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1
2014
EDITED BY: Mech. Engg. Deptt
SGI SAMALKHA
HELPING HAND FOR ME 7th SEM
2
Academic Calendar (Session August – December 2014)
B. Tech. S. No. Details Date
1. Revision Exercise before 1st sessional Exams - 3rd – 4th October, 2014 (Thursday to Saturday)
2. 1st Sessional Exams (One and half Units) - 7th -10th October, 2014 (Tuesday to Friday)
3. 1st Sessonal Result - 15th October, 2014 (Wednesday)
4. Revision Exercise before 2nd sessional Exams - 7th to 8th November, 2014 (Thursday to Saturday)
5. 2nd Sessional Exams (Next one & half Units) - 10th – 13th November, 2014 (Monday to Thursday)
6. 2nd Sessonal Result - 18th November, 2014 (Tuesday)
7. 3rd Sessional (In class Room)(Full Syllabus) - 01st – 4th December, 2014 (Monday to Thursday)
M. Tech. (CSE, ECE, EEE, CE & ME) S. No. Details Date
1. 1st Sessional Examination - 17-18th October, 2014 (Friday-Saturday)
2. 2nd Sessional Examination - 28-29th November, 2014 (Friday-Saturday)
BBA & MBA S. No. Details Date
1. 1st Sessional Examination - 7th-14th October,2014 (Tuesday to Tuesday)
2. 2nd Sessional Examination - 10th – 17th November, 2014 (Monday to Monday)
Fresher’s Party Schedule
S. No. Department Venue Date
1. C. S. E. SH1/A2 Block 20th September, 2014 (Saturday)
2. E. C. E. & E. E. E. SH1/A2 Block 27th September, 2014 (Saturday)
3. M. B. A. and B. B. A. SH1/A2 Block 18th October, 2014 (Saturday)
4. M. E. & M.E. (Auto) SH1/A2 Block 15th November, 2014 (Saturday)
5. C. E. and Aero. Engg. SH1/A2 Block 22nd November, 2014 (Saturday)
3
List of Pending Holidays in Session 2014-15 (Odd Semester)
S. No. Name of Holiday Date Day of the week
1 Raksha Bandhan 10th August SUNDAY
2 Independence Day 15th August FRIDAY
3 Janmashtmi 18th August MONDAY
4 Mahatma Gandhi Birthday 2nd October THURSDAY
5 Dusshera 3rd October FRIDAY
6 Id-ul-Zuha(Bakrid) 6th October MONDAY
7 Diwali 23rd October THURSDAY
8 Vishwa Karma Day 24th October FRIDAY
9 Haryana Day 1st November SATURDAY
10 Guru Nanak Birthday 6th November THURSDAY
11 Christmas Day 25th December THURSDAY
TABLE OF CONTENT
CONTENT
PAGE NO Scheme of Examination 3
Automobile Engineering Lecture Plan 4-5
Automobile Engineering Syllabus 6-7
Automobile Engineering Assignments 8-15
Measurement and control Lecture Plan 16-17
Measurement and control Syllabus 18-19
Measurement and control Assignments 20-27
Advanced Manufacturing Technology Lecture Plan 28-29
Advanced Manufacturing Technology Syllabus 30-31
Advanced Manufacturing Technology Assignments 32-39
Maintenance Engineering Lecture Plan 40-43
Maintenance Engineering Syllabus 44-45
4
Maintenance Engineering Assignments 46-53
Statistical Quality Control & Reliability Lecture Plan 54-56
Statistical Quality Control & Reliability Syllabus 57
Statistical Quality Control & Reliability Assignments 58-65
LABS CURRICULUM Measurment (PR) 66 Project-1 Seminar In plant Training Report
67
68
69
5
MECHANICAL ENGINNERING
B.TECH 7TH
SEMESTER
(SCHEME OF EXAMINATION) Scheme of Examination
B. Tech 7th
Sem (Mechanical Engineering)
Teaching Schedule Examination Schedule (Marks)
Duration
S. Subjects Name Code
(Hrs) Total of Exam
No
Marks (Hrs)
L T P/D Total Sessional Theory Practical/
viva-voce
1 Automobile Engineering ME 401 E 4 1 --- 5 50 100 --- 150 3
2 Measurement and control ME 403 E 50 100 --- 150 3
3
Advanced Manufacturing
Technology ME 419E 50 100 --- 150 3
4 Maintenance Engineering ME- 437E 3 1 --- 4 50 100 --- 150 3
5 Statistical Quality Control &
ME 405 E 4 1 --- 5 50 100 --- 150 3
Reliability
6 Measurement (PR) ME 407 E - - 2 2 50 --- 50 100 3
7 Project-1 ME 409 E --- --- 7 7 100 --- 100 200 3
8 Seminar ME 411 E 2 - - 2 - --- --- --- -----
9 In plant Training Report ME 413 E --- --- - - 125 --- --- 125 ---
Total 21 05 9 35 525 500 150 1175
Note: Students will be allowed to use Non-Programmable scientific calculator. However, sharing of calculator will not be permitted.
Duration of theory as well as practical exams time is three hrs for all courses.
6
LECTURE SCHEDULE OF AUTOMOBLIE ENGINERING
S. No. TOPICS
No. of
Lectures References
1.
POWER GENERATION Introduction,,Engine Balancing; Mechnical Balance,Power
Balance and Importance,Use of multicylinder engines ;
Power overlap ;power flow charts,Firing order,Valve timing
Diagram ;Valve overlap and its importance;Review of Engine
side;Ratingb of engines;Performance curves.
5 R3,R1,R2
2. TRANSMISSION
Basic requirements of transmission system
(a) Clutch: Requirement and types of clutches,Principle
of friction clutch;torque transmitted cone
clutch;single plate clutch ; Multiplate clutch: clutch
lining;Bonded material;Automatic clutch
action;Centrifugal clutches;Electromagnetic
clutch;Fluid Flywheel.
(b) Gear Box: Object of gear box;Air of wing resistance
;Gradient resistance ; rolling resistance;Tactive
Effort;Variation of trativer effort with variation of
speed,Perfoemce curves,Types of grear box,Sliding
mesh and Constant Mech type;Control Mechanism
of synchromesh devices;Automatic gear
boxes;Toroque convertor withdirect
drives;Lubrication of gear box.
(c) Propeller Shaft: Requirements;Constant Velocity
Joint,Torque tube Deive and Hotch Kiss Drive
(d) Differential: Basic requirement and Priciple of
operation ,Construction of Differentials; Differential
Lock.
(e) Axle: Live and Dead axle; rear axle types,semi
floating,Three quarter floating and fully floating.
16
5
5
1
3
2
T1
T1,T2
T1
R3
T1
3. Running System:
Wheels,Rims and tyres:Functions of a tyres,Constructional
Detail.
Brakes Functions and Methodsof operation;Types of
Barkes,Hydraulic Brakes;air brakes ,Constructional Details
and Brake Efficiency.
5
2
3
T1
7
4. Suspension System:
Objectxs of suspension ;Basic Requirements,Types of
suspension system;Rigid suspension,Indipendent
suspension,Shock absorber
4
T1
5. Steering:
Front axle;Stube axle,steering geometry,casto camber,King
pin inclination,Conbined angle ,Toe in,Fundamental
condition of correct steering ;Steering Linkages,ackerman
Linkages;Steering Ratio;Reversibilty,Steering gears,Under
steer and over steer
4
T1
6. General:
Lubrication snd cooling of automobiles;Vehicle Testing and
trouble shooting charts,Stability of Vehicles , Future Trends
In automobiles
5
T1
Note: T- Text Book; R- Reference Book.
Text Book:-
1. Automobile Engineering Vol1 & 2 By Kirpal Singh
2 Auotmobile Engineering By R.P Sharma
3 Auotmobile Engineering Vol1 & 2 By K.M Gupta
Reference Books:
1. Automobile Mechanics By Srinivasan
2. I.C Engines By Mathur and Sharma
3. Motor Vehicle By Newton and Steeds
8
B. Tech (Seventh Semester) Mechanical Engineering Automobile Engineering
ME 401 E L T P/D Total. Theory : 100 marks 4 1 5 Sessional : 50 marks
Duration of Exams. : 03 hours
NOTE: In the semester examination, the paper setter will set 8 questions in all, at least
two questions from each unit, and students will be required to attempt only 5 questions,
selecting at least one from each unit.
