PREFACE - National Institute of · PDF fileforce member, sliding friction force. Simple numerical problems. Friction: Force of friction, Laws of solid friction, Belt drives, Ratio

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PREFACE

Dear Students,

From the academic year 2014-15 there is a slight change in the syllabus structure and question paper pattern. This change is due to the philosophy of Outcome Based Education and requirement as per the National Board of Accreditation (NBA), Government of India, New Delhi.

Sixteen countries including New Zealand, Australia, Singapore, Russia and India are the signatories of the Washington Accord, which has come out with the new process of accreditation. This would enable every institution, including NIE to attain high standards of technical education in the respective countries and to create level playing ground. The outcome based education is one of the important components of NBA.

NIE is making sincere efforts in meeting the global standards through new formats of NBA and timely World Bank-MHRD initiative TEQIP (Technical Education Quality Improvement Program). Efforts are being made to revise the syllabi regularly to meet the challenges of the current technical education.

Dr. B. K. Sridhara July 2014 Dean (Academic Affairs)

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BLUEPRINT OF SYLLABUS STRUCTURE AND QUESTION PAPER PATTERN

(to be effective from the odd semester of the academic year 2014-15 for all semester students)

Blue Print of Syllabus Structure

1. Complete syllabus is prescribed in SIX units as Unit 1, Unit 2, etc.

2. In each unit there is one topic under the heading “Self Learning Exercises” (SLE). These are the topics to be learnt by the student on their own under the guidance of the course instructors. Course instructors will inform the students about the depth to which SLE components are to be studied. Thus there will be six topics in the complete syllabus which will carry questions with a weightage of 10% in SEE only. No questions will be asked on SLE components in CIE.

Blue Print of Question Paper

1. Question paper will have SEVEN full questions.

2. One full question each of 15 marks (Question No 1, 2, 3, 4, 5 and 6) will be set from each unit of the syllabus. Out of these six questions, two questions will have internal choice from the same unit. The unit from which choices are to be given is left to the discretion of the course instructor.

3. Question No 7 will be set for 10 marks only on those topics prescribed as “Self Learning Exercises”.

Dr. B. K. Sridhara July 2014 Dean (Academic Affairs)

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Administrator

Stamp

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WORK STUDY & ERGONOMICS (4:0:0)

Sub Code : IP 0411 CIE : 50% Marks

Hrs/Week : 04 SEE : 50% Marks

SEE Hrs : 03 Max. Marks : 50

Course Objective:

To Provide the basic knowledge of productivity and method study in various sectors and its effectiveness in improvement of productivity

To provide the usage of the various tools and techniques used in work measurement.

To compare and study of the existing system and propose a new method

To develop an idea for ergonomically based design for Human Machine System.

Unit 1: Productivity and Work Study: Definition of productivity, Individual enterprises, Task of management. Productivity of materials, land, building, machine and power. Measurement of productivity, Factors affecting the productivity, work content, Basic work content, Excess work content, how manufacturing job is made up? Work content due to excess product and process, Ineffective time due to short comings on part of the management Definition, objective and scope of work study. Work study and management, work study and worker. 08 Hrs

SLE: Human factors in work study and work study and supervision. Unit 2: Method Study: Definition, objective and scope of method study, Activity Recording and Tools. Charts to record moments in shop operation - process charts, Flow process charts, Travel chart and Multiple activity charts. Charts to record moment at work place - principles of motion economy, classification of moments, Two handed process chart, SIMO chart, and Micro Motion study. Development, definition and installation of the improved method, 10 Hrs

SLE: Brief concept about synthetic motion studies.

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Unit 3: Work Measurements: Definition, objectives Work measurement techniques. Work sampling – Need, confidence levels, and sample size determination, conducting study with the simple problems. 05 Hrs SLE: Benefit of work measurementand random observation Unit 4: Time study - Definition, Time study equipment, selection of job, steps in time study. Breaking jobs into elements, recording information. Rating and standard rating, standard performance, scales of rating, factors affecting rate of working, allowances and standard time determination. Predetermined motion time study - 14 Hrs SLE: Method Time Measurement (MTM).

Unit 5: Ergonomics: Introduction, areas of study under ergonomics, system approach to ergonomics model, man-machine system. Components of man-machine system and their functions. 08 Hrs SLE: Work capabilities of industrial worker Unit 6: Design of Man-Machine System: Fatigue in Industrial workers. Design principles for displays and controls. 07 Hrs

SLE: Influence of climate, noise, vibration and light on human efficiency Text Books:

1. Introduction to Work Study – ILO, 4th edition 1992

2. S. Dalela and Sourabh, “Work Study and Ergonomics”. Standard publishers 1990

Reference Books:

1. Barnes, “Motion and Time Study”, Wiley International.

2. Mark S. Sanders and Ernest J. McCormick , “Human Factors in Engineering Design”. seventh edition

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

1. Recollect the basic concepts of productivity, work content and work study

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2. Define the various charts and to construct the charts on the basis of present method and develop a new / proposed method and identify the unnecessary movements.

3. Explain the basic work measurement techniques and to gain knowledge of measurement of work.

4. Understand the importance of time study and demonstrate the rating techniques and the principles involved.

5. Demonstrate the basic concepts of ergonomics and study the components of man-machine systems.

6. Design the displays and controls of machines and able to understand the effect of environmental factors on human efficiency.

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DYNAMICS OF MACHINERY (3:2:0)




Course objectives:

1. Discuss the free body diagram of a component and calculate the forces acting on it. Derive the necessary equation in belt drives and solve problems on power transmission using belt drives.

2. Describe the D„Alembert‟s principle, engine force analysis, and dynamically equivalent system and solve problems on the same

3. Analysis of flywheel design 4. Discussion of balancing of machines of various engine

configuration 5. Solve problems related to Hartnell and Porter governor 6. Study of gyroscope and its effect on airplanes and naval

ships and solve problems on the same

Unit 1: Static Force Analysis: Introduction, Forces, Moments & Torques, Free body diagram, static equilibrium, analysis of two force member, sliding friction force. Simple numerical problems. Friction: Force of friction, Laws of solid friction, Belt drives, Ratio of belt tensions, power transmitted by a belt drive, Effect of centrifugal Tension on power transmitted, V-belt drive. Numerical problems 12 Hrs SLE: Advantages and disadvantages of V-Belt drives.

Unit 2: Dynamic force analysis: D„Alembert‟s principles, Dynamic analysis of slider crank mechanisms (Analytical method only). Engine force analysis, turning moment on crankshaft, dynamically equivalent system, and inertial force in connecting rod, Numerical problems. 10 Hrs SLE: Significance of D ‘Alembert’s principle.

Unit 3: Dynamics of Engine Mechanism: Turning moment diagram and fly wheel design 06 Hrs

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SLE: Study different turning moment diagrams for different engine configuration. Unit 4: Balancing of Machinery: Static and dynamic balancing, balancing of single rotating mass in same plane and in different planes. Balancing of several rotating masses in same plane and in different planes Balancing of reciprocating masses – Primary and secondary unbalanced forces, balancing of unbalanced primary force in a reciprocating engine, multi-cylinder in-line engines, V & W-type engine. 12 Hrs SLE: Case study of different types of V and W engines. Unit 5: Governors: Types of Governors, Force analysis of porter and Hartnell governor. Controlling force, stability resistiveness, isochronisms, effort and power (only definitions) 06 Hrs SLE: Difference between governors and flywheel. Unit 6: Gyroscope: Angular velocity and acceleration, gyroscopic couple, effect of gyroscopic couple on airplane and naval ships 06 Hrs SLE: Analyze the effects of gyroscopic torque on ships and airplanes. Text Books:

1. Machines and Mechanisms, Applied kinematic analysis , David H Myszka PHI learning – 2013

2. Theory of machines by Rattan, TMH publication – 2012 Third Edition.

Reference books:

1. Theory of Machine by Thomas Bevan, CBS publication

2. Theory of Machines and mechanisms by John J Uicker Jr, Gordon R Pennock, Shigley, TMH publication – 2012 – Third Edition.

