University Core University Elective - vit.ac.invit.ac.in/files/academics/schools/SMBS/Courses/MTech-Manufacturing... · ... E ng ineer Mathemat cs ... II General Techniques and Tools

SCHOOL OF MECHANICAL AND BUILDING SCIENCES

CURRICULUM

M.Tech Manufacturing Engg.

(2014 – 15 Onwards)

University Core

S.No Course Code Course Title L T P C 1 MAT 502 Applied Engineering Mathematics 3 1 0 4 2 ENG 601 Professional and Communication Skills 1 0 2 2 3 SET Conference I 0 0 0 2 4 SET Conference II 0 0 0 2 Total 10

University Elective

S.No Course Code Course Title L T P C 1 University Elective - I 3 0 0 3 Total 3

Programme Core

S.No Course Code Course Title L T P C 1 MEE 521 Finite Element Methods 2 1 2 4 2 MEE 522 Computer Integrated Manufacturing 2 1 2 4 3 MEE 528 Fluid Power System and Factory Automation 3 0 2 4 4 MEE 547 Quality Management 3 0 0 3 5 MEE 557 Advanced Materials and Processing 3 0 0 3 6 MEE 566 Modern Machining Processes 3 0 0 3 7 MEE 567 CNC Technology and Programming 3 0 2 4 8 MEE 699 Master Thesis - - - 16 Total 41

Programme Elective S.No Course Code Course Title L T P C

1 MEE 515 Product Design and Life Cycle Management 3 0 0 3 2 MEE 548 Metrology and Non-destructive Testing 3 0 0 3 3 MEE 550 Design for Manufacturing 3 0 0 3 4 MEE 552 Optimisation Methods 2 1 0 3 5 MEE 555 Computer Aided Process Planning 2 1 0 3 6 MEE 565 Advanced Joining Process 3 0 0 3 7 MEE 568 Machine Tool Metrology 3 0 0 3 8 MEE 569 Mechatronics in Manufacturing 3 0 0 3 9 MEE 570 Design and Metallurgy of Welded Joints 3 0 0 3

10 MEE 571 Virtual Manufacturing 3 0 0 3 11 MEE 573 Theory of Metal Forming 3 0 0 3 12 MEE 574 Additive Manufacturing Technology 3 0 0 3 13 MEE 575 Manufacturing of Composite Materials 2 1 0 3 14 MEE 576 Surface Engineered Materials Technology 3 0 0 3 15 MEE 577 Enterprise Resource Planning and Supply Chain

Management 3 0 0 3

16 MEE 578 Manufacturing System and Simulation 3 0 0 3 17 MEE 579 Maintenance Engineering and Management 3 0 0 3 18 MEE 580 Concurrent Engineering 3 0 0 3 19 MEE 581 Manufacturing Information Systems 3 0 0 3 20 MEE 582 Robotics and Industrial Automation 2 0 2 3 21 MEE 591 Computational Methods in Heat and Fluid Flow 3 0 2 4 22 MEE 603 Reliability Engineering 3 0 0 3 23 MEE 604 Design and Analysis of Experiments 2 1 0 3 24 MEE 605 Tool Engineering 3 0 0 3 25 MEE 617 Laser Material Processing 3 0 0 3 26 MEE 618 Electronic Manufacturing Assembly and Packaging 3 0 0 3 27 MEE 619 Computer Graphics and Geometric Modeling 2 1 2 4

Total Credits to be taken 19

Credit Summary

Minimum Qualifying Credits 73 UC 10 UE 3 PC 41 PE 19

ENG601 Professional and Communication Skills 1 0 2 2

Version No. 1.0 Course Prerequisites Nil Objectives To develop the professional and communication

skills of learners in a technical environment. To enable the students to acquire functional and technical writing skills. To acquire state-of-the-art presentation skills in order to present technical topics to both technical and non-technical audience.

Expected Outcome The learners will be able to exhibit their language proficiency and skill in Describing, Investigating, Designing and Making and Using Technology.

Unit 1 10 Functional Language Basic structures- Tense agreement, Prepositional

phrases Techno-words : Basic Concepts 62,63 Pronunciation : sounds of syllables: Past tense & plural endings

Technical Expression Organizational techniques in technical writing Guided writing: Paragraph Writing, Note Making

Presentation Skills Techniques of presentation (general topics : speech without visual aids) Listening to speeches and comprehending

Graphical Skills Flow chart : Process and Functional description Unit 2 10 Functional Language Basic structures- Voice, Conditionals

Techno-words : Basic Concepts 64,65,67 Pronunciation : Word Stress: two syllable words

Technical Expression Mechanics of Technical Writing and Syntax Guided writing: Letter and email

Presentation Skills Interpersonal Communication Skills Writing techniques for Power point presentation, Group Discussion

Graphical Skills Technical Illustrations and Instructions Unit 3 10 Functional Language Basic structures- Modal Verbs and Phrasal verbs

Techno-words : Basic Concepts 68,69,70,71 Pronunciation : Word Stress: compound words

Technical Expression Mechanics of Technical Writing and Syntax Guided writing: Technical Description

Presentation Skills Career advancement: Technical Resume and Company Profile Presentation and Group Discussion

Graphical Skills Pie chart, Bar chart, Line graphs: analysis and interpretation

Unit 4 10 Functional Language Basic structures- Modal Verbs and Phrasal verbs

Techno-words : Basic Concepts 72,73,74, Functional vocabulary 87 Pronunciation : Sentence Stress

Technical Expression Guided and Free writing: Abstract and Technical articles

Recommended by the Board of Studies on: 12.05.2012 Date of approval by the Academic Council: 18.05.2012

Presentation Skills Nuances of Presentation to a Technical audience Graphical Skills

Oral Presentation of graphical representation

Text Books & Software English Vocabulary in Use Advanced, McCarthy & Felicity, CUP, 2003 Sky Pronunciation CD-ROM Cambridge Advanced Learner’s Dictionary CD-ROM English Master : Grammar

Reference Books Writing, Researching, Communicating, Keith et al, Tata McGraw-Hill, 1989 Advanced English Grammar, Martin, CUP, 2006.

Mode of Evaluation Online quizzes, Speaking Skills tests, PowerPoint presentation

MAT502 APPLIED ENGINEERING MATHEMATICS 3 1 0 4 Version Number : 1.00

Course Prerequisites : Basic Engineering Mathematics Aims & Objectives:

The aim of this course is to introduce the concepts of solving Partial Differential equations by reducing to normal forms, finding solutions of differential equations by using the principles of calculus of variations along with Eigen Value problems and iteration methods.

Expected Outcome:

Upon completion of this course the student shall be able to:

Acquire good knowledge of solving differential, Partial differential equations

Solve Eigen value problems with relevant applications in their discipline

Unit-I Boundary Value Problems Linear second order partial differential equations in two independent variables – normal forms –

hyperbolic, parabolic and elliptic equations – Cauchy problem.

Unit-II Wave equations equations – solution of initial value problem – significance of characteristic curves-Laplace transform solutions – displacements in a long string – along string under its weight – a bar with prescribed force on one end – free vibrations of a string.

Unit-III Calculus of variations Concepts of functional and their stationary values – Euler’s equation and solution for the problem and for more general causes – natural boundary conditions – variational problems with moving boundaries – condition variational problems – Isoparametric problems-Direct Methods: Ritz, Kantorovich and Galerkin techniques

Unit-IV Eigen Value Problems Standard Eigen value problems – properties of Eigen values and Eigen vectors – Generalized Eigen value problems – strum sequence – Jacobi, Givens and Householder transformations. Unit-V Iteration Problems Forward and inverse iteration schemes – Graham Schmidt deflation – simultaneous iteration method – subspace iteration – Lanczo’s algorithm – Estimation of core and time requirements. References: 1. Jennings. A., Matrix Computation for Engineers and Scientists., John Wiley and Sons, 1992.

2. Prem.K.Kythe, Pratap Puri, Michael R.Schaferkotter, Introduction to Partial Differential Equations and Boundary Value problems with Mathematics, CRC Press, 2002 3. Kreyszig, Erwin, I.S., Advanced Engineering Mathematics, Wiley, 1999. 4. Ramamurthy. V., Computer Aided Design in Mechanical Engineering, Tata McGraw Hill Publishing Co., 1987. 5. Reny – Dannemeyer, “Introduction to Partial Differential Equations and Boundary Value problems”, McGraw Hill, 1968. Mode of Evaluation: Written Examination/ Assignment/ Seminar

Recommended by the Board of Studies on: 14 July 2011

Date of approval by the Academic Council: 30 Aug 2011

MEE521 Finite Element Methods 2 1 2 4 Version No. 1.00 Prerequisite Nil Objectives: To introduce the mathematical and physical principles underlying the Finite

Element Method (FEM) as applied to solid mechanics.

Expected Outcome:

Upon completion of this course, the student will be able to: • Derive finite element stiffness and mass atrices • Analyze linear solid mechanics or heat-transfer problems using commercial FEM codes.

Unit I Fundamental Concepts Physical problems, Mathematical models, and Finite Element Solutions. Finite Element Analysis asIntegral part of Computer Aided Design;. Stresses and Equilibrium; Boundary Conditions; Strain-Displacement Relations; Stress –strain relations, Linear and nonlinear material laws; Temperature Effects;Definition of Tensors and indicial notations; Deformation gradients; Classification of different types ofdeformations: Deformations and stresses in bars, thin beams, thick beams, plane strain- plane stresshypothesis , thin plate, thick plate, axisymmetric bodies..; Approximate nature of most of these deformationhypotheses; General 3D deformation (linear small deformation), Large deformation (nonlinear). Unit II General Techniques and Tools of Displacement Based Finite Element

Analysis

Energy and Variational principles for boundary value problems; Strong, or classical, form of the problem and weak, or Variational, form of the problem; Integral Formulations; Galerkin’s and Weighted residual approaches; Shape and interpolation functions for 1D, 2D & 3D applications; Use of shape(interpolation) functions to represent general displacement functions and in establishment of coordinate and geometrical transformations; Hermite, Lagrange and other interpolation functions; Numericalintegration of functions; Gauss and other integration schemes. Unit III One-Dimensional Problems: Trusses, Beams & Frames

Introduction; Local and global coordinate systems; Transformation of vectors in two and three dimensional spaces; Finite Element Modeling of a basic truss element in local coordinate system using energy approach; Assembly of the Global Stiffness Matrix and Load vector; The Finite Element Equations; Treatment of boundary Conditions; Euler Barnoulli (thin) beam element and Timoshenko (thick) beam element; Beam element arbitrarily oriented in space; Plane Trusses, Plane frames and Three-dimensional frames; Solution algorithms of linear systems.

