1

DEPARTMENT OF

MECHANICAL ENGINEERING

Scheme of Instruction and Syllabus

of

M.E. (Mechanical)

Specialization:

DESIGN FOR MANUFACTURE

Full time / Part time

(2014-15)

UNIVERSITY COLLEGE OF ENGINEERING

(Autonomous)

Osmania University

Hyderabad – 500 007, Telangana, INDIA

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With effect from the academic year 2014- 2015

Scheme of Instruction & Examination M.E. (Mechanical Engineering) 4 Semesters (Full Time)

Sl. Periods per Duration

Max. Marks

Subject week (Hrs)

No

L/T D/P

Univ. Exam Sessional

Semester - I

1. Core 3 -- 3 80 20

2. Core 3 -- 3 80 20

3. Core / Elective 3 -- 3 80 20

4. Core / Elective 3 -- 3 80 20

5. Elective 3 -- 3 80 20

6. Elective 3 -- 3 80 20

7. Laboratory - I -- 3 -- -- 50

8. Seminar - I -- 3 -- -- 50

Total 18 6 480 220

Semester - II

1. Core 3 -- 3 80 20

2. Core 3 -- 3 80 20

3. Core / Elective 3 -- 3 80 20

4. Core / Elective 3 -- 3 80 20

5. Elective 3 -- 3 80 20

6. Elective 3 -- 3 80 20

7. Laboratary - II -- 3 -- -- 50

8. Seminar - II -- 3 -- -- 50

Total 18 6 480 220

Semester - III

1. Project

-- 6 -- --

100**

Seminar*

Semester - IV

1. Dissertation -- -- -- Viva - Voce

--

(Grade ***)

Note: Six core subjects, six elective subjects, Two Laboratory Courses and Two Seminars should normally be completed by the end of semester II.

* Project seminar presentation on the topic of Dissertation only ** 50 marks awarded by the project guide and 50 marks by the internal committee. *** Excellent / Very Good / Good / Satisfactory / Unsatisfactory

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With effect from the academic year 2014- 2015

Scheme of Instruction & Examination M.E. (Mechanical Engineering) 6 Semesters (Part Time)

Sl. Periods per Duration

Max. Marks

Subject week (Hrs)

No

L/T D/P

Univ. Exam Sessional

Semester - I

1. Core 3 -- 3 80 20

2. Core / Elective 3 -- 3 80 20

3. Elective 3 -- 3 80 20

4. Lab. I /

-- 3 -- --

50

Seminar - I

Total 9 3 240 110

Semester - II

1. Core 3 -- 3 80 20

2. Core / Elective 3 -- 3 80 20

3. Elective 3 -- 3 80 20

4. Lab. I / -- 3 -- --

50

Seminar - I

Total 9 3 240 110

Semester - III

1. Core 3 -- 3 80 20

2. Core / Elective 3 -- 3 80 20

3. Elective 3 -- 3 80 20

4. Lab. II /

-- 3 -- --

50

Seminar - II

Total 9 3 240 110

Semester - IV

1. Core 3 -- 3 80 20

2. Core / Elective 3 -- 3 80 20

3. Elective 3 -- 3 80 20

4. Lab. II /

-- 3 -- --

50

Seminar - II

Total 9 3 240 110

Semester – V

1. Project

-- 6 -- --

100**

Seminar*

Semester - VI

1. Dissertation -- -- -- Viva - Voce

--

(Grade ***)

Note : Six core subjects, Six elective subjects, Two Laboratory Courses and Two Seminars should normally be completed by the end of semester IV.

* Project seminar presentation on the topic of Dissertation only ** 50 marks awarded by the project guide and 50 marks by the internal committee. *** Excellent / Very Good / Good / Satisfactory / Unsatisfactory

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Scheme of Instruction & Examination of Post Graduate course in Mechanical Engineering with specialization in Design for manufacture.

SI.NO Syllabus Ref.No. Subject

Scheme of Instruction Scheme of Examination

Periods per week

Duration in Hours Max. Marks

L/T D/P Univ. Exam Sessional

1

CORE SUBJECTS

ME 557 Design For Manufacture 3 3 80 20

2 ME 570 Quality And Reliability Engineering 3 3 80 20

3 ME 580 Design Of Manufacturing Tools 3

3 80 20

4 ME 505 Computer Integrated Manufacturing 3 3 80 20

5 ME 519 Product Design And Process Planning 3 3 80 20

6 ME 508 Finite Element Techniques 3 3 80 20

Electives

1 ME 518 Advanced Metrology 3 3 80 20

2 ME 501 Automation 3 3 80 20

3 ME 510 Computer Aided Modeling And Design 3 3 80 20

4 ME 507 Robotic Engineering 3 3 80 20

5 ME 563 Material Science And Technology 3 3 80 20

6 ME 573 Mems And Nano Technology 3

3 80 20

7 ME 522 Flexible Manufacturing Systems 3 3 80 20

8 ME 516 Theory Of Elasticity & Plasticity 3 3 80 20

9 ME 556 Failure Analysis And Design 3 3 80 20

10 ME 520 Rapid Prototyping Principles And Applications 3 3 80 20

11 ME 542 Computational Fluid Dynamics 3 3 80 20

12 ME 521 Engineering Research Methodology 3 3 80 20

13 ME 532 Computer Aided Mechanical Design

And Analysis 3 -- 3 80 20

3 3 80 20

14 ME 511 Optimization Techniques 3 3 80 20

15 ME 502 Metallurgy Of Metal Casting And Welding 3 3 80 20

16 ME 569 Mechatronics And Its Applications 3 3 80 20

17 ME 568 Non-Traditional Machining & Forming

Departmental Requirements

1 ME 523 Production Engineering Lab (Lab – I) 3 50

2 ME 524 Computation Lab (Lab –Ii) 3 50

3 ME 525 Seminar – I 3 50

4 ME 526 Seminar – II 3 50

5 ME 527 Project Seminar 6 100

6 ME 528 Dissertation 9 viva voce

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ME 557 DESIGN FOR MANUFACTURE Instruction 3 periods/ week Duration of University Examination 3 Hours University Examination 80 Marks Sessional 20 Marks UNIT-I Introduction: General design principles for manufacturability, strength and mechanical factors, Mechanisms selection, evaluation method, geometrical tolerances, tolerance control and utilization. Economic Use of Raw Materials: Ferrous steel, hot rolled steel, cold finished steel, stainless steel, non ferrous materials aluminium, copper, brass, non metallic materials, plastics, rubber and composites. UNIT-II Metallic Components Design: Metal extrusion, metal stamping, fine blanking, four slide parts, spring and wire forms, spun metal parts, cold headed parts, extruded parts, tube and section bends, rolled formed parts, power metal parts, forging electro forming parts, specialized forming methods, turned parts, machined round holes, drilled parts, milled parts. UNIT-III Metallic Components Design: Planned shaped and slotted parts, screw threaded contoured and internal Ground parts, center less ground, electrical discharged, rolled furnished parts, electro chemical and Advanced machine parts. Sand cast, die cast, investment cast and other cast products. UNIT-IV Non Metallic Components Design: Thermosetting plastic, injection moulded and rotational moulded parts, Blow moulded, welded plastic articles, ceramics. Assembled Parts Design: Welded parts, arc, resistance, brazed and soldered parts, gear box assembly, Bearing assembly. UNIT-V Assembled Parts Design: Retension, bolted connection, screwed connections, flanged connections, centred connections, press fitted connections, surface finishing, plated parts, heat treated parts, NC machining, group technology, low cost automation, computer aided manufacture, product design Requirements. Case Studies: Identification of economical design and redesign for manufacture. Suggested Reading: 1. James G. Bralla, “Hand book of product design for manufacturing” McGraw Hill Co., 1986 2. K.G. Swift “Knowledge based design for Manufacture”, Kogan page Limited, 1987.

