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Semester 1 08O101 calculus and its applications 3 2 0 4 basic concepts


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FREE VIBRATION: Basic features of vibratory systems-elements, degrees of freedom, single degree of freedom system. Undamped free vibration-equation of motion, natural frequency. Damped free vibration, equation of motion, logarithmic decrement. Critical speed of shaft. (5)

FORCED VIBRATION: Response to periodic forcing-forcing by unbalance, support motion, force and amplitude transmissibility, force transmissibility, vibration isolation. (4)


TORSIONAL VIBRATION: Torsional vibration of two and three rotor systems, geared systems, critical speed, signature analysis, two degrees of freedom system. (6)

Total 42

TEXT BOOKS:


  1. Rattan S S, “Theory of Machines”, Tata McGraw Hill, 2005.

  2. John N Uicker, Gordon R Pennock and Joseph E Shigley, “Theory of Machines and Mechanisms”, Oxford and IBH Publishing Co. Pvt. Ltd., 2003.


REFERENCES:


  1. Thomas Bevan, “Theory of Machines”, CBS Publishers & Distributors, 2005.

  2. Sadhu Singh, “Theory of Machines”, Pearson Education, 2002.

  3. John Hannah and Stephen R C, “Mechanics of Machines”, Viva Low Priced Student Edition, New Delhi, 1999.

  4. Rao J S and Dutkipatti R V, “Mechanism and Machine Theory”, Wiley Eastern Limited, New Delhi, 1992.

  5. Ghosh and Mallick A K, “Theory of Machines and Mechanisms”, Affiliated East West Private Limited, New Delhi, 1988.



08P403 THERMAL SYSTEMS AND HEAT TRANSFER

3 1 0 3.5

thermodynamics: Zeroth law, first and second laws of thermodynamics, applications, steady flow energy equation, ideal gas processes - calculation for work done, heat transfer and entropy changes, carnot cycle. (6)
POWER PLANTS: Diesel power plant, Brayton cycle, gas turbine power plant, Rankine cycle, steam power plant – energy conservation and energy audit. (6)

IC ENGINES: Otto, diesel cycles - principles of operation, valve and port timing diagrams, indicator diagrams, carburetors, diesel fuel pump and injector, need for cooling and lubrication of IC engines, conventional and electronic ignition systems, calculation of fuel consumption, mechanical, brake, thermal and indicated thermal efficiencies, heat balance performances characteristics. (9)
REFRIGERATION AND AIR CONDITIONING: Refrigerant - types - properties, vapor compression and absorption refrigeration, COP and capacity. Psychrometry - requirements for comfort and industrial air-conditioning, air washer, summer and winter air conditioning systems. (8)
HEAT TRANSFER: Heat conduction through planes, cylinder and spherical geometry, transient conduction, critical thickness of insulation, non-uniform conductivity, natural and forced convection, empirical relations for heat transfer coefficients - estimation of heat transfer. (13)
Total 42

TEXT BOOKS:

  1. Rudramoorthy R, “Thermal Engineering”, Tata McGraw Hill Publishing Company, New Delhi, 2003.

  2. Kothandaraman C P and Domkundwar S, "Thermal Engineering", Dhanpat Rai & Sons, New Delhi, 2002.


REFERENCES:

  1. Nag P K, "Engineering Thermodynamics", Tata McGraw Hill Publishing Company, New Delhi, 2004.

  2. Ganesan V, "Internal Combustion Engines", Tata McGraw Hill Publishing Company, New Delhi, 2004.

  3. Holman J P, “Heat Transfer”, Tata McGraw Hill Publishing Company, New Delhi, 2000.

08P404 WELDING TECHNOLOGY

3 0 0 3



INTRODUCTION: Comparison between casting and welding processes, definition of welding as per AWS, advantages and disadvantages of welding. Basic welding positions and joint types. (4)
GAS AND ARC WELDING: Gas welding, principle and equipment, applications and selection, arc welding, principle, electrodes, energy source characteristics. (6)
SPECIAL WELDING PROCESSES (FUSION): TIG and MIG welding processes, ESW, discussion on LBW, EBW, PAW, Carbon arc welding and Atomic Hydrogen welding, applications and selection. (6)
SPECIAL WELDING PROCESSES (NON-FUSION): Resistance welding, friction and ultrasonic welding, diffusion welding, explosion welding – applications and selection. (6)
WELDING METALLURGY: Definition, heat affected zone (HAZ), temperature distribution in welding, pre and post heat treatment, weld decay, weldability of steel, CI, Aluminium. (3)
INSPECTION AND TESTING OF WELDMENTS: Welding defects, remedies, destructive test methods, NDT of weldments. (5)
Design of Welded Joints: Basic principles, weld symbols, residual stresses and distortion, design of weldments. (4)
AUTOMATION & CAE in WELDING: Automation in welding – seem tracking and arc sensing – welding robots. Applications of CAE in modeling welding and temperature distributions. (8)
Total 42

