Dear Students, - National Institute of Engineering · Dear Students, Since it started in the year...

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PREFACE

Dear Students,

Since it started in the year 1946, NIE is promoting excellence in education through highly qualified faculty members and modern infrastructure. The Board of Directors believes in continuous improvement in delivery of technical education. Thanks to Karnataka government that designed and developed a seamless admission process through CET, many highly meritorious pre-university passed students are joining NIE, which has become a brand name among hundreds of colleges in the country. Infact, NIE is one of the top ten preferred colleges where all the seats got filled-up in the first round of 2015 admissions.

The concerted efforts of stake holders at NIE have made it get autonomous status, prestigious TEQIP-I & II and get accreditation from National Board of Accreditation, New Delhi. NIE has been granted permanent affiliation by VTU to all its courses.

Today NIE has of 7 UG, 13 PG and 5 Post-graduate Diploma programmes and 13 Centres of Excellence with overall student strength of over 3500. NIE's journey to excellence, with the main objective of continuous improvements of administrative and academic competence, is envisioned through three major pillars: intellectual infrastructure, courses/services offerings and institution building.

Our curriculum is designed to develop problem-solving skill in students and build good academic knowledge.

Dr. G.L.Shekar July 2016

Principal

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Dear Students,

Our dedicated team of highly talented faculty members are always trying to strive for academic excellence and overall personality development. The major emphasis of imparting training at NIE is to encourage enquiry and innovation among our students and lay the strong foundation for a future where they are able to face global challenges in a rapidly-changing scenario. Efforts are being made to design the curriculum based on Bloom’s Taxonomy framework, to meet the challenges of the current technical education.

NIE is making sincere efforts in meeting the global standards through new formats of National Board of Accreditation, New Delhi and timely World Bank-MHRD initiative TEQIP (Technical Education Quality Improvement Program).

I sincerely hope that your academic pursuit in NIE will be fruitful and enjoyable in every aspect Wishing you the very best.

Dr. G. S. Suresh July 2016

Dean (Academic Affairs)

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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.

Graduate Attributes

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

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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.

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.

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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.

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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.

Programme Outcomes

PO1: Apply the knowledge of mathematics, science and

engineering.

PO2: Identify, formulate and analyze problems related to

production and industrial engineering.

PO3: Design and develop production systems considering factors

related to safety and environment.

PO4: Conduct investigations of complex problems in the field of

industrial and production engineering.

PO5: Use appropriate modern tools and techniques to model and

solve complex Industrial and production engineering problems.

PO6: Understand the impact of production engineering solutions in

global, economic and societal context.

PO7: Understand the impact of production on environment and

adopt sustainable development.

PO8: Understand professional and ethical responsibilities.

PO9: Function as an individual and a team member contributing

significantly to the growth of the organization.

PO10: Communicate effectively.

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PO11: Competently manage projects understanding their financial

implications.

PO12: Possess the knowledge of contemporary issues and

engage in life-long learning.

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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.

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

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WORK STUDY & ERGONOMICS (4:0:0)

Sub Code : IP 0411 CIE : 50% Marks

Hrs/Week : 04 SEE : 50% Marks

SEE Hrs : 03 Max. Marks : 100 Course Objectives:

To Provide the basic knowledge of productivity and method study in various sectors and its effectiveness in improvement of productivity.

To provide the usage of the various tools and techniques used in work measurement.

To compare and study of the existing system and propose a new method.

To develop an idea for ergonomically based design for Human Machine System.

Unit 1 Productivity and Work Study: Definition of productivity, Individual enterprises, 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. 08 Hrs

SLE: Human factors in work study and 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, charts to record moments in shop operation - process charts, Flow process charts, Travel chart and multiple activity charts, charts to record moment at work place - principles of motion economy, classification of moments. 10 Hrs

SLE: Brief concept about synthetic motion studies.

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Unit 3 Two- Handed process chart: SIMO chart, Micro Motion study, development, definition and installation of the improved method. Work Measurement: Definition, objectives Work measurement techniques. Work sampling – Need, confidence levels, and sample size determination, conducting study with the simple problems. 08 Hrs

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 and standard rating, standard performance, scales of rating, allowances and standard time determination, Predetermined motion time study. 10 Hrs

SLE: Case study of rating in different industries.

