M.S. RAMAIAH INSTITUTE OF TECHNOLOGY
(An Autonomous Institute, Affiliated to VTU)
Department of Mechanical Engineering
MSR Nagar Post, Bangalore – 56 0054
Scheme of Teaching / Subjects / Syllabus
Master of Technology (M-Tech)
In
MANUFACTURING SCIENCE & ENGINEERING (MSE)
Programme Educational Objectives (PEOs)
Preamble:
The Mechanical Engineering Program, M.Tech-MSE is a four semester course and will provide
the advanced building blocks for conceptualizing, understanding and manufacturing systems
integrated with computer based applications. These will include advanced materials, traditional
and non-traditional manufacturing methods, advanced manufacturing techniques, advanced
foundry technology, computer aided design, product data and management, rapid prototyping,
advanced metal joining processes etc. The course includes individual project work carried out by
a student to help him understand and demonstrate his learning capability, apply the principles to
practical real time situations and would enable him to be technically and professionally equipped
and improve for taking up challenging task in the industrial sector, government organization,
research organization and pursue higher studies and to become an entrepreneur.
Programme Educational Objectives:
The Post Graduates of Manufacturing Science and Engineering will:
1. Apply the technical skills gained to model and analyze real time projects in the
field of manufacturing science and engineering.
2. Able to take up profession in industries, R&D activities, management and teaching
activity in the field of mechanical engineering.
3. Engage in industry institute interaction and lifelong learning by adhering to
ethical and environmental conditions.
Programme outcomes (POs)
The post graduates shall possess the following abilities and skills:
a) Advanced knowledge in manufacturing methods and their industrial applications.
b) Identify, formulate and solve mechanical engineering problems related to
manufacturing.
c) Design and conduct experiments, analyze the data, and interpret the experimental
results.
d) Design a system, components, or process and meet specific objectives keeping in
view the economical approaches, availability of materials and manufacturability
with increased life.
e) Visualize, work in laboratory and take up multidisciplinary tasks.
f) Skills to use modern engineering tools, software and equipment to analyze and solve
problem, will imbibe and demonstrate knowledge of ethical responsibility.
g) Good communication skills to effectively communicate both verbally, written form and
through drawings.
h) Understand the impact of engineering solutions or society in global and economic
context.
i) Motivated to engage them in continuous learning process and develop confidence
for self-education and ability for lifelong learning.
j) Knowledge and ability to respond to the happenings/ contemporary issues of the
country.
k) Succeed in the competitive examinations and research work.
l) Manage project and finance effectively.
M.S.RAMAIAH INSTITUTE OF TECHNOLOGY, BANGALORE-54
(Autonomous Institute Affiliated to VTU)
SCHEME OF TEACHING
BREAKDOWN OF SUBJECT WISE CREDIT DISTRIBUTION
Semester
/ Total
I
II
III
IV
Total
Core
Subjects
17
14
31
Electives
08
12
12
32
Project
Work
09
22
31
Seminar
Total
02
02
02
06
27
28
23
22
100
I SEMESTER M.Tech (Manufacturing Science & Engineering)
Sl
No
1
Subject Code
Credits
T P Total
1 0
4
Subject
Teaching Dept
MMSE 11
Computational Numerical Methods
Mathematics
2
MMSE 12
Finite Element Methods
4
0
0
4
3
MMSE 13
Advanced Materials Technology
4
0
0
4
4
MMSE 14
Theory of metal cutting
4
0
1
5
5
MMSE 15
Seminar-I
0
2
0
2
6
Elective-I
4
0
0
4
7
Elective-II
4
0
0
4
23
3
1
27
Mechanical
Engineering
Total
L
3
II SEMESTER M.Tech (Manufacturing Science & Engineering)
Sl
No
Subject
Code
Subject
1
MMSE 21
2
MMSE 22
Statistical modelling and experimental methods
in Manufacturing
Advances in Non Traditional Machining
3
MMSE 23
Advanced Foundry Technology
4
MMSE 24
Seminar-II
5
6
Teaching
Dept
L
Credits
T P Total
4
1
0
5
4
0
0
4
4
0
1
5
0
2
0
2
Elective-III
4
0
0
4
Elective-IV
4
0
0
4
Mechanical
Engineering
7
Elective-V
Total
4
0
0
4
24
3
1
28
III SEMESTER M.Tech (Manufacturing Science & Engineering)
Sl
No
1
Subject
Code
MMSE 31
Seminar-III
2
MMSE 32
Project Preliminaries
3
Elective-VI
4
Elective-VII
5
Elective-VIII
Subject
Teaching Dept
Credits
T P Total
2 0
2
L
0
Mechanical
Engineering
Total
0
9
0
9
4
0
0
4
4
0
0
4
4
0
0
4
12
11
0
23
IV SEMESTER M.Tech (Manufacturing Science & Engineering)
Sl
No
1
Subject
code
MMSE 41
Subject
Teaching Department
L
0
Project work
Total
*L: Lecture
T= Tutorial
0
Credits
T
P Total
0 22 22
0
22
22
P=Practical
Scheme of examination: In all theory courses students are required to answer one question
from each unit.
LIST OF ELECTIVES
Subject
NO.
Sub code
Credits
1
MMSE –E01
Theory of Metal Forming
4:0:1
2
MMSE –E02
Advances in Composite Materials
4:0:0
3
MMSE –E03
Automation in Manufacturing
4:0:0
4
MMSE –E04
Nano Technology
4:0:0
5
MMSE –E05
Ferrous & Non-ferrous foundry practice
4:0:0
6
MMSE –E06
Maintenance Engineering &Management
4:0:0
7
MMSE –E07
Product Development
4:0:0
8
MMSE –E08
Product Data Management
4:0:0
9
MMSE –E09
Smart materials & Structures
4:0:0
10
MMSE –E10
Agile Manufacturing
4:0:0
11
MMSE –E11
Rapid Prototyping ( Additive Manufacturing )
4:0:0
12
MMSE –E12
Modern Trends in Manufacturing Management
4:0:0
13
MMSE –E13
Advanced Metal Joining Processes
4:0:0
14
MMSE –E14
Surface treatment and Finishing techniques
4:0:0
15
MMSE –E15
Robotics
4:0:0
16
MMSE –E16
Condition Based Maintenance
4:0:0
17
MMSE –E17
Quality and Reliability Engineering
4:0:0
Students have to earn a total of 100 credits by choosing subjects from the above list of
electives
COMPUTATIONAL NUMERICAL METHODS
Course Code: MMSE11
Prerequisites : Nil
Credits: 3:1:0
Preamble:
The course aims to introduce Numerical methods which provide constructive methods for
obtaining numerical solutions to practical engineering problems for which exact solutions by
analytical methods are difficult and time consuming.
Course Objectives:
The Student will
1. Learn the concept of different types of errors.
2. Learn mathematical modeling of some physical problems.
3. Learn to obtain a root of algebraic and transcendental equations.
4. Learn the concept of differentiation and integration of a tabulated function.
5. Learn to solve system of linear algebraic equations and to find eigenvalues and eigenvectors of
a given square matrix.
6. Learn the concept of linear transformation matrix of linear transformation, linear models and
Gram-Schmidt Process.
UNIT – I
Approximations and round off errors: Significant figures, accuracy and precision, error
definitions, round off errors and truncation errors. Mathematical modeling and Engineering
problem solving: Simple mathematical model, Conservation Laws of Engineering.
Roots of Equations: Bracketing methods – Newton-Raphson method, Multiple roots, Simple
fixed point iteration.
UNIT – II
Roots of polynomial-Polynomials in Engineering and Science, Muller’s method, Graeffe’s
Roots Squaring Method.
Numerical Differentiation and Numerical Integration: Newton-Cotes and Guass Quadrature
Integration formulae, integration of Equations, Romberg integration, Numerical Differentiation
Applied to Engineering problems, High Accuracy differentiation formula.
UNIT – III
System of Linear Algebraic Equations And Eigen Value Problems: Introduction, Gauss
Elimination Method, Gauss-Jordan Elimination Method, Triangularization method, Cholesky
Method, Partition method, error Analysis for direct methods, iteration Methods.
UNIT – IV
Eigen values and Eigen Vectors: Bounds on Eigen Values, Jacobi method for symmetric
matrices, Givens method for symmetric matrices, Householder’s method for symmetric
matrices, Rutishauser method for arbitrary matrices, Power method.
UNIT – V
Linear Transformation: Introduction to Linear Transformation, The matrix of Linear
Transformation, Linear Models in Science and Engg.
Orthogonality and Least Squares: Inner product, length and orthogonality, orthogonal sets,
Orthogonal projections, The Gram-Schmidt process, Least Square problems, Inner product
spaces.
Text books:
1. S S Sastry – “Numerical Analysis for Engineers” – Tata Mcgraw Hill Edition.
2. Steven C Chapra, Raymond P Canale – Numerical Methods for Engineers – fourth Edition,
Tata Mcgraw Hill.
3. M K Jain, S R K Iyengar, R K Jain – Numerical Methods for Scientific and Engg.
Computation – New Age International Publishers.
Reference books:
1. Prevez Moin – Application of Numerical Methods to Engineering.
2. David C Lay – Linear Algebra and its Applications – 3rd Edition, Pearson Education.
Course Outcomes:
The Student will be able to
1. Model some simple mathematical models of physical Applications.
2. Find the roots of polynomials that arise in Science and Engineering problems.
3. Differentiate and integrate a function for a given set of tabulated data, for Engineering
Applications.
4. Solve the system of linear equations by different methods that arise in Science and Engineering
Problems.
5. Find eigenvalues and eigenvectors which deals with the modeling of the system and the
behavior of the system.
6. Find orthogonal or orthonormal basis using Gram-Schmidt Process.
FINITE ELEMENT METHODS
Subject Code : MMSE 12 / MCIM 12
Prerequisites : Nil
Credits: 4:0:0
Preamble
Finite Element Method is proving to be a very powerful technique of solving and analyzing
complex engineering problems. It is a numerical method which yields fairly accurate results for
complex engineering problems and of late has emerged as a very rapidly growing area of
research for applied mathematics. Its usefulness in various branches of engineering is due to the
ease with which the method is made amenable to computer programming, leading to a process of
iterative design.
Its uniqueness lies in the fact that complex engineering problems having no analytical solutions
can be solved with ease and iterative designs can be worked out.
Of late, this technique has found a lot of applications in the area of manufacturing as newer and
specialized techniques and materials are being used with changing technology. In this context it
is desirable to introduce the subject of FEM in the curriculum of PG course of CIM to train the
students for developing skills for designing and analyzing the various manufacturing processes to
arrive at an optimized process. The method can also be used in the development of machine
tools, newer materials and failure analysis of processes.
Course Learning Objectives
1. Introduce the various aspects of FEM as applied to engineering problems in a systematic
manner and impart the knowledge of fundamentals of Theory of Elasticity, Calculus of
Variation and Matrix Methods.
2. Apply the fundamental concepts of mathematical methods and theory of elasticity to
solve simple continuum mechanics problems.
3. Define the element properties such as shape function and stiffness matrix for the various
elements and Formulate element properties for 1D and 2D elements.
4. Develop skill to solve simple truss and beam problems using the steps of FEM and
Develop competence to analyze vibration problems of beams.
5. Develop an understanding of working of commercial FEM software and to be aware of
the latest state of the art of research
UNIT – I
Introduction , basics of TOE,Calculus of variation, Euler’s Lagrange’s equation, weighted
residual approach, principal of minimum potential energy, Rayleigh – Ritz method, problems,
Finite Element Method steps, application and advantages of FEM.
UNIT – II
Derivation for shape functions for linear and quadratic 1D element, element stiffness matrix
,temperature effect, problems on bars,Numerical integration using 1, 2 and 3 points Gaussian
quadrature formula.
UNIT – III
Geometric isotropy, Pascal triangle Pascal pyramid ,order of the interpolating polynomial
,convergence criteria, compatibility requirement, Shape functions, Jacobian matrix of 2D
elements such as CST Element, LST Element, Rectangular Element, Lagrange interpolation
shape functions for higher order elements, Iso parametric ,sub parametric and super parametric
representation of elements.
UNIT – IV
Introduction to Truss and Beam elements, Derivation of stiffness Matrix and shape functions in
local and global coordinates, Truss problems , Beam Element problems, Load vector,Shear
force and bending moment, problems,
UNIT – V
Dynamic Analysis: Dynamic Equation of motion, consistent and lumped mass matrices, free
vibration analysis, Eigen Values and Equation vectors.
Text books:
1. Introduction to Finite Element in Engineering R Chandrupatla and Belegundi, Prentice
Hall India Pub 2006.
2. The Finite Element Methods in Engineering – SS Rao, Butter worth Heinemann Pub 2005.
3. A First Course in FEM – By Daryl. L. Logan, Thomas & Learning, Pub 2007.
Reference Books
1. Finite Element Analysis Theory & Programming - C S Krishnamurthy –
Tata McGraw Hill, Pub.2000.
2. The Finite Element Method – Zienkilewicz, OC-Tata McGraw Hill, Pub 1979.
Course Outcomes
1. Evaluate and compare FEM with other numerical methods and Compile fundamentals of
theory of elasticity, calculus of variation and matrix methods for engineering applications.
2. Develop ability to identify a problem and apply the fundamental concepts of theory of
elasticity and matrix methods for continuum mechanics problems.
3. Demonstrate the ability to define and formulate the element properties for 1D and 2D
elements.
4. Develop the skills of solving truss and beam problems for various loading conditions and
competence to design and analyse problems of engineering particularly having relevance to
manufacturing and of current techniques and technologies.
5. Demonstrate ability to make use of commercial software to solve complex problems.
Mapping Course Outcomes with Program Outcomes:
Program Outcomes
Course
Outcomes PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11
1
X
X
X
2
X
X
X
X
3
X
X
X
4
X
X
X
5
X
X
X
PO12
X
ADVANCED MATERIALS TECHNOLOGY
Course Code: MMSE 13 / MCIM 13
Prerequisites: Nil
Credits: 4:0:0
Preamble:
In day to day life we are coming across different types of materials pertaining to engineering
field. We have conventional materials whose properties are already there in the hand books. As
the new inventions are taking place, the conventional materials are not fit at that place. So there
is a need for newer materials which suits to the need, with improved properties and structures.
And also there is a need for the newer materials with improved mechanical, chemical, electrical
and other properties. This course deals with the study of such advanced materials to serve the
required purpose.
