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|09PP01 STATISTICS AND QUALITY CONTROL|
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SAMPLING DISTRIBUTIONS: Sampling - Types of sampling – Sampling distributions – t distribution, F distribution, Chi-square distribution. (3)
STATISTICAL INFERENCE: Point estimation, characteristics of estimation. Methods of estimation - Interval estimation - interval estimates of mean, standard deviation, proportion, difference in means and ratios of standard deviations. (4)
TESTING OF HYPOTHESIS: Large sample tests - tests for means, variances and proportions. Small sample tests – Tests based on t,F, and chi-square distributions. (6)
DESIGN OF EXPERIMENTS AND ANALYSIS OF VARIANCE: Design of Experiments - One way and Two way classifications - Completely randomized design, Randomized block design and Latin square design. (6)
CONTROL CHARTS: Statistical basis for control charts – control limits – specification limits – tolerance limits – revised control limits – control charts for variables - charts, charts for defective - charts – charts for defects - charts. (4)
CORRELATION AND REGRESSIONS: Simple correlation and regression, multiple regression analysis, multiple and partial correlation coefficients (4)
SAMPLING CONCEPTS: Introduction - Single sampling plan – Double sampling plan – Multiple sampling plan – Type A and type B OC curves, consumer’s risk, producer’s risk. ASN, ATI, AOQ curves, MIL-STD-105D sampling plans. (8)
SAMPLING PLANS: Lot-by-Lot acceptance sampling plans for attributes – Dodge – Roming tables – Philips standard sampling system – chain sampling inspection plan – sequential sampling plan – skip-lot sampling plans. Acceptance sampling plans. Acceptance sampling for continuous productions – CSP-1 plans, CSP-2 plans. (7)
1. Walpole R E, Myers S.L. and Keying YE, “Probability & Statistics for Engineers & Scientists”, Prentice Hall, 2007.
2. Fiegenbaum AV, “Total Quality Control”, McGraw Hill, 2004.
3. Johnson R A, ”Probability and Statistics for Engineers”, Pearson Education, 2002.
4. Douglas Montgomery, “Introduction to Statistical Quality Control”, Wiley & Sons, 2001.
09PP02 TOOL DESIGN
3 2 0 4
ROLE OF DESIGN ENGINEER: Position in the organization structure, importance of tool design in PLM, importance of tool design in process planning and selection of machine tool. (2)
DESIGN OF SINGLE POINT TOOLS: Design of form tools, Selection of tool materials for different application, ISO standard for Inserts, tool holders, Selection of inserts and tool holders for specific examples. (5)
DESIGN OF MULTI POINT TOOLS: Design of Drills, Reamers, Milling cutters, Tapes and dies, Broaching tools, Gear cutting tools, Thread milling tools for CNC Machining Centers. (9)
DESIGN OF CHUCKING SYSTEMS: For CNC turning applications. (2)
DESIGN OF JIGS AND FIXTURES: Design of drill jigs and milling fixtures. Welding fixtures, modular fixtures. (6)
DESIGN OF TOOLS FOR PRESS WORK: Design of simple, compound and progressive tools, study of power presses and accessories, Application of EDM for tool making. (8)
DESIGN OF PLASTIC MOLD DESIGN: Design of Thermo plastic tools, two and three plate, design of runner, gate, cooling line, ejection. (7)
DESIGN OF GAUGES: Plug, Ring, Snap, thread gauges, Application of Sine bar, Slip gauges and Air gauges, Toolings for Casting. (3)