3. Kinematics and Dynamics of machinery by Robert L Norton Mc Graw Hill publications.

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1. Calculate the moment of a force, create a force body diagram of a general machine component, and determine the forces acting throughout a mechanism. Solve problems on power transmission using belt drives

2. Determine the forces acting on a mechanisms by D Alembert‟s principle

3. Design a flywheel

4. Appreciate the importance of static and dynamics balancing of revolving masses, reciprocating mass, inline engines, V & W engines

5. Understand the function of governors and its analysis

6. Appreciate the importance of gyroscopic torque in airplanes and naval ships.

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DESIGN OF MACHINE ELEMENTS – I (4:0:0)




Pre-requisites

Mechanics of materials. Course Objective:

Students will learn to formulate and analyze stress and strain in machine elements and structure subjected to various loads.

Unit 1 Design for Static and fatigue Strength: Static strength: Stresses and deformation due to different types of loads, uniaxial, biaxial and triaxial state of stresses. Principal planes, Important Engineering Materials and their properties: ferrous and nonferrous metals, plastics and composite materials: Designation of materials; Codes and Standards used in design. Static load, Static strength and factor of safety; Introduction: S-N Diagram, Low cycle fatigue, High cycle fatigue, fatigue strength and Endurance limit, Endurance limit modifying factors: size effect, surface effect, Stress concentration effects; Goodman and Soderberg‟s relationship; stresses due to combined loading, Cumulative fatigue damage: Miner‟s rule. Combined stress, Mohr‟s circle of stresses. 10 Hrs

SLE: Engineering materials and their properties Unit 2 Theories of failure and design for Impact strength: Theories of failure: Maximum normal stress theory, Maximum shear stress theory, Distortion energy theory; Stress concentration; Stress concentration fact, methods of reducing stress concentration. Impact stresses due to axial, bending and torsion loading, effect of inertia. 8 Hrs

SLE: Impact of different cross sections

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Unit 3 Design of Shafts: Torsion of shafts, design for strength and rigidity, ASME code for design of transmission shafting, design of shafts under different loads: Combined loads & Fluctuating loads. Keys and Couplings: Different types of keys, Design for shear and crushing strength, Design of Splines, Couplings: Design of Muff coupling, rigid flange coupling, Bush & Pin type, Oldham‟s coupling Couplings: Design of Muff coupling, rigid flange coupling, Bush & Pin type, Oldham‟s coupling. 12 Hrs

SLE: Flexible shafts, Design of Oldham’s couplings Unit 4 Threaded Elements: Threaded Fasteners: Effects of initial tension on bolts, Design of bolts for fatigue loading, impact loading, shear loading and eccentric loading. Power Screws: Mechanics of power screw, Stresses in power screws, efficiency and self-locking, Design of power screws for Screw Jack, C-Clamp, machine vice and sluice gate. 06 Hrs

SLE: Nut, bolt, screw-design and its application Unit 5

Mechanical Joints: Cotter and Knuckle Joints 06 Hrs.

SLE: Applications Unit 6 Mechanical Joints: Riveted Joints: Types, rivet materials, failure of riveted joints, Efficiency, Boiler Joints, Tank and Structural Joints, Riveted Brackets. Welded Joints: Types, Strength of butt and fillet welds, eccentrically loaded welded joints. 10 Hrs.

SLE: Different joints and its applications Design Data Hand Books:

1. Design Data Hand Book, K.Mahadevan and Balaveera Reddy,

CBS publication.

2. Design Data Hand Book Vol. 1 & 2 – Dr.K.Lingaiah, Suma publications, Bangalore.

3. PSG Design Data Hand Books PSG College of Technology Coimbatore.

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Text Books:

1. Mechanical Engineering Design – Joseph Edward Shigley & Charles & Mischke. McGraw Hill International edition, 8

th

edition. 2008. 2. Fundamentals of Machine Design Component – Robert C.

Juvinall and Kurt M.Marshek – John & sons 4th edition,

2006.

3. Design of Machine Elements – V.B.Bhandari, Tata McGraw Hill publishing Co. Ltd., New Delhi. 3

rd Edition

2010. Reference Books:

1. Machine Design – Robert. L.Norton – Pearson Educations Asia, New Delhi. 2001

2. Machine Design, Hall, Holowenko, Laughlin, (Schaum‟s Outline Series), Adapted by S.K.Somani, Tata Mc.Graw Hill Publishing Company Ltd. New Delhi, Special Indian Edition, 2008.

3. Design of Machine Elements: M.FSpotts, T.E.Shoup, L.E.Hornberger, Adapted by S.R.Jayaram and C.V.Venkatesh, Pearson Education, 2006.


1. Understand the importance of static strength and impact strength of materials.

2. Design machine components for static, impact and fatigue strength

3. Design of threaded elements and power screws.

4. Design of shafts for all types of loads

5. Design of keys and couplings.

6. Design of joints like rivet, weld, cotter and knuckle.

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CONTROL ENGINEERING (4:0:0)




Pre-requisites

Engineering Mechanics, Basic electrical Engg, Elements of Mechanical Engg.

Course Objective

The main objective of this course is to help the student to gain a basic understanding of system behavior and control. Unit 1

Introduction & Mathematical Model: Concept of automatic controls, open and closed loop systems, Regulator system, Follow up systems, concepts of feedback, requirement from an ideal control system. Mechanical system (both translational and rotational), Electrical system, DC Motors, Hydraulic systems liquid level and fluid power systems, Hydraulic servomotor. Transfer functions, Deriving transfer function of physical systems. 12 Hrs SLE: Control Action: Types of controllers – proportional, integral, proportional Integral, Proportional Integral Differential controllers (Basic concepts only).

Unit 2

Transient Response Analysis: First order Systems (Mechanical & Electrical)subjected to step and ramp input, second order mechanical system response to step input, concepts of time constant and its importance in speed of response. Time response specifications of second order system. Mathematical concept of stability, Routh stability Criterion. 08 Hrs SLE : Second order system response to ramp input. Unit 3

Block Diagrams & Signal Flow Graphs: Transfer functions definition, block diagram, Block diagram Algebra, representation of system elements, reduction of block diagrams, Signal flow graphs, Basic properties and gain formula. Mason gain formula. 08 Hrs SLE : Multiple input/outputs of block diagrams

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Unit 4 Frequency Response: Polar and rectangular plots for the frequency response, Nyquist stability criterion, system analysis using Nyquist diagrams, gain margin and phase margin. 08Hrs SLE: Relative stability concepts. Unit 5 Logarithmic Plots: Bode attenuation diagrams, stability analysis using Bode diagrams 08 Hrs SLE: Simplified Bode diagrams. Unit 6 Root Locus Plots: Definition of root loci, Rules for rapid plotting, constructing of root loci, Root locus plots. 08 Hrs SLE: Stability analysis. Text Books:

1. Modern Control engineering – K Ogatta, Prentice Hall (India) Pearson Education 2003.

2. Control Systems – I J Nagrath & M Gopal, New age International Publishers. Third edition, 2004

References:

1. Feedback Control Systems – Schaum‟s series. 2001

2. Control Systems – M Gopal, Tata McGraw Hill, New Delhi, 2

nd Edition, 2002.

3. Modern Control Systems – Richard C Dorf and Robert. H.Bishop, Addison – Wesley, 8

th edition, 1998.

4. Automatic Control Systems – B.C Kuo. Prentice Hall (India), 1995.

Course Outcomes: On Successful completion of the course, the student will able to :

1. Recall the basic concept of automatic control, represent the mathematical model of a system, convert it into transfer functions, Understand the controllers.

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2. Evaluate the response of first and second order systems for various step and ramp inputs. Analyze the stability of the system using mathematically concept of stability.