Unit 5 Allowances: Introduction, types, Standard time determination, problems; Predetermined Motion Time Study (PMTS), factors affecting rate of working. 08 Hrs

SLE: Method Time Measurement (MTM), Synthetic Motion Studies.

Unit 6 Ergonomics: Introduction, areas of study under ergonomics, system approach to ergonomics model, man-machine system, Components of man-machine system and their functions, Concepts of displays and controls. 08 Hrs

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.

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2. Mark S. Sanders and Ernest J. McCormick , “Human Factors in Engineering Design” 4th edition, 2013.

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. Understand the importance of time study and demonstrate the rating techniques and the principles involved.

5. Determine the standard time and to calculate the allowances using PMTS techniques.

6. Demonstrate the basic concepts of ergonomic and knowledge of displays and control.

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DYNAMICS OF MACHINERY (3:2:0)



SEE Hrs : 03 Max. Marks : 100

Pre-requisite:

Kinematics of Machines Course Objective:

Is to predict and analyze the dynamic forces originating in the machine component. 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. 12 Hrs

SLE: Friction: Laws of solid friction, kinds of friction, Co-efficient of friction.

Unit 2 Dynamic force analysis: Dynamic analyses of slider crank mechanisms (Analytical method only), Engine force analysis, turning moment on crankshaft, dynamically equivalent system, and inertial force in connecting rod - Numerical problems. 10 Hrs

SLE: D ‘Alembert’s principle.

Unit 3 Dynamics of Engine Mechanism: Turning moment diagram and fly wheel design. 06 Hrs

SLE: Study different turning moment diagrams for different engine configuration.

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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 12 Hrs

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). 06 Hrs

SLE: Difference between governors and flywheel.

Unit 6 Gyroscope: Angular velocity and acceleration, gyroscopic couple,

effect of gyroscopic couple on airplane and naval ships. 06 Hrs

SLE: Effects of gyroscopic torque on ships and airplanes.

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.

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Course Outcomes:


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.

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




Pre-requisites:

Engineering Mechanics

Mechanics of Materials. Course Objective:

Students will learn to formulate and analyze stress and strain in machine elements and structure subjected to 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. 12 Hrs

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. 06 Hrs

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

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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 12 Hrs

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 in power screws, efficiency and self-locking, Design of power screws for screw jack, C-Clamp, machine vice and sluice gate. 06 Hrs

SLE: Nut, bolt, screw-design and its application. Unit 5: Mechanical Joints: Cotter and Knuckle Joints. 06 Hrs

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.

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

Course Outcomes:


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.

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CONTROL ENGINEERING (4:0:0)



SEE Hrs : 03 Max. Marks : 100 Course Objective:

The main objective of this course is to help the student to gain a basic understanding of system stability and control. Unit 1 Introduction and Mathematical Model: Concept of automatic controls, open and closed loop systems, regulatory 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. 10 Hrs

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 stability Criterion. 10 Hrs

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. 08 Hrs

SLE: Multiple input/outputs of block diagrams

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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. 08 Hrs

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. 08 Hrs

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 08 Hrs

SLE: Simple concepts of State variables and state model. Text Books:

1. Control Systems – I J Nagrath and M Gopal, New age International Publishers. Fifth edition, 2014

2. Modern Control engineering – K Ogatta, Prentice Hall (India) Pearson Education 2014.

References:

1. Feedback Control Systems – Schaum’s series. 2001

2. Control Systems – M Gopal, Tata McGraw Hill, New Delhi, 2nd Edition, 2002.

3. Modern Control Systems – Richard C Dorf and Robert. H.Bishop, Addison – Wesley, 8th edition, 1998.

4. Automatic Control Systems – B.C Kuo. Prentice Hall (India), 1995.

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Course Outcomes:

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 representation and reduction.

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.

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COMPUTER INTEGRATED MANUFACTURING (4:0:0)




To learn the basic concepts of Computer Integrated Manufacturing and the benefits that can be achieved by integrating technology with manufacturing systems. Unit 1 Introduction: Role of computers in design and manufacturing, Influence of computers in manufacturing environment. 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. 10 Hrs

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. 08 Hrs

SLE: High speed machine tools.

