M.TECH. CAD / CAM - Gayatri Vidya Parishad College of ... mo… · ACADEMIC REGULATIONS COURSE...

ACADEMIC REGULATIONS

COURSE STRUCTURE AND SYLLABI

M.TECH.

CAD / CAM (Department of Mechanical Engineering)

2013 – 2014

GAYATRI VIDYA PARISHAD

COLLEGE OF ENGINEERING

(AUTONOMOUS)

Accredited by NAAC with A Grade with a CGPA of 3.47/4.00

Affiliated to JNTUK-Kakinada

MADHURAWADA, VISAKHAPATNAM – 530 048

VISION

To evolve into and sustain as a Centre of

Excellence in Technological Education

and Research with a holistic approach.

MISSION

To produce high quality engineering graduates

with the requisite theoretical and practical

knowledge and social awareness to be able to

contribute effectively to the progress of the

society through their chosen field of endeavor.

To undertake Research & Development, and

extension activities in the fields of Science and

Engineering in areas of relevance for immediate

application as well as for strengthening or

establishing fundamental knowledge.

F O R E W O R D

Two batches of students have successfully graduated from the M.Tech.

programmes under autonomous status, which gave us a lot of

satisfaction and encouragement. In the light of changing scenario of

accreditation process globally, to upkeep the quality of education

further, a major revision in the curriculum has been taken up with an

objective to provide outcome based education.

We could execute these changes through our dedicated faculty,

commendable academicians from institutions of repute, enthusiastic

representatives from Industry, affiliating University JNTU-K, and UGC

present in the Boards of Studies, Academic Council and Governing

Body.

It is hoped that the new regulations and curriculum will enhance the all-

round ability of students so that they can technically compete at global

level with native ethical standards.

PRINCIPAL

MEMBERS ON THE BOARD OF STUDIES

IN

MECHANICAL ENGINEERING

Prof. P. Bangaru Babu, Professor in Mechanical Engineering, National Institute of Technology

(NIT), Warangal – 506 004.

Sri M. Prasanna Kumar,

DGM (O & M), NTPC Simhadri, Parawada, Visakhapatnam.

Sri V. Damodar Naidu,

President, Sujana Towers Ltd., Plot No.5/A, Vengalrao Nagar,

Hyderabad – 500 038.

Prof. M.M.M. Sarcar,

Professor, Department of Mechanical Engineering , College of

Engineering (Autonomous) Andhra University, Visakhapatnam-530 003.

Dr. N. Siva Prasad,

Professor, Machine Design Section, Department of Mechanical

Engineering, IIT Madras, Chennai - 600 036.

Sri K. R. Sreenivas,

Engineering Mechanics Unit, JNCASR, Jakkur, Bangalore 560 064.

Sri P. Srikanth,

Project Manager, Software Development, Parabola Software, MVP

Double Road, Visakhapatnam.

All faculty members of the Department

http://www.andhrauniversity.info/engg

http://www.andhrauniversity.info/engg

M.TECH. ACADEMIC REGULATIONS (Effective for the students admitted into first year from the Academic Year 2013 - 14)

The M.Tech. Degree of Jawaharlal Nehru Technological University

Kakinada shall be recommended to be conferred on candidates who are

admitted to the program and fulfill all the following requirements for the

award of the Degree.

1.0 ELGIBILITY FOR ADMISSION:

Admission to the above program shall be made subject to the

eligibility, qualifications and specialization as per the guidelines

prescribed by the APSCHE and AICTE from time to time.

2.0 AWARD OF M.TECH. DEGREE:

a. A student shall be declared eligible for the award of the M.Tech.

degree, if he pursues a course of study and completes it

successfully for not less than two academic years and not more

than four academic years.

b. A student, who fails to fulfill all the academic requirements for

the award of the Degree within four academic years from the

year of his admission, shall forfeit his seat in M.Tech. Course.

c. The duration of each semester shall normally be 20 weeks with

5 days a week. A working day shall have 7 periods each of

50 minutes.

3.0 STRUCTURE OF THE PROGRAMME:

*Elective 1

GVPCE(A) M.Tech. CAD / CAM 2013

Semester No. of Courses per Semester Credits

Theory + Lab

I (5 +1*) + 1 20

II (5+1*) + 1 20

III Seminar 02

III, IV Project Work 40

TOTAL 82

4.0 ATTENDANCE:

The attendance shall be considered subject wise.

a. A candidate shall be deemed to have eligibility to write his end

semester examinations in a subject if he has put in at least 75%

of attendance in that subject.

b. Shortage of attendance up to 10% in any subject (i.e. 65% and

above and below 75%) may be condoned by a Committee on

genuine and valid reasons on representation by the candidate

with supporting evidence.

c. Shortage of attendance below 65% shall in no case be

condoned.

d. A student who gets less than 65% attendance in a maximum of

two subjects in any semester shall not be permitted to take the

end- semester examination in which he/she falls short. His/her

registration for those subjects will be treated as cancelled. The

student shall re-register and repeat those subjects as and when

they are offered next.

e. If a student gets less than 65% attendance in more than two

subjects in any semester he/she shall be detained and has to

repeat the entire semester.

5.0 EVALUATION:

The performance of the candidate in each semester shall be

evaluated subject-wise with 100 marks for each theory subject

and 100 marks for each practical, on the basis of Internal

Evaluation and External End -Semester Examination.

The question paper of the external end semester examination

shall be set externally and valued both internally and externally.

If the difference between the first and second valuations is less

than or equal to 9 marks, the better of the two valuations shall

be awarded. If the difference is more than 9 marks, the scripts

are referred to third valuation and the corresponding marks are

awarded.

a. A candidate shall be deemed to have secured the minimum

academic requirement in a subject if he secures a minimum of

40% of marks in the End Semester Examination and aggregate

minimum of 50% of the total marks of the End Semester

Examination and Internal Evaluation taken together. 2


b. For the theory subjects, 60 marks shall be awarded based on the

performance in the End Semester examination and 40 marks

shall be awarded based on the Internal Evaluation. One part of

the internal evaluation shall be made based on the average of the

marks secured in the two internal examinations of 30 marks

each conducted one in the middle of the Semester and the other

immediately after the completion of instruction. Each mid-term

examination shall be conducted for a duration of 120 minutes

with 4 questions without any choice. The remaining 10 marks

are awarded through an average of continuous evaluation of

assignments / seminars / any other method, as notified by the

teacher at the beginning of the semester.

c. For practical subjects, 50 marks shall be awarded based on the

performance in the End Semester Examinations, 50 marks shall

be awarded based on the day-to-day performance as Internal

marks. A candidate has to secure a minimum of 50% in the

external examination and has to secure a minimum of 50% on

the aggregate to be declared successful.

d. There shall be a seminar presentation during III semester. For

seminar, a student under the supervision of a faculty

member(advisor), shall collect the literature on a topic and

critically review the literature and submit it to the Department in

a report form and shall make an oral presentation before the

Departmental Committee. The Departmental Committee shall

consist of the Head of the Department, advisor and two other

senior faculty members of the department. For Seminar, there

will be only internal evaluation of 50 marks. A candidate has to

secure a minimum of 50% to be declared successful.

e. In case the candidate does not secure the minimum academic

requirement in any subject (as specified in 5.a to 5.c), he has to

reappear for the End Examination in that subject. A candidate

shall be given one chance to re-register for each subject

provided the internal marks secured by a candidate in that

subject is less than 50% and he has failed in the end

examination. In such a case, the candidate must re-register for

the subject (s). In the event of re-registration, the internal marks

and end examination marks obtained in the previous attempt are

nullified. 3


f. In case the candidate secures less than the required attendance

in any subject(s), he shall not be permitted to appear for the End

Examination in those subject(s). He shall re-register for the

subject(s) when they are next offered.

g. Laboratory examination for M.Tech. subjects must be

conducted with two Examiners, one of them being Laboratory

Class Teacher and second examiner shall be other than the

Laboratory Teacher.

