me (production engineering) first semester s. no. course

Approved by the Senate in its 83rd meeting held on March 3, 2014

ME (PRODUCTION ENGINEERING)

First Semester

S. No. Course No. Course Name L T P Cr

1 PCD 103 Mechatronics 3 1 0 3.5 2 PCD105 Computer Aided Manufacturing 3 0 2 4.0 3 PCD 106 Geometric Modeling and Analysis 2 0 4 4.0 4 PCD313 Machine Tool Design 3 1 0 3.5

5 PCL105 Statistical Methods and Algorithms

3 0 2 4.0

Total 14 2 8 19.0

Second Semester


1 PPI201 Advanced Manufacturing Processes

3 1 2 4.5

2 PCD325 Rapid Prototyping 3 1 0 3.5 3 PPI 204 Operations Management 3 1 0 3.5 4 PPI103 Quality Engineering 3 1 0 3.5 5 Elective-I 3 1 0 3.5 6 PPI291 Seminar 2 Total 15 5 2 20.5


Third Semester


1 PPI312 Metal Casting and Joining 3 0 2 4.0 2 Elective-II 3 1 0 3.5 3 PPI392 Minor Project 4.0 4 Dissertation starts

Total 6 1 2 11.5

Fourth Semester


1 PPI091 Dissertation 12 Total 12.0

List of Electives


1 PPI313 Metal Forming 3 1 0 3.5

2 PPI 315 Workstudy and Method Engineering

3 1 0 3.5

3 PPI323 Product Design and Development 3 1 0 3.5

4 PCD 316 Applied Optimization in Engineering Design

3 1 0 3.5

5 PCD203 Computer Integrated Manufacturing Systems

3 1 0 3.5

6 PCD204 Industrial Automation 3 1 0 3.5

Total Number of Credits: 63.0


PCD103 MECHATRONICS

L T P Cr

3 1 0 3.5

Prerequisite(s): None

Course Objectives: To impart interdisciplinary knowledge to study modern products like household

appliances, Digital Cameras, Mobiles etc. The aim of this course to make a bridge between Mechanical,

Electronics, Instrumentation, Computer and Controls field.

Introduction: Integration of Mechanical Engineering, Electronics & control engineering and

computer science, Elements of mechatronics system, Open system and closed system.

Physical and Mathematical Modeling of Dynamic Systems: Equations of motion,

Transforming physical model to mathematical model, Linearization, Frequency response,

Component interaction.

Control Systems: Laplace transformations, Block diagram reduction, Signal flow graph,

performance specifications, Transfer functions, Stability, Types of controller, Controller design

using frequency domain and Laplace domain methods, Digital control, Z-transforms, State space

control, Regulation problem, Tracking problems, Pole placement approach

Sensors: Displacement, Position and proximity sensors, Flow sensors, Pressure and force

sensors, Motion sensors, Optical, Mechanical and thermal sensors.

Actuators in mechatronics system: Electric actuators, Stepper motors, DC motors, and AC

motors, their types and control, Hydraulic actuators and pneumatic actuators, Types and control,

Piezoelectric actuators

Electronic Elements in Mechatronic System: Analog to digital and digital to analog converters,

Operational amplifiers, Microcontrollers, Microprocessors, Logic circuit devices and gates.

Course Outcomes:

The students will be able to

understand the basic elements of any Mechatronic device.

develop the mathematical model of any physical model from any engineering domain.

understand the key inputs and outputs of any physical device, different sensors and transducers to

measure the outputs, interfacing of the sensors and actuators to the computers.

study and design different controllers to obtain the desired performance from the system.

Recommended Books:

1. Bolton, W., Mechatronics, Pearson Education Asia (2004).

2. Kamm, L. J., Understanding Electro-Mechanical Engineering, An Introduction to

Mechatronics, Prantice Hall of India (2000).

3. Anslander, D. M. and Kampf, C. J., Mechatronics: Mechanical System Interfacing, Prantice

Hall (1995).

4. Alciatore, D. G. and Histand, M. B., Introduction to Mechatronics and Measurement

System, McGraw Hill (1999).

5. Doebelin, E. O., Measurement Systems, Application & Design, McGraw Hill (2004).

6. Nagrath, I. J. and Gopal, M., Control System Engineering, New Age International (2008).


PCD105 COMPUTER AIDED MANUFACTURING

L T P Cr

3 0 2 4.0


Course Objectives: To Introduce the students to the basic standard terminologies/ conventions, hardware,

applications, merits and demerits of general NC, CNC, DNC technology. To expose the students to

Automatic/ Computer Assisted NC tool path programming using professional software tools used for

complicated machining applications.

Introduction: Fundamental concepts in numerical control, Need of N.C. in machines tools, Its

advantages, Structure of NC System.

Part Programming: Block format and codes, Tool length and radius compensation, Flexible

tooling, Tool path simulation on lathe and milling, Advanced programming features, Tooling For

N. C. Machines: Tool and zero presetting, Work holding and setting up of CNC machine.

N.C. Machine Tools: Types, Definition and designation of control axes, Constructional details of

N. C. m/c tools, MCU structure and functions, Methods of improving accuracy and productivity

using NC, Problems with conventional NC.

