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M. Tech

Manufacturing Technology and Automation

Syllabus 201213

Total Credits: 64 Core Course: II Elective Courses: 02

FIRST SEMESTER

S. Code Subject Credit (T.L.P) Marks

Theory SessionalM 601 A Metal Forming analysis 3 (3-0-0) 100 50

M 603 A Welding and allied process 3 (3-0-0) 100 50

M 605 A Mechatronics & Product design 3 (3-0-0) 100 50

M 607 A Design, planning and control of 3 (3-0-0) 100 50production system

M 609 A Foundry Technology 3 (3-0-0) 100 50

Ext. Int.

M 611 A Computation Lab 1 (0-0-2) 25 25M 613 A Welding lab 1 (0-0-2) 25 25

M 615 A Mechatronics lab 1 (0-0-2) 25 25

Total 18 (15-0-6) 575 325

SECOND SEMESTER

S. Code Subject Credit (T-BP) Theory Sessional

M 602 A Metal Cutting Technology 3 (3-0-0) 100 50M 604 A Automation in Manufacturing 3 (3-0-0) 100 50

M 606 A CAD/CAM for Mfg. 3 (3-0-0) 100 50

M 608 A Elective1 3 (3-0-0) 100 50

M 610 A Principles of Management 3 (3-0-0) 100 50Ext. Int.

M 612 A Mfg. Metal Cutting 1 (0-0-2) 25 25

M 614 A Automation lab 1 (0-0-2) 25 25M 616 A CAD/CAM lab 1 (0-0-2) 25 25

Total 18 (15-0-6) 575 325

THIRD SEMESTER

S. Code Subject Credit (T-E-P) Theory SessionalM 701 A Computer Integrated Mfg. 3 (3-0-0) 100 50

M 703 A Material Management 3 (3-0-0) 100 50

M 705 A General ElectiveII 3 (3-0-0) 100 50Ext. Int.

M 707 A CIM Lab 1 (0-0-2) 25 25

M 709 A Seminar 1 (0-0-2) 25 25

M 711 A Minor Project 5 (0-0-10) 100 100

Total 16 (9-0-10) 150 300

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The subject will have to select one subject from list of program Elective I and one

subjects from list of general ElectiveII as under

ElectiveI

854 1 Industrial Inspection 608 A (A)

855 2 Quality control techniques 608 A (D)

856 3 Design an metallurgy of welded joints 608 A (E)

857 4 Forging 608 A (G)

858 5 Tool Design & Engg. 608A (H)

859 6 Machine tool Dynamics 608A (F)

860 7 Finite Element Method 608A(B)

861 8 Robotic Engineering 608A(C)

ElectiveII

883 1 Artificial Intelligence in Manufacturing 705A (A)

884 2 Value Engg. 705A (B)

885 3 Advance theory of vibration 705A(C)

886 4 Instrumentation and automatic control 705A (D)

887 5 Energy conversation 705A (E)

888 6 Energy, Ecology an environment 705A(F)

889 7 Total quality management 705A (F)

S. Code Subject Credit (L-T-P) Theory Sessional

Ext. Int.

M 702 A Major Project 12 (0-0-24) 400 100

Total 12 (0-0-24) 400 100

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M 601 A: Metal Forming Analysis

Stress-Strain relations in Elastic and plastic deformation. Yield criteria for ductile metals,

work hardening and anisotropy in yielding Flow curves.

Formation of plastic deformation problem, application of theory of plasticity for solving

metal forming problem using Slab method. Upper and Lower Bound Methods Slip Line

Field Theory.

Effects of temperature and strain rate in metal working, Friction and Lubrication in Hot

and Cold Working.

Technology and analysis of important metal forming process-forging, Rolling. Extrusion.

Wire drawing. Sheet metal forming process like Deep drawing. Stretch forming,

Bending.

Application of Finite Element Methods to Metal Forming Process-special discrimination,

Shape function. Stiffness matrices and their assembly, Implicit and explicit formulations,

Elastic-plastic approximation, Lagrangian vs Fularian schemes, Material integration

schemes. Auxiliary equation for contact. Friction and incompressibility. Thermo-

mechanical problem formulation, Steady state solution for Drawing, Forging. Rolling and

Extrusion problems.

Case studies analysis and validation of metal forming processes problems by standard

softwares.

Forming defects in products and their critical effects, remedies.

An introduction to use of international standards in metal forming problem solution and

system design.

Reference Books:

1. Metal Forming analysisR. H wagoner. Cambridge University Press.

2. Theory of ElasticityDally and Riley.

3.

Physical MetallurgyDieter, Megraw hill Inc.

4. Metal forming handbookFrontzek, M Kasparbauer, Springer Verleg

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M 603 A : Welding and Allied Processes

Review of welding processes like Gas. Arc and Resistance welding.

Welding Power Sources: Type of power sources. External V-l Characteristics for

constant current and constant voltage power sources. Rectifiers. Solid state rectifiers.

Inverter system. Duty cycles.

Are welding consumables: Types of electrodes. AWS and Indian system of classification

and coding of covered electrode for mild steel. Shielding gases and association mixtures.