TEXT BOOKS:

  1. Little R L, "Welding and Welding Technology", Tata McGraw Hill, New Delhi, 2004.

  2. Parmer R S, “Welding Process and Technology”, Khanna Publishers, 1994.


References:

  1. Jeffus and Larry, "Welding Principles and Applications", Delmar Publishers, New York, 1999.

  2. Howard B Cary, “Modern Welding Technology”, Prentice Hall, New Jersey, USA, 1998.

  3. Davies A C, “Welding”, Cambridge University Press, 1996.

  4. AWS Welding Handbooks, AWS New York, 1995.



08P410 MACHINE DRAWING

2 0 4 4
INTRODUCTION: Introduction to machine drawing. Importance of sectional views. (2)

Conventions: Code of practice for engineering drawing, conventional representation of details - drilled and tapped holes, countersunk and counter bored holes, internal and external threads, undercuts, grooves, chamfers, fillet radii and keyways. Conventions to represent standard components-bolts, nuts, washers, screws, cotters, pins, circlips, bearings, gears, springs and flanges. (6)
ASSEMBLY CONCEPTS: Methods and concepts of assemblies-assembly requirements, Bill of materials. Methods of assembly-bolts, nuts, studs, screws and pins. Methods of arresting motion of a member in an assembly, making free hand sketches of typical subassemblies. (8)
FITS AND TOLERANCES: Limits, fits and tolerances-need, types, representation of tolerances on drawing, calculation of minimum and maximum clearances and allowances. Geometric tolerance-uses, types of form and position tolerances, symbols, method of indicating geometric tolerances on part drawings. Surface finish symbols - methods of indicating the surface roughness. (8)

ASSEMBLY USING SOLID MODELING: Modeling and assembly using software-extracting views and sections. Modeling of components and assemblies, screw jack, universal coupling, stuffing box, tail stock assembly and gear box assembly. (4)

Total 28

TEXT BOOKS:

1. Gopalakrishna K R, "Machine Drawing", Subhas Stores, Bangalore, 1996.

2. Hart K R, “Engineering Drawing with Problems and Solutions”, ELBS Publishers, 1973.
REFERENCES:

1. “Practice of Machine Drawing using Pro/Engineer”, Prepared by CAD/CAM Centre, PSG College of Technology, 2007.

2. Varghese P I and John K C, "Machine Drawing", Jovast Publishers, Thrissur, 1993.

3. Faculty of Mechanical Engineering, PSG College of Technology," Design Data Book", M/s. DPV Printers, Coimbatore, 1993.



08P411 THERMAL ENGINEERING AND FLUID MACHINERY LABORATORY

0 0 3 1.5

1. Experimental study on valve timing diagram in 4-stroke engine cut model and experimental study on port timing diagram in 2-stroke engine cut model

2. Heat balance test on 4-stroke diesel engine

3. Performance test and determination of air fuel mixture on a variable speed diesel engine

4. Determination of drag and lift co-efficient using wind tunnel

5. Performance test on reciprocating compressor

6. Performance study on axial flow fan

7. Calibration of flow meters – venturimeter – orifice meter

8. Performance test on Pelton and Francis turbines

9. Performance test on Refrigeration tutor

10. Performance test on centrifugal pump

REFERENCE:

1. Laboratory manual prepared by Department of Mechanical Engineering



08P420 INDUSTRY VISIT

0 0 3 1.5

1. Study of pump components – observation of machine tools and processes applicable to manufacture the components.

2. Study of process parameters of a component (job order based) and preparation of process planning chart.

3. Study of vertical turning lathe (VTL) and HMT mini chucking lathe, hydraulic system, circuit diagram

4. Study of broaching machine – construction, mechanism of work

5. Study of Pressure die casting machine – construction, mechanism of work

6. Study of Arc welding, TIG welding, Gas welding, Ultrasonic welding

7. Study of jigs and fixtures – locating system clamping systems and bushes

8. Study of CNC lathe – construction, features, controls and programming

9. Study of CNC machining centre – construction, features, controls and programming

10. Study of casting process

a) Pattern and core making

b) Mould making

c) Casting process

d) Inspection techniques

SEMESTER 5

08P501 METAL FORMING PROCESSES

3 0 0 3

MECHANICS OF METAL FORMING: State of stress, components of stress, tension and compression in metal working, true stress and true strain, flow stress, effects of strain rate, temperature on metal working, Tresca yield criteria, comparison of yield criteria, Octahedral shear stress and shear strain, hot, cold and warm working, hydrostatic pressure, residual stresses, Bauschinger effect. (6)
FORGING: Forging – types of presses and hammers, classification, open die forging, closed die forging, die design, calculation of forging loads, forging, defects, causes and remedies. (7)
ROLLING: Rolling of blooms, billets, slabs and sheet, types of rolling mills, forces and geometrical relationship in rolling, analysis of rolling load, torque and power, forward slip and position of neutral point, maximum possible reduction, gauge control, factors which determine rolling load, minimum thickness and spread, rolling defects, causes and remedies. (7)
EXTRUSION: Types of extrusion process, Direct, Indirect extrusion, equipments, hydrostatic extrusion. Analysis of extrusion load, tube extrusion and production of seamless pipe and tube, extrusion defects causes and remedies. (5)
DRAWING OF RODS, WIRES AND TUBES: Simple analysis of wire and tube drawing, residual stress in rod, wire and tubes.

(3)


BENDING: Theory of bending, types of bending operation, bending load calculations, bending defects and remedies. (5)
SPECIAL FORMING METHODS: Explosive forming, electro magnetic forming, electro hydraulic forming, peen forming, high velocity forming, super plastic forming. (4)
POWDER METALLURGY: Process fundamentals, production of metal powders, characteristics, power blending, compacting, P/M product design, sintering, secondary operations, special P/M processes. (5)
Total 42

TEXT BOOKS:

  1. Taylan Altan, “Cold and Hot Forging, Fundamentals and Applications”, ASM International Materials Park Ohio, 2005.

  2. Dieter G E, “Mechanical Metallurgy”, McGraw Hill Co., New York, 2001.


REFERENCES:

  1. Sharma P C, “A Text Book of Production Engineering”, S. Chand & Co. Ltd., 2005.

  2. Serope Kalpakjian and Steven R Schmid, “Manufacturing Process for Engineering Materials”, Pearson Education Pvt. Ltd., 2003.

  3. Mikell P Groover, “Fundamentals of Modern Manufacturing”, John Wiley & Sons, 2002.



  1. Serope Kalpakjian, "Manufacturing Engineering and Technology”, Addison Wesley Publication Co., England, 1995.

  2. Taylan Altan, Soo IK Oh and Harold L Gegei, “Metal Forming Fundamentals and Applications”, ASM Metals Park, USA, 1983.

08P502 INDUSTRIAL HYDRAULICS AND PNEUMATICS

3 0 0 3

INTRODUCTION: Introduction to fluid power, properties - hydraulic fluids, air. Selection of hydraulic fluids, comparison between hydraulics and pneumatics. (5)

ELEMENTS OF HYDRAULIC SYSTEMS: Pumps and motors- types, characteristics. Cylinders, types, typical construction details. Valves for control of direction, flow and pressure, types, typical construction details. (5)

HYDRAULIC SYSTEM DESIGN: Power pack–elements, design. Pipes- material, pipe fittings. seals and packing. maintenance of hydraulic systems. Selection criteria for cylinders, valves, pipes. Heat generation in hydraulic system (5)

TYPICAL INDUSTRIAL APPLICATION OF HYDRAULIC SYSTEMS: Circuits for deceleration, regenerative circuits, differential circuits, feed circuits, sequencing circuits, synchronizing circuits, fail-safe circuits. (5)

ELEMENTS OF PNEUMATIC SYSTEMS: Compressors - types, selection. Symbols of pneumatic elements. Cylinders - types, typical construction details. Valves – direction control, flow, pressure, types, typical construction details. (5)

