Bansilal Ramnath Agarwal Charitable Trust’s Vishwakarma ...Classification of forming processes, Materials and their structures, Mechanical behavior of crystalline materials, tensile

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

Structure and syllabus of T.Y. B. Tech. Production Engineering. Pattern C-18, A.Y. 2018-19 (P a g e | 1)

Bansilal Ramnath Agarwal Charitable Trust’s

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

Structure & Syllabus of

B. Tech. (Production Engineering)

Pattern ‘C18’ Effective from Academic Year 2018-19

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



T.Y. B. Tech. Production Engineering AY 2018‐19 (C18)

Subject No.

Subject Code

Subject Name Teaching Scheme (Hrs/Week)

Examination scheme Credits

Theory Lab CA MSE ESA TotalHA LAB ESE VIVA

Semester-1 (Module-V)

S1 PR3001 Metal Forming Technologies 3 2 10 30 10 30 20 100 4 PR3002 Production Planning & Control

S2 PR3003 Production Metallurgy 3 2 10 30 10 30 20 100 4 PR3004 Quality & Reliability Engineering

S3 PR3005 Work Study & Human Factors Engineering

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

S4 PR3007 Design of Machine Elements

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

S5 PR3071 Engineering Design & Development - 1 2 4 -- -- -- -- -- 100 4 S6 PR3072 Seminar -- -- -- -- -- -- -- 100 1

Total 14 12 21 Semester-2 (Module-VI)

S1 PR3036 Additive Manufacturing 3 2 10 30 10 30 20 100 4 PR3037 Modern Manufacturing Processes

S2 PR3038 Metal Cutting & Tool Design 3 2 10 30 10 30 20 100 4 PR3039 Manufacturing Automation

S3 PR3040 Machine Tool Design 3 2 10 30 10 30 20 100 4 PR3041 Industrial Fluid Power

S4 PR3042 Statistical Methods & Research

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

S5 PR3086 Engineering Design & Development - 2 2 4 -- -- -- -- -- 100 4 S6 PR3087 Summer Training -- -- -- -- -- -- -- 100 1 S7 PR3088 **Professional Development -1 -- -- -- -- -- -- -- -- -- S8 PR3089 **General Proficiency - 2 -- -- -- -- -- -- -- -- --

Total 14 12 21 (*) Irrespective of Module in second semester

(**) Audit Course evaluated in second semester



Module V



FF No. : 654

PR3001::METAL FORMING TECHNOLOGIES

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

SECTION-1

1) Fundamentals of Metal Forming Classification of forming processes, Materials and their structures, Mechanical behavior of crystalline materials, tensile behavior work done in tensile test, types of stress and strains Engineering stress-strain and true stress-strain, Compression behavior, Strain hardening, temperature rise in plastic deformation. 2) Concept of flow stress determination, compression test Effect of temperature, strain rate, Elasticity, Mohr’s circle for three dimensional state of stress, Elasticity, Theory of plasticity- Yield criteria of Von Mises criteria and Tresca criteria. 3) Sheet metal formability: Concept of sheet metal formability and forming diagram. Sheet/plate forming techniques: Stretch Forming, Spinning, Incremental forming. 4) Forging Processes: Comparison of forging with other manufacturing processes. Classification of forging processes-open die and closed die forging, Hot and cold forging, Basic forging operations such as drawing, fullering, edging, blocking etc, Forging equipment- Hammers and presses, construction working capacities and selection of equipment. 5) Special forging techniques: Isothermal forging, Rotary swaging, Orbital forging, Liquid forging and Powder forging. 6) Forgeability: Concept of forge ability and formability tests, Analysis of forging load considering friction, Analysis of upset forging, Forging defects and remedies. 7) Advanced Forming techniques: HERF: Explosive forming- Confined and unconfined techniques, High velocity forming- principles, comparison of high velocity and conventional Forming processes. Magnetic pulse forming, Electro hydraulic forming: principal and process,

SECTION-2 1) Rolling of Metals Scope and importance of rolling. Cold rolling and Hot rolling Types of Rolling Mills- Construction and working. 2) Analysis of Rolling load: Friction in rolling, Roll bite, reduction, elongation and spread. Analysis of rolling load. Deformation in rolling and determination forces required. 3) Rolling Process variables: redundant deformation. Roll flattening, Roll camber - its effect on rolling process, mill spring. Automatic gauge control- Lubrication in rolling, Defects in rolling. List of Practical (Any Six): 1. Estimation of amount total work done in tensile deformation of mild steel 2. Estimation of amount of total work done in compressive deformation of aluminum. 3. Design of edging die profile for lever forged component.



4. Rolls pass design for box pass. 5. Estimation of extrusion ratio, shape factor and circumscribing circle diameter for

structural section of aluminum. 6. Forgeability test of notched surface of low C steel. 7. Microstructural analysis of super plastically deformed sample. 8. Study of Industry practices in any metal forming industry 9. Measurement of plastic strain ratio of sheet metal. 10. Study the effect of strain rate on flow stress of metal List of Project areas: 1) To study effect of strain rate in tensile deformation at room temperature. 2) To study effect of strain rate in Compressive deformation at room temperature. 3) Estimation of flow stress at high temperature in tensile deformation. 4) Estimation of flow stress in compressive deformation. 5) Estimation of anisotropic behavior of metals. 6) Severe plastic deformation and characterization of mechanical and microstructural properties. 7) Forgeability analysis of various metals. 8) Texture analysis of metals after mechanical working. 9) Design and manufacture mini wire drawing set up. 10) Design and manufacture mini extrusion set up. Text Books: 1) Dieter G.E., “Mechanical Metallurgy”, McGraw Hill, Co., S.I. Edition, 2001 2) P. N. Rao, Manufacturing Technology, Tata McGraw Hill Reference Books: 1. Dr. R. Narayanswamy, Metal Forming Technology, Ahuja Book Co. 2. Surender Kumar, Principles of Metal Working, Oxford & IBH Publishing Company, 1985, Edition 2. 3. ASM Metal handbook, Metal working –Bulk Forming, Vol: 14A, ASM International 4. J. N. Harris, Mechanical working of metals 5. G. W. Rowe, Principles of industrial metal working process, Edward Arnold 6. Nagpal G.R., Metal forming processes, Khanna publishers, New Delhi, 2004 Course Outcomes: Students will be able to 1. understand fundamentals of elastic and plastic deformation of metals. 2. select appropriate forging process, equipment, tools and analysis of forging load.. 3. classify rolling processes, equipment and analysis of rolling forces and defects. 4. understand wire and tube drawing machines, tools and analyse wire and tube drawing

forces. 5. understand types of extrusion process and analysis of extrusion load and metal flow. 6. compare and apply nonconventional forming techniques.



FF No. : 654

PR3002::PRODUCTION PLANNING & CONTROL

Credits: 04 Teaching Scheme: 03 Hrs/Wk

SECTION-1 Scope of Operations Management - Nature, Scope, Importance, Various Functions in Operations, Types of Production Systems – Project type, Job shop, Batch Production, Flow / Continuous Production, Mass Production - Characteristics and applicability of each type. Operations Strategies: Process choice – Select the appropriate production system, Competitiveness with Operations, Competing on cost, quality, flexibility, speed, reliability. Order Winners & Order Qualifiers. Introduction to ETO, MTO, ATO & MTS OPC and Material Requirement Planning (MRP I) - Operations Planning & Control – PPC – Functions, Operations Planning & Control Framework. Material Requirement Planning (MRP I): Inputs to MRP – MPS, BOM –Types of BOM, BOM Explosion, Inventory Transaction Files, MRP Processing (Logic) Time Phased Operation Plan, Numerical on BOM Explosion Netting Requirements, Lot sizing methods. MRP II (Manufacturing Resource Planning) - Operations Control – Gantt Charts, Planning & Scheduling Techniques: Scheduling v/s Loading, Scheduling Types – Forward Scheduling & Backward Scheduling Scheduling Techniques –Single machine scheduling- SPT, WSPT, Slack per operations, Critical Ratio, EDD, etc. –Evaluate lateness, tardiness. Hogdson algorithm, Minimizing tardiness heuristics.