Metal transfer:Short circuit/dip transfer, free light. Globular type. Spray type. Forces

affecting metal transfer. Weld bead geometry and shape factors. Weld dilution.

Are Welding Processes: Electric are welding principle, MIG: welding equipment and

processes. Shielding gas, types of metal transfer. GTAW: Principle of processes.

Application. Have and welding electrodes used CO2 welding: Difference from MIG

welding, Principle of operation, Equipment, Welding Parameters and applications.

Solid state welding: Introduction, main features and application of Ultrasonic welding

friction welding and Explosive welding.

Welding of Plastic:Difficulties in welding of plastic. Processes for welding of plastic.

Weld ability of Specific Material:Stainless steel, Aluminum and Cast iron.

Surfacing and Metal Spraying:Surfacing methods such as SMAW, MIG, TIG, SAW

Thermal spraying:Introduction, Procedures. Application. Advantage and Disadvantage.

Thermal Cutting of Metals:Introduction Types, Principles and Operation of flame and

Plasma cutting.

Under water Welding:Introduction, Methods and applications.

Automation in welding: Introduction, Semiautomatic welding, Automatic welding,

Welding mechanization. Flexible automated welding, Robotic welding, Types of welding

robots, Robot selection mechanics, Joint tracking system.

Reference Books:

1.

Modern Welding TechnologyCarry H.B (PH)

2. Welding TechnologyA.C. Devis

3. Welding and welding TechnologyLittle (TMH)

4. Welding Technology R.S. Parmar

5. AWSWelding Handbook (IV-VI) Edition

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M 605 A: Mechatronics Product Design

Introduction to Mechatronics system and components, Principles of basic electronics

Digital logic, Number system logic gates, Sequence logic flip flop system, JK flip flop.

D-flip flop.

Microprocessors and their applications Microcomputer computer

structure/microcontroller. Integrated circuits- signal conditioning processes. Various

types of amplifiers low pass and high pass filters.

Sensors Sensors and transducers, displacement, Position proximity sensors. Velocity

force sensors. Fluid presence temperature. Liquid level and light sensors. Selection of

sensors. Actuators, Pneumatic and Hydraulic system, Mechanical actuation system.

Electrical actuation system. Other Electrical electronic hardware in mechatronics system.

Principles of Electronic system communication. Interfacing AD and DA converters.

Software and Hardware principles and tools to build mechatronic systems. Basic system

models, Methematical models. Mechanical and other system building blocks.

System models Engg. System Rotational, translation. Elected mechanical. Hydraulic

mechanical system, system transfer function, First second order system in series.

Design and selection of Mechatronics statement namely sensors line encoders and

revolvers, stepper an servomotors ball screws, solenoids, line actuators and controllers

with application of CNC system, Robots. Consumer electronics products etc. Design of a

mechatronic product using available software CAD packages, MATLAB and

SIMULINK.

Reference Books:

1. MechatronicsW. Bolton. Addison Worley Longman Pvt. Ltd

2. Automation Production System and CIMSMikel P Groover, PHI

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M 607 A: Design, Planning and Control of Production Systems

Introduction to production system: Aim of production system, generalized model and

types of production system, Features compiling service organization, Life cycle approach

to production management.

Product development and design: New product development and process selection.

Stages in new product development. Use of decision tree. Breakeven analysis, Make Buy

decision, Problems for Break even analysis. Selection of location among alternatives A

case study, Systematic layout planning. Objectives, Types, Comparison and application

of different types of layouts, Assembly line balancing concept and problems for

maximum line efficiency.

Planning for production: Importance, Objectives and types of forecasting methods.

Analysis and comparison standard error of estimate. Material Requirement Planning

(MRP) objective, Dependent demand, Inputs to MRP. MRP model. Production schedule.

MRP logic comparison.

Sequencing and scheduling: Criteria for sequencing, Priority sequencing and rules, n job

2 machine, n job 3 machine, n job m machines problems.

Element of monitoring and follow up.

Reference Books:1. Production Operations ManagementBuffa. Edwood

2. Elements of Production, Planning and ControlEilon Samuel A

3. Production control: A quantitative approachBiegel. J

4. Industrial Engineering and Production ManagementMartland Telsang

5. Operation ManagementTheory and ProblemsJoseph Monks

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M-611 A: Computation Lab

Experiment No. 1 & 2

Modeling in 2-D & Image scanning using Pro-E.

Experiment No. 3 & 4

Modeling in 3-D machine tool parts like gear details. Machines tool beds. Tailstock and

assemble drawing of machine tools like lathe machine components. Power drives. Jigs &

fixture. Power presses etc. using proI.

Experiment No. 5 & 6

Use of various types of surface in 3 D modeling animation features and other editing

entities in machine tool assemblies in proE.

Experimental No. 7 & 8

Kinematics and dynamic simulation of various mechanisms in machines. Process

simulation like pro-cast, pro-Mould and other machining features

Experimental No. 9 & 10

Tool path generation, part programming G and M codes development for machining

operation using Pro E, Physical interpretation to machining features and tool

geometrics.

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613 A : Welding Lab

List of Experiments in Welding

1.