6.0 EVALUATION OF PROJECT / DISSERTATION WORK:

Every candidate shall be required to submit the thesis or

dissertation after taking up a topic approved by the

Departmental Research Committee (DRC).

a. A Departmental Research Committee (DRC) shall be

constituted with the Head of the Department as the Chairman

and two senior faculty as Members to oversee the proceedings

of the project work from allotment of project topic to

submission of the thesis.

b. A Central Research Committee (CRC) shall be constituted with

a Senior Professor as Chair Person, Heads of the Departments

which are offering the M.Tech. programs and two other senior

faculty members from the same department.

c. Registration of Project Work: A candidate is permitted to

register for the project work after satisfying the attendance

requirement of all the subjects (theory and practical subjects.)

d. After satisfying 6.0 c, a candidate has to submit, in consultation

with his project supervisor, the title, objective and plan of action

of his project work to the DRC for its approval. Only after

obtaining the approval of DRC the student can initiate the

Project work.

e. If a candidate wishes to change his supervisor or topic of the

project he can do so with the approval of the DRC. However,

the Departmental Research Committee shall examine whether

the change of topic/supervisor leads to a major change in his

initial plans of project proposal. If so, his date of registration

for the Project work shall start from the date of change of

Supervisor or topic as the case may be whichever is earlier. 4


f. A candidate shall submit and present the status report in two

stages at least with a gap of 3 months between them after

satisfying 6.0 d. The DRC has to approve the status report, for

the candidate to proceed with the next stage of work.

g. The work on the project shall be initiated in the beginning of the

second year and the duration of the project is for two semesters.

A candidate shall be permitted to submit his dissertation only

after successful completion of all theory and practical subject

with the approval of CRC but not earlier than 40 weeks from the

date of registration of the project work. For the approval by

CRC the candidate shall submit the draft copy of the thesis to

the Principal through the concerned Head of the Department and

shall make an oral presentation before the CRC.

h. Three copies of the dissertation certified by the Supervisor shall

be submitted to the College after approval by the CRC.

i. For the purpose of adjudication of the dissertation, an external

examiner shall be selected by the Principal from a panel of 5

examiners who are experienced in that field proposed by the

Head of the Department in consultation with the supervisor.

j. The viva-voce examination shall be conducted by a board

consisting of the supervisor, Head of the Department and the

external examiner. The board shall jointly report the candidate‟s

work as:

A. Excellent

B. Good

C. Satisfactory

k. If the adjudication report is not favorable, the candidate shall

revise and resubmit the dissertation, in a time frame prescribed

by the CRC. If the adjudication report is unfavorable again, the

dissertation shall be summarily rejected and the candidate shall

change the topic of the Project and go through the entire process

afresh.

7.0 AWARD OF DEGREE AND CLASS :

A candidate shall be eligible for the degree if he satisfies the

minimum academic requirements in every subject and secures

satisfactory or higher grade report on his dissertation and viva-

voce. 5


After a student has satisfied the requirements prescribed for the

completion of the program and is eligible for the award of M.Tech.

Degree, he shall be placed in one of the following three classes.

% of Marks secured Class Awarded

70% and above First Class with Distinction

60% and above but less than 70% First Class

50% and above but less than 60% Second Class

The grade of the dissertation shall be mentioned in the marks

memorandum.

8.0 WITHHOLDING OF RESULTS:

If the candidate has not paid any dues to the college or if any case

of indiscipline is pending against him, the result of the candidate

shall be withheld and he will not be allowed into the next higher

semester. The recommendation for the issue of the degree shall be

liable to be withheld in all such cases.

9.0 TRANSITORY REGULATIONS:

a. A candidate who has discontinued or has been detained for

want of attendance or who has failed after having studied the

subject is eligible for admission to the same or equivalent

subject(s) as and when subject(s) is/are offered, subject to 4.0

d, e and 2.0.

b. Credit equivalences shall be drawn for the students re-

admitted into 2013 regulations from the earlier regulations. A

Student has to register for the substitute / compulsory / pre-

requisite subjects identified by the respective Boards of

Studies.

c. The student has to register for substitute subjects, attend the

classes and qualify in examination and earn the credits.

d. The student has to register for compulsory subjects, attend

the classes and qualify in examination.

e. The student has to register for the pre-requisite courses,

attend the classes for which the evaluation is totally internal.

6


10.0 GENERAL

1. The academic regulations should be read as a whole for

purpose of any interpretation.

2. In case of any doubt or ambiguity in the interpretation of the

above rules, the decision of the Chairman, Academic

Council is final.

3. The College may change or amend the academic regulations

and syllabus at any time and the changes amendments made

shall be applicable to all the students with effect from the

date notified by the College.

4. Wherever the word he, him or his occur, it will also include

she, hers.

******

7


COURSE STRUCTURE SEMESTER – I

Course

Code

Theory / Lab L P C

13ME2101 Computer Aided Design 4 - 3

13ME2102 Rapid Prototyping 4 - 3

13ME2103 Artificial Intelligence in Manufacturing 4 - 3

13ME2104 Optimization Methods in Engineering 4 - 3

13ME2105 Advanced Tool Design 4 - 3

13ME2106

13ME2107

13ME2108

13ME2109

13ME2110

Elective – I

1. Mechatronics

2. Design for Manufacturing and Assembly

3. Manufacturing Methods & Mechanics of

Composites

4. Advanced Mechanism Design

5. Total Quality Management

4 - 3

13ME2111 Computer Aided Design and Optimization

Lab

- 3 2

TOTAL 24 3 20

SEMESTER – II

Course

Code

Theory / Lab L P C

13ME2112 Computer Numerical Control Machines 4 - 3

13ME2113 Advanced Manufacturing Technology 4 - 3

13ME2114 Industrial Robotics 4 - 3

13ME2115 Design of Fluid Power Systems 4 - 3

13ME2116 Flexible Manufacturing System 4 - 3

13ME2117

13ME2118

13ME2119

13ME2120

13ME2121

Elective – II

1. Design and Analysis of Experiments

2. Intelligent Manufacturing Systems

3. Computer Aided Process Planning

4. Computer Graphics

5. Advanced Non-Destructive Testing

Techniques

4 - 3

13ME2122 Computer Aided Manufacturing and Robotics

Lab

- 3 2

TOTAL 24 3 20

8


SEMESTER – III

Course Code SEMINAR/ PROJECT WORK CREDITS

13ME2123 SEMINAR 2

13ME2124 PROJECT WORK (Contd..) -

SEMESTER – IV

Course code PROJECT WORK CREDITS

13ME2124 PROJECT WORK 40

9


COMPUTER AIDED DESIGN

Subject Code: 13ME2101 L P C

4 0 3

Course Educational Objectives:

1. To make the student learn the various types of geometric modeling

techniques

2. To provide background knowledge necessary for the working of CAD

software

3. To make the student understand advanced aspects of the computer

aided design

Course Outcomes:

The student will be able to explain

1. the different types of modelling techniques

2. various design applications of machine components

3. the different formats of CAD/CAM data exchange

4. the principles and approaches of collaborative engineering

UNIT-I

CAD system: Product life cycle, scope of CAD/CAM, modeling

approaches, coordinate systems, basic features, datum features,

modeling strategies, model viewing, layers

Wireframe modeling: wireframe entities, curve representation, analytic

curve, parametric representation of synthetic curves, Hermite cubic

spline, Bezier curve, B-spline curve, curve manipulation

UNIT-II

Surface modeling: Surface entities, surface representation, surface

analysis, analytic surface, plane surface, ruled surface, surface of

revolution, tabulated cylinder

Synthetic surfaces, Hermite Bi-cubic surface, Bezier surface, B-Spline

surface, Coons surface, blending surface, offset surface, surface

manipulations – displaying, segmentation, trimming, intersection,

transformations

10


UNIT III Solid modeling: Solid entities, geometry and topology, solid

representation, Boundary representation (B-rep), Constructive Solid

Geometry (CSG), sweep representation, solid manipulations

UNIT-IV Design applications: Mechanical tolerances, mass properties on CAD

system, assembly modelling, assembly tree, assembly planning, mating

conditions, bottom-up assembly approach, top-down assembly approach,

assembly analysis

UNIT V

Collaborative engineering: Distributed computing, virtual reality

modelling languages, collaborative design, principles, approaches, tools,

design systems

CAD/CAM data exchange: Types of translators, IGES, STEP, ACIS,

DXF, processors

TEXT BOOKS:

1. Ibrahim Zeid, “Mastering CAD/CAM”, 1e, McGraw Hill

International, 2008

REFERENCES:

1. Ibrahim Zeid, “CAD/CAM Theory and Practice”, 5e, McGraw

Hill International, 2009.

