bansilal ramnath agarwal charitable trust’s vishwakarma ... · 5. vickers manual on industrial...

Vishwakarma Institute of Technology Issue 01 : Rev No. 1 : Dt. 24/03/17

Structure and syllabus of T. Y. B. Tech. Production Engineering. Pattern B14 Revised, A.Y. 2017-18 (P a g e | 1)

Bansilal Ramnath Agarwal Charitable Trust’s

Vishwakarma Institute of Technology (An Autonomous Institute affiliated to Savitribai Phule Pune University)

Structure & Syllabus of

B. Tech. (Production Engineering)

Pattern ‘B14 Revised’ Effective from Academic Year 2017-18

Prepared by: - Board of Studies in Industrial & Production Engineering



T.Y. B. Tech. Production Engineering AY 2017-18 (B14 REVISED)

Module 5

Course Code Course Name

Contact Hours / Week Credits

Th. Proj. Based Lab

Regular Lab

Semester - I

S1 IP351THL Industrial Fluid Power 3 -- 2 4

S2 IP352TLP Statistical Methods & Research Methodology 3 2 -- 4

S3-MOOC IP353LTH Geometric Modelling 2 2 -- 3

S4 IP354THL Metal Cutting & Tool Design 3 -- 2 4 S5 IP355TLP Design of Machine Elements 3 2 -- 4

HSS HS304OPE Employability Skills Development 2 -- -- 2 PD IP356PD Professional Development -- -- 2 2

TOTAL 16 6 6 23 Semester - II

Module 6

Course Code Course Name

Contact Hours / Week Credits

Th. Proj. Based Lab

Regular Lab

S1 IP375THL Production Metallurgy 3 -- 2 4 S2 IP376TLP Machine Tool Design 3 2 -- 4 S3-

MOOC IP377LTH Computer Aided Engineering Analysis 2 2 -- 3

S4 IP378THL Material Forming 3 -- 2 4 S5 IP379THP Additive Manufacturing Techniques 3 2 -- 4

HSS HS301OPE Project Management 2 -- -- 2 Proj IP380PRJ Mini Project -- 2 -- 2

TOTAL 16 8 4 23



FF No. : 654

IP351THL:: INDUSTRIAL FLUID POWER Credits: 04 Teaching Scheme: 3 Hours / Week

Unit 1 Introduction to Fluid Power-Basics (…7.. Hours) Pascal’s Law, properties of fluid, laminar and turbulent flow, Pressure drop in hoses/pipes, Power units and accessories, Types of hydraulic fluids - petroleum based, synthetic and water based, selection of fluids, additives, effect of temperature and pressure on hydraulic fluid. Seals, sealing materials, compatibility of seal with fluids. Types of pipes, hoses, material, quick acting couplings, Fluid conditioning through filters, strainers, sources of contamination and contamination control. Unit 2: Hudraulic Pumps (…8.. Hours) Pumps: Types, classification, principle of working and constructional details of vane pumps, gear pumps, radial and axial plunger pumps, screw pumps, power and efficiency calculations, characteristics curves, selection of pumps for hydraulic power transmission Unit 3: Actuators (…7.. Hours) Actuators: (i) Linear and Rotary. (ii) Hydraulic motors- Types- Vane, gear, piston types, radial piston. (iii) Methods of control of acceleration, deceleration. (iv) Types of cylinders and mountings. (v) Calculation of piston velocity, thrust under static and dynamic applications, considering friction, inertia loads. (vi) Design considerations for cylinders Unit 4: Control of Fluid Power (…7.. Hours) Symbols for hydraulic and pneumatic circuits. Control of fluid power: (i) Necessity of fluid control through pressure control, directional control, flow control valves. (ii) Principle of pressure control valves, direct operated and pilot operated relief valves, pressure reducing valve, sequence valve. (iii) Principle of flow control valves, pressure compensated, temperature compensated flow control valves, meter in circuit, meter out circuits, flow through restrictor. (iv) Types of directional control valves: two way two position, four way three position, four way two positions valves. Open centre, close centre, tandem centre valves, . Introduction to Cartridge valves.proportion control and servo valves- Manually operated, solenoid operated, pilot operated, direction control valves, check valve Unit 5: Industrial Circuits & System Design (…6.. Hours) Industrial circuits 1 - Simple reciprocating, Regenerative, Speed control(Meter in, meter out & bleed off), Sequencing, Synchronization, transverse & feed, circuit for rivetting machine, automatic reciprocating, fail safe circuit, counter balance circuit, actuator locking, circuit for hydraulic press, unloading circuit, motor breaking circuit Design of hydraulic/pneumatic circuit for practical application, Selection of different components such as reservoir, various valves, actuators, filters, pumps based on design. (Students are advised to refer manufacturer’s catalogues.)



Unit 6: Pneumatics (…5.. Hours) Principle of Pneumatics: (i) Laws of compression, types of compressors, selection of compressors. (ii) Comparison of Pneumatics with Hydraulic power transmissions. (iii) Types of filters, regulators, lubricators, mufflers, dryers. (iv) Pressure regulating valves, (v) Direction control valves, two way, three way, four way valves. Solenoid operated valves, push button, lever control valves. (vi) Speed regulating – Methods used in Pneumatics. (vii) Pneumatic actuators-rotary, reciprocating, Air motors- radial piston, vane, axial piston (ix) Basic pneumatic circuit, selection of components(x) Application of pneumatics in low cost Automation and in industrial automation

