Vel Tech Rangarajan Dr. Sagunthala R and D Institute of Science and Technology Courses

M.Tech. (CAD/ CAM)

---

Duration: 2 Years

Eligibility: B.Tech/ B.E.

Course Structure

Course Code	Course Title
Semester - I
PMAA02	Applied Engineering Mathematics
PCCA01	Finite Element Analysis
PCCA02	Computer Integrated Manufacturing System
PCCA03	Computer Aided Manufacturing
PCSA44	Computer Graphics
Practical
PCCA04	Computer Aided Design Lab
Semester - II
PCCA05	Computer aided process planning
PCCA06	Flexible Competitive Manufacturing System
PCCA07	Manufacturing Information systems
PCCA08	Mechatronics in Manufacturing Systems
PCCA0	Advanced Material Science
***	Elective-I
Practical
PCCA10	Computer Aided Manufacturing Lab
Semester - III
* * *	Elective II
* * *	Elective III
* * *	Elective IV
Practical
PCCA25	Project Phase I
Semester - IV
PCCA11	Project Phase II
List of Electives
PCCA12	Concurrent Engineering
PCCA13	Industrial Robotics
PCCA14	Design of Hydraulic and Pneumatic Systems
PCCA15	Design of Material Handling Equipments
PCCA16	Reliability Engineering
PCCA17	Data Communication in CAD/CAM
PCCA18	Industrial Safety Management
PCCA1	Manufacturing System and Simulation
PCCA20	Performance Modeling and Analysis of Manufacturing System
PCCA21	Advanced Vibration Engineering
PCCA22	Design for Manufacturing
PCCA23	Computer Integrated Design
PCCA24	Computational Fluid Dynamics

Course Detail

Semester - I

PMAA02   Applied Engineering Mathematics                         

Unit-I : Boundary Value Problems         

Linear second order partial differential equations in two independent variables – normal forms – hyperbolic, parabolic and elliptic equations – Cauchy problem.

Unit-II : Wave Equations                                                                                          

Wave equations – solution of initial value problem – significance of characteristic curves-Laplace transform solutions – displacements in a long string – along string under its weight – a bar with prescribed force on one end – free vibrations of a string.

Unit-III : Calculus Of Variations                                                                              

Concepts of functional and their stationary values – Euler’s equation and solution for the problem and for more general causes – natural boundary conditions – variational problems with moving boundaries – condition variational problems – Isoparametric problems-Direct Methods: Ritz, Kantorovich and Galerkin techniques

Unit-IV : Eigen Value Problems

Standard Eigen value problems – properties of Eigen values and Eigen vectors – Generalized Eigen value problems – strum sequence – Jacobi, Givens and Householder transformations.

Unit-V : Iteration Problems                                                                                     

Forward and inverse iteration schemes – Graham Schmidt deflation – simultaneous iteration method – subspace iteration – Lanczo’s algorithm – Estimation of core and time requirements.

 

PCCA01   Finite Element Analysis                                             

Unit–I: 1d Finite Element Analysis                                                      

Historical Background - Weighted Residual Methods - Basic Concepts of FEM - Variational Formulation of B.V.P - Ritz Method - Finite Element Modeling - Element Equations - Linear and Quadratic Shape functions -Bar, Beam Elements - Applications to Heat Transfer.

Unit–II:  Finite Element Analysis Of 2d Problems                           

Basic Boundary Value Problems in 2 Dimentions - Triangular, quadrilateral, higher order elements - Poissons and Laplace Equations - Weak Formulation - Elements Matrices and Vectors - Application to Solid mechanics, Heat transfer, Fluid Mechanics

Unit–III:  Iso Parametric Formulation      

Natural Co-ordinate System - Lagrangian Interpolation Polynomials - Iso-parametric Elements - Formulation -Numerical Intergration - 1D -2D Triangular elements - rectangular elements - Illustrative Examples.

Unit–IV:  Solution To Plane Elasticity Problems                              

Introduction to Theory of Elasticity - Plane Stress - Plane Strain and Axisymmetric Formulation - Principle of virtual work - Element matrices using energy approach.

Unit–V: Special Topics                                                                             

Dynamic Analysis - Equation of Motion - Mass Matrices - Free Vibration analysis - Natural frequencies of Longitudinal - Transverse and  torsional vibration - Introduction to transient field problems. Non linear analysis. Use of software - h & p elements - special element formulation.