2. P N Rao, “CAD/CAM”, 2e, Tata McGraw Hill, 2010

11


RAPID PROTOTYPING


4 0 3

Pre requisites: Basic principles of CAD/CAM


1. To explore and experience a range of materials and processes using

digital manufacturing techniques and CAD modelling software to

build engineering objects.

2. To develop strategies for the integration of digital manufactured

objects into the building of 3 dimensional forms.

3. To develop conceptual, perceptual, formal and aesthetic concerns

as related to the rapid prototyping of engineering objects.

Course Outcomes:

The student will be able to

1. competently use tools to explore digital manufacturing techniques

and CAD modelling software

2. produce a range of work which uses digital manufacturing

techniques and CAD modelling software to explore professional

and creative growth and refinement of work

3. emphasise on digital manufacturing and modelling techniques and

processes

4. identify and apply specific occupational, health and safety

measures when making works using digital manufacturing

techniques and hand making processes

UNIT – I

Introduction: Need for time compression in product development,

Product development – conceptual design – development – detail design

– prototype – tooling. Classification of RP systems, Stereo lithography

systems – Principle – process parameters – process details – machine

details, Applications.

12


UNIT – II

Direct Metal Laser Sintering (DMLS) system – Principle – process

parameters – process details – machine details, Applications. Fusion

Deposition Modeling – Principle – process parameters – process details

– machine details, Applications. Laminated Object Manufacturing –

Principle – process parameters – process details – machine details,

Applications.

UNIT -III Solid Ground Curing – Principle – process parameters – process details

– machine details, Applications. 3-Dimensional printers – Principle –

process parameters – process details – machine details, Applications,

and other concept modelers like thermo jet printers, Sander„s model

maker, JP system 5, Object Quadra system

UNIT – IV

Laser Engineering Net Shaping (LENS), Ballistic Particle

Manufacturing (BPM) – Principle. Introduction to rapid tooling – direct

and indirect method, software for RP – STL files, Magics, Mimics.

Application of Rapid prototyping in Medical field.

UNIT- V Introduction to Virtual prototyping- End to end prototyping-simulation-

components of virtual prototyping- effects- economics of virtual

prototyping.

TEXT BOOKS:

1. Chua C.K., Leong K.F. and Lim C.S., “Rapid Prototyping: Principles

and Applications”, 3e, World scientific publications, 2010.

2. Paul F Jacobs, “Rapid Prototyping and manufacturing–Fundamentals

of streolithography”, Society of Manufacturing Engineering

Dearborn, USA 1992

REFERENCES:

1. Pham,D.T. and Dimov.S.S., “Rapid manufacturing” , Springer,

London, 2001.

2. Joe Cecil, “Virtual Enginering” , Momentum Press, 2010.

13


ARTIFICIAL INTELLIGENCE IN MANUFACTURING


4 0 3

Pre requisites: Robotics


1. The objective of the course is to provide students with the

fundamentals of Artificial Intelligence and to discuss how AI

techniques have been used for problems in manufacturing systems.

2. Significant contributions achieved in Intelligent Manufacturing

Systems are evaluated and discussed.

3. Overall impact of Artificial Intelligence on Manufacturing Systems

is assessed and future directions are predicted.

Course Outcomes:


1. explain AI techniques used in solving problems in manufacturing

systems

2. use expert systems software for manufacturing applications

3. link expert systems to other software such as DBMS, MIS, MDB;

Process Control and Office Automation

UNIT-I Artificial intelligence - definition - components - scope - application

areas; knowledge - based systems (expert systems) - definition -

justification - structure – characterization.

UNIT-II Knowledge sources - expert - knowledge acquisition - knowledge

representation - knowledge base - interference strategies - forward and

backward chaining.

UNIT-III

Expert system languages - ES building tools or shells; typical examples

of shells. expert system software for manufacturing applications in

CAD, CAPP, MRP , adaptive control.

14


UNIT-IV

Robotics, process control, fault diagnosis, failure analysis; process

selection, GT etc. linking expert systems to other software such as

DBMS, MIS, MDB.

UNIT-V Process control and office automation. case studies of typical

applications in tool selection, process selection, part classification,

inventory control, process planning.

TEXT BOOK:

1. Russell, Artificial Intelligence: A Modern Approach, 2/E, Pearson

Education Inc., 2009.

REFERENCES: 1. M. Tim Jones, “Artificial Intelligence: A Systems Approach”,

Jones and Bartlett Publishers, Canada, 2009.

2. Deb. S.R., “Robotics Technology and Flexible automation”, Tata

McGraw-Hill, 1994

15


OPTIMIZATION METHODS IN ENGINEERING


4 0 3

Pre requisites: Probability and Statistics


To make the student learn

1. basic mathematical concepts of optimization

2. methods of modelling and formulating optimization problems

3. different methods of solving optimization problems

4. ways of interpreting solution of optimization problems in engineering

in general and mechanical engineering problems in particular

Course Outcomes:


1. explain the importance and basic principles of optimization

2. apply the theory to formulate design problems as mathematical

optimization problems

3. solve optimization problems using different methods or algorithms

4. learn different methods of solving unconstrained and constrained

optimization problems

5. select a suitable technique for a specific engineering problem

UNIT-I Introduction: Classification of optimization problems classical

optimization techniques: single variable optimization–multivariable with

no constraints-multivariable with equality constraints, direct substitution

method, method of Lagrange multipliers

One-dimensional unconstrained optimization: unimodal function,

methods of single variable optimization -, bisection method,

unrestricted, Dichotomous, Fibonacci

UNIT-II

Non-linear multivariable optimization without constraints: Univariate

search, Pattern search methods- Hookes-Jeeves method, Powells

method, Steepest descent method

Non-linear multivariable optimization with constraints: Penalty

approach- interior and exterior penalty function methods 16


UNIT- III Geometric programming: solution from differential calculus point of

view - solution from arithmetic-geometric inequality point of view -

degree of difficulty - optimization of zero degree of difficulty problems

with and without constraints- optimization of single degree of difficulty

problems without constraints

UNIT-IV Genetic algorithms (GA): Differences and similarities between

conventional and evolutionary algorithms, working principle,

reproduction, crossover, mutation, termination criteria, different

reproduction and crossover operators, GA for constrained optimization,

drawbacks of GA.

UNIT-V

Basic concepts of Stochastic programming, multi-stage optimization,

and Multi-objective optimization

Engineering applications: Minimization of weight of a cantilever beam,

truss, shaft; optimal design of springs.

TEXT BOOK:

1. Singiresu S. Rao, “Engineering Optimization -Theory and Practice”,

Wiley, 4th

edition, 2009.

REFERENCES:

1. Kalyanmoy Deb, "Optimization for Engineering Design-Algorithms

and Examples", PHI, 8th

reprint, 2005.

2. Ashok D. Belegundu and Tirupathi R. Chandrupatla, “Optimization

concepts and applications in engineering”, PHI, 2nd

edition, 2011

17


ADVANCED TOOL DESIGN


4 0 3

Prerequisites: Machine tools


To make the student understand

1. advanced methods for tool design and manufacture

2. various tooling materials and their classification

3. concepts of jigs and fixtures

4. fundamentals of die and mould design

Course Outcomes:


1. explain existing methods of tool design

2. select suitable tool materials for a given application

3. design simple jigs and fixtures

4. select appropriate moulds and dies in a given situation

UNIT-I Tool design methods: Introduction, design procedure, statement of the

problem, needs analysis – tentative design solutions, finished design,

drafting and design techniques in tooling drawings, punch and die

manufacturing techniques

UNIT- II Tooling materials: Introduction, properties of tool materials, metal

cutting tools, single point cutting tools, milling cutters, drills and

drilling, reamer classification, taps, tap classification, the selection of

carbide cutting tools, various heat treatments

Gages and gage design: Fixed gages, gage tolerances, the selection of

material for gages.

UNIT- III Design of jigs: Principles of clamping, drill jigs, chip formation in

drilling, general considerations in the design of drill jigs, drill jigs and

modern manufacturing, computer aided jig design 18


UNIT- IV

Design of fixtures: Types of fixtures, vice fixtures, milling fixtures,

boring fixtures, broaching fixtures, lathe fixtures, grinding fixtures,

computer aided fixture design, welding fixtures, fixture design for NC

machine tools, cutting tools for numerical control, tool holding methods

for numerical control.