UNIT I
Brief history of automobiles, Main components of an automobile, Brief description of
each component Brief description of constructional details and working of a four stroke I.C. Engine (S.I.
Engines and C.I. Engines) including lately developed overhead cam shaft, Multi-cylinder
engines, Introduction to recent developments in I.C. Engines- Direct injection systems,
Multi-point fuel injection systems, Microprocessor based fuel supply systems, Multi valve
engines, Mechanical balancing, Firing Order, Power balancing, Power overlap, Power flow
charts.
Introduction, Brief description of different components of Transmission System.
Clutch Introduction to Clutch and its different types, Principle of Friction Clutch, Clutch Lining and friction materials used in Friction Clutches, Torque transmitted, Brief
description of Cone Clutch, Single Plate and Multiplate Clutches, Dry and wet
clutches, Automatic clutch action, Centrifugal clutches, Electromagnetic clutches,
Fluid Flywheel.
UNIT II
Gear Box
Air resistance, gradient resistance and rolling resistance coming across a moving automobile,
Tractive effort, Variation of tractive effort with speed, Performance curves (object and need
of a gear box), Sliding mesh gear box, Control mechanism, Sliding type selector mechanism,
Ball type selector mechanism, Steering column gear shift control, Constant mesh gear box,
Synchromesh device, Automatic transmission in general, AP automatic gear box, Torque
converter, Torque converter with direct drive, Lubrication of Gear Box.
Propeller Shaft:
Functions and requirements of a propeller shaft, Universal joints, Constructional forms of
universal joints, Flexible-ring joints, Rubber-bushed flexible joints. Constant-velocity joints.
Differential: Principle of operation, Constructional details of a typical Differential unit, Traction control
differentials, Multi-plate clutch type
traction control device, The back axle:
Live back axles, The final drive, Single reduction live axles Torque reaction, Driving
thrust, Torque and thrust member arrangements Springs serving as torque and thrust
member, Hotchkiss Drive with torque reaction member, Single combined torque-
thrust reaction member, with springs taking only vertical and lateral loads
9
UNIT III Running System Wheels and rims, Tyre-its function and constructional details.
Brakes: Functions and methods of operation, Brake efficiency. Elementary theory of shoe brake,
brake shoe adjustments, A modern rear-wheel brake, Disc brakes, Brake linkages, Leverage
and adjustment of the brake linkage, Servo- and power-operated brakes, Vacuum brake
operation,' Hydraulic Brakes-constructional details and working, Bendix Hydrovac, Direct-
action vacuum servos, Power-operated brakes, A dual power air brake system,
Suspension system Suspension principles, Road irregularities and human susceptibility, Suspension system,
Damping, Double tube damper, Single tube damper, Lever arm type damper, Springs-Leaf
springs, Coil and torsion springs, variable rate springs, Composite leaf springs, Rubber
springs, Air springs, Adjustable and self-adjusting suspensions, Interconnected suspension
system, Interconnected air and liquid suspensions, Independent suspension system, Different
independent suspension layouts, McPherson strut type, Rear suspension-live axle,
McPherson strut rear suspension. UNIT IV
Steering Mechanism Steering geometry, Castor, Camber, Kingpin inclination, Combined angle, Toe-in, Steering
system-basic aims, Ackerman linkage, Steering linkages for independent suspension, Center
point steering, Costarring or trailing action, Cornering power, Self-righting torque, Steering
characteristics-over steer and under steer, Axle beam, Stub-axle construction, Steering
column, Reversible and irreversible steering, Rack-and-pinion steering mechanism, Effect of
toe-in on steering, Power steering, Vickers System. Recent trends in automobile engineering Multi fuel automobiles, Automobiles running on alternate sources of energy, Emission
control through catalytic converter, Double catalytic converter, Aspects of pollution control
in Automobiles. Reference and Text Books:
1. The Motor Vehicle - By Newton, Steeds and Garretle Basic 2. Automobile Engineering - By Kirpal Singh
3. Automobile Engineering -By K.M. Gupta, Umesh Publications
4. Automotive Mechanics -Grouse
10
ASSIGNMENT 1
Q.1 Write short notes on the following:-
1. Multi point fuel injection system
2. Firing order (BT-7/DX)
Q.2 (a) what is an I.C engine? How these engines areclassified?
(b) Explain with the neat sketch of fuel injection system being used in Maruti 800 car?
(c)Differentiate single cylinder engine and multiple cylinder engines? (BT-7/11)
Q.3 brieflydescribes the constructional details and working of four stroke diesel engine.
How modern C.I engine differ from 80’s engines. Enumerate the improvements in last thirty
years
(BT-7/DO8)
Q.4 Explain in brief the following terms:
A. Multi point fuel injection system
B. Multi cylinder engines
(BT-7/M-11)
Q.5 Briefly describes the constructional details and working of four stroke petrol engine with
help of neat and clean sketch.
(BT-7/M-10)
Q.6 Differentiates b/w S.I and C.I Engines? Explain in details with working
(BT-7/DO9)
11
ASSIGNMENT 2
Q.1 describes the following type clutches:
a. Cone clutch
b. Multiplate clutch (BT-7/M-
11)
Q.2 What is the function of clutch. List different type of clutches. Briefly describe single
plate clutch. How does it differ from multi plate clutch?
(BT-7/11)
Q.3 Compares wet and dry type of friction clutches. Where and why do we use multi plate
clutches. How those are different from single plate clutches. Explain the constructional
features of multi plate dry clutch.
(BT-7/DO8)
Q.4 Explain the construction, working, advantages and disadvantages of a centrifugal clutch.
(BT-7/DX)
Q.5 Differentiates b/w single plate and multi plate clutch? Explain with neat sketch and
explain about wet and dry clutch?
(BT-7/DO9)
Q.6 Explain the constructional features of single point clutch wit neat diagram (BT-7/10)
12
ASSIGNMENT 3
Q.1 (a) Describe the principle of torque convertor. Discuss its advantages and disadvantages.
(b)Describe the working of sliding mesh type of gear box. Also write advantages of
constant mesh gear box over the sliding mesh type. (BT-7/DO8)
Q.2 why gear box is required in automobiles? Briefly describe a sliding mesh gear box with
neat sketch. How does it differ from constant mesh gear box?
(BT-7/11)
Q.3 Explain the working and construction of the following:
a) Constant mesh gear box
b) Torque convertor (BT-7/DX)
Q.4 Write short notes the following :
a) Sliding mesh gear box
b) Constant mesh gear box (BT-7/M-11)
Q. 5 Explain the working and constructional details of sliding mesh type gear box with neat
diagram (BT-7/DO9)
Q. 6 Explain the working of the constant mesh gear box and also differentiate b/w sliding
mesh gear box and constant gear box. (BT-7/10)
13
ASSIGNMENT 4
Q.1Write short notes on the following
a) What are the various functions of a propeller shaft in automobile?
b) Describe the constructional details of a typical differential unit with neat sketch?
c) Discuss various forces and torques experienced by the back axle? (BT-7/M-11)
Q.2 Write short notes on the following:
a) Propeller shaft
b) Differential used in automobiles
c) Forces and torques in the rear axle of an automobile
d) Automatic transmission (BT-7/DX)
Q.3 (a) Why a propeller shaft is required in a vehicle. What are the functions of the propeller
shaft? Name different types of joints in it. Sketch any one?
(b)Describe Hotchkiss drive with neat sketch. (BT-7/11
Q.4 Explain the following:-
a) Describe Hotchkiss drive with neat sketch?
b) Which type of propeller shaft is used in ashok Leyland vehicles? Explain each
component in brief. (BT-7/DO8)
Q.5 Explains the following in details:-
a) Hotchkiss drive
b) Propeller shaft (BT-7/DO9)
Q.6 Discuss in details about the differential unit and propeller shaft in details with neat
diagram. (BT-7/10)
14
ASSIGNMENT 5
Q.1 discuss in detail:
a) Interconnected air suspensions
b) Leaf springs (BT-7/DO8)
Q.2 (a) Draw a neat sketch of a tyre and describe the function of each component in it.