List of Practicals: Any 10 out of following 1. Study of hydraulic control valves./Drawing of various hydraulic and pneumatic symbols 2. Study, construct and test Meter in.meter out,beed off circuits .(Hydraulic trainer) 3. Study, construct and test sequencing circuits .(Hydraulic trainer) 4 Study of hydraulic accumulators/Design of a circuit using accumulator. 5. Study of hydraulic intensifiers/Design of a circuit using intensifier 6. Study of hydraulic pumps-Rotary/Experiment on operating characteristics of gear pump. 7.Hydraulic power steering. 8 Direct control of pneumatic actuator using 2/2 and 3/2 valves 9.Indirect control of pneumatic actuator using 5/2 valve 10Use of shuttle valve 11Use of single piloted 5/2 dcv 12 Use of double piloted 5/2 dcv. Text Books: 1. Esposito – ‘Fluid Power with application’, Prentice hall Reference Books: 1 J. J. Pipenger – ‘Industrial Hydraulics’, McGraw Hill 2. H. L. Stewart – ‘Hydraulics and Pneumatics’, Industrial Press 3. A. Lall – ‘Oil Hydraulics’, International Literature Association 4. Yeaple – ‘Fluid Power Design Handbook’ 5. Vickers Manual on Industrial Hydraulics 6. Festo’s Manual on Pneumatic Principle, applications 7. ISO – 1219, Fluid Systems and components, Graphic Symbols 8. Majumadar, “Oil Hydraulics- Principle & Maintenance”, Tata McGraw Hill,1998 Course Outcomes: The student will be able to – 1. Understand fundamentals of fluids 2. Select appropriate pumps, for hydraulic systems 3. Select appropriate motors, cylinders for hydraulic systems. 4. Understand and select different types of hudraulic valves 5. Construct and evaluate hydraulic circuits for various industrial applications such as

machine tools, automobile, agricultural equipment 6. Apply principles of pneumatic systems for automation systems



FF No.: 654

IP352TLP::STATISTICAL METHODS AND RESEARCH METHODOLOGY

Credits: 04 Teaching Scheme: 3 Hours / Week

Unit 1: Data in Research ( 6 Hours) Meaning of Research , Motivation for Research , Research Approaches, Criteria for Good Research , Importance of communication skills in Research, Technical writing skills, Objectivity and Ethics in Research, Steps in Research process, Data in Engineering and Management Research, Types of data, Measures of Frequency Distribution Unit 2: Probability Distributions ( 8 Hours) Review of Probability Theory, concept of Random Variable, Discrete probability distributions in statistics and their analysis, Continuous probability distributions in statistics and their analysis , Functions in MS EXCEL for probability distributions Unit 3: Estimation in statistics ( 6 Hours) Sampling Distributions, Central Limit theorem, Chebyshev’s Theorem, Point estimation, Interval Estimation, Confidence Intervals, Sample size determinations for means and proportion, Large sampling versus small sampling, Methods of sampling Unit 4: Tests of Significance for Means and Proportions ( 8 Hours) Concept of significance level, Test of Significance for single mean and proportion, Errors in Hypothesis Testing, Test of significance for two sample means and proportions Unit 5: Tests of significance for variance ( 8 Hours) Chi-square distribution, Test of significance for one sample and two sample variance. Test of independence, Test of goodness of Fit, F distribution, One way ANOVA , Introduction to Design of Experiments

Unit 6: Research Methodology ( 6 Hours) Methods of primary and secondary data collection, Exploratory versus Descriptive research , Scales of Measurement, Aspects of Questionnaire design, Design of field surveys, Use of Regression and correlation in research analysis and forecasting, List of Practical: 1. Measures of Frequency Distribution 2. Discrete Probability Distributions 3. Continuous probability Distributions 4. Central Limit Theorem 5. Estimation in Statistics 6. Test of significance for means 7. Test of significance for proportion 8. Test of significance for variance 9. Test of independence 10. ANOVA



List of Project areas: 1. Questionnaire design 2. Exploratory Research using secondary data 3. Exploratory Research using primary data 4. Descriptive Research 5. Data analysis in MS Excel Text Books: 1. Richard Johnson, Probability and Statistics for Engineers, Eighth edition, Prentice Hall of India 2. Srivastava U.K., Shenoy G. V. and Sharma S.C., Quantitative Techniques for Managerial Techniques, Third edition, New Age International Publishers 3. Krishnaswamy K. N., Sivakumar A.I. and Mathirajan M., Management Research Methodology, Pearson publication 4. Kothari C. R., Research Methodology, Second Edition, New Age International Publishers Reference Books: 1. Levin Richard and Rubin David, Statistics for Management, Prentice Hall of India 2. Murray Spiegel, Schiller John, Srinivasan R. A. and Goswami Debasree, Probability and statistics (Schaum’s outline Series), Third Edition, McGraw Hill 3. Paneerselvam R., Research Methodology, Second Edition, Prentice Hall of India 4. Paneerselvam R., Design and Analysis of Experiments, Prentice Hall of India Course Outcomes: The student will be able to – 1. Explain the nature of research and data requirements 2. Calculate probability by selecting appropriate probability distribution for managerial decisions 3. Estimate confidence interval 4. Perform test of significance for means and proportion 5. Perform test of significance for variance 6. Assess the appropriateness of different kinds of research designs and methodology



FF No. : 654

IP353LTH GEOMETRIC MODELING

Credits: 03 Teaching Scheme:

2 Hours / Week + 2 Hours/ Week (Lab)

Prerequisite:

Unit 1: Fundamentals, Interpolation, and Curve Modeling (6 Hours) Geometric Modeling for integrated, manufacturing and quality engineering. Unified modeling approach to geometric approach design and conceptual design. Properties of geometric models and representation schemes, completeness, validity and unambiguity issues. Fundamentals of surface modeling and volumetric modeling, tools and techniques. Set-theory. Constructive Solid Geometry (CSG), Boundary Representation (B-rep), Feature based modeling, Integrated Polytrees. Freeform surface modeling. Explicit v/s parametric surfaces. Continuity considerations.

