Department of Industrial & Production Engineering The ...III Year-Scheme and Syllabus for the...

III Year-Scheme and Syllabus for the academic year 2018-19

Department of Industrial & Production Engineering The National Institute of Engineering, Mysuru-08

Department Vision:

The Department will be a centre of repute providing in-depth knowledge in Industrial

and Production Engineering and imbibe professional ethics through dedicated faculty,

facilities and infrastructure.

Department Mission: Equipping students with enhanced abilities to apply knowledge with proven abilities

to theorize and develop emerging systems of learning coupled with value systems to

be able to manage and lead contemporary and emerging businesses globally with

specific excellence in the areas of manufacturing.

Strengthening and expanding collaborations and partnerships across a spectrum of

industries and Centers of Excellence for offering sustained and scalable world class

training, research and higher education.

Imbibing professional ethics and encouraging entrepreneurship for inclusive growth

and global business.

Program Outcomes: 1. Engineering Knowledge: Apply the knowledge of mathematics, science, engineering

fundamentals, and an engineering specialization to the solution of complex engineering

problems.

2. Problem Analysis: Identify, formulate, research literature, and analyze complex

engineering problems reaching substantiated conclusions using first principles of

mathematics, natural sciences, and engineering sciences.

3. Design/Development of Solutions: Design solutions for complex engineering problems

and design system components or processes that meet the specified needs with appropriate

consideration for the public health and safety, and the cultural, societal, and environmental

considerations.

4. Conduct Investigations of Complex Problems: Use research-based knowledge and

research methods including design of experiments, analysis and interpretation of data, and

synthesis of the information to provide valid conclusions.

5. Modern Tool Usage: Create, select, and apply appropriate techniques, resources, and

modern engineering and IT tools including prediction and modeling to complex engineering

activities with an understanding of the limitations.

Dept. of Industrial and Production Engg, NIE, Mysuru 1

III Year-Scheme and Syllabus for the academic year 2018-19 6. The Engineer and Society: Apply reasoning informed by the contextual knowledge to

assess societal, health, safety, legal and cultural issues and the consequent responsibilities

relevant to the professional engineering practice.

7. Environment and Sustainability: Understand the impact of the professional engineering

solutions in societal and environmental contexts, and demonstrate the knowledge of, and need

for sustainable development.

8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and

norms of the engineering practice.

9. Individual and Team Work: Function effectively as an individual, and as a member or

leader in diverse teams, and in multidisciplinary settings.

10. Communication: Communicate effectively on complex engineering activities with the

engineering community and with society at large, such as, being able to comprehend and

write effective reports and design documentation, make effective presentations, and give and

receive clear instructions.

11. Project Management and Finance: Demonstrate knowledge and understanding of the

engineering and management principles and apply these to one’s own work, as a member and

leader in a team, to manage projects and in multidisciplinary environments.

12. Life-long Learning: Recognize the need for, and have the preparation and ability to

engage in independent and life-long learning in the broadest context of technological change.

Programme Educational Objectives: PEO1: Graduates get employed in professions related to Industrial and Production

Engineering adopting and adapting to advances in technology and management.

PEO2: Graduates pursue advanced studies at Institutions of higher learning to engage in

research and learning stimulations facilitating them to attain technical competence with an

aptitude for life-long learning.

PEO3: Graduates become successful professionals in a challenging environment leveraging

learnings for the growth of the organization by becoming successful intrapreneurs keeping in

mind the ethical responsibilities and volatile emerging societal needs.

Program Specific Outcomes:

PSO1: The graduates of Industrial and Production Engineering will be able to work as

production engineers in manufacturing sector adapting themselves to advances in technology

and management.

PSO2:The graduates of Industrial and Production Engineering will abe able to function as

industrial engineers and managers designing production systems by using cost effective


III Year-Scheme and Syllabus for the academic year 2018-19 methodologies.

PSO3:The graduates of Industrial and Production Engineering will be able to set up their

own industries/ consulting firms, become successful professionals in a challanging

environment.

BLUEPRINT OF SYLLABUS STRUCTURE AND QUESTION PAPER PATTERN

Blue Print of Syllabus Structure

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

2. In each unit there is one topic under the heading “Self Learning Exercises” (SLE) .

These are the topics to be learnt by the student on their own under the guidance of the

course instructors. Course instructors will inform the students about the depth to

which SLE components are to be studied. Thus there will be six topics in the complete

syllabus which will carry questions with a weightage of 10% in SEE only. No

questions will be asked on SLE components in CIE.

Blue Print of Question Paper

1. Question paper will have SEVEN full questions.

2. One full question each of 15 marks (Question No 1, 2, 3, 4, 5 and 6) will be set from

each unit of the syllabus. Out of these six questions, two questions will have internal

choice from the same unit. The unit from which choices are to be given is left to the

discretion of the course instructor.

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

Exercises”.



V SEMESTER

SCHEME OF TEACHING AND EXAMINATION FIFTH SEMESTER B.E (AUTONOMOUS SCHEME)

Sl. No.

Course Code Course

Contact Hrs. / Week No. of Credits L T P

1 IP 0411 Workstudy and Ergonomics 4 0 0 4 2 IP 0454 Dynamics of Machinery 3 2 0 4 3 IP 0413 Design of Machine Elements-I 4 0 0 4 4 IP 0414 Control Engineering 4 0 0 4 5 IP 0415 Computer Integrated Manufacturing 4 0 0 4 6 IP 0455 Manufacturing Processes – III 4 0 0 4 7 IP 0105 Machine Shop 0 0 3 1.5 8 IP 0106 Industrial Engineering Lab 0 0 3 1.5

Total Credits 27 Contact hours per week 31

VI SEMESTER

SCHEME OF TEACHING AND EXAMINATION SIXTH SEMESTER B.E (AUTONOMOUS SCHEME)

Sl. No.

Course Code Course


1 IP 0417 Fluid Power Systems 4 0 0 4 2 IP 0418 Design of Machine Elements – II 4 0 0 4

3 IP 0456 Cost Estimation and Engineering

Economics 4 0 0 4 4 IP 0420 Statistical Quality Control 4 0 0 4 5 IP 0421 Lean Manufacturing System 4 0 0 4 6 IP 0107 CNC / Robotics Lab 0 0 3 1.5

7 IP 0108 Machine Tool and Fluid Power Systems

Lab 0 0 3 1.5 8 Elective – I 3 0 0 3

Total Credits 26 Contact hours per week 29

Elective-I

Sl. No Course Code Course


1 IP0304 Advanced Manufacturing Processes 3 0 0 3 2 IP0305 Composite Materials 3 0 0 3 3 IP0306 Tool Design 3 0 0 3


III Year-Scheme and Syllabus for the academic year 2018-19 4 IP0307 Mechanical Vibrations 3 0 0 3 4 IP0331 Computational Fluid Dynamics 3 0 0 3 5 IP0332 Digital Manufacturing 3 0 0 3

V SEMESTER -SYLLABUS

WORK STUDY AND ERGONOMICS (4:0:0) Course Code : IP0411 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Outcomes: Upon successful completion of this course, the students will be able to

1. Recollect the basic concepts of productivity, work content and work study. 2. Define the various charts and to construct the charts on the basis of present method

and develop a new / proposed method and identify the unnecessary movements. 3. Explain the basic work measurement techniques and to gain knowledge of

measurement of work. 4. Determine the time required to do a job using the concepts of work measurement and

study the concepts of rating and its techniques. 5. Determine the allowances to calculate the standard time and gain knowledge of PMTS

techniques. 6. Demonstrate the basic concepts of ergonomics and design of displays of controls

Unit 1 Productivity and Work Study: Definition of productivity, task of management, productivity of materials, land, building, machine and power, factors affecting the productivity, work content, basic work content, excess work content, how manufacturing job is made up, work content due to excess product and process, ineffective time due to short comings on part of the management. 8Hrs SLE: Human factors in work study and supervision. Unit 2 Definition, Objective and scope of Work Study: Work study and management, work study and worker. Method Study: Definition, objective and scope of method study, activity recording and tools, Recording tools: Out Line Process Chart, Flow Process Chart, Flow diagram, String Diagram, Travel Chart, Multiple Activity Chart, Two- Handed process chart. 10Hrs SLE: Brief concept about synthetic motion studies. Unit 3 Principles of Motion Economy: Introduction, Classification of movements. Two- hand process chart, Micro motion study, Therbligs, SIMO Chart. Special Charts: Cyclegraph and Chronocycle graph, development, definition and installation of the improved method. Work Measurement: Definition, objectives, work measurement techniques.