Numerical Control of M/c Tools: NC, Functioning of NC, MCU Organization, CNC, DNC,

Adaptive control types, Uses & benefits, Advantages of CNC, DNC their structure, Combined

CNC/DNC systems.

System Devices: Drives, Feedback devices, Counting devices, DAC and ADCs, Interpolator

systems, Control loop circuit elements in PTP system, Contouring system, Incremental and

absolute systems.

Computer Assisted Part Programming: Automatic NC program generation from CAD models;

The APT language, Machining of surfaces, Mould, Casting and Die design and manufacture

using CAD/CAM software.

Laboratory Work

Exercises in manual part programming for turning and milling centers, Use of software for

simulation of turned and milled parts and simple surfaces, Automatic Cutter location data

generation from CAD Models in APT format and Post processing for machining on CNC

machines. Mould, Casting and Die design and manufacture using CAD/CAM software. Course Outcomes:

The students will be able to :

work individually and/or with an interdisciplinary team for the purpose of selection, design and use of

NC technology for manufacturing applications.

generate manual/automated part programs for a given part to be machined on NC/CNC system.

understand, create and demonstrate the technical reports for manufacturing automation as well as with

regard to NC machining.

Recommended Books

1. Koren, Y., Computer Control of Manufacturing systems, McGraw Hill (2009).

2. Kundra, T. K., Rao, P. N. and Tewari, N. K., Numerical Control and Computer Aided

Manufacture, McGraw Hill (2002).

3. Pabla, B.S. and Adithan, M., CNC Machines, New Age International (P) Ltd. (2007) 2nd

ed.

4. Koren, Y. and Benuri, J., Numerical Control of Machine Tools, Khanna Publishers (2005).


5. Groover, M. P. and Zimmers, E. W., CAD/CAM, Dorling Kingsley (1997).

6. Manuals of CAD/CAM Software Package on CAM Module and CNC Machines.


PCD106 GEOMETRIC MODELING AND ANALYSIS

L T P Cr

2 0 4 4.0


Course Objectives: Exposure to CAD tools for use in mechanical engineering design conceptualization,

geometric modelling, communication, analysis and optimization, further use in CAD, CAM, CAE related

courses and research work. Impart knowledge related to principles, methods and techniques of 3D

modelling in parametric CAD software. Undertake project works in use of CAD geometric modeling

software for design analysis, evaluation and optimization using a professional software.

CAD Overview: Introduction to use of computer in Product Life Cycle, Software for mechanical

engineering CAD/CAM/CAE.

Geometric Modeling: Parametric sketching, Constrained model dimensioning, Material addition

and removal for extruded, Revolved, Swept and blended features, References and construction

features of points, Axis, Curves, Planes, Surfaces and customized analysis features, Feature and

sequence of feature editing. Cosmetic features, Chamfers, Rounds, Standard holes, File formats

for data transfer. Feature patterns, Duplication, Grouping, Suppression, Assembly modeling,

Assembly analysis tools. Top-down vs. bottom-up design, Parametric relations and design

optimization parameters creation, Mass property analysis, Automatic production drawing creation

and detailing, Software automation and customization tools, Colors and rendering, Advanced

features for non parallel blend, Helical sweep, Swept blend, Variable section sweep, Draft, Ribs,

Sketched holes, Mechanism design and assembly, Customized design & CAD automation using

user defined features UDF.

Mechanical Design Analysis and Optimization: Design analysis for mass properties, Stress,

Thermal stress, Fatigue, Fluid flow, etc using CAD/CAE packages, Optimum design of machine

components using multivariable non linear optimization techniques using iterative CAD/CAE

software tools.

Laboratory Work:

Use of standard CAD and CAE packages for modeling of mechanical elements, Assembly and

Automated Drawing. Introduction to Surfacing, Sheet metal, Assembly analysis, Mechanism

design and motion analysis, Projects involving assembly and kinematic analysis of mechanisms,

Optimization of mechanical system design using CAD/CAE software tools, Projects on

mechanical systems design and analysis. Course Outcomes: Students will be able to

use parametric CAD software for geometric modeling of mechanical designs.

translate production drawings to 3D CAD models.

evaluate a mechanical design and optimize it using CAD, CAE software.

use 2D / 3D CAD and CAE for use in other courses and research thesis work.

Recommended Books

1. Manuals & Tutorials on CAD/CAE packages like Pro/Engineer, Pro/Mechanica, ANSYS,

etc latest available in the lab.

2. Kelly, D. S., Pro/Engineer Wildfire 3.0 Instructor, McGraw Hill (2008).

3. Tickoo, S., Wild fire for Engineers + Designers Version 3.0 Designing with Pro/Engineer,

Dream Technical Publication (2008).

