THE NATIONAL INSTITUTE OF ENGINEERING, … NATIONAL INSTITUTE OF ENGINEERING, MYSORE-08 ......

THE NATIONAL INSTITUTE OF ENGINEERING, MYSORE-08 DEPT. OF INDUSTRIAL & PRODUCTION ENGINEERING

Department Vision:

The Industrial and Production Engineering discipline shall be identified as the centre of

repute providing technological depth in education and having professional ethics involving

dedicated faculty, facilities and infrastructure.

Department Mission: To equip the students with good analytical ability and experimental skills, and also

imbibe in them social ethics to improve their overall personality. To encourage and support close

interaction with industry to gain exposure and entrepreneurial aptitude.

Graduate Attributes

GA 1. Acquire in-depth knowledge in production engineering systems, with wider and global

perspective and an ability to make judgment in evaluating, analyzing, disseminating new

knowledge and integrating with advanced technology.

GA2. To develop a mindset of systematic knowledge acquisition and research.

GA3. Collecting, analyzing, and interpreting data to arrive at optimal / feasible solutions for

production systems related engineering problems considering ergonomics, safety, social and

environmental factors.

GA4. Select and utilize appropriate tools, modeling and simulation techniques for solving

production systems engineering problems,

GA5. Ability to carryout collaborative research by contributing positively as a member of the

group and also as group leader.

GA6. Ability to incorporate management and financial principles in decision making.

GA7. Ability to communicate effectively with multi-disciplinary engineering community; to

write clear reports, documents, to present orally and in writing, to give and receive instructions

with clarity.

GA8. To accept responsibilities and to have professional and intellectual integrity and social

responsibility in following ethical practices.

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PROGRAM EDUCATIONAL OBJECTIVES

PEO1.

Graduates will be able to design and develop advanced production systems including advanced

materials, advanced manufacturing, fluid power, automation, and modern tool usage.

PEO2.

Persue research and development in production engineering systems using appropriate tools to

develop scientific and technical knowledge using creative ideas and efforts for continuous

improvement.

PEO3.

Able to conduct themselves in a responsible, professional and ethical manner, committed

towards life long learning, having successful careers in Indian or multinational companies / R&D

Institutions.

Program Outcomes:

PO1. Postgraduates are able to apply their relevant knowledge in their profession for the benefit

of society, in developing skills to plan, analyze, design and evaluate works related to production

engineering discipline.

PO2. Postgraduates are able to handle complex problems of any order with sound logic and

creative ideas.

PO3. Post graduates would have the ability to communicate both orally and in writing covering

across different context and audience.

PO4. Post graduates possess professional and ethical responsibilities and have environmental

awareness to cover all contemporary issues.

PO5. Post graduates are able to stay in the forefront of technology.

PO6. Post graduates to maintain a harmonious working environment through their leadership

qualities and skills.

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M.Tech Production Engineering & Systems

Technology (2014-16)

Scheme of Teaching and Examination

&

Syllabus

Department of Industrial & Production Engineering

3

I Semester M.Tech-PRODUCTION ENGINEERING & SYSTEMS TECHNOLOGY (PEST)

Department of Industrial and Production Engineering Scheme of Teaching and Examination (Autonomous Scheme)

Sl. No.

Subject Code Subject Contact Hrs. / Week No. of

Credits L T P 1 APM0401 Applied Mathematics 4 0 0 4

2 MPT0501 Advanced Material Removal Processes 4 0 2 5

3 MPT0502 Automated Manufacturing Systems 4 0 2 5

4 MPT0503 Theory of Metal Forming 4 2 0 5

5 MPT0202 Professional communication 2 0 0 2

6 Elective – I 3 2 0 4 7 Elective – II 3 2 0 4

Total number of credits 29

Contact hours per week 34

Elective-I

Sl. No Subject Code Subject

Contact Hrs. / Week No. of Credits L T P

1 MPT0403 Design For Manufacturing 3 2 0 4 2 MPT0404 Nano-Technology 3 2 0 4

3 MPT0405 Quantitative Techniques in Decision Making 3 2 0 4

4 MPT0406 Tool Design 3 2 0 4 5 MPT0407 Industrial Design & Ergonomics 3 2 0 4

Elective-II

Sl. No Subject Code Subject

Contact Hrs. / Week No. of Credits L T P

1 MPT0408 Advanced Metrology and Quality Engineering 3 0 2 4

2 MPT0409 Advanced Manufacturing Systems 4 0 0

4 3 MPT0410 Smart Materials and Structures 3 2 0 4 4 MPT0411 Flexible Manufacturing Systems 3 2 0 4 5 MPT0412 Product Lifecycle Management 3 2 0 4

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II Semester M.Tech-PRODUCTION ENGINEERING & SYSTEM TECHNOLOGY (PEST)


Sl. No.

Subject Code Subject

Contact Hrs. / Week No. of

Credits L T P 1 MPT0504 Advanced Fluid Power System 4 0 2 5

2 MPT0505 Advanced Materials & Processing 4 0 2 5 3 MPT0506 Finite Element Analysis 4 0 2 5 4 MPT0402 Advances in Joining of Materials 4 0 0 4

5 MPT0203 Research methodology 2 0 0 2 6 Elective – III 3 2 0 4 7 Elective – IV 3 2 0 4

Total number of credits 29 Contact hours per week 34

Elective-III

Sl.No. Subject Code Subject


Credits L T P

1 MPT0413 Lean Manufacturing System 3 2 0 4 2 MPT0414 Industrial Robotics 3 0 2 4 3 MPT0415 Design of experiments & Robust design 3 2 0 4 4 MPT0416 Jigs & Fixtures 3 2 0 4

5 MPT0417 Modeling & Simulation of Manufacturing systems 3 2 0 4

Elective-IV

Sl.No. Subject Code Subject


Credits L T P

1 MPT0418 Surface Treatment and Finishing 3 2 0 4 2 MPT0419 Non-Destructive Testing 3 2 0 4 3 MPT0420 Advanced Operations Research 3 2 0 4 4 MPT0421 Failure Mechanics & Analysis 3 2 0 4 5 MPT0422 Principles Of Reliability Engineering 3 2 0 4

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III Semester

M.Tech-PRODUCTION ENGINEERING & SYSTEM TECHNOLOGY (PEST) Department of Industrial and Production Engineering

Scheme of Teaching and Examination (Autonomous Scheme)

Sl. No.



Credits L T P

1 MPT0401

Industrial Training for 8 weeks duration (At the end of the training, students are required to submit a report and present a seminar )

- - - 4

2 MPT0801

Project-work (preliminary) (Students have to initiate the project work during III semester and are required to submit a report and present a seminar). Report should detail

• Literature survey • Problem definition based on

literature survey mentioning the scope and objective of the project

• Methodology to be adopted

- - - 8

3 MPT0201

Seminar on Contemporary technical Topics

The students individually have to select a current topic from production / Industrial Engineering field, prepare a report, submit the same and also present a seminar. Topics to be selected by the students by referring Journals, E-journals, reports, articles, books etc.

- - - 2


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IV Semester M.Tech-PRODUCTION ENGINEERING & SYSTEM TECHNOLOGY (PEST)


Sl. No.



Credits L T P

1 MPT2801

Project-work (Students have to submit the final project report at the end of the semester which will be evaluated followed by a Seminar Presentation and Viva-voce examination). Also a mid term evaluation is conducted. A seminar has to be presented and a report is to be submitted. Evaluation of Project work shall include weightage of 10 marks for publication of papers in Conferences and Journals

- - 28


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Applied Mathematics Sub Code : APM0401 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Total: 52hrs Max. : 100 Marks

Course Objective : Mathematics course content is designed to cater to the needs of several subjects at the PG level.

Numerical Analysis

Unit-I: Approximation & Errors. Significant figures, Accuracy & precision. Round off & truncation errors. Numerical solution of equations – Fixed point iteration method (SLE: Bisection, Graphical methods), False position method, Secant method, Newton - Raphson method, Multiple roots.

0 9 Hrs Unit-II :

Polynomials in Engineering & Science, Birge- Vieta method, Muller’s method, Horner”s method, Graeffe’s roots squaring method. Numerical differentiation (SLE: Applications to Engineering problems).

09 Hrs Unit-III: Numerical Integration – Newton cote’s quadrature formula. Trapezoidal rule (SLE: Simpson’s one third and three eighth’s rule), Boole’s rule, Weddle’s rule. Romberg integration. Numerical double integration. Gauss quadrature formulae - Gauss Legendre. Numerical solution of ODE – Taylor series method, Adam-Bashforth- Moulton method.(SLE: Runge-Kutta method of order IV)

0 8 Hrs Linear Algebra

Unit-IV:

Solution of system of linear algebraic equations (SLE: Gauss elimination method), Triangularization method, Cholesky’s method, Partition method, Gauss Seidel iterative method.

09 Hrs Unit-V:

Eigen values & Eigen vectors (SLE: Analytical method to obtain eigen values and eigen vectors),Bounds on eigen values. Given’s method, Jacobi’s method for diagonalisation of symmetric matrices , . Rutishauser method for arbitrary matrices, Power method , Inverse power method

09Hrs Unit-VI:

Vectors & vector spaces, Linear Transformations - Kernel, Range. Matrix of linear transformation. Inverse linear transformation, Inner product, Length / Norm. Orthogonality, orthogonal projections. Orthonormal bases. Gram-Schmidt process. Least square problems. (SLE: Applications).

08 Hrs

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Course outcomes :

1. Obtain roots of algebraic and transcendental equations using various numerical methods. 2. Obtain complex roots of quadratic factors of the given polynomial using iterative

methods. 3. Apply quadrature formulae to solve application problems. 4. Solve linear algebraic equations using direct and iterative methods. 5. Obtain Eigen values and Eigen vectors using iterative methods 6. Establish the homomorphism between vector spaces using Linear transform and obtain orthonormal basis and solve some application problems using the definition of inner product space

Reference :

1) Introductory Methods of Numerical Analysis – S.S. Sastry, 5th edition. 2) Numerical Methods in engineering and science – B.S.Grewal, Khanna Publications- 8th

edition, 2009. 3) Higher Engineering Mathematics – Dr. B.V. Ramana,5th edition, Tata McGraw Hill

publications. 4) Linear Algebra – Larson & Falvo (Cengage learning) 5) Numerical Methods –.M.K. Jain S.R.K. Iyengar R.K. Jain, 2nd edition, New Age

International Pvt Ltd Publishers,2011.

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ADVANCED MATERIAL REMOVAL PROCESSES (4:0:2)

Sub Code : MPT0501 CIE : 50% Marks Hrs/Week : 05 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course objectives:

Provides in depth knowledge in tool materials selection, mechanics of metal cutting, tool characteristics, thermal aspects, tool life, tool wear and non-conventional machining practices Unit I: Theory of Metal cutting: Mechanics of metal cutting, chip formation, Types of chips, geometry of chip, orthogonal cutting and oblique cutting. Determination of forces on chips, shear angle, Merchant’s circle diagram and analysis velocity Relationship, slip line field solution, oblique cutting. Theory of Lee & Shaffer, coefficient of friction, power and energy relationship, Numerical examples 10 Hrs SLE: Measurement of cutting forces, Reasons for measuring cutting forces, classification of cutting forces dynamometers, Dynamometers for Lathe, drilling and milling Unit 2: Tool Materials and their properties: Single and multipoint cutting tools, tool nomenclature, tool angle specification in ASA system Characteristics of tool materials, types of tool materials-carbon tool steels, high speed steels, cast alloys, cemented carbides, ceramics, diamonds SIALON, CBN, UCON, recommended cutting speeds for the above tools, discussion on die steels, air, water, oil hardening of tools and their applications 06 Hrs SLE: Techniques to produce multilayer coatings on tools Unit 3: Thermal aspects and cutting fluids: Introduction heat sources in metal cutting, shear plane temperature is orthogonal cutting, factors influencing tool temperature, experimental determination of tool temperature types of cutting fluids, composition of cutting fluids, Tool Wear, Tool life –Mechanisms of tool wear, Sudden & gradual wear, crater wear, flank wear, tool failure criteria, tool life equations, effect of process parameters on tool life, tool life tests, conventional & accelerated tool wear measurement, 12 Hrs SLE: Methods of application, selection of cutting fluids. Application of semi-liquid lubricants Machinability index Unit 4: Nontraditional machining – processes, need, classification and selection. Mechanical process, Ultrasonic machining, Abrasive jet machining, 06 Hrs SLE: Water jet machining, principles, parameters & characteristics curves and applications.