Unit IV Plane Stress and Plane Strain Problems & 3D Problems Plane stress and plane strain problems; Isoparametric Elements; Constant Strain Triangles (CST); Bilinear Quadrilateral Q4; Modeling boundary conditions; Orthotropic materials; Numerical integration; Higher Order Elements; Four-node Quadrilateral for Axisymmetric Problems; Hexahedral solid elements;Tetrahedral solid elements; Numerical integration. Unit V Plate elements and Dynamical Analysis Basic assumptions and formulations of classical Kirchhhoff thin plate bending elements and thick Mindlinplate elements including bending and transverse shear energies; Degenerated shell elements; Construction of stiffness matrices. Dynamical equations of motion; Consistent and lumped Mass Matrices;Damping matrices; Vibration Analysis; Eigenvalue problems and solution techniques; Transient dynamicaland structural dynamical problems, Explicit and implicit schemes of integrations, Stability issues. Text Books 1. Robert Cook, R.D. et al. Concepts and Applications of Finite Element Analysis, John Wiley & Sons, 2004. 2. Tirupathi R. Chandrapatla, Ashok D. Belegundu Introduction to Finite Element in Engineering

Prentice-Hall of India Private limited, New Delhi – 110 001. References

1. Bathe, K.J, “Finite Element Procedures”, Prentice-Hall of India Pvt. Ltd., third Edition, 1996. 2. Zienkiewicz O.C., “the Finite Element Method”, McGraw-Hill, 1989. 3. Reddy J.N., “The Finite Element Method”, McGraw-Hill, Third Edition, 1993. 4. C.S. Krishnamoorthy, Finite Element Analysis, Tata McGraw-Hill, 1994.

Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 12.05.2012 Date of Approval by the Academic Council 18.05.2012

MEE522 COMPUTER INTEGRATED MANUFACTURING 3 0 2 4 Version No. 1.00 Prerequisite Nil Objectives: • This course provides in-depth coverage of computer Integrated Manufacturing. It

contains a high proportion of hands-on study, particularly in the areas of computer Aided Design and Computer Aided Manufacturing. Apart from the key area of CAD/CAM, it includes studies of Data Communication systems (as applicable to CIM), classification systems, and Group Technology, Computer Aided Process Planning and Flexible Manufacturing systems.

Expected Outcome:

Upon completion of this course, the student shall be able to understand and • Be familiar with using CAD/CAM systems and with programming and operating of CNC machine Tools.

Unit I Upon completion of this course, the student shall be able to understand and • Be comfortable familiar with using CAD/CAM systems and with programming and operating of CNC machine Tools.

Introduction to Geometric Modelling, Geometric Modelling Approaches, Wire-Frame Modelling, Surface Modelling, Solid Modelling, Computer-Aided Design, CAD System Architecture, CAD Data Exchange and CAD Standards, CAD Kernels, Data Interoperability, Different Types of Data Translation, Dual Kernel CAD Systems, Direct Data Translator, Common/Neutral Translators. CIM Introduction, CIM Wheel, CIM Models. Unit II Computer Aided Process Planning and Manufacturing Computer-Aided Process Planning, Basic Steps in Developing a Process Plan, Principal Process Planning Approaches, Computer-Aided Manufacturing, Computer Applications in a Manufacturing Plant, Key Aspects of CAM in a Manufacturing System and Manufacturing Control, Feature Technology, Feature-Based Methodologies, Basic Concepts of Feature recognition, Classification of Feature Recognition Systems, Feature detection, Feature Generation. Unit III CNC Machine tools and Programming Principles of Numerical Control, Typical CNC Machine Tools, Machining Capabilities of a CNC Machine, Tooling for CNC Machine Tools, Material for Cutting Tools, Principal Elements of a CNC Machine Tool, Direct Numerical Control, Parallel Machine Tool, CNC Programming, Concurrent Product Modeling in a CAD/CAM System, Data Exchange Using STEP and STEP-NC, Function Block-Enabled CAD/CAPP/CAM/CNC Integration Unit IV Automated Control structures in Manufacturing systems Automated storage and retrieval systems, Robotics, Interfacing Handling and Storage with Manufacturing, Automated inspection and testing, Sensor technologies, Coordinate measuring machines, Machine vision, Cellular manufacturing, Group Technology, Flexible manufacturing systems, Programmable controllers Unit V Key technologies for the integration Artificial Intelligence, Knowledge-Based Systems, Expert Systems Technology, Applications of Genetic Algorithm, Agent-Based Technology, Virtual Business, e- Commerce Technologies, Global Manufacturing Networks, Digital enterprise technologies. Text Books 1. Xun Xu, Integrating advanced Computer Aided Design, Manufacturing and Numerical Control, IGI Global, 2009, UK Principles and implementations. 2. J.A. Rehg & H. W. Kraebber, Computer Integrated Manufacturing, Pearson Education, 2005, India References 3. M.P. Groover, Automation Production systems and Computer Integrated manufacturing, Pearson Education, 2008. 4. T.C. Chang, R. Wysk and H.P. Wang, Computer aided Manufacturing, Third Edition, Pearson Education, 2009 5. U.Rembold, O. Nnaji and A. Storr, Computer Integrated Manufacturing and Engineering, Addison Wesley Publishers, 1993. 6. Nanua Singh, Systems approach to computer integrated design and manufacturing, Wiley, 1996 7. P. Radhakrishnan, S.Subramanian, V Raju, CAD/CAM / CIM, New age International Publishers. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 12.05.2012 Date of Approval by the Academic Council 18.05.2012

Laboratory Exercises

1. 3D solid modelling and assembly using CAD/CAM system 2. Generation of CNC program and machining in CNC machine. 3. Inspection planning for automated inspection 4. Concurrent costing using DFMA software 5. Simulation of Product, Process and FMS layouts 6. Industrial Robot Programming 7. Optimisation of Computer aided Process planning 8. PLC Programming

Version No. 1.00 Prerequisite Nil Objectives: To provide a comprehensive Knowledge of fluid power systems including both

hydraulics, used for factory automation. and pneumatics. Expected Outcome:

On completion of this course the students will be able to acquire the applied knowledge of fluid power various engineering fields PLC is factory automation (and the role of)

Unit I Introduction to Fluid Power Definition- Hydraulics Vs Pneumatics – ISO symbols-Application –Pascal’s Law- Transmission and multiplication of force-Basic properties of hydraulic fluids- static head pressure-pressure loss – Power- absolute pressure and Temperature- gas laws- vacuum hydraulic power supply source- pneumatic power supply source. Unit II Control Components and Basic Circuits Cylinders-accumulators –FRL-Directional control Valves- Pressure control valves-Flow control Valves-electronic control components- DCV controlling single acting, double acting cylinder-counter balance circuit-Fail safe circuit-AND and OR valve circuit-regenerative circuit-meter in and meter out circuit-pressure intensifier circuit-accumulator circuits etc. Unit III Design of Fluid power circuit Design method consideration for sequential circuits-intuitive circuit design method-cascade method- sequential logic circuit design using KV method- compound circuit design-step counter design Unit IV Factory Automation Introduction- automation principle and strategies-basic elements of an automated system advanced automation function-levels of automation-automation and control techniques continuous Vs discrete control- introduction to control component using PLC Unit V Programmable Logic controller Introduction-architecture-hardware components-Basics of PLC programming-programming timers-programming counters-master and jump controls-Data manipulation instructions Text Books Nil References

1. James L.Johnson, Introduction to Fluid power, Delmar Thomson Learning inc, 2003 2. Antony Esposito, Fluid power system and control, Prentice hall, 1988 3. Hydraulic systems Hand book, utility Publications Ltd., Secunderabad, 1988 4. Peter Rohner, Fluid power logic circuit design, The cmillan press 1979 5. M.P Groover, Automation production systems and cam – Prentice hall 1994 6. D. A. Bradley, D.Dawson, N.C. Burd, A.J. Loader, Mechatronics - Nelson Thrones,2004


MEE 528 FLUID POWER SYSTEM AND FACTORY AUTOMATION 3 0 2 4

FLUID POWER SYSTEM AND FACTORY AUTOMATION LABORATORY Aim and Objective:

The lab provides a hands-on training on Pneumatics, Hydraulics and PLC Kits List of exercises:

1. Design, development and analysis of pneumatic circuits using Automation studio /Pneumosim

software and Pneumatic trainers.

2. Design, development and analysis of hydraulic Circuits using Automation studio / Hydrosim

software

and hydraulic trainers.

3. Automation and Electro-pneumatic / Electro-hydraulic control using PLC systems (Allen Bradley,

Siemens and Festo).

4. Study of Modular Automation Production System.

5. Development of MMI /HMI with PLC systems.

6. Study and Programming of Industrial Robot.

MEE547 Quality Management 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: To provide student with the basic understanding of the approaches and techniques to

assess and improve process and or product quality and reliability Expected Outcome:

Upon completion of this course the student will • Have good knowledge of quality management principles • Be well versed with Total Quality Management • Have good knowledge of quality implementation techniques

Unit I Introduction to Quality Management Business scene in India and world over – quality imperatives – Efficiency & Effectiveness – Definition of Quality – Vision, Mission statement – formulation – Quality policy – Customer orientation – Quality culture and mind set – Quality philosophies of Deming, Crosby, Miller Comparison. Unit II Total Quality Management TQM principles – Customer satisfaction model – Customer retention model – QFD – Customer satisfaction measurement – Evolution of TQM – System & Human components – TQM models – Deming wheel principle – Top management commitment. Unit III Problem Solving Tools Old & QC Tools – Seven new management tools – Problem solving techniques – Case studies – Problems – Continuous improvement tools – Benchmarking, Quality circle. Unit IV QM Techniques Design FMEA, Process FMEA Characteristics Matrix, Variation analysis, Process capatriling control cliants, Measurements system analysis, Tagnelilors function. Unit V Quality System Implementation ISO Certification – ISO 9000 – ISO 14000 – Principles & Methodologies, Six Sigma, Taguchi, 5S concepts, Legal aspects, TQM road map, Strategies – case studies TS 16949-2009. Text Books References 1.DaleH. Beterfield et al, “Total Quality Management”, Pearson Education Asia, 2001. 2.Jill A.Swift, Joel E. Ross and Vincent K. Omachonn, “Principles of Total Quality”, St.Lucie Press, US, 1998. 3.John Bank J.E., “Total Quality Management”, Prentice Hall, India, 1993. 4.Samuel K.Ho, “TQM- AN Integrated approach”, Kogan Page India Pvt. Ltd, 2002. 5. Introduction to statistical quality control: Mentgomery D. C. Johnley (Asia) 2001 Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 12.05.2012 Date of Approval by the Academic Council 18.05.2012

MEE557 Advanced Materials and Processing 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: • To impart the knowledge on mechanical behavior of materials.

• To acquire knowledge in various class of materials and their applications. • To import knowledge on various surface modification techniques.

Expected Outcome:

Upon completion of this course, the student shall be able to: • Describe the mechanical behavior of metallic systems and its importance • Knowledge on engineering alloys and nonmetallic materials and their selection. • Gain knowledge on different types of surface modifications of materials.