SECTION-2

Demand Forecasting -Components of Demand, Techniques of Demand Forecasting – Qualitative (Survey & Judgmental – Delphi, Expert Opinion) & Quantitative (Causal Methods – Input-Output Method, Leading Indicators Method & Time Series Analysis – Moving Average, Exponential Smoothing, Regression Method). Holts Model, Winters Model, Box-Jenkins Model. Measuring Errors in Forecasting – MAD, MFE, MSE & MAPE Aggregate Planning: Introduction, Requirement of Aggregate Plan, Steps in Developing an Aggregate Plan, Advantages of Aggregate Plan, Aggregate Planning Strategies, Planning Options. Selecting the Method in Aggregate Planning, Aggregate Planning in Services Pure Strategies – Chase, Level, Mixed Strategies, Role of Transportation. Detailed Capacity Requirement Planning, Assignment Models, Numerical in Aggregate Planning. Operations scheduling- LPT for multiprocessing machines, Flow shop Modeling-Johnson’s method – Johnson’s rule for 2,3 and M machines problem, CDS Methods, Minimize machine Idle Machine Method, Oven processing problems ,Network scheduling of jobs on parallel processing (similar Machines), Job shop scheduling-CLXspt method



List of Practicals: 1. Case study assignment on Production Systems & Operations Strategy 2. Assignment on MRP 1 – BOM Explosion & Netting Requirements 3. Assignment on Johnson’s method for 2, 3 and M machines problem 4. Assignment on Demand Forecasting – Forecast Demand & Measure Error 5. Numerical assignment on Aggregate Planning 6. Numerical assignment on operations scheduling Project Area- 1) Operations strategies Implementation 2) MRP-I Calculation & Lot sizing 3) MRP-II & Aggregate Planning 4) Scheduling Types Text Books: 1. Paneerselvam, Production & Operations Management, 3rd Edition, McGraw Hill Publications. Reference Books: 1. Chary, Production & Operations Management –1st Edition, McGraw Hill Publications 2. Chase, Production & Operations Management –1st Edition, Pearson Publications Course Outcomes: The student will be able to – 1. Understanding of Operations management strategies and its usefulness. 2. Understanding of effective measures like using of Lot Sizing mechanisms 3. Understanding different scheduling techniques used in Production system 4. Understanding different Forecasting techniques used in Production system 5. Understanding different Aggregate production strategies used in Production system 6. Understanding of Relevance of scheduling



FF No. : 654

PR3003::PRODUCTION METALLURGY Credits: 04 Teaching Scheme: 03 Hrs/Wk

SECTION-1

Introduction to Metallography: Micro and macro examination, Specimen preparation for micro & macro examination. Optical metallurgical microscope, Etching technique. Iron-Iron carbide equilibrium diagram, Critical temperatures, Allotropy, cooling curve and volume changes of pure iron. Microstructure, non-equilibrium cooling of steel, widmanstatten structure, structure property relationship. Classification and applications of plain carbon steels, specifications of some commonly used steels like BIS, EN, AISI, SAE. Introduction to heat treatment furnaces and Furnace atmospheres: Transformation products of austenite, Time-temperature- transformation diagrams, Critical cooling rate, Continuous cooling Transformation diagrams. Heat treatment of steels Quenching media, Annealing, Normalizing, Hardening, Tempering. Retention of austenite. Effects of retained austenite. Elimination of retained austenite, Tempering. Secondary hardening, Temper embrittlement, Hardenability testing. Defects due to heat treatment, causes and remedial measure. Surface hardening and Isothermal treatments – Process details, applications modifications in these treatments. Isothermal treatments like Austempering, Patenting, Iso forming, Ausforming etc. procedures of these treatments, applications

SECTION-2 Alloy Steels and Tool steels - Effects of alloying elements on properties of plain carbon steels, classification of alloying elements. Typical examples of alloy steels like HSLA, Duel phase steels, Maraging steels, Stainless Steels, Sensitization of stainless steel, weld decay of stainless steel. Tool steels and tool materials, Heat treatment of high-speed steel. Special purpose steels with applications. Special cutting materials like Stellites, Ceramics, Cermets etc. Cast irons - Differences between steels and cast irons. Classification of cast irons, Gray cast iron, White cast iron, Malleable cast iron, Ductile Iron, Chilled and alloy cast irons. Effects of various parameters on structures and properties of cast irons, Heat treatments of cast iron. Different alloy cast irons. Applications of cast irons for different components of machine tool, automobiles, pumps etc. Nonferrous alloys- Copper alloys like Brasses, Bronzes (Tin, Aluminium, Beryllium, Silicon bronzes) Copper nickel alloys, Nickel - Silver, Aluminium and aluminium alloys. Solders, Bearing materials and their properties and applications, Precipitation hardening



alloys. High Temperature materials such as Nimonics, Super alloys, Ti-alloys, Nickel alloys, Bio materials etc. Properties of these alloys and typical applications. List of Practicals: 1. Specimen preparation for micro examination. 2. Study and drawing microstructures of plain carbon steels. 3. Study and drawing microstructures of heat treated steels. 4. Study and drawing microstructures of Cast Irons. 5. Study and drawing microstructures of non ferrous alloys. 6. Hardenbility testing. List of Project areas: 1. Effect of carbon percentage on hardness after hardening. 2. Effect of Tempering temperature on hardness. 3. Use of macro examination in Metallography. 4. Hardenability testing of different steels and co relating results with composition of Steel. Text Books:

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

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

Edition, English Language Book Society. 3. K.G. Budinski, M. K. Budinski, Engineering Materials, Prentice –Hall India Pvt. Ltd. 4. Sidney H. Avner, An Introduction to Physical Metallurgy, Indian Edition Reference Books:

1. E.C. Rollason, Metallurgy for Engineers, English Language Book Society 2. Donald Clark and Wilbur Varney, Physical Metallurgy for Engineers, East- West Press

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

Thomson learning Inc. 4. A.S.M. Metals Hand book Volume 4, Heat Treatments. Course Outcomes: The student will be able to – 1. Interpret Fe-Fe3C equilibrium, microstructures & correlate structure-properties

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

mechanical properties of steels. 3. Apply the surface hardening & isothermal heat treatment techniques to enhance

mechanical properties of steels. 4. Select appropriate alloy steel and tool steel for different engineering applications 5. Select appropriate cast iron nonferrous material for different engineering applications. 6. Select appropriate non ferrous material for different engineering applications.



FF No. : 654

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

SECTION-1

1. Concepts of Quality- Meaning of Quality, Modern concept of Quality- Quality loss function, Quality Characteristics , Major aspects of Quality, Quality of Product versus Quality of Service, Quality control, Quality Assurance, Quality and Reliability, Quality Improvement, Cost of Quality, Value of Quality, Cost-Quality Trade-off, Quality and Productivity, some philosophies and their impact on Quality 2. Acceptance Sampling: 100% Inspection versus Sampling Inspection, Concept of Producer Risk and Consumers Risk, Operating Characteristics Curve, Some measures for evaluating sampling plans- AOQ, ATI, ASN, Types of Sampling Plan – Single, multiple and sequential sampling plans. Design of single sampling plans, Determining Sampling Plan on the basis of MIL, ASQ Standards 3. Statistical Process Control: Variations – Concept, Causes – Special & Common, Statistical basis for control chart, Errors in making inferences from control charts- Type I and Type II errors, Difference – Process in Control versus Process is Capable, Control Charts for variables and Attributes, Process capability Analysis, Process capability Indices, Six Sigma Limits