 

PCCA02   Computer Integrated Manufacturing System                             

Unit–I: Introduction                                                                                                         

Objectives of a manufacturing system-identifying business opportunities and problems classification production systems-linking manufacturing strategy and systems-analysis of manufacturing operations

Unit–II: Group Technology And Computer Aided Process Planning                               

Introduction-part families-parts classification and cooling - group technology machine cells-benefits of group technology. Process planning function CAPP - Computer generated time standards

Unit–III:Computer Aided Planning And Control

Production planning and control-cost planning and control-inventory management-Material requirements planning (MRP)-shop floor control-Factory data collection system-Automatic identification system-barcode technology automated data collection system.

Unit–IV:  Computer Monitoring                                                                         

Types of production monitoring systems-structure model of manufacturing process-process control & strategies direct digital control-supervisory computer control-computer in QC - contact inspection methods non-contact inspection method - computer-aided testing - integration of CAQC with CAD/CAM.

Unit–V: Integrated Manufacturing System                                                                

Definition - application - features - types of manufacturing systems-machine tools-materials handling system computer control system - DNC systems manufacturing cell. Flexible manufacturing systems (FMS) - the FMS concept-transfer systems - head changing FMS – variable mission manufacturing system - CAD/CAM system - human labour in the manufacturing system-computer integrated manufacturing system benefits. Rapid prototyping - Artificial Intelligence and Expert system in CIM.

 

PCCA03   Computer Aided Manufacturing                                            

Unit-I: Introduction to Cam Geometric Dimensioning And Tolerancing

CNC machine tools, Principle of operation of CNC,Construction features including structure, drives and CNC controllers, 2D and 3Dmachining on CNC Geometrical dimensioning andtolerancing, Tolerance stacking – types  and  remedies

Unit–II: CNC Part Programming                                                                            

Detailed Manual part programming on Lathe & Millingmachines using G & M codes,  FAPT programming (FANUC). Generation of tool path, generation of G & M codes, Optimization of tool path (to reduce machining time)

Unit–III: CNC Tooling                                                                                                                  

Different types of tools and tool holders used onCNC Machines, parameters  for selection of configuration of cutting tools, work holding devices used on CNC machines

Unit–IV: Advanced CNC Processes                                                                        

EDM, Wire EDM, Abrasive water jet, LASERcutting, RPT, (Working principles, construction or set up of process, applications)

Unit–V: 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

 

PCSA44   Computer Graphics                                                                 

Unit–I: Introduction To Computer Graphics Fundamentals                                              

Output primitives (points,lines,curves Etc.,) , 2-D transformation (Translation, scaling, rotators) windowing , view ports clipping transformation.

Unit–II: Introduction To CAD Software                                                                      

Writing interactive programs to solve design problems and production of drawings, using any languages like Auto LISP/C/FORTRAN etc. , creation of surfaces, solids etc., using solid modeling pack (prismatic and revolved parts).

Unit–III: Visual Realism                                                                                     

Hidden - Line - Surface - solid removal algorithms shading - coloring. Introduction to parametric and variational geometry based on softwares and their principles creation of prismatic and lofted parts using these packages

Unit–IV: Assembly Of Parts                                                                                           

 Assembly of parts , tolerance analysis mass property calculations, mechanism simulation

Unit–V: Solid Modelling                                                                                       

Solid modelling - Rapid prototyping - Data exchange - Documentation - Customizing - solid modelling system

 

PCCA04   Computer Aided Design Lab                                     

Contents

• Conversion of 2D to 3D solid model
• Geometric dimensioning and Tolerencing
• Modeling of Automobile components
• Perform static analysis, Modal analysis, Harmonic analysis and transient analysis
• Perform nonlinear analysis
• Perform thermal analysis
• Perform fluid flow analysis

Introduction to CAD softwares – ProE, IDEAS; Conversion of 2D drawing into 3D solid model; Automate drafting from 3D model; Geometric Dimensioning and Toloerencing; Solid modeling and Assembly of Automobile and Machine components like Piston connecting rod Assembly, Crank Case, Cylinder head, Car body design, Chassis design, Impeller and its casing; CAD data transfer through neutral file format and geometry repair.