Unit I Review of Mechanical Behavior of Materials Plastic deformation in poly phase alloys - Strengthening mechanisms - Griffith's theory of failure modes – Brittleand ductile fractures - Damping properties of materials - fracture toughness - Initiation and propagation of fatiguecracks - Creep mechanisms - Hydrogen embitterment of metals, Selection of materials for various applications. Unit II Engineering Alloys Cast iron , steels , alloy steels and stainless steels – an overview of phases and microstructure, types, specificationsapplications, heat treatment, effect of alloying elements, Aluminum, Magnesium and Ti wrought and cast alloys used in engineering applications –Types, specifications, applications, heat treatment Unit III Surface Modifications of Materials Mechanical surface treatment and coating - Case hardening and hard facing - thermal spraying – vapour deposition-ion implantation - Diffusion coating - Electroplating and Electrolysis - Conversion coating - Ceramic and organiccoatings – Diamond coating Unit IV Nonmetallic Materials Composite materials, ceramics, plastics -Introduction, an overview of processing, their characteristic features, types and applications. Unit V Modern Materials and Alloys Super alloys- Refractory metals - Shape memory alloys- Dual phase steels, Micro alloyed, High strength low alloysteel, Transformation induced plasticity (TRIP) steel, Maraging steel –SMART materials, Metallic glass – Quasicrystal and Nano crystalline materials., metal foams . Text Books 1.Callister W.D. (2006) "Material Science and Engineering- An introduction", Wiley –Eastern. 2.Raghavan, V., (2003) "Physical Metallurgy", Prentice Hall of India. References 1. Thomas H. Courtney, (2000) "Mechanical Behavior of Materials", McGraw Hill,. 2. Flinn R. A. and Trojan P. K., (1999)"Engineering Materials and their Applications", Jaico. 3. KENNETH BUDINSKI – (1988) "Surface Engineering for wear resistance ", Prentice Hall. 4. Avner S.H., (2006) "Introduction to physical metallurgy" –Tata McGraw hill,


MEE566 Modern Machining Process 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: To develop and understanding of fundamental mechanics of machining in high speed

machining, non-traditional machining and micro-machining processes. Expected Outcome:

Upon completion of this course, the student shall be able to: Understand various advanced machining processes and their practical

applications. Select suitable advanced machining processes for the new materials.

Contents Fundamentals of Machining High speed machining Non-traditional machining processes – I Non-traditional machining processes – II Micromachining

Unit I Fundamentals of Machining Mechanism of chip formation – Orthogonal and Oblique cutting – Stresses and energies in cutting - Various shear angle theories.Tool materials – Tool life and tool wear – Thermal aspects of machining – Cutting fluids and surface roughness. Unit II High Speed Machining

High speed machining (HSM) – Characteristics of HSM - Machine tools requirements for HSM – Cutting tools for HSM - Design of tools for HSM – Tool clamping systems - Applications of HSM – High speed and high performance grinding. Unit III Non-traditional machining processes – I Abrasive jet machining – Water jet machining - Abrasive water jet machining - Ultrasonic machining – Electro chemical machining – working principle – process variables – cutting parameters – process capabilities – applications. Unit IV Non-traditional machining processes – II Electric discharge machining - Laser beam machining – Electron beam machining – Plasma arc machining – Ion beam machining – working principle – process variables – cutting parameters – process capabilities – applications. Unit V Micromachining Micro machining - micro-turning, micro-milling, micro-drilling, micro EDM, micro- WEDM, micro ECM, micro LASER etc. Ultra-precision machining – Diamond turning, ductile cutting of silicon wafers, mechanism of ductile cutting, nanometric cutting, chip formation, recent developments. Text Books References

1. Boothroyd G., and Knight W.A., “Fundamentals of Metal Machining and Machine Tools”, Marcel Dekker, 1989.

2. Serope Kalpakjian and Steven R.Schmid, “Manufacturing Engineering and Technology”, Pearson Education, 2001.

3. Benedict G., “Non Traditional Manufacturing Processes”, Marcel Dekker, 1987. 4. Bert T.Erdel, “High Speed Machining”, Society of Manufacturing Engineers, 2003. 5. Jain V.K, “Introduction to Micromachining”, Narosa Publishers, 2010

Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 14 July 2011 Date of Approval by the Academic Council 30 Aug 2011

MEE567 CNC TECHNOLOGY AND PROGRAMMING 3 0 2 4

Version No. 1.00 Prerequisite Nil Objectives: To make the student to be familiar with

• Use of automation technologies in manufacturing • CNC hardware and control systems • CNC programming • Program verifications

Expected Outcome:

Upon completion the course, student will be familiar with

• Different automation strategies • How to control manufacturing operations through the use of CNC controllers • Advanced programming concepts using various controllers • Verify the tool path for complex geometries

Unit I Concept and scope of industrial automation – automation strategies - devices, drives and control circuits in automation - Semi-automats, automats and transfer lines, Introduction to NC/CNC/DNC and its role in FMS and CIMS, Basics elements of CNC System Unit II CNC Hardware Elements including drives, actuators & sensors, Construction of modern CNC machine tool controllers, microprocessor and CNC adaptive control – ACO and ACC systems. Unit III Introduction to Part Programming, Radius and Length Compensation Schemes, Tooling & Work-holding for CNC machine tools, Advanced Programming Features & Canned Cycles Unit IV Geometric Modeling for NC machining & Machining of Free-form Surfaces, NC program generation from CAD models, Unit V NC Program verification and Virtual NC, Recent developments in CNC machine tools.

Text Books 1. Mikell P. Groover, “Automation, Production Systems and Computer Integrated Manufacturing”, Pearson Education, 2005 2. T.C. Chang, R. Wysk and Wang Computer –aided Manufacturing, Prentice Hall Publications, 2003. References P.N.Rao, CAD/CAM, Tata McGraw Hill, 2003.


Laboratory Exercises

• Manual part programming on simple lathe operations

• CNC part programming on lathe, milling and drilling

• CAD/CAM integration with CNC machine tool

• Generate CNC program for machining centers

• Mould and Die design and manufacture

• Programming on CMM, Wire-cut EDM

MEE699 Master Thesis - - - 20

MEE565 ADVANCED JOINING PROCESS 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: To impart the knowledge on joining of materials.

To acquire knowledge in various class of joining processes and their applications. To impart knowledge on various arc welding techniques and its characterisation.

Expected Outcome:

Upon completion of this course, the student shall be able to: • Describe the joining technology of metallic systems and its importance • Knowledge on welding of engineering alloys and dissimilar weldments. • Gain knowledge on different types of automated welding processes.

Unit I Conventional fusion welding processes. Principal heat sources. Gas welding and cutting. Manual metal arc welding. Electrode coverings and their functions. Thermit welding. Submerged arc welding: types of fluxes, use of multiple wire and strip electrodes, significance of wire-flux combinations. Gas shielded welding: Unit II TIG, MIG and MAG/CO2 and flux-cored arc processes. Consideration of shielding gases, electrode polarity, current setting, metal transfer and arc length control. Plasma arc welding and cutting processes. Electrical power sources for welding: General characteristics of inverter, transformer, transformer-rectifier and motor-generator sets. Influence of power source characteristics on welding performance and use of pulsed currents. Unit III Resistance welding: spot, seam and projection welding. Flash and upset butt welding, percussion welding, HFRW & HFIW. Brazing and soldering. Electron beam and laser welding. Controls and applications of above processes. Power sources for resistance welding, Unit IV Pressure welding processes: solid phase bonding, friction welding, friction stir welding, ultrasonic welding, explosive welding, diffusion bonding and adhesive bonding. Unit V Weldability - weldability of cast iron, plain carbon and low alloy steels, stainless steels, determination of preheat temperature, use of Schaeffler's diagram, weldability tests, Automated welding systems; microprocessor control of arc welding and resistance welding, quality assurance in welding, welding fumes and their effect on the environment, Welding innovations Text Books References

1. Dr.R.S.Parmar “Welding processes and technology” Khanna Publishers. 2. H.S.Bawa “ Manufacturing Technology-I” Tata Mc Graw Hill Publishers New Delhi, 2007. 3. Scrope Kalpakjian,, “Manufacturing processes for Engineering Materials”, Addision Wesley, 1997.


MEE568 MACHINE TOOL METROLOGY 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: 1. To provide the fundamental knowledge on the different types of errors in a typical

machine tool. 2. To understand the measurement techniques for evaluating the machine tool

performance. 3. To analyze the effect of machine tool errors on the machining accuracy of the

components. 4. To develop the error compensation techniques for the different machine tool errors.

Expected Outcome:

Student will be able to 1. To assess, characterize and understand the accuracy of machine tools. 2. To perform the necessary tests for performance evaluation of machine tools. 3. To compare the performance of similar machines.

Unit I Introduction to machine tool errors Basic Elements and Structures of a Machine - Accuracy, Repeatability (Precision), and Resolution - Error sources in machine tools- Classification of errors- Static, quasi static, dynamic errors, Geometric error, thermal error, Spindle error, Effect on machining accuracy. Unit II Modeling of machine tools errors Linear axes errors, Rotary axes errors- Degrees of freedom-Rigid body kinematics- Homogeneous transformation matrix-Relative position of tool and work piece- Modeling and analysis of thermal errors. Unit III Error measurement in machine tools Contact and non contact methods- dial indicators- Ball bar - Inductive sensors- LVDT-Capacitive sensors-Laser interferometer-Measurement of geometric error, thermal error in machine tools- On machine measurement. Unit IV Test procedures for machine tools Schlesinger alignment tests – Straightness and flatness measurement – Reversal method- Squareness measurement - Inspection techniques for spindles-Standards for machine tool testing-ANSI/ASME/ISO-Performance tests. Unit V Error compensation techniques Error avoidance methods-Pre calibration – Active error compensation methods-Geometric error compensation in machine tools – NC code modification-Methods for reducing thermal errors-Error budgeting. Text Books Murthy, R. L. Precision Engineering in manufacturing, New Age International (P) Ltd, Delhi, 1996. References 1. Slocum, A. H., Precision Machine Design, Prentice-Hall, NJ, 1992 2. Dornfeld, D., Lee D. E., Precision Manufacturing, Springer, NY, 2008. 3. Marsh, E. R. Spindle metrology, Destech, NY, 2008.


MEE569 Mechatronics in Manufacturing 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: To provide the Basic understanding of mechatronic systems used is manufacturing

auformation such as: Basic electronics and drives in manufacturing systems Hydraulic and pneumatic systems to be used in manufacturing automation

Expected Outcome:

Upon completion the course, student will be familiar with : 1. Different automation strategies used in factory automation 2. Control of manufacturing operations through the use sensors and signal processing devices 3. Advanced concepts in hydraulic and pneumatic systems

Unit I Definition of mechatronics. Mechatronics in manufacturing, Elements of a mechatronics system, Role of mechatronics ystem in factory sutomation. Unit II Review of fundamentals of electronics. Data conversion devices, sensors, microsensors, transducers, signal processing devices, relays, contactors and timers. Microprocessors controllers and PLCs. Unit III Drives: stepper motors, servo drives. Ball screws, linear motion bearings, cams, systems controlled by camshafts, electronic cams, indexing mechanisms, tool magazines, transfer systems. Unit IV Hydraulic systems: flow, pressure and direction control valves, actuators, and supporting elements, hydraulic power packs, pumps. Design of hydraulic circuits. Unit V Pneumatics: production, distribution and conditioning of compressed air, system components and graphic representations, design of systems. Description of PID controllers. CNC machines and part programming. Industrial Robotics. Text Books 1. Boucher, T. O., Computer automation in manufacturing - an Introduction, Chapman and Hall, 1996. 2. HMT ltd. Mechatronics, Tata McGraw-Hill, New Delhi, 1988. References 1. Deb, S. R., Robotics technology and flexible automation, Tata McGraw-Hill, New Delhi, 1994. 2. Boltan, W., Mechatronics: electronic control systems in mechanical and electrical engineering, Longman, Singapore, 1999. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 14 July 2011 Date of Approval by the Academic Council 30 Aug 2011

MEE 591 Computational Methods in Heat and Fluid Flow 3 0 2 4 Version No. 1.00 Prerequisite Nil Objectives: To make the students

1. understand the computational techniques useful in the analysis of fluid flow and heat transfer; 2.expose and train in using commercial CFD software and in writing codes for specific CFD applications.