3. Manage the block diagram representation and reduction, conversion of block diagram into signal flow graph, obtaining the transfer function.

4. Understand the significance between magnitude and phase relationship between sinusoidal input and study state output.

5. Predict the transfer function of the given system using Bode plots.

6. Visualize the effects of varying system parameter on root location.

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COMPUTER INTEGRATED MANUFACTURING (4:0:0)




Pre-requisites

Computer concepts and basic steps of programming.

Course Objective: To learn the basic procedure of CIM and the benefits that can be achieved by integration in manufacturing systems and understand the CIM implementation strategies . Unit 1 Introduction: Role of computers in design and manufacturing, Influence of computers in manufacturing environment. Product cycle in conventional & computerized manufacturing environment.Introduction to CAD/CAM/CIM, NC, CNC, DNC Technology: NC, CNC, DNC modes, NC

elements, advantages and limitations of NC, CNC. 10 Hrs

SLE: Advantages and disadvantages of CAD, CAM & CIM. Functions of computer in DNC. Unit 2 CNC Machine Tools: Turning tool geometry, milling tooling

systems, tool presetting, ATC, work holding, CNC machine tools,

Overview of different CNC machining centers, CNC turning

centers. 08 Hrs

SLE: High speed machine tools Unit 3 Introduction To Robotics: Introduction, Robot Configuration,

Robot Motions, Programming the Robots, Robot – Programming

Languages, End effectors, Work Cell Control and Interlock, Robot

Sensor. 08 Hrs

SLE: Robot Applications.

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Unit 4 CNC Programming:– steps involved in development of a part

program. Manual part programming-milling & turning.APT

Programming in drilling, milling and turning with problems. 12 Hrs

SLE: Part program fundamentals. Unit 5 CIM : computer aided process Planning, computer integrated

production planning system, material requirements planning,

capacity planning, shop floor control . 07 Hrs

SLE: Future automated factory. Unit 6 Group Technology & Flexible Manufacturing: Part families, Part

classification & coding, Machine cell design & benefit of GT, FMS

work stations, planning the FMS, FMS layout configuration. 07 Hrs

SLE: Application and benefit of FMS. Text Books:

1. CAD/CAM Principles and Applications – P.N. Rao, TMH, New Delhi, 2002.

2. CAD/CAM – Mikell P-groover, Emory W.Zimrners Jr Pearson Education inc, 2003.

3. CAD/CAM/CIM P.Radhakrishnan, S.Subramanyan, U.Raju, New Age International Publication Revised Third Edition 2007

Reference Books:

1. Principles of Interactive Computer Graphics – Newman and Sproull, Tata Mc Graw Hill, 1995.

2. NC Machine programming & software Design – Chno-Hwachang, Michel.A.Melkanoff, Prentice Hall, 1989.

3. Computer Graphics by Steven Harrington, McGraw Hill Book Co.

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4. CAD/CAM-Ibrahim Zeid, Tat McGraw Hill, 1999.

5. Computer Aided Manufacturing – P.N.Rao, N.K.Tewri and T.K.Kundra Tata McGraw Hill 1999.

6. Introduction to FEM, T Chandra Putla Ashok D Belagundu, 2002

7. Basic Computer Aided Geometric Design – Ganesh M – I. K. International, New Delhi – 2008.


1. Identify how automation can be used in production systems

2. Interpret a component specification and produce an operational plan for its manufacture

3. Identify industrial robots and their applications

4. Develop industrial robot programs and be able to produce a part programme and manufacture a component

5. Apply cellular manufacturing, process planning principles

6. Apply group technology concepts for the analysis and design of flexible manufacturing systems and production of a part in a flexible manufacturing cell

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MANUFACTURING PROCESSES – III (4:0:0)




Pre-requisites

Manufacturing processes I & II

Course Objective:

To learn the basic concepts of plasticity , forming process, lubrication, rolling and extrusion of different metals and their alloys. Unit 1

Elements of theory of Plasticity: Flow curves, True stress and strain, Yield Criteria for ductile materials, Von Mises criterion and Tresca criterion. Fundamentals of Metal working: Classification of forming

process, Mechanics of Metal working, Temperatures in Metal

working, Hot working, Cold working, Warm working, strain rate

effects, Metallurgical structure. 10 Hrs

SLE: Friction and Lubrication in metal working. Unit 2

Forging of Metals: Introduction, open Die forging, Impression –

Die and closed die forging, precision forging, rotary swaging,

forging force, forging Die Design; Die-Materials and lubrication,

forgeability, forging defects, forging Mechanics. 07 Hrs

SLE: Presses and hammers. Unit 3

Rolling of Metals: Introduction, flat rolling, frictional forces, Roll force and power requirement, Geometric consideration, Defects in rolled plates and sheets, Rolling Mills, classification, shape rolling operations: Ring rolling, Thread rolling, Defects in rolled products. 06 Hrs

SLE: Production of seamless pipe and tubing.

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Unit 4

Extrusion and Drawing : Introduction, The extrusion process, extrusion force Metal flow in extrusion, Extrusion practice, Hot extrusion, Die Design and Die materials, Lubrication, cold extrusion, Impact extrusion, Hydrostatic extrusion, Extrusion defects, Extrusion equipment, The drawing process, Drawing practice, Drawing equipment, Defects and Residual stresses, 09 Hrs

SLE: Extrusion of non-metals and plastics.

Unit 5

Sheet metal forming processes: Introduction, Shearing, Sheet metal characteristics, Test methods for formability of sheet metals, Bending sheet and plate, common bending operations, Tube bending and forming, stretch forming, Deep drawing, Rubber forming, Spinning, Super plastic forming and other forming processes, Equipment for sheet metal forming, Defects in sheet metal products. 10 Hrs SLE: Explosive and magnetic pulse forming. Unit 6 Powder Metallurgy: Introduction, Basic process, powder manufacture, Rapidly solidified powder, Powder testing and evaluation, powder mixing and blending, compacting, Sintering, Hot Isostatic pressing, Secondary operations, properties of P/M products, Design of P/M products, powder Metallurgy Products, Advantages and Disadvantages of powder metallurgy. 10 Hrs

SLE: Other Techniques to Produce High Density P/M Products. Text Books:

1. Mechanical Metallurgy – Dieter G.E, Mc graw Hill 2001.

2. Manufacturing Engineering and Technology – Serope Kalpakjian, and Steven R. Schmid, PEARSON Education, 2004

3. Materials and processes in Manufacturing, E.Paul Degarmo, J.T. Black, Rouald A . Kohser, PHI 2000.

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References:

1. Principle of Industrial Metal Working Process – Rowe Edward Arnold, CBS publishers, 2002.

2. ASM – Metals Hand Book, Sach G, Fundamentals of working of metals, pergomon press.


1. Explain the Elements of Theory of Plasticity and Von Mises and Tresca criterion fundamentals of metal working.

2. Understand and explain the principles of Forging of Metals

3. Understanding of the types, forces and defects involved in Rolling of Metals

4. Explain the basic knowledge of Extrusion and Drawing metals.

5. Define the basic concept of Sheet metal forming processes

6. Explain the basic theory about powder metallurgy and its applications.

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MACHINE SHOP (0:0:3)

Sub Code : IP 0105 Max. Marks : 50

Hrs/Week : 03 Pre-requisite:

Manufacturing process – II

Course Objective: Prepare models and perform operations

on different machine tools.

Preparation of at least three models on lathe involving Plain turning, Taper turning, step turning, Thread cutting, Facing, Knurling, Drilling, Boring, Internal Thread cutting and Eccentric turning.

Cutting of V Groove/ dovetail / Rectangular groove using Shaping,

Cutting of Gear Teeth using Milling Machine, simple and

Differential indexing calculations. Cutting of Helical gear teeth

(Demonstration only)


1. Prepare 3D models on lathe involving plain, taper and step

turning, thread cutting, eccentric turning.

2. Demonstrate the types of operations like groove and gear

cutting using milling machine.