SECTION-2 1. Introduction to TQM, Quality Circles, Quality function Deployment, Benchmarking, Quality Improvement Tools- Check Sheet, Histogram, Pareto Chart, Fishbone Diagram, Run Charts, Scatter Diagram, Process Flow Chart, QM Tools – Program Decision Process Chart, Tree Diagram, Affinity Diagram, Prioritization Matrix, Matrix Diagram, Network diagram, other Quality tools like why-why Analysis, Mistake Proofing 2. Importance and overview of ISO 9000, Standard clauses, Introduction to TS16949, ISO 9000 Certification: Certifying Bodies & Accreditation Agencies, Necessity for Certification & Certification Process, Benefits of Certification 3. Introduction to Six Sigma: Definition, Concept, Six Sigma Approaches – Design for Six Sigma (DFSS) Approach & DMAIC Approach, Six Sigma Tools, Methodology, Six Sigma Organization 4. Reliability: Concept of probability, definition, Life-cycle curve and probability distribution in modeling Reliability- exponential and weibull distributions, determination of MTBF and MTTR, Active and Passive Redundancy, Evaluation of overall system reliability- series, parallel and mixed configuration Concept of Maintenance, Preventive maintenance, reliability centered maintenance, system availability and maintainability



List of Practicals: 1. Assignment on Control Charts for Variables 2. Assignment on Control Charts for Attributes 3. Assignment on Process Capability Analysis 4. Assignment on Design of Acceptance Sampling plans 5. Assignment on Determination of AOQ, AOQL, ATI and ASN 6. Construction of control chart, Run Chart, Cause & Effect Diagram, Scatter plot, Pareto Chart using MINITAB/SPSS/R software 7. Case study on application of 7 QC tools 8. Case study on application of & QM tools 9. Case study on implementation and impact of Six Sigma Projects. 10 Assignments on Reliability List of Project areas: 1. Quality Function Deployment – Constructing House of Quality: Products and Services 2. Process Improvement through Six Sigma (Define, Measure and Analyse phase) Text Books: 1. Amitava Mitra; Fundamentals of Quality Control & Improvement; 2nd edition, Pearson Education 2002 2. Phadke M. S.; Quality Engineering using Robust Design; Pearson Education 2008 3. A.V. Feigenbaum; Total Quality Control; McGraw Hill International Editions, USA.1987 4. Douglas. C. Montgomery; Introduction to Statistical quality control; 4th edition, John Wiley 2001. 5. Charles E. Ebelin; Reliability and maintainability engineering; TMH (2000) Reference Books: 1. J. M. Juran & F. M. Gryna; Quality Planning and Analysis; 5th Edition, McGraw-Hill, 1993 2. Juran’s Quality Handbook; J. M. Juran, A. Blanton Godfrey; 5th Edition, McGraw Hill Professional, 1999 3. E.L. Grant & R.S. Leavenworth; Statistical Quality Control; 7th Edition, Tata McGraw Hill 4. Kaoru Ishikawa; Guide to Quality Control; Asian Productivity Organisation, Tokyo, 1986. 5. ISO 9000 Quality Management System; International Trade Center, Geneva 6. Patrick D. T. O’Connor; Practical Reliability Engineering; 4th edition, John Wiley 1993 7. Green A. E., and Bourne A. J.; Reliability Technology; Wiley Inderscience, 1991 Course Outcomes: The student will be able to – 1. Understand and apply principles of quality management 2. Interpret for process control, identify and analyze and eliminate/reduce causes of

variation and carry out process capability studies 3. Select and design an acceptance sampling plan for sampling inspection



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

5. Understand and apply Six Sigma Methodology and QMS and its applications 6. Evaluate reliability, maintainability and availability of product/component systems



FF No.: 654

PR3005::WORK STUDY & HUMAN FACTORS ENGINEERING Credits: 4 Teaching Scheme: Th-3 Hrs/Wk + Lab/Project-2 Hrs/Wk

SECTION-1

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

Contribution of Taylor and Gilbreth, Productivity – Definition, Types, Improvement, Work Content Analysis, Definition and Scope of Work Study, Productivity study, productivity ratios, Numerical and Cases on Productivity

2. Methods Analysis - Definition, Steps in Method Study, Various Considerations to select a job for Method Study, Recording – Significance, Need, Charting Symbols, Recording Techniques - Charts and Diagrams, Examine – Questioning Techniques – Primary & Secondary Questions, Methods improvement - cost benefit analysis, Cases on Recording Techniques

3. Methods Improvement - Introduction to Principles of Motion Economy, Develop – Alternate Methods of Doing Work, Evaluate – Criteria for Evaluating & Selecting Best Method, Define – Develop Standard Operating Procedures, Work Instructions, Implement – Practical Aspects in Implementing New Method, Overcoming Resistance to Change, Maintain, Standard Operating Procedures – Developing SOPs, Standard Work Instructions

SECTION-2

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

Standard Time, Video Time Study – Elemental breakdown of tasks, types of elements, Rating – Concept, Types, Allowances – Concept, Types, Application, Calculation of Standard Time, Numerical on estimating standard time, Work Sampling – Steps Involved, Applications, Advantages

2. Predetermined Motion Time Standards – Introduction, Methods Time Measurement – Establishing Time Standards using MTM. Introduction to MOST - Basic, Mini and Maxi MOST, General Move, Control Move, Tool Use Sequence, examples on MOST

3. Introduction to Human Factors Engineering - Definition and scope, objectives, human-machine system, characteristics of human-machine system, need for application of Human Factors Engineering in industry and society, Introduction to Anthropometry, type of dimensions, use of anthropometry data, Principles in the application of anthropometric data, work space envelopes, work place design, science of seating,. Principles of seat design, design of work surfaces

List of Practical: 1. Numerical on Productivity 2. Assignment on Recording Tools & Techniques - Charts



3. Assignment on Recording Tools & Techniques - Diagrams 4. Training in Rating - Dealing Cards 5. Setting Time Standards using Time Study – Video Analysis 6. Application of anthropometric data List of Project areas: 1. Productivity improvement 2. Work content analysis 3. Methods improvement 4. Work place design 5. Work Sampling 6. Work Measurement using Time Study 7 Designing a work place using principles of Ergonomic design 8. Designing a product using principles of Ergonomic design Text Books 1. George Kanawaty, Introduction to Work Study, Fourth revised edition, Universal Book

Corporation, Bombay. International Labour Office, Geneva Reference Books 1. Kjell B. Zandin, Most Work Measurement Systems, Second revised edition, Marcel Dekker, Inc, New York 2. M. S. Sanders and Ernest J. McCormick, Human Factors Engineering and Design, Seventh edition, McGraw-Hill Inc Course Outcomes: The student will be able to – 1. Understand and apply productivity concepts and principles and analyze work content 2. Systematically record; critically examine methods of doing work to effect improvements 3. Design the workplace using principles of motion economy and develop improved methods 4. Establish standard time to carry out a specified job using stop watch time study 5. Establish standard time to carry out a specified job using video watch time study 6. Establish standard time to carry out a specified job using predetermined time standards



FF No.: 654

PR3006::CAD/CAM/CIM Credits: 4 Teaching Scheme: Th-3 Hrs/Wk + Lab/Project-2 Hrs/Wk

SECTION-1 Review of CAD/CAM systems - 3 hours Product life cycle, CAD/CAM systems and applications, 3D modeling concepts, PLM and associated databases Computer Graphics - 4 hours Transformations – 2D & 3D, Homogenous representation, concatenated transformations, Visualisation – Hidden line, surface and solid algorithms, shading, colors Geometric modeling – Curves - 6 hours Curve entities and representation, analytic curves – line, circle, ellipse, parabola, synthetic curves – Hermite cubic spline, Bezier curve, B-spline curve, NURBs, Curve manipulations Geometric modeling – Solids - 4 hours Geometry and topology, solid entities and representation, Boundary representation, Constructive solid geometry, Features

SECTION-2 Computer Aided Manufacturing- Scope-Manufacturing Planning and Manufacturing Control, CAD/CAM, Process definition and manufacturing planning – Structures of a process plan – CAD based process planning – Coding systems – Methods of CAPP – Process planning systems., Nature of the CIM system – Types of manufacturing systems – Evolution of CIM – Computers in CIM. Background – Role of MRP – II in CIM systems, NC & CNC Machine tools Basics 1)INTRODUCTION TO CNC MACHINE TOOLS Evolution of CNC Technology, principles, features, advantages, applications, CNC and DNC concept, classification of CNC Machines – turning centre, machining centre, grinding machine, EDM, types of control systems, CNC controllers, characteristics, interpolators– Computer Aided Inspection 2)STRUCTURE OF CNC MACHINE TOOL CNC Machine building, structural details, configuration and design, guide ways – Friction, Anti friction and other types of guide ways, elements used to convert the rotary motion to a linear motion – Screw and nut, recirculating ball screw, planetary roller screw, recirculating roller screw, rack and pinion, spindle assembly, torque transmission elements – gears, timing belts, flexible couplings, Bearings.