Expected Outcome:

At the end of the course the student will be able to 1. formulate equations for fluid flow and heat transfer problems 2. understand the basic concepts of CFD techniques 3. solve conduction and convection & diffusion problems 4. solve incompressible fluid flow problems 5. use FLUENT to solve problems Contents Review of the equations governing fluid flow and heat transfer • Finite difference method • Heat conduction, convection and diffusion • Solution of Navier-Stokes equations for incompressible flows • Problem solving

Unit I Introduction to equations governing fluid flow and heat transfer – Conservation of mass, conservation of energy - expanded and special forms of Navier-Stokes equations - Potential theory - Boundary layer theory - Compressible flows – Turbulent flows. Unit II Introduction to finite differences, difference equations and discretization – Finite difference methods: Explicit, implicit and Crank-Nicholson – Convergence and stability conditions - ADI – Boundary conditions - Applications to steady and transient heat conduction equations. Unit III One- and two- dimensional steady & transient conduction - Steady one-dimensional convection and diffusion - Solution methodology: upwind scheme, exponential scheme, hybrid scheme, power law scheme – Explicit, Implicit, Crank-Nicolson schemes – Stability criterion. Unit IV Representation of the pressure gradient term and continuity equation - Staggered grid - Momentum equations – Pressure and velocity corrections - Pressure correction equation - SIMPLE algorithm - Boundary conditions for the pressure correction method. Unit V Introduction to Fluent software – Problem solving using Fluent. Text Books References 1. S.V. Patankar (1994), Numerical Heat Transfer and Fluid Flow, Hemisphere, New York. 2. Y. Jaluria and K.E. Torrance (1986), Computational Heat Transfer, Hemisphere Publishing Corp. 3. J.D. Anderson, Jr. (1995), Computational Fluid Dynamics – The Basic with Applications,McGraw-Hill. 4. K.A. Hoffman (1989), Computational Fluid Dynamics for Engineering, Engineering Education System, Austin, Texas. 5. K. Muralidhar and T. Sundarajan (1995), Computational Fluid Flow and Heat Transfer, Narosa Publishing House, New Delhi. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 14 July 2011 Date of Approval by the Academic Council 30 Aug 2011

MEE570 Design and Metallurgy of Welded Joints 3 0 0 3 Version No. 1.00 Prerequisite Nil

Objectives: To make the student to be familiar with • Design of welded joints • Selection of materials for welding • Heat flow, distortion during welding • Weldability of commonly used materials

Expected Outcome:

Upon completion the course, student will be familiar with • Problems and difficulties in weld structures • How to obtain a sound weld structure • Heating and cooling cycles in welding • Metallurgy of welded joints

Unit I Introduction to importance of welding in fabrication, Problems & difficulties in welded structures, testing of welded structures and analysis Unit II Properties for selection of materials, Characteristic properties and behavior of commonly used materials, Effect of alloying materials Unit III Heat flow in welds, Heating and cooling cycles in welding, Effect of HAZ, Hot cracking, Development of phases, Microstructure etc , causes and cures for various discontinuities & defects in weldments, Unit IV Weldability, Weldability of commonly used materials, Mechanical testing of weldments, Service and fabrication weldability tests and their importance, Thermal stresses and distortion, Brittle fracture and fatigue in welded joints, NDT of welds, Unit V Introduction to engineering physical metallurgy, Joining metallurgy and microstructures, Joint preparation weld symbols, Weld joint designs for strength and quality, Automation in welding, Cost analysis Text Books References 1. John Hicks, Welded Joint design, Abington Publishing, 1999. 2. Sindo Kou, Welding Metallurgy, Second Edition John Wiley & Sons, 2003 3. Lancaster W, Metallurgy of welding, Abington Publishing, 1999.


MEE582 Robotics and Industrial Automation 2 2 3 Version No. 1.00 Prerequisite Nil Objectives: To make the student to be familiar with

• Classification and construction of robots • Serial and parallel Manipulators • Programmming method of robots • Understand various control systems

Expected Outcome:

Upon completion the course, student will be familiar with Anatomy of Robots Applications of Robots Programming languages of robots Control system and components of Robots

Unit I Introduction to Robotics: Definitions, historical development, classification, work volume, Control systems and dynamic performance. - Grippers Unit II Robot Arm Kinematics and Dynamics: Frame transformation, D-H parameters, Forward kinematics, Inverse kinematics, - Rotation matrix - Homogeneous coordinates and transformation matrix Unit III Robot Programming Methods: Manual teaching, Lead-through teaching, VAL programming. – Introduction to trajectory Planning - Introduction to Automation. Unit IV Sensing: Range sensing, proximity sensing, touch sensors, force and torque sensing, Robot Vision: System: Sensing & Digitizing, Image processing & Analysis, Application. Unit V Control system and components : Control system concepts and models, controllers, Control system analysis, Robot Activation and Feed back componens – position control - velocity control – Actuation Text Books References 1.Mikell P. Groover, “Industrial Robots”, McGraw Hill, 2005 2.S.K. Saha, Introductions to Robotics, McGraw Hill, 2009 3.L.K. Huat, Industrial Robotics: Programming, Simulation and Applications, Tata McGraw Hill, 2003. 4.Ganesh Hegde, A textbook of Industrial Robotics, Lakshmi Publication, 2006. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 14 July 2011 Date of Approval by the Academic Council 30 Aug 2011

MEE548 METROLOGY AND NON DESTRUCTIVE TESTING 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: Impart the knowledge of quality assurance and inspection techniques.

Familiarize with the various inspection and measurement techniques like contact and non-contact measurement by adapting Computer Aided Inspection.

Impart the knowledge of working principles and calibration of various Systems.

Expected Outcome:

Upon completion of this course, the student shall be able to: Acquire the knowledge in CMM and Image Processing Understand the concept of Laser Metrology and Computer Integrated Quality Assurance Acquire knowledge of magnetic particle testing

Unit I Measuring Machines Tool Makers’s microscope – Co-ordinate measuring machines – Universal measuring machine- Laser viewers for production profile checks – Image shearing microscope – Use of computers – Machine vision technology- Microprocessors in metrology. Unit II Statistical Quality Control

Data presentation – Statistical measures and tools – Process capability – Confidence and tolerance limits – Control charts for variables and for fraction defectives – Theory of probability – Sampling –ABC standard – Reliability and life testing. Unit III Liquid Penetrant and Magnetic Particle Tests

Characteristics of liquid penetrants – different washable systems – Developers – applications- Methods of production of magnetic fields- Principles of operation of magnetic particle test- Applications- Advantages and Limitations. Unit IV Radiography

Sources of ray X-ray production-properties of d and x rays – film characteristics – exposure charts – Contrasts – operational characteristics of x ray equipment – applications. Unit V Ultrasonic and Acoustic Emission Techniques

Production of ultrasonic waves – different types of waves - general characteristics of waves – pulse echo method – A, B, C scans – Principles of acoustic emission techniques – Advantages and limitations - Instrumentation – Applications. Text Books References 1. JAIN.R.K. Engineering Metrology, Khanna Publishers, 1997 2. Barry Hull and Vernon John, Non Destructive Testing, Mac Millan, 1988 3. American Society for Metals, Metals Hand Book, Vol. II, 1976. 4. Progress in Acoustic Emission, Proceedings of 10th International Acoustic Emission Symposium, Japanese society for NDI, 1990. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on Date of Approval by the Academic Council

MEE550 DESIGN FOR MANUFACTURING 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: The course is aimed at developing students to acquire skills to analyze

product design and be able to design products that are easier to manufacture, assemble, service and more friendlier to environment, etc.

Expected Outcome:

Upon completion of this course, the student shall be able to: Have customer-oriented, manufacturing and life-cycle sensitive approach to product

design and development, with product design principles and structured design methodologies.

Have Methods and approaches for developing, implementing, and nurturing an effective DFM process within the firm.

Unit I Introduction General design principles for manufacturability – strength and mechanical factors, evaluation method, Process capability - Feature tolerances- Geometric tolerances-Assembly limits- Datum features- Tolerance stacks. Unit II Factors influencing form Design Working principle, Material, Manufacture, Design – Possible solutions – Materials choice – Influence of materials on form design – form design of welded members, forgings and castings Unit III Component Design – Machining Consideration Design features to facilitate machining – drills - milling cutters – keyways – Doweling procedures,counter sunk screws – Reduction of machined area – simplification by separation – simplification by amalgamation – Design for Machinability –Design for accessibility – Design for assembly. Unit IV Robust Design and Taguchi Method Robust design - Design of experiments – Robust design process- Orthogonal arrays: Two level orthogonal arrays, three level orthogonal arrays, combined inner and outer arrays. Unit V Redesign for Manufacture and case studies Design for economy, Identification of uneconomical design – Modifying the design –Computer Applications for DFMA – Case Studies. Text Books 1.Harry Peck, “Design for Manufacture”, Pittman Publication, 1983. 2.Karl T. Ulrich, Ateven D. Eppinger “Product Design and Development” Tata McGraw-Hill, 2003. References 1. James G. Bralla, “Hand Book of Product Design for Manufacturing”, McGraw Hill co., 1986. 2. Swift K.G., “Knowledge based design for manufacture, Kogan Page Ltd., 1987. 3. Boothroyd, G., (1994), Product Design for Manufacture and Assembly, Marcel Decker, Bralla, J.G., (1999),

Design for Manufacturability Handbook, McGraw-Hill. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 12.05.2012 Date of Approval by the Academic Council 18.05.2012

MEE552 OPTIMIZATION METHODS 2 1 0 3 Version No. 1.00 Prerequisite Nil Objectives: To understand the role of optimization in Engineering design and its importance

To introduce the different optimization algorithms in linear programming and non-linear programming

To introduce the non-traditional optimization algorithm in Solving non-linear problems.

Expected Outcome:

Upon completion of this course, the student shall be able to: • Formulate the design problem in mathematical form

which can be solved by suitable optimization algorithm • Solve the design problem which involves non-linear constraints. • Compare the efficiency of different algorithms.