4. Bhatt, N. D., Machine Drawing, Charotar Publication House (2008).

5. Dhawan, R. K., Machine Drawing, S.Chand & Company (2003).

6. Sidheswar, N., Kannaiah, P. and Sastry, V. V. S., Machine Drawing, McGraw Hill (2001).


7. Shigley, J. E., Mechanical Engg. Design, McGraw Hill (2008) 8th ed.

8. Spotts, M. F. and Shoup, T. E., Design of Machine Elements, Dolly Kindersley (2006).

9. Juvinall, R. C. and Methlek, K. M., Fundamental of Machine component Design, John Wiley

and Sons (2007) 3rd

ed.


PCD313 MACHINE TOOL DESIGN

L T P Cr

3 1 0 3.5


Course Objectives: To explore various design aspects of machine tools elements like transmissions,

structures, materials, kinematics, dynamics and construction of machine tools, etc. To understand concepts

related to design of Die and Punch.

Introduction: General requirement of machine tool design, Techno-economic pre-requisites.

Machine Tools: Kinematics structure & mechanical, Hydraulic and electrical drives, Design of

hydrostatic, Hydrodynamic and antifriction guideways, Design of spindles, Design of speed box

and feed box, Stepped and step less regulations of speed and feed diagram, Ray diagram, Layout

of spindles drive and feed drive in machine tools, Machine tool structures, Design of bed, Heard

stock, Spindle supports and power screws, Machine tool dynamics.

Jigs and Fixtures Design: Applications in manufacturing, principle of location & clamping,

types of locators and clamps, Design of jigs and fixtures, selection of materials.

Die and Punch Design: Applications in manufacturing, Design of various type of dies, selection

of materials for casting and forging dies.

Course Outcomes: At the end of the course the students will be able to:

develop the conceptual design, manufacturing framework and systematic analysis of design problems on

the machine tools

apply the design procedures for different types of design problems such as gear box design, guide way

design, shaft loading and its associated parts, rolling bearings, die design and jigs and fixtures and so on.

design, develop, and evaluate cutting tools and work holders for a manufactured product.

Recommended Books

1. Mehta, N. M., Machine Tool Design & Numerical Control, McGraw Hill (2004).

2. Sen, G.C. and Bhattacharya, A., Machine Tools, Central Book Agency (1989) 2nd

ed.

3. Pandey, P.C. and Singh, C.K., Production Engineering Sciences, Standard Publishers

(2003).

4. Basu, S. K. and Palo, D.K., Design of Machine Tools, Allied Publishers (2008) 5th ed.

5. Acherkhan, N.S., Machine Tool Design, Mir Publishers (1983).

6. Boothroyd, Fundamentals of Metal Machining and M/C Tools, McGraw Hill (1998) 2nd

ed.

7. Meiroitch, L., Elements of Vibration Analysis, McGraw Hill (1980) 2nd

ed.

8. Sharma, P.C., Text of Production Engineering, S. Chand (2006).

9. Pandey, P.C. and Shan H.S., Modern Machining Processes, McGraw Hill (1980).


PPI201 ADVANCED MANUFACTURING PROCESSES

L T P Cr

3 1 2 4.5


Course Objectives: To impart knowledge about principles/methods of different non-traditional

manufacturing processes and analytical/mathematical approach to quantify amount of material removal and

of these processes. To impart knowledge about the role of controlling process parameters and selection of

different process parameters for optimal performance for different engineering materials.

Non Traditional Manufacturing Processes: Development and classification, Considerations in

processes selection. Mechanics of material removal, Tool design, Effect of process parameters on

MRR, Accuracy, Surface finish and applications of the various non-conventional machining

processes like, Ultrasonic machining (USM), Abrasive jet machining (AJM), Water jet machining

(WJM), Electro chemical machining (ECM), Electro chemical grinding (ECG), Chemical

machining (CHM), Electric discharge machining (EDM), Electron beam machining (EBM),

Plasma arc machining (PAM), Laser beam machining (LBM) and Ion beam machining (IBM)

processes.

High Energy Rate Forming Methods: Comparative study of conventional and high velocity

forming of metals, Principle, Process parameters, Equipment, Mechanics and applications of

explosive forming, Electro-hydraulic forming, Magnetic pulse forming.

Laboratory Work

Calculations of MRR, TWR for USM, EDM, LBM, PAM Processes, Use of dynamometer,

Surface finish measurement tests.

Course Outcomes:


Understand the mechanics of material removal in different nontraditional machining processes and

forming behavior during high energy rate forming processes.

Analyze the process and evaluate the process performance in each process role of each process

parameters on performance of the process during machining of different materials.

Role, selection and application of process in nonconventional machining and forming processes based

on different requirement.

Recommended Books 1. Pandey, P.C. and Shan H.S., Modern Machining Processes, McGraw Hill (2004). 2. Mishra, P.K., Non Conventional Machining, Narosa (2006). 3. Hofy, H.E., Advanced Manufacturing Process, B and H Publication (1998). 4. Bhattacharya, A., New Technology, Institution of Engineers (I) (1995). 5. Ghosh, A. and Mullick, S., Manufacturing Science, New Age International (2001). 6. Jain, S.K. and Schmid, S.R., Manufacturing Engg. & Technology, Addison Wesley (2000).