(b) Describe a dual power air brake system. (BT-7/11)
Q.3 what are the functions of a tyre in automobiles? What are different types of tyres. Explain
constructional details of a tyre in brief. Also explain various of tyre wear and factors affecting
life. (BT-7/DX)
Q.4 Differentiate b/w cross ply construction and radial ply construction in automotive tyres.
Also describe various advantages and disadvantages of radial ply tyres over bias ply tyres.
(BT-7/M-11)
Q.5 Explain in details about the various types of tyres in details? (BT-7/DO9)
Q.6 Explain in details about the braking system used in automobiles? (BT-7/10)
15
ASSIGNMENT 6
Q.1 (a) What are the various functions of a brake in the automobiles ?describe the
requirements of a good braking system.
(b)Describe the various independent suspensions system in brief? (BT-7/M-11)
Q.2 (a) Draw a well labeled diagram of inter connected air and liquid suspensions and explain
how it works.
(b) What are the important components of a good suspensions system? What should
be their characteristics? (BT-7/11)
Q.3 (a) Explain the constructional details nad working of hydraulic brakes used in
automobiles.
(b) Explain briefly the objectives of a suspensions system. Describe in brief Mchperson
strut type suspensions system. (BT-7/DX)
Q.4 (a) Discuss the properties expected in automobiles tyre?
(b)Briefly describe discs brakes. Compare them with the conventional drum type brakes.
(BT-7/DO8)
Q.5 Explain in detail about the various suspensions systems used in the automobiles.
(BT-7/DO9)
Q.6 Describe the braking system used in the automobiles. (BT-7/D10)
16
ASSIGNMENT 7
Q.1 (a) With suitable sketch discuss power steering?
(b)Explain a steering linkage for a vehicle with independent suspensions? (BT-7/DO9)
Q.2 Explain the following terms in brief:
a) Caster
b) Camber
c) Kingpin inclination
d) Combined angle
e) Under-steer
f) Over steer
g) Toe-in
h) Cornering force in steering systems
i) Self-righting torque
j) Steering ratio (BT-7/DX)
Q.3 (a) Explain the geometrical details of a steering mechanism with proper diagram and
define the technical terms used.
(b)Explain about power steering and Vickers system respectively. (BT-7/M11)
Q.4 Describe the purpose of steering system. Explain functions of steering system.
(BT-7/M-11)
Q.5 Explain the types of steering system used in automobiles. (BT-7/DO9)
Q.6 Explain about the various suspension used in details. (BT-7/D10)
17
ASSIGNMENT 8
Q.1 Write short notes on the following:
a) Multi fuel injection system
b) Pollution control in automobiles (BT-7/DX)
Q.2 Write short notes on the following
a) Alternative source of energy for vehicle
b) Emission control through catylytic convertor
c) Toe in steering geometery (BT-7/DO8)
Q.3 Write short notes on the following:
a) Multi-fuel automobiles
b) Catalytic convertors
c) Automobiles working on alternative energy sources
d) Different aspects of pollution control in automobiles
Q.4 Explain in brief with suitable sketch where necessary:
a) Fluid flywheel
b) Torque convertor
c) Main pollutions in the engine exhaust and their consequences
d) Double catalytic convertors (BT-7/11)
Q.5 Explain in brief with suitable sketch where necessary
a) Toe in steering geometery
b) Emission control through catylytic convertor (BT-7/DO9)
Q.6 Explain in detail about the different aspects of pollution control in automobiles
(BT-7/D10)
18
LECTURE SCHEDULE OF MECHANICAL MEASUREMENTS &
CONTROL
Sl.
No. TOPICS
No. of
Lectures
Reference
s
1. General:
Measurement, definition, methods, significance and
application, static calibration,
primary, secondary and tertiary measurement
4
2
2
T1
2. Measuring systems:
Generalized measurement systems: concept, definition and
application,
functional elements,
performance characteristics
Requirement for static measurement
5
1
1
2
1
T, R1
19
3. Analysis of experimental data:
Measurement data: single and multi sample, statistical
attributes, methods of presentation, usefulness of statistics,
Nature of physical measurements, Experimental errors and
causes, source,
Controllable and uncontrollable facts, error accuracy,
precision uncertainty and their estimation,
Chauvenets criteria, best linear calibration,
Significant figures and rounding off, overall uncertainty,
Common sense approach
Engineering applications.
13
2
1
3
2
2
1
2
T, R2
4. Transducers:
Definition, functions, classification
Electrostatic transducer, principle, theory, types, advantages
and limitations, uses.
Fixed contact mechano-resistive transducers; requirements,
classification
Metallic resistance strain gauges, types, operation, grid
patterns, material of construction, adhesives.
Grid and current strength matching, mounting, temperature
effects and their compensation,
Mathematical analysis of ballast and DC wheatstone bridge
circuit characteristics, comparison calibration.
12
1
2
3
3
1
2
T, R1
20
5. Measurement of non-electrical physical quantities:
Need and application, measurement of thrust load and force
with resistance strain gauges,
elastic load cells, proving rings, fluid pressure measurement
in pipe and container using strain gauges, measuring torque
in transmission, shaft under axial and bending loads in
varying conditions.
8
2
3
3
T, R2
3. Note: T- Text Book
4. Text Book:- 1) Mechanical Measurements: T. G. Beckwith and W. L. Buck
2) Instrumentation for Measurement in Engineering: S. Gupta
21
B. Tech. (Seventh Semester) Mechanical Engineering
Measurements and Control
ME 403 E L T P/D Total Theory : 100 marks
4 1 5 Sessional : 50 marks
Duration of Exams. : 03 hours NOTE: In the semester examination, the paper setter will set 8 questions in all, at least
two questions from each unit, and students will be required to attempt only 5 questions,
selecting at least one from each unit. UNIT I
Introduction: Definition, application of measurement instrumentation, functional elements’ of a
generalized measuring system, measuring standards, types of measurement, types of input to
measuring instruments and instrument system, classification of measuring instruments,
merits and demerits of mechanical measuring systems, comparison of mechanical measuring
system with electrical measuring systems, calibration.
Introduction, types of error, types of uncertainties, propagation of uncertainties in compound
quantity, Static performance parameters: accuracy, precision, resolution, static sensitivity,
linearity, hysteresis, dead band, backlash, and drift., sources of error, selection of a measuring
instruments, mechanical and electrical loading, UNIT II
Fundamentals of dynamic characteristics, generalized mathematical model of measuring
systems, types of input, dynamic performance parameters: dynamic error, speed of response
etc, dynamic response of a first order mechanical systems with different inputs e.g. step,
ramp, sinusoidal and impulse input
Introduction, types of measuring data, statistical attributes, various method of presentation,
estimation of presentation and uncertainties, confidence level, precision and statistical
treatments of single and multi sample type experimental data, Chauvenet's criteria of
rejecting a dubious data, curve fitting, best linear calibration and its precision, significant
figures and rounding off. Overall uncertainty estimation of measuring systems, common
sense approach, and engineering applications. UNIT III
Introduction, primary function, classification, electrostatic transducers: principle theory,
types, advantages, and limitations, Fixed contact mechano -resistive transducers:
classification, and uses, Metallic resistance strain gauge: types, construction theory of
operation, Adhesive: property, selection criteria, mounting of strain gauges, Mathematical
analysis of ballast and DC Wheatstone bridge circuits
Characteristic and comparison of ballast and DC Wheatstone bridge circuits, temperature
effects and their compensation
Measurement of load, force, and thrust using resistant strain gauges, Elastic load cells,
proving rings, fluid pressure measurement in pipe and containers, using strain gauges,
Measuring of torque in transmission shaft under axial and bending loads in varying ambient
conditions.
UNIT IV Introduction, classification of control systems, control system terminology, servomechanism,
process control and regulators, Manual and automatic control systems, physical systems and
mathematical models, linear control systems, Laplace transform, transfer function, block
diagram, signal flow graphs, system stability, Time and frequency domain.
22
46 Introduction, functional operation, desirable characteristics of hydraulic fluids, hydraulic
control systems: hydraulic pump, hydraulic control valve, Pneumatic control systems:
pneumatic nozzle, relay, advantages and limitation of such control systems. Reference and Text Books:
1. Mechanical measurements & control - By D.S. Kumar, Metropolitan book 2. Instrumentation and Mechanical measurements-By A.K. Tayal, Galgotia Publ.