3. Perform simple and differential indexing calculations and

execution of the same.

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INDUSTRIAL ENGINEERING LABORATORY(0:0:3)


Hrs/Week : 03

Course objective:

Students will learn the importance of workstudy, method study and work measurement techniques, plot the respective charts and study the rating factors.

1. Recording Techniques: Preparing the following charts and diagrams

- Out lines process chart

- Flow process chart

- Flow diagram

- Multiple activity chart

- String diagram, SIMO chart

- Two handed process charts

2. Application of principle of motion economy

3. Measurement of effect of work on human body (Ergometer,

Tread mill)

4. Rating exercises: Dealing of Cards, Walking on level

ground.

5. Determining the standard time for simple operations using

stop watches and PMTS

6. Application of Acceptance Sampling Techniques (single

sampling plan & Plotting the O.C. Curve)

7. Experiments to generate data and the results in normal

distribution and its interpretation.

8. Effect of Noise on human efficiency

9. Conceptual design of displays and controls.

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1. Recall basic concepts of methods study.

2. Define the parameters for various charts.

3. Construct various charts, analyze and propose a new method.

4. Demonstrate savings in time, labour which will result in removal of unnecessary movements.

5. Determine the rating factors

6. Understand the use of the PMTS techniques.

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VI Semester

(Core Courses)

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FLUID POWER SYSTEMS (4:0:0)




Pre-requisites

Fluid Mechanics

Course Objective

This course is essential in understanding the design, analysis, operation, maintenance and applications of fluid power systems. Unit 1

Introduction To Hydraulic Power & Pumps: Pascal‟s Law, structure of Hydraulic control system. Pumps: Pumping theory, Pump Classification, Gear Pumps, Vane Pumps, Piston Pumps, Pump performance, Pump selection.

Hydraulic Actuators And Motors: Linear Hydraulic Actuators (Cylinders), Mechanics of Hydraulic Cylinder Loading, cylinder cushioning, Hydraulic Rotary Actuators, Hydrostatic Transmission – open and close circuit, Performance. 14 Hrs

SLE: Gear Motors, Vane Motors, piston Motors. Unit 2

Control Components In Hydraulic Systems: Directional Control Valves (DCV), Constructional features, 2/2,3/2,4/2,4/3 DCV, Center configuration in 4/3 DCV, Actuation of DCVs, check valve, Pilot check valve, Pressure control valves – direct and pilot operated types, Pressure reducing valve, flow control valves, , Throttle check valve. 07 Hrs

SLE: Pressure compensated flow control valves. Unit 3 Hydraulic Circuit Design And Analysis: Control of single and Double acting Hydraulic cylinder, Regenerative circuit, Counter balance Valve application, Hydraulic Cylinder sequencing Circuits,

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Cylinder Synchronizing Circuits, speed Control of Hydraulic Cylinder – Meter in & Meter out, speed control of Hydraulic Motors, 06 Hrs SLE: Accumulators and accumulator circuits- Emergency power source, Auxiliary power source, Shock absorber. Unit 4

Maintenance of Hydraulic Systems: Hydraulic oils – Desirable properties, General type of fluids, Sealing Devices, Reservoir system, Filters and strainers, Problem caused by Gases in Hydraulic Fluids. Introduction To Pneumatic Control: Choice of working medium. Characteristics of compressed air. Structure of Pneumatic control system, Production of compressed air – compressors, Preparation of compressed air – Driers, Filters, regulators, Lubricators, Distribution of compressed air – Piping layout. 12 Hrs SLE: Wear of Moving Parts due to solid – Particle Contamination, Temperature control, Trouble shooting. Unit 5

Pneumatic Actuators & Valves: Linear Cylinder – Types, ventional type of cylinder – working, Directional control valve, shuttle valve, Quick exhaust value, Twin pressure valve, Direct and indirect actuation of pneumatic cylinder, memory valve, time delay valve. 07 Hrs SLE: End position cushioning, Rod less cylinders. Unit 6 Pneumatic Logic Circuits: Use of Logic functions – OR, AND, NOR, NAND, NOT functions in pneumatic applications, Practical examples involving the use of logic functions. Travel dependent controls – types – Construction – Practical applications. 06 Hrs SLE: Time dependent controls – Principle, Construction, Practical applications. Text Books:

1. Fluid Power with application‟s – Anthony Esposito, Fifth edition, Pearson Education, Inc 2000.

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2. Oil Hydraulic systems – Principles and Maintenance – S.R. Majumdar, Tata McGraw Hill Publishing Company Ltd. 2001.

3. Pneumatic systems – S.R. Majumdar, Tata McGraw Hill Publishing Co. 1995.

Reference Books:

1. Pneumatics Basic Level TP 101 – by Peter Croser & Frank Ebel, Festo Didactic publication – 1999.

2. Fundamentals of Pneumatic Control Engineering – J P Hasebrink & R Kobbler, Festo Didactic publication, 3

rd

edition 1989.

3. Pneumatic Control for Industrial Automation – Peter Rohner & Gordon Smith, John Wiley Sons publication – 1989.

4. Power Hydraulics – Michael J Pinches & John G Ashby, Prentic Hall – 1989.


1. Recall the basic concept of fluid mechanics,

represent the structure of hydraulic system, able to identify different components of hydraulic system.

2. Analyze the requirement of control components and their selection

3. Able to design the hydraulic system for various situation.

4. Plan the maintenance schedule for the system.

5. Understand the Pneumatics systems

6. Analyze the pneumatic system and apply the proper logic functions

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DESIGN OF MACHINE ELEMENTS -II (4:0:0)




Pre-requisites

Design of Machine Elements I Course Objective:

Students will understand, analyze and design different machine elements and its applications.

Unit – 1 Design of Curved Beams: Stresses in curved beam of standard cross sections used in crane hook, punching press and clamps. Cylinders and Cylinders Heads: Review of Lame‟s Equations; compound cylinders, Stresses due to different types of fits, cylinder heads and flats. 09Hrs

SLE : Different beams.

Unit – 2 Design of Springs: Types of springs - stresses in coil springs of circular and non-circular cross sections. Tension and compression springs, fluctuating load, spring in combination Leaf Springs: Stresses in le af springs. Equalized stresses: Energy stored in springs, Torsion, Belleville and Rubber springs, surge in springs Belt, Rope and Chain Drives: Stresses in Belts: Design and Selection of flat and V- Belts, Selection of wire ropes, Selection of chains 10 Hrs

SLE : Selection of V-Belts and chain

Unit – 3 Spur and Helical Gears: Introduction, Spur Gears: Stresses in Gear tooth – Lewis equation and form factor, Design for strength, Dynamic and wear load, Helical Gears, Formative number of teeth, Design for strength, Dynamic and wear load, AGMA standards of Gear Design. 09 Hrs

SLE: AGMA standards of gear design –spur , helical.

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Unit – 4 Bevel and Worm Gears: Bevel Gears: Formative number of teeth, Design for strength, Dynamic and wear load, Worm Gears, Definitions, Design for strength, Dynamic and wear load, Efficiency of worm gears, AGMA standards of Gear Design. 09 Hrs

SLE: AGMA standards of gear design –Bevel and Worm. Unit – 5 Clutches and Brakes: Design of single plate, Multiplate and cone clutches, design of Brakes, Block and band brakes, Self locking brakes, Heat generation brakes. 06Hrs

SLE: Heat generation in brake

Unit – 6 Lubrication and Bearings: Mechanisms of Lubrication, bearing materials, bearing modulus, coefficient of friction, minimum oil film thickness, Thermal equilibrium : heat generation and dissipation, Design of journal bearing and thrust bearing. Ball and Roller Bearings: Introduction, Types, Construction, Loads on Bearings, Equivalent bearing load, Life of bearing, selection of ball and roller bearings. 09 Hrs

SLE : Selection of Ball and Roller Bearing Design Data Hand Books:

1. Design Data Hand Book by K.Mahadevan and Balaveera Reddy, CBS publication. 3

rd Edition.