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ME 570 QUALITY AND RELIABILITY ENGINEERING Instruction 3 periods/ week Duration of University Examination 3 Hours University Examination 80 Marks Sessional 20 Marks UNIT-I Quality value and engineering – Quality systems – quality engineering in product design and production process – system design – parameter design – tolerance design quality costs – quality improvement. Statistical Process Control-x, R, P, C charts, process capability. Acceptance Sampling by variables and attributes, Design of Sampling Plans, Single, Double, Sequential plans. UNIT-II Loss Function, Tolerance Design – N Type, L Type, S Type; determination of tolerance for these types, nonlinear tolerances. Online Quality Control – Variable Characteristics, Attribute Characteristics, Parameter Design. UNIT-III Quality function deployment – House of Quality, QFD Matrix, Total Quality Management Concepts. Quality Information Systems; Quality Circles, Introduction to ISO 9000 Standards. UNIT-IV Reliability – Evaluation of design by tests - Hazard Models; Linear, Releigh, Weibull. Failure Data Analysis System, Reliability, Reliability of series, Parallel Standey Systems; reliability prediction and system effectiveness, reliability prediction based on weibull distribution, Reliability improvement. UNIT-V Maintainability, Availability, Economics of Reliability Engineering; Replacement of items, Maintenance Costing and Budgeting, Reliability Testing – Burn in testing by binomial, exponential models, Accelerated life testing. Suggested Reading:

1. G Taguchi, „Quality Engineering in Production Systems‟, - McGraw Hill, 1989.

2. W.A. Taylor, „Optimization & Variation Reduction in Quality‟, Tata McGraw Hill, 1991, 1st Edition.

3. Philipposs, „Taguchi Techniques for Quality Engineering‟, McGraw Hill, 1996, 2nd Edition.

4. E.Bala Guruswamy, „Reliability Engineering‟, Tata McGraw Hill, 1994.

5. LS Srinath, „Reliability Engineering‟, Affiliated East West Pvt. Ltd., 1991, 3rd Edition.

6. Grant, „Statistical Process Control‟, McGraw Hill, 1988, 6th Edition.

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ME 580 DESIGN OF MANUFACTURING TOOLS Instruction 3 Periods /Week Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks Unit-I Design Of Cutting Tools. Single Point Cutting Tool Nomenclature, Form Tool Types. Form Correction. Drill Geometry, Milling Cutters, Types & Calculation Of Minimum No. Of Teeth. Boring Tools , Determination Of Shank Sizes. Gears Calculation And Design, Generation By Gear Shapers & Hobs. Deep Hole Drilling. Unit-Ii Design Of Jigs &Fixtures: Tolerance Analysis, Economics, Principles Of Location And Clamping, Degrees Of Freedom, Classification Of Jigs , Application Of Standard Elements, Universal Jigs And Fixtures, Standard Examples Of Designing Drill Jigs, Turning , Milling ,Broaching And Boring Fixtures, Assembly Fixtures For Assembly Station & Lines. Welding Fixtures. Fixtures For Inspection And NC /CNC Machines. Unit-Iii Design Of Sheet Metal Processing Tools: Theory Of Shearing , Clearance And Its Location ,Stock Strips Lay Outs, Utilization , Various Press Tool Operations , Presses, Types And Nomenclature ,Selection Of Presses , Design Of Shearing Dies And Elements Viz Piercing And Blanking, Inverted Die, Compound Die , Progressive Dies. Theory Of Bending, Flat Blank Calculations, Spring Back Effect And Compensation Methods, Types Of Bending Dies, Construction Of Bending Dies, Force Calculation. Draw Dies, Metal Flow Theory, Blank Development Methods, Strain Factor, Severity Of Draw, Reduction Factor, Stage Wise Draw Calculations, Types Of Draw Dies And Construction .Force And Energy Calculation. Unit-Iv Design Of Plastic Processing Tools: Definition Of Plastics And Types, Methods Of Process, Mould Terminology, Design Of Feed And Ejection System, Design Of Various Moulds Viz Simple Component, Moulds For Components With External And Internal Under Cuts And Threads. Compression Mould, Transfer Moulds And Runner Less Moulds. Unit-V Design Of Die Casting Dies, Classification Of Metal Casting Processes, Terminology Applied To Machines And Processes Viz Cold Chamber And Hot Chamber Dies, Process Variables, Types Of Dies, Alignment Of Metal Flow, Types Of Alloys. Design Concepts Of Runner And Gate Calculations, Trimming And Trimming Dies. Suggested Reading: 1. Astme, Fundamentals Of Tool Design. Preantice Hall Of India Pvt Ltd New Delhi1976 2. Injection Mould Design R.G.W Pye Associated East West Press Pvt Ltd New Delhi 3. Joshi, Jigs & Fixtures .Tata Mc-Grawhills Publication 4. Die Casting Die BY HH Doehler Mc-Grawhill Book Company 5. Donald Son .Tool Design,Tata Mc-Grwahill Publication New Delhi. 6. Introduction To Jig &Tool Design By MHA Kempster Published By Viva Books Pvt Ltd New Delhi.

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ME 505

COMPUTER INTEGRATED MANUFACTURING Instruction 3 periods/week Duration of university Examination 3 hours University Examination 80 Marks Sessional 20 Marks UNIT – I Introduction to CIM The meaning of Manufacturing, Types of Manufacturing; Basic Concepts of CIM: CIM Definition, Elements of CIM, CIM wheel, concept or technology, Evolution of CIM, Benefits of CIM, Needs of CIM: Hardware and software. Fundamentals of Communication: Communications Matrix. Product Development Cycle, Concurrent Engineering: Definition, Sequential Engineering Versus Concurrent Engineering, Benefits of Concurrent Engineering, Characteristics of concurrent Engineering, Framework for integration of Life-cycle phases in CE, Concurrent Engineering Techniques, Integrated Product Development(IPD), Product Life-Cycle Management (PLM), Collaborative Product Development. UNIT – II CIM database and database management systems Introduction, Manufacturing Data: Types, sources; Database Terminology, Database requirements, Database models, Database Management System, DBMS Architecture, Query Language, Structural Query Language (SQL): Basic structure, Data definition Language (Create, Alter, Drop, Truncate, View), Data Manipulation Language (store, retrieve, update, delete). Illustration of Creating and Manipulating a Manufacturing Database. SQL as a Knowledge Base Query Language. Features of commercial DBMS: Oracle, MySQL, SQL Access, Sybase, DB2. Product Data Management (PDM), Advantages of PDM. UNIT – III CIM Technology and Systems Product Design: Needs of the market, Design and Engineering, The design Process, Design for Manufacturability (DFM): Component Design, Design for Assembly. Computer-Aided Process Planning: Basic Steps in developing a process plan, Variant and Generative Process Planning, Feature Recognition in Computer-Aided Process Planning. Material Requirements Planning (MRP), Manufacturing Resource Planning (MRP –II), Cellular Manufacturing: Design of Cellular Manufacturing Systems, Cell Formation Approaches: Machine–Component Group Analysis, Similarity Coefficients-Based Approaches. Evaluation of Cell Design. Shop-floor Control: Data Logging and Acquisition, Automated Data Collection, Programmable Logic Controllers, Sensor Technology. Flexible Manufacturing Systems: Physical Components of an FMS. Types of Flexibility, Layout Considerations: Linear Single Machine Layout, Circular Machine Layout, Cluster Machine Layout, Loop Layout; Operational Problems of FMS. FMS benefits. UNIT –IV Enterprise Wide Integration in CIM and CIM Models Introduction to Networking, Principles of Networking, Network Terminology, Types of Networks: LAN, MAN, WAN; Selection of Network Technology: Communication medium, Network Topology, Medium access control Methods, Signaling methods; Network Architectures and Protocols: OSI Model, MAP & TOP, TCP/IP, Network Interconnection and Devices, Network Performance. Framework for Enterprise-wide Integration. CIM Models: ESPRIT-CIM OSA Model, NIST-AMRF Model, Siemens Model of CIM, Digital Equipment Corporation Model, IBM Concept of CIM. UNIT – V Future Trends in Manufacturing Systems Lean Manufacturing: Definition, Principles of Lean Manufacturing, Characteristics of Lean Manufacturing, Value of Product, Continuous Improvement, Focus on Waste, Relationship of Waste to Profit, Four Functions of Lean Production, Performance Measures, The Supply Chain, Benefits of Lean Manufacturing. Introduction to Agile and Web Based Manufacturing systems. Suggested Reading:

1. S.Kant Vajpayee: Principles of Computer Integrated Manufacturing, Printice-Hall India. 2. Nanua Singh: Systems Approach to Computer Integrated Design and Manufacturing- John Wiley. 3. P.Radhakrishnan, S.Subramanyam: CAD/CAM/CIM, New Age International 4. Alavudeen, Venkateshwaran: Computer Integrated Manufacturing, Printice-Hall India

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ME 519

PRODUCT DESIGN AND PROCESS PLANNING

Instruction 3 Periods /Week

Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks UNIT-I Product design and process design functions, selection of a right product, essential factors of product design, Morphology of design, sources of new ideas for products, evaluation of new product ideas. Product innovation procedure-Flow chart. Qualifications of product design Engineer. Criteria for success/failure of a product. Value of appearance, colours and Laws of appearance. UNIT-II Product reliability, Mortality Curve, Reliability systems, Manufacturing reliability and quality control. Patents: Definitions, classes of patents, applying for patents. Trademarks and copyrights. Cost and quality sensitivity of products, Elements of cost of a product, costing methods, cost reduction and cost control activities. Economic analysis, Break even analysis Charts. Value engineering in product design, creativity aspects and techniques. Procedures of value analysis – cost reduction, material and process selection. UNIT-III Various manufacturing processes, degree of accuracy and finish obtainable, process capability studies. Methods of improving tolerances. Basic product design rules for Casting, Forging, Machining, Sheet metal and Welding. Physical properties of engineering materials and their importance on products. Selection of plastics, rubber and ceramics for product design. UNIT-IV Industrial ergonomics: Man-machine considerations, ease of maintenance. Ergonomic considerations in product design-Anthropometry, Design of controls, man-machine information exchange. Process sheet detail and their importance, Advanced techniques for higher productivity. Just-in-time and Kanban System. Modern approaches to product design; quality function development, Rapid prototyping. UNIT-V Role of computer in product design and management of manufacturing, creation of manufacturing data base, Computer Integrated Manufacturing, communication network, production flow analysis, Group Technology, Computer Aided product design and process Planning. Integrating product design, manufacture and production control. Suggested Reading: 1. Niebel, B.W., and Draper, A.B., Product design and process Engineering, Mc Graw Hill – Kogalkusha

Ltd., Tokyo, 1974. 2. Chitale, A.K, and Gupta, R.C., Product Design and Manufacturing, Prentice Hall of India Pvt. Ltd.,

New Delhi, 2004. 3. Mahajan, M. Industrial Engineering and Production Management, Dhanpath Rai & Co., 2000.

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ME 508

FINITE ELEMENT TECHNIQUES

Instruction 3 Periods /Week Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks UNIT-I Introduction to Finite Element Method of solving field problems. Stress and Equilibrium. Boundary conditions. Strain-Displacement relations. Stress-strain relations. One Dimensional Problem: Finite element modeling. Local, natural and global coordinates and shape functions. Potential Energy approach : Assembly of Global stiffness matrix and load vector. Finite element equations, treatment of boundary conditions. Quadratic shape functions. UNIT-II Analysis of trusses and frames: Analysis of plane truss with number of unknowns not exceeding two at each node. Analysis of frames with two translations and a rotational degree of freedom at each node. Analysis of Beams: Element stiffness matrix for two noded, two degrees of freedom per node for beam element. UNIT-III Finite element modeling of two dimensional stress analysis problems with constant strain triangles and treatment of boundary conditions. Two dimensional four noded isoparametric elements and numerical integration. Finite element modeling of Axisymmentric solids subjected of axisymmetric loading with triangular elements. Convergence requirements and geometric isotropy. UNIT-IV Steady state heat transfer analysis: One dimensional analysis of a fin and two dimensional conduction analysis of thin plate. Time dependent field problems: Application to one dimensional heat flow in a rod. Dynamic analysis: Formulation of finite element modeling of Eigen value problem for a stepped bar and beam. Evaluation of Eigen values and Eigen vectors. Analysis of a uniform shaft subjected to torsion using Finite Element Analysis. UNIT-V Finite element formulation of three dimensional problems in stress analysis. Finite Element formulation of an incompressible fluid. Potential flow problems Bending of elastic plates. Introduction to non-linear problems and Finite Element analysis software. Suggested Reading: 1. Tirupathi R Chandrupatla and Ashok. D. Belegundu, Introduction of Finite Element in Engineering, Prentice Hall of India, 1997.

2. Rao S.S., The Finite Element Methods in Engineering, Pergamon Press, 1989. 3. Segerland. L.J., Applied Finite Element Analysis, Wiley Publication, 1984. 4. Reddy J.N., An Introduction to Finite Element Methods, Mc Graw Hill Company, 1984

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ME 518

ADVANCED METROLOGY

Instruction 3 Periods /Week

Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks UNIT-I End & line standards for length, Airy & Bessel points, desirable features of end standards, slip gauge manufacture, calibration of end standards by interferometry. NPL gauge interferometer, calibration of line standards by micrometer microscope – superposition, coincidence and symmetric straddling, photoelectric microscope and Moir fringe techniques, measurement of large displacements using lasers, calibration of Tomlinson gauges by interferometry. Photoelectric Autocollimator, calibration of polygons & circular scales. Types of interchangeability, dimensional chains. UNIT-II Fixed & Indicating Gauges: Taylor’s principles of gauge design, limitations of ring & plug gauges, position and receiver gauges, types of indicating gauges. Comparators: Multirange Sigma comparator, Back pressure and free flow type pneumatic comparators, Differential back pressure gauge, usage of different types of jets, contact & non contact tooling. Amplification selection. Air to electric transducer, Differential transducer, Variation transducer, Pre process, In-process & Post process gauging, computation & match gauging. Usage of LVDT & Capacitive type gauge heads, Automatic inspection. UNIT-III Measuring Machines: Floating carriage diameter measuring m/c. Universal measuring m/c. Matrix internal diameter measuring machine. Optical dividing head. Coordinate measuring machine, Optical projector-light beam systems, Work tables, measurement techniques, fixturing & accessories. Sources of error in measurement. Design principles of measuring machines Abbe’s rule, Kelvin coupling, flexible steel strip, advantages & limitations of hydrostatic & aerostatic bearings. UNIT-IV Form Errors: Evaluation of straightness & flatness, usage of beam comparator, evaluation of roundness – intrinsic & extrinsic datums. Talyrond. PGC, RGC, MZC & LSC, methods, roundness evaluation for even & odd number of lobes. Surface Finish: stylus instrument (TALYSURF). M & E Systems, numerical assessment, vertical & horizontal descriptors, profile as a random process, usage of interferograms. Plastic replica technique. UNIT-V Screw Threads: Measurement of thread elements for internal & external threads, progressive periodic, drunkenness and irregular pitch errors. NPL pitch measuring machine, virtual effective diameter, thread gauging. Gears: measurement of tooth thickness, involute profile, pitch, concentricity and alignment, rolling gear test. Suggested Reading:

1. R.K.Jain, Engineering Metrology, Khanna Publishers 2. ASTME, Hand Book of Industrial Metrology, Prentice Hall of India Pvt Ltd. 3. I.C. Gupta, A Text Book of Engineering Metrology, Dhanpat Rai & Sons.