5. Measurements systems application and design-By Ernest Doebelin, McGraw-Hill
23
ASSIGNMENT 1
Q1) Discuss fundamental method of measurement with suitable example. (BT-7/D11)
Q2) Compare the advantage and limitation of mechanical and electrical measuring system.
(BT-7/D08)
Q3 (a) What Is Measurement? Explain generalized measurement system and its various
stages.
(b) Describe the significance of measurement in various fields of engineering. (BT-
7/D06)
Q4) (a) Explain with suitable examples that dissect measurement is always more accurate
than indirect measurement.
(b) Explain the functional element of a generalized measuring system with the help of
suitable example. (BT-7/DX)
Q5) Distinguish between primary, secondary and tertiary standards giving purpose of each
give at least two desirable characteristics of each. (BT-7/D11)
Q6) Explain the functional element of a generalized measuring system with the help of
suitable example. (BT-7/D11)
24
ASSIGNMENT 2
Q1) Compare the performance of digital instrument over analog instrument with respect to
1) sensitivity 2) accuracy 3) resolution 4) cost (BT-7/D07)
Q2) Compare the performance of digital instrument over analog instrument with respect to
digital system and cost (BT-7/D09)
Q3) Define the following a)error b) calibration c)hysteresis d) dead zone e) drift f) sensitivity
(BT-7/D09)
Q4) What are the different standard inputs for studying dynamic response of a system.
(BT-7/D04)
Q5) (a) explain various considerations involved in the selection of a measuring instrument.
(BT-7/D08)
b) Which are the various types of experimental errors? (BT-7/Dx)
Q6) what is an error? Name and explain different types of error giving their source and
cause? (BT-7/D04)
25
ASSIGNMENT 3
Q1) Discuss the dynamic response of first order mechanical system with ramp input , with
the help of labeled diagram? (BT-7/D06)
Q2) A resistance arrangement of 50 ohm is desired . two resistor of 100 ohm and two
resistor 25 ohm are available. Which should be used a series arrangement with 25 ohm
resistor or a parallel arrangement with the 100 ohm resistor? (BT-7/D08)
Q3) Explain the following terms: (BT-7/D09)
a) Speed of respons
b) Measuring lag
c) Dynamic error
d) Dead time and dead zone
Q4) State and explain chauvenet’s criteria for rejection of a dubious data. (BT-7/D04)
Q5) Define the dynamic response of a system and distinguish between steady state
response and transient response . (BT-7/D07)
Q6) Define periodically varying inputs and transient input , give example? (BT-7/D10)
26
ASSIGNMENT 4
Q1) Explain (BT-7/D08)
1) Dubious data
2) Precision index
Q2) Explain (BT-7/D09)
1) Confidence level
2) Standard deviation for normal curve
Q3) Explain with neat diagram: (BT-7/D10)
1) Wire wound cylinder
2) Foil type strain gauge
Q4) Explain (BT-7/D12)
1) Semiconductor strain gauge
2) Capacitive strain gauge
Q5) Derive the equation for time response of a first order system subjected to impulse input .
draw the response curve and find steady state error. Give some example (BT-7/D07)
Q6) Discuss giving relevant theory the method of measuring torque using strain gauge torsion
meter? (BT-7/Dx)
27
ASSIGNMENT 5
Q1) Discuss the null and deflection mode of a Wheatstone bridge circuit as used for
measurement of resistance and small changes of resistance occurring in temperature and
strain measuring system. (BT-7/D04)
Q2) Write constructional detail and working of load cell and also derive the expression to
measure applied load. (BT-7/D07)
Q3) Distinguish between an active and pssive transducer .give example to illustrate . discuss
various transducer actuating mechanism ? (BT-7/D08)
Q4) Explain the following types of error (BT-7/D09)
a) Scale error
b) Dynamic error
c) Noise and drift error
Q5) In modern measurement system, there is more reliance on electrical/electronic technique
of measurement. List some advantage of electrical transducer over mechanical transducer.
(BT-7/D11)
Q6) Suggest suitable transducers to convert each of the following variables into electrical
signal
1) Pressure 2) force 3) acceleration 4) liquid level 5) angular speed of shaft (BT-7/D12)
28
ASSIGNMENT 6
Q1) Explain the use of wire wound potentiometers for the measurement of linear and rotary
motion. Point out the advantage and limitations of such transducers. (BT-7/D08)
Q2) Explain the principle of working of load cell using strain gauge with the help of neat
sketches. (BT-7/D10)
Q3) What are strain gauge? Discuss their types giving their advantage and disadvantage in
each case . what is gauge factor? State its significance. (BT-7/D05)
Q4) Discuss the null and deflection mode of a Wheatstone bridge circuit as used for
measurement of resistance and small changes of resistance occurring in temperature and
strain measuring system(BT-7/D06)
Q5) Explain the principle and application of the following (BT-7/D08)
a) Proving ring
b) Fluid pressure measurement in a pipe using strain gauge
Q6) Explain the use of wire wound potentiometer for the measurement of linear and rotary
motions. Point out the advantage and limitation of such transducers. (BT-7/D11)
29
ASSIGNMENT 7
Q1) Suggest a simple control system which automatically turns on a room lamp at dusk and
turn it off in a day light. Draw the schematics and block diagram of the suggested control
system. (BT-7/D08)
Q2) What is automatic control? What are its application? (BT-7/D10)
Q3) Compare between open and closed loop system? (BT-7/D11)
Q4) What is control system? What are the basic component ? give two example of control
system. (BT-7/D14)
Q5) Describe servomechanism. Draw block diagram of servomechanism. (BT-7/D10)
Q6) ) explain the use of wire wound potentiometer for the measurement of linear and rotary
motions. Point out the advantage and limitation of such transducers. (BT-7/D10)
30
ASSIGNMENT 8
Q1) write short note on the following (BT-7/D07)
a) Describe characteristics of hydraulic fluids
b) Hydraulic control valves
c) Advantage and llimitations of pneumatic control system
Q2) Give the schematics of general pneumatic control system and describe the function of
various elements. How the force balance controller differs from the motion balance
controller. (BT-7/D08)
Q3) Sketch and explain the working of the following units as used in pneumatics control
systems (BT-7/D09)
1) Pneumatic nozzle flapper
2) Pneumatic relay
Q4) Explain how the force balance controller differs from the motion balance controller.
(BT-7/D11)
Q5) What are strain gauge? Discuss their types giving their advantage and disadvantage in
each case. What is gauge factor? State its significance. (BT-7/D11)
Q6) Explain the principle and application of the following (BT-7/Dx)
a) Proving ring
b) Fluid pressure measurement in a pipe using strain gauge
31
LECTURE SCHEDULE OF ADVANCED MANUFACTURING TECHNOLOGY
UNIT CONTENTS Scheduled
Lecture
Actual
Lecture
Books
I Hot machining, Machining of plastics, unit heads,
plastics tooling, electro forming, surface cleaning and
surface treatments, surface coating, paint coating,
coating and slushing, Adhesive bonds, Adhesive bond
joints, Adhesives, surface coating for tooling, graphite
mould coating, vacuum mould process
Introduction, types of composite materials
agglomerated materials, reinforced material,
reinforced materials, laminates, surface coated
materials, production of composite structure,
fabrication of particulate composite structure,
fabrication of reinforced composite structures,
Fabrication of laminates, machining, Cutting and
Joining of composites
4
3
T1, T2,
R1
II Introduction, Polymers, Polymerization, Addition of
polymers, Plastics, types of plastics, processing of
thermoplastic plastics, Injection moulding, Extrusion
process, Sheet forming process, Processing of
Thermosetting Plastics, Compression moulding,
Transfer Moulding, Casting of plastics, Machining of
plastics, other processing methods of plastics
Introduction, casting thread chasing, Thread rolling,
Die threading and tapping, thread milling, Thread
measurement and inspection
4
T1, T2,
R1,
R3
32
4
III Theoretical basis of metal forming, classification of
metal forming process, cold forming, hot working,
warm working, effect of variables on metal forming
processes, Methods of analysis of manufacturing
process, open die forging, rolling, power rolling,
drawing, extrusion
6
T2,
R2
UNIT CONTENTS Scheduled
Lecture
Actual
Lecture
Books
IV Introduction, Product application, limitation of die
casting, die casting machines, molten metal injection
systems, hot chamber machines, cold chamber
machines, die casting design, design of die casting
dies, types of die casting dies, die design, die
material, die manufacture, die lubrication and
coating, preheating of dies, vacuum die casting,
recent trends in die casting process
Definition, cost accounting or costing, elements of
costing, cost structures, estimation of cost elements,
methods of estimating, data requirement of cost
estimating, steps in making cost estimate, chief
factors in cost estimating, numerical examples,
calculation of machining times, estimation of total
unit time
4
5
T1, T2,
R4,
R5
Text Books
1. A text book of Production Technology by P.C Sharma
2. A text book of Production Engineering by P.C Sharma
Reference Books
1. Metallurgy and material science by O.P. Khanna
33
2. Principle of metal forming by G. Rowe
3. Principles of Manufacturing by J.S. Campbell
4. Foundary Technology by O.P. Khanna
5. Estimation and Costing by Sachdeva
B.Tech. (Seventh Semester) Mechanical Engineering ADVANCED MANUFACTURING TECHNOLOGY
ME 419 E
L T P/D Total Theory : 100 marks
4 I _ 5 Sessional : 5O marks
Duration of Exams. : 03 hours NOTE: In the semester examination, the paper setter will set 8 questions in all, at least
two questions from each unit, and students will be required to attempt only 5 questions,
selecting at least one from each unit.
