction to Cartridge valves, proportion control and servo valves- Manually

operated, solenoid operated, pilot operated, direction control valves, check valve

2 Industrial Circuits & System Design (…6.. Hours)

Industrial circuits 1 - Simple reciprocating, Regenerative, Speed control(Meter in, meter out

& bleed off), Sequencing, Synchronization, transverse & feed, circuit for rivetting machine,

automatic reciprocating, fail safe circuit, counter balance circuit, actuator locking, circuit for

hydraulic press, unloading circuit, motor breaking circuit

Design of hydraulic/pneumatic circuit for practical application, Selection of different

components such as reservoir, various valves, actuators, filters, pumps based on design.

(Students are advised to refer manufacturer’s catalogues.)



3 Pneumatics (…5.. Hours)

Principle of Pneumatics: (i) Laws of compression, types of compressors, selection of

compressors. (ii) Comparison of Pneumatics with Hydraulic power transmissions. (iii) Types

of filters, regulators, lubricators, mufflers, dryers. (iv) Pressure regulating valves, (v)

Direction control valves, two way, three way, four way valves. Solenoid operated valves,

push button, lever control valves. (vi) Speed regulating – Methods used in Pneumatics. (vii)

Pneumatic actuators-rotary, reciprocating,

Air motors- radial piston, vane, axial piston (ix) Basic pneumatic circuit, selection of

components(x) Application of pneumatics in low cost Automation and in industrial

automation

List of Practicals:

1. Drawing of various hydraulic and pneumatic symbols from book ‘Industrial Hydraulics –

by pipenger

2. Demonstration of different parts of hydraulic trainer, quick acting coupling, hoses and

seals

3. Study of a circuit using accumulator

4. Experiment on operating characteristics of gear pump

5. Study of direction control valves & pilot operated check valves & circuits

6. Study, simulation and testing of sequencing circuit

7. Study, simulation and testing of meter in, meter out and bleed off circuits

8. Drawing and study of Power Steering mechanism circuit

9. Study of Compressed air generation and distribution systems

10. Construct and test various circuits using H-simulator software

11. Control of D/A cylinder with one 3/2 and one 5/2 single solenoid valve

12. Design, simulation and testing of pneumatic circuit for control of d/a cylinder with two

13. 3/2 DCV and one 5/2 DCV


1. Determination losses in hydraulic systems

2. Selection of pumps for hydraulic system

3. Selection of valves for hydraulic system

4. Selection of cylinders for hydraulic system

5. Selection of pumps for motors hydraulic system

6. Design of hydraulic circuit for hydraulic planning machine

7. Design of hydraulic circuit for hydraulic grinding machine

8. Design of hydraulic circuit for hydraulic presses

9. Design of hydraulic circuit for hydraulic injection moulding machine

10. Design of hydraulic circuits of JCB

11. Design of hydraulic circuits of lawn cutting machine

12. Project on simulation and testing various circuits using e4 training.com website software

Text Books:

1. Esposito – ‘Fluid Power with application’, Pearson,7 th edition, ISBN 10:1-292-02387-2



Reference Books:

1 J. J. Pipenger – ‘Industrial Hydraulics’, McGraw Hill

1. H. L. Stewart – ‘Hydraulics and Pneumatics’, Industrial Press

2. A. Lall – ‘Oil Hydraulics’, International Literature Association

3. Yeaple – ‘Fluid Power Design Handbook’

4. Vickers Manual on Industrial Hydraulics

5. Festo’s Manual on Pneumatic Principle, applications

6. ISO – 1219, Fluid Systems and components, Graphic Symbols

7. Majumadar, “Oil Hydraulics- Principle & Maintenance”, Tata McGraw Hill,1998

Course Outcomes:


1. Understand fundamentals of fluids

2. Select appropriate pumps, for hydraulic systems

3. Select appropriate motors, cylinders for hydraulic systems.

4. Understand and select different types of hudraulic valves

5. Construct and evaluate hydraulic circuits for various industrial applications such as

machine tools, automobile, agricultural equipment

6. Apply principles of pneumatic systems for automation systems



FF No. : 654

IE3107::STATISTICAL METHODS FOR DATA ANALYTICS



SECTION-1

Data Analytics Introduction (6 Hours)

Introduction to big data:– Challenges of Conventional Systems - Intelligent data analysis –

Nature of Data - Analytic Processes and Tools - Analysis vs Reporting. Data in Engineering

and Management Research, Types of data, Measures of Frequency Distribution

Probability Distributions (8 Hours)

Review of Probability Theory, concept of Random Variable, Discrete probability

distributions in statistics and their analysis, Continuous probability distributions in statistics

and their analysis, Functions in MS EXCEL for probability distributions

Estimation in statistics (6 Hours)