UNIT- V Design of dies and moulds: Die-design fundamentals, blanking and

piercing die construction, pilots, strippers and pressure pads, presswork

materials, bending dies, forming dies, drawing operations

Mould design: Splits in mould, split locking, two-cavity and multi-

cavity moulds, design details of injection moulds

TEXT BOOK:

1. Donaldson Cyrll, George H.LeCain and Goold V.C., “Tool Design”,

TMH, 36th

Reprint, 2006.

REFERENCES: 1. Wilson F.W., “Fundamentals of Tool Design”, ASTME, Prentice

Hall, India, 2010.

2. G.C. Sen and A. Bhattacharya, “Principles of Machine Tools”, New

Central Book Agency, Kolkata, 2009.

19


MECHATRONICS

(Elective - I)


4 0 3

Pre requisites: Mechanical Measurements



1. fundamentals of mechatronics

2. various sensors, actuators used and their applications to mechatronic

systems

3. modelling and simulation of physical systems

4. controllers used in electro-mechanical systems

5. integration of various elements in the mechanical, electrical and

control systems engineering

Course Outcomes:


1. identify and explain various elements of a mechatronics system

2. model and simulate simple physical systems

3. suggest appropriate sensors and actuators for an engineering

application

4. write simple microcontroller programs

5. build simple homemade projects using electronic devices integrating

with mechanical systems

UNIT-I Mechatronics system design: Introduction, integrated design issues in

mechatronics, key elements, the mechatronics design process, advanced

approaches in mechatronics

Modelling and simulation of physical systems: simulation and block

diagrams, analogies and impedance diagrams, electrical systems,

mechanical translational systems, mechanical rotational systems, electro

mechanical coupling, fluid systems

20


UNIT-II Sensors and transducers: An introduction to sensors and transducers,

sensors for motion and position measurement, force, torque and tactile

sensors, flow sensors, temperature-sensing devices

Actuating devices: DC and AC drives – servo motors and stepper motor

– hydraulic and pneumatic drives – piezoelectric and magnetostrictive

actuators – micro actuators

UNIT-III Microcontroller programming: Microcontrollers, The PIC16F84

microcontroller, programming PIC, PicBasic programming

fundamentals, examples, Use of Interrupts

UNIT-IV Signals, systems and controls: Introduction to signals, systems and

controls, system representation, linearization of nonlinear systems, time

delays

Real time interfacing: Introduction, elements of a data acquisition and

control system, overview of the I/O process, installation of the I/O card

and software

UNIT-V Advanced applications in mechatronics: Sensors for condition

monitoring, mechatronic control in automated manufacturing, artificial

intelligence in mechatronics, micro sensors in mechatronics

TEXT BOOK:

1. Bolton W., “Mechatronics – Electronics Control Systems in

Mechanical and Electrical Engineering”, 3e, Pearson Education

Press, 2005.

REFERENCES: 1. Histand B.H. and Alciatore D.G., “Introduction to Mechatronics and

Measurement Systems”, 3rd

edition ,Tata McGraw Hill Publishing

Company Ltd, 2007.

2. R.K. Rajput, “A text book of Mechatronics”, 1st edition, S. Chand and

Company Ltd., 2007. 21


DESIGN FOR MANUFACTURING AND ASSEMBLY

(Elective - I)


4 0 3

Pre requisites: Production Technology



1. design principles, creativity in design and material selection for

design

2. design considerations for machining, casting, forging

3. design considerations for metal joining, extrusion, sheet metal work,

plastic processing

Course Outcomes:


1. Design the machine parts for ease of manufacturing

2. Select appropriate materials and manufacturing processes for the

optimum product cost and quality

3. Implement assembly features in design to reduce the assembly time

and cost

UNIT-I Introduction: Design philosophy – steps in design process – general

design rules for manufacturability – basic principles of designing for

economical production – creativity in design, application of linear &

non-linear optimization techniques

Materials: Selection of materials for design – developments in material

technology – criteria for material selection – material selection

interrelationship with process selection – process selection charts

UNIT-II Machining process: Overview of various machining processes – general

design rules for machining - dimensional tolerance and surface

roughness – design for machining – ease – redesigning of components

for machining ease with suitable examples, general design

recommendations for machined parts 22


Metal joining: Appraisal of various welding processes, factors in design

of weldments – general design guidelines – pre and post treatment of

welds – effects of thermal stresses in weld joints – design of brazed

joints.

UNIT-III

Metal casting: Appraisal of various casting processes, selection of

casting process, - general design considerations for casting – casting

tolerances – use of solidification simulation in casting design – product

design rules for sand casting

Forging: Design factors for forging – closed die forging design – parting

lines of dies – drop forging die design – general design

recommendations

UNIT-IV

Extrusion & sheet metal work: Design guidelines for extruded sections -

design principles for punching, blanking, bending, deep drawing –

Keeler Goodman forming line diagram – component design for

blanking.

UNIT-V

Plastics: Visco-elastic and creep behaviour in plastics – design

guidelines for plastic components – design considerations for injection

moulding – design guidelines for machining and joining of plastics

Assembly: Compliance analysis and interference analysis for the design

of assembly – design and development of features for automatic

assembly – liaison diagrams

TEXT BOOK:

1.A K Chitale, R C Gupta “ Product Design and Manufacturing”,

PHI, New Delhi, 2003.

REFERENCES:

1. George E Deiter, “ Engineering Design”, McGrawHill International,

2002.

2. BoothroydG , “Product design for Manufacture and Assembly”, First

Edition, Marcel Dekker Inc, New York, 1994. 23


MANUFACTURING METHODS AND

MECHANICS OF COMPOSITES

(Elective - I)


4 0 3

Prerequisites: Material science and Mechanics of solids

Course Educational Objectives: To make the student understand

1. fundamentals of mechanics of anisotropic materials

2. concepts of mechanics of composites

3. manufacturing methods of composites

Course Outcomes: The student will be able to

1. acquire knowledge of reinforcements and matrix materials of

composites

2. analyze mechanics of composites

3. explain various methods of manufacturing composites

UNIT – I

Basic concepts and characteristics: Geometric and Physical definitions,

natural and man-made composites, Aerospace and structural

applications, types and classification of composites

Reinforcements: Fibres- Glass, Silica, Kevlar, carbon, boron, silicon

carbide, and boron carbide fibres. Particulate composites, Polymer

composites, Thermoplastics, Thermosets, Metal matrix and ceramic

composites

UNIT – II Micromechanics: Unidirectional composites, constituent materials and

properties, elastic properties of a lamina, properties of typical composite

materials, laminate characteristics and configurations. Characterization

of composite properties.

Manufacturing methods: Autoclave, tape production, moulding

methods, filament winding, man layup, pultrusion, RTM.

24


UNIT – III

Coordinate transformations: Hooke‟s law for different types of

materials, Hooke‟s law for two dimensional unidirectional lamina,

transformation of stress and strain, Numerical examples of stress strain

transformation, Graphic interpretation of stress – strain relations. axis,

stiffness modulus, off - axis compliance.

UNIT – IV

Elastic behaviour of unidirectional composites: Elastic constants of

lamina, relationship between engineering constants and reduced stiffness

and compliances, analysis of laminated composites, constitutive

relations.

UNIT – V

Strength of unidirectional lamina: Micro mechanics of failure, Failure

mechanisms, Strength of an orthotropic lamina, Strength of a lamina

under tension and shear maximum stress and strain criteria, application

to design. The failure envelope, first ply failure, free-edge effects.Micro

mechanical predictions of elastic constants.

Analysis of laminated composite plates: Introduction, thin plate theory,

specially orthotropic plate, cross and angle ply laminated plates,

problems using thin plate theory.

TEXT BOOK: 1. R.M. Jones, “Mechanics of composite Materials”, Scripta Book

company, Washington DC, 1999

REFERENCES: 1. MadhujitMukhopadhyay, “Mechanics of composite materials and

structures”, Universalities press, 2e, 2004.

2. Isaac and M Daniel, “Engineering Mechanics of Composite

Materials”, Oxford University Press, 1994.

