M.TECH DESIGN FOR MANUFACTURING - DESIGN AND …

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD

M.Tech in DESIGN FOR MANUFACTURING/ DESIGN AND MANUFACTURING Effective from Academic Year 2017- 18 admitted batch

COURSE STRUCTURE AND SYLLABUS

I Semester

Category Course Title Int. marks Ext. marks L T P C PC-1 Advanced Mechanics of Solids 25 75 4 0 0 4 PC-2 Material Technology 25 75 4 0 0 4 PC-3 Design for Manufacturing & Assembly 25 75 4 0 0 4 PE-1 1. MEMS & Micro Systems : Design &

Manufacture 2. Advanced Finite Element Analysis 3. Special Manufacturing Processes

25 75 3 0 0 3

PE-2 1. Advanced Computer Aided Design 2. Theory of Elasticity & Plasticity 3. Quality Engineering in Manufacturing

25 75 3 0 0 3

OE-1 *Open Elective - I 25 75 3 0 0 3 Laboratory I CAD/CAM Lab 25 75 0 0 3 2 Seminar I Seminar-I 100 0 0 0 3 2

Total 275 525 21 0 6 25

II Semester

Category Course Title Int. marks Ext. marks L T P C PC-4 Design of Hydraulic and Pneumatic Systems 25 75 4 0 0 4 PC-5 Precision Engineering 25 75 4 0 0 4 PC-6 Advanced Tool Design 25 75 4 0 0 4 PE-3 1. Intelligent Manufacturing Systems

2. Product Data Management 3. Fuzzy Logic and Neural Networks

25 75 3 0 0 3

PE4 1. Optimization Techniques and Applications 2. Smart Materials & Structures 3. Vibration Analysis & Condition Monitoring

25 75 3 0 0 3

OE-2 *Open Elective - II 25 75 3 0 0 3 Laboratory II Manufacturing Simulation & Precision

Engineering Lab 25 75 0 0 3 2

Seminar II Seminar-II 100 0 0 0 3 2 Total 275 525 21 0 6 25

III Semester

Course Title Int. marks

Ext. marks

L T P C

Technical Paper Writing 100 0 0 3 0 2 Comprehensive Viva-Voce 0 100 0 0 0 4 Project work Review II 100 0 0 0 22 8

Total 200 100 0 3 22 14

IV Semester

Course Title Int. marks

Ext. marks

L T P C

Project work Review III 100 0 0 0 24 8 Project Evaluation (Viva-Voce) 0 100 0 0 0 16

Total 100 100 0 0 24 24 *Open Elective subjects must be chosen from the list of open electives offered by OTHER departments. # For Project review I, please refer 7.10 in R17 Academic Regulations.

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD M. Tech – I year II Sem. (Design for Manufacturing)

DESIGN OF HYDRAULIC AND PNEUMATIC SYSTEMS (PC - 4)

UNIT – I: Oil hydraulic systems Hydraulic pumps, types and construction details, sizing and selection. Direction control valves, flow and pressure control valves. UNIT – II: Linear actuators types Piston rod design sizing and selection, Rotary actuators, hydraulic reservoir accumulators. UNIT – III: Design of hydraulic circuits, seals and packings, hydraulic servo techniques, cylinders and air motors. UNIT – IV: Sequencing and synchronizing circuits, accumulator, low cost automation Hydro circuits, accumulators, Hydro pneumatic circuits principles of pneumatic circuit design. UNIT – V: Maintenance and trouble shooting of hydraulic and pneumatic circuits, components, PLC Automation and uses of Microprocessors. REFERENCES:

1. Oil Hydraulic Systems/ S.R. Majumdar/ Tata McGraw Hill 2. Pneumatic systems, principles and maintenance/ S.R. Majumdar/Tata McGraw Hill 3. Hydraulic and pneumatics/ Andrew Darr/ Jaico Publishing Hoise. 4. Fluid power with applications/ Antony Esponssito/ Prentice Hall

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD M. Tech – I year I Sem. (Design for Manufacturing)

PRECISION ENGINEERING (PC – 5)