Unit 2: Surface Modeling, Subdivision, and Volumes (10 Hours) Introduction, Bezier Curves, Lagrange and Hermite Interpolation, Subdivision curves, B-splines, Matrix Forms, Rational Polynomial Curves, NURBs. Surface topology, Curvature, Bezier Surfaces, B-spline Surfaces, B-spline Subdivision Schemes, Doo-Sabin and Catmull-Clark Subdivision, Triangulation and Loop Subdivision, Surface Interrogation, B-rep and Boolean Ops, Elements of CAD: Extrusion, Rotation, Lofting, Sweeping, CSG Representations and Euler Ops.

Unit 3: Tolerance & Geometric Modeling (8 Hours) Tolerance modeling: Variational Solid Modeling for Geometric Tolerance and Dimensioning. Interference analysis and Automated tolerancing. Modeling for Assembly: Spatial reasoning and constraint analysis. Automated assembly planning. Geometric Modeling for mass-property representation (FE modeling), Simulation of manufacturing processes and Computer Aides Process Planning (CAPP) Data exchange formats for geometric models. Information structures and standards

Unit 4: Applications and Advanced Research Topics (8 Hours) Voronoi Diagrams and Delaunay Triangulations, Curve and Surface Reconstruction, Registration, Simplification and Decimation, Smoothing, Discrete Differential Geometry, Parameterization, Remeshing, Shape Analysis, Deformation, Segmentation, Spectral Methods. Software Tools for Geometric Modeling

List of Practicals: 1. Interpolation in representations schemes 2. Mathematical and software modeling of parametric curves 3. Mathematical and software modeling of synthetic surfaces 4. Geometric transformation of surfaces 5. Tolerance modeling 6. Modeling for assembly 7. Modeling of manufacturing processes 8. Shape analysis



Text Books:

1. Michael E. Mortenson

Geometric Modeling 2nd Edition

Wiley International

1985

2. David Rogers and Alan Adams

Mathematical Elements of Computer Graphics

McGraw-Hill 1976

Reference Books:

1. Geral E. Farin Curves and Surfaces for CAGD

5th Edition

Elsevier 2001

2. Martii Mantyla Introduction to Solid Modeling

Computer Science Press

1988

Course Outcomes : Students will be able to: 1. Represent curves and surfaces and determine their differential properties 2. Construct sketches and place geometric and topologic constraints on them 3. Construct parametric and feature models solid models 4. Perform construction, analysis of CAD models 5. Build assembly models and fits 6. Construct mechanical drawings and annotations



FF No. : 654

IP354THL METAL CUTTING & TOOL DESIGN

Credits: 04 Teaching Scheme: 3 Hours / Week + 2 Hours/ Week (Lab) Prerequisite: Metal Cutting, Finishing & NCM Processes

Unit 1: Tool Nomenclature (6 Hours) Milling cutter, broach, Single point cutting tool, various tool elements, Designation of cutting tools in ORS & ASA Systems, Importance of tool angles, Method of machining- orthogonal, oblique cutting, Nomenclature of drill

Unit 2: Theory of Metal Cutting-1 (10 Hours) Mechanics of chips formation, types of chips, determination of shear angle, chip reduction factor, velocity relationship, merchant force circle, estimation of cutting forces, Tool dynamometer. Heat generation & tool life

Unit 3: Theory of Metal Cutting-2 (8 Hours) Heat generation in cutting, functions of cutting fluid, characteristics of cutting fluid, types of cutting fluid, Tool wear, Tool life, modified Taylor’s equation, Tool dynamometers.

Unit 4: Fundamentals of jig & fixtures (6 Hours) Introduction to jig & fixture, difference between jig & fixtures. Classification of jig & fixtures. Principle of location, types of locators. Principle of guiding elements Types of guiding elements, Principle of clamping elements, Types of clamps. Types of Jigs & Fixtures.

Unit 5: Design of jig & fixtures (6 Hours) Concept of modular fixtures. General guide lines & procedures for design of jig & fixtures, Bodies, bases & frame, Design of locators, Design of guiding elements, Analysis of number of clamping forces required & their magnitude

Unit 6: Design of cutting tools (4 Hours) Tool materials, design of single point cutting tool, form tool, drill, reamer, Design of broach & plain milling cutter List of Practicals: (Any Ten) 1. Experiment on chip formation. 2. Measurement of shear angle using chip thickness ratio criteria. 3. Study of influence of cutting parameters on surface roughness in turning. 4. Measurement of cutting forces in turning using lathe tool dynamometer. 5. Verification of metal cutting theories. 6. Tool life study on a single point turning tool. 7. Design & working drawing of one drilling jig. 8. Design & working drawing of one Fixture. 9. Design & working drawing of one Form tool. 10. Design & working drawing of any two of following cutting tools. 11. SPCT, Reamer, Broach, Plain milling cutter 12. Industrial visit report. 13. Research paper study & presentation on metal cutting processes.



Text Books:

1 P C Sharma Production Engg. Khanna publishers

2 M.H.A. Kempster

Introduction to Jigs and fixtures design

Reference Books:

1 Nagpal Tool Engg 2007 2 Dolalson, Lecain

and Gold Tool design Tata McGraw

hill 2011

3 Hoffman Introduction to Jigs and fixtures 4 A.S.T.M.E. Tool Engineering Handbook 5 Basu, Mukherjee

and Mishra Fundamentals of tool engineering and design

6 R. K. Jain Production Technology Khanna Publishers

7 Milton Shaw Metal cutting principle

Course Outcomes : Students will be able to: 1. Understand and represent cutting tools using designation systems 2. Apply metal cutting theories to estimate and represent cutting forces 3. Analyze cutting environment and cutting parameters 4. Understand design principles of location, clamping for jigs and fixtures 5. Design and draw jigs and fixtures by following design principles 6. Design and draw single and multi-point cutting tools



FF No. : 654

IP355TLP DESIGN OF MACHINE ELEMENTS

Credits: 04 Teaching Scheme: 3 Hours / Week, 2 Hours/Week (Project)

Unit 1: Design considerations of Machine Elements (08 Hours) Basic procedure of Machine Design, Materials selection, Important mechanical properties of materials used in design, Codes and standards used in design, Preferred numbers, Manufacturing considerations in design. Concept of stress and strain (Linear, lateral, shear and volumetric), Hooke’s law, Poissons ratio, modulus of elasticity, modulus of rigidity, stress-strain diagrams for ductile and brittle materials, factor of safety, Theories of failure, Design for static loading. Review of types of loads and simple stresses. Stresses due to Biaxal loads.