3. Autar K. Kaw,” Mechanics of Composite Materials”, CRC

Publishers,1997

25


ADVANCED MECHANISM DESIGN

(Elective - I)


4 0 3

Prerequisites: Theory of Machines


1. To introduce fundamentals of kinematics of mechanism

2. To familiarise the student with the mathematical formula associated

with the motion parameters of mechanisms

3. To inculcate the concept of planar mechanism synthesis

4. To introduce the Denavit – Hartenber of notation for spatial

mechanisms

Course Outcomes:


1. identify the kinematic chain in a given machine

2. analyze a complex mechanism for displacement velocity and

acceleration

3. synthesise dimensionally a mechanism for a given task

4. analyze the static and dynamic forces on a mechanism

5. estimate the motion parameters of a robot using D-H notation

UNIT– I

Introduction – review of fundamentals of kinematics - analysis and

synthesis – terminology, definitions and assumptions – planar, spherical

and spatial mechanisms‟ mobility – classification of mechanisms –

kinematic Inversion – Grashoff`s law

Position and displacement – complex algebra solutions of planar vector

equations – coupler curve generation velocity – analytical methods -

vector method – complex algebra methods – Freudenstein‟s theorem

UNIT– II

Planar complex mechanisms - kinematic analysis - low degree

complexity and high degree complexity, Hall and Ault`s auxiliary point

method – Goodman‟s indirect method for low degree of complexity

mechanisms

Acceleration – analytical methods – Chase solution - Instant centre of

acceleration. Euler-Savory equation - Bobillier construction 26


UNIT – III

Synthesis of mechanisms: Type, number and dimensional synthesis –

function generation – two position synthesis of slider crank and crank-

rocker mechanisms with optimum transmission angle – three position

synthesis – structural error – Chebychev spacing - Cognate linkages –

Robert-Chebychev theorem – Block‟s method of synthesis,

Freudenstein‟s equation

UNIT – IV

Static force analysis of planar mechanism – static force analysis of

planar mechanism with friction – method of virtual work

Dynamic force analysis of planar mechanisms - Combined static and

inertia force analysis

UNIT – V

Kinematics analysis of spatial revolute-Spherical-Spherical-Revolute

mechanism – Denavit-Hartenberg parameters – forward and inverse

kinematics of robotic manipulators

TEXT BOOK:

1. Amitabh Ghosh and Ashok Kumar Mallik, “Theory of Mechanisms

and Machines,”,3e,EWP, 1999

REFERENCES:

1. Shighley Joseph Edward and Uicker John Joseph , “Theory of

Machines and Mechanism,” ,2e,McGraw Hill,1985.

2. Arthur G. Erdman and G.N. Sandor, “Advanced Mechanism Design:

Analysis and Synthesis”, Vol. I, PHI, 1984.

3. Arthur G. Erdman and G.N. Sandor, “Advanced Mechanism Design:

Analysis and Synthesis”, Vol. II, PHI, 1984.

27


TOTAL QUALITY MANAGEMENT

(Elective - I)


4 0 3

Prerequisite: Production Planning Control and Industrial Management



1. quality standards and need for standardization

2. development and implementation of quality measurement systems

3. quality circles and quality function development

4. application of six sigma approach to various industrial situations

5. concept of total quality management

Course Outcomes:


1. explain quality standards and need for standardization

2. implement quality measurement systems in various applications

3. prepare and use control charts for SQC

4. implement six sigma approach for various industrial applications

5. suggest standards for total quality management in an organisation

UNIT –I

Introduction to quality – definitions - TQM – overview – history –

stages of evolution - elements – definitions – continuous improvement–

objectives – internal and external customers - customer satisfaction and

customer delight

UNIT-II

Quality standards – need of standardization - Institutions – bodies of

standardization, ISO 9000 series – ISO 14000 series – other

contemporary standards, quality models such as KANO, Westinghouse

Quality measurement systems (QMS) – developing and implementing

QMS – non conformance database, inspection, nonconformity reports,

QC, QA, quality costs, tools of quality

28


UNIT-III

Problem solving - problem solving process – corrective action – order of

precedence – system failure analysis approach – flow chart – fault tree

analysis – failure mode assessment and assignment matrix – organizing

failure mode analysis – pedigree analysis, cause and effect analysis,

FMEA case studies.

UNIT-IV

Quality circles – organization – focus team approach – statistical process

control – process chart – Ishikawa diagram – preparing and using control

charts, SQC, Continuous improvement – 5 S approach, Kaizen,

reengineering concepts. Quality function development (QFD, bench

marking – Taguchi analysis - Taguchi design of experiments, reliability

models, reliability studies

UNIT-V

Value improvement elements – value improvement assault – supplier

teaming, vendor appraisal and analysis, lean engineering

Six sigma approach – application of six sigma approach to various

industrial situations, case studies

TEXT BOOK:

1. Bester Field, “Total Quality Management”, 3e, Pearson Education,

Asia, New Delhi, 2002

REFERENCES:

1. Logothetis W, “Management Total Quality”, Prentice Hall of India,

New Delhi, 1999.

2. Feigenbaum A.V., “Total Quality Management”, McGraw-Hill, 1991.

3. Narayana V. and Sreenivasan N.S., “Quality Management – Concepts

and Tasks”, New Age International, 1996.

29


COMPUTER AIDED DESIGN AND OPTIMIZATION LAB


Prerequisites: CAD and Optimization methods 0 3 2


To impart knowledge to the student to

1. learn part modeling and their assemblies, drafting and animation of

the mechanical components using modelling packages

2. understand static and transient thermal analysis using FEA packages

3. carry out single and multi objective optimization problems using

MATLAB

Course Outcomes:


1. create part model and assembly model of various components using

modelling packages

2. perform static and transient thermal analysis using FEA packages

3. solve optimization problems using MATLAB

Note: Any ten exercises from the following

Introduction to various commands in solid modeling software

1. Part modeling of various components

2. Part modeling of fasteners like nut, bolt, screw, rivet etc.

3. Part modeling of I. C. engine parts

4. Drafting of I. C. engine parts

5. Assembly of screw jack

6. Animation of four bar mechanism

Introduction to various commands in analysis software 7. Static analysis of a corner bracket

8. Static analysis of truss

9. Analysis of cylindrical shell under pressure

10. Transient thermal stress in a cylinder

Introduction to various commands in MATLAB software 11. To carry out unconstrained non-linear single variable

optimization

12. To carry out unconstrained non-linear multivariable optimization

13. To carryout multi-objective optimization

14. Exercise on use of Genetic algorithm toolbox

Modelling packages: CATIA, UNIGRAPHICS, Pro-E

Analysis packages: ANSYS, NISA

Optimization: MATLAB 30


COMPUTER NUMERICAL CONTROL MACHINES


4 0 3

Prerequisites: Machine Tools



1. computer aided technologies used in manufacturing

2. various programming techniques of CNC machines

3. application of adaptive control in CNC machine

Course Outcomes:


1. explain NC, CNC and DNC machines

2. write manual part program for various machining operations

3. write computer aided part program for various machining

operations

4. apply adaptive control in CNC machine

UNIT-I:

Introduction: NC, DNC, CNC, Programmed Automations, Machine

control unit, Part program, NC tooling. NC machine tools:

Nomenclature of NC machine axes, Types of NC machine tools,

Machining centres, Automatic tool changers (ATC), Turning centres.

UNIT-II:

Machine control unit & tooling: Functions of MCU, NC actuation

systems, Part program to command signal, MCU organization,

Computerized numerical control, Transducers for NC machine tools,

Tooling for NC machining centres and NC turning machines, Tool

presetting. Adaptive control of CNC machine tools – SMART

manufacturing. Programmable logic controllers (PLC) – Hardware,

ladder logic programming of PLCs using basic functions – timers and

counters – Advanced programming with control and arithmetic

instructions.

31


UNIT-III:

Manual part programming: Part program instruction formats,

Information codes: Preparatory function, Miscellaneous functions, Tool

code and tool length offset, Interpolations, Canned cycles. Manual part

programming for drilling, milling and turning operations, Parametric

subroutines.

UNIT-IV:

APT programming: APT language structure, APT geometry: Definition

of point, time, vector, circle, plane, patterns and matrices. APT motion

commands: setup commands, point-to-point motion commands,

continuous path motion commands. Post processor commands,

complication control commands. Macro subroutines. Part programming

preparation for typical examples.

UNIT-V: Computer aided part programming: NC languages: NELAPT, EXAPT,

GNC, VNC, Preprocessor, Post processor.