Introduction to Finite Element Analysis software - Pre-processing, Solving and Post processing;  Solution of structural problems – Static Analysis, Modal Analysis, Harmonic Analysis, Transient Analysis, Spectrum Analysis, Buckling Analysis, Nonlinear Analysis, Contact Analysis, Fatigue and Fracture analysis; Solution of Thermal Problems - Steady State Thermal Analysis, Transient Thermal Analysis; Fluid flow Analysis - CFD, Acoustic

 

Semester - II

PCCA05   Computer Aided Process Planning

Unit–I: Introduction                                                                                                         

The Place of Process Planning in the Manufacturing cycle - Process Planning and Production Planning – Process Planning and Concurrent Engineering, CAPP, Group Technology

Unit–II: Part Design Representation                                                                           

Design Drafting - Dimensioning - Conventional tolerancing - Geometric tolerancing - CAD - input / output devices - topology - Geometric transformation - Perspective transformation - Data structure - Geometric modelling for process planning - GT coding - The optiz system - The MICLASS system.

Unit–III: Process Engineering And Process Planning                                                        

Experienced, based planning - Decision table and decision trees - Process capability analysis - Process Planning -Variant process planning - Generative approach - Forward and Backward planning, Input format, Al.

Unit–IV: Computer Aided Process Planning Systems                                                         

 Logical Design of a Process Planning - Implementation considerations -manufacturing system components,production Volume, No. of production families - CAM-I, CAPP, MIPLAN, APPAS, AUTOPLAN and PRO,CPPP

Unit–V:  An Intergarted Process Planning Systems                                               

Totally intergarted process planning systems - An Overview - Modulus structure - Data Structure, operation -Report Generation, Expert process planning

 

PCCA06   Flexible Competitive Manufacturing System                              

Unit–I: Manufacturing In A Competitive Environment                                                       

Automation of manufacturing processes - Numerical control - Adaptive control - material handling and movement - Industrial robots - Sensor technology – flexible fixturing - Design for assembly, disassembly and service.

Unit–II: Group Technology                                                                                                       

Part families - classification and coding - Production flow analysis - Machine cell design - Benefits

Unit–III: Flexible Manufacturing Systems

Introduction - Components of FMS - Application workstations - Computer control and functions - Planning, scheduling and control of FMS - Scheduling - Knowledge based scheduling - Hierarchy of computer control - Supervisory computer.

Unit–IV:  Software Simulation And Database of FMS

System issues - Types of software - specification and selection - Application of simulation - Manufacturing data systems - data flow - CAD/CAM considerations - Planning FMS database.

Unit-V: Just In Time

Characteristics of JIT - Pull method - quality -small lot sizes - work station loads - close supplier ties – flexible work force - line flow strategy - preventive maintenance - KANBAN  system - strategic implications - implementation issues - MRD JIT - Lean manufacture.

 

PCCA07    Manufacturing Information Systems                                           

Unit–I: Introduction                                                                                                         

The evolution of order policies, from MRP to MRP II, the role of Production  organization, Operations control.

Unit–II:  Database                                                                                                

Terminologies - Entities and attributes - Data models, schema and subschema - Data Independence – ER Diagram - Trends in database.

Unit–III:  Designing Database                                                                                      

Hierarchical model - Network approach - Relational Data model -conc    epts, principles, keys, relational operations - functional dependence -Normalization, types - Query languages

Unit–IV:  Manufacturing Consideration                                                                      

Product and its structure, Inventory and process flow - Shop floor control - Data structure and procedure - various models - order scheduling module, input / output analysis module stock status database – complete IOM database.

Unit–V:  Information System For Manufacturing                             

Parts oriented production information system - concepts and structure -computerised production scheduling, online production control systems, computer based production management system, computerised manufacturing information system - case study.

 

PCCA08    Mechatronics in Manufacturing Systems                        

Unit–I: Systems And Design                                                                                          

Definition of Mechatronics - philosophy and approach - key elements - Mechatronics in products - integrated design issues- -design process- advanced approaches in Mechatronics - integrated product design –possible design solutions -modeling , analysis and simulation- modeling electromechanical systems and fluid power systems - man-machine interface

Unit–II:  Transducers And Signal Conditioning                                                        

Transducers – characteristics - sensors for position, displacement, velocity, acceleration, force, torque, power -strain - pressure - humidity - temperature - flow-time- frequency and phase angle - noise and sound level; fibre optic devices in mechatronics -micro sensors - signal processing - preamplifiers-charge amplifiers-filters-attenuators

Unit–III: Actuators In Mechatronics System                                                            

DC and AC drives - servo motor and stepper motor - hydraulic and pneumatic drives - piezoelectric and magnetostrictive actuators - micro actuators and smart instrumentation -  vibration isolation.