Unit 2: Design for Fluctuating Loads (6 Hours) Types of variable stresses, Fluctuating stresses, Fatigue failure, fatigue strength and endurance limit, Introduction to S-N diagram, Low cycle and High cycle fatigue, Stress concentration factor and Notch sensitivity. Factors affecting fatigue strength. Goodman and Soderberg diagram, Modified Goodman’s diagrams for fatigue design. Cumulative fatigue damage.

Unit 3: Design of Shafts, Keys and Couplings (10 Hours) Design of solid and hollow shafts based on strength, rigidity, ASME code for shaft design. Keys, Types of keys, Design of keys and key ways. Couplings, Types of Couplings, Design of muff coupling, Design of rigid and flexible couplings.

Unit 4: Design of Springs (04 Hours) Types, Application and materials of springs, Stress and deflection equation for Helical springs, Styles of ends, Design of helical springs, Helical Springs in Parallel and Series, Design of Helical Springs for Variable Load.

Unit 5: Design of levers (04 Hours) Introduction to levers, Application of levers in engineering practice, Design of hand, foot and Crank Levers. Design of bell crank lever, design of rocker arm for exhaust valves

Unit 6: Design of Spur Gears (08 Hours) Introduction, Standard Proportions of Gear Systems, Gear Materials, various design considerations, Beam Strength of gear teeth- Lewis Equation, tangential loading, module Calculations, width calculations, Dynamic tooth loads, Spott’s Equation, types of gear tooth failures, Spur Gear construction, Design of Spur Gears.



List of Project areas: Students will perform projects of following designs for material selection, design calculations, assembly and detail drawing. 1. Design and drawing of Two/ Three stage Gear box used for any industrial

applications 2. Design and drawing of shaft subjected under static and dynamic loads. 3. Design and drawing of rigid/ flexible flange coupling for any industrial application. 4. Design and drawing of levers used in industry 5. Design and drawing of helical spring for any industrial application

Text Books:

1. V. B. Bhandari, Design of Machine Elements, Tata McGraw Hill Publications,

2. R. K. Jain, Machine Design, Khanna Publication, 3. Pandya and Shah Machine Design, Charotar Publication, 4. Hall, Holowenko

Laughlin Machine Design, Tata McGraw Hill

Publication,

5. J.F. Shigley Design of Machine Element, McGraw Hill Publication

6. M. F. Spotts Design of Machine Element, Pearson Education Publication,

7. PSG Design data Book Reference Books:

1. P. Kannaiah, Design of Machine Elements Scitech Publication, 2. H. Burr and

Cheatam, Mechanical Analysis and Design,

Prentice Hall Publication,

3. P. Kannaiah, Design of Transmission Systems,

Scitech Publication,

4. R. L. Norton Machine Design An Integrated Approach,

Pearson Education Publication

5. S. S. Wadhwa and S. S. Jolly

Machine Design A Basic Approach

Dhanapat Rai and Sons

Course Outcomes: Students will be able to: 1. Analyze the stress and strain mechanical components such as shaft, keys and couplings

and design the same for various industrial applications. 2. Design spur and helical gears for various applications. 3. Select different types of rolling contact bearings from manufacturer’s catalogue for

various industrial applications. 4. Analyze the stress and strain in power screw and design the same for various industrial

applications. 5. Analyze the stress and strain in threaded and welded joints and design the same for

various industrial applications. 6. Design mechanical components for fluctuating and reversible loading conditions.



FF No.: 654

IP375THL:: PRODUCTION METALLURGY Credits: 03 Teaching Scheme: 3 Hours / Week

Unit 1: Metallogryphy and Steels (07 Hours) Introduction to Metallography, micro and macro examination, Specimen preparation for

Examination, metallurgical microscope, etching. Steels: iron-iron carbide equilibrium diagram, Critical temperatures, Allotropy, cooling curve and volume changes of pure iron. Microstructure, non-equilibrium cooling of steel, widmanstatten structure, structure property relationship. Classification and applications of steels, specifications of some commonly used steels like BIS, EN, AISI, SAE. Unit 2: Heat treatments of Steels (07 Hours) Introduction to heat treatment furnaces and Furnace atmospheres, Transformation products of austenite, Time-temperature- transformation diagrams, Critical cooling rate, Continuous cooling transformation diagrams. Heat treatment of steels Quenching media, Annealing" Normalizing" Hardening" Retention of austenite" Effects of retained austenite" Elimination of retained austenite, Tempering" Secondary hardening, Temper embrittlement, Hardenability testing. Defects due to heat treatment, causes and remedial measure

Unit 3: Surface Hardening & Isothermal Treatments (06 Hours)

Process details and applications of Carburising, heat treatment after carburising, Nitriding, Carbonitriding, Flame hardening and Induction hardening. Commercial heat treatment practice of gears of different sizes, tools, springs. Isothermal heat treatments such as austempering, patenting, isoforming, martempering, ausforrning.

Modification of nitriding - Tuffride and Sursulf process and Plasma Nitriding Unit 4: Alloy Steels and Tool steels (07 Hours) Effects of alloying elements, classification of alloying elements. Typical examples of alloy steels like HSLA, Duel phase steels, Maraging steels, Stainless Steels, Sensitization of stainless steel, weld decay of stainless steel. Tool steels and tool materials, Heat treatment of high-speed steel. Special purpose steels with applications. Special cutting materials like Stellites, Ceramics, Cermets etc.