To study Heat Flow in welding

(Equipment for useGas Welding Equipment)

2. To study Bead Geometry, Hardness of Bead. Microstructure of welding Bead on

case of :

(a)MIG Welding

(b)

SAW Welding(c)FCAW Welding

(By changing electrode diameter & carriage speed)

3. To conduct under water welding (to study bead shape & microstructure

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M 615 A : Mechatronics Lab

List of Experiments

1. To verify truth table of various gates such as AND. OR. NOR. NOT. etc.

2. To realize a logic equation Y = AB + CD.

3. Selection of sensor for a particular application from catalogue / internet.

4. Design a mechatronics product/system and incorporate application of

mechatronics for enhancing product values.

5. To study the hard wares and soft ware of mechatronics kit.

6. To move a table in X-direction within the range of proximity sensors using

control X- Software.

7.

To rotate a table using DAC system.

8. To move a table in Y-direction within the range of proximity sensors using

control X software.

9. To run a motor with PLC.

10.To run a conveyor with computer.

11.To study the movement of actuating cylinders and sensors

12.To study mechatronics and their interfacing in a CNC machine.

13.Life prediction from computer programme based on mathematical model.

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M 602 A: Metal Cutting Technology

Tool geometry, Tool & work piece material: Common work and tool material.

Nomenclature system, cutting friction, controlled contact machining.

Physical principle in metal cutting: Chip formation and types of chips, work done in

cutting. BUE on metal cutting. Curling & contraction of chip, work hardening, quality of

machines surface. Effect of cutting fluid on cutting process, vibration in metal cutting.

Machining economics, cutting power, tool wear, lubrication and surface finish, cutting

fluids.

Turning, boring, and threading tools: Operation, Signature of single point tools. Design of

single point turning tool. ISO tool shaper. Design of flat and circular form tools. Boring

tools. Threading tools chip breaking methods.

Milling, Broaching, Gear cutting tools: Milling cutter design. Design of broach. Design

of Gear hobs

Tool for holes: holes starters, Remaining. Design of drills Reamer.

Grinding: Feature of grinding process. Characteristics. Shapes. Mounting. Wear. Turning,

Dress of Abrasive tools. Centre type cylindrical grinding. Centerless grinding. Interning,

grinding. Surface grinding. Grinding fluid.

Modern Machining Processes: USM, Abrasive jet machining, Water jet machining

Electro-chemical machining, Grinding, Deburring, Honing, EDM. Plasma are machining

Laser beam machining, Effect beam machining process details metal cutting mechanics

application

Reference books:

1. Metal cutting theory and cutting tool design:- v Arshinov, Mir Publishers,

Moscow Allekseev Mir Publisher, Moscow.

2. Cutting tools:- P.H. Joshi, Wheeler Publishing.

3. Theory of metal cutting:- E.M. Trent

4.

Tool design:- Donaldson

5. Production Technology:- HMT, Tata Mcgraw Hills, New Delhi

6. Modern Machining Processes:- P.C. Pandey, H.S. Shah. Tata Mcgraw Hill. New

Delhi.

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M 604 A: Automation in Manufacturing

1. Introduction: Automation in production system principles and strategies ofautomation, basic Elements of a automated system. Advanced Automation functions.

Levels of Automations, introduction to automation productivity.

2. Material Handling System: Over view of Handling system-Rotary feeders,oscillating force feeder, vibratory feeder, elevator type and Transport system storage

system.

3. Automated Manufacturing Systems: Components. Classification and overview ofmanufacturing system manufacturing cells, GT and cellular Manufacturing FMS.

FMS and its planning and implementation, Flow lines & transfer mechanism.

Fundamentals and analysis of transfer lines product design for automatic assembly.

4. Control Technologies in Automation:Industrial control system. Process industry vs

Discrete manufacturing industries. Continuous vs discrete control. Continious process

and its forms, Sensors and Actuators. Other control system components.

5. Evaluation of Automatic Production: Product manufacturability. Orientationdevices-active and passive devices, Parts orientation and Recapement.

6. Pneumatic and Hydraulic Components and Circuits: Pneumatic sensors andamplifiers. Jet destruction devices, Logic devices, Schmit triggering devices,

Developing pneumatic circuits for automatic die casting machine.

7. Modeling and Simulation for Manufacturing Plant Automation: Introduction.Need for system modeling. Building mathematical model of a manufacturing plant.

Modern tools ANN in manufacturing automation, At in manufacturing, Fuzzy

decision and control, Robots and Application of Robots for Automation.

Reference Books:

1. Handbook of Design, Manufacturing and Automation: R.C dorf, John Wiley & Sons.

2. Automation, Production system and Computer Integrated manufacturing M.P

Groover, pearson Educaiton

3. Industrial AutomationW.P. David. John Wiley and Sons

4. Computer based industrial controlKrishna Kant, EEE PHI

5.

An Introduction to Automated Process Planning Systems Tiess Chiu Chang &

Richard A Wysk.

6. Manufacturing Assembly HandbookBrunLotter

7. Anatomy of AutomationAmber, G.H and P.S. Amber, Prentice Hall

8. Performance modeling of Automated Manufacturing SystemVishwanatham. PHI.

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M 606 A: CAD/CAM

Transformation and Manipulation of Objects:Introduction. Transformation matrix 2D

transformation. Arbitrary rotation about the origin, Rotation by efferent angles.