Adaptive control systems: Introduction, adaptive control with

optimization for a milling machine, adaptive control with constraints for

lathe, adaptive control of grinding

TEXT BOOKS:

1. P.N. Rao, “CAD/CAM”, 2e,TMH, 2005.

2. Yoram Koren, “Computer control of Manufacturing Systems”,

6e,TMH, 2009.

REFERENCES:

1. Mikell P.Groover, “Automation, Production systems and computer

Integrated manufacturing” 8e,PHI, 2008.

2. D S N Murthy,” CNC Applications & Programming Techniques”,

1e, Goutam publications, 2003.

32


ADVANCED MANUFACTURING TECHNOLOGY


4 0 3

Prerequisites: Manufacturing Technology



1. fundamentals of machining

2. various cutting tool materials and cutting fluids

3. concepts of special machining and high speed machining processes

4. principles of non-traditional and micro machining processes

Course Outcomes:


1. suggest appropriate cutting tool materials and cutting fluids in

machining operations

2. explain the applications of special machining and high speed

machining processes

3. explain various non-traditional and micro machining processes

UNIT I Fundamentals of machining: Introduction - mechanics of cutting -

cutting forces and power - temperatures in cutting, Tool life, wear and

failure, surface finish, integrity and Machinability

UNIT II Cutting tool materials and cutting fluids: Introduction - High-Speed

Steels - cast-cobalt alloys - carbides - coated tools - alumina-based

ceramics - cubic boron nitride – silicon nitride based ceramics - diamond

– whisker reinforced tool materials - reconditioning of tools - cutting

fluids

UNIT III

Special machining: Deep hole drilling – gun drills – gun boring –

trepanning – honing – lapping – super finishing – AFM – MAF –

burnishing – broaching

High speed machining, application of HSM – tools for HSM - design of

tools for HSM – high speed and high performance grinding – ultra

precision machining 33


UNIT IV

Non-traditional machining: Introduction – USM, WJM, AWJM, LBM,

EBM, plasma machining ,hybrid machining processes, electro-discharge

machining (EDM) and electro-chemical machining (ECM) – mechanism

of metal removal, characteristic features and applications

UNIT V

Micro machining: various micro machining processes, application of

micro machining in semi conductor IC technology, micro actuator and

micro sensors – CVD, PVD and Ion implantation

TEXT BOOK: 1.S.Kalpakjian and S.R.Schmid, “Manufacturing Engineering and

Technology”, 4e, Pearson Education, 2001.

REFERENCES: 1. Boothroyd G. and Knight W.A., “Fundamentals of Metal

Machining and Machine Tools”, 1e, Marcel Dekker,1989.

2. P.C.Pandey and Shaw, “Modern Machining Process”, TMH,

1980.

3. Gunashekaran A, “Agile Manufacturing”, Elsevier, 2001.

34


INDUSTRIAL ROBOTICS


4 0 3 Pre requisites: Automation in Manufacturing


To impart knowledge on

1. robot configurations and components

2. sensors and actuators used in Robotics

3. programming techniques for industrial robots

4. kinematic and dynamic analysis for simple planar robots

5. robot cell design and applications

Course Outcomes:


1. identify various robot configurations and components

2. select appropriate actuators and sensors for a robot based on specific

application

3. carry out kinematic and dynamic analysis for simple serial kinematic

chains

4. write a program for pick and place operations

5. design a cell for a small manufacturing unit

4 0 4

UNIT–I Introduction: Automation and robotics. robot anatomy, robot

configuration motions, joint notation, work volume, robot drive systems,

control systems and dynamic performance, precision of movement

Control systems and components: Basic concepts and models,

controllers, control system analysis, robot activation and feedback

components, position sensors, velocity sensors, actuators, power

transmission systems

UNIT–II Motion analysis and control: Manipulator kinematics, position

representation forward transformation, homogenous transformations,

manipulator path control robot dynamics, configuration of a robot

controller 35


UNIT–III End effectors: Grippers-types, operation, mechanism, force analysis,

tools as end effectors, considerations in gripper selection and design

Sensors: Desirable features, tactile, proximity and range sensors, uses of

sensors in robotics

UNIT–IV Machine vision: Functions, sensing and digitizing-imaging, devices,

lighting techniques, analog to digital signal conversion, image storage,

image processing and analysis-image data reduction, segmentation,

feature, extraction, object recognition, training the vision system,

robotics applications

Robot programming and Languages: Lead through programming, robot

programming as a path in space, motion interpolation, WAIT, SIGNAL

and DELAY commands, branching capabilities and limitations. Textual

robot languages, generations, robot language structures, elements in

functions.

UNIT-V Robot cell design and control: Robot cell layouts-robot centered cell,

inline robot cell, mobile robot cell, considerations in work design, work

cell control, inter locks, errors detection, work cell controller

Robot applications: material transfer, machine loading/unloading,

processing operations, assembly and inspections

TEXT BOOK:

1. M.P Groover, M Weiss, R M gnagel and N G Ordrey,

“Industrial Robotics”, Tata McGraw-Hill, New Delhi, 2008.

REFERENCES:

1. R.K. Mittal, I J Nagrath, “ Robotics and Control”, Tata McGraw Hill,

2003, 6th

Reprint, 2007, New Delhi.

2. S. K. Saha, “Introduction to Robotics” , McGraw-Hill Education

India, New Delhi, 2008.

3. Saeed B. Niku, “Introduction to Robotics: Analysis, Systems,

Application” , Pearson education, 2011.

36


DESIGN OF FLUID POWER SYSTEMS


4 0 3

Pre requisites: Fluid mechanics, Hydraulic machinery



1. different components of hydraulic and pneumatic power systems such

as pumps, motors, direction control valves

2. design of hydraulic and pneumatic circuits for selected industrial

applications

3. electrical controls in fluid power systems

Course Outcomes:


1. select suitable pump, motor and other components for a specified

application

2. design the circuit for a given application and execute the same in

industry

3. attend to maintenance and trouble shooting of fluid power systems in

industry

UNIT-I Introduction to hydraulic systems and ancillary hydraulic systems:

Introduction to hydraulic systems, design and construction of hydraulic

reservoir and sizing, gravity type, spring-loaded and gas loaded type

accumulators

Hydraulic pumps: Gear pumps, vane pumps and piston pumps, sizing of

hydraulic pumps, selection of hydraulic pumps

UNIT-II

Hydraulic control valves: direction control valves, pressure control

valves, flow control valves, servo valves

Hydraulic cylinders and motors: hydraulic cylinder operation and

cylinder mountings - hydraulic cylinder design and cushions, hydraulic

motors - gear, vane and piston motors – hydraulic motor theoretical

torque, power and flow rate - hydraulic motor performance - hydrostatic

transmissions 37


UNIT-III

Hydraulic circuit design and analysis: Control of single and double

acting cylinders, regenerative and pump unloading circuit, hydraulic

cylinder sequence and synchronizing circuits, speed control of hydraulic

cylinder and motor, hydraulic motor breaking system

UNIT-IV

Pneumatics: Basic requirements for pneumatic system – air compressor

– pneumatic cylinders and air motors – pneumatic valves - basic

pneumatic circuits

Maintenance and trouble shooting of hydraulic and pneumatic systems:

oxidation and corrosion of hydraulic fluids - maintaining and disposing

of fluids - wear of moving parts due to solid particle contamination of

the fluid - problems caused by gases in hydraulic fluids - troubleshooting

of hydraulic system - maintenance and troubleshooting of pneumatic

systems

UNIT – V

Electrical controls in fluid power systems: Basic electrical devices –

electrical components, electrical controls in pneumatic systems,

examples of simple electro-pneumatic circuits with solenoid operated

direction control valve for the control of single and double-acting

cylinders

TEXT BOOKS:

1. Anthony Esposito, “Fluid Power with Applications” Sixth Edition,

Pearson Education, Inc.New Delhi, 2003.

2. S.R.Majumdar, “Pneumatic Systems – Principles and Maintenance”,

Tata McGraw Hill Publishing Company Limited, New Delhi, 1995

REFERENCES:

1. S.R.Majumdar, “ Oil Hydraulic Systems – Principles and

Maintenance”, Tata McGraw Hill Publishing Company Limited, New

Delhi, 2012.