Unit 3 Introduction to Robotics: Introduction, Robot configuration,

Robot motions, Programming the robots, Robot programming

languages, End effectors, Work cell, Control and interlock, Robot

sensor. 08 Hrs

SLE: Robot applications.

Unit 4 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

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SLE: Fundamentals of CNC hardware. Unit 5 CIM: Computer aided process planning, Computer integrated

production planning system, Material requirements planning,

Capacity planning, Shop floor control. 07 Hrs

SLE: Future automated factory.

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. 07 Hrs

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.Zimrners Jr 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.

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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. Explain the concepts of CNC machine tool technology.

3. Comprehend the applications of robots in CIM.

4. Develop CNC programs for turning and milling operations.

5. Plan and control the CIM systems effectively.

6. Apply the GT and FMS in actual manufacturing practice.

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MANUFACTURING PROCESSES – III (4:0:0)




To learn the basic concepts of plasticity, forming process, rolling, extrusion, sheet metal and powder metallurgy techniques of different metals and their alloys. 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. 10 Hrs

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. 07 Hrs

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. 06 Hrs

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

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defects, Presses used for extrusion. The drawing process, Wire

drawing process, Tube drawing process, Defects and Residual

stresses in extrusion and drawing. 09 Hrs

SLE: Extrusion of non-metals and plastics.

Unit 5 Sheet Metal Forming Processes: Introduction, Shearing, Sheet

metal characteristics, Test methods for formability of sheet metals,

Bending sheet and plate, Common bending operations, Tube

bending and forming, Stretch forming, Deep drawing, Rubber

Forming, Spinning, Super plastic forming and other forming

processes, Equipment for sheet metal forming, Defects in sheet

metal products. 10 Hrs

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. Mechanical Metallurgy – Dieter G.E, Mc graw Hill 2001

2. Manufacturing Engineering and Technology – Serope Kalpakjian, and Steven R. Schmid, PEARSON Education, 2004

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, Rouald A . Kohser, PHI 2000.

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Course Outcomes:


1. Understand the theory behind the forming 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 theory of powder metallurgy and its applications.

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MACHINE SHOP (0:0:3)

Sub Code : IP 0105 Max. Marks : 50

Hrs/Week : 03 Course Objective:

To impart training on various machine tools and prepare them for

jobs in a manufacturing industry.

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).

Course Outcomes:


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.

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INDUSTRIAL ENGINEERING LABORATORY(0:0:3)


Hrs/Week : 03 Course Objective:

Students will learn the concepts of work-study, method study, work measurement techniques and ergonomics for industrial applications. Experiments:

1. Recording Techniques: Preparing the following charts and diagrams

- Out lines process chart

- Flow process chart

- Flow diagram

- Multiple activity chart

- String diagram, SIMO chart

- Two handed process charts

2. Application of principle of motion economy

3. Measurement of effect of work on human body (Ergometer, Tread mill)

4. Rating exercises: Dealing of Cards, Walking on level ground.

5. Determining the standard time for simple operations using stop watches and PMTS

6. Application of Acceptance Sampling Techniques (single sampling plan and Plotting the O.C. Curve)

7. Experiments to generate data and the results in normal distribution and its interpretation.

8. Effect of Noise on human efficiency

9. Conceptual design of displays and controls.

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Course Outcomes:


1. Distinguish between various charts to record the different activities for existing and proposed methods.

2. Compute the rating factor for exercises considering movement of worker.

3. Comprehend the application of PMTS techniques for simple operations.

4. Demonstrate the influence of external factors on workers efficiency.

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VI Semester

(Core Courses)

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FLUID POWER SYSTEMS (4:0:0)




This course is essential in understanding the design, analysis, operation, maintenance and applications of fluid power systems. Unit 1 Introduction to Hydraulic Power and Pumps: Pascal’s Law, structure of Hydraulic control system. Pumps: Pumping theory, Pump Classification, Gear Pumps, Vane Pumps, Piston Pumps, Pump performance.

Hydraulic Actuators and Motors: Linear Hydraulic Actuators (Cylinders), Mechanics of Hydraulic Cylinder Loading, cylinder cushioning, Hydraulic Rotary Actuators, Hydrostatic Transmission – open and close circuit, Performance of hydraulic motor. 10 Hrs

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, Actuation of DCVs, check valve, Pilot check valve, Pressure control valves – direct and pilot operated types, Pressure reducing valve, flow control valves, Throttle check valve, Filters and Strainers.