Contents • Introduction to Optimization • Integer Programming, Dynamic Programming and Network Analysis • Non-Linear Programming • Non-Linear Programming and Geometric Programming • Optimization Design of Machine Elements

Unit I Linear Optimization Optimization problem statement – classification - single variable - multivariable unconstrained – equality constrained and inequality constrained. Simplex methods – dual simplex method – bounded variable technique for linear programming problems. Integer Programming & Dynamic Programming; Gomary’s cutting plane method - branch and bound method – Bellman’s principle of optimality-inventory, capital budgeting, reliability problems and simplex problem. Unit II Unconstrained Non-linear Optimization Unimodal function – Region elimination methods: Unrestricted, Dichotomous, Fibonacci, Golden Section, Bi-section - Direct search methods: Random, Univariate, Pattern search methods – Descent methods: Steepest descent, Conjugate gradient and Variable metric. Unit III Constrained Non-linear Optimization Characteristics of a constrained optimization problem - Direct methods: Cutting plane method, methods of feasible directions – Indirect methods: Interior and exterior penalty function methods – Geometric programming – Solution from differential calculus point of view – Solution from arithmetic-geometric inequality point of view. Unit IV Advanced Non-linear Optimization Genetic Algorithms -Working principle-Genetic operators-Numerical problem-Simulated Annealing - Numerical problem - Neural network based optimization-Optimization of fuzzy systems-fuzzy set theory- computational procedure. Unit V Optimization Design of Machine Elements Functional requirements- desirable and undesirable effects – functional requirements and material and geometrical parameters – adequate designs, Optimum design – primary design equation, subsidiary design equations, limit equations – basic procedural steps for methods of optimum design – constrained parameters and free variables – normal, redundant and incompatible specifications general planning. Text Books References

1. Rao, S.S., “Optimization - Theory and Applications”, Wiley Eastern, New Delhi, 1978. 2. Fox, R.L., “ Optimization Methods for Engineering Design”, Addion – Weslety, Reading, Mass, 1971. 3. Wilde, D.J., “Optimization seeking Methods”, Prentice – Hall, Englewood Cliffs, New Jersey, 1964. 4. Johnson, Ray C., “Optimum Design of Mechanical Elements”, 2nd Ed., John Wiley & Sons, Ic., New York, 1980.

5. Kalyanmoy Deb, "Optimization for Engineering Design-Algorithms and Examples", Prentice-Hall of India, 1996.


MEE604 DESIGN AND ANALYSIS OF EXPERIMENTS 1 0 3 Version No. 1.00 Prerequisite Nil Objectives: The objective of this course is to introduce experimental design techniques and

familiarize with all of the best design techniques and study the objectives, similarities, differences, advantages, and disadvantages of each.

Expected Outcome:

• On completion of this course, students will be able to: • Setup Full and Fraction Factorial Experiment Design. • Perform ANOVA and Hypothesis testing. • Learn Loss function approach to Quality Control. • Setup and analyse Robust Design.

Unit I Introduction Basic principle of DOEs, Guide lines for Designing Experiments, Terminology, ANOVA, Computation of sum of squares and Basics of quality by design, Experiments with single factor, Model Adegnacy checking, Test on means Unit II Single Factor Experiments Randomized complete block design, Latin square design, Graeco-Latin square design, Balanced Incomplete block design Unit III Factorial Design Two-Factor factorial design, General factorial design, 2k Factorial design, 3k Factorial design, Blocking and confounding, Fractional replication and Factors with mixed levels. Unit IV Robust Design Process Comparison of classical and Taguchi’s approach, variability due to noise factors, principle or robustization, classification of quality characteristics and parameters, objective functions in robust design, S/N ratios. Unit V Orthogonal Experiments Selection and application of orthogonal arrays for design, Conduct of experiments, collection of data and analysis of simple experiments, Modifying orthogonal arrays, Inner and outer OA experiments, Optimization using S/N ratios, attribute data analysis, a critique of robust design. Text Books

1. References 1. Montgomery, D.C., “Design and Analysis of Experiments”, John Wiley and Sons, 1997. 2.Philip J. Rose, “Taguchi Techniques for Quality Engineering”, Prentice Hall, 1989. 3.Nicolo Belavendram, “Quality by Design: Taguchi Techniques for Industrial Experimentation”, Prentice Hall, 1995. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 14 July 2011 Date of Approval by the Academic Council 30 Aug 2011

MEE555 COMPUTER AIDED PROCESS PLANNING 2 1 0 3 Version No. 1.00 Prerequisite Nil

Objectives: To provide the student with an understanding of the importance of process planning role in manufacturing and the application of Computer Aided Process Planning tool in the present manufacturing scenario

Expected Outcome:

Upon completion of this course, the student shall be able to: • Have a sound knowledge in process planning • Handle computer aided process planning tool

Unit I Introduction The Place of Process Planning in the Manufacturing cycle- Process planning and production planning – Process planning and Concurrent Engineering, CAPP, Group Technology. Unit II Part Design Representation Design Drafting – Dimensioning – Conventional Toloerencing – Geometric Toloerencing- CAD – input/output devices – Topology – Geometric transformation – Perspective transformation – Data Structure – Geometric modeling for process planning –GT coding – The OPITZ system – The MICLASS System. Unit III Process Engineering and Process Planning Experienced based planning – Decision table and Decision trees – Process capability analysis – Process planning – Variant process planning – Generative approach – Forward and backward planning, Input format, A1 Unit IV Computer Aided Process Planning Systems Logical Design of process planning – Implementation considerations- Manufacturing system components, Production Volume, No. of production families- CAM-I, CAPP, MIPLAN, APPAS, AUTOPLAN and PRO, CPPP. Unit V An Integrated Process Planning Systems Totally integrated process planning systems – An Overview – Modulus structure – Data structure – Operation – Report Generation, Expert process planning. Text Books

References

1.Gideon Halevi and Roland D.Weill, “Principle of process planning”, A logical approach, chapman & Hall, 1995. 2.Tien-Chien-Chang, Richard A.Wysk, “An Introduction to automated process planning systems”, Prentice Hall 1985. 3.Chang.T.C.,”An Expert Process Planning System”, Prentice Hall, 1985. 4.Nanua Singh,” Systems Approach to Computer Integrated Design and Manufacturing”, John Wiley & Sons, 1996. 5.Rao, “Computer Aided Manufacturing”, Tata McGraw Hill Publishing Co., 2000.


MEE605 TOOL ENGINEERING 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: • The main objective of the course is to give students the basic concepts of tool engineering.

• The student is guided to use these concepts in the design of jigs, fixtures and various types of dies used in production industry through assigned projects and factory visits.

Expected Outcome:

The student will able to: • Become aware of the materials used to make different types of tooling components

including tool steels, low carbon steels, cast iron, aluminum, plastics and cutting tool materials.

• Integrate CAD techniques into the design of production tooling to help understand the advantages and disadvantages for productive tool design.

• Develop an understanding of the factors involved in the design of special production inspection gages.

• Become acquainted with the development of cutting tool design for production machines and the selection of tool geometries for metal cutting methods

• Develop an understanding of the principles involved in the design of jigs and fixtures concentrating on locating methods, clamping and use of drill bushings. Standard jig and fixture designs will be reviewed.

• Develop an understanding of the principles used in the design and plastic injectionmold tooling and Composite tooling. To include cavity layout, sprue and runnerdesign, gate design, venting, cooling, and selection of tooling components.

Unit I Introduction and basic tool design principles .Broad Classification of Tools-Cutting tools, Dies, Holding and measuring tools, Tool manufacturing and Introduction to Computer aided die design applications. Unit II Design of Cutting Tools: Single Point and multi-pint cutting tools; Single Point Cutting Tools: Classification, Nomenclature, geometry, design of single point tools for lathes, shapers, planers etc. Chip breakers and their design; Multipoint Cutting Tools: Classification and specification, nomenclature, Design of drills, milling cutters, broaches, taps etc.; Design of Form Tools: Flat and circular form tools, their design and application. Unit III Design of Dies for Bulk metal Deformation-Wire Drawing, Extrusion, Forging and Rolling; Design of Dies for Sheet metal: Blanking and Piercing, Bending and Deep-drawing; Design of Dies used for Casting and Moulding. Unit IV Design of Jigs, Fixtures and Gauges: Classification of Jigs and Fixtures, Fundamental Principles of design of Jigs and Fixtures, Location and Clamping in Jigs and fixtures, Simple design for drilling Jigs, Milling fixtures etc. Indexing Jigs and fixtures. Unit V Design of Moulds: Mould making, General Mould Constructions, Intermediate Mould Design- Splits, Side core and side cavities, Moulding Internal undercuts, Runner less moulds, Aspects of practical mould design. Text Books References

1. James A Szumera, The Metal stamping Process, Industrial Press Incorp. 2. Donaldson et al., ‘Tool Engineering’, Tata Mc-Graw Hill. 3. Pollack, H.W. Tool Design, Reston Publishing Company, Inc. 4. Kempster, M.H.A. Principles of Jig and Tool Design, English University Press Ltd. 5. John G. Nee, Fundamentals of Tool Design, Author - Society of Manufacturing Engineers 6. Handbook of Fixture Design (SME)” Society of Manufacturing Engineers,McGraw-Hill.

7. D.F. Eary and E.A. Red, “Techniques of Pressworking Sheet Metal”, PrenticeHall. 8. “Tool Engineers Handbook, ASTME”, McGraw-Hill. 9. R.G.W.Pye, Injection Mould Design, Longman scientific and technical ltd.


MEE603 RELIABILITY ENGINEERING 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: • To equip the students to analyze reliability data.

• To introduce the concepts of reliability and useful life availability of products. • To impart knowledge on maintainability and availability analysis of products.

Expected Outcome:

On completion of this course, the student shall be able to acquire good knowledge on reliability of products through the failure concepts, failure distributions, Serial & parallel systems and their risk assessment.

Unit I Reliability Concept Reliability function - failure rate - Mean Time between Failures (MTBF) - Mean Time to Failure (MTTF) - a priori and a posteriori concept - mortality curve - useful life availability - maintainability - system effectiveness. Unit II Reliability Data Analysis Time-to-failure distributions - Exponential, normal, Gamma, Weibull, ranking of data - probability plotting techniques - Hazard plotting. Unit III Reliability Prediction Models Series and parallel systems - RBD approach - Standby systems - m/n configuration - Application of Baye's theorem - cut and tie set method - Markov analysis - FTA - Limitations. Unit IV Reliability Management Reliability testing - Reliability growth monitoring - Non parametric methods - Reliability and life cycle costs - Reliability allocation - Replacement model. Unit V Risk Assessment Definition and measurement of risk - risk analysis techniques - risk reduction resources - industrial safety and risk assessment. Text Books References 1. Modarres, “Reliability and Risk analysis ", Mara Dekker Inc., 1993. 2. John Davidson, “The Reliability of Mechanical system ", Institution of Mechanical Engineers,

London, 1988. 3. C.O. Smith" Introduction to Reliability in Design ", McGraw Hill, London, 1976. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 14 July 2011 Date of Approval by the Academic Council 30 Aug 2011

MEE571 VIRTUAL MANUFACTURING 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: This subject will provide students with:

• an understanding of the enterprise networking technologies and web-based tools that support modern manufacturing systems

• the knowledge to apply the Information Technology (IT) in dispersed network manufacturing, virtual manufacturing, virtual organizations (VO)/virtual enterprises (VE), work flow management, web services.

• a working knowledge and sound skills to plan, develop and implement customized IT solution for enterprise integration as well as to address industrial problems in manufacturing environment.