2. Andrew Parr, “Hydraulics and Pneumatics – A Technician’s and

Engineer’s Guide”, NinethJaico Impression, Jaico Publishing House,

Mumbai, 2005

3. www.pneumatics.com

4. www.fluidpower.com.tw 38


http://www.fluidpower.com.tw/

FLEXIBLE MANUFACTURING SYSTEM


4 0 3

Pre requisites: Automation in Manufacturing



1. automation strategies used in flexible manufacturing system (FMS)

2. computer control and software used in modern manufacturing

systems

3. group technology and FMS planning

4. components of FMS and support equipments used

Course Outcomes:


1. explain the concept of modern automated manufacturing system

2. describe planning and scheduling methods used in manufacturing

systems

3. suggest advanced material transport equipments

4. explain different types of co-ordinate measuring machines

5. identify the hierarchy of computers used in FMS

6. select suitable database and software required for FMS

UNIT-I

Types of production, production planning and control, manufacturing in

a competitive environment, concept, automation of manufacturing

process , numerical control, adaptive control, material handling and

movement, industrial robots, flexible fixturing, design for assembly,

disassembly and service. types of FMS, types of FMS layouts,

advantages and disadvantages of FMS

Group technology – composite part families - classification and coding -

production flow analysis,

UNIT-II

Planning issues: components of FMS, types of flexibility, tradeoffs,

computer control and functions, planning, scheduling and control of

FMS, scheduling and knowledge-based scheduling.

Hierarchy of computer control, supervisory computer, introduction to

turning center, machining center, cleaning and deburring equipment,

coordinate measuring machines: types, working and capabilities. 39


UNIT-III

System support equipment, types, working capability, automated

material movement and automated storage and retrieval systems,

scheduling of AGVs, cutting tools and tool management, work holding

considerations

FMS computer hardware and software, general structure and

requirements, PLCs, FMS installation and implementation, acceptance

testing

UNIT-IV

Computer software, simulation and database of FMS: System issues,

types of software, specification and selection, trends, application of

simulation, software, manufacturing data systems, data flow, CAD/CAM

considerations, planning FMS database

UNIT-V

Characteristics of JIT pull method, small lot sizes, work station loads,

flexible work force, line flow strategy. supply chain management

Preventive maintenance - Kanban system, value engineering, MRD JIT,

lean manufacture, quality concepts and management

TEXT BOOK:

1. Shivanand H.K., Benal MM, Koti V, “Flexible Manufacturing

System”, New age international (P) Limited, New Delhi, 2006

REFERENCES:

1. Mikell P. Groover “Automation, Production Systems and

Computer Integrated Manufacturing", PHI, 2008.

2. Kalpakjin, “Manufacturing Engineering and Technology ",

Addison-Wesley Publishing Co., 1995.

40


DESIGN AND ANALYSIS OF EXPERIMENTS

(Elective - II)


4 0 3

Pre requisites: Probability and Statistics


To make the student learn

1. the effect of input factors on the output parameters

2. design of experiments by different methods

3. to develop regression models and response surface methods

Course Outcomes:


1. conduct the experiment by using factorial and fractional factorial

design

2. fit the best model for the given experimental data

3. check the adequacy of the regression model using ANOVA

4. optimize using response surface method

UNIT-I Strategy of experimentation: guidelines for designing experiments,

sampling and sampling distributions, hypothesis testing, choice of

sample size.

Experiments with single factor: analysis of variance, analysis of the

fixed effects model, model adequacy checking, sample computer output,

regression approach to the analysis of variance.

UNIT-II Factorial designs: principles, advantage of factorials, two-factor factorial

design, general factorial design, fitting response curves and surfaces.

2k

factorial design: 22 design, 2

3 design, General 2

k design, single

replicate of 2k design.

UNIT-III Two-level fractional factorial designs: one-half fraction of 2

K design,

one-quarter fraction of 2K design, blocking replicated 2

K factorial design,

confounding in 2K factorial design

41


Three-level and mixed-level factorial design: 3K factorial design,

confounding in 3K factorial design, fractional replication of 3

K factorial

design, factorials with mixed levels.

UNIT-IV Regression models: Linear regression models, estimation of the

parameters, hypothesis testing in multiple regression, confidence

intervals in multiple regression, prediction of new response

observations, regression model diagnostics.

UNIT-V Response surface methods: introduction, method of steepest ascent,

analysis of second-order response surface, experimental designs for

fitting response surfaces.

TEXT BOOK:

1.D.C. Montgomery, “Design and Analysis of Experiments”, 5th

edition,

John Wiley and sons, 2009.

REFERENCES:

1. D.C. Montgomery,” Introduction to Statistical Quality Control”, 4th

edition, John Wiley and sons, 2001.

2. Angela Dean and Daniel Voss, “Design and Analysis of

Experiments”, Springer, 1999

42


INTELLIGENT MANUFACTURING SYSTEMS

(Elective - II)


4 0 3

Prerequisites: Computer Aided Manufacturing


To provide students with the concepts of

1. planning manufacturing systems

2. computer integrated manufacturing and enterprise integration

3. group Technology

4. knowledge based systems

Course Outcomes:

The student will gain the knowledge and skills to

1. assess the performance of manufacturing systems

2. develop a systematic approach for design and implementation of

manufacturing systems

3. suggest new procedures to improve the productivity of existing

manufacturing systems

4. utilise online collaboration tools to work in complex teams

UNIT I

Computer integrated manufacturing systems – structure and functional

areas of CIM system - AD, CAPP, CAM, CAQC, ASRS and advantages

of CIM

Manufacturing communication systems – MAP/TOP OSI model, data

redundancy, top-down and bottom-up approach, volume of information.

Intelligent manufacturing – system components, system architecture and

data flow, system operation

UNIT II

Components of knowledge based systems – basic components of

knowledge based systems, knowledge representation, comparison of

knowledge representation schemes, interference engine, knowledge

acquisition 43


Machine learning – concept of artificial intelligence, conceptual

learning, artificial neural networks -biological neuron, artificial neuron,

types of neural networks, applications in manufacturing

UNIT III: Automated process planning – variant approach, generative approach,

expert systems for process planning, feature recognition, phases of

process planning

Knowledge Based System for Equipment Selection (KBSES) –

Manufacturing system design, equipment selection problem, modelling

the manufacturing equipment selection problem, problem solving

approach in KBSES, structure of the KBSES

UNIT IV: Group technology: models and algorithms – visual method, coding

method, cluster analysis method, matrix formation – similarity

coefficient method, sorting-based algorithms, bond energy algorithm,

cost based method, cluster identification method, extended ci method.

UNIT V: Knowledge based group technology - group technology in automated

manufacturing system, structure of knowledge based system for group

technology (KBSGT) – data base, knowledge base, clustering algorithm

TEXT BOOKS:

1. Mikell P. Groover, “Automation, Production Systems and Computer

Integrated Manufacturing”, 8th

edition, PHI, 2008.

2. Yagna Narayana, “Artificial Neural Networks”, PHI, 2009.

REFERENCES:

1. Andre Kusaic, “ Intelligent Manufacturing Systems”, PHI,1989

2. Hamid R. Parsaei and Mohammad Jamshidi, “Design and

Implementation of Intelligent Manufacturing Systems”, PHI, 2009

44


COMPUTER AIDED PROCESS PLANNING

(Elective - II)


4 0 3

Prerequisites: Computer Aided Manufacturing



1. fundamentals of computer aided process planning

2. group technology and applications

3. simulation of machining processes

4. importance of design and manufacturing tolerances

5. role of optimal selection of machining parameters

Course Outcomes:


1. generate the structure of automated process planning system

2. use the principle of generative CAPP system for automation

3. predict the effect of machining parameters on production rate, cost

and surface quality

4. solve optimization models of machining processes

5. develop awareness about the concept of concurrent engineering

UNIT – I

Introduction to CAPP: Information requirement for process planning

system, role of process planning, advantages of conventional process

planning over CAPP, structure of automated process planning system,

feature recognition, methods

Generative CAPP system: Importance, principle of generative CAPP

system, automation of logical decisions, knowledge based systems,

inference engine, implementation, benefits

Retrieval CAPP system: Significance, group technology, structure,

relative advantages, implementation, and applications

UNIT-II

Process planning and concurrent engineering: process planning, CAPP,

concurrent engineering, design for manufacturing, advanced

manufacturing planning 45


Selection of manufacturing sequence: Significance, alternative-

manufacturing processes, reduction of total set-up cost for a particular

sequence, quantitative methods for optimal selection, examples

UNIT –III

Determination of machining parameters: reasons for optimal selection of

machining parameters, effect of parameters on production rate, cost and

surface quality, different approaches, advantages of mathematical

approach over conventional approach, solving optimization models of

machining processes

Determination of manufacturing tolerances: design tolerances,

manufacturing tolerances, methods of tolerance allocation, sequential

approach, integration of design and manufacturing tolerances,

advantages of integrated approach over sequential approach

UNIT –IV

Generation of tool path: Simulation of machining processes, NC tool

path generation, graphical implementation, determination of optimal

index positions for executing fixed sequence, quantitative methods

UNIT –V

Implementation techniques for CAPP: MIPLAN system, Computer

programming languages for CAPP, criteria for selecting a CAPP system

and benefits of CAPP, computer integrated planning systems, and

capacity planning system

TEXT BOOKS:

1. Mikell P. Groover, “Automation, Production systems and Computer

Integrated Manufacturing”, 8th

edition, PHI, New Delhi, 2010.