2. Design Data Hand Book Vol.l and Vol.2 by Dr. K. Lingaiah,, Suma publications, Bangalore.

3. PSG DesignDataHandBooksPSGCollege of Technology Coimbatore.

Text Books: 1. Design of Machine Elements by V. B. Bhandari, Tata McGraw

Hill publishing Co. Ltd., New – Delhi. Second Edition 2007.

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Reference Books:

1. Machine Design by Hall, Holowenko, Laughlin, (Schaum‟s Outline Series), Adapted by S.K. Somani, Tata Mc. Graw Hill Publishing Company Ltd. New Delsi, Special Indian Edition, 2008.

2. Design of Machine Elements by M.F. Spotts, T.E. Shoup, L.E.Hornberger, Adapted by S.R. Jayaram and C.V. Venkatesh, Pearson Education, 2006.

3. Mechanical Engineering Design by Joseph Edward Shigley and Charles and Mischke . McGraw Hill International edition, 6

th edn. 2004.

Course Outcome:

On successful completion of the course the student will able to

1. Design curved beams, springs and its uses.

2. Know stress induced in a cylinder and different drives.

3. Design spur and helical gears

4. Design bevel and worm gears

5. Design clutch and brake.

6. Know the mechanism of lubrication and types of bearing

37

COST ESTIMATION & ENGINEERING ECONOMICS (4:0:0)




Course Objective:

Provides clear understanding of the fundamentals of engineering economics.

Learn the concepts of decision making, problem solving ,comparison of the alternatives and elements of cost.

Unit 1 Introduction: Engineering Decision – Makers, Engineering and Economics, Problem solving , Intuition and Analysis, Tactics and Strategy. 06 Hrs

SLE: Decision making. Unit 2 Interest And Interest Factors: Interest rate, simple interest Compound interest, interest formulae, Time value equivalence Exercises and Discussion. 07 Hrs

SLE: Cash flow diagrams. Unit 3 Present Worth Comparison: Conditions for present worth comparisons, Basic Present worth comparisons, Present worth equivalence, Net Present worth, Assets with unequal lives, infinite lives, Pay – back comparison, Exercises, Discussions and problems. 09 Hrs

SLE: Future worth comparison. Unit 4 Equivalent Annual Worth Comparisons: Equivalent Annual worth comparison methods, Situations for Equivalent Annual Worth Comparison, Consideration of asset life, Comparison of assets with equal and unequal lives, Exercises, Problems.

38

Rate of Return Calculations: Rate of return, Minimum Acceptable Rate of Return, IRR, IRR misconceptions. 13 Hrs

SLE: Use of sinking fund method. Unit 5 Depreciation: Basic methods of computing depreciation charges, problems. Replacement Analysis: Deterioration, obsolescence, Inadequacy, Economic life cycle for replacements, problems. 10 Hrs

SLE: Causes of Depreciation. Unit 6 Estimating & Costing: Components of costs such as Direct Material Cost, Direct Labour Cost, Fixed, Over – Heads, Factory Costs, Administrative – Over Heads, First Cost, Selling price, Estimation for simple components. Case studies : To calculate the total cost of various components. 05 Hrs SLE: Marginal cost, Problems on Costing. Text Books:

1. Engineering economy – Riggs J.L., Mc Graw Hill, 2002.

2. Engineering economy – Paul Degarmo, Macmillan Pub, Co. 2001.

3. Engineering Economy – NVR. Naidu, KM Babu and G.Rajendra, New Age International Pvt. Ltd. – 2006.

Reference Books:

1. Industrial Engineering and Management - O.P Khanna, Dhanpat Rai & Sons 2000

2. Financial Management – I M Pandey, Vikas Publishing House 2002.

3. Engineering economy – Theusen. G. PHI, 2002.

39


1. Recall the basic concepts of decision making , problem solving, Tactics and Strategy.

2. Defining the time value of money, interest factors, which will help in calculations.

3. Explain the comparison by present worth method under different lives of the asset.

4. Compare the asset on the basis of EAW comparison.

5. Explain the concepts of depreciation and replacement criteria.

6. Understand the estimating procedure for different components and calculate the total cost.

40

STATISTICAL QUALITY CONTROL (4:0:0)




Pre-requisite:

Mathematics III

Mathematics IV

Course Objective: To understand the different statistical quality control

concepts, tools and fundamentals of process performance charts.

Unit 1:

Introduction: Meaning of Quality and Quality Improvement,

Dimensions of Quality, Quality Engineering Terminology, Statistical

Methods for Quality Control and Improvement, Other Aspects of

Quality Control and Improvement, Quality Philosophy and

Management Strategies, Link between Quality and Productivity,

Quality Costs, 7- QC tools, TQM, Quality assurance, 08 Hrs

SLE: Recognize and illustrate various aspects of quality in a multi-disciplinary organization Unit 2:

Process Quality: Describing Variation, Frequency Distribution and Histogram, Numerical Summary of Data, Probability Distributions, Important Discrete Distributions - Hypergeometric Distribution, Binomial Distribution and Poisson Distribution, Important Continuous Distributions - Normal Distribution, Brief Discussion on: Exponential, Gamma and Weibull Distributions, Binomial Approximation to the Hypergeometric, Poisson Approximation to the Binomial, Normal Approximation to the Binomial 10 Hrs

SLE: Application of various distribution in real world situation

41

Unit 3:

Statistical Process Control Charts: Chance and Assignable

Causes of Quality Variation, Statistical Basis of the Control Chart,

Basic Principles, Choice of Control Limits, Sample Size and

Sampling Frequency, Rational Subgroups, Analysis of Patterns on

Control Charts 06 Hrs

SLE: Analyze and illustrate the implications of patterns on

control charts vis-à-vis industrial application.

Unit 4:

Control Charts for Variables: Introduction, Control Charts for X

bar and R, Statistical Basis of the Charts, Development and Use of

and R Charts, Process Capability, Interpretation of X bar and

R Charts, Control Charts for X bar and S, Construction and

Operation of X bar and S, X bar and S Control Charts with Variable

Sample Size, Control Chart for Individual Measurements 08 Hrs

SLE: Case study and problems Unit 5:

Control Charts for Attributes: Introduction, Control Chart for

Fraction Nonconforming (p, 100p and np Charts), Control Charts

for Nonconformities (c and u Charts), Procedures with Constant

and Variable Sample Size 08 Hrs

SLE: Case study and problems Unit 6:

Acceptance Sampling: Acceptance-Sampling Problem,

Advantages and Disadvantages of Sampling, Types of Sampling

Plans, Lot Formation, Random Sampling, Single-Sampling Plans

for Attributes, Definition of a Single-Sampling Plan, OC Curve,

Designing a Single-sampling plan with a specified OC Curve,

Producers‟ and Consumers‟ Risk, Rectifying Inspection, Double

Sampling Plan. 08 Hrs

SLE: Multiple and Sequential Sampling

42

Text Book:

1. Introduction to Statistical Quality Control, Douglas C.Montgomery, 4

th Edition, 2008, Wiley India Edition

Reference Books:

1. Statistical Quality Control, Eugene L.Grant and Richard S.Leavenworth, 7

th Edition 2004, Tata McGraw-Hill

2. Quality Control, Dale H.Besterfield, 4th Edition, Prentice

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

1. Demonstrate the concept of Quality from producer‟s and consumer‟s prospective, methods for quality control

2. Demonstrate the variations of distribution of data‟s using different methods.

3. Explain the purpose and function of statistical quality control, the differences between attributes and variables and causes of variations.

4. Students will become familiar with control chart techniques for continuous quality improvement, fundamentals of tolerance and process capabilities, quality control charts and process performances and become familiar with basic methods of statistical process control.