PNEUMATIC SYSTEMS DESIGN: General approach, travel step diagram. Types - sequence control, cascade, step counter method. K.V.Mapping for minimization of logic equation. (6)

TYPICAL INDUSTRIAL APPLICATIONS OF PNEUMATIC SYSTEMS: Metal working, handling, clamping, application with counters. (6)

ADVANCED TOPICS IN HYDRAULICS AND PNEUMATICS: Electro-pneumatics, ladder diagram. Servo and Proportional valves - types, operation, application. Hydro-Mechanical servo systems. PLC-construction, types, operation, programming (5)

Total 42

TEXT BOOKS:

1. Anthony Esposito, “Fluid Power with Application”, Prentice Hall, New Jersey, 2003.

2. Werner Deppert and Kurt Stoll, “Pneumatic Controls : An Introduction to Principles“, Vogel-Druck Wurzburg, Germany, 1975.

REFERENCES:

1. Majumdar S R, “Pneumatic Systems: Principles and Maintenance”, Tata McGraw Hill, 2007.

2. Majumdar S R, “Oil Hydraulic Systems: Principles and Maintenance”, Tata McGraw Hill, 2006.

3. Srinivasan R, “Hydraulic and Pneumatic Controls”, Vijay Nicole Imprints Private Ltd., 2004.

4. Majumdar S R, “Oil Hydraulic Systems: Principles and Maintenance”, Tata McGraw Hill Publishing Company Ltd., New Delhi, Fourth Reprint, 2003.

5. Peter Rohner, “Fluid Power Logic Circuit Design – Analysis, Design Method and Worked Examples”, The Macmillan Press Ltd., UK, 1979.



08P503 PROCESS PLANNING AND COST ESTIMATION

3 0 0 3
ESTIMATION AND COSTING: Introduction – differences – qualifications of an estimator – estimation – types – preparation; different methods of costing – classification of costs – cost ladder – preparation of cost sheet – problems. (4)

LABOUR AND MATERIAL COSTS: Labour cost – direct, indirect estimation – Introduction to labour norms and time study; learning curves; incentive schemes; material cost - direct, indirect – estimation – material issue valuation; make or buy decision; cost control – labour, material variances – types - analysis. (6)

OVERHEAD COST: Elements in overhead cost – factory, administrative, sales and distribution expenses – methods of absorbing overheads – direct labour, direct material, direct labour hour, machine hour rate methods; activity based costing; accounting for capital investments - depreciation – purpose, various methods – tax implications; overhead variance analysis.(6)
PROCESS PLANNING: Production drawing – surface roughness of processes; tolerance analysis, process capability – cp, cpk; process plan – information required – procedure – process sheet – contents – selection of parameters – preparation of process sheet for standard components. (6)
GROUP TECHNOLOGY AND AUTOMATED PROCESS PLANNING: Methods of developing part families, classification and coding systems; automated process planning – variant and generative methods. (5)

COST ESTIMATION: For machined components, welded components, forged components, castings, plastic components. (6)

OPTIMUM MACHINING CONDITIONS: Taylor’s equation, deriving the equation for optimum cutting speed for minimum cost – model for maximum production condition. (3)

COST MANAGEMENT: Break even analysis – concept and different areas of applications, multi product break even; value engineering – steps – job plan, phases, function analysis system technique (FAST); cost / benefit analysis; introduction to target costing. (6)

Total 42

TEXT BOOKS:

1. Peter Scallan, “Process Planning”, Butterworth Heinemann, 2004.

2. Kannappan D, “Mechanical Estimating and Costing”, Tata McGraw Hill Publishing Co. Ltd., New Delhi, 2003.
REFERENCES:

1. Narang C B S and Kumar V, “Production and Casting”, Khanna Publishers, New Delhi, 2005.

2. Kesavon R and others, “Process Planning and Cost Estimation”, New Age International (P) Ltd., Chennai, 2005.

3. Banga T R and Sharma S C, “Mechanical Estimating and Costing”, Khanna Publishers, New Delhi, 2002.

4. Samuel Eilon, “Elements of Production Planning and Control”, MacMillan, London, 1985.

5. Haslehurst M, “Manufacturing Technology”, ELBS, 1985.

6. Chang T C and Wysk R A, “An Introduction to Automated Process Planning Systems”, Prentice Hall Inc, 1984.

7. Frederic C Jelen and James H Black, “Cost and Optimization Engineering”, McGraw Hill International Book Company, New York, 1983.