3) DRIVES AND CONTROLS Spindle drives – DC shunt motor, 3 phase AC induction motor, feed drives –stepper motor, servo principle, DC and AC servomotors, Open loop and closed loop control, Axis measuring system – synchro, synchro-resolver, gratings, moiré fringe gratings, encoders, inductosysn, laser interferometer. 4)CNC PROGRAMMING 11 Coordinate system, structure of a part program, G & M Codes, tool length compensation, cutter radius and tool nose radius compensation, do loops, subroutines, canned cycles, mirror image, parametric programming, machining cycles, programming for machining centre and turning centre for well known controllers such as Fanuc, Heidenhain, Sinumerik etc., generation of CNC codes from CAM packages. 5) TOOLING AND WORK HOLDING DEVICES -Introduction to cutting tool materials – Carbides, Ceramics, CBN, PCD–inserts classification- PMK, NSH, qualified, semi qualified and preset tooling, tooling system for Machining centre and Turning centre, work holding devices for rotating and fixed work parts, economics of CNC, maintenance of CNC machines. CAM software – Integration of computers in CIM environment List of Practicals- 1. 2D transformations of geometric entities 2. 3D transformations of geometric entities 3. Enumeration and illustration of synthetic curves 4. Toolpath optimization and simulation for milling operations 5. Toolpath optimization and simulation for turning operations 6. CNC Lathe – 4 exercises - 7. Generation of tool path, generation of NC code, Optimization of tool path (to reduce

machining time) using any CAM software Project Areas: 1. Manufacturing of complex Job on Technofour CNC TMW200 machine Text Books: 1. Groover, Zimmer-CAD/CAM: Computer-aided Design & Manufacturing 7th Edition

Pearson Education 2010 2. Ibrahim Zeid, CAD/CAM - Theory &Practice Tata McGraw Hill Reference Books: 1. Rao P N Introduction to CAD/CAM Tata McGraw Hill Publishing Co.2011 Course Outcomes- 1. Understand and appreciate use of computer in product development. 2. Apply algorithms of graphical entity generation. 3. Understand mathematical aspects of geometrical modelling 4. Understand and use finite element methods for analysis of simple components. 5. Understand hard and soft automation and CAM 6. Describe construction and working of CNC machines. 7. Understand concepts of CAM,CIM and FMS



FF No. : 654

PR3007::DESIGN OF MACHINE ELEMENTS

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

SECTION-1

Design of Shafts, Keys and Couplings Design of solid and hollow shafts based on strength, rigidity, ASME code for shaft design. Keys, Types of keys, Design of keys and key ways Couplings, Types of Couplings, Design of muff coupling, Design of rigid and flexible couplings. Design of Spur and Helical Gears Spur Gear: Introduction, Standard Proportions of Gear Systems, Gear Materials, various design considerations, Beam Strength of gear teeth- Lewis Equation, tangential loading, module Calculations, width calculations, Dynamic tooth loads, Spott’s Equation, types of gear tooth failures, Spur Gear construction, Design of Spur Gears. Helical Gears: Introduction, Terms used in Helical Gears. Proportion of the Helical Gears, Strength of Helical Gears Design of Helical Gears Design for Fluctuating Loads and Flywheel Design for Fluctuating Loads: Fluctuating stresses, Fatigue failure, fatigue strength and endurance limit, Introduction to S-N diagram, Low cycle and High cycle fatigue, Stress concentration factor and Notch sensitivity. Factors affecting fatigue strength. Goodman and Soderberg diagram, Modified Goodman’s diagrams for fatigue design. Cumulative fatigue damage.

SECTION-2 Rolling Contact Bearings Types, Static and Dynamic load Capacity, Stribeck’s Equation, Concept of equivalent load, Load life Relationship, Selection of bearing from Manufacturer’s Catalogue, Design forbearing for variable loads and Speeds, Bearings with Probability of Survival other than 90%. Lubrication and Mounting of bearings, oil Seals and packing used for bearings. Design of Threaded, Welded Joints and Power Screw Design of Power Screw -- Types, materials used, thread forms and their applications; types of stresses induced, overhauling and self-locking properties, design of nuts. Design of bolted joints subjected to transverse and eccentric loads. Design of welded joints for various loading conditions Design of Springs Types, Application and materials of springs, Stress and deflection equation for Helical springs, Styles of ends, Design of helical springs, Helical Springs in Parallel and Series, Design of Helical Springs for Variable Load. List of Project areas:



Students will perform projects of following designs for material selection, design calculations, assembly and detail drawing. 1. Design and drawing of Two/ Three stage Gear box used for any industrial applications 2. Design and drawing of shaft subjected under static and dynamic loads. 3. Design and drawing of rigid/ flexible flange coupling for any industrial application. 4. Design and drawing of levers used in industry 5. Design and drawing of helical spring for any industrial application

Text Books:

1. V. B. Bhandari Design of Machine Elements Tata McGraw Hill Publications, 2. R. K. Jain Machine Design Khanna Publication, 3. Pandya and Shah Machine Design Charotar Publication, 4. Hall, Holowenko

Laughlin Machine Design Tata McGraw Hill Publication,

5. J.F. Shigley Design of Machine Element McGraw Hill Publication 6. M. F. Spotts Design of Machine Element Pearson Education Publication, 7. PSG Design data Book

Reference Books:

1. P. Kannaiah, Design of Machine Elements Scitech Publication, 2. H. Burr and

Cheatam, Mechanical Analysis and Design, Prentice Hall Publication,

3. P. Kannaiah, Design of Transmission Systems, Scitech Publication, 4. R. L. Norton Machine Design An Integrated

Approach, Pearson Education Publication

5. S. S. Wadhwa and S. S. Jolly

Machine Design A Basic Approach Dhanapat Rai and Sons

Course Outcomes: Students will be able to: 1. Analyze the stress and strain mechanical components such as shaft, keys and couplings

and design the same for various industrial applications. 2. Design spur and helical gears for various applications. 3. Select different types of rolling contact bearings from manufacturer’s catalogue for

various industrial applications. 4. Analyze the stress and strain in power screw and design the same for various industrial

applications. 5. Analyze the stress and strain in threaded and welded joints and design the same for

various industrial applications. 6. Design mechanical components for fluctuating and reversible loading conditions.



FF No. : 654

PR3008::DESIGN FOR MANUFACTURING & ASSEMBLY Credits: 04 Teaching Scheme: Th-3Hrs + Lab-2Hrs/Wk

SECTION-1

Product Design Process Importance, design process, steps, concept, design, product life cycle, technology, development cycle, sequential vs. concurrent design approach. Economics of Process selection – General design principles of manufacturability, Material selection – Strength and Mechanical factors- Application of form design, Selection of Shapes Design for Manufacture Review of Manufacturing Processes, Selection of manufacturing Processes, Design for Casting, Design for Bulk Deformation Processes, Design for Sheet Metal Forming Processes, Design for Machining, Design for plastic processing, injection molding etc. Design for Assembly Review of Assembly Processes, Design for Welding, Design for Brazing and Soldering, Design for Adhesive Bonding. Types of assembly, DFA, evaluation of assembly, assembly cost reduction , Case studies for design for manufacture and design of assembly.

SECTION-2 Design for Reliability and Quality Design for Quality, House of quality for QFD process, Human Engineering Considerations in Product Design, Identification of controls, Design for Optimization, Design for Reliability, Approach to Robust Design, Failure Mode and Effect Analysis. Failure Mode and Effect Analysis Design for Maintainability and Safety Maintenance, Need of Maintenance Management, Maintenance practices on production machines- Lathe, Drilling, Milling, Welding, Shaper, CNCs. Rules for Design for Maintainability, Safety aspects in Manufacturing Environment, Design for Safety application for products and Equipments Design for Specific Purpose Design for Additive Manufacturing, Design for Logistics, Design for Delayed differentiation, Design for ergonomics, Design for Environment, Design for recycling, Case studies based on above DFX concepts

Text Books 1. Dieter George E "ENGINEERING DESIGN" 3rd addition Mc Graw Hills Publications

2000. 2. M Fashby and K Johnson, Materials and Design - the art and science of material selection

in product design, Butterworth-Heinemann, 2003.