Course Learning Objectives:
1. Students are initially made to know the concept of the conventional materials and their
structures such as atomic structures, electronic configuration, etc., and their applications.
2. To obtain brief descriptions for the need of newer materials which are having better
improved properties to suit with conventional materials.
3. To analyze the types of ceramic materials and their properties, processing and their
applications.
4. To evaluate the properties of different composite materials and their applications.
5. To analyze the different processing/ fabrication techniques of composite materials, their
characterization, testing, etc.
6. The students will have the knowledge to improve powder metallurgical properties with
the help of advanced methods and different techniques.
7. To apply the different methods or techniques in improving the properties of newer
materials with the use of surface treatment, squeeze casting, etc.
8. To study the overview of different advanced materials to suit the particular applications.
UNIT – I
Development of Newer Materials: Properties of materials, Structure property relationship,
newer materials-Ceramics and Composite materials, Ceramics- Fine ceramics, Types of
ceramics, Applications. Composite materials – Types – Metal matrix Composites (MMC)
Ceramic Matrix Composites (CMC) Polymer composites Structure.
UNIT – II
Properties and Applications of different composite materials: Powder Metallurgy:
Introduction, Production of Powder, Characterization and Testing.
UNIT - III
Powder Conditioning: Powder Compaction, Sintering, Finishing operations, Applications of
PM components.
UNIT - IV
Processing of Composites: Processing of MMC, CMC, Vacuum infiltration, Squeeze casting,
Pressure Die casting, Rheocasting, Compo casting, Super plastic forming, Processing of PMC,
Hand lay up, Bag moulding process, Autoclave moulding, Compression melding, Pultrusion,
Filament winding.
UNIT - V
Resin Transfer molding: Injection molding, Surface Treatment: Surface Engineering, Surface
Quality and Integrity, Concepts, Mechanical treatment, Thermal and Thermo mechanical
treatment, Thermal spraying processes and applications.
Text Books:
1. Materials and Processing in Manufacturing – E Paul Degarmo, J T Black, Ronald A
Kohser. Pub 2006
2. Powder Metallurgy – A K Sinha.Sapna Publication, 2009
Reference Books
1. Fiber Reinforced Composites – P K Mallick
2. Metal Matrix Composites – Minoru Taya, Richard J Arsenault
3. Composite Materials Hand book – M M Schwartz, McGraw Hill.
Course Learning Outcomes:
1. Students are capable to define the concept of materials i.e., conventional materials with
their structure, such as electronic configuration, structure of atom, etc.
2. Students become aware of different conventional materials such as metallic and nonmetallic materials, structures and their applications.
3. Students will be able to demonstrate the need for newer materials by comparing the
limitations of conventional materials.
4. They will be able to compare the types of newer materials along with their properties and
applications.
5. They will be able to compile about the properties, structure of ceramic materials and their
need for newer applications and processing techniques.
6. They demonstrate skill to evaluate composite materials, PMC, CMC, MMC, etc and their
properties and applications.
7. The students compile the different processing or fabrication techniques by the skilled or
semi skilled works and the design of newer dies and fabrication, their characterization
and testing.
8. The students are exposed to different types of powders with their properties and
processing by different powder metallurgy routes to get the improved properties of their
applications and limitations.
9. They will be able to express the different fabrication techniques, how the properties are
improved after they are processed through squeeze casting technique, surface treatments,
etc.
10. Finally the students are able to evaluate the newer materials, with advanced casting
techniques and to improve their properties.
THEORY OF METAL CUTTUNG
Course Code: MMSE 14
Prerequisites: Nil
Credits: 4:0:0
Preamble
Theory of metal cutting is gaining importance in the present day as almost all manufacturing
activities. Decisions regarding this are taken up on fast track basis as well as with the available
information to arrive at the optimum time required for any task. This is enabled only by
providing the necessary access to the Engineer the right information at the right time and
providing in the way it is required. This is being achieved using precision machine tools,
computers which provide the data storage, data reduction, value addition for the data, data
acquisition, retrieval and data warehousing for effective manufacturing functions. The subject
provides the basic fundamental approaches for metal cutting theory. The subject also
encompasses the practical aspects with the right information converted to measurable parameter,
particularly in manufacturing activities. Traditional machining tools, nomenclature, tool
materials, cutting force measurements, tool wear, tool life and thermal aspects related to metal
cutting, economics involved during machining are studied in detail.
Course Learning Objectives
1. Introduce the various aspects of cutting tools as applied to manufacturing engineering in
a systematic manner.
2. Impart the knowledge of fundamentals of mechanics of metal cutting.
3. Apply the fundamental concepts of mathematical methods and derive the relationships
for shear plane angle, cutting forces, tool life criterion, and effective utilization of the
tools, towards decision making processes.
4. Define the fundamental processes and procedures for tool wear, thermal aspects in
machining.
5. Clear exposure to the cutting fluids, applications and types of cutting fluids.
6. Enable to make decisions regarding economics of metal cutting.
7. Arrive at the optimum cutting speed and tool life for maximum production.
8. Provide an overview of different cutting parameters involved in machining.
9. Develop methods of working for minimizing the production cost.
UNIT-I
Mechanics of metal cutting: Mechanism of chip formation, orthogonal and oblique cutting,
types of chips, built-up edge, Determination of shear plane angle, forces on the chips, forces in
orthogonal cutting, Merchant circle diagram and analysis, Theroy of Lee & Shaffer, co-efficient
of friction, power & energy relationship, velocity relationship, shear-strain, forces and power,
problems.
UNIT-II
Tools nomenclature, tool point reference systems: Geometry of cutting tools: Single point and
multi point cutting tools, tool angle specifications-ISO and ASA systems, conversion from one
system to another. Recommended tool angles, Effect of cutting parameters on tool geometry
Tool Materials and their properties: Characteristics of tool materials, types of tool materialscarbon tool steels, high speed steels, cast alloys, cemented carbides, ceramics, diamonds,
SIALON,CBN,UCON, recommended cutting speeds for the above tools, tool and die steels-air,
water, oil hardening of tools and their applications.
UNIT-III
Measurement of cutting forces: Reasons for measuring cutting forces, Classification of cutting
force dynamometers-mechanical, hydraulic, pneumatic, optical, inductance, piezoelectric, and
strain gage type dynamometers, Dynamometers for lathe, drilling and milling, calibration of
dynamometers.
UNIT-IV
Tools wear, Tool life: Mechanisms of tool wear, sudden & gradual wear, crater wear, flank
wear, tool failure criteria, tool life equations, effect of process parameters on tool life, tool life
tests, conventional & accelerated tool wear measurement, machinability index, Thermal Aspects
in metal cutting: Heat sources in metal cutting, temperature in chip formation, temperature
distribution and experimental determination of tool temperature.
UNIT-V
Cutting fluids: Basic actions of cutting fluids, properties of cutting fluids, selection of cutting
fluids, application of cutting fluids, filtration of fluids, recommended cutting fluids. Economics
of Machining: Introduction, element of total production cost, optimum cutting speed and tool life
for minimum cost, optimum cutting speed and tool life for maximum production, problems
Lab Component:
CAM: Part programming for CNC Machines using CAM Packages to perform Turning and
Milling operations.
CNC Machining: Two models to perform Turning, Taper turning, Grooving and Threading. And
two models to perform drilling and Counter boring operations.
Machine Tool Experiments: study on Machine Tools, Cutting forces on single point cutting
Tool, Merchants circle Diagram and Analysis for cutting forces.
Machine Tools Alignment: Alignment tests on Machine Tools
Metal Forming and Forming Analysis: Typical exercises on Forming processes like Forging,
Extrusion, clogging using Metal Forming Software’s
TEXT BOOKS:
1.
2.
3.
4.
CAD/CAM principles and applications by P.N. Rao, Tata MC Graw Hill 2002
CAD/CAM by Groover, Tata MC Graw Hill 2003
Metal Forming Theory. Sinha and Prasad Khanna Publishers
CIM and Automation Lab Manual prepared in the Department.
REFERENCE BOOKS:
CAD/CAM – Ibrahim Zeid- Tata MC Graw Hill 2nd eidtion
Computer graphics- Steron Harrington-Tata MC Graw Hill 2nd eidtion
Computer aided manufacturing- P.N. Rao, Tiwar, Tata MC Graw Hill 3rd eidtion
Geometric dimensioning and Tolerancing for Mechanical design: By Gene R. Cogorno
Manufacturing Processes for engineering materials by Seropekalpakajiam and Steven R
Schimid, Pearson education, 4th edition 2007.
6. Materials & Processes In Manufacturing by Paul Degarmo E, Jt Black, Ronald A Kohser.
Prentice -hall of India,8th edition 2006
7. Principles of Industrial metal working process - G.W. Rowe, CBS Publishers. 1st edition
2005
8. Manufacturing Science, by Asok Kumar Mallik&Amitabha Ghosh - Affiliated East-west
Press Pvt Ltd , 2nd edition 2012.
9. Theory of Plasticity and Metal Forming Processes by Dr. Sadhu Singh Khanna
Publishers, 2008.
10. Metal Cutting Principles: M.C Shaw, Oxford Publication. Pub 1978
11. Metal Cutting by Edward.W. Trent.Butterwork Pub, 2006
1.
2.
3.
4.
5.
12. Fundamentals of Metal Machining & machine tools by Boothroyd. McGraw-Hill, 1975
13. Experimental techniques in Metal Cutting by V.C Venkatesh & S. Chandrasekharan
Prentice hall. Pub 1987
14. Metal Cutting & tool design by Dr. B.J. Ranganath, Vikas Publication.2007-08
15. Principles of Metal cutting by G. Kuppu Swamy, University press (1996)
Course Learning outcomes
1. Develop utilization of understanding of fundamentals of the traditional cutting tools
compare it with other approaches.
2. Identify and utilize fundamentals of metal cutting as applied to the machining.
3. Be able to identify a problem and apply the fundamental concepts and enable enable to
solve problems arising for effective assistance in decision making process.
4. Demonstrate the ability to define and formulate the properties of cutting tool materials
and characteristics of the same.
5. Develop the skills of effective utilization of the cutting fluids and applications for better
productivity
6. Become competent to design and analyze problems of engineering particularly having
relevance to manufacturing and of current techniques and technologies.
7. Demonstrate ability to make use of the optimum cutting speed for machining components
8. Demonstrate ability to arrive at cutting parameters for machining
9. Develop methods of working for minimizing the production cost.
STATISTICAL MODELLING AND EXPERIMENTAL METHODS
Course Code : MMSE 21 / MCIM 21
Prerequisites : Nil
Credits: 4:1:0
Preamble:
Experimentation is a part of any research work. M.Tech. program requires orientation towards
research, and hence requires knowledge of the various experimental and statistical methods both
for project work, for understanding of literature, and for understanding requirements of
improvement in the processes/products. This course aims at teaching the students some of the
basic aspects of statistical tools like the regression analysis, correlation analysis. The course
aims at having understanding of experiments, the various concepts of experiments, teaching how
to design and analyze experiments. Various designs of experimentation and their analysis and
applications are taught in the subject.
Course Learning Objectives:
1. To learn the importance of experimentation
2. To understand the need for reduction in the number of experimentation.
3. To learn regression analysis for various kinds of regression analysis viz. linear, quadratic,
logarithmic, curvilinear, multiple regressions. and their interpretation
4. To learn classification of experiments
5. To learn basic aspects of various experimental techniques, and aspects, terms and
terminologies of experimentation.
6. To learn how to conduct analysis of variance in different experimental methods viz. the
CRD, RBD, FD, FFD. TD, Shainin design concepts.
UNIT 1
Statistical modelling and data analysis: Introduction to data collection, causes and types of
experimental errors – Fixed errors, random errors. Statistical approximation of missing data. Introduction
to Uncertainty Analysis in engineering measurements.
UNIT 2
Regression and correlation analysis: Linear Regression models – Simple Linear Regression, method of
least squares, estimation of regression coefficients, analysis of variance of LR, determination of
correlation coefficients.
Curvilinear Regression – Logarithm and exponential models, Multiple regression analysis – Simple
examples.
UNIT 3
Design and analysis of experiments: Introduction, Basic terms, Classification DOE, Basic principles of
good design, Completely Randomized Design, Randomized Block Design, Latin Square Design, Analysis
of variance and co-variance in experimental design.
UNIT 4
Factorial Design: Two factor experiments, multifactor and 2n experiments and their graphical
representation.
UNIT 5
Fractional Factorial Design: Fractional factorial experiments, Taguchi designs. Introduction to Shainin
approach.
Text books:
1. Cocran and Cox, “Experimental Designs”, John Wiley & Sons
2. J.M. Juran, Frank M. Gryna, “Juran’s Quality Control Handbook” McGraw-Hill
International Editions 1974.
3. P. K. De, “Computer based numerical methods and statistical techniques” CBS
Publishers and Distributors, New Delhi, Time life books, 1985.
Reference Books:
1. Douglas C. Montgomery, “Design and Analysis of Experiments” 5th Edition, John Wiley
and Sons, Inc 2004.
2. Phillip J Ross Taguchi “Techniques for quality Engineering 2nd Edition”, Mc Graw- Hill
1996.
3. Richard A Johnson, “Probability and statistics for engineers”, 6th Edition, Pearson
education.
4. J. P. Holman, “Experimental methods for Engineers”, McGraw-Hill International edition
5. Kekri R Bote & Adi K Bote “World Class Quality”.
Course Outcomes:
1. Will be able to understand the importance of experimentation
2. Will be able to understand the need for reduction in number of experiments
3. Will be able to do regression analysis of various kinds, viz. linear, quadratic,
logarithmic, curvilinear, multiple regressions. and will be able to interpret the results.
4. Will know how experiments are classified, and be able to classify the experiments.
5. Will know various experimental techniques and other terms and terminologies in
experimentation, and apply the same in professional practice.
6. Will be able to conduct analysis of various in different experimental methods, viz., the
CRD, RBD, FD, and FFD. , and will be able to understand the basic aspects of Taguchi
and Shainin designs, and thus be able to contribute to improvement in product designs in
industry.
NON - TRADITIONAL MACHINING
Course Code: MMSE22
Prerequisites: Nil
Credits: 4:0:0
Preamble:
The basic objective of all machining operations is to remove excess material to obtain the desired
shape and size. Unlike in the traditional machining operation as cited above, unconventional
machining uses special technique for the removal of material. The source of energy could be
electrical, mechanical motion, chemical reaction, power radiation or fluid motion etc. Normally
the magnitude of energy involved will be highly concentrated at any given point/location. Very
rapid development of newer materials having higher hardness and other mechanical properties
which demand higher dimensional accuracy and high production rate, a need for developing
newer manufacturing process arose. This has resulted in various non-traditional machining
processes- USM Process, Abrasive jet machining, Thermal metal removal process, Chemical
machining process, Plasma arc machining, LBM process
Course learning objectives:
1) To demonstrate the need for development of newer/ non-traditional machining processes.