Concatenation 2D transformation. Projection on a 2D plane. Overall scalling, rotation

about an arbitraru point. 2D reflection. 3D Transformation. 3D scalling. 3D rotation of

object, 3D rotation about an arbitrary axis. 3D visualization reconstruction of 3D image.

Description of Curves and Surface:Line fitting. Non-linear curve fitting with a power

function, Curve fitting with a high order polynomials. Chebyshev polynomial fit. Fourier

series of discrete system, Cubic splines, Parabolic cubic splines. Non-parametric cubic

splines, Boundary conditions, Bezier curves. Differentiation of Bezier curve equation. B-

spline curve, Non-uniform rotation B-spline, Surface creation, Coons patch. Tensor

product surface. Bezier surfaces, Relational parametric surface. Parametric spline surface,

Lofied surface, Spline blended surface tangent and twisted vectors. Application software.

Solid Modeling: Introduction, Solid models and entities, Solid representation.

Regularized Booleam operation, Half spaces, B-rep and CSG modeling teahniques.

Analytic solid modeling solid manipulations.

Data Exchange Formats: Shape based formats, Product data based formats, ISO

standard, IGES-data representation, File structures and formats, Processor, PDES data

representation, STEP, ARCHITECTURE AND IMPLEMENTATION ACIS and

DXF. Crating IGES, STEP and DXF files.

Mechanical Assembly Analysis:Assembly modeling part modeling and representation.

Hierarchical relationships, Mating conditions, Representation schemes Graph structure,

location graph, virtual link, Generation of assembly sequences: precedence diagram,

liaison sequencing analysis, precedence graph, Assembly analysis.

Hidden line and Hidden surface removal algorithms:Visibility techniquesminimax

test, containment test, surface test, edge interaction, homogeneity test sorting coherence.

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Warnock algorithms, the priority or z Buffer algorithms. Watkinson scan line

algorithms ray tracing algorithms.

Process Planning: Activities, Process plan development CAPP-Benefits of CAPP.

Architecture of CAPP, CAPP approaches. Variant CAPP. Generative CAPP. Hybrid

CAPP, CAPP system.

Part Programming: Preparing CAD data for NC Machine Tools-Motion and axis of

machine tools. Point to point and continuous path moving. NC. CNC and DXC, NC

programming mathematics of tool path. Machining forces. Cutter programming. Tool

offsets G & M codes, APT programming, Tool path generation. Tool path verification.

Advances in CAD/CAM: CIM, Architecture. Objectives. CIM Implementation

manufacturing, Reverse Engineering, Concurrent engineering rapid prototyping. Virtual

manufacturing and Prototyping and factory of the future, the enterprise and the product

modeling.

Reference Books:

1. Principles of Computer Aided Design and ManufacturingPearson Prentice Hall.

2. CAD/CAM Theory and PracticeIbrahim Zeid. Tata McGraw Hill.

3. CAD/CAM/CIMP Radha KrishnanNew age International.

4. Mathematical Elements of Computer GraphicsRogers and Adams.

5. Computer Aided Design Besant and LUI. PHI.

6. Computer control of Manufacturing systemsYoram Koram, McGraw Hill.

7. Rapid manufacturing- Phalm D.T & Dinjoy S.S. Springer Verlog, London 2001

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M 612 A : MFG/Metal Cutting Lab

List of Experiments

1. To identify various angles and parameters of various single point cutting tools.

2. To identify various angles and parameters of various multi-point cutting tools.

3. To grind various angel on a single point cutting tools.

4. To identify various chips produced to Turning of Al Mild Steel at different speeds

and feeds

5. To study relative wear of electrodes during machining on electro discharge

(EDM).

6. To study wear of cutting tool in turning.

7.

To study surface finish by varying cutting parameters on surface grinding

machine.

8. To study chips in orthogonal cutting of Lead, Aluminum by printed grid

formation method on shaper.

9. To braze carbide tip on a carbon steel stool shank.

10.To study effect of cutting fluid on machining.

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M 614 A: Automation Lab

List of Experiments

1. To study hardware of a retrofit and CNC machine tools.

2. Selection of various equipments required with a specification from Internet

Catalogue: To convert a manual machine tool system into an automatic machine

tool system.

3. To wire programmer with G code and m code for a component.

4. To simulate machining of component using PRO-E.

5. Study and application of Hydraulic software.

6. Study and application of Pneumatic software.

7.

Study and application of Robotic software.

8. Study and application of PLC software.

9. To design an automated part feeder.

10.Developing pneumatic circuits for machines and systems.

11.Development pneumatic circuits for machines and systems.

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M 616 A : CAD/CAM Lab

List of Practical:

SectionI

1. Develop a general purpose code to carry out the rotation of an object about an

axis through two point.

2. Develop a general purpose code to carry out:

Orthogonal Projection.

Diametric projection (given foreshortening factor Fz).

Isometric projection.

Perspective projection given Zn. ..

3. Develop general purpose code given two arbitrary projections and the respective

transformation matrices and the reconstructed coordinates of the vertices of the

objects.

4. Develop a general purpose code to carry out the reflection of an object about an

arbitrary plane passing through three points.