3. G Boothroyd, P Dewhurst and W Knight, Product design for manufacture and assembly, John Wiley, NY: Marcel Dekkar, 1994.

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

Arnold, 1997. 2. J G Bralla, Handbook for Product Design for Manufacture, McGraw Hill, NY, 1998. 3. ASTM Design handbook. Course Outcomes: The student will be able to: 1. Understand product design process. 2. Select materials for given objects by following material selection process. 3. Understand design principles for different manufacturing processes. 4. Understand DFA principles to apply for analysis of assemblies 5. Apply the concept of quality and reliability for design and manufacturing



Module VI



FF No. : 654

PR3036::ADDITIVE MANUFACTURING TECHNIQUES Credits: 04 Teaching Scheme: Th-3Hrs + Lab-2Hrs/Wk

SECTION-1

INTRODUCTION Overview – History – Need-Classification -Additive Manufacturing Technology in product development - Materials for Additive Manufacturing Technology – Tooling – Applications CAD & REVERSE ENGINEERING Basic Concept – Digitization techniques – Model Reconstruction – Data Processing for Additive Manufacturing Technology: CAD model preparation – Part Orientation and support generation – Model Slicing –Tool path Generation – Softwares for Additive Manufacturing Technology: MIMICS, MAGICS LIQUID BASED AND SOLID BASED ADDITIVE MANUFACTURING SYSTEMS Classification – Liquid based system – Stereolithography Apparatus (SLA) - Principle, process, advantages and applications – Solid based system –Fused Deposition Modeling – Principle, process, advantages and applications, Laminated Object Manufacturing

SECTION-2

POWDER BASED ADDITIVE MANUFACTURING SYSTEMS Selective Laser Sintering – Principles of SLS process – Process, advantages and applications, Three Dimensional Printing – Principle, process, advantages and applications- Laser Engineered Net Shaping (LENS), Electron Beam Melting MEDICAL AND BIO-ADDITIVE MANUFACTURING Customized implants and prosthesis: Design and production, Bio-Additive Manufacturing - Computer Aided Tissue Engineering (CATE) – Case studies DESIGN FOR ADDITIVE MANUFACTURING PROCESSES Motivation, DFMA concepts and objectives, AM unique capabilities, Exploring design freedoms, Design tools for AM, Part Orientation, Removal of Supports, Hollowing out parts, Inclusion of Undercuts and Other Manufacturing Constraining Features, Interlocking Features, Reduction of Part Count in an Assembly, Identification of markings/ numbers etc. List of Project Areas: 1. Creation of input files for 3D Model and logic behind it 2. Analysis and modeling of different slicing strategies 3. Blending and G Code generation 4. D Printing of objects



Text Books: 1. Chua C.K., Leong

K.F. and Lim C.S. Rapid prototyping: Principles and applications

Third Edition

World Scientific Publishers

2010

2. Gebhardt A. Rapid prototyping Hanser Gardener Publications

2003

Reference Books:

1. Liou L.W. and Liou F.W

Rapid Prototyping and Engineering applications: A tool box for prototype development

CRC Press 2007

2. Kamrani A.K. and Nasr E.A.

Rapid Prototyping: Theory and practice

Springer 2006

3. Hilton P.D. and Jacobs P F

1. Rapid Tooling: Technologies and Industrial Applications

CRC press 2000

Course Outcomes: Students will be able to: 1. Understand various additive manufacturing processes for different applications 2. Use correct CAD file formats in 3D printed parts manufacturing 3. Select appropriate 3D printing parameters considering shape features, part quality and

printer specifications 4. Apply AM concepts for Bio medical and medical fields 5. Perform reverse engineering steps to prepare virtual model 6. Operate 3D printer machine to manufacture desired 3D objects



FF No. : 654

PR3037::MODERN MANUFACTURING PROCESSES Credits: 04 Teaching Scheme: 3Hrs/Wk

SECTION-1

Introduction to nontraditional machining methods - Need for non - traditional machining - Sources of metal removal - Classification on the basis of energy sources - Parameters influencing selection of process Mechanical Processes Abrasive Jet Machining – Water Jet Machining – Abrasive Water Jet Machining. (AJM, WJM and AWJM). Operating principles -Equipment -Parameters influencing metal removal - Applications -Advantages and Limitations. Ultrasonic Machining, Operating Principle and Process characteristics Thermo Electrical Energy Techniques Electrical Discharge Machining (EDM) Fundamental principle of EDM, Equipment’s required for EDM process parameters, process capabilities. Application example trouble shooting, Introduction to wire EDM, Process principle and parameters, process capacities and its applications.EDM tool design, Machine tool selection, EDM accessories / applications, electrical discharge grinding.

SECTION-2 Thermal Energy Techniques Operating principles - Equipment and sub systems - Parameters influencing metal removal- Benefits - Applications - Advantages and limitations of Electron beam machining (EBM), Plasma ARC Machining (PAM) and laser beam machining (LBM). Electron Beam Machining, EBM Principle and process characteristics Electro Chemical Machining (ECM) Background of ECM process, Classification of ECM processes. Electrochemistry of ECM, Equipment required in ECM. Process capabilities and processes parameters. Evaluation of MRR. Parameters influencing metal removal- Applications - Advantages and limitations. Electro Chemical Grinding: Process principles, process parameters, Applications Chemical Machining (CHM) Introduction, Elements of process Chemical blanking process:-Preparation of workpiece. Preparation of masters, masking with photo resists, etching for blanking, applications of chemical blanking, chemical milling (Contour machining):- Process steps – masking, Etching, process characteristics of CHM :-material removal rate accuracy, surface finish, Advantages & application of CHM. Electro-chemical Drilling and De-burring operations. List of Practicals: 1. Student will do exercises based modeling of following processes in order to predict

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



2. Exercise on Ultrasonic machining (USM), Abrasive Jet Machining (AJM) and Abrasive water jet machining (AWJM)

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

4. Exercise on Laser Beam Machining (LBM), Plasma Arc Machining (PAM) and Electron Beam Machining (EBM)

5. Exercise on Electro Chemical Machining (ECM) and Chemical Metal removal process 6. Case study on Hybrid material Removal process (ECDM, ECG, EDG etc.) List of Project areas: Students will perform projects of following processes (Any One) for experimental investigation of the process, modeling of the process and process optimization. 1. Abrasive water jet Machining 2. Electro Discharge Machining 3. Laser Beam Machining 4. Wire- Electro discharge Machining Text Books:

1. V. K. Jain Advanced Machining Processes

Edition No.,

Allied Publishers Pvt. Ltd.

2007

2. P. K. Mishra Non-Conventional Machining

Edition No.,

The Institution of Engineers (India)

1997

3. P. C. Pandey and H. S. Shan

Modern Machining Processes

Edition No.,

Tata McGraw-Hill 2007

Reference Books:

1. G. F. Benedict, Unconventional Machining Process,

Edition No.,

Marcel Dekker Publication, New York,

1987

2. McGeough, Advanced Methods of Machining,

Edition No.,

Chapman and Hall, London,

1998

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

Edition No.

New Delhi, 1995

4. P. DeGarmo, J. T. Black, and R. A. Kohser,

Material & Processes in Manufacturing

Edition No. 8

Prentice Hall of India Pvt. Ltd., New Delhi

2001

Course Outcomes: Students will be able to: 1. Understand need of advanced machining processes and select process for any industrial

job based on its complexity, cost and specifications required. 2. Apply the working principles and processing characteristics of mechanical type advanced

machining processes such as USM, AJM, WJM and Develop experimental, regression based, mathematical and physics based models for the advanced machining processes and predict MRR and surface roughness.



3. Apply the working principles and processing characteristics of electro-thermal type advanced machining processes such as EDM, wire-EDM and Develop experimental, regression based, mathematical and physics based models for the advanced machining processes and predict MRR and surface roughness.

