Production Engineering Syllabus (1)_2

8/9/2019 Production Engineering Syllabus (1)_2

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JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY

ANANTAPUR ANANTHAPURAMU-515002 (A.P) INDIA

ACADEMIC REGULATIONS COURSE STRUCTURE

ANDDETAILED SYLLABI

OF

MASTER OF TECHNOLOGYIN

PRODUCTION ENGINEERING

Regular Two Year P.G. Degree Course

(Applicable for the batches admitted from 2014-15)


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JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY ANANTAPUR

Course Structure and syllabi for

M.Tech- Production EngineeringOffered by Department of Mechanical Engineering

for affiliated Engineering Colleges 2014-15

I YEAR I Semester

S.

No

Course

codeSubject Theory Lab. Credits

1 12D87106a Theory of Metal Cutting & Tool Design 4 4

2 14D94101 Advanced Casting and Welding Technology 4 4

3 9D04206a Rapid Prototyping 4 4

4 9D04201 Advanced Optimization Techniques 4 45 1287108 Material Technology 4 4

6

9D04106a

9D04205

9D04105

Elective-I

a Quality Engineering and Manufacturing

b Mechatronics

c Advanced Manufacturing Technology

4 4

7 14D94102 Production Engineering Lab 3 2

24 3

26Total 27


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I YEAR II Semester

S.

No

Course

code

Subject Theory Lab. Credits

1 14D94201 Machine Tool Design 4 4

2 12D87203 Simulation & Modeling of Manufacturing

Systems

4 4

3 12D87101 Automation in Manufacturing 4 4

4 12D87106b Advanced Metal forming 4 4

5 12D87205 Advanced Production & Operation Management 4 4

6

12D87207

9D04206b

14D94202

Elective-II

a. Design and Manufacturing of MEMS and MICROsystems

b. Artificial Intelligence & Expert Systems

c. Performance Modeling and Analysis ofManufacturing systems

4 4

7 12D87209 Manufacturing Simulation Lab 3 2

contact periods/week 24 3

26Total 27

II YEAR (III & IV Semesters)

S.

No

Course

code

Subject credits

1 14D94401 Seminar 2

2 14D9402 Project work 16


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M. Tech. I SEM (PE) Th C

4 4

(12D87106a)THEORY OF METAL CUTTING AND TOOL DESIGN

UNIT -I:Mechanics of Metal Cutting: Geometry of Metal Cutting Process, Chip formation, Chip

Thickness ratio, radius of chip curvature, cutting speed, feed and depth of cut - Types of Chips

Chip breakers.Orthogonal and Oblique cutting processes-definition, Forces and energy calculations (Merchant

Analysis).- Power consumed MRR Effect of Cutting variables on Forces, Force measuremen

using Dynamometers.

UNIT -II:Single Point Cutting Tool: Various systems of specifications, single point cutting too

geometry and their inter-relation. Theories of formation of built-up edge and their effect, designof single point contact tools throwaway inserts.

UNIT -III:Multipoint Cutting Tools: Drill geometry, design of drills, Rake and Relief angles of twist drill

speed, feed and depth of cut, machining time, forces, milling cutters, cutting speed and feed

machining time design - from cutters.

UNIT-IVGrinding: Specifications of grinding of grinding wheel, mechanics of grinding, Effect o

Grinding conditions on wheel wear and grinding ratio. Depth of cut, speed, machining timetemperature, power.

UNIT -V:Tool Life and Tool Wear: Theories of tool wear-adhesion, abrasive and diffusion weamechanisms, forms of wear, Tool life criteria and machinability index.

Types of sliding contact, real area of contact, laws of friction and nature of frictional force in

metal cutting. Effect of Tool angle, Economics, cost analysis, mean co-efficient of friction.

UNIT-VI

Cutting Temperature: Sources of heat in metal cutting, influence of metal conditionsTemperature distribution, zones, experimental techniques, analytical approach. Use of tool-work

thermocouple for determination of temperature. Temperature distribution in Metal Cutting.


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UNIT -VII:Tool Design: Determination of shank size for single point carbide tools, Determining the inser

thickness for carbide tools.Design of jigs and fixtures: Basic principles of location and clamping; Locating methods and

devices. Jigs- Definition, Types. General consideration in the design of Drill jigs, Drill bushing

Methods of construction. Fixtures- Vice fixtures, Milling, Boring, Lathe Grinding fixtures .

UNIT-VIIICutting tool Materials and Cutting fluids : Carbon and Medium alloy steels, High Speed steels

Cast-Cobalt alloys, Carbides, Coated tools, Alumina based ceramics, Carbon boron Nitride, SNBCeramics, Whisker-Reinforced tool materials, tool reconditioning, Types of cutting fluids

Classification and selection of cutting fluids.

TEXT BOOKS:1. Metal Cutting Principles , M C Shaw , Oxford and IBH Publications, New Delhi,1969

2.