PCD325 RAPID PROTOTYPING

L T P Cr

3 1 0 3.5


Course Objectives: To explore the automatic fabrication of 3D physical parts using additive

manufacturing technology. To use of additive manufacturing for rapid prototyping takes designs from

computer aided design (CAD), tessellates them in RP software and then build the actual physical 3D

models in an additive manner layer-by-layer.

Introduction: Classification of manufacturing processes, Different manufacturing systems,

Introduction to rapid prototyping (RP), Need of RP in context of batch production, FMS and CIM

and its application; Basic Principles of RP, Steps in RP, Process chain in RP in integrated CAD-

CAM environment, Advantages of RP.

Classifications of Different RP Techniques: Based on raw material, Based on layering

technique (2D or 3D) and energy sources.

Process Technology in RP: Comparative study of stereo-lithography (SL) with photo-

polymerization, SL with liquid thermal polymerization, Solid foil polymerization, Selective laser

sintering, Selective powder binding, Ballastic particle manufacturing, both 2D and 3D, Fused

deposition modeling, Shape melting, Laminated object manufacturing, Solid ground curing,

Repetitive masking and deposition, Beam inference solidification, Holographic interference

Solidification, Special topic on RP using metallic alloys, Programming in RP, Modelling, Slicing,

Internal hatching, Surface skin fills, Support structure.

CAD Data and Programming Techniques for RP: Data requirements, Solid modeling for RP,

Surface modeling, Geometric processes, Interface formats, Model preparation, Slicing methods,

Design of support structures, Internal hatching and surface skin fills.

Materials for RP: Plastics, Ceramics, Resins, Metals, Selection criterions for materials for

different processes, The advantages and limitations of different types of materials.

Course Outcomes:


• understand the importance of Rapid Prototyping Technology over the existing traditional methods in

present competitive scenario in terms of product development cycle and cost.

• understand the insight into various modern rapid prototyping techniques, how the different processes

work, how they have developed, applications, material used and strengths as well as weaknesses of

each technology.

Recommended Books

1. Kai, C. C., Fai, L. K. and Sing, L. C., Rapid Prototyping: Principles and Applications,

World Scientific Publication (2008).

2. Grimm, T., User's Guide to Rapid Prototyping, Society of Manufacturing Engineers (2004).

3. Gebhardt, A., Rapid Prototyping, Hanser Gardner Publications (2003).

4. Upcraft, S. and Ranky, P. G., Rapid Prototyping Solutions, CIMware USA, Inc (2003).

5. Jacob, P. F., Rapid Prototyping and Manufacturing, Fundamentals of Sterolithography,

SME (1992).

6. Rapid Prototyping Reports, CAD/CAM Publishings (1991).

7. Zeid, I., CAD/CAM: Theory and Practice, McGraw Hill (2007).


PPI 204 OPERATIONS MANAGEMENT

L T P Cr

3 1 0 3.5


Course Objectives: The objective of this course is to develop understanding of the strategic role of

operations management in creating and enhancing a firm’s competitive advantages. This will help to apply

key concepts and issues of OM in both manufacturing and service organizations. Further, apply analytical

skills and problem-solving tools to the analysis of the operations problems like forecast demand, Material

Requirement Planning, Inventory etc.

Production Systems: Production/ Operations Management: meaning and scope; significance of

operations management in increasing productivity of firms; design of different production

systems (project, job shop, batch, cellular, mass production systems).

Forecasting Analysis: Need, benefits and applications, cost and accuracy of forecasting, factors

affecting demand, types of forecast based on methodology, types of forecast based on time

horizon (causal methods, tome series and qualitative methods); error analysis in quantitative

forecasting.

Aggregate Planning: Need of aggregate production planning, inputs for aggregate plan, Reactive

aggregate planning strategies, Aggressive aggregate planning strategies, pure and mixed

aggregate planning strategies, level and chase strategies, Graphical method to choose aggregate

plan.

Master Production Scheduling and MRP: Functions, planning horizon and planning periods

for master production schedule, types of master production schedule; Independent Demand versus

dependent demand, Functions of material requirements planning and manufacturing resource

planning (MRP I and MRP II), inputs for MRP system, performance characteristics of MRP

system (planning lead time, lot sizing rules, safety stocks), materials requirement planning

explosion

Inventory Management and Control: Objectives and functions of materials management,

inventory: need and types, inventory record systems, inventory costs and order quantities,

economic order quantity, economic run length.

Course Outcomes:


Deeply understand the fundamental theory of operations and production management.

Solve various kinds of problems or issue faced by service and manufacturing industries like

economic consideration, optimum utilization of resources, productivity, production planning,

inventory management and control etc.

Recommended Books 1. Monks, J. G., Operations Management: Theory and Problems, McGraw Hill, New York

(1987).

2. Krajewski, L. J., Ritzman, L. P. and Malhotra, M. K., Operations Management, Prentice

Hall, New Delhi (2009).