4. Apply the working principles and processing characteristics of thermal type advanced machining processes such as PAM, LBM, EBM machining to the production of precision components.

5. Apply the working principles and processing characteristics of chemical type advanced machining processes such as Electrochemical Machining to the production of precision micro and macro components.

6. Apply the working principles and processing characteristics of chemical type advanced machining process for production of precision components.



FF No. : 654

PR3038:: METAL CUTTING & TOOL DESIGN

Credits: 04 Teaching Scheme: 3Hrs/Wk

SECTION-1

Tool Nomenclature Milling cutter, broach, Single point cutting tool, various tool elements, Designation of cutting tools in ORS & ASA Systems, Importance of tool angles, Method of machining- orthogonal, oblique cutting, Nomenclature of drill Theory of Metal Cutting Mechanics of chips formation, types of chips, determination of shear angle, chip reduction factor, velocity relationship, merchant force circle, estimation of cutting forces, Tool dynamometer. Heat generation & tool life Heat generation in cutting, functions of cutting fluid, characteristics of cutting fluid, types of cutting fluid, Tool wear, Tool life, modified Taylor’s equation, Tool dynamometers.

SECTION-2 Fundamentals of jig & fixtures Introduction to jig & fixture, difference between jig & fixtures. Classification of jig & fixtures. Principle of location, types of locators. Principle of guiding elements Types of guiding elements, Principle of clamping elements, Types of clamps. Types of Jigs & Fixtures Design of jig & fixtures Concept of modular fixtures. General guide lines & procedures for design of jig & fixtures, Bodies, bases & frame, Design of locators, Design of guiding elements, Analysis of number of clamping forces required & their magnitude Design of cutting tools Tool materials, design of single point cutting tool, form tool, drill, reamer, Design of broach & plain milling cutter List of Practicals: (Any Ten) 1. Experiment on chip formation. 2. Measurement of shear angle using chip thickness ratio criteria. 3. Study of influence of cutting parameters on surface roughness in turning. 4. Measurement of cutting forces in turning using lathe tool dynamometer. 5. Verification of metal cutting theories. 6. Tool life study on a single point turning tool. 7. Design & working drawing of one drilling jig. 8. Design & working drawing of one Fixture. 9. Design & working drawing of one Form tool. 10. Design & working drawing of any two of following cutting tools. 11. SPCT, Reamer, Broach, Plain milling cutter 12. Industrial visit report.



13. Research paper study & presentation on metal cutting processes Text Books:

1 P C Sharma Production Engg. Khanna publishers

2 M.H.A. Kempster

Introduction to Jigs and fixtures design

Reference Books:

1 Nagpal Tool Engg 2007 2 Dolalson, Lecain

and Gold Tool design Tata McGraw

hill 2011

3 Hoffman Introduction to Jigs and fixtures 4 A.S.T.M.E. Tool Engineering Handbook 5 Basu, Mukherjee

and Mishra Fundamentals of tool engineering and design

6 R. K. Jain Production Technology Khanna Publishers

7 Milton Shaw Metal cutting principle Course Outcomes: Students will be able to: 1. Understand and represent cutting tools using designation systems 2. Apply metal cutting theories to estimate and represent cutting forces 3. Analyze cutting environment and cutting parameters 4. Understand design principles of location, clamping for jigs and fixtures 5. Design and draw jigs and fixtures by following design principles 6. Design and draw single and multi-point cutting tools



FF No. : 654

PR3039::MANUFACTURING AUTOMATION


SECTION-1 1) Hard automation Capstan Turret lathes, SPMs, automats –Single spindle and multispindle automats, Tool layouts, Cam design, Transfer lines, types, work part transfer mechanisms, control of production line, transfer line performance 2) Soft Automation- Introduction, types, major elements and optimization of FMS, Group technology, cellular manufacturing, Group technology – part families formation, classification and codification systems (DCLASS, MICLASS, OPITZ), Operational elements in a typical FMC – Typical FMS layout, Integration and Implementation issues in CAD/CAM/CIM – Introduction – Requirements for integrated manufacturing systems – Economic justification of CAD/CAM/CIM technologies – Steps to implement CIM. Conceptual understanding of Lean manufacturing, Agile manufacturing 3) Control Technologies In Automation Industrial Control Systems, process industries verses discrete-manufacturing industries, continuous versus discrete Control. Computer based control process and its forms. Open and closed loop control system. Control system components. Introduction to sensor technology, various sensors, transducers, signal processing. Programming of microprocessors using 8085 instructions. Programmable logic controllers

SECTION-2 1) Robotics ROBOTICS: Components, Configuration, Specifications of Robots Classifications of robots Work envelope Flexible automation versus Robotic technology , Forward and inverse Kinematics Machine vision system, Applications, DC and AC Servo driving units, encoders, grippers, sensors, programming. Application of robots in machining - Welding - Assembly - Material handling - Loading and unloading - CIM - Hostile and remote environments 2) Automatic material handling and inspection Automatic material handling and inspection, Automated guided vehicles systems, conveyor systems, automated inspection, Analysis, carousel storage systems, automatic gauging system 3) Factory automation, Assembly systems Factory automation, Assembly systems, automated assembly, design for automated assembly, vibratory bowl feeders, hopper feeders, rotary disc feeders. Synchronous and non synchronous material transfer, centrifugal, revolving feeders List of Practicals: 1) Tool layout of Turret lathe 2) Cam design of single spindle automat



3) Analysis of transfer lines with no internal storage 4) Analysis of AGVs. 5) Conveyor system analysis. 6) Programming on Robot for loading and unloading of job List of Project areas: 1. Design a mechatronics system-e.g System to accept different type of coins, Mechatronics

design of robotic walking machine etc. Text Books: 1. Mikell P. Grover, Automation, Production Systems and Computer Integrated

Manufacturing, Pearson Education, New Delhi. ISBN: 0132393212 2. N. Viswanandham, Y. Narhari, Performance Modeling of Automated Manufacturing

Systems, Prentice-Hall. ISBN: 0136588247 3. P. C. Sharma, Production Engineering, S. Chand and Co. New Delhi, ISBN-81-219-

0111-1 Reference Books: 1. W Bolton, Mechatronics: Electronic Control Systems in Mechanical and Electrical

Engineering, Prentice-Hall. ISBN: 0131216333 2. C D Johnson, Process Control Instrumentation Technology, Prentice Hall of India, New

Delhi. ISBN: 8120309871. Course Outcomes: The student will be able to – 1. Understand transfer line technology 2. Able to classify jobs according to group technology 3. Study various elements and applications of industrial robots 4. Understand concepts FMS 5. Understand and Analyze performance of automated conveyance and inspection systems 6. Understand principles of automated assembly systems



FF No.: 654

PR3040::MACHINE TOOL DESIGN Credits: 04 Teaching Scheme: Lecture 3 Hours/Week Lab 2 Hours/Week

SECTION-1

Design of Machine Tool Drives Stepped Regulation of Speed, Laws of Stepped Regulation, Why Geometric Progression is used against Arithmetic, Harmonic & Logarithmic despite shortcomings, Relation between Range ratio, Geometric Progression Ratio and No. of Speed Steps, 3)Design of Stepped Drives: Break up of Speed Steps, Structural Formulae, Structural Diagram, Selection of Best Structural Diagram, Ray Diagram, Speed Chart, General recommendations for Developing the Gearing Diagram, Determining the number of teeth of Gears. 4) Speed/ Feed Gear box : Limiting Transmission Ratio of Speed / Feed Gear Box. Design of Spindle Function & Requirements of Spindle Units, their Materials, Effect of Machine Tool Compliance on Machining accuracy Design of Spindle for Bending Stiffness: Deflection of Spindle Axis due to a) Bending, b) - due to Compliance of Spindle Supports, c) - due to Compliance of the Tapered Joint. Optimum Spacing between Spindle Supports, Permissible Deflection & Design for stiffness: Additional Check for Strength like Additional Supports, Location of Bearings and Drive elements Design of Spindle Supports Requirements of Spindle Supports, Features of Anti-friction Bearings, Load bearing abilities of Ball & Roller Bearings. Parameters which assess the viability of combination of roller & Ball & Roller Bearings in Spindle Units. Preloading of Anti Friction Bearing & its method Design of Sliding Bearings: Sleeve, Hydrodynamic Journal, Hydrostatic Journal, Air-Lubricated (Aerodynamic, Aerostatic).