III Year-Scheme and Syllabus for the academic year 2018-19 Work sampling – Need, confidence levels, and sample size determination, conducting study with problems. 8Hrs SLE: Benefit of work measurement and random observation. Unit 4 Time study - Definition, time study equipment, selection of job, steps in time study. Breaking jobs into elements, recording information. Rating: Systems of rating, standard rating, standard performance, scales of rating. 10Hrs SLE: Case study of rating in different industries. Unit 5 Allowances: Standard time determination, predetermined motion time study (PMTS), factors affecting rate of working, problems on allowances. 8Hrs SLE: Method Time Measurement (MTM), Synthetic Motion Studies. Unit 6 Ergonomics: Introduction, areas of study under ergonomics, man-machine system, components of man-machine system and their functions, concepts of displays and controls. 8Hrs SLE: Influence of climate, noise, vibration and light on human efficiency. Text Books: 1. Introduction to Work Study – ILO, 4th edition 1992 2. S. Dalela and Sourabh, “Work Study and Ergonomics”. Standard publishers 2013 Reference Books

1. Ralph M. Barnes, “Motion and Time Study”, Wiley International, 7th Edition. 2. Mark S. Sanders and Ernest J. McCormick , “Human Factors in Engineering Design”

4th edition, 2013. 3. B. Niebel and Freivalds, Niebel’s Methods Standards and Work Design, McGraw-

Hill, 12th Edition, 2009

DYNAMICS OF MACHINERY (3:2:0)

Course Code : IP0454 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Hrs Max. Marks: 100

Course Outcomes: Upon successful completion of this course, the students will be able to

1. Create a free body diagram of a general machine component, and determine the forces acting throughout a mechanism, solve problems on friction on inclined planes and power transmission using belt drives.

2. Evaluate the forces acting on slider crank mechanisms.



3. Design a flywheel and draw turning moment diagrams. 4. Examine the static and dynamic balancing of revolving masses in same plane and in

different planes. 5. Explain the function of a governor and analyze the same 6. Predict the gyroscopic couples in airplane and naval ships

Unit 1 Static Force Analysis: Introduction, forces, moments and torques, free body diagram, static equilibrium, analysis of two force member, sliding friction force, simple numerical problems. Friction: Friction on inclined planes, collar and pivot bearing - numerical problems. Belt drives: Ratio of belt tensions, power transmitted by a belt drive, effect of centrifugal tension on power transmitted, V-belt drive - numerical problems. 10Hrs SLE: Laws of solid friction, kinds of friction, co-efficient of friction. Unit 2 Dynamic force analysis: Dynamic analyses of slider crank mechanisms, engine force analysis, turning moment on crankshaft, dynamically equivalent system, and inertial force in connecting rod - numerical problems. 10Hrs SLE: D ‘Alembert’s principle. Unit 3 Dynamics of Engine Mechanism: Turning moment diagram and fly wheel design. 08Hrs SLE: TMD for various engine configurations. Unit 4 Balancing of Masses: Static and dynamic balancing, balancing of single rotating mass in same plane and in different planes, balancing of several rotating masses in same plane and in different planes Balancing of reciprocating masses – primary and secondary unbalanced forces, balancing of unbalanced primary force in a reciprocating engine, multi-cylinder in-line engines . 10Hrs. SLE: Application of V and W engines. Unit 5 Governors: Types of governors, force analysis of Porter and Hartnell governor, controlling force, stability, resistiveness, isochronisms, effort and power (only definitions). 07Hrs SLE: Difference between governors and flywheel. Unit 6 Gyroscope: Angular velocity and acceleration, gyroscopic couple, effect of gyroscopic couple on airplane and naval ships, stability of two wheelers and four wheelers. 07Hrs SLE: Precession Text Books:

1. Theory of machines by S S Rattan, Tata McGraw Hill publication, Fourth Edition- 2014.

Reference books:



1. Theory of Machine by Thomas Bevan, Pearson publication; Third Edition-2010. 2. Theory of Machines and Mechanisms by John J Uicker Jr, Gordon R Pennock, and

Shigley, Oxford publication; Third Edition-2009. 3. Kinematics and Dynamics of Machinery by Robert L Norton Tata McGraw Hill

publications; First Edition in SI Units-2014.

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

Course Code : IP0413 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Outcomes: Upon successful completion of this course, the students will be able to

1. Understand the importance of static strength and fatigue strength 2. Explain different theories of failure with impact stresses. 3. Design shaft considering various loads and explain various coupling 4. Classify different threaded fasteners and design various power screws for industrial

applications. 5. Design cotter joint and knuckle joint. 6. Design welded and riveted joints for various loads.

Unit 1 Design for Static and fatigue Strength: Static strength: stresses and deformation due to different types of loads, uniaxial, biaxial and triaxial state of stresses, principal planes, important engineering materials and their properties: ferrous and nonferrous metals, plastics and composite materials, designation of materials: codes and standards used in design, static load, static strength and factor of safety, stress concentration, stress concentration factor, methods of reducing stress concentration. Introduction to S-N Diagram, low cycle fatigue, high cycle fatigue, fatigue strength and endurance limit, Endurance limit modifying factors: size effect, surface effect, stress concentration effects, Goodman and Soderberg’s relationship, stresses due to combined loading, cumulative fatigue damage, Miner’s rule, combined stress, Mohr’s circle of stresses.

12Hrs SLE: Engineering materials and their properties. Unit 2 Theories of failure and design for Impact strength: Theories of failure, maximum normal stress theory, maximum shear stress theory, distortion energy theory, impact stresses due to axial, bending and torsion loading, effect of inertia. 6Hrs SLE: Impact stresses of different cross sections. Unit 3 Design of Shafts: Torsion of shafts, design for strength and rigidity, ASME code for design of transmission shafting, design of shafts under different loads, combined loads and fluctuating loads. Keys and Couplings: Different types of keys, design for shear and crushing strength, design of splines, design of muff coupling, rigid flange coupling, bush and pin type coupling, Oldham’s coupling. 12Hrs


III Year-Scheme and Syllabus for the academic year 2018-19 SLE: Flexible shafts, design of Oldham’s couplings Unit 4 Threaded Elements: Threaded fasteners, effects of initial tension on bolts, design of bolts for fatigue loading, impact loading, shear loading and eccentric loading. Power Screws: Mechanics of power screw, stresses, efficiency, self-locking, design of power screws for screw jack, C-clamp, machine vice and sluice gate. 6Hrs SLE: Nut, bolt, screw-design and its application. Unit 5: Mechanical Joints: Cotter and Knuckle Joints. 6Hrs SLE: Applications. Unit 6 Mechanical Joints: Riveted Joints: Types, rivet materials, failure of riveted joints, efficiency, boiler joints, tank and structural joints, riveted brackets. Welded Joints: Types, strength of butt and fillet welds, eccentrically loaded welded joints.

10 Hrs SLE: Different joints and its applications. Design Data Hand Books: 1. Design Data Hand Book, K. Mahadevan and Balaveera Reddy, CBS publication, 2012. 2. Design Data Hand Book Vol. 1 and 2 – Dr .K. Lingaiah, Suma publications, Bangalore, 2011. 3. PSG Design Data Hand Books, PSG College of Technology, Coimbatore, 2010. Text Books: 1. Mechanical Engineering Design – Joseph Edward Shigley and Charles and Mischke.

McGraw Hill International edition, 8th edition. 2008. 2. Design of Machine Elements – V.B.Bhandari, Tata McGraw Hill publishing Co. Ltd.,

New Delhi, 3rd Edition, 2012.