SectionII

1. Develop a general purpose code for integrated:

Cubic spline with different boundary conditions.

Bezier curve.

B-spline Its various types and best fir B-spline.

Given Coordinates of the control points, boundary condition. Order of the curve,

if required, and Match the output to projected image of any CAD/CAM package.

SectionIII

1. Develop an optimized tool path for economic machining and generated the same

in GUI (IDEA/PRO-E/CAD software) for interpretation.

2. Study of graphics formats and conversion from one format to another.

3.

Generate the meshing of the conical cylindrical surface using any simulation package.

4. Study of open GL programming for the customization of any CAD package.

5. Development of the following surface patches:

Bilinear Coons Patch.

Tensor Product Bezier surface.

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M 701 A : Computer Integrated Manufacturing

Introduction: CAD/CAM defined, Computer technology: introduction. Central

processing Unit. Types of Memory. Input/Output. Binary number system. Computer

programming languages, Automation: CIM, reasons of automation, automation strategy.

Conventional Numerical Control: Basic components of NC system. NC motion control.

Application of NC. NC controller technology. CNC. Advantage of CNC. DNC.

Components of DNC system. Function of DNC. Advantage of DNC.

NC Part Programming: Introduction. Punched tape in NC. Lape coding and Format.

NC words, Manual part programming. Computer assisted part programming. The part

programmer is job. NC part programming languages. APE language. Geometry

statements, Motion statements. Auxiliary statements.

Robotic Technology: Joints and Links Common robot configuration, Work volume.

Drive system types of robot control. Accuracy and Repeatability. End effectors. Sensors

in robotics Applications of robots.

Automated Material Handling and FMS:material handling unction. Types of material

handling equipments. Conveyor is system, types of conveyors, Automated guided vehicle

system, Application. FMC. Components of FMS. Types of system. Where to apply FMS

technology? FMS workstation, Planning the FMS.

Computer Aided Quality Control: Introduction, Terminology in quality control. The

computer in QC, Contact and non-contact Inspection methods. Optical and Non optical

methods, computer aided testing.

Computer Integrated Manufacturing System: Introduction Types of manufacturing

system, Machine Tools and related equipments, Material handling system, Computer

control system, Function of a computer in CIMS, Benefits of CIMS.

Reference Books:

1.

Automation, Production System and Computer Integrated Manufacturing

Groover M.P (PHI)

2. CAD/CAM: Zimmers and Groovers (PHI)

3. Approach to computer Integrated design and Manufacturing. Nanua Singh (John

Wiley and sons)

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M 707 A : CIM Lab

List of Experiments

1. To study general features of machining center.

2. To prepare the CNC part program for machining a prismatic component on CNC

machining centre.

3. To study the general features of a CNC training center.

4. To prepare the CNC part program for machining of a cylindrical centre.

5. Study and Application of Robotic system in automated storage and Retrieval

systems.

6.

Application and Control of robotic system in Flexible manufacturing system.

7. To study the general features of Automated Guide vehicles.

8. To study the general configuration of CMM and its application in CIM

environments.

9. Machine vision and Quality control in CIM environment.

10.Study and Applications of Conveyor System in CIM system.

11.Study and Application of CIM Software.

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M 608 A: Finite Element Methods

1. Review of basic FEM concepts

FEM Discretization and the direct stiffness method: Basic concepts of structural

modeling. Review of the stiffness method of structural analysis, modeling

stiffness, loads and displacement boundary conditions.

Formulation of Finite Elements: Mathematical interoperation of finite elements,

variational formulation development of continuum elements, shape function,

consistent loads, Isoperimetric elements for plane stress, numerical integration.

Convergence requirement.

Computer Implementation of the Finite Element methods: Pre processing model

Definition, Element level calculations. Equation assembly, Equation solver, post

processing strain and stress recovery.

2. Advance topic in linear problems; static condensation and sub-structuring patch

test and incompatible element, p-formulation.

3. Advance beam, plate and shell elements:

Timosenko Beam theory (Shear locking)

Plate and Shell theory

a. Thin plate and Mindlin plate.

b.

Mixed formulation for plate and shellc. Degenerated shell formulation

4. Dynamic analysis using FEM

a. Consistent mass and lumped mass, mass lumping technique.

b. Time integration methods: explicit, implicit, explicit implicit methods.

c. Stability, convergence and consistency.

d. Hyperbolic systems: structural dynamics and wave propagation

e. Parabolic system: Transient heat transfer.

f.

Modal solution for natural frequencies and mode shapes.

g. Model superposition method for structural dynamics

5. Non-linear analysis:

a. Non-linear solution procedure.

b. Newton-raphson and Secants methods

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c. Line search algorithms

d. Automatic time step control

6. Material non-linearity:

a. Rate independent elastoplastricity with return mapping algorithm.

b. Isotropic and kinematic hardening with Baushinger effect.

c. Consistent tangent operator.

d. Objective rate and finite rotation elastoplasticity

e. Multiplicative decomposition and finite deformation elastoplasticity

7. Geometric non-linearity

a. Generalized strain and stress.

b. Total and updated lagrangian formulation.

c.