Sampling Distributions, Central Limit Theorem, Chebyshev’s Theorem, Point estimation,

Interval Estimation, Confidence Intervals, Sample size determinations for means and

proportion, Large sampling versus small sampling, Methods of sampling

SECTION-2

Tests of Significance for Means and Proportions (8 Hours)

Concept of significance level, Test of Significance for single mean and proportion, Errors in

Hypothesis Testing, Test of significance for two sample means and proportions

Tests of significance for variance (8 Hours)

Chi-square distribution, Test of significance for one sample and two sample variance. Test of

independence, Test of goodness of Fit, F distribution, One way ANOVA, Introduction to

Design of Experiments

Research Methodology (6 Hours)

Meaning of Research, Motivation for Research, Research Approaches, Criteria for Good

Research, Importance of communication skills in Research, Technical writing skills,

Objectivity and Ethics in Research, Steps in Research process, Methods of primary and

secondary data collection, Exploratory versus Descriptive research, Scales of Measurement,

Aspects of Questionnaire design, Design of field surveys, Use of Regression and correlation

in research analysis and forecasting.

List of Practical: (Use of Excel / R / Python / Minitab / SAS / SPSS)

1. Measures of Frequency Distribution

2. Discrete Probability Distributions

3. Continuous probability Distributions

4. Central Limit Theorem

5. Estimation in Statistics



6. Test of significance for means

7. Test of significance for proportion

8. Test of significance for variance

9. Test of independence

10. ANOVA

11. Regression

12. Correlation


1. Questionnaire design in Marketing

2. Exploratory Research using secondary data from websites / magzines

3. Exploratory Research using primary data for canteen / hostel / flats

4. Descriptive Research

5. Data analysis in MS Excel

6 Discrete probability distributions in industry

7 Design of field surveys for food apps

8 Methods of sampling

9 Continuous probability distributions in industry

10 Sensex Analysis

11 Brent Crude Analysis

12 Corelation between various sectors

13 Forecasting of values

14 Academic result analysis

15 Developing small tools/programs in R/Python

Text Books:

1. Richard Johnson, Probability and Statistics for Engineers, Eighth edition, Prentice Hall of

India

2. Srivastava U.K., Shenoy G. V. and Sharma S.C, Quantitative Techniques for Managerial

Techniques, Third edition, New Age International Publishers

3. Krishnaswamy K. N., Sivakumar A.I. and Mathirajan M., Management Research

Methodology” Pearson publication

4. Kothari C. R., Research Methodology, Second Edition, New Age International Publishers

Reference Books:

1. Levin Richard and Rubin David, Statistics for Management, Prentice Hall of India

2. Murray Spiegel, Schiller John, Srinivasan R. A. and Goswami Debasree, Probability and

statistics (Schaum’s outline Series), Third Edition, McGraw Hill

3. Paneerselvam R., Research Methodology, Second Edition, Prentice Hall of India

4. Paneerselvam R., Design and Analysis of Experiments, Prentice Hall of India

Course Outcomes:


1. Explain the nature of research and data requirements

2. Calculate probability by selecting appropriate probability distribution for managerial

decisions

3. Estimate confidence interval

4. Perform test of significance for means and proportion

5. Perform test of significance for variance

6. Assess the appropriateness of different kinds of research designs and methodology



FF No.: 654

PR3043::PROJECT MANAGEMENT

Credits: 04 Teaching Scheme: 3 Hrs/Wk

SECTION-1

Introduction:

Definition & Characteristics of Project, Performance Parameters: Time, Cost & Quality.

Difference with respect to Standard Routine Production. Classification of Projects: Sector

based, Investment based, Technology based, Causation based, Need based (BMERD) -

Balancing, Modernization, Replacement, Expansion & Diversification Project Life Cycle

Phases – Concept/Initiation Phase: Parameters Involved in Project Identification. Sources of

New Project Ideas. Governmental Framework for Identification of Opportunities, Incentives

from state & central govt.; Import-substitution projects

Project Conceptualization & Feasibility Analysis

Project Definition Phase: Project Formulation & Feasibility. Types of Feasibility Studies –

Pre-feasibility, Support/Functional, Feasibility Study. Preparation of Project Feasibility

Report & Specification; Aspects of Project Feasibility Managerial/Organization: Promoters

Background, Criteria of Evaluation, Marketing/Commercial: Demand & Supply,

Competition, Market Survey, Porter’s 5 Forces, Operational/Technical: Process, Technology,

Location, Capacity, Labour, Raw Material & Utility Availability. Financial: Cost of Project,

Means of Finance, Financial Projections – Profit & Loss Account, Balance Sheet, Funds

Flow Statement, Cash Flow Statement, Schedule of Fixed Assets, Schedule of Term Loans.