UNIT I Hot machining, Machining of Plastics, Unit heads, Plastics cooling, electro forming, Surface
Cleaning and Surface Treatments, Surface Coatings, Paint Coating and Slushing, Adhesive
Bonds, Adhesive Bond Joints, Adhesives, Surface Coating for Tooling, Graphite Mould
Coating, Vacuum Mould Process. Introduction, Types of Composites materials, Agglomerated Materials, Reinforced
materials, Laminates, Surface Coated Materials, Production of Composite Structures,
Fabrication of particulate composite Structures, Fabrication of reinforced Composite,
Fabrication of Laminates, Machining, Cutting and Joining of Composites. UNIT II
Introduction, Polymers, Polymerization, Addition of Polymers, Plastics, Types of plastics,
Properties of Plastics, Processing of Thermoplastic Plastics, Injection Moulding, Extrusion
Process, Sheet forming processes, Processing of Thermosetting Plastics, Compression
Moulding, Transfer Moulding, Casting of Plastics, Machining of plastics, other processing
methods of plastics Introduction, casting, thread chasing, Thread Rolling, Die Threading and Tapping, Thread
Milling, Thread Measurement and Inspection
UNIT III Theoretical basis of metal forming, classification of metal forming processes, cold forming,
hot working, Warm working, Effect of variables on metal forming processes, Methods of
analysis of manufacturing processes, Open Die forging, Rolling Power Rolling, Drawing,
Extrusion.
UNIT IV Introduction, Product Application, Limitation of Die Casting, Die Casting Machines, Molten
metal Injection systems, I lot chamber machines, Cold chamber machines, Die casting
Design, Design of Die casting Dies, Types of Die casting Dies, Die design, Die material, Die
Manufacture, Die Lubrication and Coating, Preheating of Dies, Vacuum Die Casting, Recent
trends In Die Casting Process. Definition, Cost accounting or costing, Elements of costing, cost structures, Estimation of
cost elements, Methods of estimating, Data requirements of cost estimating, Steps in making
34
cost estimate, Chief factors in cost estimating, Numerical examples, calculation of machining
times, Estimation of total unit time.
35
54 Reference and Text Books:
1. Principles of Manufacturing - By J.S.Campbell, Tata McGraw-Hill
2. Production Engineering Sciences - By Pandey and Sinh Standard Pub.
3. A text book of Production Technology - By P.C. Sharma S.Chand & Company.
4. Manufacturing Materials and Processes - By Lindberg Prentice Hall
5. A text book of Production Engineering - By P.C. Sharma S.Chand & Company.
36
ASSIGNMENT-1
Q1. Why ‘hot machining’ is needed for some materials?
Q2. Write a short note on ‘unit heads’?
Q3. What is electro forming process? Give its advantages.
Q4. What are the various methods of surface cleaning? Write a note on paint coating and
slushing?
Q5. Explain vacumm-casting process with neat sketch?
Q6. Explain graphite mould coating with neat sketch?
37
ASSIGNMENT-2
Q1. What are the composite materials?
Q2. What are the reinforced composite materials?
Q3. Give the applications of various reinforced composite material?
Q4. What are the laminates? Write about common laminates?
Q5. What are the surface coated materials?
Q6. Write various technique of fabricating fibre-reinforced composites?
38
ASSIGNMENT-3
Q1. (a) Define the term polymer?
(b) What is polymerization?
Q2. What are the plastic materials?
Q3. Discuss the properties of plastic materials and give their limitation?
Q4. Sketch and explain the injection moulding process?
Q5. Sketch and explain the compression moulding and transfer moulding process?
Q6. Compare the various methods of processing for plastics?
39
ASSIGNMENT-4
Q1. Discuss the casting method of manufacturing threads?
Q2. Explain the function of thread dial on a lathe.
Q3. Discuss the various thread rolling machines.
Q4. List the advantages of thread rolling?
Q5. What are the various advantages of producing threads by grinding?
Q6. Give the advantage of self opening die over solid type die?
40
ASSIGNMENT-5
Q1. Differentiate between nominal stress and true stress?
Q2. Differentiate between conventional strain and true strain?
Q3. Explain the effect of variables on metal forming processes.
Q4. Give classification of metal forming process.
Q5. Explain metal forming process. Also explain hot working process.
Q6. Explain cold forming process.
41
ASSIGNMENT-6
Q1. What is the difference in hot working and cold working in metal forming?
Q2. Discuss the warm working technique?
Q3. What do you understand by term limiting draw ratio? Explain why such limit exists and
give the principle underlying the estimation of LDR in given situation?
Q4. How will you reduce the pressure in wire drawing?
Q5. Explain wire drawing process with neat and clean diagram.
Q6. Explain extrusion process with neat and clean diagram.
42
ASSIGNMENT-7
Q1. List the reason behind widespread of Die casting
Q2. What are the limitations of pressure die casting?
Q3. How the dies are opens and locked in the die casting?
Q4. What is meant by capacity of die casting? Write its usual values?
Q5. Write the steps of making casting by die casting?
Q6. Why die casting is mainly used for the non ferrous metals?
43
ASSIGNMENT-8
Q1. Compare offset and central metal injection technique.
Q2. Discuss the various factors for die casting design.
Q3. What is the difference between hot chamber and cold chamber die-casting?
Q4. With the neat diagram explain hot chamber process?
Q5. Discuss the gating design and runner design principle in die-casting?
Q6. What is vacuum die casting?
44
LECTURE SCHEDULE OF MAINTENANCE ENGINEERING
Sl.
No. TOPICS
No. of
Lectures References
1. Evolution of maintenance, objective of maintenance,
maintenance policies and philosophies, maintenance concept,
maintenance management & terotechnology,relationship with
other functional areas, importance of maintenance, elements of
good maintenance, economics of maintenance, training and
safety aspects in maintenance
6
2
4
T1,T2
45
2.
Classification of maintenance programs
corrective preventive and predictive maintenance
comparison of maintenance programs, preventive maintenance-
concept,functions, benefits, limitations.
10
2
8
T2,T3
3. Objectives, what to monitor, when to monitor, principles of
CBM, condition based
maintenance techniques, manual inspections, performance
monitoring, vibration
monitoring, current monitoring, coil debris/spectroscopy,
thermography and corrosion
a. monitoring, steps in implementation of CBM, benefits of
CBM
5
1
1
2
T2,T3
46
4. RCM logic, maintenance and RCM, benefits of RCM, total
productive maintenance
(TPM), introduction, key supporting elements of TPM,
methodology, evaluation and
benefits.
8
2
6
T1,T2,T3
5. Purpose and challenges: Techniques, visual aids-boroscopes,
endoscopes, fiber
optics scanners, magnetic particles inspection, liquid penetrants,
eddy current,ultrasonic radiography, selection of NDT
technique, metrits/demerits andapplications of various
techniques.
Basic ingredients, basic steps in maintenance management,
maintenance planning andcontrol system, documentation,
maintenance-productivity areas for improvement
7
1
3
3
T1,T2,T3
6. Techniques for improvement of operational reliability, safety
and availability of machines and
production systems, maintainability criteria, checklist to assess
the maintainability of a
system, maintainability programs, objectives, key issues in
availability improvements
program, fault diagnosis, Pareto principle Ishikawa diagram.