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ME 501

AUTOMATION

Instructions 3 periods/week Duration of university Examination 3 hours University Examination 80 Marks Sessional 20 Marks UNIT – I Introduction: Definition of automation, Types of production, Functions of Manufacturing, Organization and Information Processing in Manufacturing, Production concepts and Mathematical Models, Automation Strategies, Production Economics: Methods of Evaluating Investment Alternatives, Costs in Manufacturing, Break-Even Analysis, Unit cost of production, Cost of Manufacturing Lead time and Work-in-process. UNIT – II Detroit-Type Automation: Automated Flow lines, Methods of Workpart Transport, Transfer Mechanism, Buffer Storage, Control Functions, Automation for Machining Operations, Design and Fabrication Considerations. Analysis of Automated Flow Lines: General Terminology and Analysis, Analysis of Transfer Lines Without Storage, Partial Automation, Automated Flow Lines with Storage Buffers, Computer Simulation of Automated Flow Lines. UNIT – III Assembly Systems and Line Balancing: The Assembly Process, Assembly Systems, Manual Assembly Lines, The Line Balancing Problem, Methods of Line Balancing, Computerized Line Balancing Methods, Other ways to improve the Line Balancing, Flexible Manual Assembly Lines. Automated Assembly Systems: Design for Automated Assembly, Types of Automated Assembly Systems, Part Feeding Devices, Analysis of Multi-station Assembly Machines, Analysis of a Single Station Assembly Machine. UNIT –IV Automated Materials Handling: The material handling function, Types of Material Handling Equipment, Analysis for Material Handling Systems, Design of the System, Conveyor Systems, Automated Guided Vehicle Systems. Automated Storage Systems: Storage System Performance, Automated Storage/Retrieval Systems, Carousel Storage Systems, Work-in-process Storage, Interfacing Handling and Storage with Manufacturing. UNIT – V Automated Inspection and Testing: Inspection and testing, Statistical Quality Control, Automated Inspection Principles and Methods, Sensor Technologies for Automated Inspection, Coordinate Measuring Machines, Other Contact Inspection Methods, Machine Vision, Other optical Inspection Methods. Modeling Automated Manufacturing Systems: Role of Performance Modeling, Performance Measures, Performance Modeling Tools: Simulation Models, Analytical Models. The Future Automated Factory: Trends in Manufacturing, The Future Automated Factory, Human Workers in the Future Automated Factory, The social impact. Suggested Reading:

1) Mikell P.Grover, Automation, Production Systems and Computer Integrated Manufacturing, Pearson Education Asia.

2) C.Ray Asfahl, Robots and manufacturing Sutomation, John Wiley and Sons New York. 3) N.Viswanadham and Y.Narahari, Performance Modeling of Automated Manufacturing Syetms,

Printice Hall India Pvt. Ltd. 4) Stephen J. Derby, Design of Automatic Machinary, Special Indian Edition, Marcel Decker, New

York, Yesdee publishing Pvt. Ltd, Chennai

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ME 510

COMPUTER AIDED MODELLING & DESIGN

Instruction 3 Periods /Week

Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks UNIT-I Introduction to CAD, Criteria for selection of CAD workstations, Shigle Design Process, Design criteria, Geometric modeling, entities, 2D & 3D Primitives. 2D & 3D Geometric Transformations: Translation, Scaling, Rotation, Reflection and Shearing, conlatenation. Graphics standards: GKS IGES, PDES. UNIT-II Wire frame modeling: Curves: Curve representation. Analytic curves – lines, Circles, Ellipse, Conis. Synthetic curves – Cubic, Bezier, B-Spline, NURBS. UNIT-III Surface Modeling: Surface entities, Surface Representation. Analytic Surface – Plane Surface, Ruled Surface, Surface of Revolution, Tabulated Cyliner. Synthetic Surface-Cubic, Bezier, B-spline, Coons. UNIT-IV Solid Modeling Techniques: Graph Based Model, Boolean Models, Instances, Cell Decomposition & Spatial – Occupancy Enumeration, Boundary Representation (B-rep) & Constructive Solid Geometry (CSG). UNIT-V Advanced Modeling Concepts: Feature Based Modeling, Assembling Modeling, Behavioural Modeling, Conceptual Design & Top Down Design. Capabilities of Modeling & Analysis Packages such as solid works, Unigraghics, Ansys, Hypermesh. Computer Aided Design of mechanical parts and Interference Detection by Motion analysis. Suggested Reading: 1. Ibrahim Zeid, CAD/CAM, Theory and Practice, Mc Graw Hill, 1998. 2. Foley, Van Dam, Feiner and Hughes, Computer Graphics Principles and Practice, 2

nd Ed., Addison –

Wesley, 2000. 3. Martenson, E. Micheal, Geometric Modelling, John Wiley & Sons, 1995. 4. Hill Jr, F.S., Computer Graphics using open GL, Pearson Education, 2003.

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ME 507

ROBOTIC ENGINEERING Instruction 3 Periods/week Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks UNIT-I Brief History, Types of robots, Overview of robot subsystems, resolution, repeatability and accuracy, Degrees of freedom of robots, Robot configurations and concept of workspace, Mechanisms and transmission, End effectors and Different types of grippers, vacuum and other methods of gripping. Pneumatic, hydraulic and electrical actuators, applications of robots, specifications of different industrial robots. UNIT-II Rotation matrices, Euler angle and RPY representation, Homogeneous transformation matrices, Denavit-Hartenberg notation, representation of absolute position and orientation in terms of joint parameters, direct kinematics. UNIT-III Inverse Kinematics, inverse orientation, inverse locations, Singularities, Jacobian, Trajectory Planning: joint interpolation, task space interpolation, executing user specified tasks, sensor based motion planning: The Bug Algorithm, The Tangent Bug Algorithm, The Incremental Voronoi Graph. UNIT-IV Static force analysis of RP type and RR type planar robots, Dynamic analysis using Lagrangean and Newton-Euler formulations of RR and RP type planar robots, , Independent joint control, PD and PID feedback, actuator models, nonlinearity of manipulator models, force feedback, hybrid control UNIT-V Sensors and controllers: Internal and external sensors, position, velocity and acceleration sensors, proximity sensors, force sensors, laser range finder. Robot vision: image processing fundamentals for robotic applications, image acquisition and preprocessing. Segmentation and region characterization object recognition by image matching and based on features Suggested Readings: 1. Nagrath and Mittal, ―Robotics and Control‖, Tata McGraw-Hill, 2003. 2. Spong and Vidhyasagar, ―Robot Dynamics and Control‖, John Wiley and sons, 2008. 3. Fu. K.S, Gonzalez, R.C., Lee, C.S.G, Robotics, control, sensing, Vision and Intelligence, McGraw Hill

International, 1987 4. Steve LaValle, ―Planning Algorithms‖, Cambridge Univ. Press, New York, 2006. 5. Howie Choset, Kevin Lynch, Seth Hutchinson, George Kantor, Wolfram Burgard, Lydia Kavraki and

Sebastian Thurn, ―Principles of Robot Motion: Theory, Algorithms, and Implementations‖ , Prentice Hall of India, 2005.