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Unit 5 Thermal Removal process – EDM, principle, Mechanism of Metal Removal, Types of circuits, Material Removal Rate, Critical resistance, Parameters, applications. Laser Beam Machining, and Electron Beam Machining - principles, application, advantages & disadvantages 06 Hrs SLE: Wire cut EDM and their applications Unit 6: Electro chemical process – ECM, Principle, chemistry of ECM process, parameters, Determination of MRR, Dynamics & Hydrodynamics of the process, application advantages & disadvantages. Chemical machining – principle, advantages, disadvantages & application.

10 Hrs SLE: Electrochemical grinding, machining of ceramics, glasses and composites References: 1. Fundamentals of Metal Machining and Machine Tools by Geoffrey BoothRoyd Tata McGraw-Hill Publication 3rd edition 2006, 2. Metal Cutting principles by M.C.Shaw, Oxford Publication, 2005 3. Fundamentals of Metal Cutting & Machine Tools by B.L.Juneja & G.S.Sekhon – Newage publications, 2nd Edition, 2003 4. Experimental Methods in metal Cutting by V.C.Venkatesh & S. Chandrashekar, Prentice Hall 5. New Technology by Bhattacharya, Institute of engineers publications. 6. Modern Machining process by P.C.Pandey & H.S.Shan, Tata McGrawHill Publication, 2004

Course Outcome:

On successful completion of the course, the students will be able to:

• Identify the characteristics of traditional metal removal technique and learn about few theories associated with it. Identify the research topics in the field.

• Select appropriate tools for specific use, knowing the characteristics of the same • Explain the heat sources during metal cutting and the application of cutting fluids • Know the characteristics of non-traditional metal removal processes and the principles of

operations of mechanical processes. Identify the research topics in the field. • Explain the principle of operation of thermal metal removal processes and identify the

research topics • Explain the engineering application of electrochemical processes knowing well the

principle of operation of the same

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AUTOMATED MANUFACTURING SYSTEMS (4:0:2)

Sub Code : MPT0502 CIE : 50% Marks Hrs/Week : 05 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course objectives:

Useful to know automation and production systems technologies in modern manufacturing, material handling and storage, quality control and inspection and programmable logic controllers

Unit 1 Introduction: Production Systems, Manufacture Support System, Automation in Production Systems, Manual Labor in Production Systems, Automation Principles and Strategies Manufacturing Operations: 06Hrs SLE: Manufacturing Industries and Products, Manufacturing Operations, Production Facilities, Product/Production Relationship, Lean Production Unit 2 Automation and Control Technologies: Introduction to Automation: Basic Elements of an Automated System, Advanced Automation Functions, Levels of Automation Industrial Control Systems: Process Industries versus discrete Manufacturing Industries, Continuous Control Systems-Regulatory Control, and Feed forward Control-Steady-State Optimization-Adaptive Control-On-Line Search Strategies. Discrete Control Systems: Computer Process Control-Control Requirements-Capabilities of computer Control. Forms of Computer Process Control –Computer Process Monitoring-Direct digital Control-Programmable Logic Controllers-Supervisory Control. 10Hrs SLE: Brief discussion on Hardware components for Automation and Process Control. Unit 3 Introduction to Manufacturing Systems: Introduction, Components of a Manufacturing system-Production Machines, Material Handling System, Computer control system, Human Resources, Classification scheme for Manufacturing Systems, Single Station Cells-Multi-Station systems with Fixed Routing-Multi-Station Systems with Variable Routing. Single-Station Manufacturing Cells: Single-Station Manned Cells-Single-Station Automated Cells, Application of Single Station Cells 08 Hrs SLE: Case studies on Material Handling System & Analysis of single station systems

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Unit 4: Manual Assembly Lines: Fundamentals of Manual Assembly Lines-Analysis of Single Model Assembly Lines - The Line Balancing Algorithms- Largest Candidate Rule, Kilbridge and Wester Method, Ranked Positional weights Method, Mixed Model Assembly Lines- Mixed Model line balancing 08Hrs SLE: Workstation Considerations- consideration in Assembly Line Design-Alternative Assembly Systems Unit 5: Automated Production Lines: Fundamentals of Automated Production Lines, Work Part Transfer Mechanisms, Storage buffers, control of Production line, Automated Assembly Systems: Fundamentals of Automated Assembly systems, Parts delivery at workstations, Vibratory bowl feeder, escapement and placement devices, Orientors. Quantitative Analysis of Assembly systems, Multi-station Automated Assembly systems, single Station assembly Machines, Partial automation, 12Hrs SLE: Applications of Automated Production Lines-Analysis of Transfer Lines with or without Internal Parts Storage Unit 6: Quality Control in Manufacturing Systems Inspection Principles and Practices- Inspection Fundamentals-Sampling vs. 100% Inspection, Automated Inspection-When and Where to Inspect- On- line and off- line Inspection, Quantitative Analysis of Inspection SLE: Brief discussion on Manufacturing Support Systems (CAD, CAM and CIM) 08Hrs References:

1. Automation Production Systems and Computer Integrated Manufacturing, Mikell P.Groover, 3rd Edition, PHI Publication, 2008.

2. CAD/CAM/CIM – P.Radhakrishna, New Age International.2nd edition 3. CAD/CAM – Zeid, Mc-Graw Hill.2005 4. CAD/CAM,- P.N.Rao.TMH 2nd edition-2004 5. Koren.Y “Robotics for engineering” Mc-Graw Hill. 6. Rooks B. “Robot vision & Sensory controls vol-3 North Holland.

Course Outcome: On successful completion of the course, the students will be able to:

1. Identify the elements of manufacturing automation including CAD/CAM and CNC. 2. Identify and understand design process sequence, perform geometric modeling using

CAD software and prepare a simple CNC program and produce a sample part. 3. Understand machining processes and CNC. 4. Understand automated material handling and storage. 5. Understand robotics systems. Understand the principles of quality engineering and the

various methods of automated inspection systems. 6. Students will perform simple manufacturing material control calculations using the

concepts of just-in-time, Kanban systems.

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THEORY OF METAL FORMING (4:2:0)

Sub Code : MPT0503 CIE : 50% Marks Hrs/Week : 06 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course objective:

The main purpose of this course work is to present an account of the basic principle of metal working theory which can be understood and applied by engineers with the aim of improving production in metal working industry. Unit 1: Forming process: Introduction to metal forming classification, effect of temperature on forming process-hot working & cold working, True stress and strain, Strain energy, yield criterions, Tresca yield criteria, Von Mises yield criterion, relationship between tensile yield stress and shear yield stress, Yield under plane- strain condition, 10hrs SLE: Effect of metallurgical structure, frictional contribution in metal forming process, Effect of speed on deformation, work of plastic deformation. Unit 2: Drawing: Drawing of wide strip through wedge shaped dies by local stress evaluation, principles of rod and wire drawing, variables in wire drawing, Drawing load determination for circular rod with a conical die from local stress evaluation, tandem drawing process, Optimum die angles, determination by stress evaluation of the load for close pass drawing of thin walled tube –with slightly tapered plug and with moving a mandrel, tube sinking,. 08 hrs SLE: residual stresses in rod, tube drawing process, redundant work in tube drawing. Defects in rod and wire drawing. Unit 3: Extrusion: classification, Extrusion equipments, variables of extrusion process, stress evaluation for extrusion of round bar and flat strip, allowance for container friction, deformation in Extrusion. 06hrs SLE: Impact extrusion, extrusion defects, work done in extrusion. Unit 4: Forging: classification, various stages during forging. Forging equipments, Determination of plane strain compression load during forging a plate and flat circular disc from local stress evaluation, High friction condition. 06 hrs SLE: Forging defects. Residual stresses in forging. Unit 5:

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Rolling of metals: Classification, forces and geometrical relationships in rolling. Variables in rolling. Deformation in rolling. Roll pressure determination from local stress evaluation. Different types of roll mills. 08 hrs SLE: Defects in rolled products, residual stresses in rolled products Unit 6: Sheet metal forming: Introduction, forming methods shearing and blanking. Bending, spring back and compensation Stretch forming, deep drawing, redrawing operations. Defects in formed products. 06 hrs SLE: High Strain energy forming methods : Rubber forming, electro hydraulic forming, explosive forming, magnetic forming References :

1. Principles of Industrial Metal Working processes –Geoffrey W. Rowe- Arnold London- CBS publishers and distributors, 1996

2. Mechanical Metallurgy- Dieter G.E- McGraw-Hill publication. 3. Metals handbook-volume II-ASME. 4. Fundamentals of working of metals-Sachy. Pergamon press

Course Outcome:

• Explain the processes involved in metal forming mechanics, materials and tribology. • Understand the stress involved in drawing wire and tube to predict the load required. • To predict the extrusion load by understanding the variables of extrusion process. • Understand the forging process to reduce the problems of metal flow associated with the

filling of complex die shapes. • Explain the quantitative prediction of rolling loads from which detailed optimum rolling

schedules may be prepared • Describe sheet metal characteristics and high strain energy forming

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RAPID PROTOTYPING (2:0:0)

Sub Code : MPT0202 CIE : 50% Marks Hrs/Week : 02 SEE : 50% Marks SEE Hrs : 02 Max. Marks: 100 Course Objectives:

Students will learn & appreciate RP technology in product development, use latest software’s for modeling of prototype and produce 3D models using RP techniques. UNIT 1: Introduction: Need for the compression in product development, history of RP systems, survey of applications, and classification of RP systems. 04 Hrs SLE: Growth of RP industry UNIT 2: Stereo Lithography Systems: Principle, process parameter, process details, data files and machine details, application. 04 Hrs SLE: Data preparation UNIT 3: Selective Laser Sintering and Fusion Deposition Modeling: Type of machine, Principle of operation, process parameters, Principle of fusion deposition modeling, process parameter, path generation, Applications 06 Hrs SLE: Data preparation for SLS & Applications. UNIT 4: Solid Ground Curing: Principle of Operation, Machine Details. 04 Hrs SLE: Applications. UNIT 5: Laminated Object Manufacturing (LOM): Principle Of Operation, Process Details, Application. 04 Hrs SLE: LOM Materials UNIT 6: Concept Modeling: Principle, Thermal Jet Printer, Sander’s Model Market, 3-D Printer. Genisys Xs Printer HP System 5, Object Quadra Systems. 04 Hrs SLE: Applications. REFERENCE BOOKS:

1. Stereo Lithography And Other Rp & M Technologies- Paul F Jacobs- SME, NY 1996 2. Rapid Manufacturing- Flham D T & Dinjoy S S- VERLOG LONDON 2001 3. Rapid Automated – Lament Wood- Indus Press - NEW YORK 4. Wohler’s Report 2000 – Terry Wohlers – Wohler’s Association – 2000.

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Course outcomes: On successful completion of the course the student will able to:

• Understand product development and RP systems • Learn principles of Stereo Lithography Systems • Gain knowledge in Fusion Deposition Modeling & Laser Sintering • Use and apply the principles of Solid Ground Curing • Provide information on LOM • Apply the principles of concept modeling

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ELECTIVE I

DESIGN FOR MANUFACTURING (3:2:0)


To learn the design process and the effect of properties of different materials and provide tolerance specification and representation used in assembly.

Understand the design for casting components, gauges and their inspection.

1. Effect of Materials, Manufacturing Process and design: Major phases in design & Manufacture, Effect of material properties on design, Effect of manufacturing process on design, Cost per unit property and Weighted properties methods. Tolerancing: Tolerance specification and representation of various tolerances, their significance in assembly, Geo-material tolerances for assembly line – True position tolerancing, Cumulative effect of tolerances in assembly, Interchangeability and selective assembly in manufacturing, Process capability and its significance with reference to tolerancing. 12 hrs. SLE: Material selection process, Achieving larger machining tolerances.

2. Datum Features: Functional datum, Datum for manufacturing.

SLE: changing the datum. 04hrs.

3. Design Considerations: Design of components with casting considerations, Pattern,

Mould, and Parting line, Cored holes and Machine holes, Identifying the possible and probable parting line, Designing to obviate sand cores. 08hrs. SLE: Castings requiring special sand cores

4. Component Design: Component design with machining considerations like design for

turning components-milling, drilling and other related processes. 06 hrs SLE: finish-machining operations.