Fundamentals of Machining , Boothryd , Edward Amold publishers Ltd. 1975

REFERENCE BOOKS:1. Fundamentals of Metal cutting and Machine tools , B.L.Juneja, G. S. Sekhom and Nitin

Seth , New Age International publishers

2. Tool Engineering, G.R.Nagpal, Khanna Publishers


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4 4

ADVANCED CASTING AND WELDING TECHNOLOGY

Unit I:-Leaser Beam Welding: Type of lasers, equipment, power calculation, applications, dual

laser beam welding, use of fibre optics in LBW

Friction Stir Welding;Details of process and process parameters, specific applications.

Unit II:-

Electron Beam Welding; The interaction of electron beam with matter, mode of heatgeneration, mode of energy losses, details of the equipment, product design for EBW,

case studies.

Ultrasonic Welding; Propagation of ultrasonic waves in matter, mode of joint formation,

joint types and design of product for ultrasonic welding, details of equipment and casestudies, cutting and gauging, flame cutting plasma arc welding, laser assisted cutting.

Unit III:-

Heat flow in Welding: Significance, theory of heat flow cooling rate determination,

selection of welding parameters based on heat flow analysis, residual stresses and

distortion. Join design, analysis of fracture and fatigue of welded joints. Automatedwelding systems.

Unit IV:-Investment casting, shell moulding, squeeze casting, vacuum casting, counter-gravity

flow-pressure casting, directional and monocrystal solidification, squeeze casting,

semisolid metal casting, rheocasting.

Unit V:-Solidification Gating and Risering, Nucleation and growth, solidification of pure metals,

short and long freezing range alloys. Gating and risering desing calculation, Fluidity andits measurement.

Unit VI:-

Analysis of casting defects:Types of defects, causes and remedies

Analysis of welding defects:Types, causes and remedies

Unit VII:-


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CAE of Casting: Design for casting, application of finite element method in casting-

determination of hot spots, location of turbulence and other defects, modeling of flow in

molds, modeling of heat transfer in castings-case studies.

Unit VIII:-CAE Of Welding:Design of weldment, application of finite element method in welding

determination of distortion in weldments, modeling of temperature distribution casestudies.

TEXT BOOKS:1. Ravi B, Metal Casting: Computer Aided Design and Analysis Prentice Hall,

2005.

2. Richard L Little, Welding and Welding Technology Tata McGraw Hill, 2004.

REFERANCE BOOKS:

1.

John Campbell, Casting Practice Elsevier Science Publishing C0., 20042. Larry Jeffus, Welding Principles and Applications Delmar Publishers, 2004

3. John Campbell Casting Butterworth Heinemann, 20034. Klas Weman, Welding Processes Handbook,2003

5. Howard B Cary, Modern Welding Technology Prentice Hall, 2002

6. Larry Jeffus, Welding for Collision Repair, Delmar Publishers, 1999

7. ASM Hand Book Casting, ASM International 1998


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4 4

(9D04206a) RAPID PROTOTYPING

Unit-I Introduction: Need for the compression in product development, History of RP system

Survey of applications, Growth of RP industry and classification of RP system.

Unit II Stereo Lithography System: Principle, Process parameter, Process details, Data

preparation, Data files and machine details, Applications.

Unit III Fusion Decomposition Modeling: Principle, process parameter, Path generation

Applications.

Unit IV Solid ground curing:Principle of operation, Machine details, Applications,

Laminated Object Manufacturing: Principle of Operation, LOM materials, Process details

Applications.

Unit V Concepts Modelers:Principle, Thermal jet printer, Sanders model market, 3-D printer

Genisys Xs printer HP system 5, Object Quadra system.

Unit VI LASER ENGINEERING NET SHAPING (LENS)Rapid Tooling: Indirect Rapid tooling- Silicon rubber tooling- Aluminum filled epoxy toolingSpray metal tooling, Cast kriksite, 3Q keltool, etc, Direct Rapid Tooling Direct. AIM, Quick cas

process, Copper polyamide, Rapid Tool, DMILS, Prometal, Sand casting tooling, Laminat

tooling soft, Tooling vs. hard tooling.Software for RP:STL files, Overview of Solid view, magics, imics, magic communication, etcInternet based software, Collaboration tools.

Unit VII Rapid Manufacturing Process Optimization: Factors influencing accuracy, Datpreparation error, Part building error, Error in finishing, Influence of build orientation.

Unit VIII Allied Process: Vacuum casting, surface digitizing, Surface generation from poin

cloud, Surface modification- Data transfer to solid models.

TEXT BOOKS:

1.

stereo lithography and other RP & M Technologies, Paul F.Jacobs, SME, NY 19962. Rapid Manufacturing, Flham D.T & Dinjoy S.S,Verlog London 2001Rapid automated, Lament wood, Indus Press New York.


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4 4

(9D04201) ADVANCED OPTIMIZATION TECHNIQUES

UNIT - ILinear programming: Two-phase simplex method, Big-M method, duality, interpretationapplications.

UNIT - IIAssignment problem: Hungarians algorithm, Degeneracy, applications, unbalanced problems

traveling salesman problem.

UNIT - IIIClassical optimization techniques: Single variable optimization with and without constraints

multi variable optimization without constraints, multi variable optimization with constraints method of Lagrange multipliers, Kuhn-Tucker conditions.