2. Dr. Sadhu Singh, “Computer Aided Design and manufacturing”,

Khanna publishers, 2000.

REFERENCES: 1. Change T C and Richard A Wysk, “An Introduction to automated

process planning systems”, Prentice Hall, 1985.

2. H.P. Wang and J.K. Li, “Computer Aided Process Planning”, Elsevier

Science and Technology Publishers, 1st edition,1991.

46


COMPUTER GRAPHICS

(Elective - II)


4 0 3

Pre requisites: Computer Aided Design



1. basics of colour raster scan display devices and draw lines and

circles on it

2. fill polygons and clip lines and polygons against a window

3. procedures for transformation, rendering and shading of objects

4. hidden line removal algorithms

Course Outcomes:


1. draw lines and circles on colour raster scan display devices

2. fill polygons and clip lines and polygons against a window

3. transform, render and shade objects

4. eliminate hidden lines and surfaces using algorithms

UNIT – I Transformations: Cartesian and homogeneous coordinate systems two

dimensional and three dimensional transformations – scaling, rotation,

shearing, zooming, viewing transformation, reflection, rotation about an

axis, concatenation

UNIT –II Surface generation: Shape description requirements, parametric

functions, Bezier methods, Bezier curves, Bezier surfaces, B-Spline

methods

Unit –III Mesh generation: Meshes, Mesh elements, types of mesh operations ,

mesh representation, traversal operations , Face based mesh

representation, Half edge data structures, Constructing a mesh data

structure, constructing a half edge base mesh data structure, sub division

of surfaces, subdivision of splines, Constructing rules, Examples. 47


UNIT-IV

Solid modeling: Introduction to solid modelling, Implicit representation:

primitives and skeletal elements, combination of fields – Boolean

operations, polygonization, Solids modeling by boundary representation

and CSG.

UNIT- V Rendering and shading algorithms: Rendering - Hidden line removal

algorithms, surface removal algorithms, painters, Warnock, Z-buffer

algorithm

Shading algorithms - Constant intensity algorithm, Phong‟s shading

algorithm, Gourand shading algorithm, comparison of shading

algorithms

TEXT BOOKS:

1. D.F.Rogers , “Procedural elements for computer graphics”,

2e, TMH, 1998.

2. Donald Hearn & M.P. Bakers, “ Computer Graphics”, 2e,

Prentice-Hall, 1994.

REFERENCES:

1. Harrington, “Computer graphics”, 2e, TMH, 1987.

2. Smartech.gatech.edu/bitstream/ handle.

48


ADVANCED NON-DESTRUCTIVE TESTING TECHNIQUES

(Elective - II)


4 0 3

Pre requisites: Metrology


Understanding the basic principles of various NDT methods,

fundamentals, discontinuities in different product forms, importance of

NDT, applications, limitations of NDT methods and techniques and

codes, standards and specifications related to non-destructive testing

technology.

Course Outcomes:


1. Identify various surface and sub- surface flaws and inclusions by

using different NDT techniques .

2. apply magnetic particle inspection, ultrasound inspection, x-ray

inspection for flaw detection

3. interpret radiographs and sonographs

UNIT- I

Liquid penetrant tests: characteristics of liquid penetrants – different

washable systems – developers – applications

Magnetic particle tests: methods of production of magnetic fields-

principles of operation of magnetic particle test- applications-advantages

and limitations

UNIT-II

Radiography: Sources of ray X-ray production-properties of γ and X-

rays – film characteristics – exposure charts – contrasts – operational

characteristics of X- ray equipment – applications

Industrial Computed Tomography (CT): Computed Tomography, X-Ray

Detectors - CT image reconstruction algorithm - Capabilities,

comparison to other NDT methods - industrial CT applications, CT

System design and equipment.

Ultrasonic techniques: Production of ultrasonic waves – different types

of waves - general characteristics of waves – pulse echo method – A, B,

C scans

UNIT- III

Acoustic emission techniques: Principles of acoustic emission

techniques – advantages and limitations - instrumentation – applications 49


Acoustical Holography: Liquid Surface Acoustical Holography - Optical

System, Object size and shape, sensitivity and resolution, commercial

liquid surface equipment – Scanning Acoustical Holography -

Reconstruction, Object size, Sensitivity and resolution, Commercial

Scanning equipment - Comparison of liquid surface and scanning

systems – Read out methods, calibration, Interpretation of results -

Applications - Inspection of welds in thick materials.

UNIT –IV

Principles of Thermography: Contact and non contact inspection

methods - Heat sensitive paints - Heat sensitive papers - thermally

quenched phosphors liquid crystals - techniques for applying liquid

crystals - calibration and sensitivity - other temperature sensitive

coatings - non contact thermographic inspection - Advantages and

limitation - infrared radiation and infrared detectors, Instrumentations

and methods, applications.

UNIT –V

Optical Holography and Speckle Metrology: Laser fundamentals –

coherence – types of lasers – holography, recording and reconstruction –

holographic interferometry – real-time, double-exposure & time-

averaged techniques – holographic NDT – methods of stressing

andfringe analysis – typical applications – requirements – advantages

and disadvantages – laser speckle metrology basics – electronic speckle

pattern interferometry (ESPI) – shearography –applications.

TEXT BOOKS: 1. Barry Hulland Vernon John, "Non-destructive Testing”,MacMilan,

1988.

REFERENCES:

1. Miller, Ronnie; and Paul Mclntire, "Non-Destructive Testing

Handbook; Acoustic Emission Testing", VoL-5, 2e, Columbus, OH:

American Society for Non-Destructive Testing, 1987.

2. Spanner, J.C. “Acoustic Emission Techniques and Applications,

Evanston, I, L.: latex Publishing Co., 1974.

3. American Metals Society. Non-Destructive Examination and

QualityControl:MetalsHandBook,Vol-17,9th

Ed,Metals Park, 1989.

4. Dewit, D.P., “Theory and Practice of Radiation Thermometry”,

Wiley-lnterscience, John Wiley & Sons, Inc, 1989.

5. Non - Destructive Evaluation and Quality control, ASM Hand book,

Vol. 17. 50


COMPUTER AIDED MANUFACTURING AND ROBOTICS LAB


0 3 2

Prerequisites: Computer aided design and Computer aided

manufacturing


To impart knowledge on

1. CAM software for modelling the components

2. generating the NC code and tool path for machining

3. robot programming and kinematic analysis for simple planar robots

Course Outcomes:


1. use the software for creating the part model

2. use the software to generate the tool path for machining the

component and NC code

3. write a program for performing pick and place operations

List of Experiments

1. Tool planning and selection of sequences of operations, tool setting

on machine - Practice

2. Practice in G & M code based CNC programming for the use on a

turning machine

3. Practice in G & M code based CNC programming for the use on a

machining center / milling machine

4. Creating a 2D part and contour tool path using CAM software

5. Creating 3D geometry in CAM software

6. NC code generation and tool path simulation for drilling operations

using CAM software

7. NC code generation and tool path simulation for facing operations

using CAM software

8. NC code generation and tool path simulation for pocket milling

operations using CAM software

51


9. NC code generation and tool path simulation for profile milling


10. NC code generation and tool path simulation for plane and step

turning operations using CAM software

11. NC code generation and tool path simulation for threading


12. Practice in Robot programming and its languages

13. 3-D Robot simulation for operation of pick-place robot

Software: Master CAM, Pro-E

52


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