UNIT - I: Concepts of Accuracy: Introduction – Concept of Accuracy of Machine Tools – Spindle and Displacement Accuracies – Accuracy of numerical Control Systems – Errors due to Numerical Interpolation Displacement Measurement System and Velocity lags. Geometric Dimensioning and Tolerancing: Tolerance Zone Conversions – Surfaces, Features, Features of Size, Datum Features – Datum Oddly Configured and Curved Surfaces as Datum Features, Equalizing Datums – Datum Feature of Representation – Form controls, Orientation Controls – Logical Approach to Tolerancing. UNIT - II: Datum Systems: Design of freedom, Grouped Datum Systems – different types, two and three mutually perpendicular grouped datum planes; Grouped datum system with spigot and recess, pin and hole; Grouped Datum system with spigot and recess pair and tongue – slot pair – Computation of Transnational and rotational accuracy, Geometric analysis and application. UNIT - III: Tolerance Analysis: Process Capability, Mean, Variance, Skewness, Kurtosis, Process Capability Metrics, Cp, Cpk, Cost aspects, Feature Tolerances, Geometric Tolerances. Surface finish, Review of relationship between attainable tolerance grades and different machining process, Cumulative effect of tolerances sure fit law, normal law and truncated normal law. UNIT - IV: Tolerance Charting Techniques: Operation Sequence for typical shaft type of components, Preparation of Process drawings for different operations, Tolerance worksheets and centrally analysis, Examples, Design features to facilitate machining; Datum Features – functional and manufacturing Components design – Machining Considerations, Redesign for manufactured, Examples. UNIT - V: Fundamentals of Nanotechnology: Systems of nanometer accuracies – Mechanism of metal Processing – Nano physical processing of atomic bit units. Nanotechnology and Electrochemical atomic bit processing. Measuring Systems Processing: In processing or in-situ measurement of position of processing point-Post process and on-machine measurement of dimensional features and surface-mechanical and optical measuring systems. REFERENCES:

1. Precision Engineering in Manufacturing/Murthy R.L./New Age International (P) limited, 1996. 2. Geometric Dimensioning and Tolerancing / James D. Meadows / Marcel Dekker inc. 1995. 3. Nano Technology / Norio Taniguchi / Oxford University Press, 1996. 4. Engineering Design – A systematic Approach / Matousek / Blackie & Son Ltd., London 5. Precision Engineering/VC Venkatesh & S Izman/TMH


ADVANCED TOOL DESIGN (PC – 6)

UNIT – I: Tool Materials: Prosperities of materials: Tools steels, Cast Iron, Mild or low carbon steels, Non metallic and nonferrous materials, Heat treating UNIT – II: Design of Cutting Tools: Single Point cutting tools: Milling cutters, Drills, Selection of carbide steels – Determination of shank size for single point carbide tools, Determining the insert thickness for carbide tools UNIT – III: Design of Jigs and Fixtures: Basic principles of location and clamping: Locating methods and devices, Jigs-Definition Types, General considerations in the design of Drill jigs, Drill bushing, Methods of Construction. Fixtures-Vice fixtures, Milling, Boring Lathe Grinding fixtures. UNIT – IV: Design of Sheet Metal Blanking and Piercing Dies: Fundamentals of Die cutting operation, Power press types, General press information, Materials Handling equipment. Cutting action in Punch and die operations. Die clearance, Types of Die construction. Die design fundamentals-Banking and piercing die construction, pilots, stripper and pressure pads presswork material, Strip layout, Short run tooling for piercing. UNIT – V: Design of Sheet Metal Bending, Forming and Drawing Dies: Bending dies, Drawing dies, Forming dies, Drawing operations, Variables that effect metal flow during drawing. Determination of blank size, Drawing force, Single and double action draw dies. REFERENCES:

1. Donaldson “Tool Design”/ Tata McGraw Hill 2. Production Technology/HMT/Tata McGraw Hill/ 3. Production Technology by R.K. Jain and S.C. Gupta. 4. Mechanical Metallurgy/ George F Dieter/ Tata McGraw Hill 5. Machine Tools/C Elanchezhian & M. Vijayan/Anuradha Publications 6. Principles of Machine Tools, Bhattacharya A and Sen. G.C. New Central Book Agency 7. Hand Book of Metal forming/ Kurt Lange/ Mc Graw-Hill,.1987


INTELLIGENT MANUFACTURING SYSTEMS (Professional Elective – 3)