Reference Books: 1. Machine Design, Hall, Holowenko, Laughlin, (Schaum’s Outline Series), Adapted by

S.K.Somani, Tata McGraw Hill Publishing Company Ltd. New Delhi, Special Indian Edition, 2008.

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

CONTROL ENGINEERING (4:0:0)

Course Code : IP0414 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Outcomes:


III Year-Scheme and Syllabus for the academic year 2018-19 Upon Successful completion of this course, the students will able to

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

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

3. Understand the block diagram reduction and signal flow graphs. 4. Understand the significance between magnitude and phase relationship between

sinusoidal input and study state output. 5. Predict the transfer function of the given system using Bode plots. 6. Visualize the effects of varying system parameter on root location.

Unit 1 Introduction and Mathematical Model: Concept of automatic controls, open and closed loop systems, regulator system, follow up systems, concepts of feedback, requirement from an ideal control system, mechanical system (both translational and rotational), electrical system, DC motors, hydraulic systems -liquid level and fluid power systems, transfer functions, deriving transfer function of physical systems. 10Hrs SLE: Control Action: Types of controllers – proportional, integral, proportional Integral controllers (Basic concepts only). Unit 2 Transient Response Analysis: Transient and steady state response, first order mechanical and electrical systems subjected to step and ramp input, second order mechanical system response to step input- cases for critical damping, under damping, over damping and no damping, concepts of time constant and its importance in speed of response, time response specifications of second order system, mathematical concept of stability, Routh's stability criterion. 10Hrs SLE: Second order system response to ramp input. Unit 3 Block Diagrams and Signal Flow Graphs: Transfer functions definition, block diagram, block diagram algebra, representation of system elements, reduction of block diagrams, signal flow graphs, basic properties and gain formula. Mason gain formula. 8Hrs SLE: Multiple input/outputs of block diagrams

Unit 4 Frequency Response: Polar and rectangular plots for the frequency response, characteristic function and equation, Poles and Zeros of G(S) H(S), Nyquist stability criterion, principle of argument, system analysis using Nyquist diagrams, gain margin and phase margin. 8Hrs SLE: Relative stability concepts. Unit 5 Logarithmic Plots: Bode attenuation diagrams, asymptotic approximation and phase diagrams for Pole at origin, Zero at origin, simple Pole, simple Zero, quadratic Pole, stability analysis using Bode diagrams. 8Hrs


III Year-Scheme and Syllabus for the academic year 2018-19 SLE: Simplified Bode diagrams. Unit 6: Root Locus Plots: Definition of root loci, root locus concepts, constructing of root loci, rules for rapid plotting, root locus plots, stability analysis . 8Hrs SLE: Simple concepts of state variables and state model. Text Books:

1. Control Systems Engineering – I J Nagrath and M Gopal, New age International Publishers. Sixth edition, 2016

2. Modern Control Engineering – K Ogatta, Prentice Hall (India), 5th edition, 2014.

References: 1. Problems and Solutions of Control Systems with Essential Theory- A K Jairath,

CBS Publishers, Sixth edition, 2016. 2. Automatic Control Systems – B.C Kuo. Prentice Hall (India), 2014

COMPUTER INTEGRATED MANUFACTURING (4:0:0)

Course Code : IP 0415 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Outcomes: Upon successful completion of this course, the students will able to

1. Outline the use of computers and NC technology in CIM systems. 2. Understand the concepts of CNC machine tool technology. 3. Develop CNC programs for turning and milling operations. 4. Comprehend the applications of robots in CIM. 5. Plan and control the CIM systems 6. Apply the GT and FMS in actual manufacturing practice.

Unit 1 Introduction: Role of computers in design and manufacturing, product cycle in conventional and computerized manufacturing environment, introduction to CAD/CAM/CIM. NC Technology: NC, CNC, DNC modes, NC elements, advantages and limitations of NC and CNC. 8Hrs SLE: Advantages and disadvantages of CAD, CAM and CIM, functions of computer in DNC. Unit 2 CNC Machine Tools: Turning tool geometry, milling tooling systems, tool presetting, ATC, work holding, CNC machine tools, overview of different CNC machining centers, CNC turning centers. 8Hrs SLE: High speed machine tools.


III Year-Scheme and Syllabus for the academic year 2018-19 Unit 3 CNC Programming: Steps involved in development of a part program, manual part programming-milling and turning, ISO programming in drilling, milling and turning with numerical problems. 12Hrs SLE: Fundamentals of CNC hardware. Unit 4 Introduction to Robotics: Introduction, robot configuration, robot motions, end effectors, work cell, control and interlock, types of Robot Programming, exercises on pick and place programs, sensors, principle of working and applications of tactile, non – tactile, proximity, vision, force and torque sensors. 8Hrs SLE: Robot applications. Unit 5 CIM: Computer aided process planning, computer integrated production planning system, material requirements planning, capacity planning, shop floor control. 9Hrs SLE: IoT data management requirements. Unit 6 Group Technology and Flexible Manufacturing: Part families, part classification and coding, machine cell design and benefits of group technology, FMS work stations, planning the FMS, FMS layout configuration. 7Hrs SLE: Applications and benefits of FMS. Text Books:

1. CAD/CAM Principles and Applications – P.N. Rao, TMH, New Delhi, 2002. 2. CAD/CAM – Mikell P-groover, Emory W.ZimrnersJr Pearson Education inc, 2003.

Reference Books:

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

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

3. CAD/CAM-Ibrahim Zeid, Tata McGraw Hill, 1999. 4. Computer Aided Manufacturing- P.N.Rao, N.K.Tewri and T.K.Kundra Tata

McGraw Hill 1999. 5. An Introduction to NC/CNC machines, S. Vishal, 2nd edition, S.K. Kataria and

Sons, 2010. 6. Gerard Jounghyun Kim, “Designing Virtual Systems: The Structured Approach”,

Springer, 2005. 7. Adrian McEwan and Hakim Cassimally, “Designing the internet of things”,

Wiley, 2013.



MANUFACTURING PROCESSES – III (4:0:0)

Course Code : IP 0455 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Outcomes: Upon successful completion of this course, the students will able to

1. Understand the theory behind the forming process of the metal. 2. Demonstrate the concept of forging of metals. 3. Understanding of the types, forces and defects involved in rolling of metals. 4. Understand the basic knowledge of extrusion and drawing metals. 5. Demonstrate the basic concept of sheet metal forming processes. 6. Understand the basic theory about the powder metallurgy and its applications.

Unit 1 Elements of the Theory of Plasticity: Flow curves, true stress and true strain, yield criteria for ductile materials, Von Mises criterion and Tresca criterion. Fundamentals of Metal working: Classification of forming process, temperatures in Metal working, hot working, cold working, warm working, strain rate effects, effect of forming on metallurgical structure. 10Hrs SLE: Effect of friction and lubrication in metal working. Unit 2 Forging of Metals: Introduction, open die forging, impression – die and closed die forging, precision forging, rotary swaging, forging force, forging die design, die-materials and lubrication, forge ability, forging defects, forging mechanics. 7Hrs SLE: Presses and hammers. Unit 3 Rolling of Metals: Introduction, flat rolling, frictional forces, roll force and power requirement, geometric consideration, defects in rolled plates and sheets, rolling mills, classification, shape rolling operations, ring rolling, thread rolling, defects in rolled products. 6Hrs SLE: Production of seamless pipe and tubing. Unit 4 Extrusion and Drawing: Introduction, the extrusion process- forward and backward extrusion, extrusion force, hot extrusion, cold extrusion, impact extrusion, hydrostatic extrusion, extrusion defects, presses used for extrusion, drawing process, wire drawing process, tube drawing process, defects and residual stresses in extrusion and drawing. 9 Hrs SLE: Extrusion of non-metals and plastics. Unit 5 Sheet Metal Forming Processes: Introduction, classification of dies, press operations, sheet metal characteristics, bending sheet and plate, spring back, compensation for spring back, common bending operations, tube bending and forming, stretch forming, deep drawing,


III Year-Scheme and Syllabus for the academic year 2018-19 rubber Forming, spinning, super plastic forming and other forming processes, equipment for sheet metal forming, defects in sheet metal products. 10Hrs SLE: Explosive and Magnetic pulse forming. Unit 6 Powder Metallurgy: Introduction, basic process, powder manufacture, rapidly solidified powder, powder testing and evaluation, powder mixing and blending, compacting, sintering, hot isostatic pressing, secondary operations, properties of powder metallurgy products, design of powder metallurgy products, advantages and disadvantages of powder metallurgy. 10 Hrs SLE: Application of powder metallurgy. Text Books:

1. Manufacturing Engineering and Technology – SeropeKalpakjian, and Steven R. Schmid, PEARSON Education, 2004

2. Mechanical Metallurgy – Dieter G.E, Mcgraw Hill 2001

References: 1. Principle of Industrial Metal Working Process – Rowe, CBS publishers, 2002. 2. ASM – Metals Hand Book, Sach G, Fundamentals of working of metals, Pergomon

press. 3. Materials and processes in Manufacturing, E.Paul Degarmo, J.T. Black, Ronald A

Kohser, PHI 2000.