15

ME 563

MATERIAL SCIENCE & TECHNOLOGY

Instruction 3 Periods /Week

Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks UNIT-I Classification of Materials: Types and Crystal Structures. Imperfections. Strain hardening, Plastic range, Fracture, Fatigue, Creep and Creep properties. Recovery. Recrystallisation and Grain growth. Primary and secondary recrystallisation and sub-grain structure. Mechanism of strengthening in metals. Grain size and its relation to mechanical properties. UNIT-II Testing of Materials: Review and brief discussion on stress strain diagram of steel and the parameters for ductility toughness, strain hardening, and tensile strength percentage of elongation etc. Fracture toughness and crack growth measurement. Failure analysis, Factor -graphy and scanning electronic Microscope. Fatigue and Creep testing, testing for Residual stresses. UNIT-III Tool Materials: Selection and specification of carbon and alloy steels for general engineering purpose, Specification of materials as per various standards (IS, BS, AISI, APS etc.) Case hardening steels, Cold work tool steels, hot work tool steels, high speed tool steels. Types of modern Cutting Tool materials like Carbide, Coated carbides, Ceramics, CBN, Diamod, Sialons, Impregnated tools. Introduction to Plastics. Properties of plastics-Thermo plastics-Thermo setting plastics. Methods of processing of plastics and plastic processing machines. UNIT-IV Ferrous and Non-ferrous materials: Specifications, Properties and applications of Carbon and alloy Steels, Specification of Grey iron casting IS: 210 SG Cast Iron IS: 865, Malleable iron castings IS: 2108 and IS: 2640. Selection and specification of die casting non-ferrous zinc and Aluminium (IS and LM Series). Powder Metallurgy and New Materials: Production of powders by various methods. Compacting, Sintering applications. UNIT-V Heat treatment: Hardenability, its concepts and its role in steel specification. Hardening and annealing of tool steels. Case hardening and local hardening, methods, selection and specification of such steels study of Isothermal Transformation diagrams. Austempering, Martempering and Isothermal annealing for tool steels,. Tool failures due to improper heat treatment like Overheating, improper quenching and loading. ION Nitrating, Vacuum carburising, Chemical Vapour depositing. Heat treatment of non-ferrous materials-Aluminium Alloys. Suggested Reading: 1. Richards C.W., Engineering Material Science-Prentice-Hall of India (P) Ltd., 1965. 2. Van Vlack, Elements of Materials Science, India book house pvt, ltd., Bombay, 1975. 3. Barret C.S., Structure of Metals, Eueania Pub., New Delhi, 1968. 4. William D Callister, Materials Science and Engineering an Introduction, John Wiley & Sons, 2003 5. Aviner, Physical Metallurgy, Mc Graw Hill Book Company, 1987. 6. Raghavan V., First Course in Material Science, Prentice Hall, New Delhi, 1974. 7. IS Standards, BIS, New Delhi.

16

ME 573 MEMS AND NANO-TECHNOLOGY Instruction 3 periods/ week Duration of University Examination 3 Hours University Examination 80 Marks Sessional 20 Marks UNIT-I Micro-Electro Mechanical System ( MEMS): Introduction to Micro-manufacturing - Semiconductor Manufacturing: Lithography and Oxidation - Diffusion – Etching (Dry and Wet) and Thin Film Deposition - Ion Implantation, Interconnections and Contacts, Packaging and Yield – Clean rooms and vacuum systems – Metrology for MEMS components. Concept of Accuracy and Factors Effecting Accuracy Micro finishing Processes. UNIT-II Micro-Electro Mechanical System (MEMS): Scaling - Materials - Fabrication - LIGA, X-ray based Fabrication. UNIT-III Application of Sensors & Actuators – Mechanical – MEMS Devices (Cantilevers, anemometers, pressure transducers and micro pumps) – RF, Electrical and Magnetic MEMS – Bio-MEMS. UNIT-IV Nano-technology: Fabrication – Nanolithography – Nano-Devices – atomic force microscope–Scanning Electron Microscope – TEM – Nano indentation Spin devices. UNIT-V Technology to make components like Computer Hardware, Optical Systems, Fiber Optics & Allied components, Micro Injection Moulding and Nano Technology Suggested Reading:

1. Murthy., R.L., „Precision Engineering in Manufacturing‟, - New Age International Publishers, 1996.

2. Mohamed Gad-elHak, „The MEMS Handbook‟, CRC Press, 2002

3. Groover, M. P., „Fundamentals of Modern Manufacturing: Materials, Processes, and Systems,‟ second

edition, Wiley, 2002.

4. Jeager, „Introduction to Microelectronic Fabrication‟, Addison-Wesley, 1993.

5. Zant, „Microchip Fabrication‟, fourth edition, McGraw Hill, 2000.

6. Quirk, Serda, „Semiconductor Manufacturing Technology‟, Prentice Hall, 2001

17

ME 522

FLEXIBLE MANUFACTURING SYSTEMS

Instruction 3 periods/ week Duration of University Examination 3 Hours University Examination 80 Marks Sessional 20 Marks UNIT-I Evolution of Manufacturing Systems: FMS definition and description, General FMS considerations , Manufacturing cells, Cellular versus Flexible Manufacturing. Systems Planning: Objective, introduction planning, preparation guidelines, the project team, supplier selection, system description and sizing, facility preparation planning, FMS layouts. Human resources: staff considerations, team work, communication and involvement, the supervisors role, personnel selection, job classifications, employee training. UNIT-II Manufacturing’s Driving Force: Definition, description and characteristics. Just in-time manufacturing, definition and description, benefits and relationship to FMS, implementation cornerstones, quality and quantity application principles. Single manufacture Cell – design scheduling of jobs on single manufacturing cells. Group Technology: Concepts, classification and coding, benefits and relationship to FMS, design of group technology using rank order clustering technique. UNIT-III FMS Design – Using Bottleneck, Extended bottleneck models, Processing and Quality Assurance: Turning centres, Machining centre, construction and operations performed, axes, programming, and format information, work-holding and work-changing equipment, automated features and capabilities, cleaning and deburring – station types and operation description, importance to automated manufacturing, coordinate measuring machines, types, construction and general function, operation cycle description, importance to flexible cells and systems. UNIT-IV Automated movement and storage systems–AGVs, Robots, automated storage and retrieval systems, storage space design, queuing carousels and automatic work changers, coolant and chip Disposal and recovery systems, auxiliary support equipment, cutting tools and tool Management – introduction, getting control of cutting tools, Tool Management, tool strategies, data transfer, tool monitoring and fault detection, guidelines, work holding considerations, General fixturing, Modular fixturing. FMS and the relationship with workstations – Manual, automated and transfer lines design aspects. UNIT-V FMS: computer Hardware, Software, Communications networks and Nanotechnology – general functions, and manufacturing usages, hardware configuration, programmable logic controllers, cell controllers, communications networks. FMS implementation. Suggested Reading: 1. Parrish, D.J., ‗Flexible Manufacturing‘, - Butter Worths – Heinemann, Oxford, 1993. 2. Groover, M.P., ‗Automation, Production Systems and CIM‘, - Prentice Hall India, 1989. 3. Kusiak, A., ‗Intelligent Manufacturing Systems‘, - Prentice Hall, 1990. 4. Considine,D.M., & Considine,G.D., ‗Standard Handbook of Industrial Automation‘,-Chapman & Hall,

1986 5. Ranky, P.G., ‗Design and Operation of FMS‘, - IFS Publishers, UK, 1988

18

M.E 516 THEORY OF ELASTICITY AND PLASTICITY

Instruction /Week 3 Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks UNIT - I ELASTICITY: Two dimensional stress analysis - Plane stress - Plane strain - Equations of compatibility - Stress function - Boundary conditions. PROBLEM IN RECTANGULAR COORDINATES - Solution by polynomials - Saint Venent's principles - Determination of displacement - Simple beam problems. PROBLEMS IN POLAR COORDINATES - General equations in polar coordinates - Stress distribution symmetrical about axis - Strain components in polar coordinates - Simple and symmetric problems. UNIT - II ANALYSIS OF STRESS AND STRAIN IN THREE DIMENSIONS: Principle stresses - Homogeneous deformations - Strain spherical and deviatoric stress - Hydrostatic strain. General theorems: Differential equations of equilibrium and compatibility - Displacement - Uniqueness of solution - Reciprocal theorem. UNIT - III BENDING OF PRISMATIC BARS: Stress function - Bending of cantilever beam - Beam of rectangular cross-section - Beams of circular cross-section. UNIT - IV PLASTICITY: Plastic deformation of metals - Structure of metals - Deformation - Creep stress relaxation of deformation - Strain rate condition of constant maximum shear stress - Condition of constant strain energy - Approximate equation of plasticity. UNIT - V METHODS OF SOLVING PRACTICAL PROBLEMS: The characteristic method - Engineering method - Compression of metal under press - Theoretical and experimental data drawing. Suggested Reading:

1) Theory of Elasticity/Timoshenko S.P. and Goodier J.N./Koakusha Publishers 2) An Engineering Theory of Plasticity/E.P. Unksov/Butterworths 3) Applied Elasticity/W.T. Wang/TMH 4) Theory of Plasticity for Engineers/Hoffman and Sacks/TMH 5) Theory of Elasticity and Plasticity/Sadhu Singh/ Khanna Publishers 6) Theory of Elasticity and Plasticity/Harold Malcolm Westergaard/Harvard University Press

19

ME 556

FAILURE ANALYSIS AND DESIGN Instruction 3 periods/week Duration of university Examination 3 hours University Examination 80 Marks Sessional 20 Marks

UNIT - I DESIGN FUNDAMENTALS Importance of design- The design process-Considerations of Good Design – Morphology of Design – Organization for design– Computer Aided Engineering –Concurrent Engineering – Product and process cycles –Market Identification – Competition Bench marking. Identification of customer needs- customer requirements- Product Design Specifications- Human Factors in Design – Ergonomics and Aesthetics. UNIT- II DESIGN METHODS Creativity and Problem Solving –Creativity methods-Theory of Inventive Problem Solving(TRIZ)– Conceptual decomposition-Generating design concepts-Axiomatic Design – Evaluation methods-Embodiment Design-Product Architecture-Configuration Design- Parametric Design. Role of models in design-Mathematical Modeling – Simulation – Design for Reliability –Introduction to Robust Design-Failure mode Effect Analysis. UNIT - III BUCKLING AND FRACTURE ANALYSIS IN VESSELS Buckling phenomenon – Elastic Buckling of circular ring and cylinders under external pressure – collapse of thick walled cylinders or tubes under external pressure – Effect of supports on Elastic Buckling of Cylinders – Buckling under combined External pressure and axial loading. UNIT – IV FRACTURE AND FATIGUE CRACK PROPOGATION Failure analysis and determination of stress patterns from plastic Flow observations – Dynamic loading– Fracture types in tension—Fatigue crack growth– Fatigue life prediction- Cumulative fatigue damage-Stress theory of failure vessels-Thermal stress fatigue . UNIT – V APPLICATIONS OF FRACTURE MECHANICS Introduction –Through cracks emanating from holes – Corner cracks at holes – Cracks approaching holes-Combined loading-Fatigue crack growth binder- Mixed mode loading-Fracture toughness of weld metals-Service failure analysis Suggested Reading: 1. Dieter, George E., ―Engineering Design - A Materials and Processing Approach‖, McGraw Hill,

International Editions, Singapore, 2000. 2. Pahl, G, and Beitz, W.,‖ Engineering Design‖, Springer – Verlag, NY. 1984. 3. David Broek, ‖Elementary Engineering Fracture Mechanics ―, Fifthoff and Noerdhoff International

Publisher, 1978. 4. Preshant Kumar, ―Elements of Fracture Mechanics‖, Wheeler Publishing, 1999 5. John F. Harvey, Theory and Design of Pressure Vessels, CBS Publishers and Distributors, 1987. Henry H. Bedner, ―Pressure Vessels, Design Hand Book, CBS publishers and Distributors, 1987

20

ME 520

RAPID PROTOTYPING PRINCIPLES AND APPLICATIONS

Instruction 3 Periods/Week Duration of University Examination 3 hours

University Examination 80 Marks Sessional 20 Mraks

UNIT – I Introduction: Prototyping fundamentals, Historical development, Fundamentals of Rapid Prototyping, Advantages and Limitations of Rapid Prototyping, Commonly used Terms, Classification of RP process, Rapid Prototyping Process Chain: Fundamental Automated Processes, Process Chain. UNIT – II Liquid-based Rapid Prototyping Systems: Stereo lithography Apparatus (SLA): Models and specifications, Process, working principle, photopolymers, photo polymerization, Layering technology, laser and laser scanning, Applications, Advantages and Disadvantages, Case studies. Solid ground curing (SGC): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies Solid-based Rapid Prototyping Systems: Laminated Object Manufacturing (LOM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Fused Deposition Modeling (FDM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. UNIT – III Powder Based Rapid Prototyping Systems: Selective laser sintering (SLS): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Three dimensional Printing (3DP): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Rapid Tooling: Introduction to Rapid Tooling (RT), Conventional Tooling Vs RT, Need for RT. Rapid Tooling Classification: Indirect Rapid Tooling Methods: Spray Metal Deposition, RTV Epoxy Tools, Ceramic tools, Investment Casting, Spin Casting, Die casting, Sand Casting, 3D Keltool process. Direct Rapid Tooling: Direct AIM, LOM Tools, DTM Rapid Tool Process, EOS Direct Tool Process and Direct Metal Tooling using 3DP. UNIT – IV Rapid Prototyping Data Formats: STL Format, STL File Problems, Consequence of Building Valid and Invalid Tessellated Models, STL file Repairs: Generic Solution, Other Translators, Newly Proposed Formats. Rapid Prototyping Software’s: Features of various RP software’s like Magics, Mimics, Solid View, View Expert, 3 D View, Velocity 2, Rhino, STL View 3 Data Expert and 3 D doctor. UNIT –V RP Applications: Application – Material Relationship, Application in Design, Application in Engineering, Analysis and Planning, Aerospace Industry, Automotive Industry, Jewelry Industry, Coin Industry, GIS application, Arts and Architecture. RP Medical and Bioengineering Applications: Planning and simulation of complex surgery, Customised Implants & Prosthesis, Design and Production of Medical Devices, Forensic Science and Anthropology, Visulization of Biomolecules. Suggested Reading: 1. Rapid prototyping: Principles and Applications - Chua C.K., Leong K.F. and LIM C.S, World Scientific

publications , Third Edition, 2010. 2. Rapid Manufacturing – D.T. Pham and S.S. Dimov, Springer , 2001 3. Wholers Report 2000 – Terry Wohlers, Wohlers Associates, 2000 4. Rapid Prototyping & Manufacturing – Paul F.Jacobs, ASME Press, 1996.

21

ME 542

COMPUTATIONAL FLUID DYNAMICS

Instruction 3 periods/week Duration of University Exam 3 Hours University Exam. 80 Marks Sessional 20 Marks UNIT-I Review of basic equations of fluid dynamics: Continuity, Momentum and Energy equations, Navier Stokes equations, Reynolds and Favre averaged N – S equations. Differential equations for steady and unsteady state heat conduction. Differential equations for diffusion. Introduction to turbulence, Turbulence models-mixing length model, K- turbulence Model. UNIT-II Classification of PDEs – Elliptic, parabolic and hyperbolic euqations. Initial and boundary value problems. Concepts of Finite difference methods – forward, backward and central difference. Errors, Consistency, Stability analysis by von Neumann. Convergence criteria. UNIT-III Grid Generation- Types of grid O,H,C. Coordinate transformation, algebraic methods. Unstructured grid generation. UNIT-IV Finite difference solutions-Parabolic PDEs – Euler, Crank Nicholson, Implicit methods, Elliptic PDEs – Jacobi, Gauss Seidel, ADI, methods. FD- solution for Viscous incompressible flow using Stream function – Vorticity method & MAC method. UNIT- V Introduction to Finite volume method. Finite volume formulations for diffusion equation, convection diffusion equation. Solution algorithm for pressure velocity coupling in steady flows. Use of Staggered grids SIMPLE Algorithm. Suggested Reading: 1. Pradip Niyogi, Chakrabartty SK, Laha M.K., ‗Introduction to Computational Fluid Dynamics‘, Pearson

Education, 2005. 2. Muralidhar K, Sundararajan T, ‗Computational Fluid flow and Heat transfer‘, Narosa Publishing

House, 2003. 3. Chung, T J, ‗Computational Fluid Dynamics‘, Cambridge University Press, 2002. 4. John D Anderson, ‗Computational Fluid Dynamics‘, Mc Graw Hill, Inc., 1995. 5. Patankar, S.V, ‗Numerical Heat transfer and Fluid flow‘, Hemisphere Publishing Company, New York,

1980.