5. Design of Gauges: Design of gauges for checking components in assembly with

emphasis on various types of limit gauges for both hole and shaft. 04hrs SLE: case studies

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6. Case Studies: Related to above topics and also including the followings Redesign to suit manufacture of typical assemblies, tolerance design of typical assemblies, Design to minimize cost of a product 14 hrs SLE: Computer Aided DFMA

References: 1. Harry peck, “design for manufacture”, pitman publications. 1983 for topics 2 to 5. 2. Dieter – “Machine design”, McGraw Hill publications for topic 1. 3. R.K.Jain “Metrology” Khanna publications for topic 6. 4. Geoffrey Boothroyd, peter dewhurst, Winston Knight, “Product design for manufacture and assembly”. Mercel dekker. Inc. Newyork.

Course Outcome: • Understand the role of manufacturing within the design process • Evaluate and select manufacturing processes relevant to any industry • Quantify cost and metrics for manufacturing processes relevant to any industry • Review and select suitable manufacturing processes for a complex, well-defined

component • Assess the risks of manufacturing processes, consistent with the expected responsibilities

and accountabilities of a professional engineer to manage risk. • Design a complex, well-defined component accounting for manufacturing.

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NANO TECHNOLOGY (3:2:0)

Sub Code : MPT0404 CIE : 50% Marks Hrs/Week : 05 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100

Course Objective:

• By studying the above subject, the student has an exposure to various fields of application of nano-materials in engineering systems.

Unit 1: Metal based nanocomposites- Metal-Oxide or Metal-Ceramic composites, Different aspects of their preparation techniques and their final properties and functionality. Metal-metal nanocomposites, some simple preparation techniques and their new electrical and magnetic properties 10hrs SLE: Nano-composites Unit 2: Design of Super hard materials- Super hard nanocomposites, its designing and improvements. 06hrs SLE: Mechanical Properties. Unit 3: Nanofiller synthesis, applications, Polymer nanocomposites, particulate and fiber modified nanocomposites, matrices and fibres, polymer- filler interphase, pull- out strength, 08hrs SLE: Effect of various treatments. Unit 4: Mechanics of polymer nanocomposites, Interfacial adhesion and characterization, factors influencing the performance of nanocomposites, physical and functional properties. Nano composite fabrication, matrices, methods, additives, moulding processes. 10hrs SLE: Matrix, molding process Unit 5: Polymer-carbon nanotubes based composites, processing methods and characterization using SEM, XRD, TEM 06hrs SLE: Characterization using TEM

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Unit 6: Characterization of Polymer nanotubes based composites for Mechanical, Electrical and Thermal Properties and their applications - Polymer / nanofillers (metallic nanopowders) systems, Rheological measurements, processing characteristics Testing of nanocomposites, Thermal analysis such as TGA, TMA, DSC, and DMTA 12hrs SLE: Testing of nanocomposites References:

1. Text Book of Polymer Science - Fred W. Billimeyer, Jr - Wiley Interscience Publication - third edition 1994.

2. Polymer Science and Technology - Joel R. Fried - Prentice- Hall, Inc. Englewood Cliffs, N. J., USA – 2003, 2nd edition

3. New Developments and Technology -Hand book of Elastomers - (Eds. A. K. Bhowmic and H. C. Stephense), Marcel - Dekker Inc., New York - 1995.

4. Polymer Blends - D. R. Paul and S. Newman - Academic Press, New York - 1978. 5. Short Fibre Reinforced Thermoplastics - M. J. Folkes - John Wiley, New York - 1982.


• Apply the different aspects of Metal-Ceramic composites • Identify mechanical properties of nano-composites • Provide variuos treatments for reinforcement • Fabricate nano-composites • Identify different processing methods • Understand polymer nanofillers and their properties

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QUANTITATIVE TECHNIQUES IN DECISION MAKING (3:2:0)


Course objective:

To understand statistics, operations research techniques and learn mathematical tools that are needed to solve optimization problem Unit 1: Introduction: Statistics and managerial decisions, statistical data and Operations Research techniques. Presentation and Analysis of Statistical data: Tables and graphs as data presentation devices, histogram and cumulative frequency curves. 08 Hrs SLE: Frequency distribution Unit 2: Fundamentals of Statistics, probability and probability distributions: Measures of central tendency and location, Measure of dispersion, skewness and kurtosis, Probability and rules of probability, Random variables and probability distributions – Binomial, Poisson, Hyper geometric and Normal. Decision making under Uncertainty: Alternative criteria for decision under uncertainty, 08 Hrs SLE: Bayesian approach and Incremental analysis. Unit 3: Correlation, Regression and Multivariate Analysis: Bivariate frequency distribution and scatter diagram, Correlation analysis and Regression analysis, Non linear regression, auto correlation and multiple regression analysis, Multivariate analysis. Linear Programming Problem: Formulation of L.P.P., Solution of L.P.P. by graphical method, Solution of L.P.P. by simplex method, Concept of duality and solution of dual problems. 10 Hrs SLE: Solution of L.P.P. by dual simplex method. Unit 4: Transportation and Assignment Problems: Structure of transportation problem and various methods of find I.B.F.S., Optimality test of transportation problems, Assignment problems and solution by Hungarian method Theory of Games: Two person zero sum game, Minimax and maximin strategies, Solution of game by dominance rules, arithmetic and algebraic methods, Solution of game by graphical method and method of matrices, Solution of game by Linear programming approach and approximate and algebraic methods to solve game problems. 10Hrs SLE: Traveling Salesman problem.

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Unit 5: Network Analysis: PERT and CPM, Network construction and determination of critical path, Calculation of ES, EF, LS, LF, TF, FF AND IF, Crashing of a project 08Hrs SLE: Scheduling of a project. Unit 6: Waiting Line: Basic structure of queuing systems and characteristics, Expressions for M/M/1 queuing model. Simulation of Management systems: Simulation and Monte Carlo method, waiting line 08 Hrs SLE: Inventory simulation models. References:

1. Srivastava U.K. et. All – “Quantitative Techniques for managerial decisions”, New Age International Private Limited.

2. Gupta and Heera – “Operations Research: An Introduction”, S.Chand and Company 3. H.Taha “Operations Research”, Prentice Hall India 6th edition.

Hillier and Liberman “Introduction to Operations Research”, McGraw Hill International.


• Select the suitable statistical tool for decision making • Explain the variations of distribution of data using different statistical models • Demonstrate the variations of distribution of statistical data • Make good decision in real time situation using assignment and transportation technique • Explain the purpose and function of statistical quality control. • To design new simple models, like: CPM, PERT to improve decision-making and

develop critical thinking and objective analysis of decision problems

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TOOL DESIGN (3:2:0)


Course Objective:

Students will be able to design, draft, and draw different tool materials used in machines for various operations Unit 1: Tool-design Methods: Introduction, the design procedure, drafting and design techniques in tooling drawing Tool-making Practices: Introduction, tools of the tool maker, hand finishing and polishing, screws and dowels, hole location, jig-boring practice, installation of drilling bushings, punch and die bushings, punch and die manufacture, EDM, tracer and duplicating mills for cavity applications, low-melting tool materials. Tooling Materials and Heat Treatment: Introduction, properties of materials, ferrous tooling materials, non-ferrous tooling materials, non-metallic tooling materials, heat treatment and tool design. 11Hrs SLE: EDM for cavity applications Unit 2: Design of Cutting Tools: Introduction, the metal cutting process, revision of metal cutting tools-single point cutting tools, milling cutters, drills and drilling, reamers, taps. Selection of carbide tools, determining the insert thickness for carbide tools Design of Tools for Inspection and Gauging: Introduction, work piece quality criteria, principles of gauging, types of gages and their applications, amplification and magnification of error, gage tolerances, indicating gages, automatic gages, gauging positionally tolerance parts, problems. 11Hrs SLE: Selection of material for gages Unit 3: Locating and Clamping Methods: Introduction, basic principle of location, locating methods and devices, basic principle of clamping. Design of Drill Jigs: Introduction, types of drill jigs, general considerations in the design of drill jigs, drill bushings, methods of construction Design of Fixtures: Introduction, types of fixtures, fixtures and economics. 09Hrs SLE: Drill jigs and modern manufacturing. Unit 4: Design of Press-working Tools: Power presses, cutting operations, types of die-cutting operations - and their design, evolution of blanking and progressive blanking.

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Design of Sheet Metal Bending, Forming and Drawing Dies: Introduction, bending dies, forming dies, drawing dies. Evolution of a draw die, progressive dies. Strip development for progressive dies, examples of progressive dies. Extrusion dies, drop forging dies and auxiliary tools, problems. 08Hrs SLE: Selection of progressive dies. Unit 5: Tool Design for Joining Processes: Introduction, tooling for physical joining processes, tooling for soldering and brazing, tooling for mechanical joining processes, problems. Tooling for Casting: Introduction, tooling for sand casting, metal moulding and die-casting, problems 06Hrs SLE: Shell moulding Unit 6: Tool Design for NC Machine Tools: Revision of NC control, fixture design for NC machine tools, cutting tools and tool-holding methods, automatic tool chargers and tool positioners. Plastics as Tooling Materials Introduction, plastics commonly used as tooling materials, application of epoxy plastic tools, construction methods, and metal forming operations with Urethane dies . Problems 07Hrs SLE: Forces calculation for Urethane pressure pads References books:

1. Tool Design - Cyril Donaldson, GH Lecain and VC Goold - TMH Publishing Co Ltd., New Delhi, - 4th editions, 2012.

2. Fundamentals of Tool Design – ASTME - PHI (P) Ltd., New Delhi -1987. 3. Press working of metals – Hinman - McGraw Hill – 1950. 4. “Tool Engineering & Design” G.R Nagpal Khanna Publishers 6th Edition ,2009

Course Outcome:

On successful completion of the course, the students will be able to: • Know the basics of tool design method, tool making practices, material used for tooling

and heat treatment methods to be used • Design the cutting tool used in machining process, and tool for inspection and gauging • Understand the principles of locating and clamping so as to design drill, jigs and fixtures • Design press working tools, sheet metal bending, forming and drawing dies • Explain the features of tooling required for joining and casting process • Explain the procedure of tooling required for NC machine tools and explore the

possibilities of plastics as a tooling material

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INDUSTRIAL DESIGN AND ERGONOMICS (3:2:0)

Sub Code : MPT0407 CIE : 50% Marks Hrs/Week : 05 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Objective: The objective is to improve the efficiency of operation by taking into account a typical person's size, strength, speed, visual acuity, and physiological stresses, such as fatigue, speed of decision making, and demands on memory and perception. To achieve the best mutual adjustment of man and his work. To achieve greater efficiency of both man and machine. Unit-1 Introduction: An approach to industrial design, Elements of design structure for industrial design in engineering application in modern manufacturing systems Ergonomics and Industrial Design: Introduction to Ergonomics, Communication system, general approach to the man-machine relationship, Human Component of work system, Machine component of work system, Local Environment-light, Heat, Sound. 10 Hrs SLE: Design of layouts Unit-2 Ergonomics and Production: Ergonomics and product design, Anthropometric data and its applications in ergonomic, working postures, Body Movements, work Station Design, Chair Design. 08 Hrs SLE: Design and drawing of workstations Unit-3 Displays: Design Principles of visual Displays, Classification, Quantitative displays, Qualitative displays, check readings, Situational awareness, Representative Displays, Design of Pointers, Signal and warning Lights, color coding of displays, Design of multiple displays Controls: Design considerations, controls with little efforts – Push button, Switches, rotating Knobs. Controls with muscular effort – Hand wheel, Crank, Heavy lever, Pedals. Design of controls in automobiles, Machine Tools 10 Hrs SLE: Design and Drawing of domestic & Industrial displays and controls. Unit-4 Visual Effects of Line and Form: The mechanics of seeing, Psychology of seeing, Figure on ground effect. Gestalt’s perceptions – Simplicity, Regularity, Proximity, Wholeness. Optical Illusions, Influences of line and form. 08 Hrs SLE: Parts of Eye, structure of cones and rods

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Unit-5 Colour: Colour and light, Colour and objects, Colour and the eye – after Image, Colour blindness, Colour constancy, Colour terms – Colour circles, Munsel Colour notation, reactions to colour and colour combination – colour on engineering equipments, Colour coding, Psychological Effects, colour and machine form, colour and style. 08 Hrs SLE: Use of colours in Industries. Unit-6 Aesthetic Concepts: Concept of unity, Concept of order with variety, concept of purpose, style and environment, aesthetic expressions – symmetry, balance, contrast, continuity, proportion. Style – the components of style, house style, style in capital good. 08 Hrs SLE: Golden ratio and Use of aesthetics in design

References books:

1. Mayall W.H. “Industrial design for Engineers”, London Hiffee books Ltd., 1988. 2. Brain Shakel (Edited), “Applied Ergonomics Hand Book”, Butterworth scientific.