Pressure compensated flow control valves-relief and reducing tyte. 12 Hrs

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, Hydraulic Cylinder sequencing Circuits, Cylinder Synchronizing Circuits, speed Control of Hydraulic Cylinder – Meter in and Meter out, speed control of Hydraulic Motors, Relays, Relay circuit for single and double solenoid circuits. 08 Hrs

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SLE: Accumulators and accumulator circuits- Emergency power source, Auxiliary power source, Shock absorber. Unit 4 Introduction To Pneumatic Control: Choice of working medium. Characteristics of compressed air, Structure of Pneumatic control system, Production of compressed air – compressors, Preparation of compressed air – Driers, Filters, regulators, Lubricators, Distribution of compressed air – Piping layout. 06 Hrs

SLE: Maintenance of Hydraulic Systems: Sealing Devices, Reservoir system, problem caused by gases in Hydraulic Fluids reasons for failure.

Unit 5 Pneumatic Actuators and Valves: Linear Cylinder – Types, conventional type of cylinder – working, Directional control valve, shuttle valve, Quick exhaust value, Twin pressure valve, Direct and indirect actuation of pneumatic cylinder, memory valve, time delay valve. 08 Hrs

SLE: End position cushioning, Rod less cylinders.

Unit 6 Pneumatic Logic Circuits: Use of Logic functions – OR, AND, NOR, NAND, NOT functions in pneumatic applications, Practical examples involving the use of logic functions. Travel dependent controls – types – Construction – Practical applications. 08 Hrs

SLE: Time dependent controls –practical applications. Text Books:

1. Fluid Power with applications – Anthony Esposito, Seventh edition, Pearson Education, Inc 2015.

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.

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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.

Course Outcomes:


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 pneumatics system and compressed air preparation.

5. Understand the Pneumatics systems.

6. Analyze the pneumatic system and apply the proper logic functions.

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



SEE Hrs : 03 Max. Marks : 100 Pre-requisite:

Design of Machine Elements I Course Objective:

Students will be able to design different machine components subjected to various loads and understand the concept of lubrication in bearings. 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. 10 Hrs

SLE: Different beams and Selection of V-Belts and chain. 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. 09 Hrs

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. 09 Hrs

SLE: AGMA standards of gear design –spur, helical.

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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. 09 Hrs

SLE: AGMA standards of gear design –Bevel and Worm.

Unit 5 Clutches and Brakes: Design of single plate, Multiplate and cone clutches, design of Brakes, Block and band brakes, Self locking brakes, Heat generation brakes. 05 Hrs

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. 10 Hrs

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.

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

Course Outcomes:


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.

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



SEE Hrs : 03 Max. Marks : 100 Course Objectives:

Provides clear understanding of the fundamentals of engineering economics.

Learn the concepts of decision making, problem solving, and comparison of the alternatives and elements of cost.

Unit 1 Introduction: Engineering Decision – Makers, engineering and economics, Problem solving, intuition and analysis, tactics and strategy. 06 Hrs.

SLE: Decision making.

Unit 2 Interest and Interest Factors: Interest rate, simple interest compound interest, interest formulae, Time value equivalence exercises and discussion. 07 Hrs.

SLE: Cash flow diagrams.

Unit 3 Present Worth Comparison: Conditions for present worth comparisons, basic present worth comparisons, Present worth equivalence, net present worth, assets with unequal lives, infinite lives, pay – back comparison, problems and discussions. 09 Hrs.

SLE: Future worth comparison.

Unit 4 Equivalent Annual Worth Comparisons: Equivalent annual worth comparison methods, situations for equivalent annual worth comparison, consideration of asset life, comparison of assets with equal and unequal lives, Exercises, Problems. Rate of Return Calculations: Rate of return, minimum acceptable rate of return, 13 Hrs. SLE: Use of sinking fund method, IRR and IRR misconceptions.

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Unit 5 Depreciation: Introduction, types, Basic methods of computing depreciation charges, problems. Replacement Analysis: Deterioration, obsolescence, Inadequacy, economic life for cycle replacements, problems. 10 Hrs.

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. Case studies: To calculate the total cost of various components. 07 Hrs.