5. Understand the Operating Characteristic Curve and prepare the acceptance sampling plan

6. Describes knowledge on QC tools and techniques.

43

LEAN MANUFACTURING SYSTEM (4:0:0)




Course Objective:

To learn the basic concept of Lean Manufacturing and methods to be adopted for implementing lean practices.

Unit 1

Introduction

Mass production system – origin of lean production system –

necessity – lean revolution in toyota – systems and systems

thinking – basic image of lean production–customer focus 08Hrs

SLE: Muda (waste). Unit 2

Stability of lean system

Standards in the lean system –– total productive maintenance –

standardized work –elements of standardized work – charts to

define standardized work – man power reduction – overall

efficiency - standardized work and kaizen – common layouts.

08 Hrs SLE: 5S system Unit 3

Standardization of operations: job rotation. Improvement

activities to reduce work force and increase worker morale

foundation for improvements.

Just In Time Principles of jit – jit system – kanban – kanban rules – expanded role of conveyance – production leveling – pull systems – value stream mapping. 10 Hrs SLE: Multi-function workers

44

Unit 4

Shortening of production lead times: Reduction of setup times,

practical procedures for reducing setup time.

Jidoka concept – poka-yoke (mistake proofing) systems –

inspection systems and zone control – types and use of poka-yoke

systems 10 Hrs

SLE: Implementation of Jidoka

Unit 5

Worker Involvement and Systematic Planning Methodology

Involvement – activities to support involvement – quality circle

activity – kaizen training - suggestion programmes – hoshin

planning system (systematic planning methodology) – phases of

hoshin planning. 08 Hrs

SLE: Lean culture Unit 6

Managing lean enterprise: Global enterprises and their benefits.

Case study on “Application of Lean manufacturing concepts to

production /process/product.” 08 Hrs

SLE: Application of Lean manufacturing concepts to production service industries Text books:

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

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

References:

1. Production and Operations Management-ChaselAquilino

45

2. Toyoto production system –An integrated approach to just in time by Yasuhiro Monden – Engineering aild Management press – Institute of Industrial Engineers Norcross Georgia.

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

4. Straight talk on design of experiments by Launshy and Weese.

5. Amaldo Hernandez: “Just in Time Manufacturing” PH International.

6. “The Machine that changed the World” by Daniel Roos

7. “Lean thinking” James P.Womack and Daniel T.Jones

8. Jeffrey Liker, The Toyota Way: Fourteen Management Principles from the World‟s Greatest Manufacturer, McGraw Hill, 2004.

9. Michael L. George, Lean Six SIGMA: Combining Six SIGMA Quality with Lean Production Speed, McGraw Hill, 2002.

10. Taiichi Ohno, Toyota Production System: Beyond Large-Scale Production, Taylor & Francis, Inc., 1988.

Course Outcome:

On successful completion of the course the student will able to

1. Recognize the underlying philosophy of the Toyota

Production System.

2. Know the concepts and implementation of Jidoka and

poka-yoke systems.

3. Analyze the different concepts of 5S, 3M, etc. to keep

clean and standardizing the operation.

4. Discover how to look at one‟s own shop floor in terms of

lead-time reduction, waste elimination and material flow.

46

5. Implementing the continuous improvement concept and

Taylor‟s principles.

6. Develop and understanding of how to manage people in a

Lean environment in order to sustain improvements in

production method.

47

CNC / ROBOTICS LAB (0:0:3)


Hrs/Week : 03 Course Objective:

To learn part program by using CNCturn and CNCmill softwares.

Writing and execution of manual part programming using ISO codes for machining of simple parts involving turning, taper turning, form turning and thread cutting, use of radius compensation, canned cycles, macros etc. CNC milling – Writing and execution of part program for contour milling.

Programming of robots by manual, lead through and off line methods, Use of robot programming languages to pick and place, stacking of objects in increasing or decreasing size, Palletizing operations, assembly and inspection operation etc.


1. Equipped with the knowledge of CNC post processors and distributed numerical control, operation of CNC Lathe and milling machines and programming and machining complex engineering parts

2. Students will be familiarized with fundamental concepts of industrial robotic and gain hands on experience of motion control

48

MACHINE TOOL AND FLUID POWER SYSTEMS LAB (0:0:3)


Hrs/Week : 03

Pre –requisite:

Fluid mechanics and hydraulics machines

Fluid power systems

Manufacturing process II

Course Objective: To conduct experiments on various machine tools to know

the cutting forces involved in machining respective dynamometers.

1. Acceptance tests on Lathe, Drilling machine, Milling machine.

2. Determination of cutting forces during turning using Lathe tool dynamometer.

3. Determination of thrust and torque during drilling with drill tool dynamometer.

4. Measurement of cutting tool temperature using thermo-couple.

5. Determination of chip-reduction ratio during orthogonal cutting on a lathe.

6. Assembly & Disassembly of Screw jack

7. Assembly & Disassembly of Tail stock

8. Assembly & Disassembly of Tool head of shaper

9. Assembly & Disassembly of Indexing head

10. Pressure intensification circuit.

11. Regenerative cylinder.

12. Comparison of open centre and closed centre directional control valve.

13. Speed control of cylinder: Meter-in and Meter-out circuits.

49


1. Explains the basic principles of acceptance tests on

various machines.

2. Defines clearly the concept of thrust and torque during

drilling using drill tool dynamometer

3. Demonstrate assembly and disassembly of various

machine parts

4. Explain the basic principles involved in chip-reduction ratio

and its measurement during orthogonal cutting on lathe.

5. Build up re-generative cylinder, meter-in and meter-out

circuits in hydraulics.

50

ELECTIVES

(Group – I)

51

ADVANCED MANUFACTURING PROCESSES (3:0:0)




Pre- requisite:

Manufacturing process – I

Manufacturing process – II

Course Objective:

Introduce the principles of un conventional machinery methods facilitating them to choose between different manufacturing methods. Unit 1

Introduction: History, Need for Non-traditional Machining

processes, Classification, process selection.

Mechanical Process: Ultrasonic Machining (USM): Introduction,

Equipment, tool materials and tool Size, Abrasive slurry,

Magnetostriction assembly, Tool cone (Concentrator), Exponential

concentrator of circular cross section & rectangular cross sections.

Effect of parameters:- Effect of amplitude and frequency, Effect of

grain diameter, Effect of applied static load, Effect of slurry, Tool &

work material., USM process Characteristics: Material removal

rate, tool wear, Accuracy, surface finish., Applications,

Advantages& Disadvantages of USM. 10Hrs

SLE: Comparison between conventional and non-conventional machining. Unit 2

Abrasive Jet Machining (AJM): Introduction, Equipment,

Variables in AJM, Carrier Gas, Size of abrasive grain, velocity of

the abrasive jet, Mean no. abrasive particles per unit volume of the

carrier gas, Work material, stand-off distance (SOD), Process

52

characteristics-Material removal rate. Nozzle wear, Accuracy &

surface finish, Applications, Advantages & Disadvantages of AJM.

06Hrs SLE: Type of abrasive and their applications. Unit 3

Electrochemical machining Process (ECM): Introduction,

Elements of ECM process: Cathode tool, Anode work piece,

source of DC power, Electrolyte, Chemistry of the process, ECM

process characteristics- Material removal rate, Accuracy, Surface

finish., Tool & insulation materials, Tool size, Electrolyte flow

arrangement, Applications, Simple problems. 06 Hrs

SLE: Electrochemical turning, Electrochemical Grinding, Electrochemical Honing, Electrochemical deburring Unit 4

Chemical Machining (CHM): Introduction, Elements of the

process, Chemical blanking process: Preparation of workpiece,

preparation of masters, masking with photo resists, etching for

blanking, Accuracy of chemical blanking,. Chemical milling

(Contour machining):- Process steps-masking, Etching, etc.