1. C Donaldson, “Tool Design”, Tata McGraw Hill, 2008.
2. E G Hoffman, “Jigs and Fixtures Design”, Thomson Learning, 2004.
3. Pye R G W, “Injection Mold Design”, East West Press, 2001.
4. Kempster M H A, “An Introduction to Jig and Tool Design”, Viva books, 1998.
5. HMT, “Production Technology”, Tata McGraw Hill, 1992.
6. Arshinov V, “Metal Cutting Theory and Cutting Tool Design”, MIR, 1979.
7. Publications from Sandvik, Widia, Taegutec, Ceramtec.
8. Ostergaurd D E, “Advanced Die Making”, Tata McGraw Hill.
09PP03 ADVANCED METROLOGY AND QUALITY ENGINEERING
3 0 0 3
LASER METROLOGY: Free electron laser – optical alignment, measurement of distance – interferometry, reversible counting, refractive index correction, reversible counting, refractive index correction, surface topography and optical component testing, beam modulation telemetry, pulse-echo techniques surface velocity measurements using speckle patterns – laser spectroscopy – modular beam spectroscopy, saturation spectroscopy, two photon spectroscopy. (6)
HOLOGRAPHY: Basic principles – holographic interferometry – double exposure holographic interferometery – sandwich holograms, real time holography, time-average holographic interferometer – character recognition. (6)
COORDINATE MEASURING MACHINE (CMM) AND MACHINE VISION: Fundamental features of CMM – development of CMMs – role of CMMs – types of CMMs – modes of operation – types of probes – probe calibration – non-contact type probes – direct computer control – software packages – operational modes – metrological features – co-ordinate systems – portable arm CMMs – machine vision systems – illumination – magnification – vision system measurement – multisensor systems. (6)
QUALITY IN MANUFACTURING ENGINEERING: Importance of manufacturing planning for quality – initial planning for quality – concept of controllability: self controls – defining quality responsibilities on the factory flow – self inspection – automated manufacturing – overall review of manufacturing planning – process quality audits – quality and production floor culture. (6)
QUALITY IN DESIGN ENGINEERING: Opportunities for improvement product design - early warning concepts and design assurance - designing for basic functional requirements – designing for time oriented performance (reliability) – availability – designing for safety – designing for manufacturability – cost and product performance – cost of quality – design review – concurrent engineering – improving the effectiveness of product development. (6)
QUALITY MANAGEMENT SYSTEM: Need for quality management system – design of quality management system - quality management system requirements – ISO 9001 and other management systems and models - improvements made to quality management systems. (6)
CONTINUOUS IMPROVEMENT: Basic quality engineering tools and techniques - statistical process control - techniques for process design and improvement - Taguchi methods for process improvement - six sigma - the ‘DRIVE’ framework for continuous improvement. (6)
1. Oakland J S, “Total Quality Management - Text with Cases”, Butterworth – Heinemann – An Imprint of Elseiver, First Indian Print, 2005.
2. Nambiar K R, “Lasers – Principles, Types and Applications’, New Age International Limited Publishers, 2004.
3. Dotson C, Harlow R and Thompson R, “Fundamentals of Dimensional Metrology”, Thomson Delmer Learning, Singapore, 4th Edition, 2003.