London 1988. 3. Introduction to Ergonomics R.C.Bridger, McGraw Hill Publications. 4. Human factor Engineering – Sanders & McCormick McGraw Hill Publications.


• Assess the effect of physical environment factors on comfort and performance. • Apply principles of good ergonomic design of work areas and equipment to a range of

occupational settings and Apply anthropometrics data in the design of work environments.

• To design displays and controls using the design concepts. • Use the concepts line form in industry. • Use of in colours in industry. • Aesthetic concepts in design

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ELECTIVE II

ADVANCED METROLOGY AND QUALITY ENGINEERING (3:0:2)

Sub Code : MPT0408 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Objective: To understand the advanced level of measurements and metrological study of measuring devices and apply the technique to quality control. Unit 1: Laser Metrology: Free electron laser – optical alignment, measurement of distance – interferometry, reversible counting, refractive index correction, reversible counting, refractive index correction, surface topography and optical component testing, beam modulation telemetry, pulse-echo techniques, surface velocity measurements using speckle patterns – laser spectroscopy – modular beam spectroscopy, saturation spectroscopy. 06 Hrs SLE: Two photon spectroscopy Unit 2: Holography: Basic principles – holographic interferometry – double exposure holographic interferometery – sandwich holograms, real time holography. 06 Hrs SLE: Time-average holographic interferometer – character recognition. Unit 3: Coordinate Measuring Machine (CMM) and Machine Vision: Fundamental features of CMM, development of CMMs , role of CMMs, types of CMMs, modes of operation, types of probes, probe calibration, non-contact type probes, direct computer control, software packages, operational modes, metrological features, co-ordinate systems, portable arm CMMs, machine vision systems, illumination, magnification. 10 Hrs SLE: Vision system measurement – multisensor systems. Unit 4: Quality in Manufacturing Engineering: Importance of manufacturing planning for quality, initial planning for quality, concept of controllability: self controls, defining quality responsibilities on the factory flow, self inspection, automated manufacturing, overall review of manufacturing planning, process quality audits. 06 Hrs SLE: Quality and production floor culture.

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Unit 5: Quality in Design Engineering: Opportunities for improvement product design, early warning concepts and design assurance, designing for basic functional requirements, designing for time oriented performance (reliability) , availability, designing for safety, designing for manufacturability, cost and product performance, cost of quality, design review, concurrent engineering. 10 Hrs SLE: Improving the effectiveness of product development. Unit 6: Quality Management System: Need for quality management system, design of quality management system, quality management system requirements, ISO 9001 and other management systems and models, improvements made to quality management systems. 06 Hrs Continuous Improvement: Basic quality engineering tools and techniques, statistical process control - techniques for process design and improvement, Taguchi methods for process improvement. 08 Hrs SLE: Six sigma - the ‘DRIVE’ framework for continuous improvement. References: 1. Oakland J S, “Total Quality Management - Text with Cases”, Butterworth – Heinemann – An

Imprint of Elseiver, First Indian Print, 2005. 2. Nambiar K R, “Lasers – Principles, Types and Applications’, New Age International Limited

Publishers, 2004. 3. Dotson C, Harlow R and Thompson R, “Fundamentals of Dimensional Metrology”,

Thomson Delmer Learning, Singapore, 4th Edition, 2003. 4. John A Bosch, Giddings and Lewis Dayton, “Coordinate Measuring Machines and Systems”,

Marcel Dekker, Inc., 1999. 5. Juran J M and Gryna F M, “Quality Planning and Analysis”, Tata McGraw Hill Edition,

1995. 6. Wilson J and Hawker J F B, “Lasers – Principles and Applications”, Prentice Hall, 1987. Course Outcome: On successful completion of the course, the students will be able to:

• Understand the laser metrology technique • Understand the Holography measurement technique • Understand the Coordinate Measuring Machine principle • Understand and appreciate the importance of Quality in Manufacturing Engineering • Understand and appreciate the importance of Quality in Design Engineering • Understand and appreciate the need for Quality Management System & Continuous

Improvement

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ADVANCED MANUFACTURING SYSTEMS (3:2:0)


Course objective:

Learn JIT and TQC concepts for eliminating waste and cutting cost in manufacturing industries by applying lean tools and practices. Unit 1: Introduction: Need of CPC for a company, what CPC can do, CPC-getting the right tool. JIT: Introduction – The spread of JIT Movement, some definitions of JIT, core Japanese practices of JIT, Creating continuous Flow Manufacture, Enabling JIT to occur, Basic elements of JIT. 08 hrs SLE: Benefits of JIT. Unit 2: Just in Time Production: Primary purpose, profit through cost reduction, Elimination of over production, Quality control, Quality Assurance, Respect for Humanity, Flexible work Force, Adapting to changing production Quantities, process layout for shortened lead Times, Standardization of operation, Autonomation 08 hrs SLE: JIT Production Unit 3: Sequence and scheduling used by suppliers: Monthly and daily Information. Sequenced withdrawal system by sequenced schedule table, problems and counter measures in applying the Kanban system to sub contractors Toyota Production System: The philosophy of TPS, Basic Frame work of TPS, Kanbans. Supplier Kanban and the Sequence Schedule for Use by Suppliers

a) Later Replenishment System by Kanban. b) Sequenced Withdrawal System. c) Circulation of the Supplier Kanban within Toyota.

Production Smoothing in TPS Production Planning Production Smoothing Adaptability to Demand Fluctuations Sequencing Method for the Mixed Model Assembly Line to Realize Smoothed Production of Goal. 10 hrs SLE: Determining the Number of Kanbans in Toyota Production System.

a. Kanban Number under Constant Quantity Withdrawal System. b. Constant Cycle, Non-constant quantity withdrawal System.

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Unit 4: Just-in-Time Production with Total Quality Control: Just in time concept, cutting lot sizes, cutting set-up times, cutting purchase order costs, JIT cause-effect chain, Scrap/Quality Improvements, Motivational effects, Responsibility effects, small group improvement activities, Total Quality Control concept. 08 hrs SLE: withdrawal of Buffer Inventory. Unit 5: Total Quality Control: Introduction-Total Quality Control concepts, responsibility, learning from the west, TQC concepts categorized, Goals, Habit of improvement, perfection, Basics, process control, Easy to see Quality control as facilitator, small lot sizes, Housekeeping, Less than full capacity scheduling, Daily machine checking, Techniques and Aids, Exposure of problems, Fool proof devices, Tools of analysis, QC Circles, 12 hrs. SLE: TQC in Japanese-owned US electronics plant, TQC in Japanese-owned automotive plants. Unit 6: Plant Configurations: Introduction-ultimate plant configuration, job shop fabrication, Frame welding, Forming & frame parts from Tubing, Dedicated production lines, overlapped production, the daily schedule, Forward linkage by means of Kanban, physical merger of processes, Adjacency, mixed models, Automated production lines. 06 hrs SLE: Pseudo Robots, Robots, CAD and Manufacturing, Conveyors and stacker cranes, Automatic Quality Monitoring. References:

1. Japanese manufacturing techniques – by Richard Schonberger. 2. Just in time manufacturing – Kargoanker 3. Wind-chill reference manual. 4. Toyota Production system – An integrated approach to just in time – by Yasuhiro

Monden 5. Lean Thinking – By James Womack. 6. The machine that changed the World – The story of Lean production – by James P.

Womack, Daniel T Jones, and Daniel Roos – Harper Perennial edition published 1991. Course Outcome:

1. Study the basic CPC and JIT concepts. 2. Know the cost reduction and elimination of waste in production through JIT. 3. Demonstrate sequence and scheduling used by suppliers and determine the number of

kanban by TPS 4. Learn how to cut lot sizes, setup time, purchase order cost using JIT concepts. 5. Understand TQC, its concepts and categorization. 6. Study the various plant configurations and its application for different types of industries.

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SMART MATERIALS AND STRUCTURES (3:2:0)

Sub Code : MPT0410 CIE : 50% Marks Hrs/Week : 05 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Objective: Students will learn, select, and construct smart materials suitable for different applications. Unit 1: Overview of Smart Materials: Structures and Products Technologies. Smart Materials (Physical Properties): Piezoelectric Materials, Electrostrictive Materials, Magnetostrictive Materials, Magneto electric Materials. Magneto-rheological Fluids, Electrorheological Fluids, Fiber Optic Sensors 10Hrs SLE: Shape Memory Materials Unit 2: Smart Sensors Smart Sensors: Accelerometers; Force Sensors; Load Cells; Torque Sensors; Pressure Sensors; Microphones; Impact Hammers, Sensor Arrays SLE: MEMS Sensors Unit 3: Actuator and Transducer Technologies: Smart Actuators: Displacement Actuators; Force Actuators; Power Actuators; Vibration Dampers; Shakers; Fluidic Pumps; Motors. Smart Transducers: Ultrasonic Transducers: Sonic Transducers: 10 hrs. SLE: Air Transducers Unit 4: Measurement, Signal Processing, Drive and Control Techniques: Quasi-Static and Dynamic measurement Methods; Signal-Conditioning Devices; Constant Voltage, Constant Current and Pulse Drive Methods;; Structural Dynamics and identification Techniques; Passive, Semi-Active and Active Control; Feedback and Feed forward Control Strategies. 14 hrs SLE: Calibration Methods Unit 5: Design, Analysis, Manufacturing Case studies incorporating design, analysis, manufacturing and application issues involved in integrating smart materials and control capabilities to engineering smart structures and products. 10 hrs SLE: Devices with signal processing

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Unit 6: Applications of Engineering Smart Structures and Products Emphasis on structures, automation and precision manufacturing equipment, automotives, sporting products, computer and telecommunications products as well as medical and dental tools and equipment 08 Hrs SLE: Consumer products References:

1. M.V.Gandhi and B.So Thompson, Smart Materials and structures, chapman and Hall, London; New York, 1992 (ISBN: 0412370107).

2. B.Culshaw, Smart Structures and Materials, Artech House, Boston, 1996 (ISBN: 0890066817).

3. A.V.Srinivasan, smart Structres: Analysis and Design, Cambridge University Press, Cambridge; New York, 2001 (ISBN: 0521650267).

4. A.J.Moulson and J.M.Herbert, Electroceramics: Materials, Properties, Applications 2nd Edition, John Wiley and sons, Chichester, West Sussex; New York, 2003 (ISBN: 0471497479).

5. G. Gautschi, Piezoelectric Sensorics: Force, Strain, pressure, acceleration and acoustic emission sensors. Materials and Amplifiers, Springer, Berlin; New York, 2002 (ISBN: 3540422595).

6. K.Uchino, Piezoelectric Actuators and Wtrasonic Motors, Kluwer Academic Publishers, Boston, 1997 (ISBN: 0792398114).

7. G. Engdahl, Handbook of Giant Magnetostrictive Materials, Academic Press, San Diego, Calif; London, 2000 (ISBN: 012238640x).

8. K.Otsuka and C.M.Wayman, Shape Memory Materials, Cambridge University press, Cambridge; New York, 1991 (ISBN: 052144487).

9. Eric udd, Fiber optic sensors: An introduction for Engineers and Scientists, John Wiley and sons, Newyork, 1991 (ISBN: 0471830070).

10. Andre preumont, Vibration Control of Active Structurs: an introduction, 2nd Edition, Kluwer Academic Publishers, Dordrecht; Boston, 2002 (ISBN: 1402004966).