Kirchhoff stress and Cauchy stress

8. Boundary non-linearity

a. Frictionless contact problems.

b. Penalty, Lagrange multiplier. Augmented multiplier, and perturbed

lagranges multiplier methods.

c. Frictional contact problems including frictional return mapping algorithm

d. Rigid flexible contact and flexibleflexible contact.

e. Multiplicative decomposition and finite deformation elastoplasticity.

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M 608 A: Robotic Engineering

1. Introduction: Automation and Robotics, Historical Development. Definitions.

Basic structure of Robots. Robot Anatomy. Complete classification of Robots.

Fundamentals about Robot technology. Factors related to use robot performance.

Basic Robot configuration and their relative merits and demerits types of drive

system and their relative merits. The wrist & gripper subassemblies. Concepts and

Model about basic control system. Transformation and block diagram of spring

mass system control loops of robotic system, PTP and CP trajectory planning.

Different types of controllers control approaches of Robots.

2. Kinematics of Robot Manipulator: Introduction General description of Robot

manipulator, Mathematical preliminaries on vectors & matrices homogeneous

representation of objects robotic manipulator joint co-ordinate system. Fuler

Angle & Displacement matrics for standard configurations, geometrical approach

to inverse Kinetics. Homogeneous robotic Differential transformation

introduction. Jacobian transformation in Robotic Manipulation.

3. Robotic Workspace & Motion Trajectory: Introduction General Structures of

Robotic Workspaces. Manipulations with n revolute joints. Robotic Workspace

performance index. Extreme Reaches of robotic Hands. Robotic task Description.

Robotic Motion trajectory design:- Introduction trajectory interpolators. Basic

structure of Trajectory interpolators, cubic trajectories, general design

consideration on Trajectories: 4-3-4 & 3-5-3 trajectories. Admissible motion

trajectories.

4. Dynamics of Robotic Manipulators:- Introduction, Bond Graphs modeling of

Robotic manipulators, Example of bond Graph Dynamic Modeling of Robotic

Manipulator. Brief discussion on Lagrange-Euler (LE) Dynamic modeling of

Robotic Manipulators:- Preliminary Definitions, Generalized Robotic coordinates,

dynamic constraints velocity & acceleration of moving Frames. Robotic mass

Distribution & Inertia tensors. Newtons Equations, The lagrange & Equations

Application of lagrange-Euler (LE) dynamic modeling of robotic manipulators:-

velocity of joints kinetic Energy of Arm. Potential Energy V of Robotic Arm the

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Lagrange L. two Robotic Dynamics with distributed Mass. Dynamic Equation of

Motion for a general Six Axis Manipulator.

5. Robot Teaching: Introduction, various Teaching Methods task programming

survey of Robot level programming Languages. A robot program As a path in

Space. Motion Interpolation. WAIT. SIGNAL & DELAY commands. Branching

Robot Lagrange structure, various textual Robot Lagranges such as VAL II. RaII.

AML., an their Futures, typical programming examples such as Pelletizing.

Loading a machine Etc.

6. Robot Sensing & Vision: Various sensor and their classification use of sensor

and sensor based system in Robotics. Machine vision system Description Sensing.

Digitizing, Image Processing and analysis and Application of machine vision

system Robotic Assembly sensors and Intelligent sensors.

7. Industrial Application: Objectives Automation in Manufacturing Robot

Application in Industry, Task Programming. Goals of Al research, Al Techniques

Robot Intelligence and Task Planning. Modern Robots Features Application and

Challenges and Case studies.

8. Languages Such as VAI II, RAIL, AML and their Features, Typical

Programming Examples such as palletizing, loading a Machine ETC.

Reference books1. A Robot Engineering Textbook-Mohsen Shahinpoor Harper & Row

Publishers, New York.

2. Robotics, Control vision and intelligence. Fu. Lee and Gonzalez McGraw.

3. Introduction to Robotics. John J. Craig, Addison Wesley Publishing.

4. Robotics for Engineers, Yoram Koren, McGraw Hill International.

5. Robot Technology Fundaments, Keramas. Thomson Vikas Publication.

6. Industrial Robotics, Groover, Weiss, Nagel, McGraw Hill international.

7.

Company Fundamental of Robotics Analysis and control, Schilling, PHI.

8. Introduction of Robotics, Niku, Pearson Education, Asia.

9. Foundation of Robotics yoshikawa. PHI (EEE)

10.Robotic EngineeringAn Integrated approach, Klafter, Chmielewski and Negin, PHI.

11.Robot vision and sensor controls, Books B. Vol-3 North Hoiland.

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M 608 A: Industrial Inspections

Design Consideration for Gauges and measuring instruments material selection for

gauges. Hardness and surface finish, tolerance for linear and dimensional chains limits.

Fit and tolerance as per India and International standards. Design of plug gauge. Snap

gauge, Center Distance gauges.

Inspection on threads an gears: thread gauge design thread size measurement by two wire

and three wire methods, venire gear and tooth gauge design.

Surface textures: Components of machined surface texture. Specification of surface

texture. Surface roughness measuring device and techniques design of pneumatic gauge

in process gauging methods.

Geometrical and Positional tolerances

Geometrical and Physical Limitations of measuring devices.