Unit 5: Cast Irons and Alloy cast irons (06 Hours) Cast irons- Differences between steels and cast irons. Classification of cast irons, Gray cast iron, White cast iron, Malleable cast iron, Ductile Iron, Chilled and alloy cast irons. Effects of various parameters on structures and properties of cast irons, Heat treatments of cast iron. Different alloy cast irons. Applications of cast irons for different components of machine tool, automobiles, pumps etc. Unit 6: Non-Ferrous Alloys (07 Hours) Copper alloys - Brasses, Bronzes-: Tin, Aluminium, Beryllium, Silicon Copper nickel alloys, Nickel - Silver, Aluminium and aluminium alloys. Solders, Bearing materials and their applications, Precipitation hardening alloys. High Temperature materials such as Nimonics, Super alloys, Ti-alloys Bio materials etc. Properties of these alloys and typical applications



List of Practicals: (For THL course) 1. Specimen preparation for Micro examination of metals & alloys 2. Macroexamination of steel 3. Study and drawing of microstructure of Plain carbon steels 4. Study and drawing of microstructure of annealed and normalized Plain carbon steels 5. Study and drawing of microstructure of hardened and Tempered Plain carbon steels 6. Study of carbon on hardness of Plain carbon steels after Hardening 7. Study the effect of tempering temperature on hardness after tempering on Plain carbon

steels 8. Study and drawing of microstructure of cast irons. 9. Study and drawing of microstructure of Non-ferrous alloys. 10. Jominy End quench harden ability test on steel sample. Text Books: 1. Kodgire V. D., Material science and metallurgy for Engineers, Everest Publishing House,

Pune. 2. K. G. Bundinski, M. K. Bundinski, Engineering Materials Preatice - Hall of India Pvt.

Ltd., New- Delhi . 3. Higgins, Engineering Metallurgy, Part-I Applied Physical Metallurgy, English

Language book Society / Edward Arnold. Reference Books: 1. Smith W. F., Principles of Material Science and Engineering, McGraw- Hill Inc. 2. Rollason E. C., Metallurgy for Engineers, ELBS Publishing. 3. Clark and Varney W. R., Physical Metallurgy for Engineers, East-West Press Pvt. Ltd., New Delhi. 4. Avner, An introduction to physical metallurgy, TMH publication. 5. A.S. M. Metals Hand Book Volume 4 Heat Treatment Course Outcomes: The student will be able to – 1. Interpret Fe-Fe3C equilibrium, microstructures & correlate structure-properties

relationship of steels & cast irons. 2. Use the concept of TTT, CCT diagrams & apply the heat treatment techniques to enhance

mechanical properties of steels. 3. Apply the surface hardening & isothermal heat treatment techniques to enhance

mechanical properties of steels. 4. Select appropriate alloy steel and tool steel for different engineering applications 5. Select appropriate cast iron nonferrous material for different engineering applications. 6. Select appropriate non ferrous material for different engineering applications.



FF No. : 654

IP376TLP: MACHINE TOOL DESIGN

Credits: 04 Teaching Scheme: Theory: 3 Hours/ Week

Lab: 2 Hours/Week

Unit 1: Design of Machine Tool Drives (10 Hours) Stepped Regulation of Speed, Laws of Stepped Regulation, Why Geometric Progression is used against Arithmetic, Harmonic & Logarithmic despite shortcomings, Relation between Range ratio, Geometric Progression Ratio and No. of Speed Steps, 3)Design of Stepped Drives: Break up of Speed Steps, Structural Formulae, Structural Diagram, Selection of Best Structural Diagram, Ray Diagram, Speed Chart, General recommendations for Developing the Gearing Diagram, Determining the number of teeth of Gears. 4) Speed/ Feed Gear box : Limiting Transmission Ratio of Speed / Feed Gear Box.

Unit 2: Design of Machine Tool Structure (10 Hours) Function & Requirement of Machine Tool Structure, Design Criteria from Strength & Stiffness considerations, Concept of Unit Rigidity, Unit Strength under Tension, Unit Strength under Torsion & Unit Strength under Bending for Material of Machine Tool Structures, Compare Steel & Cast Iron on the basis of Material Properties, Manufacturing Problems and Economy, Role of Static & Dynamic Stiffness in the design of elements of machine tools, Profiles of Machine Tool Structures, Factors affecting stiffness of machine tool structures & methods of improving it, Basic Design procedure of machine tool structures

Unit 3: Design of Spindle (6 Hours) Function & Requirements of Spindle Units, their Materials, Effect of Machine Tool Compliance on Machining accuracy Design of Spindle for Bending Stiffness: Deflection of Spindle Axis due to a) Bending, b) - due to Compliance of Spindle Supports, c) - due to Compliance of the Tapered Joint. Optimum Spacing between Spindle Supports, Permissible Deflection & Design for stiffness: Additional Check for Strength like Additional Supports, Location of Bearings and Drive elements

Unit 4: Design of Spindle Supports (6 Hours) Requirements of Spindle Supports, Features of Anti-friction Bearings, Load bearing abilities of Ball & Roller Bearings. Parameters which assess the viability of combination of roller & Ball & Roller Bearings in Spindle Units. Preloading of Anti Friction Bearing & its method Design of Sliding Bearings: Sleeve, Hydrodynamic Journal, Hydrostatic Journal, Air-Lubricated (Aerodynamic, Aerostatic).