Expected Outcome:

Upon completion of this course, the student shall be able to: • Have good amount of knowledge on paradigms of virtual manufacturing, Sterio

vision. • Bridges gap between virtual reatity and computer vision in managaituids • Have good amount of knowledge of manufacturing process simulation • Have good amount of knowledge on dispersed network manufacturing Send

application of virtual manufacturing Unit I

Paradigms of VM: Design-centered VM, Production-centered VM and Control-centered VM. Generic VM Issues - relationships between VM, Virtual Prototyping, the Virtual Enterprise. Role of object oriented technology in VM. Unit II Promising areas of VM and manufacturability analysis, validation and evaluation of process plans, partnering in agile enterprises, process design, and optimization of production plans and schedules. Tools for manufacturability analysis. Case study. Unit III Virtual Manufacturing over the Internet. Transmitting VM Information over the Internet. Manufacturing resource models for distributed manufacturing. Case study. Unit IV Manufacturing process simulation -Factory level, Machine level, Component level, Process level. Integrated Simulation Method to Support Virtual Factory Engineering. Application of Virtual Reality Simulation of a Mechanical Assembly Production Line. Case studies. Unit V Dispersed Network Manufacturing - Virtual factory, enterprise collaborative modeling system, virtual manufacturing (VM) system, Web-based work flow management, collaborative product commerce, applications of multi-agent technology, e-supply chain management and tele-manufacturing Text Books Warim Ahmed Khan Abdul Raouz, Kari Chens, Virutal Manufacturing, Springer Series in Advanced Manufacturing. References

1. Crabb, C. H., The Virtual Engineer-21st Century Product Development, Society of Manufacturing Engineers, 1998.

2. Rao Ming, Qun Wang, Jianzhong Cha, Integrated Distributed Intelligent Systems in Manufacturing (Intelligent Manufacturing), Chapman & Hall (1993).

3. Prasant Banerjee, Virtual manufacturing a willey, I addition (2001), ISBN:-10: 0471354430 Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 14 July 2011 Date of Approval by the Academic Council 30 Aug 2011

MEE573 THEORY OF METAL FORMING 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: 1. To understand the basic principles of Metal Forming Theory

2. To know the various types of forming processes 3. To know about advanced metal forming methods

Expected Outcome:

Student will be able to 1. Choose forming techniques for various applications 2. Estimate power requirement for forming processes 3. Calculate the forming limit for various processes

Unit I Theory of Plasticity

Theory of Plasticity - stress tensor – hydrostatic & deviator components of stress – flow curve – true stress strain – yielding criteria – yield locus – octahedral shear stress and shear strains – invariants of stress strain – slip line field theory plastic deformations of crystals. Unit II Plastic Forming of Metals – Forging Basics of plastic forming & forging- mechanics of metal working – temperature in metal working – strain rate effects – friction and lubrication – deformation zone geometry. Forging process – classification – equipment – calculation of forging loads – forging defects – residual stresses. Unit III Plastic Forming of Metals – Rolling and Extrusion Rolling and Extrusion – classification -rolling mills - rolling of bars & shapes – rolling forces – analysis of rolling – defects in rolling- theories of hot & cold rolling – torque & power estimation. Extrusion: classification-equipment – deformation lubrication and defects – analysis – hydrostatic extrusion – tube extrusion. Unit IV Plastic Forming of Metals – Drawing and Sheet metal Forming Drawing & Sheet Metal Forming- rod & wire drawing equipment – analysis – deep drawing – tube drawing – analysis, residual stresses. Sheet metal forming – methods – shearing and blanking – bending – stretch forming – deep drawing – forming limit criteria – defects -Stretch forming – press brake forming – explosive forming. Unit V Unconventional Forming Methods Electro hydraulic forming – magnetic pulse forming – super plastic forming – electro forming – fine blanking – P/M forging-Isothermal forging – HERF. Text Books Gerorge E Dieter, Mechanical Mettulurgy , TataMcGraw Hill, 2007 References

1. B L Juneja, Fundamentals of Metal Forming Processes, New Age International. 2. John A Schey, Introduction to Manufacturing Process, Allied, ND. 3. ASM, Hand book: Forming and Forging.


MEE574 Additive Manufacturing Technology 3 0 0 3

Version No. 1.00 Prerequisite Nil Objectives: 1. To introduce students the basics of rapid prototyping/manufacturing technologies and

systems and its applications in various fields, reverse engineering techniques, CAD modeling techniques such as surface and solid models, and their use in rapid prototyping applications. 2. To familiarize students how commercial rapid prototyping systems use these models to perform activities such as part building, materials used etc. 3. To teach students about mechanical properties and geometric issues relating to specific rapid prototyping applications.

Expected Outcome:

1. Demonstrate the knowledge of Rapid Prototyping/Manufacturing technologies. 2. Get exposed to commercial Rapid Prototyping systems. 3. Possess the knowledge of Rapid Prototyping software. 4. Model and manufacture RP components.

Unit I Classification of manufacturing processes, Different manufacturing systems, Introduction to rapidprototyping (RP), Need of RP in context of batch production, FMS and CIM and their application, Basic principles of RP, Steps in RP, Process chain in RP in integrated CAD- CAM environment, Advantages of RP,Medical applications. Unit II Classification of different RP techniques – based on raw materials, layering technique (2-D or 3-D) and energy sources: Process technology and comparative study of: Stereo-lithography (SL) with photopolymerisation, SL with liquid thermal polymerisation, Solid foil polymerisation, Unit III Selective laser sintering, Selective powder binding, ballistic particle manufacturing – both 2-D and 3-D, Fused deposition modelling, Shape melting, Laminated object manufacturing, Solid ground curing, Repetitive masking and deposition, Beam interference solidification, Holographic interference solidification. Unit IV Special topic on RP using metallic alloys – Laser Engineered Net Shaping and Electron Beam Melting, Shape Deposition Manufacturing (SDM): Introduction, basic process, shape decomposition, mold SDM and applications. Selective Laser Melting, Electron Beam Melting – Rapid Manufacturing, Rapid tooling. Unit V Reverse Engineering, RP data preparation: Solid modelling – Representation of 3D model in STL format, Repair of STL files, Tesselated model - File formats - Build orientation and support structures Object Slicing methods, Tool path generation. Programming in RP. Text Books 1. Chua C. K., Leong K. F., and Lim C. S., (2003), Rapid Prototyping: Principles and Applications, Second Edition, World Scientific Publishers. 2. Ma W. and Venuvinod P., Rapid Prototyping and Other Laser based processes, 2004, Kluwer Academic Press. References 1. Peter D. Hilton, Hilton/Jacobs, Paul F. Jacobs, (2000), Rapid Tooling: Technologies and Industrial Applications, CRC Press. 2. Beaman, J. J. et al., (1997), Solid Freedom Fabrication, Kluwer. 3. Burns, M., (1993), Automated fabrication, Prentice-Hall. 4. Liou W. Liou, Frank W. Liou, (2007), Rapid Prototyping and Engineering applications: A Tool Box for Prototype Development, CRC Press. 5. Ali K. Kamrani, Emad Abouel Nasr, (2006), Rapid Prototyping: Theory and Practice, Springer. 6. Jacobs, P. F., (1996), Stereolithography and other RP&M technologies, ASME. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 14 July 2011 Date of Approval by the Academic Council 30 Aug 2011

MEE575 Manufacturing Of Composite Materials 2 1 0 3 Version No. 1.00 Prerequisite Nil Objectives: To understand the fundamentals of composite materials.

Understand the manufacturing of various composites. To Understand and analyze the reinforced composite design and performance for

different combinations and orientations of reinforcements. To understand the properties and Hygro-Thermo-Mechanical degradation of

composite materials and conduct application oriented case studies. Expected outcome Students would be able to understand, analyse and select suitable manufacturing

Expected Outcome:

Students would be able to understand, analyse and select suitable manufacturing

Unit I INTRODUCTION AND MATERIALS Definition –Need – General Characteristics, Reinforcements and Matrices – Polymer, Ceramic, Metal Matrix and Carbon/Carbon composites – Nano composites. Superiority of composites to conventional materials, Applications in automotive, mechanical, civil and aerospace se Unit II RAW MATERIALS Introduction, Reinforcements manufacturing, Matrix materials manufacturing, Fabric constructions, 3D Braided performs, Pepregs, Moulding compounds-SMC,BMC,DM Unit III COMPOSITES MANUFACTURING Manufacture of PMCs, RRIM, VARTEM and SCRIMP, Manufacture of MMCs C/C and CMCs, Solid State Fabrication Techniques - Diffusion Bonding - Powder Metallurgy Techniques - Plasma Spray, Chemical and Physical Vapour Deposition of Matrix on Fibres - Liquid State Fabrication Methods - Infiltration -Squeeze Casting - Rheo Casting – Compocasting, stir casting, sol-gel method - Interdiffusion, electrostatic, chemical, mechanical. Fabrication of FRP reinforced concrete, CAD/CAM. Unit IV SECONDARY MANUFACTURING OF COMPOSITES Fundamentals of design for manufacturing, Implementation, Design evaluation method, Design for assembly, Joining and jointing of composites, Welding of thermoplastics and MMCs, Bonding of ceramic matrix composites, Machining and cutting of composites, conventional and unconventional methods of machining, Unit V Composite Performance

Mechanical behaviour of laminated plates. Composite beams in tension, compression, shear and Flexure, Composite beam in Torsion, Different mode of failure of the composite structures, Failure of lamina and laminated structures, Failure of sandwich composite, Long term environmental effect, Inter-laminar failure, Failure due to fracture and fatigue, Damage due to impact loads, Creep, Health monitoring of composite structures, Interface damage. Text Books Sanjay K Majumdar, Composites Manufacturing, CRC Press , 2001. References 1.Mallick, P.K., Fiber –Reinforced Composites: Materials, Manufacturing and Design”, Marcel Dekker Inc, 1993. 2. Derek Hull and TW Clyne, Introduction to composite Materials, Cambridge University Press, 1996. 3. Agarwal, B.D., and Broutman L.J., “Analysis and Performance of Fiber Composites”, 4. John Wiley and Sons, New York, 1990. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 12.05.2012 Date of Approval by the Academic Council 18.05.2012

MEE576 Surface Engineered Materials Technology 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: 1. To teach students the basic concepts of surface engineering and its

development 2. To provide students the knowledge of coatings and the formation of technological

surface layers 3. To enable the students understand the basic principles of Laser Technology and

Plasma Coating Technology Expected Outcome:

Student will be able to 1. Develop and apply various surface modifications technologies 2. Find applications of coating processes in industries