4. John A Bosch, Giddings and Lewis Dayton, “Coordinate Measuring Machines and Systems”, Marcel Dekker, Inc., 1999.
5. Juran J M and Gryna F M, “Quality Planning and Analysis”, Tata McGraw Hill Edition, 1995.
6. Wilson J and Hawker J F B, “Lasers – Principles and Applications”, Prentice Hall, 1987.
09PP04/09PD07 ADVANCED MATERIALS ENGINEERING
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CLASSIFICATION: Metals, ceramics, glasses, elastomers, polymers, composites, smart materials, members of each class, nano science materials, material properties viz mechanical, thermal, wear, corrosion / oxidation. (3)
MATERIAL SELECTION: Selection strategy, property limits and material indices, function objectives and constants, performance maximizing criteria, strengthening mechanisms. (3)
MATERIAL PROPERTY CHARTS: Modulus - density, strength – density, modulus – strength, specific stiffness and specific strength, fracture toughness, modulus fracture etc. (3)
SELECTION OF MATERIALS AND SHAPE: Shape factors, elastic extrusion, elastic body and twisting, failure, bending and twisting, axial loading and column buckling, efficiency of standard sections, material limits for shape factors, microscopic shape and shape factors. (4)
CHARACTERIZATION OF MATERIALS: X-ray diffraction, SEM, TEM - crystal structure and phase identification, residual stress measurement, thermal analysis, fractography. (4)
FERROUS AND NON FERROUS ALLOYS: Types of cast irons, properties, structures, compositions and applications, plain carbon steels, low alloy steels and effects of alloying elements, high alloy steels, stainless steels and types, tool steels, manganese steels, heat resistant steels, HSLA, UHSLA, Dual phase steels, TRIP and IF steels, maraging steels, Alloys of aluminium, copper, nickel, magnesium, titanium, lead, tin, zinc and other important alloys- compositions, heat treatments, structures, properties, applications, castability, formability, machinability, hardenability and weldability of ferrous and non ferrous material, selection of materials as case studies. (12)
SUPER ALLOYS: Fe base, Ni base, Co base, ODS super alloys. (2)
NON-METALLIC MATERIALS: Ceramics, refractories, abrasives, enamels, sealants and adhesives, glasses,: Polymers and polymerisation - structure and properties of thermoplastics and thermosets - engineering applications, elastomers, electrical conducting polymers. (4)
ELECTRICAL, MAGNETIC AND SMART MATERIALS: P and N type semiconductors, single crystals, soft and hard magnetic materials, superconductors, MEMS, nano structured materials, shape memory alloys. (4)
COMPOSITES: Types of composites, volume fraction - lamellar composites, various reinforcement materials, properties of composites, Selection of composites for axial, bending, torsional load applications, applications of composites. (3)
COMPLIANCE RELATED TO MATERIALS: ROHS compliance – restricted materials like lead, cadmium, mercury, hexavalent, chromium etc. ROHS compliance, material recycling – ELOV, REACH.
09PP05 / 09PD05 DESIGN FOR MANUFACTURE
3 1 0 4
DFM APPROACH: DFM approach, guidelines, standardization – comparison of materials on cost basis, design for assembly, DFA index, poka-yoke, lean principles, six sigma concepts. (2)
TOLERANCE ANALYSIS: Cumulative effect of tolerances – Worst case method, root sum square method, dimensions following truncated normal distributions, Monte Carlo simulation. Tolerance synthesis, non linear tolerance tolerance analysis, tolerance cost relationships. Process capability, mean, variance, Cp, Cpk, cost aspects, feature tolerances, geometric tolerances – ISO standards – surface finish, review of relationship between attainable tolerance grades and different machining and sheet metal processes. (8)
GEOMETRIC DIMENSIONING AND TOLERANCING: Introduction to GD&T, ASME Y 14.5 standard - Examples for application of geometric tolerances - True Position Theory - Comparison between co-ordinate and convention method of feature location, tolerancing and true position tolerancing, virtual size concept, floating and fixed fasteners, projected tolerance zone, zero true position tolerance, functional gauges, paper layout gauging, compound assembly, examples. Datums, datum feature, simulate datum feature, datum targets - Grouped datum system with spigot and recess, pin and hole - computation of translational and rotational accuracy, geometric analysis and applications. (12)