Unit 5: Design of Guide-ways (6 Hours) Design Criteria (Wear Resistance & Stiffness) and Calculations for Slide-ways operating under semi liquid friction condition, ‘Stick Slip’ phenomena affects accuracy of setting & working motions. Comparison of Design & stiffness of Hydrodynamic, Hydrostatic & Aerostatic Slide-ways, Design of Antifriction Guide-way, Concept of Combination Guide-ways. Function & Types of Guide-ways, Types of Slide-ways & Antifriction Ways, Functional features of Slide-ways, its Shapes & Materials, Methods of adjusting Clearance;



Unit 6: Design of Power Screws (4 Hours) Design of Sliding friction Power Screw for Wear Resistance, Strength, Stiffness, & Buckling Stability. Design of Rolling friction Power Screw for Strength under static loading, Strength under cyclic loading, & Stiffness

List of Practicals: 1. Design and Working Drawing of Speed Gear Box for Lathe 2. Design and Working Drawing of Feed Gear Box for Drilling Machine 3. Design and Working Drawing of Spindle for Lathe 4. Design and Working Drawing of Spindle-Support for Lathe 5. Design and Working Drawing of Sliding Friction Power Screw 6. Design and Working Drawing of Rolling Friction Power Screw List of Project areas: 1. Design Case Studies of Bed of Lathe Column & Base of Milling Machine 2. Design Case Studies of Column of Milling Machine 3. Design Case Studies of Base of Milling Machine

Text Books:

1. N. K. Mehta, Machine Tool Design,

2nd Edition, Tata McGraw Hill, 2011.

2. D. K Pal, S. K. Basu,

Design of Machine Tool,

4th Edition, Oxford, 2005.

3. G. C. Sen, A. Bhattacharya

Principles of Machine Tool

2nd Edition New central book agency Calcutta

1967

Reference Books:

1. N. S. Acherkan, V. Vermakov

Machine Tool Design Vol 2

1st Edition, MIR publication

2000.

2. F. Koenigsberger, Design Principles of Metal Cutting Machine Tools,

1st Edition., The Macmillan Company

1964.

Course Outcomes: The student will be able to – 1. Design stepped speed gear boxes 2. Analyze and design various machine tool structure using principle of free body diagram and using minimum deflection design criterion 3. Design spindles using minimum deflection criterion 4. Design proper bearings for spindle supports 5. Design sliding and rolling friction guideways 6. Design sliding and rolling friction power screws



FF No. : 654

IP377LTH COMPUTER AIDED ENGINEERING ANALYSIS

Credits: 03 Teaching Scheme: 2 Hours/Week + 2 Hours/Week (Lab)

Unit 1: Introduction to Analytical Methods (6 Hours) Methods to solve engineering problems- analytical, numerical, experimental, their merits and comparison, discretization into smaller elements and effect of size/ shape on accuracy, importance of meshing, boundary conditions, Computer Aided Engineering (CAE) and design, chain-bumping-stages vs concurrent-collaborative design cycles, computer as enabler for concurrent design and Finite Element Method (FEM), degree of freedom (DOF), mechanical systems with mass, damper and spring, stiffness constant K for tensile, bending and torsion; Practical applications of FEA in new design, optimization/ cost-cutting and failure analysis,

Unit 2: CAE Analyses (10 Hours) Types of analysis in CAE, static (linear/ non linear), dynamic, buckling, thermal, fatigue, crash nVh and CFD, review of normal, shear, torsion, stress-strain; types of forces and moments, tri-axial stresses, moment of inertia, how to do meshing, 1-2-3-d elements and length of elements; force stiffness and displacement matrix, Rayleigh-Ritz and Galerkin FEM; analytical and FEM solution for single rod element and two rod assembly.

Unit 3: Two Dimensional Problems (8 Hours) Two-dimension meshing and elements for sheet work and thin shells, effect of mesh density and biasing in critical region, comparison between trial and quad elements, quality checks, jacobian, distortion, stretch, free edge, duplicate node and shell normal.

Unit 4: Three Dimensional Problems (8 Hours) Three-dimension meshing and elements, only 3 DOF, algorithm for trial to tetra conversion, floating and fixed trials, quality checks for tetra meshing, brick meshing and quality checks, special elements and techniques, introduction to weld, bolt, bearing and shrink fit simulations, CAE and test data correlations, post processing techniques

List of Practicals: 1. Introduction to analytical methods 2. Elements and their properties 3. Steps in stress analyses 4. Introduction to analysis software 5. Stress analysis of beams (Cantilever, Simply supported & Fixed ends) 6. Stress analysis of a plate with a circular hole. 7. Stress analysis of rectangular L bracket 8. Stress analysis of 3D objects

Text Books:

1. Gokhle Nitin

Practical Finite Element Analysis;

Finite to Infinite

2. Chennakesava RA

Finite Element Methods-Basic Concepts and App

PHI Learning

3. Reddy JN An introduction to finite TMH



element method Reference Books:

1. Desai Chandrakant S Introduction to finite element Method

CBS Pub

2. Rao, S.S. The Finite Element Method in Engineering

Peragamon Press, Oxford

3. Chandrupatla, T.R. and Belegundu, A.D.

Introduction to Finite Elements in Engineering

PHI

Course Outcomes : Students will be able to: 1. Apply mathematical skills in the design and analysis of model generations and

analysis. 2. Exercise analytical skills in model verifications and interpretations of FEA results. 3. Apply knowledge from component design in projects 4. Use Industry-standard software packages and analytical tools



FF No. : 654

IP378THL::MATERIAL FORMING Credits: 04 Teaching Scheme: 5h (3h Theory + 2h Lab) Hours/ Week Unit 1 (8 Hrs) Fundamentals of Metal forming

Classification of forming processes, Engineering stress-strain and true stress-strain, Strain hardening, work done in tensile test, temperature rise in plastic deformation, Concept of flow stress determination, compression test Effect of temperature, strain rate, Mohrs circle for three dimensional state of stress Theory of plasticity- Yield criteria of Von Mises criteria and Tresca criteria. Concept of formability and forming diagram.