UNIT - IVNumerical methods for optimization: Nelder Meads Simplex search method, Gradient of function, Steepest descent method, Newtons method, types of penalty methods for handling

constraints.

UNIT - VGenetic algorithm (GA) :Differences and similarities between conventional and evolutionary

algorithms, working principle, reproduction, crossover, mutation, termination criteria, differenreproduction and crossover operators, GA for constrained optimization, draw backs of GA,

UNIT - VIGenetic Programming (GP): Principles of genetic programming, terminal sets, functional setsdifferences between GA & GP, random population generation, solving differential equations using

GP.

UNIT VIIMulti-Objective GA: Paretos analysis, Non-dominated front, multi objective GA, Non

dominated sorted GA, convergence criterion, applications of multi-objective problems .

UNIT VIIIApplications of Optimization in Design and Manufacturing systems: Some typica

applications like optimization of path synthesis of a four-bar mechanism, minimization of weigh

of a cantilever beam, optimization of springs and gears, general optimization model of amachining process, optimization of arc welding parameters, and general procedure in optimizing

machining operations sequence.


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Text Books:1. Optimal design Jasbir Arora, Mc Graw Hill (International) Publishers

2. Optimization for Engineering Design Kalyanmoy Deb, PHI Publishers3. Engineering Optimization S.S.Rao, New Age Publishers

REFERENCES:1.Genetic algorithms in Search, Optimization, and Machine learning D.E.Goldberg, Addison

Wesley Publishers

2. Genetic Programming- Koza3. Multi objective Genetic algorithms - Kalyanmoy Deb, PHI Publishers


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4 4(12D87108) MATERIALS TECHNOLOGY

UNIT I:Elasticity in metals and polymers, mechanism of plastic deformation, role of dislocationsyield stress, shear strength of perfect and real crystals, strengthening mechanism, work

hardening, solid solution, grain boundary strengthening

UNIT-II

Poly phase mixture, precipitation, particle, fiber and dispersion strengthening, effect o

temperature, strain and strain rate on plastic behavior, super plasticity, deformation of non

crystalline material.

UNIT III:

Griffths Theory, stress intensity factor and fracture Toughness, Toughening MechanismsDuctile and Brittle transition in steel, High Temperature Fracture, Creep, Larson Miller

Parameter, Deformation and Fracture mechanism maps.

UNIT IV:

Fatigue, Low and High cycle fatigue test, Crack Initiation and Propagation mechanismand Paris Law, Effect of surface and metallurgical parameters on Fatigue, Fracture of non

metallic materials, fatigue analysis, Sources of failure, procedure of failure analysis..

UNIT V:Selection for Surface durability, Corrosion and Wear resistance, Relationship between

Materials Selection and Processing, Case studies in Materials Selection with relevance toAero, Auto, Marine, Machinery and Nuclear Applications.

Motivation for selection, cost basis and service requirements, Selection for MechanicaProperties, Strength, Toughness, Fatigue and Creep

UNIT VI:Modern Metallic Materials: Dual Phase Steels, Micro alloyed, High Strength Low alloy

(HSLA) Steel, Transformation induced plasticity (TRIP) Steel, Maraging SteelIntermetallics, Ni and Ti Aluminides

UNIT-VIISmart Materials, Shape Memory alloys, Metallic Glass, Quasi Crystal and NanoCrystalline Materials. Metal-Matrix composites

UNIT-VIII

Nonmetallic Materials: Polymeric materials and their molecular structures, ProductionTechniques for Fibers, Foams, Adhesives and Coatings, Structure, Properties and

Applications of engineering Polymers


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TEXT BOOKS:

1. Mechanical Behaviour of Materials, Thomas H. Courtney, 2nd Edition, McGraw

Hill,2000.

2. Mechanical Metallurgy, George E. Dieter, McGraw Hill,1998.

REFERENCE BOOK:1. Selection and use of Engineering Materials,Charles J.A, Butterworth Heiremann


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4 4(9D04106a) QUALITY ENGINEERING AND MANUFACTURING

Elective-I

UNIT-I Quality value and Engineering: An overall quality system, quality engineering in

production design, quality engineering in design production processes.

UNIT-II Loss function and quality level: Derivation and use of quadratile loss function

economic consequences of tightening tolerances as a means to improve quality, evaluations andtypes tolerances (N-type-, S-type and L-type)

UNIT-III Tolerance Design and Tolerancing: Functional limits, tolerance design for N-type, Ltype and S-type characteristics, tolerance allocation for multiple components.

UNIT-IV Parameter and tolerance design: Introduction to parameter design, signal to noise

ratios, parameter design strategy, Introduction to tolerance design, tolerance design using the losfunction, identification of tolerance design factors.

UNIT-V Design of Experiments: Introduction, Task aids and Responsibilities for DOE processteps, DOE process steps description.

Analysis of variance (ANOVA): no-WAY ANOVA, One-way ANOVA, two-way ANOVA

Critique of F-test, ANOVA for four level factors, multiple level factors.