SECTION-2 Design of Machine Tool Structure Function & Requirement of Machine Tool Structure, Design Criteria from Strength & Stiffness considerations, Concept of Unit Rigidity, Unit Strength under Tension, Unit Strength under Torsion & Unit Strength under Bending for Material of Machine Tool Structures, Compare Steel & Cast Iron on the basis of Material Properties, Manufacturing Problems and Economy, Role of Static & Dynamic Stiffness in the design of elements of machine tools, Profiles of Machine Tool Structures, Factors affecting stiffness of machine tool structures & methods of improving it, Basic Design procedure of machine tool structures Design of Guide-ways Design Criteria (Wear Resistance & Stiffness) and Calculations for Slide-ways operating under semi liquid friction condition, ‘Stick Slip’ phenomena affects accuracy of setting & working motions. Comparison of Design & stiffness of Hydrodynamic, Hydrostatic & Aerostatic Slide-ways, Design of Antifriction Guide-way, Concept of Combination Guide-



ways. Function & Types of Guide-ways, Types of Slide-ways & Antifriction Ways, Functional features of Slide-ways, its Shapes & Materials, Methods of adjusting Clearance Design of Power Screws Design of Sliding friction Power Screw for Wear Resistance, Strength, Stiffness, & Buckling Stability. Design of Rolling friction Power Screw for Strength under static loading, Strength under cyclic loading, & Stiffness

List of Practicals: 1. Design and Working Drawing of Speed Gear Box for Lathe 2. Design and Working Drawing of Feed Gear Box for Drilling Machine 3. Design and Working Drawing of Spindle for Lathe 4. Design and Working Drawing of Spindle-Support for Lathe 5. Design and Working Drawing of Sliding Friction Power Screw 6. Design and Working Drawing of Rolling Friction Power Screw

…. List of Project areas: 1. Design Case Studies of Bed of Lathe Column & Base of Milling Machine 2. Design Case Studies of Column of Milling Machine 3. Design Case Studies of Base of Milling Machine 4. Analyze and Design Lathe machine stepped gearbox

Text Books:

1. N. K. Mehta, Machine Tool Design,

2nd Edition, Tata McGraw Hill,

2011.

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

4th Edition, Oxford, 2005.

3. G. C. Sen, A. Bhattacharya

Principles of Machine Tool

2nd Edition New central book agency Calcutta

1967

Reference Books:

1. N. S. Acherkan, V. Vermakov

Machine Tool Design Vol 2,

1st Edition, MIR publication,

2000.

2. F. Koenigsberger, Design Principles of Metal Cutting Machine Tools,

1st Edition., The Macmillan Company,

1964.

Course Outcomes: The student will be able to – 1. Design stepped speed gear boxes. 2. Design spindles using minimum deflection criterion 3. Design suitable bearings for spindle supports. 4. Analyze and design various machine tool structure using principle of free body diagram

and using minimum deflection design criterion 5. Design sliding and rolling friction guideways 6. Design sliding and rolling friction power screws



FF No.: 654

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

SECTION-1

1 Introduction to Fluid Power-Basics (…7.. Hours) Pascal’s Law, properties of fluid, laminar and turbulent flow, Pressure drop in hoses/pipes, Power units and accessories, Types of hydraulic fluids - petroleum based, synthetic and water based, selection of fluids, additives, effect of temperature and pressure on hydraulic fluid. Seals, sealing materials, compatibility of seal with fluids, Types of pipes, hoses, material, quick acting couplings, Fluid conditioning through filters, strainers, sources of contamination and contamination control. 2 Hudraulic Pumps (…8.. Hours) Pumps: Types, classification, principle of working and constructional details of vane pumps, gear pumps, radial and axial plunger pumps, screw pumps, power and efficiency calculations, characteristics curves, selection of pumps for hydraulic power transmission 3 Actuators (…7.. Hours) Actuators: (i) Linear and Rotary. (ii) Hydraulic motors- Types- Vane, gear, piston types, radial piston. (iii) Methods of control of acceleration, deceleration. (iv) Types of cylinders and mountings. (v) Calculation of piston velocity, thrust under static and dynamic applications, considering friction, inertia loads. (vi) Design considerations for cylinders

SECTION-2 1 Control of Fluid Power Symbols for hydraulic and pneumatic circuits, Control of fluid power: (i) Necessity of fluid control through pressure control, directional control, flow control valves. (ii) Principle of pressure control valves, direct operated and pilot operated relief valves, pressure reducing valve, sequence valve. (iii) Principle of flow control valves, pressure compensated, temperature compensated flow control valves, meter in circuit, meter out circuits, flow through restrictor. (iv) Types of directional control valves: two way two position, four way three position, four way two positions valves. Open centre, close centre, tandem centre valves. Introduction to Cartridge valves, proportion control and servo valves- Manually operated, solenoid operated, pilot operated, direction control valves, check valve 2 Industrial Circuits & System Design (…6.. Hours) Industrial circuits 1 - Simple reciprocating, Regenerative, Speed control(Meter in, meter out & bleed off), Sequencing, Synchronization, transverse & feed, circuit for rivetting machine, automatic reciprocating, fail safe circuit, counter balance circuit, actuator locking, circuit for hydraulic press, unloading circuit, motor breaking circuit Design of hydraulic/pneumatic circuit for practical application, Selection of different components such as reservoir, various valves, actuators, filters, pumps based on design. (Students are advised to refer manufacturer’s catalogues.)



3 Pneumatics (…5.. Hours) Principle of Pneumatics: (i) Laws of compression, types of compressors, selection of compressors. (ii) Comparison of Pneumatics with Hydraulic power transmissions. (iii) Types of filters, regulators, lubricators, mufflers, dryers. (iv) Pressure regulating valves, (v) Direction control valves, two way, three way, four way valves. Solenoid operated valves, push button, lever control valves. (vi) Speed regulating – Methods used in Pneumatics. (vii) Pneumatic actuators-rotary, reciprocating, Air motors- radial piston, vane, axial piston (ix) Basic pneumatic circuit, selection of components(x) Application of pneumatics in low cost Automation and in industrial automation List of Practicals: 1. Study of hydraulic control valves./Drawing of various hydraulic and pneumatic symbols 2. Study, construct and test Meter in, meter out, beed off circuits .(Hydraulic trainer) 3. Study, construct and test sequencing circuits (Hydraulic trainer) 4 Study of hydraulic accumulators/Design of a circuit using accumulator. 5. Study of hydraulic intensifiers/Design of a circuit using intensifier 6. Study of hydraulic pumps-Rotary/Experiment on operating characteristics of gear pump. 7.Hydraulic power steering. 8 Direct control of pneumatic actuator using 2/2 and 3/2 valves 9.Indirect control of pneumatic actuator using 5/2 valve List of Project areas: 1. Construct and Design multi actuator fluid power System Text Books: 1. Esposito – ‘Fluid Power with application’, Pearson,7 th edition, ISBN 10:1-292-02387-2 Reference Books: 1 J. J. Pipenger – ‘Industrial Hydraulics’, McGraw Hill 1. H. L. Stewart – ‘Hydraulics and Pneumatics’, Industrial Press 2. A. Lall – ‘Oil Hydraulics’, International Literature Association 3. Yeaple – ‘Fluid Power Design Handbook’ 4. Vickers Manual on Industrial Hydraulics 5. Festo’s Manual on Pneumatic Principle, applications 6. ISO – 1219, Fluid Systems and components, Graphic Symbols 7. Majumadar, “Oil Hydraulics- Principle & Maintenance”, Tata McGraw Hill,1998

Course Outcomes: The student will be able to – 1. Understand fundamentals of fluids 2. Select appropriate pumps, for hydraulic systems 3. Select appropriate motors, cylinders for hydraulic systems. 4. Understand and select different types of hudraulic valves