Unit–IV: Automatic Control Systems                                                                           

Automatic control and real time control systems - embedded microprocessor systems – hardware structure - software design and communication - feedback principle, implication of measurements - error detectors - final actuating elements - proportional controls - relays - servo amplifiers - architecture of PLC- input / output processing - programming - internal relays, timers and counters - data handling - analog input / output.

Unit–V: Advanced Applications In Mechatronics                                                      

Case studies of Mechatronics systems -CNC machines - micro machines – precision manufacturing systems- computer aided inspection – CMM, AFM, Talysurf instruments.  Mechatronics control in condition monitoring, machine diagnostics - automated manufacturing, artificial intelligence and fuzzy logic applications.

 

PCCA0   Advanced Material Science

Unit–I: Review Of Mechanical Behavior Of Materials                                            

Plastic deformation in poly phase alloys - Strengthening mechanisms - Griffith's theory of failure modes – Brittle and ductile fractures - Damping properties of materials - fracture toughness - Initiation and propagation of fatigue cracks - Creep mechanisms - Hydrogen embitterment of metals, Selection of materials for various applications.

Unit–II:  Engineering Alloys                                                                                          

Cast iron , steels , alloy steels and stainless steels – an overview of phases and microstructure, types, specifications applications, heat treatment, effect of alloying elements, Aluminum, Magnesium and Ti wrought and cast alloys used in engineering applications –Types, specifications, applications, heat treatment

Unit–III: Surface Modifications Of Materials                                                                      

Mechanical surface treatment and coating - Case hardening and hard facing - thermal spraying – vapour deposition-ion implantation - Diffusion coating - Electroplating and Electrolysis - Conversion coating - Ceramic and organic coatings – Diamond coating

Unit–IV: Nonmetallic Materials                                                                        

Composite materials, ceramics, plastics -Introduction, an overview of processing, their characteristic features, types and applications

Unit–V:  Modern Materials And Alloys                                                             

Super alloys- Refractory metals - Shape memory alloys- Dual phase steels, Micro alloyed, High strength low alloy steel, Transformation induced plasticity (TRIP) steel, Maraging steel –SMART materials, Metallic glass – Quasi crystal and Nano crystalline materials., metal foams

 

PCCA10   Computer Aided Manufacturing Lab          

Contents 

• NC programming
• Metal cutting
• Generation of manufacturing drawings
• Process planning
• Part program
• Generate CNC program for DECKEL MAHO 3 axis machining centre
• Evaluate High speed machining in Unigraphics
• Know about knowledge ware in Machining processes

Introduction to numerical control- coordinate systems, tooling, tool changing, tool storage, tool offset, linear, circular interpolation, fixed cycles; fundamentals of metal cutting, cutting tool  materials and cutting  fluids, machining centers & machine tool structures; generating manufacturing drawings  using Solidworks , CATIA & Unigraphics - engine cover, crank case, cylindrical clutch plate, wheel hub, engine  blocks; process planning CAM using  SOLIDCAM, and CIMATRON; Computer Aided Manufacturing and Virtual Machining; Introduction to Rapid Prototyping Technologies.

Manual part programming for lathe and milling machine; NC parameters for 3D machining, CNC code generation by using CAM software, simulation of machining operation using any CAM softare, generating RP parts using 3D printer; a study on multi axis machining in CATIA and Unigraphics; a study of GRIP and UFUNC in Unigraphics; evaluation of high speed machining in Unigraphics; knowledge ware in machining processes.

 

List of Electives 

PCCA12   Concurrent Engineering                                

Unit–I: Introduction                                                                                             

Extensive definition of CE - CE design methodologies - Organizing for CE - CE tool box collaborative product development

Unit–II: Use Of Information Technology                                                        

IT support - Solid modeling - Product data management - Collaborative product commerce - Artificial Intelligence - Expert systems - Software hardware co-design.