Course Outcome:

On successful completion of the course, the students will be able to: • Provide the physical properties of smart materials. • Study the aspects of smart sensors • Analyze smart actuators used in different technologies • Identify different techniques of signal processing • Study smart materials for different application • Identify different application of smart materials in industry

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FLEXIBLE MANUFACTURING SYSTEMS (3:2:0)

Sub Code : MPT0411 CIE : 50% Marks Hrs/Week : 05 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Objective:

Help students in acquainting with the concepts of flexible manufacturing system (FMS), network protocols, work centers, robotic workstations, material handling systems and interfacing with computer for project planning. UNIT 1: Introduction to FMS - concepts, advantages, components and examples of FMS, Distributed Numerical Control (DNC) - Communication between DNC computers. 07 Hrs SLE: MCU UNIT 2: Distributed data processing in FMS - Computer network protocols - Interfacing of CAD and CAM - Part programming in FMS tool data base - Clamping devices. 07 Hrs SLE: Fixtures data base UNIT 3: Equipment of FMS: Primary equipment, Work centers, Universal machining centers (prismatic FMSs) Turning centers (rotational FMSs), Grinding machines, Nibbling machines. Process centers: Wash machines, Robotic workstations, Manual workstations. Secondary equipment: Support stations, Pallet/fixture/ load/unload stations 10 Hrs SLE: Tool commissioning/setting area. UNIT 4: Types of FMS: Sequential FMS, Random FMS, Dedicated FMS, Modular FMS. FMS layouts: progressive layout, closed loop layout, ladder layout, open field layout. Application of FMS: Metal-cutting machining, Metal forming, Assembly, Joining-welding (arc, spot), gluing. 10 Hrs SLE: Surface treatment, Inspection, Testing. UNIT 5: Material Handling systems - ASRS - AGVs – features of industrial robots - robot cell design and control. Inspection - CMM – In cycle gauging - Sensors for robots 10 Hrs SLE: FMS controls.

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UNIT 6: Interfacing of computer - machine tool controllers and handling systems: communications standards - programmable Logic Controllers (PLC's) – Interfacing - Computer aided Project planning 08 Hrs SLE: Inventory control References: 1) Mikell P Groover, “Automation Production systems, Computer Integrated Manufacturing”, Prentice Hall, 2001. 2) Paul Ranky., “The design and operation of FMS”, IFS publication.,, 1983. 3) Viswanathan, N & Nahari, Y, “Performance modeling of automated manufacturing systems”, PrenticeHall,1992. 4) Nanua Singh-Computer aided design/Manufacturing. Course Outcome:

On successful completion of the course, the students will be able to: • Understand the concepts of FMS • Interface CAD & CAM with FMS • Design robotic workstations and support stations • Analyze and design different layouts and • Design material handling system for FMS • Program PLC’s

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PRODUCT LIFECYCLE MANAGEMENT (3:2:0)


Make students to understand the benefits of concurrent engineering with respect to Japanese and US industries, solid modeling, lifecycle design and analysis of products for optimal structure design UNIT 1: Introduction: Extensive definition of Concurrent Engineering (CE), CE design methodologies, Components of CE. Review of CE techniques like DFM (Design for manufacture), DFA (Design for assembly), QFD (Quality function deployment), RP (Rapid prototyping), TD (Total design), for integrating these technologies, Organizing for CE, CE tool box, Benefits of Concurrent Engineering. 12 hrs SLE: Collaborative product development UNIT 2: Survey of CE techniques: Japanese Success, European Environment and CE in US Automotive industries 06 hrs SLE: Case studies related to US automotive industries UNIT 3: Use of Information Technology: IT supports, Solid modeling, Product data management, Collaborative product commerce, expert systems, Software hardware component design. 08 hrs SLE: Artificial Intelligence UNIT 4: Design Stage: Lifecycle design of products, Opportunities for manufacturing enterprises, Modality of concurrent engineering design, automated analysis Idealization control, CE in optimal structural design. 08 hrs SLE: Real time constraints. UNIT 5: Need for PLM: Importance of PLM, Implementing PLM, and Responsibility for PLM, and Benefits to different managers, Components of PLM, Emergence of PLM, and Opportunities to seize. 08 hrs SLE: Lifecycle problems

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UNIT 6: Components of PLM: Components of PLM, Product lifecycle activities, Product organizational structure, Human resources in product lifecycle, Methods, techniques, Practices, Methodologies, Processes, System components in lifecycle, , Interfaces, Information, Standards. 10 hrs SLE: Slicing and dicing the systems. Text Books:

1. Integrated Product Development M.M. Anderson and L Hein IFS Publications 2. Design for Concurrent Engineering J.Cleetus CE Research Centre, Morgantown 3. Concurrent Engineering Fundamentals: Integrated Product Development, Prasad

Prentice hall India 4. Concurrent Engineering in Product Design and Development I Moustapha

New Age International 5. Product Lifecycle Management John Stark Springer-Verlag, UK 6. Product Lifecycle Management Michael Grieves McGraw Hill 7. Concurrent Engineering: Automation tools and Technology Andrew

Kusiak Wiley Eastern Course Outcome

• Understand the importance of collaborative product development and benefits of concurrent engineering

• Analyze the survey of CE techniques. • Importance of Information Technology in the lifecycle of a product • Explain the various aspects of design stage of a product • Understand the importance of PLM and its applications for a problem solving in an

industry • Analyze the various components of PLM and be able to practice its methodologies

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II SEMESTER(Core subjects) ADVANCED FLUID POWER SYSTEM (4:0:2)

Sub Code : MPT0504 CIE : 50% Marks Hrs/Week : 05 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Objective:

This course is essential in understanding the advances in design, analysis, operation of fluid power systems. UNIT 1 Hydraulics systems: Introduction, Pascal Law, Advantages of Fluid Power, Applications of Fluid Power, Components of a Fluid Power system, Pumping Theory, Pump Classification, Gear Pumps, (Vane Pumps- simple, balanced & pressure compensated vane pump, Vane design) Piston Pumps- Radial, Axial (Bent axis & Swash plate), Pump Performance,. Linear actuator- cylinders, Mechanics of Hydraulic cylinder loading, limited rotation hydraulic actuator, cylinder cushioning, motor performance, Hydrostatic transmission 10 hrs SLE: Pump Noise, Ripple in pumps, Gear, Vane & Piston motor UNIT 2 Valves-Directional Control Valves- 2/2, 3/2,4/2 & 4/3 ways DCV’s, Different Centre configurations in 4/3 way valves, actuation of DCV’s, solenoids for valve actuation, relays, relay circuit design, sensors-contact and non contact type, optical type, Indirect actuation, Valve Lap – Lap during Stationary and during Switching. Pressure Control Valves: Classification, opening & Closing Pressure difference, Cracking Pressure, Pressure Relief Valve – Simple & Compound type, Pressure reducing valve, Pressure switches. Flow Control valves – Fixed throttle, Variable throttle, Pressure Compensations principles, pressure compensated Flow control valves – Reducing & Relief type. Check valve, Pilot operated check valve, Throttle check valve 12hrs SLE: Proportional valve technology, proportional solenoids, proportional directional valves, proportional pressure control valves UNIT 3 Electro hydraulic circuit design & analysis: Control of Single & double acting cylinder using 4/2 and 4/3 solenoid valves, Regeneration circuit, cylinder sequencing & Synchronizing circuit, automatic cylinder reciprocation using sensors. Speed control of cylinder & Motors, Analysis of Hydraulic system with frictional losses, Relay circuit design for electro hydraulics for different application, Accumulators & accumulator circuits 08 hrs SLE: Servo Valve technology, torque motor, single and multistage servo valves

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UNIT 4 Pneumatic System: Introduction, –, Pneumatic cylinder & air motor – different types of cylinder, cushion assembly. Directional control valves and its actuation methods, impulse valve, memory valve, pressure regulator, flow control valve, check valve , pilot check valve, throttle check valve, Quick exhaust valve, shuttle valve, Twin pressure valve, reflex nozzle, Time delay valve 08 hrs SLE: Generation and preparation of compressed air, air receiver, servicing FRL unit, Air filter, pressure regulation, lubricator UNIT 5 Design of Pneumatic Circuit & Logic Circuits: Control of single and double acting cylinder, impulse operation, speed control- supply air and exhaust air throttling, , - circuit design, AND,OR, NOT, NAND, NOR, YES Function, Logic circuits design using shuttle valve & twin pressure valve. SLE: Sequencing circuits and its applications and pressure dependent controls 08 Hrs UNIT 6 Advanced Pneumatic circuit: Binary Arithmetic, logic & Boolean Algebra, , Cascading circuits, Signal overlapping elimination. 06 hrs SLE: Use of Kannaugh- Veitch map for pneumatic circuit design References: 1. Fluid Power with application, 5th edition, Anthony Esposito, Peason Education. 2. Oil hydraulics -Principles & maintenance , S.R. Majumdar, Tata M C Graw Hill 3.Pneumatic system, principles and maintenance, S.R. Majumdar, Tata M C Graw Hill publication. 3. Hydraulics Trainer- Volume1. Components & application, Rexroth - Bosch group Publication 4. Proportional and Servo valve technology- The Hydraulic trainer, Volume 2, Rexroth - Bosch group Publication 5. Pneumatics: Theory and applications, Rexroth - Bosch group Publication 6. Electro Pneumatics Vol. 2, Rexroth - Bosch group Publication.

Course Outcome:

• Identify fluid power components and their symbols as used in industry. • Interpret and adapt existing fluid power circuit and Describe the function and operation

of fluid power components • Design, construct and test pneumatic and hydraulic circuits for engineering applications

in a safe manner • Calculate the forces applied by actuators and the speed of actuator movement. • Describe the treatment of hydraulic fluids necessary for reliable system operation and

protection of the environment • Size and specify actuator and control components for given applications.

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ADVANCED MATERIALS AND PROCESSING (4:0:2)


Will be able to select proper materials to fabricate composites using different techniques, characterize and test. Unit 1: Materials in manufacturing: classification, Metals, ceramics, glasses, elastomers, polymers, composites, nano science materials. mechanical, thermal, wear, corrosion / oxidation. 08 hrs SLE: Material properties Unit 2: Composite materials: Introduction, definition, classification, Characteristics of composite materials, fiber, laminated, particulate composites, sandwiches. Design criteria 08 hrs SLE: Application of composites. Unit 3: Fiber reinforced plastic processing: Thermoset and Thermoplastic, Open and closed mould processing, Hand layup techniques, Bag moulding and filament winding, Pultrusion, pulforming, thermoforming, Injection moulding 12 hrs SLE: ASTM standards for testing Unit 4 Manufacturing of composites: Cutting, Machining and Joining, Types of defects, NDT Methods. 08 hrs SLE: Tooling, Quality assurance Unit 5: Metal Matrix Composites: Reinforcement materials, types, Characteristics and selection, fabrication and application Ceramics: nature and structure of Ceramics – Refractory – Abrasives glasses – glass ceramics – Advanced ceramics – processing methods. 10 hrs SLE: Shape Memory Alloys

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Unit 6: Characterization of materials: X – ray diffraction, SEM, TEM – crystal structure and phase identification, residual stress measurement, thermal analysis, fractography. 06 hrs SLE: Repair of composites.

References:

1. Chawla K K “Science and Engineering” Composite Materials 2nd edition, Springer- 1988. 2. William D Callister, R Balasubramaniam, Materials Science and Engineering Wiley India

(Pvt) Ltd., 2007 3. Raymond and Higgens, Engineering Metallurgy, ELBS/EA 4. James.F.shackleford – Introduction to Material Science and Engineering, Mc Millan, NY 5. Powder Metallurgy-Metals Hand Book, Vol.7, ASM,USA,1997 6. Chawla K.K., ‘Composite Materials’ – Science and Engineering’ –– verlag, Newyork 7. P.K. Rohagti “Cast Metal matrix compostes, ASM Metals Hand Book, V15. 8. Van Vlack L.H. “Elements of Material science and Engineering, Addison Wesley, NY

Course Outcome: At the end of the course the students will be able to:

• Identify & use the correct material for relevant industrial application. • Know the various types of composites with fibers and fillers • Manufacture different composites using techniques • Test composites used non-destructive testing • Manufacture metal matrix composites and characterize • Characterize composites using sophisticated instruments

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FINITE ELEMENT ANALYSIS (4:0:2)


Course objective:

To learn the basic concepts of FEM & theory of elasticity and apply effectively the FEM method to problems in structural engineering and vibration problems that arises in engineering UNIT I: Introduction to FEM and Theory of Elasticity: Basic procedure of FEM, Theory of Elasticity, and 3D & 2D equations of equilibrium, principle stresses and strains, equations in cylindrical and polar coordinates. Axi symmetric bodies. Strain analysis, stress strain relations and generalized hooks law, plane stress and plane strain problems, and strain energy. 08 Hrs SLE: Theories of failures, Saint Venant’s principle. UNIT II: Basic Concept of FEM: Discreitization of continuum, finite elements, Nodes, DOF, shape functions of 1D, 2D and 3D elements. Higher order elements, linear, quadratic and cubic shape functions, sub parametric, iso-parametric and super parametric concepts. Local and global coordinate system and element characteristics, polynomial function and Pascal triangle. Principle of Potential. Energy and Rayleigh Ritz method. 12 Hrs SLE: Principle of virtual work and Gelarkin method. UNIT III One Dimensional Analysis: Bar elements with linear shape functions – B matrix K matrix – Body force and load vector – Assembly and Boundary conditions – Elimination approach – Solution to overall equation, calculation of stresses and other results, Numerical Problems, Penalty approach, Discussion of Bar element with Quadratic shape function. 10hrs. SLE: Discussion on convergence of finite element solution, characterstics of [K] and computer storage. UNIT IV: Truss Element & Beam Element: Local and Global Coordinate system, Transformation matrix. Stiffness matrix and assembly, stress calculation. Temperature stresses, numerical problems on simple truss structures. Equation of bending, potential energy function,. Simple beam element and DOF – Hermite shape functions – K matrix and load vectors, – shear force and bending moment vectors. 07hrs SLE: Elementary beam theory.