SLE: Marginal cost, Estimation of simple components. Text Books:

1. Engineering economy – Riggs J.L., Mc Graw 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. 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, interest factors, this will help in calculations.

3. Explain the comparison by present worth method under different lives of the asset.

4. Compare the asset on the basis of EAW comparison.

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5. Explain the concepts of depreciation and replacement criteria.

6. Understand the estimating procedure for different components and calculate the total cost.

43

STATISTICAL QUALITY CONTROL (4:0:0)




Course Objective:

To understand the different statistical quality control concepts, tools and fundamentals of process performance charts. Unit 1 Introduction: Meaning of Quality and Quality Improvement, Dimensions of Quality, Quality Engineering Terminology, Statistical Methods for Quality Control and Improvement, Other Aspects of Quality Control and Improvement, Quality Philosophy and Management Strategies, Link between Quality and Productivity, Quality Costs, 7- QC tools, TQM, Quality assurance, 08 Hrs

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 - Hypergeometric Distribution,

Binomial Distribution and Poisson Distribution, Important

Continuous Distributions - Normal Distribution, Brief Discussion on:

Exponential, Gamma and Weibull Distributions, Binomial

Approximation to the Hypergeometric, Poisson Approximation to

the Binomial, Normal Approximation to the Binomial. 10 Hrs

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 06 Hrs

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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

X bar 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. 08 Hrs

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). 08 Hrs

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. 08 Hrs

SLE: Multiple and Sequential Sampling. Text Book:

1. Introduction to Statistical Quality Control, Douglas C.Montgomery, 6th Edition, 2014, Wiley India Edition.

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.

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3. Total quality management, Dale H Besterfield, 4th Edition, Pearson.

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.

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LEAN MANUFACTURING SYSTEM (4:0:0)




Course Objective:

To learn the basic concept of Lean Manufacturing and methods to be adopted for implementing lean practices.

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. 08 Hrs

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, value stream mapping. 08 Hrs

SLE: Case study on application of lean tools.

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. 10 Hrs

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 systems and zone control, types and use of poka-yoke systems. 10 Hrs SLE: Implementation of Jidoka.

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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. 08 Hrs 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”. 08 Hrs

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: Theoritical, 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

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6. “Lean thinking” James P.Womack and Daniel T.Jones, 1996.

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.

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CNC / ROBOTICS LAB (0:0:3)


Hrs/Week : 03

Course Objective:

To learn part program by using CNC turn and CNC mill softwares. Experiments:

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.

Course Outcomes:


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. Write the fundamental concepts of industrial robotic and gain hands on experience of motion control.

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


Hrs/Week : 03 Course Objectives:

To conduct experiments on various machine tools to establish the cutting forces during machining using dynamometers.

Know the components of machine tool parts by disassembling and assembling the same.

To 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. Pressure intensification circuit.

11. 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 system.

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15. Building up of AND and OR logic functions in pneumatic system.

16. Demonstration of programming logic controllers.

Course Outcomes:


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 and pneumatics circuits to control the

machine tool parts.

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ELECTIVES

(Group – I)

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ADVANCED MANUFACTURING PROCESSES (3:0:0)




Is to introduce the principles of unconventional machining processes facilitating them to choose between different manufacturing methods. Unit 1 Introduction: History, need for non-traditional machining processes, classification, process selection. Mechanical Process: Ultrasonic Machining (USM): Introduction, equipment, tool materials and tool size, abrasive slurry, magnetostriction assembly, tool cone (concentrator), exponential concentrator of circular cross section and rectangular cross sections. Effect of parameters: Effect of amplitude and frequency, effect of grain diameter, Effect of applied static load, Effect of slurry, tool and work material. USM process characteristics: material removal rate, tool wear, accuracy, surface finish, applications, advantages and disadvantages of USM. 10 Hrs

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. 06 Hrs

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,

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tool and insulation materials, tool size, electrolyte flow arrangement, applications, Simple problems. 06 Hrs

SLE: Electrochemical Turning, Electrochemical Grinding, Electrochemical Honing, Electrochemical deburring

Unit 4 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. 06 Hrs

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 tools (electrodes), electrode material selection, and 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. 06 Hrs

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. 06 Hrs

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

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2. New Technology by Bhattacharaya, Institution of Engineering Publication.