Unit–III: Design Stage                                                                            

Life-cycle design of products - opportunity for manufacturing enterprises - modality of CE Design - Automated analysis idealization control - Concurrent engineering in optimal structural design - Real time constraints.

Unit–IV: Manufacturing Concepts And Analysis                                           

Manufacturing competitiveness - Checking the design process - conceptual design mechanism – Qualitative physial approach - An intelligent design for manufacturing system - JIT system - low inventory - modular - Modeling and reasoning for computer based assembly planning - Design of Automated manufacturing.

Unit–V: Project Management                                                                             

Life Cycle semi realization - design for economics - evaluation of design for manufacturing cost – concurrent mechanical design - decomposition in concurrent design - negotiation in concurrent engineering design studies - product realization taxonomy - plan for Project Management on new product development – bottleneck technology development.

PCCA13   Industrial Robotics                                                                                         

Unit–I: Basic Of Robotics                                                                        

Definition, need and scope of industrial robots– Classification - selection of robot - Robot anatomy - Robot configurations - work volume - Precision movement - Basic robot motions - safety considerations

Unit–II: Robot Kinematics And Dynamics      

Robot kinematics - Direct and inverse kinematics- Vector operations - Translational transformations and Rotational transformations - Properties of transformation matrices-Homogeneous transformations and Manipulator - Forward solution - Inverse solution-Trajectory planning - Differential kinematics & statics - Robot dynamics -Methods for orientation and location of objects - Rigid body mechanics.

Unit–III: Drives, Controls And Robot End Effectors                                                

Design of drive systems-Hydraulic and Pneumatic drives-Linear and rotary actuators and control valves-Electro hydraulic servo valves - electric drives. End effectors design - Mechanical - Magnetic -Vacuum - Adhesive - air operated grippers.  Force analysis and Robot motion control - Adaptive and optimal control - electronic control- feedback control- interfacing.

Unit–IV: Sensors In Robotics And Applications                                            

Robot position sensors - proximity and range sensors – tactile sensors – velocity and acceleration sensors - force and  torque sensing devices- sensing joint forces and slip. Robot work cell design - Robot cell layouts -Multiple robots and machine interference-Robot cycle time analysis-Industrial applications of robots - material handling - processing - assembly and inspection- tele operations

Unit–V: Programming Of Robots And Vision Systems                                

Robot programming methods and languages - lead through programming -Motion interpolation. Computer control and Robot Softwares - task planning. Robotic vision system-Image components and representation - Hardware - Image processing and analysis- Object recognition and categorization- Image segmentation- Software consideration- Training of vision system.  Robot intelligence-Artificial intelligence techniques - problems representation in AI - Problem reduction and solution techniques - Application of AI and knowledge based expert systems in robots.

 

PCCA14   Design Of Hydraulic and Pneumatic Systems

Unit–I: Hydraulic Systems And Actuators                                                                  

Basic principles-Hydraulic Principles. Hydraulic Power Generators - Selection and specification of pumps, pump characteristics. Hydraulic Actuators – Linear, Rotary - Selection –Characteristics

Unit–II:  Control And Regulation Elements                                                               

Hydraulic Valves: Pressure, Flow, Direction Controls- proportional control valve. Fluid power symbols.

Unit-III: Design Of Hydraulic Circuits

Hydraulic circuits:- Reciprocating, Quick return , Sequencing, synchronizing and other industrial circuits like press circuits - hydraulic milling machine - grinding, planning, copying, forklift, earth mover circuits - design and selection of components - safety and emergency mandrels. 

Design of Hydraulic circuits – Selection and sizing of components-calculation of frictional head loss-equivalent length for various components- actuator load calculation- pump sizing

Unit–IV:  Pneumatic Systems And Circuits                                                                

Pneumatic system fundamentals: FRL, actuators and valves. Logic Circuits - Position - Pressure Sensing, switching, electro-pneumatic. Design of Pneumatic circuits using– Karnaugh maps. Cascade-Step counter

Unit–V: Installation, Maintenance And Special Circuits                                        

Pneumatic equipments - selection of components - design calculations -application - fault finding – hydro pneumatic circuits - use of microprocessors for sequencing - PLC, Low cost automation - Robotic circuits.