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UNIT V: Two and Three dimensional Analysis: 2 D stress strain relations, constant strain triangle, nodes, DOF, displacement functions – Jacobian and B Matrix, Expression for Ke –Load vectors – stress calculation – temperature effects – Problems, modeling and Boundary conditions – simple problems, Axi-symmetric elements and its applications 3 D stress strain relationship, Shape functions , Jacobin Matrix , K – Matrix , problem Modeling. 07 hrs SLE: Tetrahedral and Hexahedral elements. UNIT VI Dynamic Analysis: Introduction to vibration and Basic definitions. Potential energy and Kinetic energy of vibrating bodies. Lagrangian and Hamilton principle. Equation of motion using Lagrangian operator. Element Mass Matrix for bar element – Truss Element, Eigen value and Eigen vectors, Lumped Mass Matrices, simple problems. 08 hrs SLE: Study the basics of engineering vibration. References:

1. Introduction to Finite Elements in Engg., T.R. Chandrupatla, PhD, P E, Ashok. D. Belegundu, 4th edition 2011.

2. Fundamentals of Finite Elements Method, 2nd Edition, - Dr. S.M.Murigendrappa., International Publication- 2009.

3. A First Course in Finite Element Method, 3rd Edition Dory. L. Logan, University of Wisconsin, Platteville Thamson.

4. Finite Element Method , R.D. Cook , John Willy International, New edition. 5. Introduction to Finite Element Method , Chandrakantha S. Desai, John F.Abel East, West

publication.

Course Outcome: Upon completing this course, the students should be able to:

1. Formulate the three dimensional stress, strain equations using theory of elasticity 2. Evaluate engineering problems by Rayleigh-Ritz method 3. Solve the 1D problem using FEM. 4. Analyze the truss and beam element using FEM 5. Solve the 2D problem by FEM. 6. Formulate the vibration of machine elements and structures using FEM

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ADVANCES IN JOINING OF MATERIALS (4:2:0)


Course objective:

This course will help students to get the advances in the area of metal joining process and the engineering materials used considering both destructive and non-destructive test under various conditions. UNIT 1: Thermal Effects of Welding: Grain size Control, Micro structure control, Internal Stresses, control, Distortion, methods to avoid distortion. Stresses in Joint Design. Welding and Cladding of dissimilar materials, overlaying and surfacing different methods and applications, thermal –Spray coating or metalizing. 08 hrs SLE: Determining stress distribution. UNIT 2: Types of Welding: Forge welding, Electro Slag Welding, Electron Beam Welding, Plasma arc Welding, Laser Beam Welding, Explosion Welding, Diffusion Welding, Ultrasonic Welding, Friction welding. 12 hrs SLE: Thermit welding. UNIT 3: Weldability of metals like stainless steel, Cast iron, Copper, and Aluminium. Advanced soldering and brazing processes-different types. Welding of plastics- different methods. 10 hrs SLE: Weldability of other non-ferrous metals. UNIT 4: Welding design- principles of sound welding design, welding joint design, welding positions, Allowable strength of welds under steady loads, allowable fatigue strength of welds, Design of welds subjected to combined stresses. 08 hrs SLE: Numerical examples. UNIT 5: Welding symbols-Need for representing the welds, Basic weld symbols, location of weld, supplementary symbols, dimensions of weld, examples Adhesive bonding: adhesive materials and properties, non-structural and special adhesives, surface preparation and joint design considerations . 06 hrs SLE: Process capabilities.

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UNIT 6: Inspection of Welds: ASTM standards for testing weldments, Destructive techniques like Tensile, Bend, Nick break, Impact & Hardness. Non Destructive techniques like ‘X’ rays, Ultrasonic, Magnetic particle, Dye penetrant . 08 hrs. SLE: Gamma ray inspection.

References:

1. Welding Engineering Handbook by A.W.S. Ninth Edition 2. Advanced Welding processes – G.Nikolaev & N.Olshansky, MIR Publications 1977. 3. Welding Technology by O.P. Khanna, Dhanpat Rai Publication 2008 4. Welding and welding Technology by Richard Little Tata Mc Graw hill 2005. 5. ASM handbook on welding, brazing and soldering, vol 6, 2005.

Course Outcome:

Upon completing this course, the students should be able to:

• Understand the importance of grain size control, methods to avoid destruction and residual stresses. Also know the techniques of surfacing and cladding of surface

• Interpret and understand the advantages and limitations of different advanced welding process knowing fully the characteristic features, identify research topics in the wear of welding and related processes

• Explain the weld ability of engineering materials and the advanced soldering and brazing processes

• Know the different techniques of welding of plastics • Inspect to welds in accordance with ASTM standards employing both destructive and

non-destructive methods represent the weldment with standard symbols • Design welds for various conditions or loads and explain the method of adhesive bonding

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RESEARCH METHODOLOGY (2:0:0)

Sub Code : MPT0203 CIE : 50% Marks Hrs/Week : 02 SEE : 50% Marks SEE Hrs : 02 Max. Marks: 50 Objectives

To gain insights into scientific research, review of literature, assessing the research trends, basic statistics involved in data presentation and documentation UNIT 1 Introduction to Research Methods Philosophy of Science, Evolutionary Epistemology, Scientific Methods, Hypotheses Generation and Evaluation, Definition and Objectives of Research, Various Steps in Scientific Research, Types of Research; Research Purposes - Research Design - Survey Research - Case Study Research. 05 hrs SLE: Code of Research Ethics UNIT 2 Data Collection and Sampling Design Sources of Data: Primary Data, Secondary Data; Procedure Questionnaire- Survey and Experiments – Design of Survey and Experiments - Sampling Merits and Demerits - Control Observations - Procedures – Sampling Errors. 05 hrs SLE: Selection of appropriate method for data collection UNIT 3 Statistical Modeling and Analysis, Time Series Analysis Probability Distributions, Fundamentals of Statistical Analysis and Inference, Multivariate methods, Concepts of Correlation and Regression, Fundamentals of Time Series Analysis and, Error Analysis. 06 hrs SLE: Spectral Analysis, Applications of Spectral Analysis UNIT4 Descriptive Statistics: Measures of central tendency: Mean , median , mode, Measure of dispersion , kurtosis. 03 hrs SLE: Measures of relationships-covariance, rank correlation. UNIT 5 Evolutionary Algorithms : Introduction to evolutionary algorithms - Fundamentals of Genetic algorithms, Simulated Annealing, Neural Network based optimization. 04 hrs SLE: Optimization of fuzzy systems.

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UNIT 6 Research Reports Structure and Components of Research Report, techniques of interpretation, Types of Report, Layout of Research Report, Mechanism of writing a research report 03 hrs SLE: Precautions of writing reports, Oral presentation Reference Books

1. C.R. Kothari, Research Methodology Methods and Techniques, 2/e, Vishwa Prakashan, 2006.

2. Bendat and Piersol, Random data: Analysis and Measurement Procedures, Wiley Interscience, 2001.

3. Shumway and Stoffer, Time Series Analysis and its Applications, Springer, 2000. 4. Jenkins, G.M., and Watts, D.G., Spectral Analysis and its Applications, Holden Day,

1986. 5. Richard I Levin amp; David S.Rubin, Statistics for Management, 7/e. Pearson

Education, 2005. 6. Donald R. Cooper, Pamela S. Schindler, Business Research Methods, 8/e, Tata

McGraw-Hill Co. Ltd., 2006. 7. Fuzzy Logic with Engg Applications, Timothy J.Ross, Wiley Publications, 2nd Ed[d] 8. Simulated Annealing: Theory and Applications (Mathematics and Its Applications, by

P.J. Van Laarhoven & E.H. Aarts[e] 9. Genetic Algorithms in Search, Optimization, and Machine Learning by David E.

Goldberg

Course Outcome

• Ability to critically evaluate current research and propose possible alternate directions for further work

• Ability to develop hypothesis and interpret data for sampling. • To develop statistical model and analyze the research results. • To use various statistical tools to achieve research parameters. • Ability to comprehend and deal with complex research issues in order to communicate

their scientific results clearly for peer review. • To represent the research data and report generation.

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ELECTIVE III

LEAN MANUFACTURING SYSTEM (3:2:0)


Course Objective:

To learn the concepts of Lean Manufacturing and methods to be adopted for implementing lean practices. Unit 1: Introduction The mass production system – origin of lean production system – necessity – lean revolution in Toyota – systems and systems thinking – basic image of lean production–customer focus – MUDA(waste). SLE: Case study on MURI, MURA and MUDA 08hrs Unit 2: Stability of lean system Standards in the lean system – 5S system – Total Productive Maintenance – standardized work –elements of standardized work – charts to define standardized work – man power reduction – Overall Equipment Efficiency - standardized work and kaizen – common layouts. SLE: Case study on 5S, TPM 08 hrs Unit 3: Standardization of operations: Multi-function workers and job rotation. Improvement activities to reduce work force and increase worker morale foundation for improvements. Just In Time Principles of JIT – JIT system – Kanban – Kanban rules – expanded role of conveyance – production leveling – pull systems – value stream mapping. SLE: Case studies on employee involvement and Value Stream Mapping. 10hrs Unit 4: Shortening of production lead times: reduction of setup times, practical procedures for reducing setup time.

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Jidoka concept – Poka-yoke systems; inspection systems and zone control; types and use of poka-yoke systems; Implementation of jidoka. SLE: Case studies on reduction of cycle time and Poka – Yoke systems 10 hrs Unit 5: Worker Involvement and Systematic Planning Methodology Involvement – activities to support involvement – quality circle activity – kaizen training - suggestion programmes – Hoshin planning system – phases of hoshin planning – lean culture

08 hrs. SLE: Case study on Hoshin Planning Unit 6: Managing lean enterprise: Global enterprises and their benefits. Mini Project on “Application of Lean manufacturing concepts to production /process/product/service industries.” 08 hrs SLE: Case study on managing lean enterprise. Text books:

1. Pascal Dennis, Lean Production Simplified: A Plain-Languge Guide to the World’s Most Powerful Production System, (Second edition), Productivity Press, New York, 2007.

2. Mike Rother and John Shook, Learning to See: Value Stream Mapping to Add Value and Eliminate MUDA, Lean Enterprise Institute, 1999.

References:

1. Production and Operations Management-Chasel Aquilino 2. Toyota production system –An integrated approach to just in time by Yasuhiro Monden

– Engineering aild Management press – Institute of Industrial Engineers Norcross Georgia.

3. Japanese Manufacturing Techniques. The Nine Hidden Lessons by simplicity by Richard Schourberger.

4. Amaldo Hernandez: “Just in Time Manufacturing” PH International. 5. “The Machine that changed the World” by Daniel Roos 6. “Lean thinking” James P.Womack and Daniel T.Jones 7. Jeffrey Liker, The Toyota Way: Fourteen Management Principles from the World’s

Greatest Manufacturer, McGraw Hill, 2004. 8. Taiichi Ohno, Toyota Production System: Beyond Large-Scale Production, Taylor &

Francis, Inc., 1988.