Process characteristics of CHM:- material removal rate, accuracy,

surface finish, application of CHM. 06 Hrs

SLE: Applications of chemical blanking Unit 5

Thermal Metal Removal Processes: Electrical discharge

machining (EDM)-introduction, mechanism of metal removal,

dielectric fluid, spark generator, EDM tools(electrodes) , electrode

material selection, Machining time. Flushing: suction flushing, side

flushing, pulsed flushing synchronized with electrode movement,

EDM process characteristics: Metal removal rate, accuracy,

surface finish, Heat affected Zone. Machine tool selection,

applications, electric discharge grinding, traveling wire EDM.

06 Hrs. SLE: Electrode feed control, Electrode manufacture, Electrode wear

53

Unit 6

Plasma Arc Machining (PAM): Principle of generation of plasma

Equipment, Non-thermal generation of plasma, selection of gas,

Mechanism of Metal removal, PAM parameters, Process

characteristics..

Laser Beam Machining (LBM):, Principle of generation of lasers,

Equipment and Machining procedure, Types of lasers, process

characteristics, applications. 06 Hrs

SLE: Safety precautions and applications of PAM & LBM.

Text Books:

1. Modern machining process by P C PANDEY AND H S SHAN, Tata McGraw Hill,2008

2. New technology by BHATTACHARAYA, Institution of Engineering Publication.

References:

1. Production Technology, by HMT Tata McGraw Hill.

2. Modern Machining Methods by Dr. M.Adithan, Khanna Publishers ,2008

3. Non-conventional Machining by P K Mishra, Reprint 2006, Narosa publishing House, New – Delhi.


1. Recall the principle of operation of a variety of non conventional machining process and select an appropriate process depending on the situation.

2. Explain the constructional features, principle of operation and process parameters involved in ultrasonic machining (USM) abrasive jet machining (AJM) in which material removal takes places through mechanical means.

3. Analyze the ECM process and the various factors affecting the machining rate.

54

4. Define the process parameters involved in chemical machining where metal removal takes place through chemical means knowing the principle of operation of the same.

5. Explain the various aspects of Electric discharge machining(EDM)

6. Explain the basics of plasma and laser generation and its application in manufacturing.

55

COMPOSITE MATERIALS (3:0:0)




Pre-requisites

Material science and Metallurgy

Course Objective:

The students will be able to process thermoplastics and thermosets using different fabricating process and implement various manufacturing methods.

Unit 1 Introduction to Composite Materials: Definition, classification and characteristics of composite materials – fibrous composites, laminated composites, particulate composites, Properties and types of reinforcement and matrix materials. 07 Hrs

SLE: Thermosets and thermoplastics Unit 2 Fibre Reinforcement Plastic Processing: Lay-up and curing, fabricating process – open and closed mould process – hand lay-up techniques – structural laminate bag molding, production procedures for bag molding – filament winding, pultrusion, pulforming, thermo – forming, injection, injection molding. 08 Hrs SLE: Processing of Thermoplastics. Unit 3 Fabrication of Composites: Cutting, drilling, mechanical fasteners and adhesive bonding, joining. Ceramic Matrix Composites and their Fabrication Technologies 06 Hrs SLE: Machining of composites.

56

Unit 4 Application of Composites, Characterization of composites. Application of Industrial experimentation for fabrication and testing of composites. 06 Hrs

SLE: Mechanical and Tribological Characterization Unit 5 Properties of MMC’s: Physical Mechanical, wear, machinability and other properties. Effect of size, shape and distribution of particulate on properties production process. 07 Hrs

SLE: Manufacturing methods of MMC Unit 6 Advanced composites such as polymer based sandwich structures of nano composites 06 Hrs

SLE: Introduction to shape memory alloys Text Books:

1. Composite Science and Engineering – K.K. Chawala Springer Verlag 1998.

2. Introduction to composite materials – Hull and Clyne, Cambridge University Press, 2

nd Edition, 1990.

References:

1. Composite Materials hand book – Meing Schwaitz, McGraw Hill Book Company, 1984.

2. Mechanics of Composite Materials – Robert. M.Jones, McGraw Hill Kogakusha Ltd., 1998.

3. Forming Metal hand book – 9th edition, ASM handbook,

V15, P327-338. 1988 4. Mechanics of composites – Autar K kaw, CRC Press,

2002. 5. Composite Materials – S.C.Sharma, Narora publishing

house, 2000. 6. Principles of Composite Material mechanics – Ronald.

F Gibron, McGraw Hill International, 1994.

57

Outcome: On successful completion of the course the student will able

to

1. Identify the properties of fiber and matrix materials used in

commercial composites, as well as some common

manufacturing techniques.

2. Understand the various manufacturing process of

composites

3. Predict the elastic properties of both long and short fiber

composites based on the constituent properties.

4. Understand the applications and characterization of

composites .

5. Analyze a laminated plate in bending, including finding

laminate properties from lamina properties and find

residual stresses from curing and moisture.

6. An exposure to recent developments in composites,

including metal and ceramic matrix composites.

58

TOOL ENGINEERING AND DESIGN (3:0:0)




Pre-requisite

Manufacturing process – II Course Objective:

To know the different properties of tooling materials used in the cutting process and design the appropriate jigs and fixtures for tools.

UNIT - 1

Tooling Materials and heat treatment: Brief explanation on different properties of materials, ferrous tooling materials, non ferrous tooling materials, heat treating, Factors affecting heat treating, heat treatment and tool design.

Locating and Clamping Methods: Introduction, basic principle of location, locating methods and devices, basic principle of clamping. 06 Hrs

SLE: Study the different tooling materials based on application and also the heat treatment process involved. UNIT - 2

Design of Cutting tools: Mechanics and geometry of chip formation, Merchant circle diagram and analysis, problems, Design consideration of cutting tools from strength and rigidity points of view, problems. 06 Hrs

SLE: Design of single point tool, twist drill and milling cutters UNIT – 3

Design of Tools for Inspection and Gauging: Introduction, work piece quality criteria, principles of gauging, types of gauges and their applications, amplification and magnification of error, gauge tolerances, selection of material for gages, indicating gauges, automatic gauges, problems. 06 Hrs

59

SLE: Taylors principles UNIT – 4

Design of Drill Jigs: Introduction, types of drill jigs, general considerations in the design of drill jigs, drill bushings, methods of construction, drill jigs. Design of Fixtures: Introduction, fixtures for boring, broaching, lathe and grinding. Tooling for Casting: Introduction, tooling for sand casting, shell moulding, metal moulding and die-casting, problems. 08Hrs

SLE: Types of fixtures. UNIT – 5

Design of Press-working Tools:Introduction to Die cutting operations, power press types, cutting action in punch and die operations die clearance, die design fundamentals, pilots, strippers and pressure pads. Design of Sheet Metal Bending, Forming and Drawing Dies: Introduction, bending dies, forming dies, drawing operations determining blank size, drawing force, problems. 08Hrs

SLE: Single and double action draw dies. UNIT – 6

Tool Design for Joining Processes: Introduction, tooling for physical joining processes, tooling for soldering and brazing, problems. Plastics as Tooling Materials Introduction, plastics commonly used as tooling materials, application of epoxy plastic tools, construction methods. 06 Hrs

SLE: Tooling for mechanical joining processes

TEXT BOOKS:

1. Tools Design C Donaldson- G.H. Le CAIN V.C Goold, TMH –Special Indian edition 2012.

2. Tooling data -P. H. Joshi, Wheeler Publication – 2005.

60

3. Metal Cutting and Tool design - Dr. B.J. Ranganath, Vikas Publishing house - 1993,

4. “Tool Engineering & Design” G.R Nagpal Khanna Publishers 6

thEdition ,2009

REFERENCE BOOKS:

1. Metal cutting theory and Tool Design- Arshinav MIR Publications

2. Jigs & Fixtures- Grant – 1976.

3. Introduction to Jigs & Fixtures- Kempster. ELBS, Edn. 1974.

4. Fundamentals of Tools Design- ASTME – Prentice Hall India Publications – 1983.

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

1. Design specific production tooling required for the industry.

2. Explain the different materials and heat treatment methods used in tooling.

3. Design cutting tools like single point tools, twist drills and milling cutters and tools for inspection and gauging.

4. Define the basic principles of location, locating methods, devices followed by design of jigs and fixtures.

5. Explain the principles involved in tooling for casting and joining processes.

6. Define the cutting process involved in punch and die operations, die clearance, die design fundamentals followed by design of sheet metal bending, forming and drawing dies..