Data processing systems for integrated maintenance,
maintenance information and reporting
systems.
10
1
2
7
T2,T3
Text Books:
1. Maintenance Planning and Control by Higgin L.R., McGiaw Hill Book Co1,1900
2. Maintenance Planning and Control by Kelly Anthony, East West Press
Private Ltd, New Delhi, 1991.
3. Maintainability principle and practices by Blanchard B.S. and Lowey E.E.
McGrawHill Book co.
47
4. Practical NOT by Raj B. Jaya Kumar T and Thavasimulyi K., Narora Publishing
House, New Delhi, 1996.
5. Engineering Maintenance Management by Niebel Benjamin W. Marcel Dekher,
48
B. Tech. (Seventh Semester) Mechanical Engineering
MAINTENANCE ENGINEERING
ME 437 E
L T P T Total Sessional : 50 marks
4 1 - 5 Theory : 100 marks
Duration of Exam : 3 hrs.
NOTE: In the semester examination, the paper setter will set 8 questions in all, at least
two questions from each unit, and students will be required to attempt only 5 questions,
selecting at least one from each unit.
UNIT I
Evolution of maintenance, objective of maintenance, maintenance policies and
philosophies, maintenance concept, maintenance management & terotechnology,
relationship with other functional areas, importance of maintenance, elements of good
maintenance, economics of maintenance, training and safety aspects in maintenance.
Classification of maintenance programs, corrective preventive and predictive
maintenance, comparison of maintenance programs, preventive maintenance-concept,
functions, benefits, limitations.
UNIT II
Objectives, what to monitor, when to monitor, principles of CBM, condition based
maintenance techniques, manual inspections, performance monitoring, vibration
monitoring, current monitoring, coil debris/spectroscopy, thermography and corrosion
monitoring, steps in implementation of CBM, benefits of CBM.
RCM logic, maintenance and RCM, benefits of RCM, total productive maintenance
(TPM), introduction, key supporting elements of TPM, methodology, evaluation and
benefits.
UNIT III
Purpose and challenges: Techniques, visual aids-boroscopes, endoscopes, fiber
optics scanners, magnetic particles inspection, liquid penetrants, eddy current,
ultrasonic radiography, selection of NDT technique, metrits/demerits and
applications of various techniques.
Basic ingredients, basic steps in maintenance management, maintenance planning and
control system, documentation, maintenance-productivity areas for improvement
UNIT IV
Techniques for improvement of operational reliability, safety and availability of machines
and
production systems, maintainability criteria, checklist to assess the maintainability of a
system, maintainability programs, objectives, key issues in availability improvements
program, fault diagnosis, Pareto principle Ishikawa diagram.
Data processing systems for integrated maintenance, maintenance information and reporting
systems.
Text Books:
1. Maintenance Planning and Control by Higgin L.R., McGiaw Hill Book Co1,1900
49
2. Maintenance Planning and Control by Kelly Anthony, East West Press
Private Ltd, New Delhi, 1991.
3. Maintainability principle and practices by Blanchard B.S. and Lowey E.E.
McGrawHill Book co.
4. Practical NOT by Raj B. Jaya Kumar T and Thavasimulyi K., Narora Publishing
House, New Delhi, 1996.
5. Engineering Maintenance Management by Niebel Benjamin W. Marcel Dekher,1994.
50
ASSIGNMENT NO. 1
Q1. (a) Write ten important function of a maintenance department.
(b) Define three important principles of maintenance management. (BT-7/M-11)
Q2. (a) Discuss three important element of effective maintenance planning.
(b) Define five important indices that can be used to evaluate overall performance of a
Maintenance Department. (BT-7/M-11)
Q3. A test is conducted on a large number of identical components which are put in
operation. Failure time of each component in noted down by continuous monitoring system.
Discuss various possible failure distributon which may occur in this type of system. Which of
the distribution will be best suited from the analysis point of view? Justify your answer with
suitable examples. How does failure rate behave for the considered distribution? That is how
does failure rate changes with the increase of operation time. (BT-7/M-11)
Q4. Explain Economics of maintenance. (BT-7/DX)
Q5. Explain Maintenance philosophies. (BT-7/DX)
51
ASSIGNMENT NO. 2
Q1. Write briefly on concepts of corrective, preventive and predicative maintenance.
(BT-7/DX)
Q2. (a) Define maintenance and its role in industry.
(b) Discuss various challenges to be faced in industry in the execution of maintenance
function. (BT-7/D11)
Q3. (a) Discuss best maintenance practices of an organization.
(b) The prime objective of maintenance is productivity improvement through maximum
availability at optimark cost. Justify this statement with suitable examples. (BT-7/D11)
Q4. What is maintenance excellence in an industry? Write its element for the development of
an integrated maintenance plan. (BT-7/D11)
Q5. Discuss m out OF n redundancy used for large industrial systems.
(BT-7/D11)
52
ASSIGNMENT NO. 3
Q1. Define markav process its properties and limitations. Five suitable examples.
(BT-7/M-11)
Q2. Discuss the following with suitable examples:
(i) Role of computer in maintenance planning.
(ii) Economics of maintainability and reliability.
(iii) Mission availability. (BT-7/M-11)
Q3. What important steps are needed to develop maintenance software? (BT-7/M-11)
Q4. Discuss the following
(i) Asset management and asset Register.
(ii) Unplanned work and their reporting. (BT-7/M-11)
Q5. Discuss the concepts of CBM. Also describe steps in CBM and its benefits.
(BT-7/DX)
53
ASSIGNMENT NO. 4
Q1. Discuss concepts, benefits and elements of TPM. (BT-7/DX)
Q2. Write various used and limitations of “CMM’’ system over the “MMS’’.
CMM ― Computerized maintenance management
MMS __ Manual maintenance system (BT-7/D11)
Q3. Classify maintenance performance indicators. Discuss each and give the branch mark
value for a steel industry. (BT-7/D11)
Q4. Define the following in reference to the world class equipments
(i) Reliability and availability
(ii) Maintainability (BT-7/D11)
Q5. A system is comprised of four serially related components each having a weibull time
distribution with parameter as given below. computer system reliability for 100 hrs operation
time.
Components 1 2 3 4
Scale parameter 100 150 510 720
Shape parameter 1.20 0.87 1.80 1.00 (BT-7/D11)
54
ASSIGNMENT NO. 5
Q1. Discuss the role of condition based monitoring and its significance in a manufacturing
industry. (BT-7/M-11)
Q2. Define the role of redundancy and its economics in improving system availability.
(BT-7/M-11)
Q3. (a) What are the six big losses in an industry? Write steps for reducing these losses.
(b) Define overall equipment effectiveness. What are its elements? Give their values for
world class equipment. (BT-7/M-11)
Q4. Write short note on Ultrasonic radiography.
Q5. Write short note on Magnetic particles inspection. (BT-7/DX)
55
ASSIGNMENT NO. 6
Q1. Discuss the concepts of maintenance management. Also discuss documentation required
in maintenance. (BT-7/DX)
Q2. Discuss maintenance budgeting its measured for control in industry. (BT-7/D11)
Q3. If the cost of each replacement in rupees is 2000 then what will be the total cost of
operation per year for the selected replacement policy. A system is scheduled to operate for
2000 hrs per year. The system MTBF and MTTR are 400 hrs and 20 hrs respectively.
Calculate the annual labour cost of corrective maintenance if the maintenance labour cost is
rupees 100 per hour. (BT-7/D11)
Q4. Discuss various parameter of maintainability
(b) An electrification system contains 12000bulbs. When any bulb fails it is replaced. The
cost of replacing a bulb individually is Rs 10 only. If all the bulbs are replaced at the same
time, the cost per bulb would be Rs 4 only. The percentages of surviving bulbs is the end of
month l and p (t) is the probability of failure during the month t are given as:
t 0 1 2 3 4 5 6
S (t) 100 97 90 70 30 15 0
P(t) … .03 .07 .020 .40 . 15 .15
Find the optimal replacement plan. (BT-7/D11)
56
ASSIGNMENT NO. 7
Q1. Define RCM and its role in improving equipment availability. (BT-7/M-11)
Q2. Discuss important goals and principles of RCM. How four components of RCM will help
in reducing failure? (BT-7/M-11)
Q3. Write short notes on the following:
(a) Safety in maintenance.