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Course Outcome Upon completing this course, the students should be able to:

• Understand the underlying philosophy of the Toyota Production System. • Know the concepts and implementation of Jidoka and poka-yoke systems. • Discover how to look at one’s own shop floor in terms of lead-time reduction, waste

elimination and material flow. • Develop an understanding of how to manage people in a Lean environment in order

to sustain improvements in production method. • Analyze the different concepts of 5S, 4M etc… to develop organized and standard

operations • Implementing continuous improvement concept and Taylor’s principles

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INDUSTRIAL ROBOTICS (3:0:2)

Sub Code : MPT0414 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Objective: To imbibe in students the concepts, mechanism and controls of robot system for developing robotic program used in manufacturing systems. Unit 1: Fundamental Concepts of Robotics: History, present status and future trends, Robotics. Robot, Definition. Robotics Systems and Robot Anatomy. Resolution, Repeatability and Accuracy of a Manipulator. 08 Hrs SLE: Specification of Robotics. Unit 2: Robot Drives: Power transmission systems and control Robot drive mechanisms, hydraulic-electric-pneumatic drives. Mechanical transmission method – Rotary-to-Rotary motion conversion. Rotary-to-linear motion conversion end effectors – types-gripping problem, Control of Actuators in Robotic Mechanisms. 08 Hrs SLE: Remote Centered compliance Devices Unit 3: Sensors and Intelligent Robots: Sensory devices – Non-optical-Position sensors – Optical position sensors – velocity sensors – proximity sensors: Contact and non-contact type-Touch and slip sensors – Force and Torque Sensors . Computer Vision for Robotics Systems: Robot vision systems – Imaging components – Image representation – Hardware aspects-Picture coding – Object Recognition and Categorization- Visual inspection – software considerations – applications – commercial – Robotic vision systems. 10 Hrs SLE: AI and Robotics. Unit 4 Computer Considerations for Robotic Systems: Computer architecture for robots, hardware, Computational elements in robotic applications – Robot programming – sample programs path planning. 08 Hrs SLE: Robot’s computer system. Unit 5 Transformations and Kinematics: Homogeneous Co-ordinates – Co-ordinate Reference Frames – Homogeneous Transformations for the manipulator – the forward and inverse problems

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of manipulator kinematics – Motion generation – Euler’s angles representation: Links, joints and their parameters. 08 Hrs SLE: D.H.Matrices. Unit 6 Robot Cell Design and Control: Specifications of Commerical Robots – Robot Design and Process specifications – motor selection in the design of a robotic joint – Robot Cell layouts – Economic and Social aspects of robotics. Applications of Robots: Capabilities of Robots – Robotics Applications – Obstacle avoidance – Robotics in India. 10 Hrs SLE: The future of Robotics. References:

1. Robotics Engineering An integrated approach - Richard D Klafter, Thomas A Chmielewski, Michael Negin – Prentice Hall of India Pvt. Ltd. - Eastern Economy Edition, 1989.

2. Robotics: Control Sensing, Vision, intelligence - Fu KS Gomaler R C, Lee C S G - McGraw Hill Book Co. - 1987.

3. Handbook of Industrial Robotics - Shuman Y. Nof - John Wiley & Sons, New York - 1985.

4. Robotics Technology and Flexible Automation - Deb SR - McGraw Hill BookCo. - 1994.


• Know the fundamentals of robotic system • Understand the various drive system involved in robots • Understand the importance of sensors and computer vision for robotic system • Understand different programming methods and various languages of robots • Get familiar with the kinematic motions of robot • Write the program for the robot • Apply design of robots and cell layouts

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DESIGN OF EXPERIMENTS AND ROBUST DESIGN (3:0:2)


Course Objective:

Students will be able to understand analysis of data, do mathematical modeling using statistical tools and plot charts, and also develop mathematical model. UNIT 1 Introduction: Need for statistical DOE, Terminologies used in DOE; Normal Distribution, t- Distribution and F-Distribution, Confidence Intervals, Hypothesis Tests 08 hrs SLE: Review of Statistics UNIT 2 Experimental Design Strategies-1: Single factor Experiments, Factorial Experiments; 2k

designs, Blocking and Confounding in 2k design, Introduction to DOE softwares, Factor Effects, Measures of Variability, Probability plots. 08 hrs SLE: Factor Effect Plots UNIT 3 Analysis of Data and Mathematical Modeling: Introduction to statistical Analysis softwares, Analysis of variance (ANOVA) in factorial experiments, YATE’s algorithm for ANOVA, Mathematical models from experimental data, illustration through numerical examples. 10 hrs SLE: Regression analysis UNIT 4 Experimental Design Strategies: Fractional Factorial Design, 3k designs, Response Surface Design, Development of mathematical models 08hrs SLE: Analysis of Experimental data UNIT 5 Introduction to Taguchi Techniques: Quality Loss function, Estimation of Quality loss,; Nominal-the-better, smaller-the-better and larger-the-better, Robust design concepts; System Design, Parameter Design, Tolerance Design, S-N Ratio, Illustrations through numerical examples 08hrs SLE: Types of Quality characteristics

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UNIT 6 DOE using Taguchi’s Orthogonal Arrays: Types of orthogonal arrays, Selection of standard orthogonal arrays, Linear graphs and interaction assignment, Signal to Noise ratio (S-N Ratios); Evaluation of sensitivity to noise, D e t e r m i n a t i o n o f Signal to noise ratios, Determination of optimum values of factor levels, Grey relational analysis for multi-response evaluation, Illustrations through numerical examples. 10hrs SLE: Different Strategies for constructing orthogonal arrays. Text Books:

1. Quality Engineering using Robust Design - Madhav S. Phadake: Prentice Hall, Englewood Clifts, New Jersey 07632, 1989.

2. Design and analysis of experiments - Douglas Montgomery: Willey India Pvt. Ltd., V Ed., 2007. 3. Techniques for Quality Engineering - Phillip J. Ross: Taguchi 2nd edition.

McGraw Hill Int. Ed., 1996. Reference Books:

1. Quality by Experimental Design - Thomas B. Barker : Marcel Dekker Inc ASQC Quality Press, 1985

2. Experiments planning, analysis and parameter design optimization - C.F. Jeff Wu, Michael Hamada: John Willey Ed., 2002.

3. Reliability improvement by Experiments - W.L. Condra, Marcel Dekker: Marcel Dekker Inc ASQC Quality Press, 1985

Course Outcome:

On successful completion of the course the student will able to: • Do hypothesis testing for the given data • Draw probability charts • Use statistical tools and apply ANOVA • Develop different mathematical models • Understand and apply Taguchi concepts and check for robust design • Select and apply orthogonal arrays

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JIGS & FIXTURES (3:2:0)

Sub Code : MPT0416 CIE : 50% Marks Hrs/Week : 05 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Objectives: Able to learn the economics approach of designing JIGS and Fixtures and different locating systems Unit 1: Introduction: Production equipment. The economics approach to the provision of special equipment. The design of jigs and fixtures; principles of jig and fixture design, construction methods and materials used. 07 hrs SLE: The function and organization of the jig office Unit 2: Definition of Jigs & fixtures, differences between Jigs & Fixtures, principles of Jigs & Fixtures, advantages. 07 hrs SLE: Applications Unit 3: Principles of Location, Six degrees of freedom, Duty of the location system, Choice of location system ,Redundant location , 3-2-1 Location, Types and methods of location. Principles of clamping, Requirements of the clamping system, Position of the clamps, Design of clamps, Types of clamps, Cam clamp, Toggle clamp. 10 hrs SLE: Equalizing clamp, latch clamp Unit 4 Guiding elements: Introduction, Guiding the tools, Types of drill bushes. Work holding devices: vice, ‘V’ Block, Magnetic chuck, Mandrels, Vacuum chucking and 10 hrs SLE: Electro static chuck. Unit 5 Types of Jigs & Fixtures: Like plate Jig, Box Jig, Leaf Jig, Channel Jig 08 hrs SLE: Latch Jig. Unit 6 Simple Milling fixtures: for straddle milling, string Milling, Pendulum Milling. Simple Grinding & Turning fixtures: Indexing methods, design with reference to costs and method of manufacture. 10 hrs SLE: Economical aspects of Jigs & Fixture

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References:

1. Introduction to Jigs & Tool Design by Henry.C.Mishkoff, BPB Publications, New Delhi, 2. Jigs & Fixtures by P.H.Joshi, Tata Mc Graw Hill,2010 3. Introduction to Jig and Tool Design 3rd edition by M.H.A Kempster,2004, ,VIVA

Publisher ISBN-97881856


• Know the economics of special equipment used in jigs and fixtures • Understand the principles of jigs and fixtures • Use different location system for clamping • Select different work holding devices • Use different types of jigs and fixtures • Index milling and grinding fixtures

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MODELING & SIMULATION OF MANUFACTURING SYSTEMS (3:2:0)


Course objectives: Will make students learn modeling and simulation techniques, use of different distribution and able to design simulation experiment Unit 1: Principle of Computer Modeling and Simulation: Monte Carlo simulation. Nature of computer- modeling and simulation. Limitations of simulation. 07 Hrs SLE: Areas of applications Unit 2 System and Environment: Components of a system -discrete and continuous systems, Models of a system -a variety of modeling approaches. Discrete Event Simulation: Concepts in discrete event simulation, manual simulation using event scheduling, two server queue, simulation of inventory problem.

10 Hrs SLE: Single channel queue

Unit 3: Statistical Models in Simulation: Discrete distributions, continuous distributions. Random Number Generation: Techniques for generating random numbers- Mid square method -the mod product method -Constant multiplier technique -Additive congruential method -Linear congruential method -Tests for random numbers -The Kolmogorov-Smimov test -the. Ulfaskluna and Annita borsen Dohlgvist Publisher Artechhouse. 12Hrs SLE: Chi-square test Unit 4: Random Variable Generation: Inversion transforms technique-exponential distribution. Uniform distribution, weibull distribution, continuous distribution, generating approximate normal variates. 08 Hrs SLE: Erlang distribution Unit 5: Empirical Discrete Distribution: Discrete uniform -distribution poisson distribution -geometric distribution -acceptance -rejection technique for Poisson distribution. 07 Hrs SLE: Gamma distribution

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Unit 6 Design and Evaluation of Simulation Experiments: variance reduction techniques -antithetic variables, variables-verification. Simulation Software: Selection of simulation software, simulation packages. 08 Hrs SLE: Validation of simulation models. References:

1. Discrete Event System Simulation - Jerry Banks & .John S Carson II - Prentice Hall Inc.-1984.

2. Systems Simulation - Gordan. G. - Prentice Hall India Ltd - 2004. 3. System Simulation with Digital Computer - Nusing Deo - Prentice Hall of India -

1979. 4. Computer Simulation and Modeling - Francis Neelamkovil - John Wilely & Sons -

1987. 5. Simulation Modeling with Pascal - Rath M.Davis & Robert M O Keefe - Prentice Hall

Inc. - 1989.


• Learn the strengths and weaknesses of different approaches, giving them a foundation for selecting methodologies and software that are appropriate for different classes of problems.

• Introduce to the different technologies used to develop make decisions where there is uncertainty.

• Understand various human decision-making approaches: intuition, analysis, consensus, guessing, etc.

• Use different distributions • Learn Poisson distribution and its applications • Design variance distribution

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ELECTIVE IV

SURFACE TREATMENT AND FINISHING (3:2:0)

Sub Code : MPT 0418 CIE : 50% Marks Hrs/Week : 05 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course objective: Students will be able to learn different surface treatment technique of metals and non-metals. Unit 1: Information on the Surface Treatment of Metals and Plastics: Industries using surface treatments, Industry structure and economic background, Specific industry activities, other emissions. 08 Hrs SLE: Key environmental issues Unit 2 Surface preparation and pre treatment: Objective of surface preparation and the phenomena, mechanical surface preparation, flame cleaning, blast cleaning etc. chemical surface preparation, solvent wiping and degreasing, alkali cleaning, emulsifiable solvent cleaning, steam cleaning, acid cleaning, pickling, phosphoric acid. 08 Hrs SLE: Electrolytic pickling. Unit 3 Fundamentals of Electroplating: Galvanizing, Hot dip metal coating, Tin coating, Chromium plating, Nickel Plating. Vacuum coating: PVD & CVD Metal spraying,-Methods, Surface preparation, Mechanical properties of sprayed metals, plasma coating. 08 Hrs SLE: DLC and carbide coating (Diamond like coating). Unit 4 Plastic coating of Metals: Pretreatment of plastics (etching) Conditioning of plastics. Etching or pickling of plastic, PVC coating, spherodising Process details, phosphate coating, Mechanism of formation. 08 Hrs SLE: Electro plating of Plastics. Unit 5 Testing of surface coating methods. Heat treatment methods: Annealing, Normalizing, Tempering, Case hardening methods, Flame Hardening, sub zero treatment. Quench polish Quench (QPQ) and Plasma Nitriding. 10 Hrs SLE: Anodizing.