8. ASME, “Manufacturing Planning and Estimation-Hand Book”, McGraw Hill, Inc., New York, 1963.

08P504 METROLOGY AND QUALITY CONTROL

3 0 0 3

INTRODUCTION TO METROLOGY: Accuracy, precision, resolution and sensitivity of measuring instruments, classification of errors in measurements, alignment errors, evaluation and propagation of errors. (4)

ANGULAR MEASUREMENTS: Sine bar, angle gauges, autocollimator, angle dekkor, tool maker’s microscope. (4)

THREAD AND GEAR MEASUREMENT: Standard thread profiles, Measurement of major, minor and effective diameter, 3 wire method and best wire size, gear tooth profile measurement, run out and composite error measurement, gear pitch measurements. (5)

SURFACE METROLOGY: Sources of surface irregularity in manufacturing, functional significance of surfaces, elements of surface texture and surface integrity, analysis of surface traces, amplitude and spatial surface roughness parameters and their measurements, measurement of geometric forms; straightness, flatness and roundness, measurement of parallelism and perpendicularity. (8)

ADVANCES IN METROLOGY: Coordinate measuring machine (CMM), classification, construction, applications, touch trigger probe, programming; interferometry, laser interferometer, working principle, applications, alignment and errors; Machine Vision, elements of vision system, applications in manufacturing; introduction to atomic force microscopy (AFM), Scanning tunneling microscopy (STM), nanometrology. (7)

INSPECTION GAUGES AND COMPARATORS: Gauge blocks – assembling gauge block stacks, limit gauge types, Taylor’s principle of gauge design, gauge repeatability and reproducibility, height master - optical profile projector. Comparators – Mechanical, Electrical, Electronic and Pneumatic comparators, in process gauging, measurement of coating thickness. (6)

QUALITY CONTROL: Production systems and quality assurance, quality control charts for variables and attributes and their interpretation, acceptance sampling, operating characteristic (OC) curve, design of single and double sampling plans, Average out going quality limit (AOQL), approach to six sigma, ISO 9000 quality systems - concepts and practices, ISO/TS 16949. (8)

Total 42

TEXT BOOKS:

    1. Connie L Dotson, “Fundamentals of Dimensional Metrology”, Thomson Delmer Learning, 2006.

2. Stephen B Vardeman and Marcur Jobe J, “Statistical Quality Assurance Methods for Engineers”, John Wiley & Sons, 2000.

REFERENCES:

        1. Douglas Montgomery, “Introduction to Statistical Quality Control”, John Wiley and Sons, 2005.

        2. Gerald M Smith, “Statistical Process Control and Quality Improvement”, Pearson Education, 2004.

        3. Gupta I C, “Text Book of Engineering Metrology”, Dhanpat Rai Publishers, 2003.

        4. Liam Blunt and Xiang Jiang, “Advanced Techniques for Assessment of Surface Topography”, Butterworth Heinemann, 2003.

        5. Gary J Griffith, “Geometric Dimensioning and Tolerancing: Applications and Inspection”, Prentice Hall, 2002.

        6. Francis T Farago and Mark A Curtis, “Hand Book of Dimensional Measurements”, Industrial Press, 1994.

        7. J F W Gayler and C R Shotbolt, “Metrology for Engineers”, ELBS, 1988.

        8. Kennady, Hoffman and Bond, “Inspection and Gauging”, Industrial Press, 1987.


08P505 THEORY OF METAL CUTTING##

3 0 0 3
Mechanism of material removal: Importance of material removal, classification of material removal operations, plastic deformation and fracture, concept of shear plane, shear strain, chip formation, type of chips.