Unit 2 (8 Hrs) Forging Processes

Comparison of forging with other manufacturing processes. Classification of forging processes-open die and closed die forging, Hot and cold forging, Basic forging operations such as drawing, fullering, edging, blocking etc, Forging equipment- Hammers and presses, construction working capacities and selection of equipment.. Other forging techniques-, Isothermal forging, rotary swaging, Orbital forging. Concept of forgeability and formability tests, Determination of forging load considering friction Forging defects and remedies.

Unit 3 (8 Hrs) Rolling of Metals

Scope and importance of rolling. Cold rolling and Hot rolling Types of Rolling Mills- Construction and working. Friction in rolling, Roll bite, reduction, elongation and spread.Analysis of rolling load. Deformation in rolling and determination forces required. Process variables, redundant deformation. Roll flattening, Roll camber - its effect on rolling process, mill spring. Automatic gauge control- Lubrication in rolling, Defects in rolling

Unit 4 (8 Hrs) Rod, Wire and tube drawing

Introduction rod and wire drawing machines - construction and working.Preparation of stock for wire drawing. Wire drawing dies, material and design. Variables in wire drawing, Maximum reduction in wire in one pass, forces required in drawing. Multiple drawing, work hardening, lubrication in wire drawing. Tube drawing: Methods, force calculation, stock preparation. Lubrication in tube drawing

Unit 5 (8 Hrs) Extrusion of Metals

Types: Direct, reverse, impact, hydrostatic extrusion. Dies for extrusion, stock penetration. Extrusion ratio Force equipment (with and without friction), types of metal flow in extrusion, Extrusion load analysis, Impact extrusion. Extrusion dies Extrusion defects and remedies. Analysis of extrusion load.



Unit 6 (8 Hrs) Advanced forming processes

High speed metal forming, Effects of high speeds on metal deformation, High speed forming machines, Explosive forming, High velocity forming- principles, comparison of high velocity and conventional Forming processes. Explosive forming, Magnetic pulse forming. Applications of High velocity forming and case studies of components produced by advanced forming

Laboratory work 2 Hrs/week List of experiments ( Any 10 experiments)

1) Estimation of amount total work done in tensile deformation of mild steel 2) Estimation of amount of total work done in compressive deformation of aluminum. 3) Forgeability test of notched surface of low C steel. 4) Design of edging die profile for lever forged component. 5) Estimation of extrusion ratio, shape factor and circumscribing circle diameter for

structural section of aluminum. 6) Severe Plastic deformation of non heatreatable aluminum alloy. 7) Characterization of mechanical properties of super plastically deformed sample. 8) Microstructural analysis of super plastically deformed sample. 9) Roll pass design for box pass. 10) Measurement of plastic strain ratio of sheet metal. 11) Study the effect of strain rate on flow stress of metal

Text Books: 1) Dieter, Mechanical Metallurgy 2) P. N. Rao, Manufacturing Technology, Tata McGrawHill Reference Books: 1. Dr. R. Narayanswamy, Metal Forming Technology, Ahuja Book Co. 2. Surender Kumar, Principles of Metal Working. 3. ASM Metal handbook Vol: 4 forming. 4. J. N. Harris, Mechanical working of metals 5. G. W. Rowe, Principles of industrial metal working process, Edward Arnold Course Outcomes: Students will be able to: 1. Understand fundamentals of elastic and plastic deformation of metals. 2. Select appropriate forging process, equipment, tools and analysis of forging load.. 3. Classify rolling processes, equipment and analysis of rolling forces and defects. 4. Understand wire and tube drawing machines, tools and analyse wire and tube drawing

forces. 5. Understand types of extrusion process and analysis of extrusion load and metal flow. 6. Compare and apply nonconventional forming techniques.



FF No. : 654

IP379THP::ADDITIVE MANUFACTURING TECHNIQUES Credits: 04 Teaching Scheme: 5h (3h Theory + 2h Lab) Hours/ Week Unit 1 : (8 Hrs) INTRODUCTION Overview – History – Need-Classification -Additive Manufacturing Technology in product development - Materials for Additive Manufacturing Technology – Tooling – Applications.

Unit 2 (8 Hrs) CAD & REVERSE ENGINEERING Basic Concept – Digitization techniques – Model Reconstruction – Data Processing for Additive Manufacturing Technology: CAD model preparation – Part Orientation and support generation – Model Slicing –Tool path Generation – Softwares for Additive Manufacturing Technology: MIMICS, MAGICS.

Unit 3 (8 Hrs) LIQUID BASED AND SOLID BASED ADDITIVE MANUFACTURING SYSTEMS Classification – Liquid based system – Stereolithography Apparatus (SLA)- Principle, process, advantages and applications – Solid based system –Fused Deposition Modeling – Principle, process, advantages and applications, Laminated Object Manufacturing

Unit 4 (8 Hrs) POWDER BASED ADDITIVE MANUFACTURING SYSTEMS Selective Laser Sintering – Principles of SLS process – Process, advantages and applications, Three Dimensional Printing – Principle, process, advantages and applications- Laser Engineered Net Shaping (LENS), Electron Beam Melting.

Unit 5 (8 Hrs) MEDICAL AND BIO-ADDITIVE MANUFACTURING Customized implants and prosthesis: Design and production, Bio-Additive Manufacturing - Computer Aided Tissue Engineering (CATE) – Case studies

Unit 6 (8 Hrs) DESIGN FOR ADDITIVE MANUFACTURING PROCESSES Motivation, DFMA concepts and objectives, AM unique capabilities, Exploring design freedoms, Design tools for AM, Part Orientation, Removal of Supports, Hollowing out parts, Inclusion of Undercuts and Other Manufacturing Constraining Features, Interlocking Features, Reduction of Part Count in an Assembly, Identification of markings/ numbers etc.