SELECTIVE ASSEMBLY: Interchangeable part manufacture and selective assembly, deciding the number of groups- Model-I: Group tolerances of mating parts equal; Model-II: total and group tolerances of shaft equal. Control of axial play - introducing secondary machining operations, laminated shims, examples. (6)
FORM DESIGN OF CASTINGS AND WELDMENTS: Redesign of castings based on parting line considerations, minimising core requirements, redesigning cast members using weldments, form design aspects of sheet metal components. (6)
TOLERANCE CHARTING: Operation sequence for typical shaft type of components. Preparation of process drawings for different operations, tolerance worksheets and centrality analysis, examples. (6)
DESIGN FOR THE ENVIRONMENT: Introduction – Environmental objectives – Global issues – Regional and local issues – Basic DFE methods – Design guide lines – Example application. (1)
DESIGN FOR DISASSEMBLY: Case studies. (1)
09PP06 / 09PD18 PRODUCTION AND OPERATIONS MANAGEMENT
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FOReCASTING: Introduction, types of forecasting, qualitative forecasting techniques, Time series analysis – Simple and weighted moving average, Exponential smoothing, seasonal and cyclic forecasting, measures of forecasting accuracy, decomposition of time series, limitations of time series. (5)
INVENTORY ANALYSIS AND CONTROL: Need for inventory, Definitions, EOQ model, EMQ model, continuous and periodic review policies, lot sizing techniques, inventory models with uncertain demand and lead times, risk pooling, ABC inventory system, vendor managed inventory, simulation of inventory systems. (5)
SEQUENCING AND SCHEDULING: Objectives in scheduling, single machine models – SPT and EDD sequences, mean flow time, weighted mean flow time, number of tardy jobs and mean tardiness, Parallel machine models – minimizing makespan and weighted mean flow time, Flow shop models – Johnson’s algorithm, Jobshop models – branch and bound approach. (6)
SCHEDULING WITH RESOURCE CONSTRAINTS: Allocation of units for a single resource – Lang’s algorithm, Brook’s algorithm, TIMRES approach, allocation of multiple resources. Line balancing– Helgeson-Birnie approach, region approach, Ranked positional weights approach, Stochastic mixed– product line balancing. (5)
PROJECT MANAGEMENT: PERT, Network stochastic considerations, CPM, time-cost trade off. Project monitoring, Line of balance. (5)
AGGREGATE PLANNING AND MASTER PRODUCTION SCHEDULING: Approaches to aggregate planning-graphical, empirical, optimization and parametric. Development of a master production schedule, Make-to-stock, assemble-to-order, make-to-order/engineer-to-order, materials requirement planning (MRP-I) manufacturing resource planning (MRP-II) and ERP.
LEAN PRODUCTION AND JIT: Elements of lean production, MRP Vs JIT, cycle time, takt time, KANBAN, SMED, OEE, 5S, theory of constraints – drum, buffer and rope, Agile manufacturing. (5)
SUPPLY CHAIN MANAGEMENT: Definition, global optimization, bull-whip effect, push-pull supply chain, delayed differentiation, downward substitution, product and process modularity, mass customization. (5)
1. Chary S N, “Production and Operations Management”, Third Edition, Tata McGraw Hill Publishing Company Limited, 2004.
2. Mukhopadhyay S K, “Production Planning and Control – Text and Cases”, Prentice Hall of India Private Limited, 2004.
3. Baker K, “Introduction to Sequencing and Scheduling”, John Wiley and Sons, 2004.
4. David Simchi-Levi, Philip Kaminsky and Edith Simchi-Levi, “Designing and Managing the Supply Chain – Concepts, Strategies and Case Studies”, Third Edition, Tata McGraw Hill Publishing Company Limited, 2004.
5. Norman Gaither and Greg Frazier, “Operations Management”, Thomson Asia Private Limited, 2002.
6. Elwood S Buffa, Rakesh K Sarin, “Modern Production and Operations Management”, John Wiley & Sons Inc, 2002.
7. Richard B Chase, Nicholas J Aquilano and F Robert Jacobs, “Production and Operations Management – Manufacturing and Services, Eight Edition, Tata McGraw Hill Inc, 2000.
8. Bedworth D D, "Integrated Production Control Systems Management, Analysis, Design", John Wiley & Sons, 1987.
9. Johnson L A and D C Montgomery, “Operations Research in Production Planning, Scheduling, and Inventory Control”, John Wiley & Sons, 1974.