MACHINE SHOP (0:0:3)

Course Code : IP 0105 Hrs/Week : 03 Max. Marks : 50 Course Outcomes: Upon successful completion of this course, the students will be able to

1. Develop 3D models on lathe involving plain, taper and step turning, thread cutting, eccentric turning and the like.

2. Explain the applications of shaping machine after getting hands on experience on the same.

3. Apply simple and differential indexing calculations to cur gear teeth on a blank using milling machine.

Experiments: Preparation of at least three models on lathe involving plain turning, taper turning, step turning, thread cutting, facing, knurling, drilling, boring, internal thread cutting and Eccentric turning. Cutting of V groove/ dovetail / rectangular groove using shaping, cutting of gear teeth using milling machine, simple and differential indexing calculations, cutting of helical gear teeth (Demonstration only).



INDUSTRIAL ENGINEERING LABORATORY (0:0:3)

Course Code : IP 0106 Hrs/Week : 03 Max. Marks : 50 Course Outcomes: Upon successful completion of this course, the students will be able to

1. Use various charts to record the different activities for existing methods, analyze the existing method and proposing an improved method.

2. Compute the rating factor for different exercises based on pace. 3. Determine the standard time for simple operation by stop watch time study. 4. Determine the standard time using PMTS techniques. 5. Demonstrate the influence of external factors on workers efficiency. 6. Understand the concepts of Goniometer and sound level meter

Experiments: 1. Exercises on Recording Techniques: Outline process chart, Multiple Activity Chart,

Flow process chart, Flow diagram, String diagram, Two handed process charts, Application of principles of motion economy.

2. Exercises on Pace and Performance rating : walking on level ground, dealing of cards 3. Determining the standard time for simple operations using stopwatch time study. 4. Determining the standard time using PMTS techniques. 5. Measurement of effect of work on human body ( Ergo meter, Treadmill) 6. Effect of noise on human efficiency 7. Use and application of Goniometer and sound level meter 8. Conceptual design of displays and controls.

VI Semester FLUID POWER SYSTEMS (4:0:0)

Sub Code : IP0417 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Outcomes: Upon successful completion of this course, the students will be able to 1. Recall the basic concept of fluid mechanics; identify different components of hydraulic system. 2. Analyze the requirement of control components and their selection. 3. Design the hydraulic system for various situations. 4. Recall the structure of pneumatic system and compressed air preparation . 5. Understand the structure of pneumatics systems. 6. Analyze the pneumatic system and apply the proper logic functions. Unit 1


III Year-Scheme and Syllabus for the academic year 2018-19 Introduction to Hydraulic Power and Pumps: review of fluid mechanics, Pascal’s Law, structure of hydraulic control system. pumps: pumping theory, pump classification, gear pumps- external and internal type, vane pumps- simple, balanced, pressure compensated types, piston pumps- radial and axial (both swash plate and bent axis type), pump performance. Hydraulic Actuators and Motors: Linear hydraulic actuators - single acting, double acting, tandem cylinder, telescopic rod cylinder, mechanics of hydraulic cylinder loading, cylinder cushioning, hydraulic rotary actuators, hydrostatic transmission – open and close circuit, performance of hydraulic motor. 10Hrs SLE: Gear motors, vane motors, piston motors. Unit 2 Control Components in Hydraulic Systems: directional control valves (DCV), constructional features, 2/2,3/2,4/2,4/3 DCV, center configuration in 4/3 DCV- open, closed, tandem, regenerative, floating centre configuration, actuation of DCVs- manual, mechanical, solenoid, and indirect actuation, relays for the solenoid operation, check valve, pilot check valve, pressure control valves – direct and pilot operated types, pressure reducing valve, flow control valves- fixed throttle, and variable throttle, throttle check valve, pressure compensated flow control valve- relief and reducing type. 12Hrs SLE: Valve lap, lap during switching. Unit 3 Hydraulic Circuit Design and Analysis: control of single and double acting hydraulic cylinder, regenerative circuit, counter balance valve application, cylinder sequencing circuits, cylinder synchronizing circuits, speed control of hydraulic cylinder – meter in and meter out, speed control of hydraulic motors, relay circuit design for the operation of solenoid directional control valve- single and double solenoid relay circuit, Accumulators and accumulator circuits. 8Hrs SLE: Maintenance of Hydraulic Systems: sealing devices, reservoir system, filters and strainers, problem caused by gases in hydraulic fluids, reasons for hydraulic system failure. Unit 4 Introduction To Pneumatic Control: choice of working medium, characteristics of compressed air, structure of pneumatic control system, supply, signal generators, signal processor, final control elements, actuators, , preparation of compressed air – driers, filters, regulators, lubricators, distribution of compressed air – piping layout. 6Hrs SLE: Production of compressed air – Reciprocating and rotary compressors. Unit 5 Pneumatic Actuators and Valves: cylinder- different types- Bellow, single acting, double acting, tandem, multi-position, telescopic rod cylinders, pressure reducing valve, directional control valve-3/2, 4/2, 5/2 - manual and mechanical actuation, memory valve, shuttle valve, quick exhaust value, twin pressure valve, direct and indirect actuation of pneumatic cylinder, time delay valve. 6Hrs SLE: End position cushioning, Rod less cylinders.


III Year-Scheme and Syllabus for the academic year 2018-19 Unit 6 Pneumatic circuits and logic circuits: supply air and exhaust air throttling, will dependent circuits, travel and time dependent controls – types – construction – practical applications, cylinder sequencing circuits, travel step diagrams, practical examples involving two or three cylinders, signal overlapping and its elimination, cascading principle of circuit design, use of logic functions – OR, AND, NOR, NAND, YES, NOT functions in pneumatic applications, practical examples involving the use of logic functions. 10Hrs SLE: Pressure dependent controls –practical applications. Text Books:

1. Fluid Power with applications – Anthony Esposito, Seventh edition, Pearson Education, Inc 2014.

2. Pneumatic systems – S.R. Majumdar, Tata McGraw Hill Publishing Co. 2012. Reference Books:

1. Oil Hydraulic systems – Principles and Maintenance – S.R. Majumdar, Tata McGraw Hill Publishing Company Ltd. 2012

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

3. Fundamentals of Pneumatic Control Engineering – J P Hasebrink and R Kobbler, Festo Didactic publication, 3rd edition 1989.

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

5. Power Hydraulics – Michael J Pinches and John G Ashby, Prentic Hall – 1989.

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

Sub Code : IP0418 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Outcomes: Upon successful completion of this course, the students will be able to

1. Design curved beams and v-belts. 2. Distinguish types of springs and design leaf springs for various applications. 3. Design spur gear and helical gear. 4. Design bevel gear and worm gear 5. Design simple clutch and different types of brake considering thermal applications. 6. Comprehend the mechanism of lubrication and compare design of bearing for

different applications with thermal equilibrium as basis. Unit 1 Design of Curved Beams: Stresses in curved beam of standard cross sections used in crane hook, punching press and clamps. Belt, Rope and Chain Drives: Stresses in belts: design and selection of flat and V- Belts, Selection of wire ropes, Selection of chains. 10Hrs SLE: Different beams and Selection of V-Belts and chain.