Unit I Development of surface engineering Development of surface Engineering – Solid surface – Geometrical and mechanical concepts- Wear- Abrasive wear- Erosion wear – Erosion – Corrosion- Surface roughness- Metallogrphic structure – Need for surface coatings- Enhancement of wear and prevention of corrosion Unit II Concepts of coating Coatings- Concepts of coatings – Metallic and non metallic coatings- Galvanizing – Spray and cladded coatings- Principles parameters of coatings – Thickness measurement – Physico and chemical parameters of coatings – Surface characterization – GIXRD - microstructure - SIMS - Roughness measurement – Profilometer. Unit III Formation of Technological Surface Layers Formation of technological surface layers – Techniques – Physical vapor deposition – Chemical vapor deposition - electron beam technology – Principles underlying the electron beam impingement – Acceleration of electrons – Electron guns – Interaction of electron beam with treated material – Applications of electron beam coating in surface engineering Unit IV Laser Technology Laser technology – CO2 and Nd: YAG lasers - processing parameters – Continuos and pulsed operations – Properties of laser – Temperature distribution in laser treated material – Depth of penetration of photons – Hard coatings – Applications of laser in surface engineering - Ion implantation techniques – Physical principal of ion beam implantation – Pulsed and continuos ion beam implantation – Tribological properties of ion implanted materials – Strength – Hardness and adhesion of implanted materials- Advantages and disadvantages Unit V Plasma Coating Technology Plasma coating technology – Processing parameters- Plasma nitriding – Oxy nitriding – Nitro carburizing - boriding- Characterization of Cr –N coatings – Plasma nitrided steels and titanium alloys – Corrosion and wear behavior – Super hard biocompatible coating for medical implants – Carbon like diamond coating- -Nano surface coatings- Comparative study of various coating process in industry Text Books Plasma surface engineering, (2004), Proce DAE-BRNS workshop References 1. D.Setas , A.Tacton, Mercel –Dekker, (2001), Coatings technology handbook I Editors: 1. Bharat Bhushan, (2000), Principles and application of tribology, John Wiley Sons 2. Surface Modification Technologies Vol. XI and XII, Ed: T. Sudarshan et al – TMS Conference

Proceedings Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on: 14 July 2011 Date of approval by the Academic Council: 30 Aug 2011

MEE577 Enterprise Resource Planning And Supply Chain Management 3 0 0 3

Version No. 1.00 Prerequisite Nil Objectives: Expected Outcome:

Having successfully completed the course, the student will be able to: 1. Understand ERP systems and its modules and its application to industries 2. Understand ERP related technologies and its module design 3. Understand the effect of supply chain on business operations 4. Be able to formulate basic supply network distribution models

Unit I Introduction To ERP, Evolution of ERP, Reasons for the growth of ERP, Scenario and Justification of ERP in India, Evaluation of ERP, Various Modules of ERP, Advantage of ERP.

Unit II Integrated Management Information, Business Modelling, ERP for Small Business, ERP for make to order companies, Business Process Mapping for ERP Module Design, Hardware Environment and its Selection for ERP Implementation.

Unit III ERP and Related Technologies, Business Process Reengineering (BPR), Management Information System (MIS), Executive Information System (EIS), Decision support System (DSS), ERP Modules: Quality Management, Materials Management

Unit IV Understanding the Supply Chain, Objectives of Supply chain, Importance of Supply chain decision, Decision phases in a supply chain, Supply chain performance,

Unit V Drivers of Supply Chain Performance, Framework for structuring drivers, Role of distribution in the supply chain, Design options for a distribution network, Role of network design in supply chain, Case studies and related problems, Role of IT in supply chain

Text Books References

1. Joseph A Brady, Ellen F Monk, Bret Wagner, “Concepts in Enterprise Resource Planning”, Thompson Course Technology, USA, 2001.

2. Vinod Kumar Garg and Venkitakrishnan N K, “Enterprise Resource Planning – Concepts and Practice”, PHI, New Delhi, 2003

3. Alexis Leon, “ERP Demystified”, Tata McGraw Hill, New Delhi, 2000 4. Chopra, Sunil, Peter Meindl, Supply Chain Management: Strategy, Planning and Operations, 3rd

Edition, Pearson Education, USA, 2006

Mode of Evaluation Seminar Quiz/Assignment/ Seminar/Written Examination

Recommended by the Board of Studies on 14 July 2011 Date of Approval by the Academic Council 30 Aug 2011

MEE515 Product design and life cycle management 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: Machine design, Manufacturing Technology, Work Study. Objectives To make the student to be

familiar with The new product management process Product lifecycle management stages The DFx concepts from the conception to recovery or disposal Applying analytic methods for all stages of product planning, development, la

and control Expected Outcome:

Upon completion the course, student will be familiar with

The new product management process Product lifecycle management stages The DFx concepts from the conception to recovery or disposal Applying analytic methods for all stages of product planning, development, launch,

and control Development and implementation of a product development and management strategy

within a simulated environment, including product platform, branding, pricing, distribuand promotion decisions.

Performing the decision analysis on new product development Assessing and improving product development and management performance in the

context of a case study Unit I Introduction Product development – Trends affecting product development – Best practices for product development – Product development process and organizations – Collaborative product development – concurrent engineering – risk management - Stages of Product development Unit II Product Development Life cycle – I Early design – Requirement Definition and Conceptual design - Trade-off Analysis – Optimization using cost and utility metrics – Trade-off analysis models and parameters- design to cost – Design to Life cycle cost – Design for warranties. Unit III Product Development Life cycle – II Detailed design – Analysis and modeling – Best practices for detailed design – Design analyses – Prototypes in detailed design – Test and Evaluation – Design review, prototyping – simulation and testing – Manufacturing – Strategies – planning and methodologies. Unit IV Product Development Life cycle – III Supply chain – Logistics, packaging, supply chain and the environment – ISO 14000/210 – Design for people – Ergonomics, Repairability, maintainability, safety and product liability – Task analysis and failure mode analysis. Unit V Producibility and Reliability Reducibility – strategies in design for manufacturing – requirements for optimizing design and manufacturing decisions – Simplification – commonality and preferred methods – Modularity and scalability – part reduction – functional analysis and value engineering – Reliability – Strategies and practices – Testability – Design for test and inspection. Text Books References 1. John W. Priest and Jose M. Sanchez, “P r o d u c t development and design for manufacturing- A 2. collaborative approach to produciability and reliability”, Marcel Dekker Publications, 2001. 3. Stephen C. Armstrong, “ Engineering and pr o duc t develo pment ma na ge me nt – t he h ol i s ti c

approach”, Cambridge university press, 2001. 4. Thomas A. Sabomone, “What every engineer should know about concurrent engineering”, Marcel Dekker

Publications, 1995. 5. Karl T. Ulrich, Ateven D. Eppinger “Product Design and Development” Tata McGraw-Hill, 2003. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 14 July 2011 Date of Approval by the Academic Council 30 Aug 2011

MEE578 Manufacturing System And Simulation 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: Ability to understand the underlying features of discrete event simulation

and how it is applicable for analyses and development of manufacturing systems.

To understand the concept of simulation and to learn the simulation language. To enable application of simulation to manufacturing systems and to gain hands

on experiences from how discrete event simulation is applied based on an industrial needs.

Expected Outcome:

Upon completion of this course the student shall be able to: Identify and formulate advance problems and apply knowledge of mathematics

and simulation packages to solve manufacturing problems. Use the techniques, skills, and modern packages, necessary for professional

practices. Unit I Computer modeling and simulation system Introduction to simulation- steps in simulation-nature of computer modeling and simulation- types of models- Monte Carlo simulation, limitation of simulation, areas of application, examples. Components of a system- discrete and continuous systems- Examples, Model of a system-variety of modeling approaches. Unit II Random number generation Properties of random numbers, Random number generation techniques-the mid product method- constant multiplier technique- additive congruential method- linear congruential method, Test for random numbers- frequency tests- test for autocorrelation. Unit III Random variable generation Random variable generation –inverse transform technique- exponential distribution – uniform distribution- Weibull distribution- triangular distribution. Empirical continuous distribution- generating approximate normal variates- Erlang distribution. Unit IV Distribution and evaluation of experiments Discrete uniform distribution- Poisson distribution- geometric distribution- acceptance and rejection technique for poisson , gamma distribution. Variance reduction techniques- antithetic variables- Validation of simulation models- Verification of simulation models. Unit V Discrete event simulation Concepts in discrete-event simulation- manual simulation using event scheduling, simulation of queuing system, simulation of inventory systems. Simulation of manufacturing and material handling systems. Introduction to Simulation packages – simulation using spreadsheet, SimQuick, WITNESS, ARENA, GPSS. Programming for discrete event systems in GPSS- case studies. Text Books

1. Jerry Banks, John S. Carson II and Barry L. Nelson. “Discrete- Event System Simulation”. Prentice hall Inc.1984.

2. G. Gordon, “System Simulation” Prentice hall Inc.1991. References

1. Francis Neelamkovil, “Computer Simulation and Modeling.” John wiley & Sons, 1987. 2. Narsing Deo, “ System Simulation with Digital Computer.’ Prentice hall of India, 1979. 3. Ruth M. Davis and Robert M.O’ keefe, “ Simulation Modeling with Pascal.” Prentice Hall Inc,

1989. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 14 July 2011 Date of Approval by the Academic Council 30 Aug 2011

MEE579 Maintenance Engineering And Management 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: Reliability, Quality Management.

To introduce Maintenance Engineering and Engineering Management as a specialized discipline for high operational efficiency and minimized downtime.

• To acquaint with the principles of Condition Based Maintenance as the most cost effective and reliable maintenance policy involving various condition monitoring techniques for effective diagnosis.

Expected Outcome:

Upon completion of this course, the student shall be able to: • Familiarize the general maintenance procedures followed in

practice regarding preventive schedules, network and queuing policies, spares management and replacement policies.

Contents • Introduction • Reliability Engineering • Maintenance Planning and Organization • Quantitative Techniques and Network Analysis • Integrated logistics support – ILS concept, Life-cycle costs,

maintenance engineering analysis, support requirements. Unit I Introduction to maintenance engineering and management, profitability, function, objectives, planning and control. Failure statistics – probability theories and functions, decision making, weibull distribution, application and limitations of failure statistics to maintenance management. Unit II Reliability engineering and maintenance – reliability prediction of series and paralle connected components, reliability testing and preventive maintenance, maintainability rediction and testing equipment availability. Unit III Maintenance planning – policies, preventive and corrective, condition based, opportunity and design-out maintenance, determination of maintenance plan, maintenance organization, Computer Aided Maintenance Management. Organization of maintenance resources – resources structure, administrative structure, work planning and scheduling. Unit IV Quantitative techniques – Preventive replacement – Individual breakdown replacement policy – Individual preventive replacement policy – Preventive group replacement – Preventive verses breakdown maintenance – Queuing theory applications in maintenance planning and control of spare parts – Regular spares – Insurance spares – Capital spares – Rotable spares – Spares inventory control – models for evaluating EOQ, safety stock, two-bin and periodic system maintenance policy Unit V Management techniques in maintenance management-job reform, motivation and reorganization of maintenance trade force Text Books References

1. Siegmund Halpen, “The assurance sciences”, Prentice Hall of India, 1979. 2. A.Kelly and MJ Harris, “Management of Industrial Maintenance”, Newnes – Butter worths, 1978. 3. Kishan Bagadia, “Micro-Computer Aidede Maintenance Management”,

Marcell - Dekker, 1987. 4. David J Smith, “Reliability and Maintainability in perspective”, The Macmillan

Press Ltd., 1981. 5. Chary S.N., “Production and Operations Management”, Tata McGraw Hill

Publishing Company, New Delhi, 1992. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 14 July 2011 Date of Approval by the Academic Council 30 Aug 2011

MEE580 Concurent Engineering 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: To introduce the concepts of concurrent engineering, design

methodologies and use of information technology in manufacturing. To familiarize with intelligent design for manufacturing.

Expected Outcome:

On completion of this course, the student shall be able to acquire knowledge on concurrent engineering process for advanced manufacturing systems.