09PP07 ADVANCED METAL FORMING
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THEORY OF PLASTICITY: Theory of plastic deformation – principle stresses – two dimensional and three dimensional stress pattern – stress and strain tensor – true stress and true strain – Von-mises and Tresca yield criterion for plane strain problems – role of friction in metal forming. (8)
CONSTITUTIVE RELATIONSHIP AND INSTABILITY: Uniaxial tension test – mechanical properties – work hardening – compression test, bulge test, plane strain compression stress, plastic instability in uniaxial tension stress, plastic instability in biaxial tension tests. (6)
THEORY AND PRACTICE OF BULK FORMING PROCESSES: Analysis of plastic deformation in forging, rolling, extrusion and drawing processes – effect of friction, calculation of forces, torque and power – process parameters, equipments used – defects – cause and remedies. (8)
THEORY OF SHEET METAL FORMING: Theory of bending – analysis of bending process - cold rolling theory – Hill’s anisotropic theory, Hill’s general yield theory – analysis of deep drawing processes – spinning process. (8)
SPECIAL FORMING PROCESSES: HERF techniques – explosive forming, electro hydraulic forming, magnetic pulse forming – super plastic forming – thermo forming – petro forge hammer and Dynapak process, near net shape manufacturing. (7)
CAE IN FORMING: Analysis of forging process using software packages. (5)
09PP08 ADVANCED WELDING AND CASTING
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REVIEW OF ADVANCED WELDING PROCESSES: Electron beam welding, laser beam welding, friction stir welding, plasma arc welding and ultrasonic welding. (3)
LASER BEAM WELDING: Types of lasers, equipment, power calculation, applications and case studies, dual laser beam welding, use of fibre optics in LBW. (4)
FRICTION STIR WELDING: Details of process and process parameters, specific applications. (3)
ELECTRON BEAM WELDING: The interaction of electron beam with matter, mode of heat generation, mode of energy losses, details of the equipment, product design for EBW, case studies. (5)
ULTRASONIC WELDING: Propagation of ultrasonic waves in matter, mode of joint formation, joint types and design of product for ultrasonic welding, details of equipment and case studies, cutting and gauging, flame cutting, plasma arc welding, laser assisted cutting. (7)
Review of Advanced Casting Processes: Investment casting, shell moulding, squeeze casting, vacuum casting, counter-gravity low - pressure casting, directional and monocrystal solidification, squeeze casting, semisolid metal casting and forging. (5)
CAE OF WELDING AND CASTING: Design of weldment, application of finite element method in welding – determination of distortion in weldments, modeling of temperature distribution - case studies. Design for casting, application of finite element method in casting - determination of hot spots, location of turbulence and other defects, modeling of flow in molds, modeling of heat transfer in castings – case studies. (11)
NDT FOR CASTING AND WELDING: Radio graphic, visual inspection, ultrasonic and magnetic particle inspection techniques. (4)
1. Ravi B, “Metal Casting: Computer Aided Design and Analysis”, Prentice Hall, 2005.
2. Richard L Little, “Welding and Welding Technology”, Tata McGraw Hill, 2004.
3. John Campbell, “Casting Practice”, Elsevier Science Publishing Co., 2004.
4. Larry Jeffus, "Welding: Principles and Applications", Delmar Publishers, 2004.
5. John Campbell, "Casting", Butterworth Heinemann, 2003.
6. Klas Weman, “Welding Processes Handbook”, 2003.
7. Howard B Cary, “Modern Welding Technology”, Prentice Hall, 2002.
8. Larry Jeffus, “Welding for Collision Repair”, Delmar Publishers, 1999.
9. ASM Hand Book, “Casting”, ASM International, 1998.
09PP09 ADVANCED MANUFACTURING SYSTEMS
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INTRODUCTION: Overview of machine tools, types of CNC machines, multitask machines, hard machining. (4)
CNC TURNING CENTRE: constructional features - structures, guide/slide ways, ball screws, guideways, turret, curvic coupling, power pack, spindle, bearings, programming: interpolators, ISO and EIA standards, G and M codes, canned cycles. (7)
CNC MACHINING CENTRE: constructional features, automatic tool changer, tool magazine, automatic pallet changer, feed drives, spindle drives, feed back devices, programming, programming using CAM packages. (7)
OTHER CNC DRIVEN MACHINES: Laser, plasma cutting, EDM, ECM. (5)
ROBOTICS: Introduction, overview, classification of robots, major components of robot, specification, applications, recent trends, constructional features - mechanical elements used in robot, motion conversion, end effectors, electrical elements, control of robotic joints, robotic sensory devices, robot kinematics. (7)
ADVANCED CONCEPTS: Cellular manufacturing, group technology, flexible, lean manufacturing. (5)
MATERIAL HANDLING: Industrial trucks, manual, powered automated guided vehicles, types of vehicles and AGVS application, vehicle guidance technology, vehicle management and safety, conveyors, cranes and hoists. (4)
SIMULATION: Simulation of job shop, flow shop, factory layout and inventory system. (3)
1. Joshi P H, “Machine Tool Hand Book, Design and Operation”, Tata McGraw Hill, 2007.
2. Jerry Banks and John S Carson, "Discrete Event System Simulation", Prentice Hall of India, New Delhi, 2003
3. Steve Krar, “Computer Numerical Control Simplified”, Industrial Press, 2001.
4. Richaerd D Klafter, Thomas Achmielewski and Mickael Negin, “Robotic Engineering – An Integral Approach”, Prentice-Hall India, 2001.