List of Project Areas: 1. Creation of input files for 3D Model and logic behind it 2. Analysis and modeling of different slicing strategies 3. Blending and G Code generation 4. 3D Printing of objects



Text Books: 1. Chua C.K., Leong

K.F. and Lim C.S. Rapid prototyping: Principles and applications

Third Edition

World Scientific Publishers

2010

2. Gebhardt A. Rapid prototyping Hanser Gardener Publications

2003

Reference Books:

1. Liou L.W. and Liou F.W

Rapid Prototyping and Engineering applications: A tool box for prototype development

CRC Press 2007

2. Kamrani A.K. and Nasr E.A.

Rapid Prototyping: Theory and practice

Springer 2006

3. Hilton P.D. and Jacobs P F

Rapid Tooling: Technologies and Industrial Applications

CRC press 2000

Course Outcomes: Students will be able to: 1. Understand various additive manufacturing processes for different applications 2. Use correct CAD file formats in 3D printed parts manufacturing 3. Select appropriate 3D printing parameters considering shape features, part quality and

printer specifications 4. Apply AM concepts for Bio medical and medical fields 5. Perform reverse engineering steps to prepare virtual model 6. Operate 3D printer machine to manufacture desired 3D objects



FF No. : 654

Credits: 02 Teaching Scheme: - Theory 2 Hrs/Week

Unit I (8 Hrs) Introduction:

Definition & Characteristics of Project, Performance Parameters: Time, Cost & Quality. Difference with respect to Standard Routine Production. Classification of Projects: Sector based, Investment based, Technology based, Causation based, Need based (BMERD) - Balancing, Modernization, Replacement, Expansion & Diversification Project Life Cycle Phases – Concept/Initiation Phase, Project Definition Phase, Project Planning & Organization Phase, Project Implementation Phase, Cleanup & Shutdown Phase. Governmental Framework for Identification of Opportunities, Incentives from state & central govt.; Import-substitution projects.

Unit II (8 Hrs) Project Planning & Organization

Project Planning, Scheduling & Monitoring, Statement of Works, Project Specifications, Work Breakdown Structure, Network Analysis & Duration Estimating Network Diagrams – PERT/CPM, Estimate Activity Times, Milestone Scheduling. Resource Leveling, Resource Smoothening, Project Crashing. Implementation Phase: Activities Involved: Erection & Commissioning, Installation, Trial Runs & Commencement of Commercial Production. Cleanup/Shutdown Phase: Handover to Client, Settlement of Accounts. Project Organization & Management. Project Organization Structure, Role of Project Manager.

Unit III (8 Hrs) Project Monitoring & Contract Management

Project Cost Estimation: Need, Causes of Cost & Time Overruns. Nature of Cost Estimates, Types of Project Cost Estimates, Estimation of Manpower & Utilities. Project Budgeting & Control, Earned Value Management System: Concept of AC, PV, EV, Variances, etc. Contract Management: Responsibility Sharing Matrix, Types of Contract Payments, Risk Factors in Contracts – Contractor & Owner. Critical Chain Project Management. Project Management Information System and Control, Management Pitfalls.

Unit IV (8 Hrs) Computer Applications in Project Planning & Control

Introduction to MS Projects – Understanding the MS Project screen & different views, Defining the project, Working with calendar, Outline the project, Create dependencies between tasks, Creating WBS, Format task list and Gantt chart, Resource planning, leveling and preparing resource graph, Working with baseline, tracking the project. Home Assignment on Exercise with MS Projects Software.

HS301OPE:: PROJECT MANAGEMENT



Text Books 1. Narendra Singh; Project Management & Control; Himalaya Publishing House,

Mumbai. 2. S. Choudary, Project Management, Tata McGraw Hill 3. Prasanna Chandra; Project: Preparation, Appraisal, Budgeting & Implementation 4. Pinto, Project Management – Achieving Competitive Advantage & MS Projects,

Pearson Education

Reference Books 1. Maylor, Project Management, Pearson Education, 2. Gopal & Ramamurthy; Project Management Handbook; Macmilan. 3. Project Management Body of Knowledge 4. Practical Project Management by Ghatak & Sandra, Pearson Education (Singapore)

Pte. Ltd, 2001 5. Handbook on Project Appraisal & Follow-up, SARDA, Govind Prakashan,2001

Course Outcomes: Students will be able to: 1. Learn the basic concepts of project and project management 2. Plan and schedule small and medium projects to achieve the triple constraint of time, cost

and quality using software package 3. Understand the concept of earned value management system and critical chain in

managing projects 4. Monitor the progress of projects to determine variances and recommend corrective

actions using software package



FF No. : 654

IP380PRJ :: MINI PROJECT

Credits: 02 Teaching Scheme: - Laboratory 2 Hrs/Week

Prerequisites: Nil

Guidelines 1. Mini Project can be an individual or a group activity depending on the depth and

scope of the topic. 2. The project work can be any of the form given below (but not restricted to below

mentioned topics only) : a) Making physical working models, prototypes, scaled models, of a concept

machine. b) Making virtual / CAD models of machines / concepts. c) Making study, modeling, analysis, programming and simulation of a system /

machine operation / process. d) Making study / teaching modules of a sufficiently complex topic for pedagogy

purposes. 3. A complete assembly and details drawings of the project should be submitted along

with a detailed project report, where applicable. 4. A Detailed background / field / literature survey, related to the topic must be made

presented in the report. 5. Entire work should be presented at the end of the Semester.

Course Outcomes : Students will be able to 1. Survey literature for problem identification. 2. Apply basic engineering fundamentals in the domain of practical applications to

analyze a concept/system/machine operation/process etc. 3. Cultivate the habit of working in a team and attempt a problem solution in a right

approach 4. make physical working model/charts/prototype/scaled model/ CAD model etc, carry

out a survey/ conduct experimentation 5. prepare project report and present at the end of semester

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