Reference books:

1. Metrology:- l.C. Gupta (Dhanpat Rai Publication)

2. Engg. Methology:- R.K. Rajput (S.K. Kataria and sons)

3. Metrology:- R.K. Jain

4. PSG design data book for gauge design .

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M 608 A: Quality Control Techniques

Statistical concept in quality control graphical representation of Grouped data.

Continuous and Discrete probability distributions control limit theorem.

Introduction to QC. Process control and product control. Chance and Assignable causes

of quality variation. Advantage of shewhart control charts. Process control charts for

variables. X R and charts, Fixation of control limits. Type I and Type II Errors. Theory

of runs. Interpretation of out of control points. Probability limits. Initiation of control

charts, trial control limits Determination of aimed at value of process setting. Rational

method of sub grouping control charts parameters, control limit and specification limits.

Natural tolerance limits. Relationship of a process in control to upper and lower

specification limits, process capability studies.

Special control charts for variables, Group control chart arithmetic moving X and R

charts. Geometric moving chart. Control chart with reject limits steady trend in process

average with constant dispersion. Trend chart with sloping limits. Variable subgroup size.

Variable inspection and attributes inspection. Relative merits and demerits. Control charts

for attributes. P charts, varying control limits, high defectives and low defectives special

server test limits. C chart, U chart, Dodge demerit chart, Quality rating, CUSUM or

cumulative sum control chart, Average run length (ARL) relative efficiency or sensitivity

of control chart.

Probability theory binomial and Poisson distribution. Acceptance Inspection. 100%

Inspection. No inspection and sampling Inspection. Operating characteristic curve (O.C.

Curve). Effect of sample size and acceptance number type A and type B O.C. Curves,

single, Double and Multiple sampling plans, SS Plan. Acceptance rejection and

Acceptance Rectification Plans, Producers Risk and consumers risk. Indifference

Quality level, Average outgoing Quality (AOQ) curve, AOQL. Quality protection offered

by a sampling plan, Average sample number (ASN) curve, Average total Inspection.

Reference Book:

1. Statistical Quality control by E.L Grant.

2. Quality control and Industrial Statistical by A.J. Duncan.

3. Quality control by Dale H. Best field.

4. Total Quality control by A.Y. Feigenboum.

5. Elementary S.O.L. by I.W. Burr. M. Dekkar.

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M 608 A : Design and Metallurgy of Welded Joints

Weld defects:Common weld defects like weld cracks. LOP. LOF. Propensity blow holes

etc. remedies and control, welding symbols.

Cost analysis of Welded Joints:Costing factors o welding jobs-fabrication cast material

cost, preparation cost, finishing cost, over head cost etc., economy in preparation and

welding a job. Labor accomplishment factor, cost calculation of welded jobs.

Prediction and Control of Distortion: Calculation of longitudinal contraction,

transverse contraction, angular contraction due to single weld pass. Control of welded

distortion, and calculation of shrinkage.

Residual stresses: Introduction, types, effect of thermal stresses control of residual

welding stresses.

Destructive and Non Destructive Testing of Welds: Destructive tests, equipment

required and test piece geometry for tensile test, bent test, impact test hardness test, brittle

and fatigue failure tests, non destructive tests for welds dye penetrate inspection magnetic

particle inspection etc.

Weld Ability Tests:Definition and concept of weld ability purpose and types of weld

ability tests such as hot cracking test, root cracking tests, hydrogen induced cracking test

cruciform test.

Weld Ability of Metals:Welding techniques, preparation of joints an electrode types for

gray cast iron welding aluminum welding austenitic steels, titanium and its alloys.

Welding Metallurgy: Thermal effect of welding on parent metal, structure of fusion

welds, effect of cooling rate, weld metal solidification and heat affected zone.

Automation in Welding:Introduction and concept, classification of welding automation

economics of welding automation.

Reference Books:

1. Modern welding technology :- carry H.B. (PH)

2.

Welding technology:- A.C. Devis

3. Welding and welding technology:- Little (TMH)

4. Welding technology:- R.S. Parmar

5. AWS-welding Handbook (IV-VI) Edition

6. Element of machine design:- Pandya an shah

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M 608 A : Machine Tool Dynamics

Chatter in Machine Tools: Source of chatter primary chatter regenerative chatter,

chatter frequency, force vibration for machine tools, forced vibration due to perturbance

of the cutting process, forced vibration due to perturbance of equivalent elastic system

theories of machine tool chatter: Tlustys Kundinoys, toblas theories.

Machine Tool Stability: Dynamic characteristic of the cutting process, general

procedure for assessing the dynamic characteristic of machine tool in single degree an

many degree of freedom system, methods of reducing the instability in machine tool

dynamic acceptance tests.

Damping in Machine Tools:Requirement of damping system. Viscous dampers active

dampers.

Static and Dynamic Analysis of Machine Tools: Lumped parameter method finite

element method.

Chatter in grinding machine

Reference Books:

1. Principles of Machine Tools:- G.C. Sen and Amithab Bhattacharya (New Central

book agency Calcutta).

2. Machining Tool Design:- S.K. Mehta (TMH)

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M 705 A : Artificial Intelligence in Manufacturing

Definition, Basic concept of artificial intelligence. Scope role an potential of artificial

intelligence in manufacturing. Expert system, Popular Al application.