5. HMT, “Mechatronics”, Tata McGraw Hill, 1998.
6. Radhakrishnan P, “Computer Numerical Control, (CNC) Machines”, Newness – Butterworth and Co. Publisher Limited, 1992.
7. Kulwise R A, “Basics of Materials Handling” M.H. Institute, New York, 1986.
09PP11 / 09PD09 ENGINEERING ECONOMICS
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INTRODUCTION: Present economic policy, liberalization, privatization, globalization, scope for industrial growth, interest and time value of money, cash-flow diagram, simple interest, compound interest, single payments, uniform series payments, interest factors and tables, nominal and effective interest rates, continuous compounding, uniform continuous payments. (5)
METHODS FOR EVALUATION OF TANGIBLE ALTERNATIVES: Present worth comparison - equal, unequal lived assets, study period, assets with infinite life, capitalized cost, bond valuation. Equivalent uniform annual cost comparison, situations for EUAC, rate of return comparisons – IRR – MARR – IRR misconceptions. (6)
Replacement Analysis: Review of conventional approach, group replacement, analysis with time value accounting, replacement due to deterioration, obsolescence, inadequacy, economic life for cyclic replacements, current salvage value of the defender, defender and challenger with different lives, additional one year assessment. (4)
Project Feasibility Analysis: Case study, report preparation. Depreciation, reasons, depreciation accounts, causes of declining value, depreciation methods. Cost, volume, profit analysis: review of conventional approach, analysis with time value, linear, non-linear, multi product break even analysis. Review of project management, PERT – CPM, crashing, cost system. Product costing. (6)
Marketing Feasibility: Types of market, identification of investment opportunities, market and demand analysis, forecasting demand (review), forecast control, secondary sources of information. (4)
Technical Feasibility: Product design, concept of concurrent engineering, make Vs buy decisions, BPO, value analysis, FAST approach, product life cycle management. (7)
Financial Feasibility: Means of financing, financial institutions, all India, state level, profitability, cash flows of a project, financial leverage of a business. Tax factors in investment analysis, effects of inflation in economic analysis. (6)
Risk AND MULTI STAGE SEQUENTIAL dECISION Analysis: Recognising risk, including risk in economic analysis, expected value, payoff table, decision tree, discounted decision tree. (4)