2) The student will be able to compare the traditional machining processes with nontraditional machining processes with respect to the advantages, applications.
3) The student will be able to identify different energy sources like fluid motion, electric
current, high speed electrons, high energy radiation, etc.
4) To analyse the concept, mechanism, parameters associated with the processes.
5) To demonstrate the operational principles, advantages applications, limitations of the
various non-traditional machining processes.
6) To selectively select a process /a combination of processes for a specific application/
need/situation depending upon the availability of sources.
UNIT-1
Introduction: Need for non-traditional machining processes. Selection, classification,
comparative study of different processes. Machining process: Ultrasonic machining-DefinitionMechanism of metal elements of the process-Tool feed mechanism, Theories of mechanics of
cutting, Effect of parameters, applications. Abrasive jet machining: principles-parameters of the
process applications-advantages and disadvantages.
UNIT-2
Thermal Metal Removal Process: Electric discharge machining, Principle of operationmechanism of metal removal, basic EDM circuitry – spark erosion-analysis of relaxation type of
circuit. Material removal rate- critical resistance parameters in RC circuit-dielectric fluids –
Electrodes for spark – surface finish- Applications
UNIT-3
Electro chemical processes: Electro chemical Machining (ECM) Classification- principle of
ECM- chemistry of the ECM-parameters determining the metal removal rate- dynamics of the
ECM process- hydrodynamics of the ECM process-polarization-tool design- advantages and
disadvantages- applications. Electro chemical grinding-electrochemical honing-electro chemical
deburring.
UNIT-4
Plasma Arc Machining: Introduction- generation of plasma and equipment-mechanism of metal
removal, PAM parameters- process characteristics- types of torches, applications
Electron Beam Machining: Introduction- equipment for production of electron beam-theory of
electron beam machining-thermal and non thermal types-characteristics and applications
UNIT-5
Laser Beam Machining: Introduction-principle of generation of lasers-equipment and machining
procedure-types of lasers- process characteristics- advantages and disadvantages- applications.
Ion Beam Machining: Introduction- Mechanism of metal removal and associated equipmentprocess characteristics- advantages and disadvantages- applications.
Chemical Machining: Introduction – fundamental principle- types of chemical machining
Maskants-Etchants- advantages and disadvantages- applications.
Reference books:
l. Bhattacharya “New technology” Institution of Engineers, India
2. H MT “Production technology” Tata Mc Graw Hill.
3. P .C Pandy & H.S. Shan “Modem Machining Process” Tata McGraw Hill.
4. ASM “Metals hand book” Vol-3.
5. F .M Wilson “High velocity forming of metals” ASTME PreticeHall.
6. Adithan “Modem Manufacturing Method”
7. K . Mishra “Modem Machining Processes”.
Course Outcomes:
1. Student learns and understands, explains the need- history for the development of newer/
non-traditional machining process.
2. The students will demonstrate the comparison between non-traditional machining
processes with the traditional machining processes with respect to the different
parameters- Energy sources; Economics of the processes; Shape and size of material etc.
3. The students analyse the concept, mechanism of material removal with respect to
different processes.
4. Different parameters associated with the process, their influence on the machining, will
be analyzed.
5. Advantages, applications and limitations of the various non-traditional machining
processes will be evaluated.
6. Finally, the students will be able to recognize/ identify a process suitable for a particular
material/ for a particular situation based on the availability of the sources.
ADVANCED FOUNDRY TECHNOLOGY
Course Code: MMSE23
Prerequisites: Nil
Credits: 4:0:1
Preamble
The subject comprises a wider and deeper on the engineering aspects of the materials and
methods involved in making castings. It covers bigger spectrum for manufacture products by the
casting techniques with require attributes specify for certain purpose such as intricacy, features
detail, soundness and others. The topics are based upon the recent developments in this field and
include Foundry Metallurgy, Solidification, Casting design, Riser Design, Gating Design,
Furnace Technology, Metal melting & treatment, Cast Iron, Aluminum and Magnesium foundry
practices, Foundry Mechanization and Modernization, casting quality & evaluation. It is aimed
to improve the professionalism and status of casting technology, and with it the products, whilst
the subject has been seen in an industrial context, it has been considered equally essential to
include ideas arising from basic research in the field of casting. It is hoped that such a treatment
will help to strengthen the links between the industry and the centers of education and research.
Course Learning Objective
At the end of this course, the student would be able to understand:
1. Foundry metallurgy and concept of solidification of metals. Interpretation and Use of
Cooling Curves
2. Design aspects of casting, Riser and gating system
3. Advanced melting techniques and control of casting quality
4. Cast iron foundry, particular attention to grey cast iron, ductile iron and malleable iron
5. Aluminum alloy foundry practice discussing principal alloys such as Al-Si, Al-Cu and
Al-Zn-Mg
6. Copper alloy foundry practice
7. Mechanization and Modernization of foundry. Robotic applications
UNIT - I
Foundry Metallurgy: Oxidation of liquid metals, gas dissolution in liquid metals, methods of
degassing, fluidity, factors affecting fluidity, fluidity tests, hot tearing, Shrinkage of liquid
metals.
Solidification of Casting: Concept of solidification of metals. Homogenous and heterogeneous
nucleation. Growth mechanism. Solidification of pure metals and alloys. Mechanism of
columnar and dendritic growth. Coring or Segregation. Solidification time and Chvorinov’s rule.
Concept of progressive and directional solidification. Interpretation and Use of Cooling Curves
(Thermal Analysis), X-Ray Imaging of Solidification Processes and Microstructure Evolution.
UNIT – II
Casting Design: Initial considerations in design, Functional design, Simplification of foundry
practices, Metallurgical design, Economic considerations.
Riser Design: Types of risers and their application, Optimum riser design, Feed metal volume,
Riser location, Progressive and directional Solidification, Feeding Distance, NRL method,
Feeding aids used in riser design, Factors in riser size, computerized method of riser design.
Gating Design: Components of Gating system, Effects of gates on aspiration, turbulence and
dross trap, Presurised versus unpressurized systems, Vertical versus horizontal gating systems.
UNIT – III
Furnace Technology: Cupola and its recent developments, charge calculation, Electron Beam
Melting, Plasma Melting and Heating, Electroslag Remelting.
Casting Quality Control: Casting defects: Shaping faults arising in pouring, Inclusions and
sand defects, Gas defects, Shrinkage defects, Contraction defects, Dimensional errors,
Compositional errors and segregation. Different inspection and testing methods to evaluate the
casting. Coating of Castings, Quality control activities in a foundry.
UNIT – IV
Cast Iron Metallurgy: Classification of cast iron, Composition and graphitization, Carbon
equivalent, Graphite morphology, effect of various elements.
Grey cast iron foundry practice: Melting practice, Inoculation, grey iron alloying, pouring,
Gating and feeding systems, Foundry properties and engineering properties, Specification, Heat
treatment, Applications.
Ductile iron foundry practice: Melting practice, Desulfurization methods, Composition control,
magnesium treatment, inoculation, casting and solidification, Engineering Properties,
Austempered Ductile iron (ADI),Applications.
Malleable iron foundry practice: Melting practice, Structure of White-heart and black-heart
malleable cast iron, Pearlitic malleable iron, Properties and applications.
UNIT – V
Aluminium alloy foundry practice: Melting practice, Moulding, Gating and Risering system,
Effects of alloying and impurity elements, grain refinement effects, modification and refinement
of Al-Si, Al-Cu and Al-Zn-Mg alloys, heat treatment, Properties and applications.
Magnesium alloy foundry practice: Melting practice, Moulding, Alloying additions, Properties
and Applications.
Foundry Mechanization and Modernization: Introduction to modernization. Mechanization of
foundry and its advantages. Mechanization of sand plant, moulding and core making
mechanization in melting, pouring and shakeout units. Material handling equipments and
conveyor systems. Brief sketches and description of layouts of job. Captive and mechanized
foundries. Foundry robotic applications.
Lab Component:
Student carryout experiments under sand testing (base sand tests, mix sand tests), melting and
casting, material properties evaluation, characterization with respect to wear.
Reference Books:
1. R W Heine, C R Loper, and P C Rosenthal, Principles of Metal Casting, 2nd ed, Tata
McGraw Hill, 1976.
2. Beelely, P.R. Foundry Technology, Butterworth, 2001 edition.
3. ASM Handbook, Casting, Vol. 15, ASM Publication, Materials Park, Ohio, 2008.
4. Lal, M. Khanna, O.P., A test book of Foundry Technology Dhapat Rai & Sons
Publication, 2007.
Course Outcome
At the end of this course, the student develops the ability to
1. Design casting, gating and risering systems
2. Deepens the knowledge of science and engineering of solidification of advanced alloys,
interpretation of cooling curves, imaging of solidification process and microstructure
evaluation
3. Ability to select melting and molding techniques for a particular alloy
4. Ability to control casting quality, knowledge in inspection, testing methods and statistical
quality control activities
5. Ability to use the techniques, skills and engineering tools to produce castings of grey cast
iron, ductile iron and malleable iron
6. Foundry practices in advanced Aluminum and copper alloys
7. Ability to implement computer and robot technology in the foundry process to meet
desired needs and to function on multi disciplinary team
8. Broad education to understand the impact of mechanization in melting, pouring and
material handling
9. Ability to engage in foundry practices for various materials and components
THEORY OF METAL FORMING
Course Code: MMSE-E01
Prerequisites: Nil
Credits: 4:0:1
Preamble
The basic objective of forming process is to produce the components having superior properties
compared with the other manufacturing process. The components obtained from this process can
be used for the critical applications. The present course deals with various processes such as
forging, rolling, drawing, extrusion and sheet metal forming process. The various parameters,
load calculations and the defects occurred during the manufacture of wrought products will be
studied
Course Learning Objective
1. The aim of the course is to provide the students, with an opportunity to gain the
knowledge in the field of metal working process with other manufacturing techniques
2. The students learns the different methods of forming process for different materials
3. The students should analyze the basic concepts of stress, yield criteria
4. To gain the knowledge for various parameters affecting forming process
5. To learn the methods, load determination and various defects in the forging process
6. To know various process, rollers , load calculations and defects formed during the
rolling process
7. To learn the methods ,variables ,defects occurred for the drawing and Extrusion of
various products
8. Students should be able to under stand the various processes, defects occurred for the
manufacture of sheet metal products.
UNIT I
Introduction to forming process: Introduction to forming process, classification, properties of
wrought products. Concept of stresses: true stress, true strain and their relation ships,
Determination of principal stresses, stress, determination flow stress, Yield criteria, plane stress
and plane strain, deformation analysis, Numerical problems.
Effect of temperature, metallurgical structure, speed of deformation, Deformation Zone
geometry, Friction and Residual stresses in metal forming process.
UNIT II
Forging: Classification, various stages during forging process, Forging equipment,
determination of forging load using slab analysis, friction hill, design of forging die, forging
defects, residual stresses in forging , Numerical problems.
UNIT III
Rolling: Classification, Rolling mills, rolling of bars and shapes, Theories of hot and cold rolling
Determination of rolling load using slab analysis, forces and geometrical relation ships, Effect of
front and back tension in rolling process, Determination of roll separating force, torque , power
and power losses in bearing , Numerical problems, defects in rolled products, residual stresses in
rolled products.
UNIT IV
Drawing: Introduction, principles of rod and wire drawing, analysis of wire/rod drawing, tube
drawing, analysis of tube drawing, Numerical problems, residual stresses in rod, wire and tubes,
Defects in wire, rod and tubes.
Extrusion: Classification, Extrusion equipment, analysis of extrusion process, Numerical
problems, Deformation in Extrusion, Lubrication and Extrusion defects, Production of Seamless
pipe and tubing
UNIT V
Sheet metal forming: Introduction, forming methods, operations, deep drawing, Forces in
circular cup drawing, Drawability of sheet metal, forming limit diagram, Deep drawing with
tractrix dies, Numerical problems, High energy rate forming processes.
Lab component
Exercises using DEFORM, ESPIRIT (Turning, milling) ect. To be carried out.
Reference Books:
1. Mechanical Metallurgy-Dieter G.E.-Mc Graw publications
2. Principles of metal working- R.Rowe-Amold London
3. Metals Hand book – volumeII-ASM
4. Fundamentals of forming processes-B.L Juneja, New age International Publishers
5. Fundamentals of working of metals- sach G. Pergamon press
Course Outcome
1. The students should learn and understand necessity of forming process compared with
other manufacturing techniques
2. The learning of various methods forming gives an idea for the section of process for
different materials
3. They will be to analyze the stresses and yield criteria used for the deformation analysis of
the process
4. The students should know the parameters effect on the processing of the wrought
products
5. Students should be able to select the process, load required and possible reason the
formation defects for the forged components
6. They should be to identify the process, load calculations and reasons for the formation
defects for the rolled products
7. The students should have the knowledge to identify production of wire, rod , tubes
using different process and problems occurred in the process
8. The students can select the different process for the various sheet metal components
COMPOSITE MATERIALS
Course Code: MMSE-E02
Prerequisites: Nil
Credits: 4:0:0
Preamble
In day to day life we are coming across different types of materials pertaining to engineering
field. We have conventional materials whose properties are already there in the hand books. As
the new inventions are taking place, the conventional materials are not fit at that place. So there
is a need for newer materials which suits to the need, with improved properties and structures.
And also there is a need for the newer materials with improved mechanical, chemical, electrical
and other properties. This course deals with the study of such advanced materials to serve the
required purpose in the field of aerospace and specialty areas, where light weight and high
strength areas of interested.
Course learning Objectives:
1. Students are initially made to know the concept of the conventional materials and their
applications.
2. To obtain brief descriptions for the need of newer materials which are having better
improved properties to suit with conventional materials.
3. To analyze the types of composite materials and their properties, and their applications.
4. To identify the different reinforcement and matrix materials and their properties and
applications.
5. To analyze the different processing/ fabrication techniques of composite materials
especially fiber components
6. The students will have the knowledge of casting of particulate composites and different
processing techniques.
7. To study the micro and macro structural analysis of orthotropic materials, derivation of
equations and application to problem solving.