Overview of expert system, Architecture. Comparison with procedural programming.

Developing Expert system for typical manufacturing domains. Implementation and

maintenance. State of art expert system application., Case study

Al theory problems, Problem space and search, Heuristic search technique, Knowledge

acquisition and knowledge representation, Predicate logic. Procedurals declarative

knowledge, Forward V/s backward reasoning Al architecture, Overview of advanced

features, Planning, Learning, Natural language processing, Neural nets. Fuzzy logic.

Object oriented programs

Case studies, Example of Al, Theoretical concept to manufacturing problem, CAD,

CAPP, scheduling GT. CIM system.

Domains: Welding, Casting, Forming, Metal cutting, Maintenance.

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M 705 A: Advance Theory of vibration

Single degree of freedom systems. Two degree of freedom system: Spring coupled, Mass

coupled. Vibration absorbers and Vibration isolation.

Multi Degree of Freedom System:Lagranges equation close couples and far coupled

systems. Dunkerleys approximation method, Rayleigh method. Matrix method. Matrix

iteration. Orthogonality principle. Orthogonality expansion theorem and modal analysis.

Stodola method., Holzer method. Galerkin method. Rayleigh-ritz method.

Myklestedprohl method for far coupled system. Transfer matrix method.

Experimental Method in Vibration Analysis: Vibration instruments. Vibration

exciters, transducers and measurement devices. Analyzers. Vibration tests: Free and

forced vibration tests.

Vibration of Continuous System: Transverse Flexural. Torsional vibration of beams,

Timosenko beam, Hamilton principle, Vibration of plates, Collection method, Myklested-

prohl method.

Transient Vibration: Duhamels integral, method of step input. Phase plane method.

Method of Laplace transformation drop test spectra by laplace transformations.

Non-Linear Vibrations:Non-linear vibration and superposition principle. Examples of

non-linear vibrations. Method of dealing with non-linear vibration, Phase plane

trajectories, Method of direct integration. Perturbation method iteration method. Fourier

series.

Reference Book:

1. Theory of vibration with application W.T. Thomson (PHI)

2. Theory and Practice of mechanical vibrations J.S. Rao & K. Gupta (Wiley

eastern)

3. Mechanical vibrationS. S. Rao (Addison Wesley)

4. Vibration and noise for engineersKewal Pujara (Dhanpat rai and Co)

5.

Mechanical vibrationG. K grover and Nigam (Nemchand and sons)

6. An introduction to mechanical vibrationSteidal (John Wiley)

7. Elements of vibration analysisMeirovitch (THM)

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M 705 A: Energy, Ecology and Environment

Origin of the earth, Earth its Temperature and Atmosphere. Sun as a source of energy.

Nature and its radiation, Biological processes, Photo synthesis, Food Chains marine

ecosystem, Ecosystem theories Autecologys. Sources of energy, Classification of energy

sources, Quality and concentration of an energy source. Characteristics temperature,

Fossil fuel: coal, oil gas geothermal, tidal and nuclear energy. Solar, Wind. Hydropower,

biomass, resources of energy and energy use pattern in different regions of the world

environmental degradation primary and Secondary pollutants. Thermal and radioactive

pollution. Air and water pollution. Micro climatic effects of pollution. Pollution from

stationary and mobile sources, Biological effects of radiation, heat and radioactivity

disposal, Pollution abatement methods.

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M 705 A: Total Quality Management

Introduction QualityBasic concepts. Dimensions. Economics of quality. Quality TQM:

Definition. Evolution Journey from inspection to TQ. Comparison at different stages.

Dimensions of TQM. TQM view points, Reason for adopting TQM.

Introspection to TQM environment Sphere of TQM. Components of TQM. TQM

managing total quality factors affecting TQM environment. Classification and interaction

among factors. Researchers viewpoint. TQM as a system. Steps in TQM implementation.

Reasons for TQM failure.

Role of soft options in TQM:Hard vs. Soft factors, Role and expectation of employer,

Employee. Customer and Supplier from organization an vice verse, Human factor in

TQM. Role of top management commitment. Work culture, motivation. Coordination.

Attitude, Innovation.

Qualitative Initiatives in Organization: Role of tools and techniques in TQM.

Classification of tools and techniques Problem identification. Data analysis. Graphical

Creativity, Company wide.

Brief description of Quality awardsMBNQA. Deming award European quality award.

Australian quality award.

TQM Effectiveness: Impact of TQM, Need and difficulty in measuring TQM.

Parameters governing effect of TQM and the attributes thereof.

Reference Books:

1. Total Quality ManagementOakland (Butterworth-Heinemann Ltd).

2. Managing for Total quality from Deming to Taguchi and SPC-Logothesis N

(PHI).

3. Total Quality ControlFeigenbaum A.V. (MGH)

4. Total Quality ManagementBester field Data H (Pearson education)

5. A slice by slice guide of TQMJohn gilbert (East West Press).

6.

The TQM Toolkit a guide to practical techniques for TQM Waller Jenny,

Allen Derek and Andrew (Kogan page).

Note:

Each student will review a research paper on TQM as a part of assignment which will

carry due weight age.