3. Ebert, J and Adams, D.J., Production/Operations Management, Prentice Hall of India, New

Delhi (2007).

4. Chase, R. B., Aquilano, N. J. and Jacob, F. R., Production and Operations Management:

manufacturing and services, Tata McGraw Hill, New Delhi (1999).


PPI103 QUALITY ENGINEERING

L T P Cr

3 1 0 3.5


Course Objectives: To impart knowledge about the significance of quality and the various tools/ concepts

of building quality into products. To learn the techniques used for quality control and quality improvement.

To impart knowledge about plans for acceptance sampling and quality systems.

Introduction: Quality - meaning and significance, Essential components of quality, Phases or

elements for building quality, Evolution of the concepts of quality, Spiral of progress of quality,

Changing scope of quality activities, Ishikawa’s seven quality tools, Quality Circles, Quality

system economics, Hidden quality costs, Economic models of quality costs.

Taguchi’s Quality Loss Function: System approach for quality management, Juran’s quality

trilogy, Quality planning activities, Sporadic and chronic quality problems, Causes of variation,

General quality control methodology.

Statistical Quality Control: Control charts for variables: X bar-R, X bar-S, median, X-MR

charts, Control charts for attributes: p, np, c charts, Product reliability, Process capability

analysis.

Acceptance Sampling: Plans and tables for attributes and variables, Sampling methods, Type of

plans, Operating characteristic curves, Quality improvement methodology, Just-in-time

philosophy, Quality assurance systems.

ISO 9000 Philosophy: Documentation, Implementation and certification process, Management

commitment to quality, Team work approach, Training and motivation.

Course Outcomes:


Appreciate the importance of product quality and use various quality tools.

Prepare and analyze various charts/ methods for quality control and improvement.

Understand and use plans for sampling and concepts of quality system management.

Recommended Books 1. Juran, J.M. and Gryna, F.M., Quality Planning & Analysis, McGraw Hill (2001). 2. Grant, E.L., Statistical Quality Control, McGraw Hill (2008). 3. Feignbaum, A.V., Total Quality Control, McGraw Hill (1991). 4. Juran, J.M., Juran’s Quality Control Handbook, McGraw Hill (1988) 4th ed.


PPI312 METAL CASTING AND JOINING

L T P Cr

3 0 2 4.0


Course Objectives: To inculcate the principle, thermal and metallurgical aspects during solidification of

metal and alloys. To impart knowledge about principles/methods of casting with detail design of

gating/riser system needed for casting, defects in cast objects and requirements for achieving sound casting.

To impart knowledge about welding behaviour of machine and process during welding, analysis of

common and newer welding techniques and metallurgical and weldability aspects of different common

engineering materials.

Casting Technology & problems, Survey and scope, Interfacial Heat Transfer, Thermodynamics

& metallurgical aspects in solidification of pure metals and alloys, Solidification of actual

castings, Homogeneous and heterogeneous nucleation, Codification for pure metals and alloys.

Grain refinement techniques,

Riser Design: Risering curves, NRL, Caine method, Feeding distance, Rising of complex

castings, Gating systems and their characteristics. Type of gates and design consideration, Chills

pattern design consideration, Sand testing, Advanced metal casting processes, Casting defects,

Their causes & redressal, Heat treatment of castings, Heat treatment of castings, Gases in metals.

Metal Joining: Classification – Welding power source, Arc and arc characteristics, Behavior of

arc with variation in current and voltage, Welding electrodes, ISI specification of electrodes,

Electrode selection, Newer welding process- such as plasma arc, Laser beam, Electorate,

Ultrasonic welding, Joining by braking, Soldering and adhesive bonding.

Welding Metallurgy: Heat flow is welding metallurgical transformation, Implication of cooling

rate, HAZ, Weldability of plain carbon steels, SS, CI, Al and its alloys, Design of elements,

Residual stresses and distorting, Welding defects, Testing-destructive and NDT.

Course Outcomes:


Analyze the thermal, metallurgical aspects during solidification in casting and welding and their role on

quality of cast or weld objects.

Design the gating and riser system needed for casting and requirements to achieve defect free casting.

Analyze the welding process behavior for common and newer welding techniques and requirements to

achieve sound welded joint while welding different similar and dissimilar engineering materials.

Recommended Books 1. Ramana Rao, T. V., Metal Casting – Principles and Practice, New Age International Pvt.

Ltd. (2003). 2. Rao, P. N., Manufacturing Technology, McGraw Hill (2008). 3. Campbell, J., Castings, Butter Worth – Heinemann Publishers (2003). 4. Nadkari, S. V., Modern Arc Welding Technology, Oxford & India Book House Pvt. Ltd.

(2005) 2nd ed.


PPI313 METAL FORMING

L T P Cr

3 0 2 4.0


Course Objectives: To impart knowledge about principles and criteria of yielding during forming of

metals, analysis of different bulk and sheet metal forming processes following different analysis approach.

To understand the process mechanics with role of different controlling process parameters.