 

PCCA15   Design Of Material Handling Equipments                        

Unit–I: Materials Handling Equipment                                                                       

Material handling equipment: fixed path equipment - conveyors, sorting consolidating and diverting devices, cranes-Automatic Storage and Retrieval System - Magnetic handling systems, AGV, robotics and mobile material handling , etc,.Types, selection and applications.

Unit–II: Design Of Hoists                                                                                               

Design of hoisting elements: Welded and roller chains - Hemp and wire ropes - Design of ropes, pulleys, pulley systems, sprockets and drums, Load handling attachments. Design of forged hooks and eye hooks - crane grabs - lifting magnets - Grabbing attachments - Design of arresting gear - Brakes: shoe, band and cone types.

Unit–III: Drives Of Hoisting Gear                                                                                

and and power drives - Traveling gear - Rail traveling mechanism - cantilever and monorail cranes - slewing, jib and luffing gear - cogwheel drive - selecting the motor ratings.

Unit–IV: Conveyors                                                                                                          

Types - description – design and applications of Belt conveyors, apron conveyors and escalators Pneumatic conveyors, Screw conveyors and vibratory conveyors

Unit–V: Elevators                                                                                                  

Bucket elevators: design - loading and bucket arrangements - Cage elevators - shaftway, guides, counter weights, hoisting machine, safety devices - Design of form lift trucks.

 

PCCA16   Reliability Engineering                                 

Unit–I: Reliability Concept                                                                                             

Reliability function - failure rate - Mean Time Between Failures (MTBF) - Mean Time to Failure (MTTF) - a priori and a posteriori concept - mortality curve - useful life availability - maintainability - system effectiveness.

Unit–II:  Reliability Data Analysis                                                                               

Time-to-failure distributions - Exponential, normal, Gamma, Weibull, ranking of data - probability plotting techniques - Hazard plotting

Unit–III:  Reliability Prediction Models                                                                      

Series and parallel systems - RBD approach - Standby systems - m/n configuration - Application of Baye's theorem - cut and tie set method - Markov analysis - FTA - Limitations.

Unit–IV:  Reliability Management                                                                                

Reliability testing - Reliability growth monitoring - Non parametric methods - Reliability and life cycle costs - Reliability allocation - Replacement model

Unit–V:  Risk Assessment                                                                                               

Definition and measurement of risk - risk analysis techniques - risk reduction resources - industrial safety and risk assesment.

 

PCCA17   Data Communication in CAD/CAM                                      

Unit–I:  Digital Computers And Microprocessors                                                     

Digital computer-block diagram-digital components-register transfer and micro operations-instruction code-training and control instruction cycle-I/O Interrupt design of basic computer. Machine language-assembly language-the assembler. Registers ALU and Bus systems-timing and control-machine cycle and timing diagram. History of microprocessors -block diagram of 8086 and its functions and operation. Features of Pentium Processors

Unit–II: Operating Systems And Environments                                                       

Operating systems-types-functions-UNIX & WINDOWS NT-Architecture-GUI. Compliers-Analysis of the source program-the phases of a complier-cousin of the complier, the grouping of phases-complier construction tools.

Unit–III: Communication Model                                                                                   

Overview of Data communication and Networking-Analog / Digital signals and transmission-protocols and architecture-data communication concepts and terminology-network topologies and transmission media-wireless transmission-data encoding-asynchronous and synchronous communication-Physical layer standards-RS 232C, RS 44, RS442A.

Unit–IV: Computer Networks                                                                                        

Evolution of computer networks-LAN and WAN Layered networks-architecture-the OSI reference model services-network standardization-case studies-managing remote systems in network-file systems-networking in manufacturing.

Unit–V: Internet                                                                                                    

Internet-basic concepts-internet services-protocols-intranet services-mail based services-system and network requirements-internet tools-Usenet-E-mail-IRC-www-FTP-Telnet

 

PCCA18  Industrial Safety Management                    

Unit–I: Safety Management                                                                               

Evaluation of modern safety concepts - Safety management functions - safety organization, safety department - safety committee, safety audit - performance measurements and motivation - employee participation in safety - safety and productivity.

Unit–II: Operational Safety                                                                               

Hot-metal Operation - Boiler, pressure vessels - heat treatment shop - gas furnace operation-electroplating-hot bending pipes - Safety in welding and cutting. Cold-metal Operation - Safety in Machine shop - Cold bending and chamfering of pipes - metal cutting - shot blasting, grinding, painting - power press and other machines.