1. James L Riggs, David D Bedworth and Sabah U Randhawa, “Engineering Economics”, McGraw Hill Book Company, 2004.
2. Prasanna Chandra, "Projects - Preparation, Appraisal and Implementation", Tata McGraw Hill, 2004.
3. William G Sullivan and others, “Engineering Economy” , Pearson Education Inc., 2001.
4. John A White et al, "Principles of Engineering Economic Analysis", John Wiley and Sons, 1998.
5. Leland T Blank and Anthony J Tarquin, "Engineering Economy", McGraw Hill Book Company, 1998.
6. Norman N Barish, "Economic Analysis for Engineering and Managerial Decision Making", McGraw Hill Book Company, 1983.
09PP12 / 09PD06 DESIGN BY FINITE ELEMENT METHOD
3 1 0 4
FORMULATION OF SOLID AND STRUCTURAL MECHANICS PROBLEMS: Generalized Hooke's law, Strain Energy density function, Elastic symmetry, Stress strain relationship, strain displacement relationship, boundary conditions, compatibility equations, Equilibrium equations. First law of thermodynamics and energy Equation. (7)
ENERGY AND VARIATIONAL PRINCIPLE: Calculus of variations: The variational operator, Extremum of functional, Natural and essential boundary conditions, Principle of virtual displacements, Principle of total potential energy, Principle of virtual forces and complimentary potential energy, Hamilton principle, Castigliano's theorems. (7)
BASIC PROCEDURE OF FEM: Discretization of the domain, basic element shapes, discretization process, node numbering scheme, assemblage of element equations and incorporation of boundary conditions. (7)
INTERPOLATION MODELS: Polynomial form of interpolation functions, selection of the order of the interpolation polynomial, simplex, complex and multiplex elements, interpolation polynomial in terms of nodal degrees of freedom, convergence requirements, linear interpolation polynomials in terms of global coordinates and for vector quantities, coordinate transformation. (7)
STATIC ANALYSIS OF SOLID MECHANICS PROBLEMS: Analysis of bar, space truss, beam, plates - triangular membrane, rectangular, isoparametric formulation and axisymmetric formulation. case studies. (7)
DYNAMIC ANALYSIS OF SOLID MECHANICS PROBLEMS: Dynamic equations of motion, consistent and lumped mass matrices, free vibration analysis, dynamic response using finite element method, case studies. (7)
1. Reddy J N, “An Introduction to the Finite Element Method”, Second Edition, Tata McGraw Hill, 2006.
2. Singerasu So Rao, "The Finite Element Method in Engineering", Butterworth Heinemann, 2005.
3. Klaus Jurgen Bathe, "Finite Element Procedures", Prentice Hall Inc. 2004.
4. Reddy J N, “Energy Principles and Variational Methods in Applied Mechanics”, Second Edition, John Wiley & Sons, 2002.
09PP13 / 09PD21 RAPID PROTOTYPING
3 0 0 3
INTRODUCTION: Need for the compression in product development, history of RP systems, survey of applications, growth of RP industry, classification of RP systems. (4)
FUSED DEPOSITION MODELING: Principle, process parameters, path generation, applications (5)
SELECTIVE LASER SINTERING: Types of machines, principles of operation, process parameters, data preparation for SLS, applications. (5)
STEREOLITHOGRAPHY SYSTEMS: Principle, process parameters, process details, data preparation, data files and machine details, applications. (4)
LAMINATED OBJECT MANUFACTURING: Principle of operation, LOM materials, process details, applications.
SOLID GROUND CURING: Principle of operation, machine details, applications.
LASER ENGINEERED NET SHAPING (LENS): Net shaping development at Sandia National Lab. (2)
CONCEPT MODELERS: Principle, Thermo jet printer, Sander's model market, 3-D printer, Genisys Xs printer, JP system 5, object quadra system. (4)
RAPID TOOLING: Indirect rapid tooling - silicone rubber tooling, aluminum filled epoxy tooling, spray metal tooling, cast Kirksite, 3D Keltool, etc., direct rapid tooling - direct AIM, quick cast process, copper polyamide, rapid tool, DMILS, prometal, sand casting tooling, laminate tooling, soft tooling Vs hard tooling. (7)
SOFTWARE FOR RP: STL files, overview of solid view, magics, mimics, magics communicator, etc., internet based softwares, collaboration tools. (4)
RAPID MANUFACTURING PROCESS OPTIMIZATION: Factors influencing accuracy, data preparation errors, part building errors, errors in finishing, influence of part build orientation. (2)
ALLIED PROCESSES: Vacuum casting, surface digitizing, surface generation from point cloud, surface modification, data transfer to solid models. (5)
09PP14 IT IN MANUFACTURING
3 0 0 3
INTRODUCTION: Role of internet and information technology in manufacturing, present market constraints, extended enterprises, B2C and B2B, PLM and PDM. (6)