III Year-Scheme and Syllabus for the academic year 2018-19 Unit 2 Design of springs: Types of springs - stresses in coil springs of circular and non-circular cross sections, tension and compression springs, fluctuating load, spring in combination leaf springs: stresses, semi-elliptical leaf springs. 9Hrs SLE: Springs in different industrial applications.

Unit 3 Spur and Helical Gears: Introduction, spur gears: stresses in gear tooth – Lewis equation and form factor, design for strength, dynamic and wear load, helical gears, formative number of teeth, design for strength, dynamic and wear load, AGMA standards of gear design. 9Hrs SLE: AGMA standards of gear design –spur, helical. Unit 4 Bevel and Worm Gears: Bevel gears: formative number of teeth, design for strength, dynamic and wear load, worm gears, definitions, design for strength, dynamic and wear load, efficiency of worm gears, AGMA standards of gear design. 9Hrs SLE: AGMA standards of gear design –Bevel and Worm. Unit 5 Clutches and Brakes: Design of single plate, Multi-plate and cone clutches, design of Brakes, Block and band brakes, Self locking brakes, Heat generation brakes. 5Hrs SLE: Heat generation in brake.

Unit 6 Lubrication and Bearings: mechanisms of lubrication, bearing materials, bearing modulus, coefficient of friction, minimum oil film thickness, thermal equilibrium: heat generation and dissipation, design of journal bearing and thrust bearing. Ball and Roller Bearings: Introduction, types, construction, loads on bearings, equivalent bearing load, life of bearing, selection of ball and roller bearings. 10Hrs SLE: Selection of Ball and Roller Bearing. Design Data Hand Books: 1. Design Data Hand Book, K.Mahadevan and Balaveera Reddy, CBS publication, 2012. 2. Design Data Hand Book Vol. 1 and 2 – Dr.K.Lingaiah, Suma publications, Bangalore, 2011. 3. PSG Design Data Hand Books, PSG College of Technology, Coimbatore, 2010. Text Books: 1. Mechanical Engineering Design – Joseph Edward Shigley and Charles and Mischke, McGraw Hill International edition, 8th edition, 2008. 2. Design of Machine Elements – V.B. Bhandari, Tata McGraw Hill publishing Co. Ltd., New Delhi, 3rd Edition, 2012. Reference Books:

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



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

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

4. Fundamentals of Machine Component Design – Robert C. Juvinall and Kurt M.Marshek – John and sons 4th edition, 2006.

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

Sub Code : IP0456 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Outcomes: Upon successful completion of the course, the students will be able to

1. Recall the basic concepts of decision making, problem solving, tactics and strategy. 2. Defining the time value of money concept, interest formulae. 3. Explain the comparison by present worth method for different lives of the asset. 4. Compare the asset on the basis of EAW comparison. 5. Explain the concepts of depreciation and replacement criteria. 6. Calculate the total cost of a component and explain the process for estimating simple

components. Unit 1 Introduction: engineering decision – makers, engineering and economics, problem solving, intuition and analysis, tactics and strategy with an example. 6Hrs. SLE: Decision making. Unit 2 Interest and Interest Factors: Interest rate, simple interest compound interest, interest formulae, time value equivalence exercises, problems and discussion. 8 Hrs. SLE: Cash flow diagrams. Unit 3 Present Worth Comparison: Conditions for present worth comparisons, rule 72, basic present worth comparisons, present worth equivalence, net present worth, assets with equal and unequal lives, comparison of assets assume to have infinite lives, exercises and problems. 12Hrs SLE: Future worth comparison. Unit 4 Equivalent Annual Worth Comparisons: Situations for equivalent annual worth comparison, net annual worth of a single project, comparison of net annual worth’s, definitions of asset life, comparison of assets with equal and unequal lives, exercises and problems. Rate of Return Calculations: rate of return, minimum acceptable rate of return. 10Hrs. SLE: Use of sinking fund method, IRR and IRR misconceptions.


III Year-Scheme and Syllabus for the academic year 2018-19 Unit 5 Depreciation: Introduction, methods of depreciation, problems. Replacement Analysis: Reasons- Deterioration, obsolescence, inadequacy, replacement criteria problems. 10Hrs SLE: Causes of depreciation, reasons for replacement. Unit 6 Estimating and Costing: components of costs such as direct material cost, direct labour cost, Fixed, over – heads, factory costs, administrative – over heads, first cost, selling price, calculation of the total cost of various components, mensuration, estimation of simple components. 6 Hrs. SLE: Estimation, Marginal cost. Text Books:

1. Engineering economy – Riggs J.L., McGraw Hill, 2002. 2. Engineering economy – Paul Degarmo, Macmillan Pub, Co., 2001.

Reference Books: 1. Engineering Economy – NVR. Naidu, KM Babu and G.Rajendra, New Age

International Pvt. Ltd., 2006. 2. Industrial Engineering and Management - O.P Khanna, Dhanpat Rai and Sons,

2000. 3. Financial Management – I M Pandey, Vikas Publishing House, 2002. 4. Engineering Economy – Theusen. G. PHI, 2002.

STATISTICAL QUALITY CONTROL (4:0:0) Sub Code : IP0420 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Outcomes: Upon successful completion of the course, the students will be able to: 1. Understand the concept of Quality from producers and consumers prospective, methods

for quality control. 2. Illustrate the variations of distribution of data’s using different methods. 3. Explain the purpose and function of statistical quality control, the differences between

attributes and variable control chart and causes of variations. 4. Illustrate the variable control chart techniques for continuous quality improvement. 5. Illustrate the attribute control chart techniques for continuous quality improvement. 6. Understand the Operating Characteristic Curve and prepare the acceptance sampling

plan.

Unit 1 Introduction: meaning of quality and quality improvement, dimensions of quality, quality engineering terminology, statistical methods for quality control and improvement, other


III Year-Scheme and Syllabus for the academic year 2018-19 aspects of quality control and improvement, quality philosophy and management strategies, link between quality and productivity, quality costs, 7-QC tools, TQM, quality assurance. 8Hrs SLE: Recognize and illustrate various aspects of quality in a multi-disciplinary organization. Unit 2 Process Quality: describing variation, frequency distribution and histogram, numerical summary of data, probability distributions, important discrete distributions - hyper geometric distribution, binomial distribution and Poisson distribution, important continuous distributions - normal distribution, brief discussion on: exponential, gamma and Weibull distributions, binomial approximation to the hyper geometric, Poisson approximation to the binomial, normal approximation to the binomial. 10Hrs SLE: Application of various distributions in real world situation. Unit 3 Statistical Process Control Charts: Chance and assignable causes of quality variation, statistical basis of the control chart, basic principles, and choice of control limits, sample size and sampling frequency, rational subgroups, analysis of patterns on control charts. 6Hrs SLE: Analyze and illustrate the implications of patterns on control charts vis-à-vis industrial application. Unit 4 Control Charts for Variables: Introduction, control charts for X bar and R, statistical basis of the charts, development and use of rab X and R charts, process capability, interpretation of X bar and R charts, control charts for X bar and S, construction and operation of X bar and S, X bar and S control charts with variable sample size. 8Hrs SLE: Control Chart for Individual Measurements. Unit 5 Control Charts for Attributes: Introduction, control chart for fraction nonconforming (p, 100p and np Charts), control charts for nonconformities (C and U Charts). 8Hrs SLE: Procedures with Constant and Variable Sample Size. Unit 6 Acceptance Sampling: Acceptance-sampling problem, advantages and disadvantages of sampling, types of sampling plans, plot formation, random sampling, single-sampling plans for attributes, definition of a single-sampling plan, OC curve, designing a single-sampling plan with a specified OC curve, producers’ and consumers’ risk, rectifying inspection, double sampling plan. 8Hrs SLE: Multiple and Sequential Sampling. Text Book: 1. Introduction to Statistical Quality Control, Douglas C. Montgomery, 6th Edition, 2014, Wiley India Edition.


III Year-Scheme and Syllabus for the academic year 2018-19 Reference Books: 1. Statistical Quality Control, Eugene L. Grant and Richard S. Leavenworth, 7th Edition,

2004, Tata McGraw-Hill. 2. Quality Control, Dale H. Besterfield, 4th Edition, Prentice Hall. 3. Total Quality Management, Dale H Besterfield, 4th edition, Pearson.