8. To study the overview of different composite materials to suit the particular applications.
UNIT-I
Introduction to Composite Materials: Definition, Classification, Types of Materials, Types of
reinforcements, Need of Composite Materials .etc
Characteristics and selection of Fiber Composites, laminated composites, Particulate composites,
Prepegs, sandwich construction
UNIT-II
Manufacturing: Layup and curing open and closed mould process, Hand Lay techniques-Bag
Moulding and filament winding Pultrusion, Pulforming, Thermoforming, Injection Moulding.
Cutting, machining and joining, tooling, quality assurance, Introduction to Materials
qualification, Types of defects, NDT methods
UNIT-III
Application, Developments, aircrafts, missiles, space Hardware, automobile, electrical and
electronics, Marine, recreational and Sports equipments, future potential of composite materials
Metal matrix composite & Reinforcement materials , types, characteristics and selection. Base
metals –selection, application & properties.etc
UNIT-IV
Micro mechanical analysis of lamina, Introduction, volume and mass fractions, density and void
content, Evaluation of four elastic moduli. Ultimate strength of unidirectional lamina
Micromechanical analysis of lamina. Introduction, review of definitions, Hookes Law of
different types of materials.Hookes law for two dimensional unidirectional lamina, Hooke’s law
for two dimensional angular lamina. Invariant form of stiffness and compliance matrices for an
angular laminae.hygrothermal stresses and strains in a lamina
UNIT-V
Micromechanical analysis of laminates
Introduction, laminate code, stress strain relations for a laminate, Inplane and flexural modulus
of laminate, hydrothermal effects of laminate
Failure, analysis and design of laminates. Introduction, special cases of laminates, failure criteria
for laminate, design of laminated composite. Other mechanical design issues
Reference Books
1. Rober M.Jones “Mechanics of composite Materials” McGraw Hill Kogakusha Ltd.
2. Michael W,Hyer “ Stress analysis of fiber Reinforced composite materials”,
Graw Hill International
Mc
3. Krishnan K Chawla, “Composite material science and Engineering”, Springer
4. P.C.Mallik, “Fibre reinforced composites” Marcel Decker
Course Outcomes:
1. Students will be able to demonstrate the need for composite materials by comparing the
limitations of conventional materials.
2. The students are given a thorough knowledge of different fabrication techniques and also
by giving on hand practical knowledge of casting.
3. The students are given a thorough knowledge about the materials having light weight to
high strength ratio.
4. The students have thorough knowledge about the composite materials, hybrid composites
and their properties and applications.
5. The students are exposed for the area of usage of composite materials in the field of biomedical areas, high performance areas, high usage areas etc.
6. They demonstrate skill to evaluate composite materials, PMC, CMC, MMC, etc and their
properties and applications.
7. The students compile the different processing or fabrication techniques by the skilled or
semi skilled works and the design of newer dies and fabrication, their characterization
and testing.
8. The students are exposed to different microstuctural and macrostructural analysis.
9. They will be able to express the different fabrication techniques, how the properties are
improved after they are processed through squeeze casting technique, surface treatments,
etc.
10. Finally the students are able to evaluate the composite materials, with advanced casting
techniques and to improve their properties.
AUTOMATION IN MANUFACTURING
Subject Code: MMSE E03 / MCIM E03
Prerequisites: Nil
Credits: 4:0:0
Preamble:
Automation technology such as robotics, machine tools, handling systems, controllers and
computers are the basis of almost all important industries in the world and provide
manufacturing industry with the means to improve quality, reduce errors, increase productivity
and reduce cycle times. Manufacturing has had a long history, ranging from the initial creation of
simple, hand-crafted items, to the development of large complex factories that include a host of
factory-related production and fabrication techniques. The study of the systems of manufacturing
and production has evolved into a complex field of research in its own right. Manufacturing and
production in the contemporary world faces many challenges
This Course is designed to emphasize the knowledge on the quality improvement,
automation, and advanced manufacturing techniques and impart the student with knowledge of
concepts and techniques, which have recently been applied in many practical situations. It gives
a framework of knowledge that allows the students to develop an interdisciplinary understanding
and integrated approach to overcome the challenges of automation in manufacturing.
Course Learning Objective:
1. The aim of the course is to define the concept of Automation and Building blocks,
Fundamentals of Manufacturing.
2. To enable student to understand components of automated production, methods and types of
transfer mechanism deployment of storage buffers in automated production line
3. To explain the concept of partial automation, automated assembly system and line balancing
4. To enable a student to develop ladder logic diagrams and PLC programming for industrial
automation applications.
5. To enable the student to understand the concept of on line computer control of industrial
automated processes
UNIT –I
Automation and Building Blocks:
Automation, Reasons for Automation, Basic Elements of Automated system, advanced
automation functions, Levels of automation, Automation Strategies, Production concept and
Mathematical Models, Functions of Manufacturing.
UNIT –II
Detroit-type Automation:
Methods of transport, Transfer Mechanisms, Buffer storage, Automation for machining
operations, Design and Fabrication considerations, Automated Flow lines, Analysis of automated
Flow Lines with and without buffers
UNIT –III
Partial automation, analysis of assembly lines and line balancing
Partial automation, assembly systems, manual and automated assembly lines, analysis of
multistage assembly lines, line balancing problems, methods of line balancing
UNIT –IV
Logic Diagrams:
Logic networks, Ladder Logic Diagrams, Timers, Response diagram. Programmable Logic
Controllers: Introduction, PLC cycle, PLC internal features, PLC programming
UNIT –V
Application programs,
Advantages and Disadvantages of PLCs, On line Computer Control: Process control computers,
Levels of implementations, Control strategies, Process interface, Interrupters, Process Computer
Programming.
Text Books:
1. Performance Modeling of Automated Manufacturing Systems By Vishwanadhan. PHI.
2. Principles and applications of PLC, by Webb, McMillan 1992.
3. Automation, Production systems and CIM by Mikell P Grover, Person Education, Asia
Reference Books:
1. Robotics and Manufacturing Automation, by C Ray Asfahl, John Wiley and Sons,
Inc, Second edition.
2. Principles of CIM by Vajpayee, PHI.
Course Outcome:
1. Students will be able to evaluate the Manufacturing Lead Time (MLT), Production Rate,
Plant capacity by applying the concepts of automated production.
2. Students will be able to involve in the design of transfer mechanisms required for work
part transfer in manufacturing sector and exposed to the deployment of buffer storage
mechanisms that are used in automated production line.
3. Students will be able to implement partial automation, automated assembly system and
the concept of Line balancing
4. Students will be able to develop ladder logic diagrams and PLC programming for
industrial automation applications.
5. Students will be able to implement the concept of on line computer control of industrial
automated processes
NANO TECHNOLOGY
Course Code: MMSE-E04
Prerequisites: Nil
Credits: 4:0:0
Preamble
The world of materials science is witnessing a revolution in the exploration of matter at the small
scale. Sub-atomic particles have been a fascination since the first half of the 20th century. The
science of nanometer scale objects is nanoscience. The resulting technology is called
nanotechnology. Nanotechnology involves achieving the capability to manipulate matter in a
desired fashion, atom by atom. At this scale, the constituents of matter do functions, which are
different from those of the constituents or bulk materials. The course introduces the fundamental
concepts, principles, fabrication, characterization and application of nanomaterials
Course Learning Objective
At the end of this course, the student would be able to understand:
1. Physics of Nano Science
2. Semiconductor Nanostructures
3. Chemistry of Nanoscience
4. Fabrications of Nanostructures
5. Characterization of Nanostructures
6. Nano Tribology
7. Nanomechanical properties
Unit - I
Introduction: Overview of Nanoscience and Nanotechnology, Classification of nanostructures,
Nanoscale Architecture, Scaling and miniaturization laws
Electronics Properties Of Atoms and Solids: The isolated atom - Bonding between atoms LCAOs. - Van der Waals forces- Dispersion interaction - Orientation interaction _ Induction
interaction, Stating Schrodinger’s wave equation and its importance - Physical Significance of
wave function - Eigen values and Eigen functions. The Free electron (particle) model and energy
bands- particle in 1¬ D potential well of infinite height (discussion on energy values, wave
functions - normalization and probability densities), Particle in 1- D potential well of finite
height - Concept of tunneling- Heisenberg’s uncertainty principle- Derivations of Density of
states for 3D, 2D, I D and OD, and graphical representations.
Effects of Nanometer Length Scale: Changes to the system total energy, Changes to the system
structure, Effect of nanoscale dimensions on properties- structural, thermal, Chemical,
mechanical, magnetic, optical and electrical.
Inorganic Semiconductor Nanostructures: semiconductor, Doping, concept of effective mass,
Carrier transport, mobility and electrical conductivity, Optical property of semiconductors, The
P-N junction, Phonons, Types of semiconductors
Quantum Confinement in Semiconductor Nanostructures: Quantum confinement in one
dimension- quantum well; Quantum confinement in two dimensions- quantum wires; Quantum
confinement in three dimensions- quantum dots, Super lattices, Band offsets.
Unit - II
Fullerenes: structure and synthesis, chemical reactivity-Chemistry of higher fullerenesapplications.
Nanotubes: carbon forms structured by energetic species-amorphous nanotubes and crystalline
forms, Carbon- an ideal model system to study structuring by energetic species, structuring of
amorphous carbon forms, structuring of ordered Sp2 forms, structuring carbon forms. Synthesis
and purification of multiwalled and single walled carbon nanotubes: Electric arc (arc
evaporation) technique, laser ablation, catalytic decomposition of hydrocarbons purification.
Structure and properties of carbon nanotubes, Inorganic nanotubes- structure, synthesis and
properties. Electron transport in nanotubes, Ballistic, Spintronics, Coulomb blockade and Nano
wires, Organic semiconductors, Organic light emitting diodes.
Self-Organization: Phase behavior of Nano particle suspensions, hard sphere Behavior, soft
repulsions, and weakly attractive suspensions.
Catalysis: Nano crystalline zeollites- Hydrothermal synthesis of nanocrystalline zeollitesapplication in environmental catalysis, selective partial oxidation reactions of hydrocarbons and
photo catalytic decomposition of organic contaminations using nanocrystalline zeollites.
Nanoclusters- Properties and applications in catalysis.
Surface and Interface Chemistry: Colloid systems - Colloids theory of coagulation, micells,
nanocrystals and their super lattices. Background of the measurement of surface forces and
interface forces. Optical, thermal and magnetic properties of nanomaterials: ApplicationsBiosensors, Optical tweezers, Paints Laser materials, Membranes and mesoporous materials,
Water Purification. Molecular motors, Nanospring, Nanobalance. Atomic manipulation Quantum corrals, Quantum mirage.
Unit - III
Fabrications of Nanostructures: Top-Down Processes-Milling; Silicon VLSI fabrication
processes - Doping, Oxidation / Deposition, Etching; Lithographic processes - Photo, e-beam,
Focused ion beam, X¬-ray: Soft Lithography; Machining - Micromachining, Micromachining,
and LlGA. (MEMS processes); Applications- Nano- and Micro-machines (NEMS and MEMS)
Nanotube FET, Interconnects and Electron emitters
Bottom - Up Processes: Vapor deposition methods - MBE, OMVPE; Hetrostructures, Quantum
Wells, Multiple Quantum Wells; Quantum Wires and Quantum Dots; Modulation doping
devices, Resonant Tunneling Devices;
QWIP, Quantum Well lasers, photonic crystals, Nano computing; Liquid Phase methods molecular and biological computing; Colloidal methods; Sol-gel methods; Electrodeposition;
Self-assembly and self-organization processes
Unit - IV
Basics Of Scattering Physics Related to Characterization:
X-rays and their interaction with matter.
Electron and their interaction with matter.
Phonon scattering.
Plasmon scattering.
Single-electron excitation.
Direct radiation losses.
Neutrons and their interaction with matter.
Ions and their interaction with matter. Elastic scattering and diffraction.
Technology of Characterization:
Profilometry, Optical microscope, SEM, TEM, FIB.
STM, AFM, Surface Raman Scattering, Wettability (contact angle) measurements, Small angle
X-ray diffraction and electron diffraction
Unit - V
Nanotribology: Composition and structure of surfaces natural condition: oxide and hydrocarbon
films surface segregation and reaction with environments, thermodynamics structure of surfaces,
atomistic simulations methods to study composition and structure of surfaces composition Auger electron spectroscopy, X -ray photoelectron spectroscopy
Structure-LEED,STM/AFM,XRD,HRE, Chemical interactions on surfaces, adsorption and
deposition on surfaces (physisorption and chemisorption); Langmuir adsorption isothenn,
desorption from surfaces: Electronic properties and surface reactions relevant to tribology,
density functional studies analysis structure sensitivity lubricant degradation.
Nanomechanical properties: Determination of surface mechanical Properties (AFM/
nanoindentation), simple friction theories -effects of surface composition and structure: on
friction environmental and temperature effects, relationship with surface chemistry, mixed and
boundary lubrication, failure mechanisms.
REFERENCE BOOKS:
1. Handbook of Nanoscience Engineering and Technology, Ed. William A. Goddard III,
Donald W.Brenner, Sergey Edwart Lyschevski and Gerald J.Iafrate, CRC Press, New
York (2003).
2. Microlithography Fundamentals in Semiconductor Devices and Fabrication Technology,
by Ueno T., Ito T. and Nonogaki S., Marcel Dekker (1998).
3. Semiconductor Lithography: Principles, Practices and Materials, by William Moreau,
Plenum Press (1988).
4. Sub-Half Micron Lithography for ULSI, Ed. by Matsui S., Ochiai Y., and Suzuki, K.,
Cambridge University Press (1999).
5. Nanolithography: A Borderland between STM, EB, IB and X-ray Lithographies, Ed. by
Gentili M., Giovannella c., and Se1ci S., NA TO Asi Series E: Applied Sciences, vol.
264, Kluwer Academic Publishers (1994).
6. Solid State Physics, by G.I. Epifanov, Mir Publishers (1979).
7. Semiconductor Devices - Physics and Technology, by S.M. Sze, John Wiley & Sons
(2003).
8. Introduction to Semiconductor Devices, by Kevin F. Brennan, Cambridge University
Press (2005).
9. The MEMS Handbook, by M.Gad-EI-Hak.
10. Nanoscale Science and Technology, Ed. by Robert Kelsall, lam Hamley and Mark
Geoghegan, John Wiley & Sons (2005).