PRODUCT DEVELOPMENT AND ISSUES: Product lifecycle, sequential engineering Vs concurrent engineering, concurrent engineering and information technology, Global Product and Product Complexity, product development and its relevance, make to stock, assemble to order, engineer to order situations. (9)
USE OF CAD, CAE AND CAM: Modelling of geometry of parts, modeling of assemblies, different modeling packages and standards for data exchange between different softwares, use of analysis softwares, use of manufacturing process simulation softwares. (9)
AUTOMATED PROCESS PLANNING: Process planning, structure of a process planning software, information requirements for process planning, operation of a typical computer aided process planning software, group technology. (5)
PLANNING OF RESOURCES FOR MANUFACTURING THROUGH IT: Background, role of MRP-II, MRP software, manufacturing applications, engineering applications, financial applications, marketing applications, dynamic enterprises, ERP, SCM, virtual manufacturing, knowledge of inventory and BOM. (6)
COLLABORATIVE ENGINEERING: Faster design throughput, web based design, changing design approaches, engineering change management, product configuration management, extended enterprises, enterprise wide product visualization, enterprise application integration for PLM. (7)
09PP15 APPLIED HYDRAULICS AND PNEUMATICS
3 0 0 3
ELEMENTS OF PNEUMATIC SYSTEMS: Pneumatic Vs hydraulics, compressors - types, selection. Symbols of pneumatic elements. Cylinders - types, typical construction details. Valves – direction control, flow, pressure, types, typical construction details. (8)
PNEUMATIC SYSTEMS DESIGN: General approach, travel step diagram. Sequential circuit design, step counter method. K.V. Mapping for minimization of logic equation, fringe condition modules, sizing of components in pneumatic systems. (10)
TYPICAL INDUSTRIAL APPLICATIONS OF PNEUMATIC SYSTEMS: Metal working, handling, clamping, application with counters. (8)
ADVANCED TOPICS IN PNEUMATICS: Electro pneumatics, ladder diagram. Servo and proportional valves - types, operation, application, hydro-mechanical servo systems. PLC-construction, types, operation, programming. (8)
DESIGN OF TYPICAL HYDRAULIC SYSTEMS: Total design of a fluid power system for an industrial application. Specifications of the circuit, circuit design, selection of elements based on force, speed, travel and time, sizing of pipes, design of power packs/selection of compressor, piping layout and accessories. (8)
1. Anthony Espisito, “Fluid Power with Application”, Pearson Education Private Limited, Fifth Edition, First Indian Reprint, 2003.
2. Majumdar S R, “Oil Hydraulic Systems: Principles and Maintenance”, Tata McGraw Hill Publishing Company Limited, Fourth Reprint, 2003.
3. Majumdar S R, “Pneumatic Systems : Principles and Maintenance”, Tata McGraw Hill Publishing Company Limited, Fourth Reprint, 2003.
4. Peter Rohner, “Fluid Power Logic Circuit Design – Analysis, Design Method and Worked Examples”, The Macmillan Press Limited, 1979.
5. Werner Deppert and Kurt Stoll, “Pneumatic Controls : An Introduction to Principles“, Vogel-Druck Wurzburg, 1975.
09PP16 / 09PD16 OPTIMIZATION TECHNIQUES
3 0 0 3
NONLINEAR OPTIMIZATION: Introduction, unconstrained optimization, one-dimensional optimization, elimination methods, Fibonacci method, golden section methods, interpolation methods, quadratic, cubic interpolations, direct root methods, multivariable optimization, direct search methods, pattern search methods, univariate method, Hooks and Jeeves method, Powel’s method, simplex method, descent methods, steepest descent, conjugate gradient, Newton methods. (9)
CONSTRAINED NONLINEAR OPTIMIZATION: Direct methods, the complex method, cutting plane method, indirect methods, transformation techniques, interior and exterior penalty function methods, Kuhn-Tucker conditions, Lagrangian method. (6)
INTEGER PROGRAMMING: Introduction to integer programming, solution techniques- graphical method & branch and bound technique, Gomory’s cutting plane method, examples on the application in manufacturing systems and design. (4)
DYNAMIC PROGRAMMING: Bellman’s principle of optimality, examples on the application on routing problem, inventory problem, marketing problem. (3)
NETWORK OPTIMIZATION MODELS: Terminology of networks, the shortest route problem, the minimum spanning tree problem, the maximum flow problem, the minimum cost flow problem, the network simplex method. (6)
INTRODUCTION TO NON-TRADITIONAL OPTIMIZATION: Computational complexity, NP-hard, NP-complete, no free lunch theorem. (2)
RANDOM SEARCH METHODS: Genetic algorithms, Simulated annealing, ant colony algorithm, particle swap algorithm, Tabu search, neural networks, hybrid algorithms - simple applications. (12)