Socio-Economic: Socio-Cost Benefit Analysis. Effective Rate of Protection, Domestic

Resource Cost.

Project Planning, Implementation & Control

Planning & Organization Phase: Project Planning, Scheduling & Monitoring, Statement of

Works, Project Specifications, Work Breakdown Structure, Network Analysis & Duration

Estimating Network Diagrams – PERT/CPM, Estimate Activity Times, Milestone

Scheduling. Resource Leveling, Resource Smoothening, Project Crashing.

Project Organization & Management. Project Organization Structure, Role of Project

Manager.

SECTION-2

Project Cost Management

Project Cost Estimation: Need, Causes of Cost & Time Overruns. Nature of Cost Estimates,

Types of Project Cost Estimates, Estimation of Manpower & Utilities. Project Budgeting &

Control, Earned Value Management System: Concept of AC, PV, EV, Variances, etc.

Contract Management: Responsibility Sharing Matrix, Types of Contract Payments, Risk

Factors in Contracts – Contractor & Owner.

Project Management Information System and Control, Management Pitfalls.

Project Implementation & Control

Implementation Phase: Activities Involved: Erection & Commissioning, Installation, Trial

Runs & Commencement of Commercial Production. Cleanup/Shutdown Phase: Handover to



Client, Settlement of Accounts. Project Risk Management, Responsibility Sharing Matrix,

Critical Chain Project Management – Critical Path vs Critical Chain, Concept of Buffers –

Project buffer, resource buffer, feeding buffer.

Computer Applications in Project Planning & Control

Introduction to MS Projects – Understanding the MS Project screen & different views,

Defining the project, Working with calendar, Outline the project, Create dependencies

between tasks, Creating WBS, Format task list and Gantt chart, Resource planning, leveling

and preparing resource graph, Working with baseline, tracking the project.

Home Assignment on Exercise with MS Projects Software.

List of Experiments:

1. Preparation of Project Feasibility Report

a. Project Identification, Definition

b. Project Feasibility – Managerial/Organizational Perspective

c. Project Feasibility – Marketing, Exit Plan

d. Project Feasibility – Operational

e. Project Feasibility – Financial, Financial Projections

2. Assignment on Capital Budgeting – PBP, Discounted PBP, NPV, IRR, Annual Worth

3. Exercises, Cases on Networks: Calculation of Floats, Determination of Critical Path &

Project Duration

4. Exercises, Cases on Networks: Probabilistic Models

5. Exercises, Cases on Project Crashing

6. Exercises, Cases on Resource Leveling & Resource Smoothening

7. Exercises, Cases on Earned Value Management System

8. Exercises, Cases on Project Risk Management

9. Exercises, Cases on Critical Chain Project Management

10. Project Planning & Scheduling (Using MS Projects) 1 – Preparation of Statement of

Works, WBS

11. Project Planning & Scheduling (Using MS Projects) 2 – Network Diagram, Gantt Charts,

Costs & Resource Estimation

12. Project Planning & Scheduling (Using MS Projects) 2 – Project Monitoring

List of Course Project Areas:

1. Preparation of Project Feasibility Report for a New Startup

2. Capital Budgeting – PBP, Discounted PBP, NPV, IRR, Annual Worth

3. Work breakdown Structure

4. Networks: Probabilistic Models

5. Project Cost Estimation

6. Resource Planning

7. Earned Value Management System

8. Project Risk Management

9. Critical Chain Project Management

10. Project Planning & Scheduling (Using MS Projects)

Text Books

1. Narendra Singh; Project Management & Control; Himalaya Publishing House, Mumbai

2. S. Choudary, Project Management, Tata McGraw Hill



3. Prasanna Chandra; Project: Preparation, Appraisal, Budgeting & Implementation

4. Pinto, Project Management – Achieving Competitive Advantage & MS Projects, Pearson

Education

Reference Books

1. Maylor, Project Management, Pearson Education,

2. Gopal & Ramamurthy; Project Management Handbook; Macmilan.

3. Project Management Body of Knowledge

4. Practical Project Management by Ghatak & Sandra, Pearson Education (Singapore) Pte.

Ltd, 2001

5. Handbook on Project Appraisal & Follow-up, SARDA, Govind Prakashan,2001

Course Outcomes:


1. Learn the basic concepts of project and project management

2. Ascertain the feasibility of small and medium projects with respect to managerial,

marketing, operational, financial and socio-economic perspectives

3. Plan and schedule small and medium projects to achieve the triple constraint of time, cost

and quality using software package

4. Understand the concept of earned value management system and critical chain in

managing projects

5. Understand the concepts of project risk management and critical chain project

management

6. Monitor the progress of projects to determine variances and recommend corrective

actions using software package

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