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Unit 6 Heat treatment methods: for gears, spindles, cutting tools. Advanced Coating Technologies: Hard facing, Electro deposition technique. 07 Hrs SLE: Nano coatings, coating characterization. References:

1. Surface Preparations & Finishes for metals, James A Murphy Mc.Graw Hill. 2. Principles of Metal surface treatment and protection, Pergamon press-Gabe, David

Russell. 3. Handbook of metal treatment and testing-John wiley & Sons. 4. Heat treatment of metals by Zakrov, MIR publications. 5. Metal handbook – ASM. 1993 6. Integrated pollution Prevention and control, reference document on best available

techniques for the “Surface treatment of metals and plastics” Aug 2006 ,European commission report.


• Get exposure different Surface treatment methods • Identify factors influencing surface treatments • Select appropriate surface treatment process • Differentiate metals and non-metals adapted for different surface treatment method • Review different surface coating techniques • To analyze advanced coating technologies

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NON DESTRUCTIVE TESTING (3:2:0)

Sub Code : MPT0419 CIE : 50% Marks Hrs/Week : 05 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course objectives: Students will get an insight on different non-destructive testing techniques and application in various industries Unit 1: Introduction to ND testing: selection of ND methods, leak testing, Liquid penetration inspection, its advantages and limitation. 08Hrs SLE: Visual inspection Unit 2: Magnetic particle inspection: Methods of generating magnetic field, types of magnetic particles and suspension liquids steps in inspection 08Hrs SLE: Application and limitations Unit 3: Eddy current inspection: Principles, operation variables, procedure, inspection coils, and detectable discontinuities by the method. . 12Hrs SLE: Microwave inspection: Microwave holography, applications and limitations Unit 4: Ultrasonic inspection: Basic equipment characteristics of ultrasonic waves, variables inspection, inspection methods pulse echo A,B,C scans transmission, resonance techniques, transducer elements couplants, search units, contact types and immersion types inspection standards 10 Hrs SLE: Standard reference blocks Unit 5: Radiography inspection: Principles, Radiation sources- X-rays and gamma rays, X-ray tube, radio graphic films, neutron radiography, equipment inspection methods applications. 10 Hrs SLE: Thermal inspection principles Unit 6: Optical Holography: Basics of Holography, recording and reconstruction - Acoustical Holography: systems and techniques applications. 06 Hrs SLE: Indian standards for NDT.

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References: 1. Mc Gonnagle JJ” Non Destructive testing” – Garden and reach New York 2. Non destructive Evolution and quality control” volume 17 of metals hand book 9 edition 1989 3. Davis H.E Troxel G.E wiskovil C.T the Testing instruction of Engineering materials” Mc graw hill.


1. Know the basic concepts of NDT. 2. Detect discontinuities using magnetic particle inspection techniques. 3. Use the principles of eddy current inspection for the detection of discontinuities. 4. Learn the concepts of ultrasonic inspection by different methods for the detection of

defects. 5. Evaluate the defects using radiography and its techniques 6. Understand the concepts of optical holography for the detection of defects by using

different methods.

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ADVANCED OPERATIONS RESEARCH (3:2:0)

Sub Code : MPT 0420 CIE : 50% Marks Hrs/Week : 05 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Objectives:

The student will get experience in modeling, solving and analyzing problems using operations research models. Emphasis will be stressed on theory, applications and computer usage, solve and interpret the models and infer solutions to the real world problems. Unit-1 Basics of Operations Research: Origin, art of modeling, phases of OR, applications. Linear Programming: Formulation, graphical solution, simplex method, duality, dual simplex method. Assignment model, Transportation model 10 Hrs SLE: Degeneracy problem, multiple solution problems. Unit-2 Integer Programming: Definition, classification, Gomory’s cutting plane method. 08 Hrs SLE: Branch and bound method Unit-3 Dynamic Programming: Introduction features and characteristics, recursive equation, Bellman’s principle, minimum path problem, cargo loading problem, reliability problem. 08 Hrs SLE: Capital budgeting problem. Unit-4 Markov Analysis: Markov process, state transition matrix, tree diagram, steady state condition, Markov analysis algorithm. Waiting line model: Introduction, terminology, Queuing system, queuing models, multi-channel queues. 10Hrs SLE: Birth and death process derivations Unit-5 Simulation: Introduction, uses of simulation, simulation terminology, Monte-Carlo simulation, generation of random numbers, typical problems. 08 Hrs SLE: Simulation languages

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Unit-6 Replacement Model: Introduction, replacement policies for item that deteriorate without change in money value, with change in money value, items that fail completely, group replacement. 08 Hrs SLE: Staffing problems References

1. Taha H.A-Operations Research, Mc Millan. 2. Philips, Ravindran and Soleberg-principles of Operations Research-Theory and Practice,

PHI 3. S.D. Sharma – Operations Research, Kedarnath, Ramnath & Co. 4. Hiller and Liberman – introduction to Operations Research, McGraw Hill 5. Kanthi swarup – Operations Research, Sultanchand and sons.

Course Outcome:

On successful completion of the course, the students will be able to: 1. Understand the mathematical tools that are needed to solve optimization problems. 2. Explain clearly basic concepts of linear and integer programming. 3. Solve a practical problem multi-stage recourse problems 4. Solve problems under uncertain conditions using simulation models 5. Formulate real-life applications in terms of appropriate Markov chain stochastic models

of operations research 6. Formulation of the most economic replacement policy which is in the interest of the

system

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FAILURE MECHANICS AND ANALYSIS (3:2:0)

Sub Code : MPT 0421 CIE : 50% Marks Hrs/Week : 05 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100

Course objective: To make aware of different failure modes in Engineering components and to take suitable remedial actions. Unit 1 Fundamental causes of failure of materials 08 Hrs SLE: Modes of failure Unit 2 Classifications of failure: Instantaneous Damage and cumulative damage, Failure patterns and distributions, failure data Analysis, Objective of failure analysis, step by step procedure for metallurgical failure analysis. Tools of Metallurgical failure analysis, Principles of Optical Microscopy and Scanning Electron Microscopy 10 Hrs SLE: Principles of Transmission Electron Microscopy. Unit 3 Ductile and brittle fracture, micro mechanism of fracture, Fundamental of crack propagation. Corrosion failure, Wear failures, fretting failure high temperature failures, creep and stress ruptures. 08 Hrs SLE: Environment induced fractures Unit 4 Plain bearing failure of friction surfaces. Gear failures-failure of friction surface 08 Hrs SLE: Seal failures Unit 5 Shaft failure, Failure of pressure vessels 10 Hrs

SLE: Case studies

Unit 6

Failure detection methods 08 Hrs

SLE: Case studies

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References: 1. Kh.B. Krdonsity, “Models of failure”, Springer Verlag – 1969. 2. L.F.Pau “Failure Diagnosis and performance monitoring”, Marcel Dekker Inc. 3. “Lubrication and wear”, the institution of Mechanical Engineering. 4. H.P. Garg “Industrial Maintenance


• .Identify various types of failures encountered in real life situation. • Analyze the failures using step by step procedure • Analyze various modes of failures in materials. • Understand the types of failures in bearings and gears. • Know the failure modes in shafts and pressure vessels.

Use sophisticated metallurgical instruments for the analysis of failures

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PRINCIPLES OF RELIABILITY ENGINEERING (3:2:0) Sub Code : MPT 675 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Objective:

Students will learn the aspects of reliability engineering, reliability models, prediction, data analysis, design, maintenance and management. Unit 1: Introduction: What is reliability engineering? Why teach reliability engineering? Why do engineering items fail? Probabilistic reliability, Repairable and non repairable items, Reliability Program activities, Reliability Economics and Management, The development of reliability engineering, The study of reliability and maintainability, Concepts, terms and definitions, Applications. Time dependent failure models: The Weibull distribution, Normal distribution, The Log Normal distribution. Component life models: (Basic Reliability Models) Failure distribution: The reliability function, Mean time to failure, Hazard rate function, Hazard rate function, Bathtub curve, Conditional reliability Constant failure rate model: The exponential reliability function, Failure modes, Applications, The Two Parameter Exponential distribution, Poisson process, Redundancy and CFR model exercises 10 Hrs SLE: Organizations involved in reliability work Unit 2: Reliability prediction and modelling: Reliability of Systems, Serial Configuration, Parallel Configuration, Combined Series-Parallel system, Block Diagram analysis, States Dependent systems, System structure function, Minimal cuts and Minimal paths. Common mode failure, Three state devices, State space analysis (Markov analysis), Load sharing systems, Standby systems, B Graded systems, Reliability Apportionment, Fundamental Limitations of Reliability Prediction, Reliability Databases, Modular Design 08 hrs SLE: Fault Tree Analysis (FTA), Petri nets Unit 3: Failure Data Analysis: Data Collection, Empirical Methods, Static Life Estimation, Product Testing, Reliability Life Testing, Test Time Calculations, Burn-In Testing, Acceptance Testing, Accelerated Life Testing, Experimental Design, Competing Failure Modes, Identifying Candidate Distributions, Parameter Estimation for Covariate Models, Accelerated Test Data Analysis, Reliability Analysis of Repairable Systems, Reliability Demonstration. 08Hrs SLE: Reliability Growth Monitoring.

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Unit 4: Design for reliability: Computer Aided Engineering (CAE), Environment, Reliability specification and systems measurement, Reliability allocation, Design methods, Failure analysis, Load strength analysis (LSA), Failure modes, Effects and critical analysis, Hazard and operability study (HAZOPS), Human reliability, Design analysis for processes, Critical Item list, Management of Design review, Parts Materials and Process (PMP) Review. Physical reliability models: Distributed load and strength, Analysis of Load Strength Interferences, Effect of Safety Margin and Loading Roughness on Reliability. Covariate models, Static Models, Dynamic Models , Mechanical Stress, Strength, Fracture, Fatigue, Creep, Wear, Corrosion, Reliability of Electronic components, Circuit and system aspects, Electronic system reliability prediction, Reliability in electronic system design, Software in engineering systems, Software Errors, Preventing errors. 10 Hrs SLE: Software structure and modularity, Data reliability, Software checking, Software design analysis methods Unit 5: Maintainability Maintenance and Availability: Analysis of Downtime, The repair-time Distribution, Stochastic Point Processes, System Repair Time, Reliability Under Preventive Maintenance, Maintenance Time Distributions, Preventive Maintenance Strategy, FMECA and FTA in Maintenance Planning, Maintainability Prediction, Maintainability Demonstration, Maintenance Requirements, Design Methods, Human Factors and Ergonomics, Maintenance and Spares Provisioning, Maintainability Prediction and Demonstration. Availability Concept and Definitions,ExponentialAvailabilityModel,SystemAvailability. 08 Hrs SLE: Inspection and Repair Availability Model, Design Trade-off Analysis. Unit 6: Reliability Management: Corporate Policy for Reliability, Integrated Reliability Programmes, Reliability and Costs, Safety and Product Liability, Standards for Reliability, Quality and Safety, Specifying Reliability, Contracting for Reliability Achievement, Managing Lower–level Suppliers, The Reliability Manual, The Project Reliability Plan, Use of External Services, Customer Management of Reliability, Selecting and Training for Reliability, Organization for Reliability, Managing Production Quality, Quality Audit, Quality Management Approaches. 08 Hrs SLE: Case Studies on Reliability, Availability and Maintainability Analysis Reference Books:

1. Charles E. Ebling, An Introduction to Reliability and Maintainability Engineering, Tata McGraw Hill MLM1004, 2000, ISBN: 007 0421382.

2. Patrick D.T. Oconnor, etal - Practical Reliability Engineering, John Wiley and Sons, 2002, 4th Edition, ISBN: 9812-53-045-2

3. Dr. E. Balaguru Swamy – Reliability Engineering, McGraw Hill, 2003, 4th Edition 4. L.S. Srinath, Reliability Engineering, Affiliated East West Press Pvt Ltd, 1991, 3rd

Edition, ISBN: 81 85336393

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Course Outcome: • Insight into reliability management concepts • A clear understanding of various reliability models and their applications. • Enhanced ability to design systems and processes for reliability. • Understand the failure data and modeling. • Design static and dynamic models for reliability. • Proficiency in utilizing various tools available in reliability engineering to model

and predict reliability.

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