LEAN MANUFACTURING SYSTEM (4:0:0)

Sub Code : IP 0421 CIE : 50% Marks Hrs/Week : 04 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Outcomes: Upon successful completion of this course, the students will be able to:

1. Recognize the underlying philosophy of the Toyota Production System. 2. Analyze the different concepts of 5S, 3M, etc. to keep clean and standardizing the

operation. 3. Recall the concepts and implementation of Jidoka and poka-yoke systems. 4. Explain how to look at one’s own shop floor in terms of lead-time reduction, waste

elimination and material flow. 5. Understand the continuous improvement concept and Taylor’s principles. 6. Explain how to manage people in a Lean environment in order to sustain

improvements in production method.

Unit 1 Introduction: Mass production system, origin of lean production system, necessity, lean revolution in Toyota, systems and systems thinking, basic image of lean production, customer focus. 8Hrs. SLE: Muda (waste). Unit 2 Stability of lean system: Standards in the lean system, total productive maintenance, standardized work , elements of standardized work, charts to define standardized work, man power reduction, overall efficiency - standardized work and kaizen, common layouts. Lean tools: 5S system, why-why analysis, Ishikawa diagram. 8Hrs. SLE: Case study on lean tool implementation. Unit 3 Standardization of operations: job rotation, Improvement activities to reduce work force and increase worker morale foundation for improvements. Just In Time: Principles of JIT, JIT system, Kanban, Kanban rules, expanded role of conveyance, production leveling, pull systems, value stream mapping. 10Hrs. SLE: Multi-function workers. Unit 4 Shortening of production lead times: Reduction of setup times: practical procedures for reducing setup time, Jidoka concept, poka-yoke (mistake proofing) systems, inspection


III Year-Scheme and Syllabus for the academic year 2018-19 systems and zone control, types and use of poka-yoke systems. 10Hrs. SLE: Implementation of Jidoka.

Unit 5 Worker Involvement and Systematic Planning Methodology: Involvement, activities to support involvement, quality circle activity, Kaizen training, suggestion programmes, Hoshin planning system (systematic planning methodology), phases of Hoshin planning. 8Hrs. SLE: Lean culture. Unit 6 Managing lean enterprise: Global enterprises and their benefits. Mini project on “Application of Lean manufacturing concepts to production/ process/ product”. 8Hrs. SLE: Application of Lean manufacturing concepts to production service industries. Text books

1. Pascal Dennis, Lean Production Simplified: A Plain-Language Guide to the World’s Most Powerful Production System, (Second edition), Productivity Press, New York, 8th edition 2014.

2. Lean and Agile Manufacturing: Theoretical, Practical and Research Futurities, S.R. Devadasan, V.Mohan Sivakumar, R.Murugesh, P.R.Shalij, 2012 edition.

References:

1. “The Machine that changed the World” by Daniel Roos, 2007. 2. Toyoto production system –An integrated approach to just in time by Yasuhiro

Monden – Engineering and Management press – Institute of Industrial Engineers Norcross Georgia 3rd edition 1998.

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

4. Japanese Manufacturing Techniques. The Nine Hidden Lessons by simplicity by Richard Schourberger, 1982.

5. “Just in Time Manufacturing” , M. G. Korgaonker MacMillan. Reprinted 2011 6. “Lean thinking” James P.Womack and Daniel T.Jones, 1996.

CNC / ROBOTICS LAB (0:0:3)

Sub Code : IP 0107 Hrs/Week : 03 Max. Marks : 50 Course Outcomes: Upon successful completion of this course, the students will be able to

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

2. Understand the fundamental concepts of industrial robotics and gain hands on experience of motion control.

Experiments:


III Year-Scheme and Syllabus for the academic year 2018-19 Writing and execution of manual part programming using ISO codes for machining of simple

parts involving turning, taper turning, form turning and thread cutting, use of radius

compensation, canned cycles, macros etc.

1. CNC milling – Writing and execution of part program for contour milling.

2. Programming of robots by manual, lead through and off line methods, Use of robot

programming languages to pick and place, stacking of objects in increasing or decreasing

size, Palletizing operations, assembly and inspection operation etc.

3. CNC CAPS turn and CAPS mill.

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

Sub Code : IP 0108 Hrs/Week: 03 Max. Marks: 50 Course Outcomes: Upon successful completion of this course, the students will able to

1. Demonstrate how the machine tools can be tested for their accuracy by conducting acceptance tests.

2. Explain the important elements of a machine tool part by performing disassembly and assembly.

3. Evaluate the cutting forces during machining operations with the help of dynamometers.

4. Build hydraulic circuits to control the machine tool parts. Experiments: 1. Acceptance tests on lathe, drilling machine, milling machine. 2. Determination of cutting forces during turning using lathe tool dynamometer. 3. Determination of thrust and torque during drilling with drill tool dynamometer. 4. Measurement of cutting tool temperature using thermo-couple. 5. Determination of chip-reduction ratio during orthogonal cutting on a lathe. 6. Assembly and disassembly of screw jack 7. Assembly and disassembly of tail stock 8. Assembly and disassembly of tool head of shaper 9. Assembly and disassembly of indexing head 10. Building up of hydraulic pressure intensification circuit. 11. Building up of hydraulic regenerative cylinder. 12. Comparison of tandem centre and closed centre directional control valve. 13. Speed control of cylinder: meter-in and meter-out circuits. 14. Study of will, travel and time dependent control in pneumatic systems. 15. Building up of AND and OR logic functions in pneumatic system.

ELECTIVES-I



ADVANCED MANUFACTURING PROCESSES (3:0:0)

Sub Code : IP 0304 CIE : 50% Marks Hrs/Week : 03 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100

Course Outcomes: Upon successful completion of the course, the students will be able to

1. Understand the need for advanced manufacturing process and explain the principle of operation of ultrasonic machining process.

2. Explain the characteristic features of Abrasive Jet Machining (AJM) 3. Define the process parameters influence the material removal rate with the help of

characteristics curves. 4. Explain the principle of chemical machining and chemical milling process. 5. Summarize the various aspects of Electric discharge machining (EDM). 6. Explain the principle of generation plasma and laser and their application in

machining. Unit 1 Introduction: History, need for non-traditional machining processes, classification, process selection. Mechanical Process: Ultrasonic Machining (USM): Introduction, equipment, tool material and tool size, abrasive slurry, magnetostriction assembly, tool cone (concentrator), exponential concentrator of circular cross section and rectangular cross sections, effect of parameters, amplitude, frequency, grain diameter, applied static load and slurry, tool and work material. USM process characteristics: material removal rate, tool wear, accuracy, surface finish, applications, advantages and disadvantages of USM. 10Hrs SLE: Comparison between conventional and non-conventional machining. Unit 2 Abrasive Jet Machining (AJM): Introduction, equipment, variables in AJM: carrier gas, size of abrasive grain, velocity of the abrasive jet, mean no. abrasive particles per unit volume of the carrier gas, work material, stand-off distance (SOD), process characteristics-material removal rate. nozzle wear, Accuracy and surface finish, Applications, advantages and disadvantages of AJM. 6Hrs SLE: Type of abrasives. Unit 3 Electrochemical Machining Process (ECM): Introduction, elements of ECM process: Cathode tool, anode work piece, source of DC power, electrolyte, chemistry of the process, ECM process characteristics - material removal rate, accuracy, surface finish, tool and insulation materials, tool size, electrolyte flow arrangement, applications, simple problems. 6Hrs SLE: Electrochemical Grinding, Electrochemical Honing, Electrochemical deburring Unit 4