Elementary Theory of Plasticity: Stress / strain / strain-rate characteristics, Slip-line field

theory, Levy mises and prandti – reuse stress-strain relationship, Experimental investigation,

Plastic potential theory and plastic work, Upper bound solution, Stab method.

Rolling and Drawing Mechanics: Rolling pressure, Driving torque and power requirements

through frictionless dies. Metal drawing, Die design, Analysis of tube drawing process, Defects in

drawn components.

Forging Processes and Mechanics: Determination of forces in strip forging and disc forging,

Defects, Forging die design.

Bending and Extrusion: Process, Parameters and determination of workload from stress analysis

and energy, Drawing and extension of strip through tapered dies considerations, Power loss

variables, Extrusion and bending defects. Two-dimensional deformation model and fracture

analysis for punching and blanking, Theory of high energy rate forming.

Course Outcomes:


Understand the basic mechanics of yielding and yield criteria.

Analyze the different bulk and sheet metal forming process mechanics using different analysis

approach.

Evaluate the effect of process parameters on the process mechanics during bulk and sheet metal

forming.

Recommended Books 1. Rowe, G.W., Principles of Industrial Metal Working Process, CBS Publishers (2004). 2. Avitzur, B., Metal Forming Analysis, McGraw Hill (1998). 3. ASTME, High Velocity Forming of Metals, Prentice Hall (1995). 4. Ghosh, A. and Malik, S., Manufacturing Science, Affiliated East-West Press (2001). 5. Johnson, W. and Mellore, P.B., Plasticity for Mechanical Engineers, Van Nostrand (1995). 6. Narayan, S.R., Metal Forming Technology, Ahuja Book Publishers (2001). 7. Haffmann, O., Introduction to the Theory of Plasticity-Metal Forming Applications,

McGraw Hill (1995).


PPI 315 WORK STUDY AND METHOD ENGINEERING

L T P Cr

3 1 0 3.5


Course Objectives: To inculcate specialized knowledge and skill in production process optimization using

the principles and methods of engineering analysis and design. To cultivate the ability to build and

implement new improved methods resulting in creation and distribution of value in operations. To cultivate

work space design capability. To develop the skill in systems integration by fostering the ability to work

with inter-disciplinary groups in professional, industry and research organizations.

Introduction to Productivity: Definition of productivity, Productivity and production,

Importance and role of productivity, Factors affecting productivity, Industrial productivity.

Productivity Evaluation, Measurement Approaches: Need for productivity measurement,

Productivity measurement approaches, Total and partial productivity, Productivity measurement

models and their comparisons, Work study and productivity.

Productivity Improvement, Implementation Factors and Techniques: Internal and External,

Productivity analysis – productivity appraisal, Approaches to productivity analysis, Strategy and

structure of productivity improvement, Organizational approaches to productivity improvement,

Productivity improvement and implementation techniques.

Introduction to Work Study: Definition, Scope, Inter-relation between method study and work

measurement, Human aspects, Role in improving plant productivity and safety.

Method Study: Objectives and step-wise procedure for method analysis, Recording & evaluation

techniques, Micro-motion and macro motion study, Therbligs and Simo-charts, Principle of

motion economy, Normal work areas and design of work places, Principles of work design,

Multiple activity chart, Flow process chart, String diagram, Travel charts.

Work Measurement: Work measurement objectives, Techniques & criteria for selection of

technique, Stop watch time study, Systems of performance ratings, Calculation of standard time,

Introduction to allowances, Production study, Work sampling, MTN & Work Factor system,

Standard data usage, Engineered time standard, Predetermined motion time system (PMTS), Job

evaluation & merit rating, Incentive schemes.

Course Outcomes:


Address issues related to productivity assessment and improvement.

Critiquing operations and using systematic approach to improving shop floor operations.

Use tools for analysis and design of operations.

Determine time standards and conditions of work.

Assist in the design of layout of shop floor.

Pre-emptive assessment and design of methods of operations.

Develop wage incentive policy.

Reference Books

1. Barnes, R. M., Motion and time study: design and measurement of work, Wiley, (1980), 7th

ed.

2. Kanawaty, G., Introduction to work study, ILO, Geneva (1992) 4th ed.

3. Niebel , Methods Standards Work Design, McGraw-Hill Education, (2000), 10th ed.

4. Meyers, F. E., Stewart, J. R., Motion and Time Study for Lean Manufacturing, Prentice


Hall, (2002), 3rd

ed.

5. Freivalds, A., Niebel, B., Niebel's Methods, Standards, and Work Design, McGraw-Hill

Higher Education, (2013), 13th ed.

6. Mundel, M. E., Motion and Time Study: Principles and Practice, New York: Prentice-Hall,

(1950).

7. Groover, M. P., Work Systems: The Methods, Measurement and Management of Work,

Pearson Prentice Hall, (2007).

8. Christopher. W. F., Productivity measurement handbook: how to measure productivity

performance for plant operations, administration and services, profit centers and total

company, Productivity, Inc., (1985), 2nd

ed.