(4)


analysis of machining: Concept of orthogonal and oblique cutting, cutting forces, Merchant circle, relation between angles and forces - theoretical value of shear angles, temperature distribution in the machining zone, adaptation of orthogonal cutting to turning, milling and drilling, measurement of cutting forces and cutting temperature in machining. (8)
Machinability and Surface INTEGRITY: Tool wear, tool life, Taylor's equation, machinability, surface texture and the concept of surface integrity in machining, chatter in machining, cutting fluids and their applications. (5)
Cutting TOOLS: Requirements for cutting tool, different types of cutting tool materials and their capabilities, processes to develop cutting tool materials, manufacturing of inserts, edge preparation and chip breakers, PVD and CVD coating on inserts, selection of inserts and tool holders. (6)

Abrasive finishing: Analysis of the grinding process, grinding wheel wear, effect of grinding conditions on wheel behavior, selection of grinding wheels, lapping, honing, buffing and super finishing, analysis and applications. (7)
SELECTION OF CUTTING TOOLS: Design of general purpose lathe tools and boring tools, tool strength and rigidity calculations, tools for boring, nomenclature, classification and selection of twist drills, milling cutters, taps, thread chasers, reamers, broaches, gear hob and gear shaper cutters, design aspects of milling cutters, drill bit and broaches. (8)
OTHER MACHINING PROCESSES: Diamond tuning, hard turning, high speed machining, machining of ceramic, composites and aerospace materials. (4)
Total 42

TEXT BOOKS:

  1. Milton C Shaw, "Metal Cutting Principles", Oxford University Press, Indian Edition, 2005.

  2. Stephenson D A and Agapiou J S, “Metal Cutting Theory and Practice”, CRC Press, 2005.


REFERENCES:

1. Juneja B L, Shekhon G S and Nitin Seth, “Fundamentals of Metal Cutting and Machine Tools”, New Age International, 2005.

2. Erick Oberg, Franklin D Jones, “Machinery's Handbook”, Industrial Press, 2004.

3. Groover M P, “Fundamentals of Modern Manufacturing, Materials, Processing and Systems”, John Wiley, 2003.

4. HMT, “Production Technology”, Tata McGraw Hill, 2002.

5. Boothroyd G and Knight W A, “Fundamentals of Metal cutting and Machine Tools", Marcel and Dekker, 2000.

6. Edward M Trend and Paul K Wright, “Metal Cutting”, Butterworth Publications, 2000.

7. Sadasivan T A and Sarathy D, “Cutting tools for Productive Machining”, Widia India Ltd., Bangalore, 1999.

8. Ashok Kumar Mallik and Amithabha Ghosh, “Manufacturing Science”, East West Press, 1988.

9. Bhattacharya A, “Metal Cutting Theory and Practice”, New Central Book Agency Pvt. Ltd., 1984.


## - The course includes atleast one assignment with mathematical modeling and/ or simulation of a practical situation.

08P510 MANUFACTURING TECHNOLOGY LABORATORY

0 0 3 1.5


1. Spur gear shaping

2. Surface grinding

3. Plastic injection moulding

4. Grinding of single point cutters

5 Grinding of multipoint cutters

6. Subtractive Rapid Prototyping

7. Study on Robotics

8. Electro Discharge Machining

9. Electro chemical machining

10. Ultrasonic welding


REFERENCE:

1. Laboratory manual prepared by Department of Mechanical Engineering



08P511 METROLOGY AND INSTRUMENTATION LABORATORY

0 0 3 1.5


1. Angular measurement using of sine bar and bevel protractor.

2. Optical profile projector - study of profile of gear tooth, screw threads.

3. Tool maker's microscope - to study cutting tool geometry, screw threads.

4. Gear Inspection- Composite error and run out error of spur gears.

5. Thread inspection- major, minor and effective diameter using floating carriage bench micrometer

6. Tool wear and surface finish measurement.

7. Dimensional measurement of machined components using, bore gauge, air gauge and Height master

8. Vibration study of machine tools using accelerometer.

9. Measurement of cutting force and torque in drilling & turning using dynamometer.

10. Demonstration of computer vision system and virtual instrumentation system.



REFERENCE:

1. Laboratory manual prepared by Department of Production Engineering



08P520 MINI PROJECT

0 0 2 1

The mini-project involves the following:

  • Preparing a project - brief proposal including

  • Problem Identification

  • A statement of system / process specifications proposed to be developed (Block Diagram / Concept tree)

  • List of possible solutions including alternatives and constraints

  • Cost benefit analysis

  • Time Line of activities

  • A report highlighting the design finalization [based on functional requirements & standards (if any) ]



  • A presentation including the following:



  • Implementation Phase (Hardware / Software / both)