61

MECHANICAL VIBRATIONS (3–0–0)




Course Objective:

To analyze and implement simple components for degrees of freedom, damping concepts and different numerical analysis techniques in relation to mechanical vibrations.

Unit – 1

Undamped Free Vibrations Types of vibrations, S.H.M, principle of super position applied to Simple Harmonic Motions. Beats, Fourier theorem and simple problems. Single degree of freedom systems.Introduction, Undamped free vibration-natural frequency of free vibration, stiffness of spring elements. 06 Hrs

SLE: Effect of mass of spring, Fourier Method Unit – 2

Damped Free Vibrations: Single degree freedom systems, different types of damping, Viscous damping concept of critical damping and its importance, study of response of viscous damped systems for cases of under damping, critical and over damping, Logarithmic decrement. 06 Hrs

SLE: Coloumb Damping. Unit – 3

Forced Vibrations: Single degree freedom systems, steady state solution with viscous damping due to harmonic force, solution by complex algebra.Concept of response, Reciprocating and rotating unbalance, vibration isolation-transmissibility ratio. Energy dissipated by damping, sharpness of resonance, base excitation. Vibration measuring instruments:Whirling of shafts with and without air damping. Discussion of speeds above and below critical speeds. 08 Hrs

SLE: Accelerometer and Vibrometers.

62

Unit – 4

Systems With Two Degrees of Freedom: Introduction, principle modes and Normal modes of vibration, co-ordinate coupling, generalized and principal co-ordinates, Free vibration in terms of initial conditions. Dynamic vibration absorber, Geared systems. 08 Hrs

SLE: Vehicle suspension, Dynamics of reciprocating Engines. Unit – 5

Multi Degree of Freedom Systems & Continuous Systems: Governing differentional equation for a MDOF system, Introduction to continuous systems, vibration of string, longitudinal vibration of rods, Torsional vibration of rods. 06 Hrs

SLE: Euler’s equation for beams Unit – 6

Numerical methods for Vibration Analysis: Introduction, influence coefficients, Maxwell reciprocal theorem, Dunkerley‟s equation. Rayleigh‟s method, Rayleigh Ritz method for beam vibrations.Orthogonality of principal modes.Orthogonality principle, Stodola Method Holzer‟s method.Geared and branched systems. 06 Hrs SLE: Method of matrix iteration. TEXT BOOKS:

1. Theory of Vibration and Applications by William T. Thomson and Maric Dillon Dhlech. Pearson Education , 5th Edn. 2001

2. Mechanical Vibration by V.P.Singh, New Delhi Publishers,. REFERENCE BOOKS:

1. Fundamentals of Vibration by Leonard Meirovitch, Tata Mc. Graw Hill, 2001.

2. Mechanical Vibrations by S.S.Rao, Pearson Education, 4th Edition, 2009.

3. Mechanical Vibration by G.K. Grover, Nem Chand and Bros. Roorkee (UP) 1986.

63


1. Analyze and derive vibration characteristics of undamped

free vibration systems using fundamental concepts of

mathematics and physics.

2. Demonstrate and characterize the effect of damping on

free vibration characterise.

3. Analyze and derive characteristics of forced vibrations and

use various systems for vibration measurement.

4. Characterise two degree vibration systems in terms of

natural frequency, mode shapes and coupling phenomena.

5. Demonstrate the characteristic of vibration of multi degree

freedom systems of both translation and rotational vibrating

systems.

6. Demonstrate the application of numerical methods to study

the characterise of vibration of multi degrees of freedom

systems.

64

ADVANCED FOUNDRY TECHNOLOGY (3:0:0)




Course Objective:

To design a simple casting, By selecting and considering all features using a pattern and study different furnaces used in the casting process. Unit 1

Foundry Management: Planning of new foundry project – basic steps involved. Computer applications in foundries. Foundry Mechanization: Need for modernization and

mechanization. Area of mechanization – sand reclamation etc.,

pollution control in foundries, plant layout for foundries. 06 Hrs

SLE: Recent trends in foundry management. Unit 2

Casting Design : Initial consideration in design, Economics

characteristics, Technical characteristics, process and alloy

selection – casting process, property criteria and design, sources

of design data for cast alloys, physical design features – molding

factors in casting. Design consideration at the casting stage,

machining factors in casting design. 08 Hrs

SLE: Casting design of non ferrous alloys Unit 3

Pattern and Core Box Design: Types of patterns, pattern

allowance, common pattern materials, pattern layout and

preparation of patterns, core prints, their purpose, calculation of

core print dimensions. Master pattern design and its use, Core and

its functions, types of cores. 08 Hrs

SLE: Use of CAD and CAM concept for pattern manufacturing.

65

Unit 4

Melting furnaces and practice: Cupola- Construction, operation

and preparation, Air Furnace, rotary melting Furnace, open hearth

Furnace, direct arc Furnace, indirect arc Furnace resistance

heating Furnace, core type and core less type induction Furnace.

06 Hrs SLE: Energy requirements of furnaces.

Unit 5

Solidification of castings: Crystallization and development of cast

Structure – Nucleation, Growth and dendritic growth, Independent

nucleation. Eutectic Freezing, peritectic reactions.Structure of

castings – significance and practical control of cast structure, grain

shape and orientation, grain size, refinement and modification of

cast structure. Concept of progressive and directional solidification,

Solidification time and derivation of Chvorinov‟s equation influence

of mould characteristics on cast metal, Properties of solidification

process. 08 Hrs

SLE: Differences in solidification of ferrous and non-ferrous metal. Unit 6

Feeding of Castings: Feeding characteristics of alloys, geometric

influence on solidification.Methods of feeding of castings – cost

and concept of yield, orientations, gating techniques, casting

temperature and pouring speed, design and location of feeder

heads. 04 Hrs

SLE: Chillers and cooling towers Text Books:

1. Foundry Technology by Beeley. P.R.(Buttersworth)-2nd

edition 2001

2. Principles of Metal Casting – Heine, Loper and Rosenthal, TATA McGraw Hill

66

References:

1. Metal Casting – ASME hand book

2. Metal Casting Technology by P.C. Mukerji

3. Principles of Solidification by B.Chalmers,

4. Metal Casting – Principles & Practice by T.V.Raman Rao, New Age International (p) Ltd. Course Outcome: On successful completion of the course the student will able to

1. Study in the field of foundry technology is oriented towards the education of foundry technologists and metallurgists, research workers, quality and foundry managers.

2. Creatively apply their knowledge in the area of the production of castings of all types and all kinds of materials and also managerial skills.

3. Complemented with information about the properties of moulding materials, design and application of foundry machines and equipment.

4. Gain the knowledge in the various types of furnaces and their melting temperatures

5. Analyze the process of solidification and related characteristics of casting process.

6. Understand the various feeding mechanism in use

67

INDUSTRIAL VISIT /INTERNSHIP

Sub Code : IP 0113

SEE : 50 Marks Course Objective:

To expose students to industrial working environment All students should visit either a product industry or a process industry during the semester and submit a report by the end of the semester.

For internship students should undertake minimum two weeks of industrial training in a reputed company at the end of fifth semester examination and submit a report during the beginning of sixth semester.

Course Outcome:

By undergoing training/ visit, students will know the

challenges present in industries and understand the techniques

involved in running and maintaining a unit which satisfies the

customer requirement.

Documents

PREFACE - National Institute of · PDF fileforce member, sliding friction force. Simple numerical problems. Friction: Force of friction, Laws of solid friction, Belt drives, Ratio