(b) NDT techniques of inspection. (BT-7/DX)
Q4. Write short notes on the following:
(c) Optimum design configuration for cost effectiveness.
(d) Management Information System for maintenance.
(BT-7/M-11)
Q5. Discuss concepts objectives and key issues in a maintainability program.
(BT-7/DX)
57
ASSIGNMENT NO. 8
Q1. Write in detail, on key ingredients of a maintenance information and reporting system.
(BT-7/DX)
Q2. Discuss various replacement models and their limitations. (BT-7/D11)
Q3. Define / discuss various failure patterns. Which may occur in industrial equipments.
(BT-7/D11)
Q4. Write short notes on the followings
(I) Role of RCM to achieve the goal of high equipment availability.
(ii) Role of CBM in the assessment of equipment performance.
(II) ‘OEE’ and its measure for world class equipments.
(II) TPM and its role in industry. (BT-7/D11)
58
LECTURE SCHEDULE OF Statistical Quality Control and Reliability
Sr.
No.
Topic covered No. of
lecture
taken
Actual
lecture
taken
References
1 Introduction: (11) R1, R2
1.1 Quality-Basic Concepts: Issues in
quality
1 R1, R2
1.2 Factors affecting quality, creating
quality by design, product development
cycle,
2 R1, R2
1.3 Economics of quality various
definitions,
1 R1, R2
1.4 ISO definition of quality and it’s
meanings
1 R1, R2
1.5 Various phases till TQM and it’s
meaning to industries, customers and
employees
1 R1, R2
1.6 Contribution of quality gurus etc.
towards quality concepts.
1 R1, R2
1.7 Total quality Management: its scope,
application and implementation
1 R1, R2
1.8 Quality circle: its objectives, structure
and techniques.
1 R1, R2
1.9 Variability concept in manufacturing-
cycle, fishbone diagrams, charts in time
philosophy
2 R1, R2
2 Quality Control: 12
2.1 Basic statistical concepts, various types
of distributions, general theory X and R
chart
2 R1, R2,R3
59
2.2 Decision preparatory to the control
charts. Trial control limits.
2 R1, R2,R3
2.4 Selection of subgroups. Charts with
variable subgroups, reject specification
limits
2 R1, R2,R3
2.5 Practical limitations. Control charts for
fraction defectives, calculation and
plotting of control limits, sensitivity of
P-chart
2 R1, R2,R3
2.6 Applications. Control charts for Defects,
difference between defect and defective,
calculation and plotting of control limits,
applications. Pi-charts and u-charts,
plotting of charts. Tests for various
control charts. Process capability-
inherent and potential capability.
4 R1, R2,R3
3 . Acceptance Sampling : 12
3.1 Purpose of acceptance by attributes ,
Single sampling plans. O.C. curve,
2 R1, R2,R3
3.2 Selection of sampling plans, acceptance
number, Type A and Type B
2 R1, R2,R3
3.3 O. C. Curves, Double sampling plan and
its analysis, Multiple and sequential
sampling, A.O.Q.L. , Acceptance
sampling plans under risk.
3 R1, R2,R3
3.4 Design of various sampling plans,
Dodge-Roming type system for
2 R1, R2,R3
3.5 Acceptance sampling by attributes (use
of various tables). Determination of
process average, acceptance sampling by
variables .
3 R1, R2,R3
4 Reliability: 10
4.1 Control of reliability, factors affecting
reliability, ,
2 R1, R2,R3
60
pattern of failure, mean time to failure 1 R1, R2,R3
Fundamental of statically concepts,
consideration of reliability in series and
parallel system,
3 R1, R2,R3
effect of redundancy and reliability,
method of reliability evaluation,
reliability optimization,
2 R1, R2,R3
Availability and maintainability, means
to improve reliability, reliability control
during manufacture.
2 R1, R2,R3
Reference and Text Books:
R1 Statistical Quality Control - By Grant and Leaven, McGraw-Hill
R2 Quality Control and Reliability - By Mahajan, Dhanpat Rai.
R3 Quality Control By Hansen, Prentice-Hall.
61
B. Tech. (Seventh Semester) Mechanical Engineering Statistical Quality Control and Reliability
ME 405 E L T P/D Total Theory : 100 marks
4 1 5 Sessional : 50 marks
Duration of Exams. : 03 hours NOTE: In the semester examination, the paper setter will set 8 questions in all, at least
two questions from each unit, and students will be required to attempt only 5 questions,
selecting at least one from each unit.
UNIT I Quality -Basic Concepts: Issues in Quality, factors affecting quality, creating quality by
design, product development cycle, economics of quality, Various definitions, ISO definition
of quality and its meanings, and various phases till TQM and its meaning to industries,
customers and employees, contribution of quality gurus etc. towards quality concepts. Total
Quality Management: its scope, application and implementation. Quality Circle: its
objectives, structure and techniques. Variability concept in manufacturing-cycle, fishbone
diagrams, charts in time philosophy
UNIT II Basic statistical concepts, various types of distributions, General theory X and R chart.
Decision preparatory to the control charts. Trial control limits. Selection of subgroups. Charts
with variable subgroups, Reject and Revoke, limits for average on X charts, modified control
limits, specification limits, practical limitations. Control charts for fraction defectives,
calculation and plotting of control limits, sensitivity of p chart, applications. Control charts
for Defects, difference between defect and defective, calculation and plotting of control
limits, applications, pi charts and u charts, plotting of charts. Tests of various control charts.
Process capability- inherent and potential capability.
UNIT III Purpose of Acceptance by Attributes, Single sampling plans. O.C. curve, selection of
sampling plans, Acceptance number, Type A and Type B, O.C. curves, Double sampling plan
and its analysis, Multiple and sequential sampling, A.O.Q.L, Acceptance sampling plans
under risk. Design of various sampling plans, Dodge-Roming type system for acceptance
sampling by attributes (use of various tables). Determination of process average, Acceptance
sampling by variables.
UNIT IV Control of reliability, factors affecting reliability, pattern of failure, mean time to failure,
Fundamental of statistical concepts, consideration of reliability in series and parallel system,
effect of redundancy and reliability, method of reliability evaluation, reliability optimization,
Availability and Maintainability, means to improve reliability, reliability control during
manufacture.
Reference and Text Books: 1. Statistical Quality ControlBy Grant and Leaven, McGraw-Hill 2. Quality Control and ReliabilityBy Mahajan, Dhanpat Rai. 3. Quality Control By Hansen, Prentice- Hall
62
ASSIGNMENT 1
Q1. What is quality? Discuss in detail fundamental factors affecting quality?
Q2- What is the importance of quality control in a manufacturing organisation.discuss briefly
the factors affecting quality of the outgoing product in an industry?
Q3- Define quality assurance and identify the objectives of a quality assurance system in an
organization?
Q 4- Explain various costs associated with quality. To derive the quality cost, what
relationship among these cost exist? Derive the same?
Q5- What is inspection? Discuss the important activities assigned to the quality control
department in an industry.discusss under what condition ‘statistical quality control ‘would be
preferred to 100% inspection?
Q6- What is meant by control? How Quality control is maintained in any industrial.
63
ASSIGNMENT 2
Q.1 What do you know by cost of quality and value of quality? How to balance them?
Q.2 State the various stages, which need to be controlled for ensuring proper quality of
product and for ensuring improvement in quality.
Q.3 Differentiate between:
a) Cost of quality and value of quality.
b) Inspection and quality control
c) Quality of design and quality of conformance.
d) Quality of conformance and quality of performance.
Q.4 Define T.Q.M. Explain how T.Q.M. can be ensured.
Q.5 Describe the following in connection with T.Q.M.
A) people involvement
B) J.I.T. manufacturing
C) Workers attitude
D) Zero defect concept
Q.6 a) Explain the term “Quality Assurance Function”.
b) State the activities assigned to quality assurance function .
c) State the advantages of quality assurance .
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ASSIGNMENT 3
Q1. Discuss the importance of control charts for variables and attributes?
Q2. Discuss the methods of drawing x-bar and r-charts. State the formulae used in both the
cases?
Q3. Distinguish between a p-chart and c-chart. Discuss some situation in which c-chart is
most appropriate?