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.

Course Outcomes:


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) knowing its applications.

3. Define the process parameters of Electrochemical Machining (ECM) knowing their influence on material removal rate.

4. Explain the principle of chemical machining and chemical milling process.

5. Explain the various aspects of Electric discharge machining (EDM).

6. Explain the basics of plasma and laser generation and their application in machining.

56

COMPOSITE MATERIALS (3:0:0)




The students will be able to process thermoplastics and thermosets using different fabricating process and implement various manufacturing methods.

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. 07 Hrs

SLE: Thermosets and Thermoplastics.

Unit 2 Fibre Reinforcement Plastic Processing: Fabricating process: open and closed mould process. Hand layup technique, Bag molding, Filament winding, Pultrusion, Pulforming, Thermo- forming, Injection molding. 08 Hrs

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. 06 Hrs

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. 06 Hrs SLE: Tribological Characterization.

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Unit 5 Properties of MMC’s: Physical Mechanical, Wear, Machinability, Effect of size, shape and distribution of particulate on properties production process. 07 Hrs

SLE: Manufacturing methods of MMC.

Unit 6 Advanced Composites: Polymer Nanocomposites – Introduction, Nanoclay, Carbon Nanofiber, Carbon Nanotubes. 06 Hrs

SLE: Introduction to shape memory alloys. 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 – Meing Schwaitz, 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.

Course Outcomes:


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

2. Understand the various manufacturing process of composites.

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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 nanocomposites.

59

TOOL ENGINEERING AND DESIGN (3:0:0)




Course Objective:

Is to make students understand the design of tools for different manufacturing processes.

Unit 1 Location and Clamping: Introduction, basic principles of locating

and locating devices, basic principles of clamping and clamping

devices. 05 Hrs

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. 07 Hrs

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. 07 Hrs

SLE: Principle of Operation, Applications and Advantages of: Extrusion Blow Moulding, Resin Transfer Moulding, and Thermoforming

Unit 4 Mould Design: Design Characteristics of al Mould Elements

including cores, cavities, inserts, pillars, gates, runners, runner

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layout, parting surfaces, ejection system, simple numerical

examples of plastic mould designs. 10 Hrs

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. 06 Hrs 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. 07 Hrs

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 Edition 2009 2. Plastic Product Material and Process Selection Handbook

by Rosato, Elsevier, 2004 3. Plastipedia: Online Encyclopedia of Plastics.

www.bpf.co.uk/plastipedia

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Course Outcomes:


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.

62

MECHANICAL VIBRATIONS (3–0–0)




To analyze and implement simple components for degrees of freedom, damping concepts and different numerical analysis techniques in relation to mechanical vibrations.

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. 07 Hrs

SLE: Effect of mass of spring, Fourier Method.

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. 07 Hrs

SLE: Coloumb 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. 08 Hrs

SLE: Accelerometer and Vibrometers. Unit 4 Systems With Two Degrees of Freedom: Introduction, principle modes and Normal modes of vibration, co-ordinate coupling,

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generalized and principal co-ordinates, Free vibration in terms of initial conditions, Dynamic vibration absorber, Geared systems. 08 Hrs SLE: Vehicle suspension, Dynamics of reciprocating Engines.

Unit 5 Multi Degree of Freedom Systems and Continuous Systems: Governing differentional equation for a MDOF system, Introduction to continuous systems, vibration of string, longitudinal vibration of rods, Torsional vibration of rods. 06 Hrs SLE: Euler’s equation for beams.

Unit 6 Numerical methods for Vibration Analysis: Introduction, influence coefficients, Maxwell reciprocal theorem, Dunkerley’s equation, Rayleigh’s method, Rayleigh Ritz method for beam vibrations, Orthogonality of principal modes, Orthogonality principle, Stodola Method Holzer’s method, Geared and branched systems. 06 Hrs

SLE: Method of matrix iteration. 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, Nem Chand and Bros. Roorkee (UP), 1986.

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Course Outcomes:


1. Identify and derive vibration characteristics of undamped free

vibration systems using fundamental concepts of mathematics

and physics.

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.

65

FOUNDRY TECHNOLOGY (3:0:0)




Course Objective:

Is to design a simple casting by selecting and considering all features using a pattern and study different furnaces used in the casting process. Unit 1 Foundry Management: Planning of new foundry project, basic steps involved, Computer applications in foundries.