22

M.E 521 ENGINEERING RESERCH METHODOLOGY

UNIT-I Research Methodology: Objectives and Motivation of Research, Types of Research, Research Approaches, Significance of Research, Research Methods verses Methodology, Research and Scientific Method, Important of Research Methodology, Research Process, Criteria of Good Research, Problems Encountered by Researchers in India, Benefits to the society in general. Defining the Research Problem: Definition of Research Problem, Problem Formulation, Necessity of Defining the Problem, Technique involved in Defining a Problem. UNIT-II Literature Survey: Importance of Literature Survey, Sources of Information, Assessment of Quality of Journals and Articles, Information through Internet. Literature Review: Need of Review, Guidelines for Review, Record of Research Review. UNIT-III Research Design: Meaning of Research Design, Need of Research Design, Feature of a Good Design, Important Concepts Related to Research Design, Different Research Designs, Basic Principles of Experimental Design, Developing a Research Plan, Design of Experimental Set-up, Use of Standards and Codes. UNIT-IV Data Collection: Exploring the data, Description and Analysis of Data, Sample Design and Sampling, Role of Statistics for Data Analysis, Functions of Statistics, Estimates of Population, Parameters, Parametric V/s Non Parametric methods, Descriptive Statistics, Points of Central tendency, Measures of Variability, Measures of relationship, Inferential Statistics-Estimation, Hypothesis Testing, Use of Statistical software. Data Analysis: Deterministic and random data, Uncertainty analysis, Tests for significance: Chi-square, student’s‘t’ test, Regression modeling, Direct and Interaction effects, ANOVA, F-test, Time Series analysis, Autocorrelation and Autoregressive modeling. UNIT-V Research Report Writing: Format of the Research report, Style of writing report, References/Bibliography/Webliography, Technical paper writing/Journal report writing. Research Proposal Preparation: Writing a Research Proposal and Research Report, Writing Research Grant Proposal. Suggested Reading:

1) C.R Kothari, Research Methodology, Methods & Technique; New Age International Publishers,

2004 2) R. Ganesan, Research Methodology for Engineers, MJP Publishers, 2011

3) Y.P. Agarwal, Statistical Methods: Concepts, Application and Computation, Sterling Publs., Pvt.,

Ltd., New Delhi, 2004 5) Vijay Upagade and Aravind Shende, Research Methodology, S. Chand & Company Ltd., New

Instruction /Week 3 Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks

4) P. Ramdass and A. Wilson Aruni, Research and Writing across the Disciplines, MJP Publishers, Chennai, 2009

23

ME 532

COMPUTER AIDED MECHANICAL DESIGN AND ANALYSIS Instruction 3 Periods /Week Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks UNIT-I Design of pressure Vessels: Introduction and constructional features of pressure ves sels, stresses in pressure vessels, shrink fit stresses in built up cyliners, autofrettage of thick cylinders, thermal stresses and their significance. UNIT-II Stresses in flat plates: Introduction, Bending of plate in one direction, Bending of plate in t wo perpendicular directions, Thermal stresses in plates, Bending of circular plates of constant thickness, Bending of uniformly loaded plates of constant thickness. UNIT-III Fracture Mechanics: Introduction, Modes of fracture failure Griffith Analysis, Energy release rate, Energy release rate of DCB specimen; Stress Intensity Factor: SIF‘s for edge and centre line crack, Fracture toughness, Elastic plastic analysis through J-integral method: Relevance and scope, Definition of J - integral, Path independence, stress strain relation, Strain Energy Release Rate Vs J -integral. UNIT-IV Eigen Value Problems: Properties of Eigen values and Eigen Vectors, Torsional, Longitudinal vibration, lateral vibration, Sturm sequence. Subspace iteration and Lanczo‘s method, Component mode synthesis, Eigen value problems applied to stepped beams and bars. UNIT-V Dynamic Analysis: Direct integration method, Central difference method, Wilson- method, Newmark method, Mode superposition, Single degree of freedom system response, Multi degree of freedom system response, Rayleigh damping, Condition for stability. (Note: The related algorithms and codes to be practiced by students) Suggested Reading: 1. John, V. Harvey, Pressure Vessel Design: Nuclear and Chemical Applications, Affiliated East West

Press Pvt. Ltd., 1969. 2. Prasanth Kumar, Elements of Fracture Mechanics, Wheeler Publishing, New Delhi -1999. 3. V. Rammurti, Computer Aided Mechanical Design and Analysis, Tata Mc Graw Hill-1992. 4. Bathe, J., Finite Element Procedures, Prentice Hall of India-1996.

24

ME 511 OPTIMISATION TECHNIQUES

Instruction 3 Periods/week Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks UNIT – I Simulation: Introduction, Types of Simulation, Simulation Models, Monte Carlo Simulation, Random Number, Pseudo Random Number, Mid-Square Method of generating Random Numbers, Application & Limitation, Application of Simulation to Inventory Control and Queuing Problem UNIT – II Decision Theory: Introduction, Decision, Decision Making & Decision Theory, Types of Decisions, decision making process, Types of Decision making Environment: Decision making under certainty –Expected Monetary Value (EMV), Expected Opportunity Loss (EOL) Criterion & Expected Value of Perfect Information (EVPI) Criterion Decision making under risk- Criterion of Pessimism or Manimax, Criterion of Optimism or Maximin, Minimax Regret Criterion, Criterion of Realism & Criterion of Rationality Decision making under uncertainty and Decision tree analysis: Introduction, Procedure of Constructing Decision Trees & Solution through Decision Tree Analysis. UNIT – III Integer Programming: Introduction, Types of Integer Programming Problems, Gomory‘s Cutting Plane method. Branch and Bound method for all Integer Programming Problems & Mixed Integer Programming Problems UNIT – IV Dynamic Programming: Introduction- Bellman‘s principle of optimality-Application of dynamic programming-Linear programming problem-Capital budgeting problem UNIT – V Classical Optimization: Introduction; Unconstrained problems of maxima and minima, constrained problems of maxima and minima; Constraints in the form of equations – Lagrangian method; Constraints in the form of inequalities -Kuhn-tucker conditions. Suggested Reading: 1. S.S.Rao, Optimization Theory and Applications, NAI Publishers, Hyderabad, 1995. 2. S.D.Sharma, Operations Research, Kedarnath and Co. Publishers, Meerut, 2004. 3. V. K. Kapoor, Operations Research, S. Chand, New Delhi, 2004. 4. Hamdy A.Taha, Operations Research, Pearson Education, New York, 2001. 5. Bronson-Schaum Series, Operations Research, McGraw Hill, Singapore, 1983. 6. David Goldberg, Genetic Algorithms, S Chand Publications, 2006.