UNIT-VI Orthogonal Arrays: Typical test strategies, better test strategies, efficient tesstrategies, conducting and analyzing an experiment.

UNIT-VII Interpolation of experimental results: Interpretation methods, percent contribution

estimating the mean

UNIT-VIII ISO-9000 Quality system, BDRE, 6-sigma, bench marking, quality circles-brain

storming-fishbone diagram-problem analysis.

TEXT BOOKS:

1.

Taguchi techniques for quality engineering/Philip J.Ross / McGraw Hill Intl. 2nd

Edition1995.

REFERENCES:1. Quality Engineering in Production systems/G.Taguchi, A.Elasayed et al/Mc.Graw Hil

Intl. Edition, 1989.2. Taguchi methods explained: Practical steps to Robust Design/Papan P.Bagchi/Prentic

Hall Ind. Pvt. Ltd. New Delhi.


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4 4(9D04205) MECHATRONICS

Elective-I

Unit I Introduction:Definition of Mechatronic products, design considerations and trade offsOverview of Mechtronic products. Intelligent machine Vs Automatic machine economic and

social justification.

Unit II Actuators and drive systems: Mechanical, Electrical, hydraulic drive systemsCharacteristics of mechanical, Electrical, Hydraulic and pneumatic actuators and their limitations.

Unit III Motion Control: Control parameters and system objectives, MechanicaConfigurations, Popular control system configurations. S-curve, motor/load inertia matching

design with linear slides.

Unit IV Motion Control algorithms: Significance of feed forward control loops, shortfallsfundamentals concepts of adaptive and fuzzy control. Fuzzy logic compensatory control o

transformation and deformation non- linearitys.

Unit V Architecture of intelligent machines: Introduction to Microprocessor and

programmable logic controls and identification of systems. System design classification, motion

control aspects in design.Unit VI Manufacturing data bases:Data base management system, CAD/CAM data bases

graphic data base, introduction to object oriented concepts, objects oriented model language

interface, procedures and methods in creation, edition and manipulation of data.

Unit VII Sensor interfacing: Analog and digital sensors for motion measurement, digitatransducers, human-Machine and machine- Machine inter facing devices and strategy.

Unit VIII Machine vision:Feature and pattern recognition methods, concepts of perception and

cognition in decision-making.

Text books:1. 1.Designing intelligent machines, open university, London.Michel B.Histand and david

G. Alciatore.

2. 2.Introduction to Mechatronics and Measurement systems, Tata Mc Graw Hill.

3.

3.C.W.desilva, Control sensors and actuators, Prentice Hall.


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4 4(9D04105) ADVANCES IN MANUFACTURING TECHNOLOGY

Elective-I

Unit - IWelding Processes: Fusion and Solid state welding process, Automation in Welding, Design

aspects of welds, Weldability of aluminium alloys, titanium alloys and High strength low alloysteels, Non destructive testing of welds, Residual stresses and distortion in weldments.

Unit - IISurface Processing Operations: Plating and Related Processes, Conversion Coatings, Physica

Vapor Deposition, Chemical Vapor Deposition, Organic Coatings, Porcelain Enameling and othe

Ceramic coatings, Thermal and Mechanical Coating Processes.

Unit - III

Un-conventional Machining Methods-I:Abrasive jet machining - Elements of the process, mechanics of metal removal proces

parameters, economic considerations, applications and limitations, recent developments.

Ultrasonic machining: Elements of the process, machining parameters, effect of parameters onsurface finish and metal removal rate, mechanics of metal removal process parameters, economi

considerations, applications and limitations.

Unit - IVUn-conventional Machining Methods-II:

Electro-Chemical Processes:Fundamentals of electro chemical machining, metal removal rate inECM, Tool design, Surface finish and accuracy economics aspects of ECM.

Wire EDM Process: General Principle and applications of Wire EDM, Mechanics of meta

removal, Process parameters, selection of tool electrode and dielectric fluids, methods surfacefinish and machining accuracy.

Unit - V

Un-conventional Machining Methods-III:Electron Beam Machining: Generation and control of electron beam for machining, theory o

electron beam machining, principle, advantages, limitations, comparison of thermal and nonthermal processes.

Plasma Arc Machining: Principle, machining parameters, effect of machining parameters on

surface finish and metal removal rate, applications, limitations

Laser Beam Machining:Principle, effect of machining parameters on surface finish, applications

and limitations.


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Unit - VIRapid Prototyping: Working principle, methods-Steriolithography, Laser sintering, Fused

deposition method, applications and limitations.

Unit VIINano Technology:Nano milling processes, wet milling, dry milling, nano materials, fabricationof nano tubes, advantages of nano tubes, mechanical properties.

TEXT BOOKS:1. Manufacturing Technology - P. N. Rao, TMH Publishers

2. Fundamentals of Modern Manufacturing, Mikell P. Groover, John Wiley & Sons Publishers

REFERENCES:1.Production Technology - HMT

2.Manufacturing Science - Cambel

3.Welding Technology - R.S, Parmar,4.Introduction to Nanotechnology - Poole and Owens, Wiley (2003).