Unit–II: Safety Measures                                                                                   

Layout design and material handling - Use of electricity - Management of toxic gases and chemicals – Industrial fires and prevention - Road safety - highway and urban safety - Safety of sewage disposal – Control of environmental pollution - Managing emergencies in Industries - planning, security and risk assessments - onsite and offsite, control of major industrial hazards.

Unit–III: Accident Prevention                                                                           

Human side of safety - personal protecive equipment - Causes and cost of accidents. Accident prevention programmes - Specific hazard control strategies - HAZOP - Training and development of employees - First Aid- Fire fighting devices - Accident reporting, investigation

Unit–IV: Safety, Health, Welfare & Laws                                                       

Safety and health standards - Industrial hygiene - occupational diseases prevention - Welfare facilities - History of legislations related to safety-pressure vessel act-Indian boiler act - Environmental protection act – Electricity act - Explosive act.

 

PCCA1   Manufacturing System and Simulation                               

Unit–I:  Computer Modeling And Simulation System                                              

Introduction to simulation- steps in simulation-nature of computer modeling and simulation- types of models- Monte Carlo simulation, limitation of simulation, areas of application, examples. Components of a system- discrete and continuous systems- Examples, Model of a system-variety of modeling approaches.

Unit–II:  Random Number Generation                                                            

Properties of random numbers, Random number generation techniques-the mid product method- constant multiplier technique- additive congruential method- linear congruential method, Test for random numbers- frequency tests- test for autocorrelation.

Unit–III:  Random Variable Generation                                                                     

Random variable generation –inverse transform technique- exponential distribution – uniform distribution- Weibull distribution- triangular distribution. Empirical continuous distribution- generating approximate normal variates- Erlang distribution.

Unit–IV:  Distribution And Evaluation Of Experiments                                          

Discrete uniform distribution- Poisson distribution- geometric distribution- acceptance and rejection technique for poisson , gamma distribution. Variance reduction techniques- antithetic variables- Validation of simulation models- Verification of simulation models.

Unit–V: Discrete Event Simulation                                                                               

Concepts in discrete-event simulation- manual simulation using event scheduling, simulation of queuing system, simulation of inventory systems. Simulation of manufacturing and material handling systems. Introduction to Simulation packages – simulation using spreadsheet, SimQuick, WITNESS, ARENA, GPSS. Programming for discrete event systems in GPSS- case studies.

 

PCCA20   Performance Modeling and Analysis of Manufacturing Systems      

Unit–I: Manufacturing Systems And Simulation                                                      

Modeling automated manufacturing systems- role of performance modeling-performance measures- performance modeling tools- Simulation models- Analytical models. Automated manufacturing systems- introduction- product cycle-manufacturing automation- Economics of scale and scope.  Manufacturing system- input-output model- plant configurations. Performance measures- manufacturing lead time- work in process-machine utilization- throughput- capacity- flexibility- performability- quality. Computer control system- control system architecture- factory communications- local area networks- factory networks- open system interconnection model- net work to network interconnections- manufacturing automation protocol- data base management system.

Unit–II: Manufacturing Process                                                                                   

Examples of Stochastic processes- Poison process, Discrete time Markov Chain models- Definitions and notation- Sojourn Times in States- Examples of DTMCs in manufacturing- Chapman-Kolmogorov equation- Steady state analysis. Continuous Time Markov chain models- Definition and notation-Sojourn times in states- Examples of CTMCs in manufacturing- Equation for CTMC evolution- Markov model of a transfer line- Birth and Death Process in manufacturing.

Unit–III: Queuing Models                                                                                               

Notation for queues- Examples of queues in manufacturing-Performance measures-the M/M/m queue- queues with general distributions- queues with breakdowns- Analysis of a flexible machining center

Unit–IV: Queuing Networks                                                                                           

Examples of queuing network models in manufacturing- Little’s Law in queuing networks- Open queuing network- closed queuing networks- Product form queuing networks.

Unit–V: Petri Nets                                                                                                 

Classical Petri nets- Stochastic Petri net- Generalized stochastic Petri nets modeling of KANBAN system- Manufacturing models. 

 

PCCA21   Advanced Vibration Engineering                                        

Unit–I: Single And Two Degrees Of Freedom System                                             

Introduction to free, forced, transient and damped vibrations, terminology and applications. Discrete systems – single degree and two degree systems, response to free forced motions (steady state and transient) applications to vibration isolation and absorption.