Q4. What are the necessary steps in connection with control charts for function rejected?
Q5. What is the analytically difference between p and np charts?
Q6. State and explain the condition favorable for economic use of control charts for defects
per unit?
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ASSIGNMENT 4
Q1. Control charts for x-bar & r are maintained on certain dimensions of a manufactured
parts measured in mm . The sub group size is 4. The values of x-bar & r are computed for
each sub group. After 20 subgroups sigma x bar = 412.83 & sigma r = 3.39 computes the
values of 3 sigma limits for the x- bar & r charts & estimate the values of tau as the
assumption that the process is in statistical control.
Q2. Determine the control limits for x – bar & r charts if sigma x-bar = 357.50 , sigma r =
9.90
Q3. Control chart for x bar and r, sigma are to be maintained on drawing from abowl of chips
the distribution of which is approximately normal . Subgroup size is 5,x bar is 60 and sigma
is 8 assume that 3 sigma control limits are to be based on x bar and sigma .compute the value
of the upper control limit, the control line and lower control limit for x bar ,r and sigma
charts?
Q4. A subgroup of 5 items each are taken from manufacturing process at a reguler interval a
certain quality characteristics is mea sured and x bar ,r value computed .after 25 sub groups ,it
is found that Σx bar=357.50 and Σr=8.80 .if specification limits are 14.40-/+.40 ,and if the
process is in statistical control .what conclusion can you draw about the ability of process to
produce items within specification ?
Q5. Control charts for x bar and r charts are maintained on tensile strength mkg if a certain
yarn .sub group size is 5. Value of x bar and r are computed for each sub group. After 25
groups Σx bar =568.5and Σr=122 ,compute value of 3 sigma limits. For x bar and r chart
,also determine process capability.
Q6. Control charts for x bar and r are to be prepared for a certain dimension of a component.
Sub group size is 4.after 20 subgroups ,it is found that Σx bar=826.50 and Σr=5.65mm.
a) Compute center line and and control limits on x bar and r charts , take
d2=2.059,d4=2.28 ,d3=0
b) If the specified dimension is 41.0+/-.45 and process is in control and is
normally distributed ,can it meet the specification requirement ?if not
determine %age of rejection ?
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ASSIGNMENT 5
Q1. a) State and explain the advantages and limitations of acceptance sampling over 100%
inspection.
b) Compare random sampling and stratified sampling.
Q.2 Explain the OC curve with reference to sampling inspection and the meaning of the
terms:
1. AQL
2. LTPD
3. IOL
4. Producers risk
5. Consumers risk
Q.3 a) Explain the various types of sampling plans which are in practice in industry with
there respective acceptance criteria.
b) Differentiate between single sampling plan and double sampling plan.
Q.4 a) what is ATI? How will you compute the ATI for single sampling and double sampling
plans?
b) Differentiate between AQL AND AOQL?
Q.5 Write short notes on any three of the following.
1. Single sampling plan
2. Double sampling plan
3. Systematic sampling
4. Consumers risk and producers risk
5. Multiple sampling plan
Q.6 In a double sampling plan N= 50, n1=3, c1= 0, n2=6, c2=1
Using the correct combinational formulas compute the probability that a lot exactly 2%
defective will be accepted by this plan.
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ASSIGNMENT 6
Q.1 Construct OC and AOQ curves for the following attributes single – sampling plans:
A) n=10 , c=1
B) n=50, c=2
C) n=100 , c=4
D) n=200 , c=8
Locate the α0.50,β0.10 split risk , AOQL percent defective values , for each of the plans
above .
Q.2 Determine the equations of the rejection and acceptance lines for an item –by- item
sequential plan in which
P0.50 =0.05
P0.10=0.15
Compute the respective acceptance and rejection numbers when n is 20 , 40, 60 ,and 80, 100 .
in this calculation make the rejection number the next whole number above d2 and the
acceptance number the next whole number below d1.
Q.3 In a double sampling 2% AOQL acceptance / rectification plan :
n1=32 , n2 =38
c1 = 0 , c2=2
N=1000
Determine :
1) the probability of acceptance of 2% defective lot
2) the average total inspection .
Q4. A single sampling plan uses a sample size of 111115, and an acception number 1. Using
hypergeometric probabilities , compute the probabilities of acceptance of lots of articles, 2%
defective?
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Q5. In a double sampling plan , n=5000, n1=100 c1=0,n2=100 nd c2=1.
Use possions table to compute the probability of acceptance of a 1% defective lot .
Assume that a lot rejected by this sampling plan will be 100% inspected . What will be the
aoq if the submitted product is 1% defective ? Considering both the inspection of rejected lots
, what will be the average no. Of articles inspected per lot if the submitted product is 1%
defective?
Q6. In a single sampling plan, n=10000,n=300 & c=1 . This is used with stipulation that all
rejected lots are to be screened. Compute aoq if all lots submitted are .5%defective?
ASSIGNMENT 7
Q. 1 A certain type of electrical component has a uniform failure rate of 0.00001 / hr. .What
is it’s reliability for a specified period of service of 10000 hrs. ?
Q.2 Given a θ of 50000 hrs. and a uniform failure rate . What is the reliability associated
with a specified service period of 200 hrs
Q.3 The following reliability requirements have been set on the subsystems of a
communication system
Subsystem Reliability(for a hour
period )
Receiver 0.970
Control system 0.989
Power supply 0.995
Antenna 0.996
What is the expected reliability of the overall system?
Q.4 A unit has a reliability of 0.99 for a specified mission time . If 2 identical units are used
in parallel redundancy, what overall reliability will be obtained ?
Q.5 A) Define reliability?
B) Explain the importance of reliability.
Q.6 A) what are the basic elements of reliability?
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B) Explain the failure pattern for complex products .
ASSIGNMENT 8
Q.1 Explain the following in connection with reliability:
1. Quality and reliability
2. Cost of reliability
3. System reliability
4. Availability
Q.2 Write short notes on the following:
1. MTTR 2. Maintenance and reliability
Q3. Define Availability and maintainability.
Q.4 Write short notes on the following:
1. MTBF
2. Marginal testing
Q5. Explain various means to improve reliability, reliability control during manufacture.
Q6. Explain effect of redundancy.
70
B. Tech. (Seventh Semester) Mechanical Engineering Measurement and Control (Practical)
ME 407 E P/D Total Practical : 25 marks 2 2 Sessional : 50 marks
Duration of Exams. : 03 hours
List of Experiments 1. Study of a strain gage based cantilever beam and measurement of
strain on the beam
2. Study of a LVDT and measurement of linear displacement
3. Study of an inductive pick up and measurement of linear displacement
4. Study of a LDR and measurement of linear displacement
5. Study of capacitive pick up and measurement of angular displacement
6. Study of temperature transducers and measurement of temperature of fluid
7. Study of a LVDT (strain gage based) and measurement of linear
displacement.
8. Study of a torque pick up and measurement of torque .
9. Study of a pressure pick up and measurement of pressure of fluid.
10. Study of load cell and measurement of load with load cell
11. Study of non-contact type speed pick up and measurement of rotational
speed
12. Comparison of sensitivity of thermocouple, thermister and RTD Note: Total Ten experiments must be performed. At least eight experiments should be
performed from the above list. Remaining two experiments may either be performed
from the above list or outside the list.
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B. Tech. (Seventh Semester) Mechanical Engineering
Project I
ME 409 E P/D Total Viva voce : 75 marks 7 7 Sessional : 100 marks
Duration of Exams. : 03 hours
The students expected to take up a project under the guidance of teacher from the college.
The project must be based on mechanical engineering problems, which can be extended up to
the full academic session. The students may be asked to work individually or in a group not
more than four students in a group. Viva- voce must be based on the preliminary report
submitted by students related to the project.
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B. Tech. (Seventh Semester) Mechanical Engineering Seminar
ME 411 E P/D Total 2 2 Sessional: 50 marks Student will give a talk on some technical topics.
Note: The seminar will continue in eighth semester and will be evaluated in eighth
semester.
.
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B. Tech. (Seventh Semester) Mechanical Engineering Practical training report
ME 413 E P/D Total Sessional : 75 marks
- - Duration of Exams. : 03 hours Student will submit summer training (about 8 weeks’ industrial training) report for his/her
assessment.