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M. Tech. I SEM (PE) L C

3 2

(14D94102) PRODUCTION ENGINEERING LAB

Experiments on

a) Sand moulding with cores and spilt cores

b) Mould hardness testingc) Evaluation of green sand mould parameters such as permeability, moisture etc.

d) Friction stir weldinge) Gear cutting at least two types on gear hobbing machine

f) Measurement of machining parameter such as force, temperature etc.

g) At least two experiments on Rapid Prototyping


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M. Tech. II SEM (PE) Th C

4 4

(14D94201)MACHINE TOOL DESIGN

UNIT-IKinematics of Machine Tools: Shaping of geometrical and real surfaces, Developing and

designing of kinematic schemes of machine tools, kinematics structures of lathe, drillingmilling, grinding, gear shaping and gear hobbing machines.

UNIT-II

Kinematic Design: Kinematic design of speed and feed boxes. Productivity loss. Stepped

and stepless regulation, clutched drive.

UNIT-IIIStrengths and Rigidity of Machine tool Structures: Basic principles of design for strengthDifferent types of structures. Overall compliance of machine tools.

UNIT-IV

Structure Design: Design of beds, bases, columns, tables, cross rail for various machinesVarious types of guide ways, their relative advantages. Materials for machine too

components including plastic guide way (PTFE).

UNIT-VAnalysis of Spindles, Bearings and Power Screws: Design of spindles subjected to

combined bending and torsion. Layout of bearings. Pre-loading. Anti-friction slide waysRolling contact hydrodynamic, hydrostatic, Hydrodynamic design of Journal bearings

Magneto bearings.

UNIT-VIMachine Tool Vibrations: Effect of vibrations on machine tool. Free and Forced

vibrations. Machine tool chatter. Elimination of vibrations.

UNIT-VIITesting, Maintenance and Erection of Machine Tools: Testing equipment, Preventive and

Corrective maintenance, general inspection, Installation of machine tools.


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UNIT-VIII

Economics of machine tool selection: Estimation and comparison of costs, operation time

various methods of machine selection: Method of total cash flow, present worth, break

even analysis.

TEXT BOOKS:

1. Sen and Battacharya, Principles of Machine Tools, Central Book publishers

Calcutta 1995.

REFERANCE BOOKS:

1.G.R. Nagpal, Machine Tool Engineering, Khanna Publishers.2.SK BASU Design of Machine Tools Oxford and IBH Publishing Co.Pvt. Ltd.,

3.N.K. Mehta, Machine Tool Design and Numerical Control, Tata McGraw Hill, 1997


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4 4

(12D87203)SIMULATION AND MODELLING OF MANUFACTURING SYSTEMSUNIT - I:System ways to analyze the system Model - types of models Simulation Definition

Types of simulation models steps involved in simulation Advantages and Disadvantages.

UNIT-IIParameter estimation estimator properties estimate point estimate confidence intervaestimates independent dependent hypothesis types of hypothesis- steps types 1 & 2 errors

Framing Strang law of large numbers.

UNIT - III:Building of Simulation model validation verification credibility their timing principles o

valid simulation Modeling Techniques for verification statistical procedures for developingcredible model.

UNIT-IVModeling of stochastic input elements importance various procedures theoretical distribution

continuous discrete their suitability in modeling.

UNIT - V:Generation of random variants factors for selection methods inverse transform composition

convolution acceptance rejection generation of random variables exponential uniform

Weibull normal Bernoullie Binomial uniform Poisson.

UNIT-VISimulation languages comparison of simulation languages with general purpose languages

Simulation languages vs Simulators software features statistical capabilities G P S S SIMAN- SIMSCRIPT Simulation of M/M/1 queue comparison of simulation

languages.QUEST, WITNESS, PROMODEL and AUTOMOD

UNIT - VII :Output data analysis Types of Simulation with respect to output data analysis warm up period

Welch algorithm Approaches for Steady State Analysis replication Batch means methods

comparisons

UNIT VIII :Applications of Simulation flow shop system job shop system M/M/1 queues with infinite

and finite capacities Simple fixed period inventory system Newboy paper problem.


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TEXT BOOKS:1. Simulation Modelling and Analysis, Law, A.M.& Kelton , McGraw Hill, 2nd Edition

New York, 1991.

2. Discrete Event System Simulation, Banks J. & Carson J.S., PH , Englewood Cliffs, NJ

1984.3. Simulation of Manufacturing Systems, Carrie A. , Wiley, NY, 1990.

4. A Course in Simulation, Ross, S.M., McMillan, NY, 1990.

5. Simulation Modelling and SIMNET , Taha H.A. , PH, Englewood Cliffs, NJ, 1987

6. Performance modeling and analysis of manufacturing systems,ViswanatNarahari,PHI


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4 4

(12D87101)AUTOMATION IN MANUFACTURING

UNIT-I:Introduction to Automation: Automation in Production Systems-Automated ManufacturingSystems, Computerized Manufacturing Support Systems, Reasons for Automation, Automation

Principles and Strategies.