Foundry Mechanization: Need for modernization and mechanization, Area of mechanization, sand reclamation etc., pollution control in foundries, and plant layout for foundries. 06 Hrs

SLE: Recent trends in foundry management.

Unit 2 Casting Design: Initial consideration in design, Economics

characteristics, Technical characteristics and alloy selection,

casting process, property criteria and design, sources of design

data for cast alloys, physical design features, and molding factors

in casting. Design consideration at the casting stage, machining

factors in casting design. 08 Hrs

SLE: Casting design of non ferrous alloys.

Unit 3 Pattern and Core Box Design: Types of patterns, pattern

allowance, common pattern materials, pattern layout and

preparation of patterns, core prints, their purpose, calculation of

core print dimensions, Master pattern design and its use, Core and

its functions, types of cores. 06 Hrs

SLE: Use of CAD and CAM concept for pattern manufacturing.

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Unit 4 Melting Furnaces and Practice: Cupola-Construction, operation

and preparation, Air furnace, rotary melting furnace, open hearth

furnace, direct arc furnace, indirect arc furnace resistance heating

furnace, core type and core less type induction furnace 08 Hrs

SLE: Energy requirements of furnaces.

Unit 5

Solidification of Castings: Crystallization and development of

cast Structure – Nucleation, Grain Growth and dendritic growth,

Independent nucleation. Eutectic Freezing, peritectic reactions,

Structure of castings – significance and practical control of cast

structure, grain shape and orientation, grain size, refinement and

modification of cast structure. 08 Hrs

SLE: Differences in solidification of ferrous and non-ferrous metal.

Unit 6 Feeding of Castings: Feeding characteristics of alloys, geometric

influence on solidification. Methods of feeding of castings, cost and

concept of yield, orientations, gating techniques, casting

temperature and pouring speed, design and location of feeder

heads. 06 Hrs

SLE: Chillers and cooling towers. Text Books:

1. Foundry Technology by O P Khana 17th edition, 2011

2. Principles of Metal Casting – Heine, Loper and Rosenthal, Tata McGraw Hill.

References:

1. Metal Casting – ASME hand book.

2. Foundry Technology by Beeley. P.R (Buttersworth), 2nd edition, 2001.

3. Metal Casting Technology by P.C. Mukerji.

4. Principles of Solidification by B. Chalmers.

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5. Metal Casting – Principles and Practice by T.V. Raman

Rao, New Age International (p) Ltd.

Course Outcomes:


1. Understand the importance of foundry technology which leads towards the education of foundry technologists and metallurgists, research workers, quality and foundry managers.

2. Apply their knowledge in the area of the production of castings of all types and all kinds of materials and also managerial skills.

3. Recall the properties of molding materials, design and application of foundry machines and equipment.

4. Understand the importance of furnaces and their melting temperatures.

5. Analyze the process of solidification and related characteristics of casting process.

6. Recognize the importance of feeding mechanism in foundry.

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COMPUTATIONAL FLUID DYNAMICS (3-0-0)

Sub Code : IP0331 CIE : 50% Marks



Course Pre requisites:

1. Fluid Mechanics 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. 05 Hrs

SLE: Applications & Future of CFD.

Unit 2 Governing Equations for CFD: Basic concepts of fluid dynamics

and principles of conservation, Eulerian & 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. 09 Hrs

SLE: Inter-conversion between various models of flow.

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. 09 Hrs

SLE: Analytical solution to PDE.

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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. 08 Hrs

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. 07 Hrs

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. 07 Hrs

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 Dynamics – A practical approach by Jiyuan Tu, Guan Heng Yeoh and Chaoqun Liu, Butterworth-Heinemann (ELSEVIER), 2008.

References:

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

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Assessment Methods:

1. Written Tests (Test, Mid Semester Exam & Make-Up Test) are evaluated for 20 Marks each.

2. Assignments will be evaluated for 10 marks.

Course Outcomes:


1. Understand the Philosophy of CFD,

2. Formulate the governing equations for laminar and turbulent flow simulations and their physical behavior.

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.

Dear Students, - National Institute of Engineering · Dear Students, Since it started in the year...

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