UNIT - I: Computer Integrated Manufacturing Systems Structure and functional areas of CIM system, - CAD, CAPP, CAM, CAQC, ASRS. 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. UNIT - III: Machine Learning - Concept of Artificial Intelligence, Conceptual Learning, Artificial Neural Networks - Biological Neuron, Artificial Neuron, Types of Neural Networks, Applications in Manufacturing. UNIT - IV: 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, Modeling the Manufacturing Equipment Selection Problem, Problem Solving approach in KBSES, Structure of the KRSES. UNIT - V: 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. Knowledge Based Group Technology - Group Technology in Automated Manufacturing System. Structure of Knowledge based system for group technology (KBSCIT) — Data Base, Knowledge Base, Clustering Algorithm. REFERENCES:

1. Intelligent Manufacturing Systems/ Andrew Kusiak/Prentice Hall. 2. Artificial Neural Networks/ Yagna Narayana/PHI/2006 3. Automation, Production Systems and CIM / Groover M.P./PHI/2007 4. Neural networks: A comprehensive foundation/ Simon Haykin/ PHI. 5. Artificial neural networks/ B. Vegnanarayana/PHI 6. Neural networks in Computer intelligence/ Li Min Fu/ TMH/2003 7. Neural networks/ James A Freeman David M S kapura/ Pearson education/2004 8. Introduction to Artificial Neural Systems/Jacek M. Zurada/JAICO Publishing House Ed. 2006.


PRODUCT DATA MANAGEMENT (Professional Elective – 3)

UNIT - I: Introduction-Need for IPPD – strategic importance of product development – integration of customer, designer, material supplier and process planner, Competitor and costumer – behavior analysis. Understanding customer – promoting customer understanding – involve customer in development and managing requirements – Organization – process management and improvement – Plan and establish product specification. UNIT - II: Concept Generation and Selection: Task – Structured approaches – Clarification – Search – Externally and internally – explore systematically – reflect on the solutions and process – concept selection – methodology – benefits. Product Architecture: Implications – Product change – variety – component standardization – product performance – manufacturability. UNIT - III: Product Development Management: Establishing the architecture – creation – clustering – geometric layout development – fundamental and incidental interactions – related system level design issues – secondary systems – architecture of the chunks – creating detailed interface specifications. Industrial Design: Integrate process design – Managing costs – Robust design – Integrating CAE, CAD, CAM tools – simulating product performance and manufacturing processing electronically – Need for industrial design – impact – design process. UNIT - IV: Investigation of customer needs – conceptualization – refinement – management of the industrial design process – technology driven products – user – driven products – assessing the quality of industrial design. UNIT - V: Design for Manufacturing and Product Development: Definition – Estimation of manufacturing cost – reducing the component costs and assembly costs – Minimize system complexity. Prototype basics – Principles of prototyping – planning for prototypes – Economics analysis – Understanding and representing tasks – baseline project planning – accelerating the project execution. REFERENCES:

1. Product Design and Development / Kari T. Ulrich and Steven D. Eppinger / McGraw Hill International Edns. 1999.

2. Concurrent Engg/integrated Product development / Kemnneth Crow / DRM Associates, 26/3, Via Olivera, Palos Verdes, CA 90274(310)377-569, Workshop Book.

3. Effective Product Design and Development / Stephen Rosenthal / Business One Orwin, Homewood, 1992, ISBN, 1-55623-603-4.

4. Tool Design–Integrated Methods for Successful Product Engineering / Staurt Pugh / Addsion Wesley Publishing, Neyourk, NY, 1991, ISBN 0-202-41369-5.

5. Production and Operations Management/Chase/TMH


FUZZY LOGIC AND NEURAL NETWORKS (Professional Elective – 3)

UNIT- I Fuzzy Set Theory and Fuzzy Logic Control: Basic concepts of fuzzy sets- Operations on fuzzy sets- Fuzzy relation equations- Fuzzy logic control- Fuzzification –Defuzzificatiuon- Knowledge base- Decision making logic- Membership functions – Rule base. UNIT- II Adaptive Fuzzy Systems: Performance index- Modification of rule base0- Modification of membership functions- Simultaneous modification of rule base and membership functions- Genetic algorithms-Adaptive fuzzy system- Neuro fuzzy systems. UNIT- III Artificial Neural Networks: Introduction- History of neural networks- multilayer perceptions- Back propagation algorithm and its Variants- Different types of learning, examples. UNIT- IV Mapping and Recurrent Net works: Counter propagation –Self organization Map- Congnitron and Neocognitron- Hopfield Net- Kohonnen Nets- Grossberg Nets- Art-I, Art-II reinforcement learning UNIT- V Case Studies: Application of fuzzy logic and neural networks to Measurement- Control- Adaptive Neural Controllers – Signal Processing and Image Processing TEXT BOOK:

1. Vallum B. R And Hayagriva V.R C++, Neural networks and Fuzzy logic, BPB Publications, New Delhi, 1996

REFERENCE BOOKS:

1. Fuzzy logic &Neural Networks/ Chennakesava R. Alavala/ New Age International, 2008 2. Neural Networks for control, Millon W. T, Sutton R.S and Werbos P.J, MIT Press 1992 3. Fuzzy sets Fuzzy logic, Klir, G.J anfd Yuan B.B Prentice Hall of India Pvt. Ltd.,, New Delhi 4. Neural Networks and Fuzzy systems, Kosko.. Prentice hall of India Pvt. Ltd.,, New Delhi 1994 5. Introduction to Fuzzy control, Dirankov D. Hellendoorn H, Reinfrank M., Narosa Publications

House, New Delhi 1996 6. Introduction to Artificial Neural systems, Zurada J. M Jaico Publishing House, New Delhi 1994


OPTIMIZATION TECHNIQUES AND APPLICATIONS (Professional Elective – 4)

UNIT- I Single Variable Non-Linear Unconstrained Optimization: One dimensional Optimization methods:- Uni-modal function, elimination methods, ,, Fibonacci method, golden section method, interpolation methods – quadratic & cubic interpolation methods. UNIT- II Multi variable non-linear unconstrained optimization: Direct search method – Univariant method - pattern search methods – Powell’s- Hook -Jeeves, Rosenbrock search methods- gradient methods, gradient of function, steepest decent method, Fletcher Reeves method, variable metric method. UNIT- III Linear Programming: Formulation – Sensitivity analysis. Change in the constraints, cost coefficients, coefficients of the constraints, addition and deletion of variable, constraints. Simulation – Introduction – Types- steps – application – inventory – queuing – thermal system UNIT - IV Integer Programming: Introduction – formulation – Gomory cutting plane algorithm – Zero or one algorithm, branch and bound method Stochastic programming: Basic concepts of probability theory, random variables- distributions-mean, variance, correlation, co variance, joint probability distribution- stochastic linear, dynamic programming. UNIT - V Geometric Programming: Polynomials – arithmetic - geometric inequality – unconstrained G.P- constrained G.P (<= TYPE ONLY) Non-traditional optimization Techniques: Genetic Algorithms-Steps-Solving simple problems-Comparitions of similarities and dissimilarities between traditional and non-traditional techniques-Particle Swarm Optimization (PSO)- Steps(Just understanding)-Simulated Annealing-Steps-Simple problems. REFERENCES:

1. Optimization theory & Applications / S.S. Rao / New Age International. 2. Engineering Optimization-Kalyan Deb/ PHI 3. Introductory to operation Research / Kasan & Kumar / Springar 4. Optimization Techniques theory and practice / M. C. Joshi, K. M. Moudgalya/ Narosa Publications 5. Operation Research / H. A. Taha /TMH 6. Optimization in operations research / R. L Rardin 7. Optimization Techniques /Benugundu & Chandraputla / Pearson Asia


SMART MATERIALS AND STRUCTURES (Professional Elective – 4)

UNIT - I Overview of Smart Materials, Structures and Products Technologies. UNIT - II Smart materials (Physical Properties) Piezoelectric Materials, Elecrostrictive Materials, Magnetostrictive Materials, Magneto electric Materials. Magnetorheological Fluids, Electroheological Fluids, Shape Memory Materials, Fiber-Optic Sensors. UNIT - III Smart Sensor, Actuator and Transducer Technologies: Smart Sensors: Accelerometers; Force Sensors; Load Cells; Torque Sensors; Pressure Sensors; Microphones; Impact Hammers; MEMS Sensors; Sensor Arrays Smart Actuators; Displacement Actuators; Force Actuators; Power Actuators: Vibration Dampers; Shakers; Fluidic Pumps; Motors ; smart Transducers: Ultrasonic Transducers; Sonic Transducers. UNIT- IV Measurement, Signal Processing, Drive and Control Techniques: Quasi -static and Dynamic Measurement Methods; Signal conditioning devices; Constant voltage, Constant-current and Pulse drive methods; Calibration methods; Structural dynamics and Identification techniques; Passive, Semi -active and Active control; Feedback and feed forward/control strategies UNIT - V Design, Analysis, Manufacturing and Applications of Engineering Smart Structures and Products: Case studies incorporating design, analysis, manufacturing and application issues involved in integrating smart materials and devices with signal processing and control capabilities to engineering smart structures and products; Emphasis on structures, automation and precision manufacturing equipment, automotives, consumer products, sporting products, computer and telecommunications products, as well as medical and dental tools and equipment. REFERENCES:

1. Smart Materials and Structures/ M. V. Gandhi and_B.So Thompson/ Chapman & Hall, London; New York, 1992 (ISBN 0412370107).