UNIT-IIManufacturing operations, Production Concepts and Mathematical Models. Costs o

Manufacturing Operations, Basic Elements of an Automated Systems, Advanced Automation

Functions, Levels of automation.

UNIT-III:Introduction to Material Handling, Overview of Material Handling Equipment, Considerations inMaterial Handling System Design, The 10 Principles of Material Handling. Material Transpor

Systems, Automated Guided Vehicle Systems, Monorails and other Rail Guided Vehicles

Conveyor Systems, Analysis of Material Transport Systems.

UNIT-IVStorage Systems, Storage System Performance, Storage Location Strategies, Conventional Storage

Methods and Equipment, Automated Storage Systems, Engineering Analysis of Storage SystemsAutomatic data capture-overview of Automatic identification methods, bar code technology, othe

ADC technologies.

UNIT -V:Manual Assembly Lines - Fundamentals of Manual Assembly Lines, Alternative Assembly

Systems, Design for Assembly, Analysis of Single Model Assembly Lines,

UNIT-VILine balancing problem, largest candidate rule, Kilbridge and Wester method, and Ranked

Positional Weights Method, Mixed Model Assembly Lines, Considerations in assembly linedesign.

UNIT-VII:Transfer lines, Fundamentals of Automated Production Lines, Storage Buffers, and Application

of Automated Production Lines. Analysis of Transfer Lines with no Internal Storage, Analysis o

Transfer lines with Storage Buffers.


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UNIT-VIII:Automated Assembly Systems, Fundamentals of Automated Assembly Systems, Design foAutomated Assembly, and Quantitative Analysis of Assembly Systems - Parts Delivery System a

Work Stations, Multi- Station Assembly Machines, Single Station Assembly Machines , Partia

Automation.

TEXT BOOKS:1. Automation, Production systems and computer integrated manufacturing, Mikel P

Groover, Pearson Eduction.

REFERENCE BOOKS:1. CAD CAM : Principles, Practice and Manufacturing Management, Chris Mc Mohan

Jimmie Browne , Pearson edu. (LPE)

2.

Automation, Buckinghsm W, Haper & Row Publishers, New York, 19613. Automation for Productivity, Luke H.D, John Wiley & Sons, New York, 1972.


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4 4

(12D87106b) ADVANCED METAL FORMINGUNIT - I:Fundamentals of Metal Forming: Classification of forming processes, mechanisms of meta

forming: slab method, Upper and lower bound analysis, Deformation energy method and finitelement method temperature of metal working, hot working, cold working, friction and lubricants.

UNIT - II:Rolling of metals: Rolling processes, forces and geometrical relationship in rolling, simplified

analysis, rolling load, rolling variables, theories of cold and hot rolling, problems and defects in

rolling, torque and power calculations, Problems.

UNIT - III:

Forging: Classification of forging processes, forging of plate, forging of circular discs, open dieand closed-die forging, forging defects, and powder metallurgy forging. problems on flow stres,true strain and forging load.

UNIT - IVPress tool design: Design of various press tools and dies like piercing dies, blanking dies

compound dies and progressive blanking dies, design of bending, forming and drawing dies.

UNIT - V:Extrusion: Classification, Hot Extrusion, Analysis of Extrusion process, defects in extrusion

extrusion of tubes, production of seamless pipes. Problems on extrusion load.

UNIT - VIDrawing: Drawing of tubes, rods, and wires: Wire drawing dies, tube drawing process, analysis o

wire, deep drawing and tube drawing. Problems on drawforce.

UNIT - VII:Sheet Metal forming: Forming methods, Bending, stretch forming, spinning and Advanced

techniques of Sheet Metal Forming, Forming limit criteria, defect in formed parts.

UNIT - VII

Advanced Metal forming processes: HERF, Electromagnetic forming, residual stresses, in-procesheat treatment and computer applications in metal forming. problems on Blanking force, Blank

diagram in Cup Diagram, Maximum considering shear.


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Text Books:1. Mechanical Metallurgy , G.E. Dieter , Tata McGraw Hill, 1998. III Edition2. Principles of Metal Working , Sunder Kumar

References:1. Principles of Metal Working processes , G.W. Rowe

2. ASM Metal Forming Hand book.


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4 4

(12D87205) ADVANCED PRODUCTION AND OPERATIONS MANAGEMENTUNIT- IOverview of Production and Operations Management (POM): Introduction-Definition

Importance- Historical Development of POM-POM scenario todayProduct Development: Role of product development- Product development process-Tools fo

efficient product development(brief treatment)

UNIT- II

Process Design and Value AnalysisDetermination of process characteristics- Types of processes and operations systems- Continuou

Intermittent-Technology issues in process design- Flexible Manufacturing Systems- AutomatedMaterial Handling Systems

Value Analysis: Definition- Objectives; Types of Values-Phases- Tools; FAST diagram-StepsAdvantages-Matrix method-Steps.

UNIT -IIIPlant Location and Plant layout: Factors affecting locations, decisions-Location planningmethods-Location factor rating -Centre of Gravity method-Load distance method. Plant layout

Definition-Objectives-Types of layouts-Design of product layout-Line balance-Terminology-RPW

method.