9. Sumanth, D. J., Productivity engineering and management: productivity measurement,

evaluation, planning, and improvement in manufacturing and service organizations,

International student edition, McGraw-Hill, (1984).

10

.

Maynard, H., Zandin, K., Maynard's Industrial Engineering Handbook, McGraw-Hill

Education, (2001).

http://www.google.co.in/search?tbo=p&tbm=bks&q=inauthor:%22Kjell+Zandin%22&source=gbs_metadata_r&cad=6


PPI323 PRODUCT DESIGN AND DEVELOPMENT

L T P Cr

3 1 0 3.5


Course Objectives: To introduce the objectives of product design and the requirements of a good product

design. To expose the students to different design principles like designing for function, production,

installation and handling, maintenance, packaging etc. To expose them to the latest CAD/CAM/CAE

software for different design and development functions.

The Process of Product Design: Design by evolution, Limitations of evolutionary method in

modern design situation, Structure of design process, Morphology of design, Standards of

performance, Environmental factors, Creativity techniques in design problem.

Strategies for Search of Design Concepts: Physical realizability, Economic and financial

feasibility, Designing for function, Iterative value engineering, Designing for production,

Tolerance analysis, Use, Maintenance, Designing for handling and installing, Economics of

design, Human factors in design, Optimization of design, Reverse engineering of ergonomic

shape designs.

Use of CAD / CAM /CAE: Software for concurrent engineering design. Case studies in design of

products for manufacture, Aesthetics, Surface styling and shaping tools in modern CAD software,

Exercises in design, Design optimization using automated CAE software, Analysis, Reverse

engineering a product using CAD, CAM, CAE, 3D scanner, Reverse engineering and surface

design and review software.

Laboratory/ Tutorial Work

Exercises to practice the concepts taught in theory using hardware and software tools available in

the laboratory on CAD/CAM/CAE.

Course Outcomes:


understand the objectives of product design and the requirements of a good product design.

use a systematic design process being fully aware of its benefits.

translate the concepts of economics in design, optimization of design and human factors approach to

product design.

use CAD/CAM /CAE software for Concurrent Engineering design, 3D scanning and reverse

engineering of products.

Recommended Books 1. Gupta, V. and Murthy, P.N., Introduction to Engineering Design Method, McGraw Hill

(1980). 2. Chitale and Gupta, Product Design and Manufacturing, Prentice Hall of India (2004) 3rd

ed.


PCD316 APPLIED OPTIMIZATION IN ENGINEERING DESIGN

L T P Cr

3 1 0 3.5


Course Objectives: The main objective of this course is to provide the thorough knowledge of formulating

an optimization problem, classification of optimization techniques, different solution strategies, and

performance criterion. The course will also highlight the basics of evolutionary optimization techniques as

compared to classical techniques.

Optimization Studies: Problem formulation, Solution Strategies, Performance Criteria,

Classification of Optimization techniques.

One-dimensional Optimization Methods: Optimality Criteria – necessary and sufficient

conditions, Bracketing methods, Region-Elimination methods, Point Estimation method, Gradient

based methods, Sensitivity analysis.

Multi-dimensional Optimization Methods: Optimality Criteria, Unidirectional search, Direct

Search methods, Gradient-based methods. Conjugate-direction methods, Quasi-Newton methods.

Constrained Optimization Methods: Constrained Optimization Criteria, Penalty Methods,

Method of Multipliers, Direct search methods, Linearization methods, Feasible Direction method,

Generalized Reduced Gradient Method, Gradient Projection method, Quadratic Approximation,

and Concept of Duality. Applications of Unconstrained and Constrained Optimization.

Linear programming Methods: Formulation of problems, Analytical and Graphical solutions,

Simplex Method, Integer Programming, Interior Point Methods. Duality Theory.

Specialized Optimization Techniques: Introduction to Multi-Objective optimization; Global

Optimization: Criteria, Simulated Annealing, Steepest Descent method; Introduction to Genetic

Algorithms.

Course Outcomes:


study as well as solve one-dimensional and multi-dimensional optimization problems.

formulate as well as analyze unconstraint as well as constraint optimization problems.

develop Analytical and Graphical solutions of LP problems, Simplex Method

appreciate the concepts of Integer Programming as well as Duality Theory.

understand the basic concepts of Multi-Objective optimization and Genetic Algorithms.

Recommended Books:

1. Deb, K., Optimization for Engineering Design Algorithms and Examples, Eighth printing,

Prentice Hall of India Pvt. Ltd., 2005.

2. Deb, K., Multi-objective Optimization using Evolutionary Algorithms, First, John Wiley and

Sons, 2009.

3. Rao, S.S., Engineering Optimization Theory and Practice, Fourth Edition, John Wiley and

Sons, 2009.

4. Belegundu, A.D., Chandrupatla, T.R., Optimization Concepts and Applications in

Engineering, Second Edition, Cambridge University Press, 2011.