III Year-Scheme and Syllabus for the academic year 2018-19 Chemical Machining (CHM): Introduction, elements of the process, chemical blanking process: preparation of work piece, preparation of masters, masking with photo resists, etching for blanking, accuracy of chemical blanking. Chemical Milling (Contour machining):- Process steps-masking, etching, etc. process characteristics of CHM: - material removal rate, accuracy, surface finish, application of CHM. 6Hrs SLE: Applications of chemical blanking. Unit 5 Thermal Metal Removal Processes: Electrical Discharge Machining (EDM) - Introduction, mechanism of metal removal, dielectric fluid, spark generator, EDM tool (electrode), electrode material selection, machining time, flushing: suction flushing, side flushing, pulsed flushing synchronized with electrode movement, EDM process characteristics: metal removal rate, accuracy, surface finish, heat affected zone, machine tool selection, applications, electric discharge grinding, traveling wire EDM. 6Hrs SLE: Electrode feed control, electrode manufacture, electrode wear. Unit 6 Plasma Arc Machining (PAM): Principle of generation of plasma, equipment, non-thermal generation of plasma, selection of gas, mechanism of metal removal, PAM parameters, process characteristics. Laser Beam Machining (LBM): Principle of generation of lasers, equipment and machining procedure, types of lasers, process characteristics, applications. 6Hrs SLE: Safety precautions and applications of PAM and LBM. Text Books:

1. Modern Machining Process by P C Pandey and H S Shan, Tata McGraw Hill,2008 References:

1. Production Technology, by HMT Tata McGraw Hill. 2. Modern Machining Methods by Dr. M.Adithan, Khanna Publishers, 2008. 3. Non-conventional Machining by P K Mishra, Reprint 2006, Narosa publishing

House, New – Delhi.

COMPOSITE MATERIALS (3:0:0)

Sub Code : IP 0305 CIE : 50% Marks Hrs/Week : 03 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Outcomes: Upon successful completion of this course, the students will be able to



1. Identify and classify the different types of fiber and matrix materials used in commercial composites.

2. Understand the various manufacturing process of composites. 3. Summarize various methods of composite fabrication techniques and also

understand the importance of ceramic matrix composites. 4. Outline various applications of composites and its characterization. 5. Explain the importance of metal matrix composites and its fabrication processes. 6. Understand the importance of recent advances in composites, includes polymer

nano composites. Unit 1 Introduction to Composite Materials: Definition, classification and characteristics of composite materials, fibrous composites, laminated composites, particulate composites, properties and types of reinforcement and matrix materials. 7Hrs SLE: Thermosets and Thermoplastics. Unit 2 Fiber Reinforcement Plastic Processing: Fabricating process: open and closed mould process. hand layup technique, bag molding, filament winding, pultrusion, pulforming, thermoforming, injection molding. 8Hrs SLE: Processing of Thermoplastics. Unit 3 Fabrication of Composites: cutting, drilling, mechanical fasteners adhesive bonding, and joining. Ceramic Matrix Composites: Introduction, properties and fabrication technologies. 6Hrs SLE: Machining of composites. Unit 4 Application of Composites: Uses and characteristics of composites in automobile, electrical and electronic, marine, aircraft, spacecraft, sports and recreational industries, characterization of composites and testing of composites. 6Hrs SLE: Tribological Characterization. Unit 5 Properties of MMC’s: physical mechanical, wear, machinability, effect of size, shape and distribution of particulate on properties production process. 7Hrs SLE: Manufacturing methods of MMC. Unit 6 Advanced Composites: Polymer nanocomposites – introduction, nanoclay, carbon nanofiber, carbon nanotubes. 6Hrs SLE: Introduction to shape memory alloys.


III Year-Scheme and Syllabus for the academic year 2018-19 Text Books:

1. Composite Science and Engineering – K.K. Chawala Springer Verlag, 2nd edition, 2006.

2. Introduction to Composite Materials – Hull and Clyne, Cambridge University Press, 2nd Edition, 1990.

References:

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

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

3. Mechanics of Composites – Autar K Kaw, CRC Press, 2002. 4. Composite Materials – S.C.Sharma, Narora publishing house, 2000. 5. Fiber-Reinforced Composites – Materials, Manufacturing and Design by P.K

Mallick, CRC Press, 3rd Edition, 2013.

TOOL DESIGN (3:0:0)

Sub Code : IP 0306 CIE : 50% Marks Hrs/Week : 03 SEE : 50% Marks SEE Hrs : 03 Max. Marks: 100 Course Outcomes: Upon successful completion of this course, the students will be able to:

1. Explain the significance of location and clamping in the design of fixtures. 2. Design Jigs and Fixtures of varying complexities. 3. Discuss the applications and properties of various plastics and their techniques. 4. Design rudimentary injection moulds for plastics. 5. Design simple blanking and piercing dies 6. Design simple bending and drawing dies.

Unit 1 Location and Clamping: Introduction, basic principles of locating and locating devices, basic principles of clamping and clamping devices. 5Hrs SLE: Locating methods and Clamping methods. Unit 2 Jigs: Introduction, Types of drill jigs, general considerations in design of drill jigs, drill bushings. Fixtures: Introduction, fixtures and economics, types of fixtures, steps involved in designing a fixture; design of milling, turning and grinding fixtures. 7Hrs SLE: Design of Broaching and Boring fixtures. Unit 3 Plastic Processing: Introduction, history of plastics, classification, properties and application of plastics. plastic processing techniques: injection moulding, extrusion, injection blow moulding, rotational moulding, compression moulding. 7Hrs


III Year-Scheme and Syllabus for the academic year 2018-19 SLE: Principle of Operation, Applications and Advantages of: Extrusion Blow Moulding, Resin Transfer Moulding, and Thermoforming Unit 4 Mould Design: Design characteristics of mould elements including cores, cavities, inserts, pillars, gates, runners, runner layout, parting surfaces, ejection system, simple numerical examples of plastic mould designs. 10hrs SLE: Plastics commonly used as tooling materials, construction methods and applications of Plastic Tooling. Unit 5 Progressive Die: Stripping devices, pressure pads, pilots, shedders, clearances, centre of pressure, cutting forces, press tonnage, methods of reducing cutting forces, strip lay-out, tool materials, progressive press tool design: numerical examples. 6Hrs SLE: Principle of operation, applications and advantages of compound dies Unit 6: Bending: Introduction, bending dies, bending methods, spring back, bending allowance, bending force, problems. Drawing: Introduction, drawing operations, factors affecting drawing, determination of blank size, drawing force, design of drawing dies. 7Hrs SLE: Forming: Principle of Operation, Factors influencing forming, advantages and Applications. Text Books: 1.Tools Design C Donaldson- G.H. Le Cain V.C Goold, TMH – Special Indian edition, 2012. 2.Handbook of Plastic Processes by Charles A. Harper, John Wiley and Sons, 2006

Reference Books:

1. Tool Engineering and Design by G.R. Nagpal, Khanna publications, 6th Ed, 2009 2. Plastic Product Material and Process Selection Handbook by Rosato, Elsevier, 2004

MECHANICAL VIBRATIONS (3-0-0)

Sub Code : IP 0307 CIE : 50% Marks Hrs / Week : 03 SEE : 50 %Marks SEE Hrs : 03 Max. Marks: 100 Course Outcomes: Upon successful completion of this course, the students will be able to: 1. Identify and derive vibration characteristics of undamped free vibration systems using

fundamental concepts of mathematics and physics.