  • Testing & Validation of the developed system

  • Learning in the Project



  • Consolidated report preparation

SEMESTER 6

08P601 DESIGN OF MACHINE ELEMENTS

3 2 0 4


INTRODUCTION: Preferred numbers – basic and derived series – mechanical properties of materials – Types of stresses – stress-strain diagram in tension – static stress equation in axial, bending and torsional loading – criteria for failure – factor of safety - eccentric loading of members - combination of normal and shear stresses - principal stresses. (5)
STATIC FAILURE THEORIES: failure of ductile materials under static loading – distortion energy theory, maximum shear stress theory maximum normal stress theory; failure of brittle materials under static loading – Coulomb-Mohr theory, modified – Mohr theory; fracture mechanics theory, fracture toughness Kc. (7)
FATIGUE FAILURE THEORIES: Mechanism of fatigue failure, fatigue failure models – stress life approach, strain life approach, fatigue loads, S-N curve; theoretical estimation of fatigue strength, correction factors, Soderberg, modified Goodmann and Gerber equations – stress concentration factor, notch sensitivity factor - finite life - designing for multiaxial stresses in fatigue, cumulative damage in fatigue, Miner’s rule. (7)
DESIGN OF SHAFTS AND COUPLINGS: Forces on shafts due to gears, belts and chains, estimation of shaft size based on strength and critical speed, couplings, types and applications, rigid couplings, flexible flange couplings, selection - design of square keys, use of standards. (6)
SPRINGS: Spring configurations spring rate, spring materials, helical compression springs, end details, active coils, spring index, stresses in helical compression spring, buckling, design for static and fatigue loading helical tension spring, coil preloads, design of leaf springs. (6)
BOLTED AND WELDED JOINTS: Threaded fasteners, Thread forms stresses in threads, Preloaded fasteners in tension, joint stiffness factor, controlling preload, fasteners in shear - eccentrically loaded joints - types of welded joints, weld symbols, strength of welds, centrally loaded, unsymmetrical sections, axially loaded and eccentrically loaded joints. (6)

BEARING SELECTION: Static and dynamic load capacity, cubic mean load, variable load, probability of survival, selection of bearings - (deep groove, angular contact ball bearings and taper roller bearings). Hydrodynamic and hydrostatic bearings - (theory, applications, advantages and limitations), Sommerfield number, dimensionless parameters, optimum bearings, newer bearing materials, design of hydrodynamic bearings. (5)
Total 42

TEXT BOOKS:

  1. Robert L Norton, “Machine Design an Integrated Approach”, Pearson Education, New Delhi, 2005.

  2. Joseph E Shigley and Charles R Mischke, “Mechanical Engineering Design”, Tata McGraw Hill, New Delhi, 2004.


REFERENCES:

  1. Bhandari V B, “Design of Machine Elements”, Tata McGraw Hill, New Delhi, 2007.

  2. Bernard J Hamrock, Jacobson B O and Stern R Schmid, “Fundamentals of Machine Elements”, McGraw Hill Inc., USA, 2006.

  3. Gitin M Maitra and Prasad L V, “Handbook of Mechanical Design”, Tata McGraw Hill, New Delhi, 2006.

  4. Faculty of Mechanical Engineering, PSG College of Technology, "Design Data Book", M/s. DPV Printers, Coimbatore, 1993.

  5. Acherkhan, "Machine Tool Design", Vol. 2 & 4, MIR Publisher, Moscow, 1983.

08P602 INDUSTRIAL ENGINEERING AND OPERATIONS RESEARCH##

(Also common with 08A502)



3 0 0 3

INTRODUCTION: Evolution of industrial engineering – fields and functions; industrial productivity – types, measurement; work systems engineering - recording tools and techniques, motion study, PMTS, therbligs, work sampling, work measurement, rating systems, ergonomics. (7)

PLANT DESIGN: Plant location – decision analysis; plant layout – types, characteristics, design techniques – systematic layout planning (SLP), computerized relative allocation of facilities technique (CRAFT); material handling principles – equipments; introduction to line balancing. (6)

PRODUCTION PLANNING AND CONTROL: Functions – demand management – forecasting techniques, forecast errors – sources; scheduling – basics – single machine scheduling; flow shop scheduling; job shop scheduling, heuristic procedures; priority dispatching rules. (6)

OPERATIONS RESEARCH: Origin, scope, areas of application; mathematical modeling and solving a problem; linear programming – problem formulation, deriving the solution – graphical, simplex methods; duality theory. (6)