11. Fundamental of Machine Elements, by Hamrock, Jacobson and Schmid.
12. Tribology, Principles and Design Applications, by Amell et al.
13. Tribology Handbook, by B.Bhushan.
14. Principles and Applications ofTribology, by B. Bhushan. Fluid Film Lubrication, by
Hamrock
Course Outcome
At the end of this course, the student will have
1. The ability to appreciate the current trends in nanotechnology and critical evaluation of
the technological potential of inorganic nanostructured materials.
2. Able to understand the physics and chemistry of Nanoscience
3. Gain knowledge of various fabrication processes and classification techniques for
preparing nanostructures.
4. Gain knowledge of various nanoscale characterization tools and their use to characterize
nanostructured materials.
5. To understand Nanotribology and Nano mechanical properties
FERROUS AND NON-FERROUS FOUNDRY PRACTICE
Course Code: MMSE-E05
Prerequisites: Nil
Credits: 4:0:0
Preamble
Metal castings are fundamental building blocks, the three-dimensional integral shapes
indispensable to practically all other manufacturing industries. Although the manufacturing path
from the liquid to the finished shape is the most direct, this directness involves the greatest
difficulty. This is because so much needs to be controlled simultaneously, including melting,
alloying, molding, pouring, solidification, finishing, etc. Every one of these aspects has to be
correct since failure of only one will probably cause the casting to fail. The course introduces the
fundamental concepts, principles, melting practices, molding and heat treatment of ferrous and
non ferrous alloys.
Course Learning Objective
At the end of this course, the student would be able to understand:
1. Foundry metallurgy and concept of solidification of metals. Interpretation and Use of
Cooling Curves
2. Advanced melting techniques and Foundry automation
3. Cast iron foundry, particular attention to grey cast iron, ductile iron and malleable iron
4. Synthesis and Processing of Alloy steels, Cast Metal-Matrix Composites and Ti alloys
5. Foundry practice in Aluminum alloys, Magnesium alloys, Copper alloys and Nickel
alloys
Unit – I
Foundry Metallurgy: Oxidation of liquid metals, gas dissolution in liquid metals, methods of
degassing, fluidity, factors affecting fluidity, fluidity tests, hot tearing, Shrinkage of liquid
metals.
Solidification of Casting: Concept of solidification of metals. Homogenous and heterogeneous
nucleation. Growth mechanism. Solidification of pure metals and alloys. Mechanism of
columnar and dendritic growth. Coring or Segregation. Solidification time and Chvorinov’s rule.
Concept of progressive and directional solidification. Interpretation and Use of Cooling Curves
(Thermal Analysis), X-Ray Imaging of Solidification Processes and Microstructure Evolution.
Unit – II
Furnace Technology: Study of various furnaces used in foundry, construction and operation of
crucible and hearth furnaces. Resistance, Arc and Induction furnaces-their construction,
operation and application. Cupola and its recent developments, charge calculation, Electron
Beam Melting, Plasma Melting and Heating, Electroslag remelting. Heat treatment furnaces and
drying ovens used in foundry.
Foundry Mechanization and Modernization: Introduction to modernization. Mechanization of
foundry and its advantages. Mechanization of sand plant, molding and core making
mechanization in melting, pouring and shakeout units. Material handling equipments and
conveyor systems. Brief sketches and description of layouts of job. Captive and mechanized
foundries. Foundry robotic applications.
Coating of Castings, Quality control activities in a foundry
Unit – III
Gray Cast - Iron Foundry Practice: Chemical Composition and structure of gray cast iron.
Molding, gating and risering techniques. Melting of gray cast iron in Cupola and induction
furnace. Inoculation of gray cast iron. Application of gray cast iron castings.
Malleable Cast Iron: Chemical composition and structure of White-heart and black-heart
malleable cast iron. Melting malleabilisation heat treatment and application of malleable cast
iron.
Ductile Cast Iron: Chemical composition and structure of ductile cast iron. Melting and
spherodisation treatment. Inoculation of ductile iron Properties and application of ductiles iron
casting.
Unit – IV
Alloy Steel Technology: Processing, microstructure & mechanical properties of different alloy
steels such as HSLA steels, Dual phase steels, IF steels, stainless steels, silicon steels, high speed
steels, ball bearing steels, Had field steels
Synthesis and Processing of Cast Metal-Matrix Composites: Solidification Processing of
MMCs and Possible Effects of Reinforcement on Solidification, Stir Casting, Centrifugal
casting, Infiltration Processes, Effects of Reinforcement Present in the Liquid Alloy on
Solidification, Fly-Ash-Filled Syntactic Foams, Cast Metallic Foams.
Titanium and Titanium Alloy Castings: Alloy Systems, Effects of Alloying Elements, Melting
and Pouring, Molding Methods, Heat Treatment of Titanium Castings.
Unit – V
Aluminum Foundry Practice: Composition, properties and application of common aluminum
alloy casting. Melting and casting of AI-alloys. Gating and risering of Al-alloy casting.
Magnesium alloy foundry practice: Melting practice, Moulding, Alloying additions, Properties
and Applications.
Copper Alloy Foundry Practice: General characteristics of common cast copper alloys.
Melting and casting of copper alloys. Gating and risering of cu-alloy castings.
Nickel and Nickel Alloy Castings: Compositions, Melting Practice and Metal Treatment,
Pouring Practice, Gating Systems, Risers, Heat Treatment.
REFERENCE BOOKS:
1. R W Heine, C R Loper, and P C Rosenthal, Principles of Metal Casting, 2nd ed, Tata
McGraw Hill, 1976.
2. Beelely, P.R. Foundry Technology, Butterworth, 2001 edition.
3. ASM Handbook, Casting, Vol. 15, ASM Publication, Materials Park, Ohio, 2008.
4. Lal, M. Khanna, O.P., A test book of Foundry Technology Dhapat Rai & Sons
Publication, 2007.
5. F.P. Edneral: Electrometallurgy of Steel and Ferro – Alloys, Vol. I, Mir Publishers, 1979.
6. R.W.K.Honeycomb: Steels, Microstructures and Properties, Edward Arnold.
7. P.G.Shewmon, Transformations in Metals, McGraw Hill.
8. Dr. S. Smith, Principles of Materials Science and Engineering, McGraw Hill.
Course Outcome
At the end of this course, the student will have
1. Deepens the knowledge of science and engineering of solidification of advanced alloys,
interpretation of cooling curves, imaging of solidification process and microstructure
evaluation
2. Learnt to select melting and molding techniques for a particular alloy
3. Learnt to use the techniques, skills and engineering tools to produce castings of grey cast
iron, ductile iron and malleable iron
4. Foundry practices in advanced Aluminum, Magnesium, Nickel and copper alloys
5. Gain knowledge in Synthesis and Processing of Cast Metal-Matrix Composites, Alloy
steels, Titanium alloys.
MAINTENANCE ENGINEERING AND MANAGEMENT
Course code: MMSE06
Prerequisite: Nil
Credits: 4:0:0
Preamble
Maintenance is one of the most indispensable jobs in any organization. With the growth of
industry and its modernization, new challenges are being faced by maintenance personal in their
efforts to minimize the down time and consequently ensure a longer trouble free working life of
numerous machinery and equipment. The art of optimizing the available resources of Manpower,
materials, tools and equipments with in a set of constraints, to help achieve the goals and
objectives of organizations. whether the goals is to produce and sell a product at a profit or is
simply to perform a mission in a cost effective manner, the maintenance principles are apply
equally to any type of organizations . Maintenance is one of the most essential and important
activities in any organization whether it may be product oriented or service oriented sectors.
Managerial skill must be incorporated in maintenance design and procedures .to this end the
engineering education system has included maintenance engineering as a part of its curriculum.
the present topic introduces the basics of maintenance for Postgraduate students of engineering
and provides them broad views of maintenance that would assist in taking better managerial
decisions wherever a situation demands.
Course learning objective
1. To provide basic of the maintenance objectives, functions and organization structure of the
maintenance department in any organization. the students, with an opportunity to gain the
knowledge of Maintenance in the field of production as well as service sectors.
2. To understand different modes of maintenance to be incorporated in any organization To
Learn the different methods of Metalworking process for different materials
3. To analyze modes of failure of a facility in any organization, application of statistics in
failure analysis through some simple models.
4. Development of preventive maintenance concept is introduced in this topic based on
maintenance budget.
5. Inspection concept and optimal inspection frequency is to be expose to the students to design
optimal inspection frequency concept for any organization.
6. Students can able to under stand concept of maintenance planning and scheduling techniques
7. To gain the knowledge of repair cycle, repair complexity and maintenance control indices,
individual replacement and group replacement concept to take best replacement decisions.
8. Students can learn the concept of optimal repair, replacement and overhaul concept to take
best decision to run the plant in optimal way.
9. To learn the basic concept of non destructive testing methodology and lubrication program as
a part of maintenance activities in a organization.
10. To learn the meaning of spare parts, spare parts control to run the plant efficient manner.
The fundamental concept of CPM and PERT techniques and there application in maintenance
projects are to be study.
UNIT – I
1. Objectives and functions of Maintenance, Maintenance Strategies. Organization for
Maintenance. Characteristics, Benefits, Objectives and Policies of maintenance, Organization
and structure of maintenance system: Mechanics of maintenance system.
2. Maintenance Systems: Fixed Time Maintenance, Condition based Maintenance, Operate to
Failure, opportunity maintenance, Design out maintenance, total productive maintenance
UNIT – II
3. Failure Statistics: Breakdown time distributions, Poisson, Exponential and Normal
distribution.
4 .Development of preventive maintenance schedule: Planned prevention of breakdowns –
Predictive maintenance - Condition monitoring - Equipment codification and classification Maintenance budgeting and cost control - Production maintenance integration
UNIT - III
5. Inspection Decision: Optimal Inspection frequency (for maximization of profit and
minimization of downtime)
6 Maintenance Planning scheduling: Planning and scheduling maintenance activities
Scheduling techniques
UNIT - IV
7. Replacement Decisions: Optimal interval between preventive replacements of equipment
subject to breakdown, group replacement. Repair cycle, Repair Complexity and Maintenance
control Indices. Concept of Terrotechnology.
8. Optimal Overhaul, Replacement and Repair: Meaning and Difference, optimal
overhaul/Repair / Replace maintenance policy for equipment subject to breakdown.
UNIT - V
9. Non-destructive Testing [NDT]
in Maintenance Engineering, concept and applications
Inspection, Lubrication program development,
10. Application of CPM and PERT in maintenance engineering, Spare parts Management,
References:
1. Hand book of Maintenance Management _Frank Herbaty-2000
2. Gopala Krishna & A K Banerji “Maintenance and Spare parts Management”
3. Kelly and M.J. Harries “Management of Industrial Maintenance “Butterworth and
company Limited.
4.
Mishra and Pathak K “Maintenance Engineering and Management “PHI New
Delhi2003
5. Maintenance Engineering. Handbook-Higgins
6. Maintenance planning and control-Anthony Kelly
7. Industrial maintenance -H.P.Garg
8. Plant Engineering Hand book - Stainer
9.
10.
11.
12.
13.
14.
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
Maintainability Principles and Practices by Blanchard, B.S., McGraw Hill, New York 1969.
Maintenance Management by Carder, A.S., McGraw Hill, NY, 1976.
Joseph D patton “ preventive Maintenance” instrument society of America
Srivastava S K “Industrial maintenance and management” PHI New Delhi
Ireson & Grant “Hand book of Industrial Engg & management “ PHI New Delhi
Siachi Nakajima “A gudi to TPM”
Course learning outcome
The students are able to understand the meaning of Maintenance, objective and functions of
maintenance departments and importance of maintenance and organization for maintenance.
Students had the basic concepts of modes of maintenance and selection maintenance methods
for various types of organizations like product oriented and service oriented sectors based on
the understanding.
Failure statistics was understood in this topic, simple models were used to analyze the failure
rate and failure parameters.
Preventive maintenance [PM] concept and implementation of PM advantages and
disadvantages are understood by the students .maintenance budget cost control techniques
were understood at this level.
Inspection of plant and optimal inspection frequency of a plant based on maximization of
profit and minimization of down time was studied.
Maintenance planning and different maintenance scheduling techniques were thought at this
level
Repair cycle, repair complexity maintenance control indices were understood from the
students, based on this concept students are able to under stood replacement concept very
clearly
Concept of repair, replacement and overhaul were studied in this chapter. Optimal repair /
replacement / overhaul was developed for minimize the over all cost and maximize the
profit
In this chapter students are exposed to NDT methods generally used in maintenance activities
and there importance to run the plant in efficient way. The fundamental concept of PERT and
CPM was discussed with numerical example to understand the basic concept and application
of PERT and CPM in maintenance engineering.
The meaning of spare parts, types of spare parts, spare parts control like ABC analysis,
VEIN, VED, and MUSIC-3D approach were studied in this topic.
PRODUCT DEVELOPMENT
Course code: MMSE E07
Prerequisites: Nil
Credits: 4:0:0
Preamble
This subject aims at developing process for successful product development. Concepts, product
planning and product specification. Further it also emphasizes on identifying customer needs,
design and manufacturing concepts.
Unit - I
Introduction: Characteristics of successful product development who Designs and develops
products, duration and cost of product development, the challenges of product development.
Development Processes and Organizations: A generic development process, concept
development: the front-end process, adapting the generic product development process, the AMF
development process, product development organizations, the AMF organization.
Product Planning: The product planning process, identify opportunities. Evaluate and prioritize
projects, allocate resources and plan timing, complete pre project planning, reflect all the results
and the process.
Unit - II
Identifying Customer Needs: Gather raw data from customers, interpret raw data in terms of
customer needs, organize the needs into a hierarchy, establish the relative importance of the
needs and reflect on the results and the process.
Product Specifications: What are specifications, when are specifications established,
establishing target specifications setting the final specifications.
Unit - III
Concept Generation: The activities of concept generation clarify the problem search externally,
search internally, explore systematically, reflect on the results and the process.
Concept Selection: Overview of methodology, concept screening, concept scoring, caveats.
Concept Testing: Define the purpose of concept test, choose a survey population, choose a
survey format, communicate the concept, measure customer response, interpret the result, reflect
on the results and the process.
Unit - IV
Product Architecture: What is product architecture, implications of the architecture,
establishing the architecture, variety and supply chain considerations, platform planning, related
system level design issues.
Industrial Design: Assessing the need for industrial design, the impact of industrial design,
industrial design process, managing the industrial design process, is assessing the quality of
industrial design.
Design for Manufacturing: Definition, estimation of manufacturing cost, reducing the cost of
components, assembly, supporting production, impact of DFM on other factors.