UNIT- IV

Aggregate Planning: Definition- Objectives-Basic strategies for aggregate production planningAggregate production planning method-Transportation model- Master Production SchedulingMRP-I & MRP-II Systems.

Material Requirement Planning: Terminology-Logic-Lot sizing methods-Advantages and

Limitations , MRP for multilevel multi product environments.

UNIT - VWork Study : Work study: method study definition-objectives-steps-Charts used- Work

measurement-Time study- Definition-steps- Determination of standard time- Performance ratingAllowances. Work sampling- steps- comparison with time study.

UNIT -VIQuality Management: Economics of quality assurance-Control charts for variables and fo

attributes Acceptance sampling plans-Total Quality Management-ISO 9000 series standards-Six

sigma


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UNIT - VIIScheduling: Need-basis for scheduling- Scheduling rules- Flow shop and Job shop schedulingLine of Balance and dispatching rules in scheduling.

UNIT -VIIIProject management: PERT- Critical path determination- Probability of completing project in a

given time- CPM- Types of floats- Critical path determination- Crashing of simple networks

Optimum project schedule.

TEXT BOOKS:1. Operations Management for Competitive Advantages- Chase Aquinano - TMH, 2009

2. Operations Management: Theory and Practice: B.Mahadevan Pearson.

3. Industrial Engineering and Mangement: Dr.Ravi Shankar- Galgotia.

REFERENCES:1. Modern Production and Operations Managemet: Buffa, Wiley

2.

Theory and Problems in Production and Operations Managemet:SN Chary TMH.3. Operations Management 8e Process and Value Chains: Lee Krajewski et. all Pearson

4. Operations Management, Amol Gore, Roberto Pawzzolo, Lengage,2012


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4 4

(12D87207) DESIGN AND MANUFACTURING OF MEMS AND MICRO SYSTEMSElective-II

UNIT - I:Overview and working principles of MEMS and Microsystems: MEMS and Microsystems

Evolution of Micro fabrication, Microsystems and Microelectronics, Microsystems and

miniaturization, Applications of MEMs in Industries, Micro sensors, Micro actuation, MEMS withMicro actuators Micro accelerometers, Micro fluidics

UNIT - II:Engineering Science for Microsystems Design and Fabrication: Atomic structure of MatterIons and Ionization, Molecular Theory of Matter and Intermolecular Forces, Doping o

Semiconductors, The Diffusion Process, Plasma Physics, Electrochemistry, Quantum Physics.

UNIT - III:Engineering Mechanics for Microsystems Design: Static Bending of Thin plates, Mechanica

Vibration, Thermo mechanics , Fracture Mechanics, Thin- Film Mechanics, Overview of FiniteElement Stress Analysis

UNIT - IV:Thermo Fluid Engineering and Microsystems Design: Overview of Basics of Fluid Mechanicin Macro and Mesoscales, Basic equations in Continuum Fluid Dynamics, Laminar Fluid Flow in

Circular Conduits, Computational Fluid Dynamics, Incompressible Fluid Flow in Micro conduitsFluid flow in Sub micrometer and Nano scale,

UNIT VOverview of Heat conduction in Solids, Heat Conduction in Multilayered Thin films and in solidin sub micrometer scale, Design Considerations, Process Design

UNIT VIMechanical Design, Mechanical design using FEM, Design of a Silicon Die for a Micro pressuresensor.

UNIT VII & VIIIMaterials for MEMS and Microsystems and their fabrication: Substrates and Wafers, Activ

substrate materials, Silicon as a substrate material, Silicon compounds, Silicon Piezo resistors

Gallium Arsenide, Quartz, Piezoelectric Crystals and Polymers,

Photolithography, Ion implantation, Diffusion and oxidation, Chemical and Physical vapo

deposition, etching, Bulk micro manufacturing, Surface Micromachining, The LIGA Process.


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TEXT BOOK:1. MEMS and Microsystems. Design and Manufacturing, Tia-Ran Hsu, TMH 20022. Foundation of MEMS, Chang Liu,Pearson, 2012

REFERENCES:1. An Introduction to Microelectromechanical Systems Engineering. Maluf, M., Artech House

Boston 2000

2. Micro robots and Micromechnaical Systems, Trimmer , W.S.N., Sensors & Actuators, Vo19, 1989

3. Applied Partial Differential Equations, Trim., D.W., PWS-Kent Publishing, Boston, 1990


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4 4(9D04206b) ARTIFICIAL INTELLIGENCE & EXPERT SYSTEMS

Elective-II

Unit-IArtificial Intelligence : Introduction, definition, underlying assumption, Important of Al, Al &

related fields State space representation, defining a problem, production systems and it

characteristic, search and control strategies Introduction, preliminary concepts, examples o

Search , problems.

Unit-IIUniformed or preliminary Concept:Examples of search problems, Uniformed or Blind SearchInformed Search, Or Graphs, Heuristic Search techniques- Generate and Test, Hill climbing, Bes

first search, Problem reduction, Constraint satisfaction, Means- Ends Analysis.