25

ME 502 METALLURGY OF METAL CASTING AND WELDING Instruction 3 Periods /Week Duration of University Examination 3 Hrs University Examination 80 Marks Sessional 20 Marks UNIT-I Metallurgy of Cast Steel and Cast Iron: Solidification microstructure, effect of cooling rate, carbon content, malleable and ductile Cast Iron. Solidification of Castings: Solidification of pure metals and alloys, solidification rate and directional solidification, grain structure of cast metals, shrinkage, gases in cast metals, degassification. Miscellaneous Practices: Refractories, metallurgical control, Inoculation, malleabilisation. Heat treatment of cast steel, cast iron, stress relieving, solution treatment, age hardening of castings. UNIT-II Metallurgy of copper base alloys-brass, bronze, Berillium Bronze, Chromium copper. Alluminium alloys – Heat treated and not heat treated. Zinc based die casting alloys, Nickel chromium high temperature alloys, Foundry practices of copper, aluminium and magnesium base alloys. UNIT-III Welding metallurgy – Weld zone, Fusionboundary zone, Heat affected Zone. Heat treatment and relatged processes in Fusion welding – Annealing, Normalizing, Austempering stress relieving, Solution treatment. UNIT-IV Microstructural products in weldments – Schaeffler diagram, Delta Ferrite, Austenite, pearlite, Martensite. Effect of alloying elements on microstructure. Welding stresses – Residual stresses, effects, methods of relieving. UNIT-V Weldability aspects of low alloy steels, strainless steels, aluminium alloys, Magnesium and Titanium alloys. Weld cracks – cold and hot cracks; Liquation cracks, Hydrogen Induced cracks, Lamellar cracks. Suggested Reading: 1. Taylor, Flemings & Wulff, Foundry Engineering, N.Y,Wiley & Song,Inc,1987

2. Heine, Richard.W, and others, Principles of metal casting, Tata McHill, New York, 1983.

3. Udin Funk & Wulff, Welding for Engineers, N.Y.John Wiley,1954.

4. J.F. Lancaster, Metallurgy of welding, London,George Allen & Unwio,1970.

5. R.S. Parmar, Welding Processes & Technology, Delhi, Khanna Publishers, 1992.

26

ME 569 MECHATRONICS AND ITS APPLICATIONS Instruction 3 periods/ week Duration of University Examination 3 Hours University Examination 80 Marks Sessional 20 Marks UNIT-I Introduction to Mechatronics: Concepts of system integration- Mechanical systems with electronic actuation, sensoring, Monitoring and control – Applications of Mechatronics in Mechanical industries. UNIT-II Sensors for various parameters – portion sensors – potentiometer – LVDT – proximity sensors – ultrasonic, inductive, optical, Hall effect – force sensors – tactile sensors. Various types of Actuators like electrical, hydraulic and pneumatic actuators –Solenoids, relays, DC motors, stepper motors, servo motors – Hydraulic and pneumatic systems – system components. UNIT-III Digital circuits and systems: Digital representation, combinational logic gates – timing diagrams – Boolean expressions and truth tables – sequential logic. UNIT-IV Data Analysis tools- MATLAB and LABVIEW software-features and capabilities of the software. Applications to machine control, Robotics and Engines. UNIT-V Electronic inter facing–introduction to data acquisition–quantizing theory–Hardware for DAC and ADC Fundamentals of digital signal processing – Microcontrollers and principles of their programming- Embedded single chip computer Systems – Digital signals processors. Suggested Reading:

1. Bolton,W, „Machatronics‟, Addison Wesley, Longma, 1999.

2. D.Neseuleseu, „Mechatronics‟, Pearson Education in Asia, 2002.

3. Ogate,K, System Dynamics, Prentice Hall, 1992.

4. MB Histand and DA Alciatore, „Introduction to Mechatronics and Measurement System‟, McGraw Hill,

1999.

27

ME 568

NON-TRADITIONAL MACHINING AND FORMING Instruction 3 periods/ week Duration of University Examination 3 Hours University Examination 80 Marks Sessional 20 Marks

UNIT-I Introduction: Need for non-traditional machining processes. Processes selection, classification, comparative study of different processes. Mechanical Process: Ultrasonic Machining-Definition-Mechanism of metal elements of the process- Tool feed mechanism. Theories of mechanics of causing effect of parameter applications. Abrasive Jet Machining: Principles - parameters of the process, applications, advantages and disadvantages. Water Jet Machining (WJM): Schematic diagram, equipment used, advantages and applications. UNIT-II Thermal Metal Removal Process: Electric discharge machining Principle and operation – mechanism of meta removal, basic EDM circuitry-spark erosion. Analysis of relaxation type of circuit material removal rate in relaxation circuits- critical resistance parameters in Ro Circuit-Die electric fluids- Electrodes for surface finish. Applications. Wire EDM principle and operation. Wire materials, wire tension and its parameters. Applications UNIT-III Electro Chemical and Chemical Processes: Electro chemical machining (ECM) Classification ECM process-principle of ECM Chemistry of the ECM parameters of the processes-determination of the metal removal rate - dynamics of ECM process-Hydrodynamics of ECM process-polarization. Tool Design-advantages and disadvantages - applications. Electro Chemical Grinding-Electro Chemical holding Electrochemical deburring. Plasma Arc Machining: Introduction-Plasma-Generation of Plasma and equipment Mechanism of metals removal, PAN parameters-process characteristics - type of torches applications. . UNIT-IV Electron Beam Machining (EBM): Introduction-Equipment for production of Electron beam - Theory of electron beam machining Thermal & Non thermal types characteristics – applications. Laser Beam Machining (LBM): Introduction-principle of generation of lasers Equipment and Machining procedure-Types of Lasers-Process characteristics-advantages and limitations-applications Ion Beam Machining: Introduction-Mechanism of metal removal and associated equipment-process characteristics applications UNIT-V High Velocity Forming Process: introduction - development of specific process selection-comparison of conventional and high velocity forming methods - Types of high velocity forming methods- explosion forming process-elector hydraulics forming magnetic pulse forming. Electro-Magnetic Forming. Rubber Pad Forming: Principle of the process, process details, process variants - Guerin, wheelon, Marforming and Hydro forming processes and applications. Suggested Reading :

1. New Technology Institution of Engineers - Bhattacharya - India 2. Production Technology - HMT - Tata Mc Graw Hill - ISBN-10; 3. High Velocity Forming of Metals - F.M Wilson - ASTME Prentice Hall 4. Modern Manufacturing Method - Adithan - New Age International (p) Limited 5. Modern Machining Processes - P.K. Mishra - Narosa Publishing House, New Delhi - 1997

28

ME 523

PRODUCTION ENGINEERING LAB Instruction 3 Periods/week Sessional 50 Marks List of Experiments:

1. Study of the morphology of chips produced from different materials and machining processes.

2. Effect of tool geometry on chip flow direction in simulated orthogonal cutting conditions.

3. Study of cutting ratio/chip thickness ratio in simulated orthogonal cutting with different materials

and tool geometry.

4. Evaluation of cutting forces using 3-D dynamometer in simple turning process.

5. Estimation of torque and thrust on a twist drill and effect of tool geometry and axial feed rate.

6. Evaluation of tool faces temperature with thermocouple method.

7. Roughness of machined surface. Influence of tool geometry and feed rate.

8. Electro chemical machining. Effect of flow rate of electrolyte and material structure on machining

characteristics.

9. Study of the ultrasonic machining setup and simple experiments on mach inability of glass and

other typical materials.

10. Study and operation of abrasive jet machining with simple experiments on M.R. with flow rate and

standoff distance.

11. Study of the construction and operating parameters of metal spinning Lathe.

12. Study of the water hammer equipment and hydrostatic extrusion setup.

13. Extrusion of cylindrical billets through dies of different included angles and exit diameters and their

effect on extrusion pressure.

14. Practice and study of blanking and punching process and their characteristic features on

mechanical press with existing dies.

29

ME 524

COMPUTATION LABORATORY Instruction 3 Periods/week Sessional 50 Marks List of Experiments:

1. Introduction to Finite Element Analysis Software.

2. Static Analysis of a corner bracket.

3. Statically indeterminate reaction force analysis.

4. Determination of Beam stresses and Deflection.

5. Bending analysis of a Tee-shaped beam.

6. Analysis of cylindrical shell under pressure.

7. Bending of a circular plate using axisymmetric shell element.

8. Stress analysis in a long cylinder.

9. Solidification of a casting.

10. Transient Heat transfer in an infinite slab.

11. Transient Thermal stress in a cylinder.

12. Vibration analysis of a Simply supported beam.

13. Natural frequency of a motor-generator.

14. Thermal-Structural contact of two bodies.

15. Drop test of a container (Explicit Dynamics).