Unit - V
Prototyping: Prototyping basics, principles of prototyping, technologies, planning for
prototypes.
Product Development Economics: Elements of economic analysis, base case financial mode,.
Sensitive analysis, project trade-offs, influence of qualitative factors on project success,
qualitative analysis.
Managing Projects: Understanding and representing task, baseline project planning,
accelerating projects, project execution, postmortem project evaluation.
Text Book:
1. Product Design and Development: Karl. T. Ulrich, Steven D Eppinger,. Irwin
McGrawHill-2000.
2. Successful Product Design, Hollins. B and Pugh S, Butterworths, London, 1990.
3. Handbook of Product Design for Manufacture, Bralla, J.G., McGraw- Hill, New York,
1988.
Reference Books:
1. Product Design and Manufacturing: A C Chitale and R C Gupta, PH1
2. New Product Development: Timjones. Butterworth Heinmann,, Oxford. UCI. 1997
3. Product Design for Manufacture and Assembly: Geoffery Boothroyd, Peter Dewhurst and
Winston Knight.
PRODUCT DATA & MANAGEMENT
Course Code: MMSE E08
Prerequisites: Nil
Credits: 4:0:0
Preamble
With change in technology different methods of storing data pertaining to the manufacturing
field have evolved. There are continuous studies on improvement of the product life by using
various techniques. There are some standard methods of preparing the data and storing the same.
And also there is a need to improve the methods of manufacturing. This course deals with the
study of such advanced manufacturing to serve the required purpose.
Course Learning Objectives:
1. Students are initially made to know the concept of the subject Products Data and its
managing ability, Life cycle of the product, methods of manufacturing etc.
2. Students will have the knowledge to study life cycle of the product and its management
3. To analyze different processes/ terminologies of the change management and its
applications
4. To obtain brief description of structure of management and its configuration with
different resources for creating data
5. The students will have the knowledge to improve different methods of management such
as concept of agility, enterprise integration etc.
Unit-I
INTRODUCTION: PDM-present market constraints, need for collaboration- Internet and
developments in server-client computing, Components of a typical PDM, set-up hardware and
software, document management, creation and viewing of documents, creating parts-version,
control of parts and documents, case studies.
Unit-II
CONFIGURATION MANAGEMENT: Software configuration management, Computer
hardware configuration management, Maintenance systems, Configuration Management and
Engineering Change Control, Configuration Control, Base lines-product structure, configuration
management, case studies.
Unit -III
Product life cycle :Life cycle of a product- life cycle management, automating information flow -
work flows, Creation of work flow templates, life cycle, work flow integration, case studies.
Unit-IV
CHANGE MANAGEMENT: Change Management (An It Perspective)change issue, change
request, investigation, change proposal-change activity, Borland Change Management Solutions,
Change Management System, Case Studies.
Unit-V
Database and Database Users: Introduction, Building blocks, Database design, ER Diagram
(Entity-relationship model) advantages and implementation of database approach
Agile supply CHAINS management: Introduction, characteristics of Agile Manufacturing Concept
of Agile Manufacturing Strategy Of Agile Manufacturing, Methodology Of Marketing, Key
Issues in Agile Manufacturing, Future Of Agile Manufacturing
Text books:
1. David Bed worth. Mark Henderson &. Philips Wolfe, "Computer Integrated Design and
Manufacturing"', McGraw Hill Inc., 1991.
2. Product Design and Manufacturing, A.C. Chitale and R.C. Gupta, PHI 4th edition 2007.
3. ‘Agile Manufacturing- Forging Mew Frontiers’, Poul T Kidd, Amagow Co. UK, ISBN-0201-63163-6, 1994
4. Fundamentals of Database Systems, Ramez Elmasri and Shanmkanth B. Navathe, 3rd
Edition, Addison Pearson.
Reference books:
1. Terry Quatrain "Visual Modeling with Rational Rose and UML",Addison Wesley, 1998.
2. Wind-chill RS.O Reference manuals. 2000.
Course Outcomes:
1. Students are capable to define the concept of the subject Products Data and its managing
ability, Life cycle of the product, methods of manufacturing etc. (PO: a, b, e, f, j)
2. Students are capable and they can define the life cycle of the product and its
management(PO: c,b, e, f)
3. Students are capable to understand the methods/ processes involved in the change
management. (PO: a, b, e, f, j, l)
4. Students become aware of configuration management and structure of management with
different types of data resource management. (PO: a,b, e, f)
Students are capable to compile about the different methods of management.(PO: a, c,
PRODUCT DATA & MANAGEMENT
Course Code: MMSE E08
Prerequisites: Nil
Credits: 4:0:0
Preamble
With change in technology different methods of storing data pertaining to the manufacturing
field have evolved. There are continuous studies on improvement of the product life by using
various techniques. There are some standard methods of preparing the data and storing the same.
And also there is a need to improve the methods of manufacturing. This course deals with the
study of such advanced manufacturing to serve the required purpose.
Course Learning Objectives:
6. Students are initially made to know the concept of the subject Products Data and its
managing ability, Life cycle of the product, methods of manufacturing etc.
7. Students will have the knowledge to study life cycle of the product and its management
8. To analyze different processes/ terminologies of the change management and its
applications
9. To obtain brief description of structure of management and its configuration.
10. The students will have the knowledge to improve different methods of management such
as concept of agility, enterprise integration etc.
11. To study the overview of different resources for creating data
Unit-I
INTRODUCTION: PDM-present market constraints, need for collaboration- Internet and
developments in server-client computing, Components of a typical PDM, set-up hardware and
software, document management, creation and viewing of documents, creating parts-version,
control of parts and documents, case studies.
Unit-II
CONFIGURATION MANAGEMENT: Software configuration management, Computer
hardware configuration management, Maintenance systems, Configuration Management and
Engineering Change Control, Configuration Control, Base lines-product structure, configuration
management, case studies.
Unit -III
Product life cycle :Life cycle of a product- life cycle management, automating information flow -
work flows, Creation of work flow templates, life cycle, work flow integration, case studies.
Unit-IV
CHANGE MANAGEMENT: Change Management (An It Perspective)change issue, change
request, investigation, change proposal-change activity, Borland Change Management Solutions,
Change Management System, Case Studies.
Unit-V
Database and Database Users: Introduction, Building blocks, Database design, ER Diagram
(Entity-relationship model) advantages and implementation of database approach
Agile supply CHAINS management: Introduction, characteristics of Agile Manufacturing Concept
of Agile Manufacturing Strategy Of Agile Manufacturing, Methodology Of Marketing, Key
Issues in Agile Manufacturing, Future Of Agile Manufacturing
Text books:
5. David Bed worth. Mark Henderson &. Philips Wolfe, "Computer Integrated Design and
Manufacturing"', McGraw Hill Inc., 1991.
6. Product Design and Manufacturing, A.C. Chitale and R.C. Gupta, PHI 4th edition 2007.
7. ‘Agile Manufacturing- Forging Mew Frontiers’, Poul T Kidd, Amagow Co. UK, ISBN-0201-63163-6, 1994
8. Fundamentals of Database Systems, Ramez Elmasri and Shanmkanth B. Navathe, 3rd
Edition, Addison Pearson.
Reference books:
3. Terry Quatrain "Visual Modeling with Rational Rose and UML",Addison Wesley, 1998.
4. Wind-chill RS.O Reference manuals. 2000.
Course Outcomes:
5. Students are capable to define the concept of the subject Products Data and its managing
ability, Life cycle of the product, methods of manufacturing etc.
6. Students are capable and they can define the life cycle of the product and its management
7. Students are capable to understand the methods/ processes involved in the change
management.
8. Students become aware of configuration management and structure of management.
9. Students are capable to compile about the different methods of management.
10. The students are exposed to different types of data resource management.
11. Finally the students are able to evaluate the different methods of data storing and its
management.
SMART MATERIALS AND STRUCTURES
Course code: MMSE E09
Prerequisites: Nil
Credits: 4:0:0
Preamble
Smart Materials are being developed since last decade in the laboratories all around the world.
These are materials which are capable of generating controllable response to the environment. As
actuators, they can produce controllable force to modify the response of a system. As sensors, the
same material could be used to monitor the response of the system. Smart materials are being
traditionally used in aerospace applications since last decade. Using smart actuators one can
modify the flexible modes of a system such that the control effort would not interfere with the
vibrating frequencies of the structure. The course introduces the fundamental concepts,
principles, measurement, Design, Manufacturing and application of Engineering Smart
Structures and Products.
Course Learning Objective
At the end of this course, the student would be able to understand:
1. Physical Properties of Smart Materials
2. Smart Sensor, Actuator and Transducer Technologies
3. Measurement and Signal Processing
4. Design, Analysis, Manufacturing and applications of Smart Structures
Unit - I
Overview of Smart Materials, Structures and Products Technologies.
Smart Materials (Physical Properties) Piezoelectric Materials, Electrostrictive Materials,
Magnetostrictive Materials, Magnetoelectric Materials. Magnetorheological Fluids,
Electrorheological Fluids, Shape Memory Materials, Fiber-Optic Sensors.
Unit - II
Smart Sensor, Actuator and Transducer Technologies: Smart Sensors: Accelerometers; Force
Sensors; Load Cells; Torque Sensors; Pressure Sensors; Microphones; Impact Hammers; MEMS
Sensors; Sensor Arrays Smart Actuators: Displacement Actuators; Force Actuators; Power
Actuators; Vibration Dampers; Shakers; Fluidic Pumps; Motors Smart Transducers: Ultrasonic
Transducers; Sonic Transducers.
Unit - III
Measurement, Signal Processing, Drive and control Techniques: Quasi-Static and Dynamic
Measurement Methods; Signal Conditioning Devices; Constant Voltage, Constant Current and
Pulse Drive Methods; Calibration Methods; Structural Dynamics and Identification Techniques;
Passive, Semi-Active and Active Control; Feedback and Feed forward Control Strategies.
Unit - IV
Design, Analysis, Manufacturing of Engineering Smart Structures and Products: Case
studies incorporating design, analysis, manufacturing and application issues involved in
integrating smart materials and devices with signal processing and control capabilities to
engineering smart structures and products.
Unit - V
Information Processing: Neural Network, Data Processing, Data Visualization and Reliability.
Applications of Engineering Smart Structures and Products: Emphasis on structures,
automation and precision manufacturing equipment, Aerospace, automotives, consumer
products, sporting products, computer and telecommunications products, as well as medical and
dental tools and equipment.
Reference Books:
1. Smart Materials and Structures - M. V. Gandhi and B. So Thompson, Chapman and Hall,
London; New York, 1992 (ISBN: 0412370107).
2. Smart Structures and Materials - B. Culshaw, Artech House, Boston, 1996 (ISBN:
0890066817).
3. Smart Structures: Analysis and Design - A. V. Srinivasan, Cambridge University Press,
Cambridge; New York, 2001 (ISBN: 0521650267).
4. Electroceramics: Materials, Properties and Applications - A. J. Moulson and J. M.
Herbert. John Wiley & Sons, ISBN: 0471497429
5. Piezoelectric Sensories: Force, Strain, Pressure, Acceleration and Acoustic Emission
Sensors. Materials and Amplifiers, Springer, Berlin; New York, 2002 (ISBN:
3540422595).
6. Piezoelectric Actuators and Wtrasonic Motors - K. Uchino, Kluwer Academic Publishers,
Boston, 1997 (ISBN: 0792398114).
7. Handbook of Giant Magnetostrictive Materials - G. Engdahl, Academic Press, San
Diego, Calif.; London, 2000 (ISBN: 012238640X).
8. Shape Memory Materials - K. Otsuka and C. M. Wayman, Cambridge University Press,
Cambridge; New York, 199~ (ISBN: 052144487X).
Course Outcome
1. Learnt about development of actuators and sensors and their integration into a smart
structure
2. Gain knowledge about measurement, Signal Processing and control strategies
3. Learnt the issue Design, Analysis and manufacturing of embedding sensors and
actuators, sensor fusion and incorporation of basic intelligence to such systems will be
addressed
4. Get knowledge about application areas of smart materials
AGILE MANUFACTURING
Course code: MMSEE10
Prerequisites : Nil
Credits: 4:0:0
Preamble
Current industry scenario is undergoing lot of changes at a very fast pace. The challenges posed
to industries are of great concern to the present competitive environment. As a consequence,
rapid changes, the industries are required to apply new techniques related to manufacturing
activity considering the future trends. The subject deals with the change management analysis,
control, skill and knowledge enhancing techniques for the improvements.
Unit -1
Introduction: What is agile manufacturing-Competitive environment of the future of business
case for agile manufacturing conceptual frame work for agile manufacturing.
Four Core concepts: Strategy driven approach-integrating organization, people technology
interdisciplinary design methodology.
Unit -2
Agile Manufacturing and Change Management: The change implications. Post failures in
advanced manufacturing, changes on the way, traditional management accounting, paradigm,
investment appraisal, product costing-performance, measurement and control systems.
Unit -3
Traditional organization: Control technological and design paradigms traditional problems in
workplace-organizational issues-role of technology
Unit -4
Agile Manufacturing Enterprise Design: Agile manufacturing-enterprise design..system
concepts as the basic manufacturing theory-joint technical & organizational design and a model
for the design of agile manufacturing enterprise. Enterprise design process insights into design
processes, what is interdisciplinary design, main issues-simple design example.
Unit -5
Skill & Knowledge Enhancing Technologies for Agile Manufacturing: Skill and Knowledge
enhancing Technologies-scheduling-technology design strategic-Design concepts. Design and
skill of knowledge enhancing technologies for machine tool systems-Historical overview,
Lessons, problems and future development.
Reference Books:
1. Paul T. Kidd - Agile manufacturing - Forging new Frontiers, Addison Wesley
Publication-1994.
2. Dr. M.P Chowdiah (Editor) - Agile Manufacturing - Proceeding of International
Conference on agile manufacturing - TAT A Mc Graw Hill Publications 1996
3. Paul T Kidd - Agile manufacturing - Forging Neat Furniture's Addition Wesley Pub
(1994)
4. Part T Kidd - Concurrent Engg.
5. Part T Kidd - World Class Manufacturing
RAPID PROTOTYPING
Course Code: MMSE- E11
Prerequisites: Nil
Credits: 4:0:0
Preamble
The current marketplace is undergoing an accelerated pace of change that challenges companies
to innovate new techniques to rapidly respond to the ever changing global environment. A
country's economy is highly dependent on the development of new products that are innovative
with shorter development time. Organizations now fail or succeed based upon their ability to
respond quickly to changing customer demands and to utilize new innovative technologies. In
this environment, the advantage goes to the firm that can offer greater varieties of new products
with higher performance and greater overall appeal.