Unit–II: Several Degrees Of Freedom                                                                         

Multi degree systems – techniques of analysis such as Dunkerley, Rayleigh, Holzer, Matrix iteration, Transfer matrices and modal analysis

Unit-III: Continuous and Torsional Vibration

Continuous systems Free and forced vibrations of bars for longitudinal, shear, torsional and transverse vibrations, Beams with attached masses rotor dynamics and FEM applications.

Unit–IV: Non-Linear Vibrations                                                                        

Non-linear vibrations, jump phenomenon and stability. Applications including self excited and parameter excited vibrations.

Unit–V: Random Vibrations                                                                                            

Random vibrations – stationary and non-stationary, ergodic systems, response of single degree systems to random excitation.

 

PCCA22   Design for Manufacturing                                         

Unit–I: Introduction                                                                                             

General design principles for manufacturability - strength and mechanical factors, mechanisms selection, evaluation method, Process capability - Feature tolerances - Geometric tolerances - Assembly limits – Datum features - Tolerance stacks

Unit–II:  Factors Influencing Form Design                                                    

Working principle, Material, Manufacture, Design - Possible solutions - Materials choice - Influence of materials on from design - from design of welded members, forgings and castings.

Unit–III:  Component Design-Machining Consideration                            

Design features to facilitate machining - drills - milling cutters - keyways - Doweling procedures, counter sunk screws - Reduction of machined area - simplification by separation - simplification by amalgamation - Design for machinability - Design for economy - Design for clampability - Design for accessibility - Design for assembly

Unit–IV: Component Design - Casting Considerations                               

Redesign of castings based on parting line considerations - Minimizing core requirements, machined holes, redesign of cast members to obviate cores.

Unit–V:  Redesign For Manufacture And Case Studies                               

Identification of uneconomical design - Modifying the design - group technology - Computer Applications for DFMA

 

PCCA23   Computer Integrated Design                                   

Unit–I: Introduction                                                                                             

Phases of design - Standardization and interchangeability of machine elements - Tolerances for process and function - Individual and group tolerances - Selection of fits for different design situations - Design for assembly and modular constructions - Concepts of integration.

Unit–II:  Shafting                                                                                      

Analysis and design of shafts for different applications - detailed design - preparation of production drawings -Integrated design of shaft, bearing and casing - Design for rigidity.

Unit–III: Gears And Gear Boxes.                                                                      

Principles of gear tooth action - Gear correction - Gear tooth failure modes - Stresses and loads – Component design of spur, helical, bevel and worm gears - Design for sub assembly - Integrated design of speed reducers and multispeed gear boxes - application of software packages.

Unit–IV: Clutches                                                                                      

Integrated design of automobile clutches and over running clutches.

Unit–V: Brakes                                                                                                       

Dynamic and thermal aspects of vehicle braking - Integrated design of brakes for machine tools, automobiles and mechanical handling equipments

 

PCCA24   Computational Fluid Dynamics                               

Unit–I:  Governing Differential Equation And Finite Difference Method                       

Classification, Initial and Boundary conditions, Initial and Boundary value problems. Finite difference method, Central, Forward, Backward difference, Uniform and non-uniform Grids, Numerical Errors, Grid Independence Test.

Unit–II: Conduction Heat Transfer                                                                              

Steady one-dimensional conduction, Two and Three dimensional steady state problems, Transient one dimensional problem, Two-dimensional Transient Problems.

Unit–III:  Incompressible Fluid Flow                                                              

Governing Equations, Stream Function - Vorticity method, Determination of pressure for viscous flow, SIMPLE Procedure of Patankar and Spalding, Computation of Boundary layer flow, Finite deference approach

Unit–IV:                                                                                                       

 Steady One-Dimensional and Two-Dimensional Convection - Diffusion, Unsteady one-dimensional convection -Diffusion, Unsteady two-dimensional convection - Diffusion - Introduction to finite element method - Solution of steady heat conduction by FEM - Incompressible flow - Simulation by FEM.

Unit–V:                                                                                                                     

Algebraic Models - One equation model, K-I Models, Standard and High and Low Reynolds number models,Prediction of fluid flow and heat transfer using standard codes.