Unit IIIKnowledge Representation Issues: Representations and Mapping, Approaches, Issues in Kr

Types of knowledge procedural Vs Declarative, Logic programming, Forward Vs Backward

reasoning, Matching, Non monotonic reasoning and it logic.

Unit-IVUse of Predicate Logic: Representing simple facts, Instance and is a relationships, Syntax andSemantics for Propositional logic, FOPL, and properties of Wffs, conversion to casual form

Resolution, Natural deduction

.

Unit-VStatistical and Probabilistic Reasoning:Symbolic reasoning under uncertainly, Probability and

Bayes theorem, Certainty factors and Rule based systems, Bayesian Networks, Dempster- Shafe

Theory, Fuzzy Logic

Unit-VIExpert Systems: Introduction, Structure and uses, Representing and using domain knowledgeExpert System Shells. Pattern recognition, introduction, Recognition and classification process

learning classification patterns, recognizing and understanding speech.

Unit-VIIIntroduction to Knowledge Acquisition: Types of learning, General learning model, and

performance measures.


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Unit-VIII1. Typical Expert Systems: MYCIN, Variants of MYCIN, PROSPECTOR DENDRAL

PRUFF etc.

2. Introduction to Machine Learning:Perceptons, Checker Playing examples,

Learning, Automata, Genetic Algorithms, Intelligent Editors.

TEXT BOOKS1. Artificial Intelligence, Elaine Rich & Kevin Knight,M/H 19832. Artificial Intelligence in Business, Wendry B.Ranch, Science & Industry Vol -I

application, Ph 1985.

3. A Guide to Expert System Waterman, D.A., Addison, Wesley inc. 1986.4. Building expert systemHayes, Roth, Waterman, D.A (ed), AW 1983.

5. Designing Expert System, S.M. and Kulliknowske Weis, London Champion Hull 1984.


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4 4

(14D94202) PERFORMANCE MODELING AND ANALYSIS OF

MANUFACTURING SYSTEMS

Elective-IIUnit I:-

Manufacturing Systems & Control:Automated Manufacturing Systems Role of performance modeling simulation models

Analytical models. Product cycle Manufacturing automation Economics of scale andscope input/output model plant configurations.

Unit II:-

Performance Measures:- Manufacturing lead time Work in process Machine utilization

Throughput- Capacity Flexibility Performability Quality Control Systems Control system architecture Factory communications Local area networkinterconnections Manufacturing automation protocol Database management systems.

Unit III:-

Manufacturing Processes:Examples of stochastic processes Poisson process Discrete time Markov models

Definition and notation Sojourn times in states Examples of DTMCs in manufacturing Chapman Kolmogorov equation Steady state analysis.

Unit IV:-

Analysis:Continuous Time Markov Chain Models Definitions and notation Sojourn times in

states examples of CTMs in manufacturing Equations for CTMC evolution Markovmodel of a transfer line. Birth and Death Processes in Manufacturing Steady state

analysis of BD Processes Typical BD processes in manufacturing.

Unit V:-Queuing Model:

Notation for queues Examples of queues in manufacturing systems Performancemeasures Littles result Steady state analysis of M/M/m queue, queues with general

distributions and queues with breakdowns Analysis of a flexible machine center.


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Unit VI:-

Queuing Networks:

Examples of QN models in manufacturing Littles law in queuing networks Tandem

queue An open queuing network with feedback An open central server model for FMS Closed transfer line

Unit VII:-

Petri nets Fundamentals:

Classical Petri Nets Definitions Transition firing and reachability Representational

power properties Manufacturing models.

Unit VIII:-Stochastic Petri Nets Exponential time Petri Nets Generalized Stochastic Petri Nets

modeling of KANBAN systems-Manufacturing models.

REFERENCES:

1. Performance Modelling of Automated Manufacturing Systems/ Viswanadham, Nand Narahari, Y/ Prentice Hall of India, New Dehhi, 1994.

2. Probability and Statistics with Reliability, Queuing and Computer Science

Applications/Trivedi, K.S./Prentice Hall, New Jersey, 1982.

3. Fundamentals of Mathematical Statistics/ Gupta S.C & Kapoor V.K./3rd

Edition,Dehli, 1988.


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M. Tech. II SEM (PE) L C

3 2

(12D87209) MANUFACTURING SIMULATION LAB

1.Study of elements , entities , activities and basic models of a simulation package modeling

and simulation

2.Throughput analysis of a individual production facility using simulation.

3. Modeling of a typical manufacturing facility and study its performances.

4. Breakdown analysis of a production facility with one machine

5. Breakdown analysis of a production system having multiple machines

6.Modeling and Simulation of layouts

7.Study of transport system in a shop floor

8.Buffer size design

9.Identification of bottleneck machine on a given shop floor

10.Study of conjunction, collision and dead locks through simulation

Lab Facilities

Adequate number of Computer Systems in Networked Environment

Packages : 1. QUEST

2.PROMODEL

3.FLEXSIM

4.AUTOMOD5.WITNESS

Documents

Production Engineering Syllabus (1)_2