Unit I Introduction Extensive definition of CE - CE design methodologies - Organizing for CE - CE tool box collaborative product development. Unit II Use of Information Technology IT support - Solid modeling - Product data management - Collaborative product commerce – Artificial Intelligence - Expert systems - Software hardware co-design. Unit III Design Stage Life-cycle design of products - opportunity for manufacturing enterprises - modality of CE Design - Automated analysis idealization control - Concurrent engineering in optimal structural design - Real time constraints. Unit IV Manufacturing Concepts and Analysis Manufacturing competitiveness - Checking the design process - conceptual design mechanism – Qualitative physial approach - An intelligent design for manufacturing system - JIT system - low inventory - modular - Modeling and reasoning for computer based assembly planning - Design of Automated manufacturing. Unit V Project Management

Life Cycle semi realization - design for economics - evaluation of design for manufacturing cost – concurrent mechanical design - decomposition in concurrent design - negotiation in concurrent engineering design studies - product realization taxonomy - plan for Project Management on new product development – bottleneck technology development. Text Books References

1. Anderson MM and Hein, L. Berlin, "Integrated Product Development", Springer Verlog, 1987.

2. J. Cleetus "Design for Concurrent Engineering", Concurrent Engg. Research Centre, Morgantown, WV, 1992.

3. Andrew Kusaik, "Concurrent Engineering: Automation Tools and Technology", Wiley, John and Sons Inc., 1992.

4. Prasad, "Concurrent Engineering Fundamentals: Integrated Product Development", Prentice Hall, 1996.

5. Sammy G Sinha, "Successful Implementation of Concurrent Product and Process", Wiley, John and Sons Inc., 1998.


MEE581 Manufacturing Information Systems 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: To familiarize with designing data base.

To introduce the concepts of information systems for manufacturing Expected Outcome:

On completion of this course, the student will be able to acquire knowledge of manufacturing information systems, production control systems, database models and shop floor control models.

Unit I Introduction The evolution of order policies, from MRP to MRP II, the role of Production organization, Operations control. Unit II Database Terminologies - Entities and attributes - Data models, schema and subschema - Data Independence – ER Diagram - Trends in database. Unit III Designing Database Hierarchical model - Network approach - Relational Data model -concepts, principles, keys, relational operations - functional dependence -Normalisation, types - Query languages. Unit IV Manufacturing Consideration Product and its structure, Inventory and process flow - Shop floor control - Data structure and procedure - various models - order scheduling module, input / output analysis module stock status database – complete IOM database. Unit V Information System for Manufacturing Parts oriented production information system - concepts and structure -computerised production scheduling, online production control systems, computer based production management system, computerised manufacturing information system - case study. Text Books References

1. Luca G. Sartori, " Manufacturing Information Systems ", Addison-Wesley Publishing Company, 1988.

2. C.J. Date., “An Introduction to Database systems ", Narosa Publishing House, 1997. 3. G. Orlicky, " Material Requirements Planning ", McGraw-Hill Publishing Co., 1975. 4. R. Kerr, “Knowledge based Manufacturing Management ", Addison-Wesley, 1991.


MEE617 Laser Materials Processing 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: • To make student familiar with use of laser for industrial application

• To train students on the material processing applications of laser for automotive, aerospace and shipbuilding applications

Expected Outcome:

At the end of the course, student will be familiar with all material processing capabilities of LASER and its implications in the production processes.

Unit I Main industrial lasers: He-Ne, CO2, Excimer, Nd:YAG, Diode, Fiber and Ultra-short pulse lasers and their output beam characteristics; laser beam delivery systems. Overview of Industrial & Scientific Applications of laser: Metrological applications, Holography, Laser Isotope Separation, Laser fusion. Unit II Laser processing fundamentals: Laser beam interaction with metal, semiconductor and insulator, Ultra-short laser pulse interaction, heat flow theory and metallurgical considerations. Unit III Laser Material Processing Applications: Laser cutting and drilling: Process characteristics, material removal modes, practical performances. Laser welding: Process mechanisms like keyhole and plasma effect, operating characteristics and process variation. Laser surface modifications: Heat treatment, surface remelting, surface alloying and cladding, surface texturing, LCVD and LPVD. Unit IV Laser rapid manufacturing. Laser metal forming: Mechanisms involved including thermal temperature gradient, buckling, upsetting. Laser peening: Fundamentals of Laser Shock Processing, Effects of various laser and process parameters, Mechanical effects and microstructure modification during laser shock processing. Unit V Theoretical modelling of laser material processing. On-line Process monitoring & control: Laser and process parameters, and workpiece characteristics. Economics of Laser Applications in Manufacturing. Laser Safety: Laser safety standards and safety procedures. Text Books 1. Steen, William M., Mazumder, Jyotirmoy, Laser Material Processing by William M.Steen, Springer-Verlag 3rd Ed., 2010 References 2. Elijah Kannatey-Asibu, Jr, Principles of Laser Materials Processing, John Wiley & Sons, USA, 2009 3. John IonLaser Processing of Engineering Materials: Principles, Procedure and Industrial Application, Butterworth Heinemann,2005. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 12.05.2012 Date of Approval by the Academic Council 18.05.2012

MEE618 Electronic Manufacturing Assembly And Packaging 3 0 0 3 Version No. 1.00 Prerequisite Nil Objectives: • To educate the manufacturing engineering students the importance of electronic

materials and manufacturing • To enable the students to learn about electronic materials characterization • To teach the students the elements of electronic packaging, assembly and reliability

Expected Outcome:

• At the end of the course the student should be able to master the manufacturing techniques of electronic materials. • The student should be able to characterize the electronic materials • Understand and be able to work on projects involving electronic packaging, assembly and reliability.

Unit I Electronic materials and Manufacturing Introduction to electronic materials, Silicon and compound semiconductors, Single polycrystalline and amorphous semiconductors and manufacturing, Czochralski, Bridgeman and Float zone techniques, Neutron Transmutation Doping, Thick film and Thin films , Vapour deposition and Solution based processes to grow semiconductors, Equipment details for manufacturing. Unit II Wafer Manufacturing and Characterization Wafer production, Slicing, Lapping, Polishing, Photolithography, Screen printing, Diffusion processes, Wafers for semiconductor devices and Photovoltaic applications, Semiconductor characterization techniques- Thermal, Sonic, Microscopic, Spectroscopic and Optical methods, X ray characterization, Etching and etch pit dislocations, Equipment for wafering and characterization, Quality control. Unit III Fundamentals of Electronic Packaging Micro and Nanosystems packaging, The need , characteristics and packaging road map, Types of electronic packaging, Metal, ceramic and plastic packaging, ICs and IC packaging, Dual and quad packaging, BGAs, Wafer Level, Flip-chip and Multichip packaging, Role of these packages in automotive, computer, telecom, medical, consumer electronics and MEMS applications. Unit IV Electronic Assembly Different stages of IC manufacture, Finished wafer dicing, Die attach to lead frames, Wire bonding, Packaging-encapsulation and sealing, Singulation, Instruments, Equipment and Stations used for IC assembly, PCB and PWB manufacturing, Solder materials and soldering, Interconnects, Microvia boards, Surface mount technology, Through hole assembly, Applications, Statistical fundamentals in manufacturing and assembly. Unit V Design, Failure and Reliability in Electronic Packaging Design factors in microsystem packaging, CAD tools for electronic packaging and assembly, Thermal management of Devices, Boards and Electronic equipment, Fundamentals of failures-Electrical, Chemical and Thermo-mechanically induced Failures, Reliability and Durability ( environmental attack and protection), Reliability qualification tests, Fatigue , Design for environment in electronics, toxicity free manufacturing, Life cycle assessment and management. Text Books Rao R Tummala, Fundamentals of Microsystems Packaging, McGraw –Hill, 2001. References 1. Charles A Harper, Electronic packaging and interconnection handbook, 4th Ed, McGraw -Hill hand books. 2004. 2. Subash Mahajan and K S Sree Harsha, Principles of growth and processing of semiconductors- McGraw-Hill Series, 1998. 3. Dhanaraj G, Byrappa K, Prasad V, Dudley M- Springer Hand book of crystal growth, 1st Ed, 2010. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 14 July 2011 Date of Approval by the Academic Council 30 Aug 2011

MEE 619 Computer Graphics and Geometric Modeling 2 1 2 4

Version No. 1.00 Prerequisite Nil Objectives: This course Provides comprehensive introduction to computer applications

including geometric modeling and computer graphics. Expected Outcome:

On completion of this course the students will be able to acquire knowledge of the applications of computers in design and manufacturing activity

Unit I Introduction to Computer graphics and Database Definition, Product cycle & CAD/CAM, Automation & CAD/CAM Introduction, Software configuration of a Graphic system, Functions of a Graphics package, Data Base Structure and Content, CAD applications, Line, Circle and Ellipse drawing algorithms, Windowing and Clipping, Lighting and shading, Hidden surface/solid removal, Color models, Two dimensional transformations, Three-dimensional transformations, Linear transformations. Unit II Geometric Modeling Dimensions of models, Types of models, Construction of solid models. Wire frame Models, Wire frame Entities, Curve Representation. Parametric Representation of Analytic Curves - Review of Vector Algebra, Lines, Circles, Ellipses, Parabolas, Hyperbolas, Conics. Parametric Representation of Synthetic Curves - Hermite Cubic Splines, Bezier Curves, B-Spline Curves, Rational Curves. Curve Manipulations. Unit III Surface Modeling Introduction Surface Models, Surface Entities, Surface Représentation, Parametric Representation of Analytic Surfaces - Plane Surface, Ruled Surface, Surface of Revolution, Tabulated Cylinder. Parametric Representation of Synthetic Surfaces - Hermit Bicubic Surface, Bezier Surface, B-Spline Surface, Coons Surface, Blending Surface, Offset Surface, Triangular Patches, Sculptured Surface, Rational Parametric Surface. Unit IV Assembly Modeling Mechanical Assembly: Introduction, Assembly Modeling - Parts Modeling & Representation, Hierarchical Relationships, Mating Conditions. Inference of position from mating conditions. Representation schemes - Graph structure, Location graph, Virtual Link. Generation of Assembling Sequences - Precedence Diagram, Liaison-Sequence analysis, Precedence Graph. Assembly Analysis. Unit V Recent Developments Data exchange standards, Multi-resolution models, Heterogenous modeling, Meshing algorithms, Surface reconstruction from point cloud data, computational geometry applications in CAD, Collaborative design, product data modeling. Text Books

1. CAD/CAM: Principles and Applications 3rd Edition, Tata McGraw Hill, India, 2010, Veera B. Anand 2. Ibrahim Zeid and R. Sivasubramaniam, 2nd Edition, Tata McGraw Hill, India, 2009

References 3. Micheal E. Mortenson, Geometric Modeling, Wiley, 1997. 4. Gerald E. Farin, Hans Hagen, Hartmut Noltemeier and Walter Knödel, Geometric Modeling, Springer-Verlag, 1993 5. Anupam Saxena, Birendra Sahay, Computer aided Engineering design, Springer, 2010. Mode of Evaluation Quiz/Assignment/ Seminar/Written Examination Recommended by the Board of Studies on 12.05.2012 Date of Approval by the Academic Council 18.05.2012

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