At the center of this environment is a new generation of customers. These customers have forced
organizations to look for new methods and techniques to improve their business processes and
speed up the product development cycle. As the direct result of this, the industry is required to
apply new engineering philosophy such as Rapid Response to Manufacturing (RRM). RRM
concept uses the knowledge of previously designed products in support of developing new
products.
Course Learning Objective
1. The aim of the course is to provide the students, with an opportunity to conceive, design,
and implement products quickly and effectively, using the latest rapid prototyping
methods and CAD/CAM technology
2. The students will be exposed to the history of product development and its stages in the
manufacturing arena
3. Technologies associated with material addition process are identified and its advantages
are evaluated.
4. The students learn to differentiate various process parameters associated with Rapid
manufacturing technique
5. Selectively choose tooling techniques for a specific application
6. Learn how relative improvements can be established by using computers and
optimization techniques as compared to initial, manual solution.
7. The software associated with rapid prototyping techniques are explained to enable the
students choose specific tools for a specific application
8. correct material for the job
9. The students are in a position to incorporate the productivity sequence by choosing the
right CAD
10. The students can demonstrate and organize in selection of right software for the job on
shop floor enabling quicker build time and fewer prototyping errors and better production
cost.
UNIT - I
Introduction: Prototype Fundamentals, History of RP system, Fundamentals of RP, Growth of
RP industry, classification of RP system.
Stereo Lithography Systems: Principle, Process parameter, Data preparation, data files and
machine details, application.
UNIT - II
Selective Laser Sintering: Type of machine principle of operation, process parameters, Data
preparation for SLS, application.
Fusion Deposition Modelling Principle, process parameter, path generation, application
UNIT - III
Laminated Object Manufacturing: Principle of operation, LOM materials. Process details,
application.
Rapid Prototyping Data Formats: STL format, STL file problems, Building valid and invalid
tessellated models, STL file repair, other translators, new formats, standards for representing
layered manufacturing
UNIT - IV
Rapid Manufacturing Process Optimization Factors influencing accuracy, data preparation
errors, Part building errors, Error in finishing, influence of build orientation.
Materials for RP: Introduction, Types of materials, liquid based materials, solid based
materials, powder based materials, case studies.
UNIT - V
Rapid Tooling: Indirect methods for RT, Direct methods for RT
Reverse Engineering: Measuring Devices, CAD Model construction from point cloud, data
handling and reduction methods, application and trends,
Industry Perspective: Guidelines for Implementation, Operating Issues, Managing Issues,
Service Bureaus, Rapid Prototyping Consortia
Text Books
1. Stereo lithography and other RP & M Technologies, Paul F.Jacobs: “SME, NY 1996.
2. Rapid manufacturing, FIham D.T & Dinjoy S.S verlog London 2001.
3. Rapid Prototyping: Principles and Applications By C. K. Chua, K. F. Leong, C. S. Lim
4. Rapid Prototyping: Principles and Application…(Hardcover) by Rafiq I. Noorani
Reference Books
1. Rapid prototyping, Terry Wohler’s Report 2000” association 2000.
2. Rapid prototyping materials by Gurumurthi. IISc Bangalore.
3. Rapid automated by lament wood. Indus press New York.
Course Outcome
1. The students can express the concept of product design stages and methods, thereby
making him a better product designer.
2. The stages of development in rapid prototyping technology will help the students to
evaluate and look forward for newer techniques and processes in the future
3. The student can assess and implement RP techniques for specific application leading to
better ROI for the company that uses RP machines
4. The students can enhance the production sequence of tooling process by choosing the
Solid Ground Curing: Principle of operation machine details, applications, case studies
MODERN TRENDS IN MANUFACTURING AND MANAGEMENT
Course Code: MMSE-E12
Prerequisites: Nil
Credits: 4:0:0
Preamble
Modern trends in manufacturing and management is a new domain featuring tools and
techniques that help manufacturers gain productivity and enable constant monitoring
mechanisms helping industry focus on reduced lead time and enhanced work rejection rates.
Areas such as just in time production is discussed with use of software packages making
production system move to the next level. Quality control and its methods enable companies to
ensure quality products reach market and various techniques available to enhance the checking
process thereby enabling the overall quality process.
Course learning Objectives:
1. To make a student understand the concept of JIT, types, their principles, economics and
applications.
2. To know the implementation and production of different types of JIT for manufacturing
systems. Also understand the process of Scheduling and Sequencing.
3. The student is able to understand the concepts of Kanban system implemented in Toyota
and concept of production planning.
4. To learn Quality Testing and enable real time applications in Quality Policy with
examples.
5. To Study various process in designing and manufacturing.
Unit-1
Just in Time Ideas: Introduction of JIT concepts, difference between conventional material
control technique and JIT, Steps in implementing JIT, J.I.T. as a management Kaizen
concept, Feasibility of JIT concepts to Indian Industries, Implementing a Program for
continuous Improvement.
Unit-2
Japanese concept of continuous improvement: (KAIZEN mean continuous improvement)
Innovation: concept of improvement, need for continuous improvement, Steps in
implementing continuous improvement.
Unit-3
Quality Circles: Definition of quality circles, quality circles as a tool for problem solving,
Q.C. as a group oriented Kaizen. Kanban System: Definition of Kanban.
Unit-4
Difference between PULL & PUSH Systems of Material Control, KANBAN as a Push
System, KANBAN as JIT concept.
Unit-5
Concurrent Engineering: Definition of concurrent engineering. Design for Manufacturing
and Assembly (DFMA). Concurrent Engineering, Team, Advantages of concurrent
Engineering.
Course Outcome:
1. Student understands the concept of JIT, types, their principles, economics and
applications. .(PO: a, d, e, f, k)
2. Students implement production of different types of JIT for manufacturing systems. Also
understand the process of Scheduling and Sequencing. (PO: a, b, e, f, j)
3. Student is able to understand the concepts of Kanban system implemented in Toyota and
concept of production planning. .(PO: c, e, f)
4. Student will be able to implement Quality Testing and enable real time applications in
Quality Policy with examples. (PO:b, e, f)
5. Students are capable to design and plan for manufacturing. (PO: a, c, d, j)
Reference Books:
1. Amaldo Hernandez: ” Just in Time Manufacturing” PH International
2. David Hutehins:” Just in Time-Productivity Process” Jaco Publications
3. Ingle Sord: ”Quality Circles”.
ADVANCED METAL JOINING PROCESSES
Course code: MMSE-E13
Prerequisites: Nil
Credits: 4:0:0
Preamble:
This subject helps the student to understand the different aspects related to the metal joining
processes. The subject deals with the different techniques of welding processes, improving the
weld quality by the study of the defects, improving productivity in detail. With this, the student
will be able to assess the weld defects using both destructive and non-destructive methods
Course learning objectives:
1. To demonstrate the need for development of newer metal joining process.
2. The student will be able to compare the traditional metal joining processes with
respect to the advantages, applications.
3. The student will be able to identify different energy sources like electron beam, laser
beam, plasma arc, explosion welding, ultrasonic welding etc
4. To analyse the concept, mechanism, parameters associated with the processes.
5. To demonstrate the operational principles, advantages applications, limitations of the
various non-traditional machining processes.
6. To selectively select a process for a specific application/ need/situation depending
upon the availability of sources.
7. To study the representation of welding symbols, welded joints
8. To study the quality control aspects related to welding
9. To analyse the different weld defects, using different techniques
UNIT I
Distortion, Types of distortion and methods to control distortion. Residual Stresses in welds,
definition, concept types causes and effects, Residual stress measurement. Metal Spraying,
classification of thermal spraying process equipments,
UNIT II
Electro Slag, Welding Electron Beam Welding, Plasma arc Welding, Laser Beam Welding,
Explosion Welding, Diffusion Welding, Ultrasonic Welding, Friction welding and Thermit
welding. , concepts, principle of operation, equipments, advantages, disadvantages and
applications of the above processes.,Welding electrodes -Types, selection of electrodes.
Applications of coated electrodes.
UNIT III
Welding of dissimilar metals, concepts, metallurgical problems,Plastic welding processes,
fusion welding processes, advantages and disadvantages of each processes Advanced soldering
and Brazing processes, different typesof soldering and brazing processes
UNIT IV
Inspection of Welds: Stages, Destructive techniques like Tensile, Bend, and Nick break, Impact
& Hardness tests. Non-Destructive techniques like 'X' rays, Ultrasonic, Magnetic particle, Dye
Penetrant, Gamma ray inspection.Weld quality,fac tors to be considered,Discontinuities in welds,
their causes and remedies ,Quality conflicts
UNIT V
Welding Symbols- Need for representing the welds, Basic weld symbols, Location of Weld,
Supplementary symbols, Dimensions of welds, Examples. Welding Design - Introduction,
Principles of sound welding design, Welding joint design. Welding positions, Allowable
strengths of welds, under steady loads. welding cost estimation,main components, factors,basic
costing procedure.
Reference Books:
1. Welding Engineering Hand Book by AWS.
2. Welding Engineering by Rossi
3. Advanced Welding Processes-Nikolacv .G.O.L Shansky MIR Publications.1997
4. Welding Technology by O.P.Khanna.
5. Welding for engines by Udin, Funk & Wulf
6. Welding and welding technology-R.L.Little
Course Outcomes:
1. Student learns and understands, explains the need- history for the development of newer
welding process.
2. The students will demonstrate the comparison with respect to the different parameters.
3. Energy sources
4. Economics of the processes
5. Shape and size of material etc.
6. The students analyse the concept, mechanism of metal joining with respect to different
processes.
7. Different parameters associated with the process, their influence on the machining, will
be analyzed.
8. Advantages, applications and limitations of the various welding processes will be
evaluated.
9. Students will demonstrate the different welding symbols for assembly, welding design etc
10. Students will demonstrate the quality assurance with respect to welds, analyze the defects
and suggest remedies
11. Weld design procedures will be demonstrated
12. Finally, the students will be able to recognize/ identify a process suitable for a particular
material/ for a particular situation based on the availability of the sources.
SURFACE TREATMENT AND FINISHING
Course Code: MMSE-E14
Prerequisites: Nil
Credits: 4:0:0
Preamble:
Surface Engineering is a multidisciplinary activity intended to tailor the properties of the
surfaces of engineering components so that their function and serviceability can be improved.
The ASM Handbook defines surface engineering as "treatment of the surface and near-surface
regions of a material to allow the surface to perform functions that are distinct from those
functions demanded from the bulk of the material. New coatings and treatment processes may
create opportunities for new products which could not otherwise exist. It can increase
performance, reduce costs and control surface properties independently of the substrate, offering
enormous potential.
Course Learning Objective:
At the end of this course, the student would be able to understand:
1. Electro plating and diffusion processes
2. Thin films and Thermal spray coatings
3. Hard Facing Processes
4. Plasma Surface Engineering of Plastics and High-energy Surface Modifications
5. Heat Treatment of Tool steels, Super alloys, Titanium alloys and Cast iron.
UNIT I
Plating Processes: Fundamentals of Electro deposition, Hard chromium plating, Nickel and
nickel alloy plating, Electroless nickel plating, and Continious hot dip coatings, Chemical
conversion coatings.
Diffusion Processes: Pack carburizing, Gas carburizing, Liquid Carburizing, Gas nitriding, Salt
nitriding, Ion nitriding, Carbo nitriding, Properties of diffusion coatings.
UNIT II
Thin Film Coatings: Thermal evaporation, Sputter deposition, Ion plating, Pulsed laser
deposition, CVD processes and systems, Plasma enhanced CVD, Laser enhanced CVD, Metal
organic CVD.
Advanced Thermal spray Coatings: Plasma spray, Detonation gun and High velocity oxy-fuel
process, Surface preparation, Equipment and processes, Structure and Properties. Uses of
thermal spray coating, Bonding mechanisms, Coating materials. Thermal barrier coatings and
applications.
UNIT III
Characterization and Testing of Coatings: Film thickness measurements using optical and
mechanical techniques; Measurement of coating adhesion-peeling test, Blister test, Scratch test,
Tensile type test; Residual stresses in coatings- Measurement using X-ray diffraction, Hole
drilling method, Stoneys method; Nano-indentation test to measure hardness, elastic properties,
creep and stress relaxation; Thermal properties measurements; Microstructure characterizationWorking principle of Scanning electron microscope, Transmission electron microscope and
Optical microscope; Chemical composition analysis-Energy dispersion X-ray analysis, Electron
and Ion spectroscopy; Corrosion testing of Coatings-Hot corrosion, Corrosion tests in simulated
atmosphere, Salt spray test, Immersion test; Wear and erosion testing of coatings.
UNIT IV
High-energy Surface Modifications: Electron beam surface treatments, Electron beam
hardening-Materials and techniques; Laser hardening- Materials and techniques; Laser hard
facing; Ion implantation- Equipment, Metallurgical consideration, Application.
Fusion Hard Facing Processes: Shielded metal arc welding, Gas tungsten arc welding, Flux
cored arc welding, submerged arc welding, Plasma arc welding.
Plasma Surface Engineering of Plastics: Plasma processing equipment, Plasma surface
modification, Plasma Polymerization.
UNIT V
Heat Treatment of Tool Steels: Processes and furnace equipments Control of Distortion in tool
steels.
Heat Treatment of Superalloys: Heat treatment operations, Heat treating solid solution
strengthened Iron- Nickel- and Cobalt- base superalloys.
Heat Treatment of Titanium and Titanium alloys
Heat Treatment of Cast Iron: Ductile iron-Hardening, Quenching and Tempering,
Austempering; Grey iron-Hardening and tempering, Austempering, Martempering, Induction
hardening
Defects and Distortion in Heat Treated Parts: Overheating and Burning, Effects of residual
stress, Quench cracking; Types of distortion, Methods of preventing distortion.
Reference Books:
1. K.G. Budinski, Surface Engineering for Wear Resistances, Prentice Hall, Englewood
Cliffs, 1988.
2. M. Ohring, The Materials Science of Thin Films, Academic Press Inc, 2005
3. ASM Handbook, Surface Engineering, Vol. 5, ASM Publication, Materials Park, Ohio,
2001.
4. ASM Handbook, Heat Treating, Vol. 4, ASM Publication, Materials Park, Ohio, 2001.
5. Jamal Takadoum,Materials and Surface Engineering in Tribology, John Wiley & Sons,
Inc.,2008.