5. Construct and evaluate hydraulic circuits for various industrial applications such as machine tools, automobile, agricultural equipment

6. Apply principles of pneumatic systems for automation systems



FF No.: 654

PR3042::STATISTICAL METHODS & RESEARCH METHODOLOGY


SECTION-1 Need for data in Research Meaning of Research , Motivation for Research , Research Approaches, Criteria for Good Research, Importance of communication skills in Research, Technical writing skills, Objectivity and Ethics in Research, Steps in Research process, Data in Engineering and Management Research, Types of data, Measures of Frequency Distribution Review of Probability Theory Concept of Random Variable, Discrete probability distributions in statistics and their analysis, Continuous probability distributions in statistics and their analysis, Functions in MS EXCEL for probability distributions Sampling Distributions Concept of a Sampling Distributions, Central Limit theorem, Chebyshev’s Theorem, Point estimation, Interval Estimation, Confidence Intervals, Sample size determinations for means and proportion, Large sampling versus small sampling, Methods of sampling, Concept of significance level, Test of Significance for single mean and proportion,

SECTION-2 Hypothesis Testing Errors in Hypothesis Testing, Test of significance for two sample means and proportions, Chi-square distribution, Test of significance for one sample and two sample variance. Test of independence, Test of goodness of Fit, F-distribution Analysis of Variances (ANOVA) One way ANOVA , Introduction to Design of Experiments, Various Methods of design of experiments, Taguchi method of DOE Research surveys Methods of primary and secondary data collection, Exploratory versus Descriptive research, Scales of Measurement, Aspects of Questionnaire design, Design of field surveys List of Practicals: 1. Measures of Frequency Distribution 2. Discrete Probability Distributions 3. Continuous probability Distributions 4. Central Limit Theorem 5. Estimation in Statistics 6. Test of significance for means 7. Test of significance for proportion



8. Test of significance for variance 9. Test of independence 10. ANOVA List of Project areas: 1. Questionnaire design 2. Exploratory Research using secondary data 3. Exploratory Research using primary data 4. Descriptive Research 5. Data analysis using R / Python 6. Data analysis in MS Excel Text Books: 1. Richard Johnson, Probability and Statistics for Engineers, Eighth edition, Prentice Hall of India 2. Srivastava U.K., Shenoy G. V. and Sharma S.C, Quantitative Techniques for Managerial Techniques, Third edition, New Age International Publishers 3. Krishnaswamy K. N., Sivakumar A.I. and Mathirajan M., Management Research Methodology, Pearson publication 4. Kothari C. R., Research Methodology, Second Edition, New Age International Publishers Reference Books: 1. Levin Richard and Rubin David, Statistics for Management, Prentice Hall of India 2. Murray Spiegel, Schiller John, Srinivasan R. A. and Goswami Debasree, Probability and statistics (Schaum’s outline Series), Third Edition, McGraw Hill 3. Paneerselvam R., Research Methodology, Second Edition, Prentice Hall of India 4. Paneerselvam R., Design and Analysis of Experiments, Prentice Hall of India Course Outcomes: The student will be able to – 1. Explain the nature of research and data requirements 2. Calculate probability by selecting appropriate probability distribution for managerial decisions 3. Estimate confidence interval 4. Perform test of significance for means and proportion 5. Perform test of significance for variance 6. Perform test of ANOVA



FF No.: 654

PR3043::PROJECT MANAGEMENT Credits: 04 Teaching Scheme: 3 Hrs/Wk

SECTION-1 Introduction: Definition & Characteristics of Project, Performance Parameters: Time, Cost & Quality. Difference with respect to Standard Routine Production. Classification of Projects: Sector based, Investment based, Technology based, Causation based, Need based (BMERD) - Balancing, Modernization, Replacement, Expansion & Diversification Project Life Cycle Phases – Concept/Initiation Phase: Parameters Involved in Project Identification. Sources of New Project Ideas. Governmental Framework for Identification of Opportunities, Incentives from state & central govt.; Import-substitution projects Project Conceptualization & Feasibility Analysis Project Definition Phase: Project Formulation & Feasibility. Types of Feasibility Studies – Pre-feasibility, Support/Functional, Feasibility Study. Preparation of Project Feasibility Report & Specification; Aspects of Project Feasibility Managerial/Organization: Promoters Background, Criteria of Evaluation, Marketing/Commercial: Demand & Supply, Competition, Market Survery, Porter’s 5 Forces, Operational/Technical: Process, Technology, Location, Capacity, Labour, Raw Material & Utility Availability. Financial: Cost of Project, Means of Finance, Financial Projections – Profit & Loss Account, Balance Sheet, Funds Flow Statement, Cash Flow Statement, Schedule of Fixed Assets, Schedule of Term Loans. Socio-Economic: Socio-Cost Benefit Analysis. Effective Rate of Protection, Domestic Resource Cost. Project Planning, Implementation & Control Planning & Organization Phase: Project Planning, Scheduling & Monitoring, Statement of Works, Project Specifications, Work Breakdown Structure, Network Analysis & Duration Estimating Network Diagrams – PERT/CPM, Estimate Activity Times, Milestone Scheduling. Resource Leveling, Resource Smoothening, Project Crashing. Implementation Phase: Activities Involved: Erection & Commissioning, Installation, Trial Runs & Commencement of Commercial Production. Cleanup/Shutdown Phase: Handover to Client, Settlement of Accounts. Project Organization & Management. Project Organization Structure, Role of Project Manager.

SECTION-2 Project Cost Management Project Cost Estimation: Need, Causes of Cost & Time Overruns. Nature of Cost Estimates, Types of Project Cost Estimates, Estimation of Manpower & Utilities. Project Budgeting & Control, Earned Value Management System: Concept of AC, PV, EV, Variances, etc. Contract Management: Responsibility Sharing Matrix, Types of Contract Payments, Risk Factors in Contracts – Contractor & Owner. Critical Chain Project Management. Project Management Information System and Control, Management Pitfalls



Computer Applications in Project Planning & Control

Introduction to MS Projects – Understanding the MS Project screen & different views, Defining the project, Working with calendar, Outline the project, Create dependencies between tasks, Creating WBS, Format task list and Gantt chart, Resource planning, leveling and preparing resource graph, Working with baseline, tracking the project. Home assignment on Exercise with MS Projects Software. List of Experiments/Project areas: 1. Preparation of Project Feasibility Report

a. Project Identification, Definition b. Project Feasibility – Managerial/Organizational Perspective c. Project Feasibility – Marketing, Exit Plan d. Project Feasibility – Operational e. Project Feasibility – Financial, Financial Projections

2. Assignment on Capital Budgeting – PBP, Discounted PBP, NPV, IRR, Annual Worth 3. Numerical on PERT/CPM – Calculation of Floats, Determination of Critical Path &

Project Duration 4. Case let - Project Crashing 5. Case let - Resource Leveling & Resource Smoothening 6. Project Planning & Scheduling (Using MS Projects) 1 – Preparation of Statement of

Works, WBS 7. Project Planning & Scheduling (Using MS Projects) 2 – Network Diagram, Gantt Charts,

Project Monitoring Text Books 1. Narendra Singh; Project Management & Control; Himalaya Publishing House, Mumbai 2. S. Choudary, Project Management, Tata McGraw Hill 3. Prasanna Chandra; Project: Preparation, Appraisal, Budgeting & Implementation 4. Pinto, Project Management – Achieving Competitive Advantage & MS Projects, Pearson

Education Reference Books 1. Maylor, Project Management, Pearson Education, 2. Gopal & Ramamurthy; Project Management Handbook; Macmilan. 3. Project Management Body of Knowledge 4. Practical Project Management by Ghatak & Sandra, Pearson Education (Singapore) Pte.

Ltd, 2001 5. Handbook on Project Appraisal & Follow-up, SARDA, Govind Prakashan,2001 Course Outcomes: Students will be able to: 1. Learn the basic concepts of project and project management 2. Ascertain the feasibility of small and medium projects with respect to managerial,

marketing, operational, financial and socio-economic perspectives



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

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

5. Monitor the progress of projects to determine variances and recommend corrective actions using software package

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