2. Smart Structures and Materials/ B.Cui Shaw/Artech House, Boston, 1996 (ISBN:0890066817) 3. Smart Structures; Analysis and Design/ A.V. Srinivasan/ Cambridge University Press, Cambridge;

New York, 2001 (ISBN: 0521650267). 4. Electro ceramics: Materials, Properties/ A.J. Moulson and J.M-Herbert/ Wiley/ 2nd Edition, (ISBN:

0471497479). 5. Piezoelectric Sensories: Force, Strain, Pressure, Acceleration and Acoustic Emission Sensors.

Materials and Amplifiers/ G. Gautschi/ Springer, Berlin; New York,2002 (ISBN:3540422595) 6. Piezoelectric Actuators and wtrasonic Motors/ K.Uchino/ Kluwer Academic Publishers, Boston,

1997 (ISBN: 0792398114)


M. Tech – I year II Sem. (Design for Manufacturing)

VIBRATION ANALYSIS AND CONDITION MONITORING (Professional Elective – 4) UNIT - I Causes and effects of vibration, Vibration of single Degree and Multi Degree of freedom systems. Steady state and transient characteristics of Vibration. UNIT - II Introduction to Condition Monitoring, Failures types, investigation and occurrences. Causes of failure, Characteristics of vibration ~SHM, Periodic motion, Displacement, Velocity and acceleration. Peak to peak & RMS, Linear and logarithmic scales and phase angle. UNIT - III Vibration measuring instruments, vibration transducers, signal conditioning elements. Display and recording elements. Vibration meters and analyzers. UNIT - IV Condition monitoring through vibration analysis. Frequency analysis, Filters, Vibration signature of active systems, vibration limits and standards. Contaminant analysis, SOAP and other contaminant monitoring techniques, UNIT - V Special vibration measuring techniques Change in sound method, Ultrasonic measurement method, Shock pulse measurement, Kurtosis, Acoustic emission monitoring, Cepstrum analysis, Modal analysis, critical speed analysis, shaft -orbit & position analysis.. REFERENCES:

1. Mechanical Fault Diagnosis and Condition Monitoring/ Collacott. R.A./ Chapman & Hall, London, 1982, 2. Introduction to Machinery Analysis and Monitoring/ John S. Mitchell/ Perm Well Books, Perm Well

Publishing Company, Tulsa, Oklahoma,1993, 3. Vibration Measurement and Analysis/ Nakra. B.C .Yadava, G.S. and Thuested .L./ National Productivity

Council, New Delhi, 1989.


M. Tech – I year II Sem. (Design for Manufacturing)

MANUFACTURING SIMULATION & PRECISION ENGINEERING LAB A. MANUFACTURING SIMULATION The students will be given training on the use and application of the following software to manufacturing problems:

1. Auto MOD Software. 2. PROMODEL 3. SLAM-II 4. CAFIMS 5. Flexsim

They also learn how to write sub routines in C-language and interlinking with the above packages. Problems for modelling and simulation experiments:

1. AGV planning 2. ASRS simulation and performance evaluation 3. Machines, AGVs and AS/RS integrated problems 4. JIT system 5. Kanban flow 6. Material handling systems 7. M.R.P. Problems 8. Shop floor scheduling etc.

B. PRECISION ENGINEERING

1. Hydraulic and Pneumatic circuits 2. Closed loop control systems 3. Study of the chip formation in turning process 4. Study of operation of tool and cutter grinder, twist drill grinder, Centreless grinder 5. Determination of cutting forces in turning 6. Experiments in unconventional manufacturing processes-AJM and study of USM, EDM, Laser

Machining and Plasma spraying 7. Inspection of parts using tool makers microscope, roughness and form tester 8. Study of micro-controllers, programming on various CNC machine tools and also controllers 9. Studies on PLC programming 10. Study and programming of robots 11. Condition monitoring in machining process using acoustic emission.

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