Course Outcome:
1. Learnt to select the suitable surface engineering process for the particular material and
application.
2. Gains the knowledge of science and engineering of platting Processes, Diffusion
Processes, Thermal spray processes and thin films deposition processes.
3. Gains knowledge about advanced characterization techniques and testing of thin films
and coatings.
4. Learnt about High-energy Surface Modifications, Hard Facing Processes and Plasma
Surface Engineering of Plastics
5. Ability to choose heat treatment conditions for superalloys, Tool steels, Titanium alloys
and cast iron.
ROBOTICS
Course Code: MMSE-E15
Prerequisites: Nil
Credits: 4:0:0
Preamble:
This course provides an overview of robot mechanisms, dynamics, and intelligent controls.
Topics include planar and spatial kinematics, and motion planning; mechanism design for
manipulators and mobile robots, multi-rigid-body dynamics, exposure is given to 3D graphic
simulation; control design, actuators, and sensors; wireless networking, task modeling, humanmachine interface, and embedded software.
Students are exposed to the concept of DH Methods, transformation matrices. A wide scope is
give to the area of Applications where in students understand as to how robotics can be applied
in area of welding machine loading and unloading, die casting, forging, spray painting and
drilling. Various leg configuration are discussed followed by programming sequence, planning,
path planning, obstacle avoidance are discussed.
Course Learning Objectives:
1) The Aim of the course is to provide the students, with an opportunity to conceive design
and implement robotics systems quickly and effectively, using the various techniques
available in robotic technology
2) The students will be exposed to the history of robotics and its stages and developments in
various industries
3) Processes associated with robotics planning customization, algorithms, basic
transformation are evaluated and its advantages explained
4) The students learn the various applications of robotics in different fields of engineering,
medicine.
5) Selectively choose mobile robots for specific applications
6) Learn how relative improvements can be established by using concept of degree of
steerability, mobility, manoeuvrability techniques as compared to manual solution
7) The software associated with robotic programming are explained to enable the students
choose specific programs and customized programs for a specific application
UNIT I
Basic Concepts of Robotics: Introduction to robotics, Definition of robot, Basic structure of
robot, Numerical control of Machine tools, Resolution, Accuracy and Repeatability, Position
representation, Performance specification: Pay load, Speed. Classifications and Structures of
Robotics Systems: Point-to-point and Continuous path systems, Trajectory Planning,
UNIT II
Physical configurations and work volumes of an Industrial robot: The wrist and its motions,
Grippers and types, Kinematic Analysis and Coordinate Transformations: Direct kinematics
problem in Robotics, Euler’s angle representation, Basic transformations, Rotation about an
arbitrary axis, Homogeneous transformation matrices, Denvit and Hertanberg Convention,
Applications of D-H Method- Three axis Robot Arms, Three axis wrists, Six axis Robot
Manipulators.
UNIT III
Industrial Applications of Robots: Welding Machine loading: Multiple Robot & Multiple
Machine loading, Sequential machine loading, forging and Die Casting. Spray painting and
drilling. Assembly: Engine Assembly, Electrical and Electronics machine assembly, General
assembly, Unusual applications: Sheep-shearing Robots, Robot in Construction, Autonomous
Mobile Robots: Introduction, Locomotion-key issues for locomotion, Legged Mobile Robots
UNIT IV
Leg configurations and stability: Wheeled Mobile Robots, Difference between wheeled and
legged mobile Robots, Mobile Robot Kinematics: Introduction, Kinematics Models and
Constraints, Representing robot position, Forward kinematics models, Wheel kinematics
constraints, Robot kinematics constraints. Mobile Robot Maneuverability: Degree of Mobility,
Degree of Streeability, Robot maneuverability.
UNIT V
Mobile Robot Planning and Navigation: Introduction, Competences for Navigation Planning
and Reacting, Path Planning, Obstacle avoidance, Navigation architectures-Modularity –
Modularity code reuse and sharing, Control localization, Techniques for decomposition.
Programming Languages: Introduction, Levels of Programming Languages, Introduction to
VAL, RAIL and AML languages. Example of programming by VAL II.
Text Books:
1. M P Grover “Industrial Robotics” MGH.
2. Yoren and Koren, “Robotics for Engineers” MGH
3. Robotics and Manufacturing Automation, by C Ray Asfahl, John Wiley and Sons, Inc,
Second edition.
Reference Books:
1. Robotics by Fu and Lee
2. Robotics for Engineers by Philippe Coffet, Volume 01 to 08
3. Walking machines- An introduction to Legged Robots by D J Todd.
Course Outcome:
1. The students can express the concept of developmental stages in robotics
2. The stages of development in robotic technology will help the students to evaluate and
look forward for newer techniques and processes in the factories of future
3. Students can selectively choose various methods that are available in robotics that can
provide
4. The student can assess and implement robotic process for specific application leading to
better ROI for the company that uses robots in their work flow
5. Students can selectively increase the mobility and speed of robots for specific application
6. Students can enhance the productivity of robots for specific applications by selecting the
appropriate programming language and techniques
CONDITION BASED MAINTENANCE
Course Code: MMSE E16
Prerequisites: Nil
Credits: 4:0:0
Preamble:
Condition Based Maintenance (CBM) is continually evolving its conceptual basis which can be
traced back to the earliest development of machinery, and the use of human senses to monitor the
state of Industrial equipment. In today’s industry augmented by scientific and sophisticated
instrumentation.CBM is widely employed
in sophisticated instrumentation allows the
quantification of the health or condition of industrial machinery and equipment, so that
problems can be diagnosed early in their development and corrected by suitable maintenance,
before they become serious enough to cause failure and plant breakdown.
Course learning Objectives:
To make a student understand the concept of Maintenance and condition based maintenance,
types, their principles, economics and applications.
1. To know the implementation of different types of monitoring techniques applicable to
various manufacturing systems. general NDT application and specialized techniques used
in CBM and their importance in modern plants
2. The student is able to understand the concepts of Acoustic emission examination,
Thermography techniques used in CBM and various other methods and Instrumentation
used in these techniques.
3. Student is able to understand the monitoring technique incorporated in Bearings, to learn
the basic concept of condition monitoring technique by case studies included in bearing
failure, history of failure, Analysis of failure, faulty detection and symptoms and
monitoring of cracks, misalignment and vibration monitoring.
4. To learn trend monitoring techniques, performance parameters with appropriate case
studies and examples.
5. Students are able to understand, analyze and take appropriate decision for live problems
observed in the Industries at the end of the course.
UNIT I
Condition based Maintenance: Introduction, principles, Economics and application: Condition
Monitoring Methods, Economics of condition monitoring, sets up a condition Monitoring
Activates. Implementation of condition based Maintenance, Consequences of implementation of
CBM, Information Systems, selection of Monitoring Methods, Assessment of Monitoring
techniques, case studies.
Non –Destructive testing and Specialized techniques: Introduction, visual testing, liquid
penetrate inspection, Water washable method.. Precleaning, penetrate application, Dwell time,
excess surface penetrate removal, surface drying, Developer application, Dwell time, Excess
surface penetrate removal, Surface drying, Developer application, Interpretation, Postemulsifiable penetrates, Solvent-soluble penetrates.-
UNIT II
Radiographic examination: X-Ray apparatus, X-Ray generation, Tube Shielding Control
console, Other X-Ray Sources, Electrostatic or VenDegraffgenerators, Linear accelerators.
Gamma –Ray Radiography, Sources –Radium, Thallium 170, Iridium 192, cobalt 62.Isotope
Projectors- geometric factors, Radiographic film, Radiograph, safety hazards and Government
control
Ultrasonic’s Examination: Ultrasonic triangulation fault location acoustic emission technique
(AET) – Instrumention,Transducers,Preamplifier and filter, Main amplifier, and signal
processing display unit, Signals and processing, Magnetic testing Methods, current flow
magnetization, Induction Magnetic Flow method, Induction threading bar method, Induction
Magnetizing coli method, Induced current flow method, Magnetic particle Inspection links,
strippable Magnetic film,
UNIT III
Thermography
and Performance Trend Monitoring: Eddy current apparatus, cost.
Thermography- thermo graphic Equipment, Application of thermography. Introduction,
Thermodynamic and fluid dynamic analysis, Primary and Secondary, Performance parameter,
steam turbine performance parameters, case studies and Examples.
Vibration Monitoring and Analysis: Introduction, Machinery signatures, selection of
Transducers. Analysis Techniques, Machine failure Modes, Measurement location, Vibration
severity criteria, Vibration frequency analysis. Permanent monitoring, case studies.
UNIT IV
Vibration Monitoring of ball and roller bearings: Introduction, shock pulse method (SPM),
SPM for testing Antifriction bearings, Manual monitoring. Continuous monitoring, the kurtosis
method, Fiber optics system, Vibration signature analysis, contact resistance method, case
studies. SPM and its applications.
Corrosion Monitoring and wears monitoring: Need for corrosion monitoring, fields of
application, Monitoring Techniques, Resistance Techniques. Other probe techniques- Analytical
technique and others.Wear process monitoring techniques – Direct debris detection methods,
Debris collection methods.
UNIT V
Lubricant analysis: Introduction, source of contamination, significant oil contaminants, used oil
contamination-time trends, changes in the carrier fluid, erratic wear debris. Lubricant sampling
methods, Lubricant analysis methods, interpretation of results, indications from the amount of
debris present, indication from the size distribution of debris, Application of chemical analysis of
debris, wears detection using proximity monitors, case examples.
Condition Monitoring case studies & Applications: Failure of fan bearings, History of
failures, Analysis of the failures, solution. High frequency vibration of gas compressor – History
of trouble, Analysis of trouble, solution. Monitoring of cracks in rotors – Turbo compressor
misalignment. Detection of faulty electrical components. Turbine shell distortion. Symptoms
and Detections.
Reference Books:
1. L. F. Pau Marcel Dekker “Failure Diagnosis and Performance Monitoring”.
2. Update CEP ISTE New Delhi “ Condition Monitoring and condition based
maintenance”Current Literature.
3. DAVIS.A. Hand Book of condition Monitoring: Techniques and Methodology:
Chapman & Hall,Madras,NewYork,Tokyo,Mellborne.
4. R. A. Caollacatt Chapman “Mechanical Fault Diagnosis and Condition monitoring”,
Chapman and hall 1977.
Course Outcomes:
1. Students are able to demonstrate concept of Maintenance and condition based
maintenance, types, their principle, economics and application.
2. Students introduced to the advanced NDT methods like Radiographic examination
and Ultrasonic examination used to improve the availability, maintainability of the
modern plant for optimal running condition.
3. The concept of Ultrasonic application ,Acoustic emission examination
,Thermography techniques used in
condition Monitoring
and
various
Instrumentation used in these techniques by visual observation by plant visits are
demonstrated
4. Concept of advanced monitoring and analysis techniques like Vibration monitoring,
Corrosion monitoring, Wear monitoring and Lubricant monitoring and analysis are
demonstrated to students through Industrial visits.
5. Awareness of Failure, history of failure, Analysis of failure, faulty detection methods,
symptoms, monitoring of cracks, misalignment and vibration monitoring methods are
developed.
QUALITY AND RELIABILITY ENGINEERING
Course Code: MMSE-E17
Prerequisites: Nil
Credits: 4: 0: 0
Preamble:
Quality is the most important aspect of manufacturing industry. It is very much required for
survival in today’s competitive world. Everything is focused on customer satisfaction thus to
improve market share. Quality alone is not sufficient, the product should be reliable. Otherwise,
operating cost and maintenance cost will go up thus both these are important in keeping the
customer happy. It is with this intension the course is formed to emphasize the knowledge of
quality and reliability concepts and various techniques to students.
Course learning objectives:
1. To study the basic concepts of quality , quality cost ,inspection and total quality control
2. To teach the students about the various graphical tools and data
3. To make them learn probability rules, events, probability distributions like hyper
geometric binomial, poisson & normal distributions and to solve related numerical
problems.
4. To teach the students to draw variable control charts like X & R charts and S charts.
5. To teach them attribute control charts like P, np, C & U charts.
6. To teach them basics of acceptance sampling, types of sampling problems.
7. To teach the basics of reliability maintainability, life testing.
8. To teach them the methods to improve reliability and cost, FMEA.
UNIT I
Basic concepts: Definitions of quality and quality control, Inspection, SQC, Benefits, Quality
costs, quality characteristics, Total quality, Probability Distributions :Discrete and continuous
distributions, Addition and multiplication rule, Types of events, Hyper geometric, Binomial,
Poisson and Normal distribution problems
UNIT II
Variable Control Charts: Chance causes and assignable causes, Central Limit Theorem,
Interpretation of control charts, Type I and Type II errors, Process capability, X and R Charts,
Problems.
UNIT III
Attribute Control charts: P Chart, nP, C and U Charts, problems
UNIT IV
Acceptance Sampling: Fundamentals, Single sampling plan, OC curve, AQL, LTPD, AOQL,
Producers' risk, and consumers’ risk, double and Sequential Sampling, Problems.
UNIT V
Reliability: Definition, maintainability, availability, Mean life, Life testing, Bath tub curve,
Failure rate and MTBF, MTTR, MTTF. System Reliability: Series, Parallel and Mixed
configuration, Problems, Reliability improvement, Methods, Redundancy, Reliability cost
tradeoff, Hazard models: Constant and linearly increasing hazard, Introduction to Failure mode
and Effect analysis
Reference books:
1. Halpern, seigmund(1978)”The assurance sciences “PHI New Jersey, USA
2. Juran and gryana F M (1982): quality planning and analysis Tata McGraw-Hill
Publishing company Ltd, New Delhi India
3. Shrinath K.S (1985) concepts in reliability engineering affiliated east west press Private
Ltd New Delhi India
4. Blanchard Benjamin S (1986) Logistics engineering and management, PHI, New Jersey
USA.
5. Introduction to Statistical quality control second edition Douglas C. Montgomery, John
Wiley & sons
Course outcomes:
1. Student learns the basic concepts of quality, types of quality cost etc.
2. Student learns various tools types of data to apply in solving problems
3. Student learns the mean , standard deviation of different distributions, & to refer to
probability tables
4. Students will be able to draw X & R charts or S charts & to draw conclusion about the
process control
5. Student will be able to draw P/np, C/U charts for attribute data
6. The student will be able to draw OC curve , to calculate Pa , ATI etc
7. To learn the basics of reliability , methods to improve reliability, MTTR, MTBF etc