5. Dasgupta, B., Applied Mathematical Methods, First, Pearson Education India, 2006.


PCD203 COMPUTER INTEGRATED MANUFACTURING SYSTEMS

L T P Cr

3 1 0 3.5


Course Objectives: To impart knowledge about the integration of interdisciplinary fields of computer

aided design, computer aided manufacturing, automatic identification system, automatic storage &

retrieval system, design and analysis of various automatic material handling systems as a whole. To make

the students aware about various techniques of reverse engineering, data collection and its availability to

automated subsystems.

Introduction: Types of production systems and their automation, CAD/CAM integration.

Concept of FMS and CIMS.

Elements of a General CIM System: Types of CIM systems, CAD-CAM link for CIMS,

Benefits of CAM, FMS and CIMS, Automated material handling systems, equipment and their

functions. Integration of Robots in CIMS, Automatic Storage and Retrieval Systems (AS/RS),

Carousel, Palletization and fixtures.

CIMS configurations: DNC based factory management and control, Integrated CAD/CAM

system and shared database.

Introduction to Rapid Prototyping, and Rapid Tooling: Reverse engineering, Concept of

concurrent engineering, Product life cycle management.

Group Technology: Concept and terminology, Part family formation, Classification and coding

systems for components, Group technology machine cells.

Computer Aided Process Planning: CAPP and route sheet development, CAPP system,

Computer aided plant layout.

Computer Aided Production Planning and Control: Inventory control and MRP. Computer

aided shop floor control, process monitoring, Computer aided inspection & quality control, Shop

floor data collection systems, Shop floor control, Sensors used, Tool management system,

Automatic identification systems, Barcode system.

Introduction to fundamentals of computer communications: Networking, Computer-

machine-personnel communication links, Network architectures & techniques, Information flow

in networks, Network standards.

CIM Database and Database Management Systems: Types, Management information

system, Manufacturing data preparation.

Course Outcomes: With this course students will be able to

understand the structure of modern day computer integrated manufacturing system and design to

improve the existing manufacturing facility

effectively participate in the integration of multidisciplinary capabilities and applications of different

fields in automation of any existing facility

improve the shop floor management and data collection system

understand the importance of product life cycle and product quality

Recommended Books:

1. Groover, M. P. and Zimmers, E. W., CAD/ CAM, Dorling Kingsley (2008).

2. Groover, M. P., Automation, Production systems and Computer Integrated Manufacturing,

Pearson Education Asia (2009).

3. Vajpayee, K.S., Principles of Computer Integrated Manufacturing, Prentice Hall (2006).

4. Rao, P. N., Tewari, N. K. and Kundra, T. K., Computer Integrated Manufacturing, McGraw

Hill (1998).


5. Software Manuals for tutorial on reverse engineering and quality control using 3D scanner-

Scan tools, Surface modeling, Die Design, Automated part programming-2, 3, and 5 axis,

QUEST, PLM software like Intralink, WindChill, etc. available from the supplier, in

laboratory.


PCD204 INDUSTRIAL AUTOMATION

L T P Cr

3 1 0 3.5


Course Objectives: To inculcate the ability to design of hydraulic, pneumatic and electro-pneumatic logic

circuits for automating processes in manufacturing, demonstrate problem-solving skills in automation, and

safely use the machines in the industries. Also, to explore the use of different sensors, control valves,

controllers and actuators for electro-pneumatic & hydraulic circuits.

Introduction to Factory Automation and Integration: Basic Concepts, Types of automation,

Automation strategies.

Introduction to Hydraulics/Pneumatics Electro-pneumatic controls and devices, Basic

elements hydraulics/pneumatics, Electro-pneumatic systems, Fluid power control elements and

standard graphical symbols for them, Construction and performance of fluid power generators,

Hydraulic & pneumatic cylinders - construction, design and mounting, Hydraulic & pneumatic

valves for pressure, Flow & direction control, Servo valves and simple servo systems with

mechanical feedback, Solenoid, Different sensors for electro-pneumatic system, hydraulic,

pneumatic & electro-pneumatic circuits.

Design of pneumatic logic circuits for a given time displacement diagram or sequence of

operation. Pneumatic safety and remote control circuits and their applications to clamping,

Traversing and releasing operations, Automatic transfer systems: Automatic transfer, Feeding and

orientation devices.

Automatic transfer machines: Classifications, Analysis of automated transfer lines, Without

and with buffer storage, Group technology and flexible manufacturing system.

Assembly automation: Types of assembly systems, Assembly line balancing, Performance and

economics of assembly system.

Course Outcomes:


understand the benefits and applications of automation in various manufacturing systems.

design and simulate various logic circuits for different automating processes in manufacturing systems.

solve the complex industrial problems by different automation approaches

Recommended Books:

1. Groover, M. P., Automation, Production System & Computer Integrated Manufacturing,

Pearson Education Asia (2009).

2. Nakra, B. C., Automatic Control, New Age International (2005).

3. Morriss, S. B., Automataed Manufacturing Systems, McGraw Hill (2006).

4. Majumdar, S. R., Pneumatic Systems, McGraw Hill (2005).

me (production engineering) first semester s. no. course

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