III Year-Scheme and Syllabus for the academic year 2018-19 2. Demonstrate and characterize the effect of damping on free vibration characterize. 3. Analyze and derive characteristics of forced vibrations and use various systems for

vibration measurement. 4. Characterize two degree vibration systems in terms of natural frequency, mode shapes

and coupling phenomena. 5. Demonstrate the characteristic of vibration of multi degree freedom systems of both

translation and rotational vibrating systems. 6. Demonstrate the application of numerical methods to study the characterize of vibration

of multi degrees of freedom systems. Unit 1 Undamped Free Vibrations: Types of vibrations, S.H.M, principle of super position applied to simple harmonic motions, beats, Fourier theorem and simple problems. single degree of freedom systems, introduction, undamped free vibration-natural frequency of free vibration, stiffness of spring elements. 7Hrs SLE: Effect of mass of spring, Unit 2 Damped Free Vibrations: Single degree freedom systems, different types of damping, viscous damping concept of critical damping and its importance, study of response of viscous damped systems for cases of under damping, critical and over damping, logarithmic decrement. 7Hrs SLE: Coulomb Damping. Unit 3 Forced Vibrations: Single degree freedom systems, steady state solution with viscous damping due to harmonic force, solution by complex algebra, concept of response, reciprocating and rotating unbalance, vibration isolation-transmissibility ratio, energy dissipated by damping, sharpness of resonance, base excitation. vibration measuring instruments: whirling of shafts with and without air damping, discussion of speeds above and below critical speeds. 8Hrs SLE: Accelerometer and Vibrometers. Unit 4 Systems With Two Degrees of Freedom: introduction, principle modes and normal modes of vibration, co-ordinate coupling, generalized and principal co-ordinates, free vibration in terms of initial conditions, geared systems. 8Hrs SLE: Dynamic vibration absorber Unit 5 Multi Degree of Freedom Systems and Continuous Systems: Governing differential equation for a MDOF system, introduction to continuous systems, vibration of string, longitudinal vibration of rods, torsional vibration of rods. 6Hrs SLE: Euler’s equation for beams. Unit 6 Numerical methods for Vibration Analysis: Introduction, influence coefficients, Method of matrix iteration, Dunkerley’s equation, Rayleigh’s method, Rayleigh Ritz method for beam vibrations, orthogonality of principal modes, orthogonality principle, Stodola Method


III Year-Scheme and Syllabus for the academic year 2018-19 Holzer’s method, geared and branched systems. 6Hrs SLE: Maxwell reciprocal theorem. Text Books: 1. Theory of Vibration and Applications by William T. Thomson and Maric Dillon Dhlech. Pearson Education, 5th Edn. 2001. 2. Mechanical Vibration by V.P.Singh, New Delhi Publishers. Reference Books: 1. Fundamentals of Vibration by Leonard Meirovitch, Tata Mc. Graw Hill, 2001. 2. Mechanical Vibrations by S.S.Rao, Pearson Education, 4th Edition, 2009. 3. Mechanical Vibration by G.K. Grover, Nemi Chand and Bros. Roorkee (UP), 1986.

COMPUTATIONAL FLUID DYNAMICS (3-0-0)

Sub Code: IP0331 CIE: 50% Hrs / Week: 03 SEE: 50% SEE: 3 Hrs Max. Marks: 100

Course Outcomes: Upon successful completion of this course, the student will be able to:

1. Understand the philosophy of CFD, 2. Formulate the governing equations for laminar and turbulent flow simulations and their

physical behaviour. 3. Apply FDM discretization techniques for solving various governing PDE's. 4. Apply FVM discretization techniques for solving various governing PDE's. 5. Analyse and evaluate the intricacies of the subject by simulating real life problems

using commercial CFD-Software. 6. Demonstrate self-learning capability in the course.

Unit - 1 Introduction: Introduction to computational fluid dynamics, CFD solution procedure, Elements of CFD code, problem set up-pre-process, numerical solution – CFD solver, result report and visualization-post-process. Introduction to vector calculus, concepts of gradient, divergence and curl, volume integral, surface integral, stokes's theorem and Gauss divergence theorem, simple problems. 5Hrs SLE: Applications & Future of CFD Unit - 2 Governing Equations for CFD: Basic concepts of fluid dynamics and principles of conservation, Eulerian and Lagrangian approaches, Reynolds transport theorem, models of flow, the substantial derivative, divergence of velocity field- its physical meaning, the, derivation of continuity equation, Navier-Stokes equations, Euler equations, and energy approximate solutions of partial differential equations (Poiseuille flow and Couette flow) equation. 9Hrs SLE: Inter-conversion between various models of flow.


III Year-Scheme and Syllabus for the academic year 2018-19 Unit - 3 Partial Differential Equations (PDE): Introduction, physical and mathematical classification of quasi-linear PDE, Eigen value method, hyperbolic, parabolic and elliptic equations, well posed problems, initial and boundary conditions- types and description, cell zones. 9 Hrs SLE: Analytical solution to PDE. Unit - 4 Finite Difference Method: Introduction to finite differences, difference equations, explicit and implicit approaches, errors and analysis of stability. FDM applied to one and two dimensional steady state heat conduction. 8Hrs SLE: Grid transformations ξ and ἠ co-ordinate system

Unit – 5 Finite Volume Method: Discretization rules, FVM for one and two dimensional steady state diffusion problem, numerical examples on 1D steady state conduction. 7Hrs SLE: Numerical Examples on 2D Unsteady state diffusion process. Unit - 6 CFD Solution Analysis: Introduction, consistency, stability, convergence, accuracy, efficiency, grid independent and time independent study, stability analysis of parabolic equations (1-D unsteady state diffusion problems) CFD Solution Techniques: simple algorithm, Lax-Wendroff technique, Macormack’s technique. 7hrs SLE: Solution of numerical examples using CFD software Text Books:

1. Computational Fluid Dynamics – The basics and applications by Anderson J.D. Jr, (1995), McGraw-Hill, New York.

2. Computational Fluid Dynamic – A practical approach by JiyuanTu, Guan HengYeoh and Chaoqun Liu, Butterworth-Heinemann (ELSEVIER), 2008.

Reference Books:

1. An introduction to CFD by H. Versteeg and W. Malalashekara, Pearson, Education, 2nd Edition, 2008.

DIGITAL MANUFACTURING (3-0-0)

Sub Code : IP0332 CIE : 50 % Hrs / Week : 03 SEE : 50 % SEE Hrs : 3 Hrs Max. Marks: 100

Course Outcomes: Upon successful completion of this course, the student will be able to: 1. Comprehend the growth of digital manufacturing and their advantages. 2. Understand CAM and reverse engineering 3. Evaluate different Concept Modelers. 4. Distinguish direct and indirect tooling systems for Rapid Prototyping.


III Year-Scheme and Syllabus for the academic year 2018-19 5. Understand digital factory and virtual manufacturing 6. Comprehend the importance of Internet of Things Unit 1 Introduction To Digital Manufacturing: Definition of digital manufacturing, Operation Mode and Architecture of Digital Manufacturing System. CAD Modeling: Design process and role of CAD, Types and applications of design models, geometrical modeling techniques – wire frame modeling, surface modeling and solid modeling 8Hrs SLE: Parametric modeling, Assembly modeling. Unit 2 Computer Aided Manufacturing: Component modeling, Machine and tool selection, Defining process and parameters, Tool path generation, Simulation, Post processing. Reverse Engineering: Need, Reverse engineering process, Reverse engineering hardware - Contact Methods, Noncontact Methods and Destructive Method ,software – Classification and Phases. 8Hrs. SLE: Fundamental Reverse Engineering Operations Unit 3:

Concepts Modelers: Principle, 3D Systems Thermo Jet Printer, Sander's Model Marker II, Stratasys Genisys Xs 3D Printer, JP system 5. 6Hrs SLE: Object Quadra system

Unit 4:

Rapid Tooling: Indirect Tooling: Role in tool production, Metal deposition tools, RTV tools, Epoxy tools, 3D Keltool process. Direct Tooling: Classification, Direct ACES Injection Moulds, Laminated Object Manufactured Tools, DTM Rapid Tool process. 8Hrs SLE: Soft Tooling vs. hard tooling Unit 5 Digital Factory and Virtual Manufacturing: Introduction, Scope, Methods and Tools Used in Virtual Manufacturing, Benefits. 6Hrs SLE: Virtual factory simulation. Unit 6 Internet of Things: Introduction, Architecture of IoT, Technological challenges, RFID and the Electronic Product Code (EPC) network, The web of things, Applications of IoT 6Hrs SLE: Issues in implementing IoT. Text Books:


III Year-Scheme and Syllabus for the academic year 2018-19 1. Zude Zhou , Shane (Shengquan) Xie Dejun Chen, “Fundamentals of Digital

Manufacturing Science”, Springer-Verlag-London-2012. 2. Vinesh Raja and Kiran J Fernandes, “Reverse Engineering-An Industrial Perspective”,

Springer-Verlag, 2008 3. Pham D T and Dimov S S, “Rapid Manufacturing: The Technologies and Applications

of Rapid Prototyping”, Springer-Verlag, 2001. 4. Journal papers


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