TRANSPORTATION MODEL: Formulation, solution – northwest corner, Vogel’s, stepping stone, MODI methods; degeneracy; Assignment models – Hungarian algorithm; Sequencing models – processing ‘n’ jobs through two machines and three machines, processing two job through ‘n’ machines. (6)

INVENTORY MODELS: Classification of fixed order quantity models, deterministic demand models - types, inventory models with probabilistic demand, price breaks, quantity discount, safety stocks, selective inventory control techniques. (6)

QUEUING MODELS: Elements, operating characteristics; single channel queuing theory – models for arrival and service times; models for multichannel queuing theory. (5)

Total 42

TEXT BOOKS:

  1. Frederick S Hillier and Gerald J Liberman, “Introduction to Operations Research”, Tata McGraw Hill Publishing Company Ltd., New Delhi, 2006.

  2. Chase R B, Jacob F R and Aquilano NJ, “Operations Management for Competitive Advantage”, Tata McGraw Hill, New Delhi, 2004.

REFERENCES:

  1. Jay Heizer and Barry Render, “Production and Operations Management”, Prentice Hall, 2008.

  2. Gupta P K and Hira D S, “Operations Research”, S. Chand & Co., New Delhi, 2008.

  3. Paneerselvam R, “Production and Operations Management”, Prentice Hall of India (P) Ltd., 2007.

  4. Hamdy A Taha, “Operations Research; an introduction”, Prentice Hall of India, 2002.

  5. Kanti Swarup et al, “Operations Research”, S. Chand & Sons, New Delhi, 2000.

  6. Dilworth B James, “Operations Management Design, Planning and Control for Manufacturing Services”, McGraw Hill Inc., 1992.

  7. Elwood S Buffa, “Modern Production / Operations Management”, Wiley Eastern, 1991.

  8. Gaither N, “Production and Operations Management”, Dryden Press, 1990.

## - The course includes atleast one assignment with mathematical modeling and/ or simulation of a practical situation.

08P603 DESIGN OF PRODUCTION TOOLING

3 0 2 4


TOOL DESIGN: Tool design objectives, tool design in manufacturing, planning the design, challenges to the tool designer, production devices - Inspection devices. (2)

PRINCIPLES OF SUPPORTING AND LOCATING ELEMENTS: Referencing, basic rules of locating, planes of movement, locating from a flat surface, locating from a internal diameter, locating from a external diameter, locating from external profile, ejectors; principles of clamping and work holding - principles of work holders, basic rules of clamping, types of clamps, chucks and vises, non mechanical clamping, clamping accessories. Materials used in Jigs and Fixtures. (4)

DESIGN OF Jigs: Drill bushes – different types of jigs-plate latch, channel, box, post, angle plate, angular post, turnover, pot jigs-Automatic drill jigs-Rack and pinion operated, air operated jigs components, design and development of jigs for given components, cost estimation. (5)

DESIGN OF Fixtures: General principles of boring, lathe, milling and broaching fixtures- Grinding fixtures, assembly, Inspection and welding fixtures- Modular fixtures. Design and development of fixtures for given component. Fixtures for CNC Machining centres; chucks for CNC lathes - power operated 3 jaw chucks, closed centre, open centre, centrifugal force compensated, indexing, diaphragm, face driving, face clamping, pull back/ ball lock. (7)
POWER PressES: Press working terminology, different types of presses, press brakes, shearing machines, CNC Turret punch and bending, press accessories, computation of capacities and tonnage requirements. (2)

DESIGN OF PROGRESSIVE AND COMPOUND DIES: Design and development of progressive and compound dies for blanking and piercing operations. Die block-die shoe. Bolster plate-punch plate-punch holder-guide pins and bushes, strippers, knockouts, stops, pilots, selection of standard die sets strip lay out-strip lay out calculations. (8)
Manufacturing of punches and Dies: CNC Wire cut, EDM. (2)

Forming Dies: Drawing die, stamping die, forging die. (2)

DESIGN OF PLASTIC INJECTION MOLDING DIES: Introduction to plastics, various plastic processing process and machines, two plate injection mold assembly design, design of gates, runners, ejectors, under cut molds, finger cam design, three plate injection mold, hot / runner less mold, mold materials, mold manufacturing, polishing. (10)
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