T.E.
(Production)
302081
Material Science & Composite Materials
Teaching
Scheme:
Examination Scheme:
Lectures: 4Hrs / Week
Theory: 100 Marks
Practicals : 2Hrs / Week
Term work: 50 Marks
UNIT
I
8Hrs. Steels: Introduction to Metallography,
micro and macro 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
II
8Hrs. Heat treatment of Steels:
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, Quench cracks, Hardenability testing"
Defects due to heat treatment and remedial measure.
UNIT
III
8Hrs. Surface Hardening &
Isothermal Treatments: Carburising, heat treatment after carburising,
Nitriding, Carbonitriding, Tuffride and Sursulf process. 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.
UNIT
IV
8Hrs Alloy Steels & Cast
Iron: Alloy Steels - Effects of alloying elements, classification of
alloying elements. 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.
Cast irons- Classification, 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. Applications of cast irons for different components of
machine
tool, automobiles, pumps etc.
UNIT
V
8Hrs Non-Ferrous Alloys:
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 etc.
UNIT
VI
10Hrs Modern Engineering
Materials: Composites- Types, Characterization, Production techniques
& applications. Metal - Matrix composites, Particulate & Fiber
composites. Biomaterials, Nano materials, Sports materials.
List
of Experiments
1.
Testing of Composite materials (Like Hardness, Impact, Tension etc.)
2.
Study and drawing of microstructures of mild steel, medium carbon steel,
eutectoid steel and hypereutectoid steel.
3.
Study and drawing of microstructures of white, malleable, grey and nodular
cast iron.
4.
Study and drawing of microstructures of alpha brass, alpha-beta brass,
aluminum bronze, tin bronze and bearing metal.
5.
Study and drawing of microstructures of hardened steel, tempered steel.
6.
Hardening of steel- study of effect of carbon on hardness of hardened steel.
7.
Tempering of steels - study of effect of temperature on hardness of tempered
steel.
8.
Study of change in microstructure on annealing and normalizing of tempered
steel.
9.
Sulphur print test on a steel specimen & flow lines examination of a
forged component. 10. Jominy Hardenability test on a steel sample.
10.
Jominy Hardenabilitytest on steel sample.
Text-books:
House,
Pune.
Pvt. Ltd. , New- Delhi.
Language book Society / Edward Arnold.
4. Smith W. F., " Principles of Material Science and
Engineering", McGraw- Hill Inc.
Reference
books:
1.
Rollason E. C., "Metallurgy for Engineers", ELBS Publishing.
2.
Clark and Varney W. R. "Physical Metallurgy for Engineers",
East-West Press
Pvt. Ltd., New Delhi.
Avner, "An introduction to physical metallurgy", TMH
publication.
3.
Donald R. Askeland & Pradeep Phule. , The science of engineering
materials,
Thomson series.
T.E.
(Production & Production S/w)
302082
- Kinematics and Design of Manufacturing Machines
Teaching
Scheme:
Examination Scheme:
Lectures:
4Hrs I Week
Theory:
100 Marks Practical: 2Hrs I Week
Term
work: 50 Marks
UNIT
I
10 Hrs
Computer Aided Analysis and Synthesis of mechanisms and kinematics
structure of machine tools: Computer Aided Analysis and coupler curves for
four bar mechanism and slider crank mechanism, dimensional synthesis of
mechanisms, three position synthesis of slider crank mechanism, Over lay
method, Bloch Synthesis, Least square technique
Machine
tool motion and their transmissions, Kinematic balancing equation for motion
transmitting elements, Kinematic analysis of machine tool structure: gear
hobbling, gear shaping, bevel gear generator.
Design
for fluctuating loads: Stress Concentration and remedies, S.N.Diagram,
Endurance limit, Factors affecting Endurance Strength, Design for Finite and
Infinite life under reverse stresses, Cumulative damage, Sodberg's and
Goodman's Diagram, Design of components like shaft, bolted joints, springs
etc. subjected to variable loading.
UNIT
III
8 Hrs
Spur
Gears:
various design considerations, Beam Strength, tangential loading, module
Calculations, width calculations, types of gear tooth failures, Estimation of
dynamic load by velocity factor and Spott's equation.
Helical
Gears:
Normal Module, Virtual no. of teeth, force analysis, Beam and wear . strength,
Design of Helical Gears.
UNIT
IV
8 Hrs Rolling Contact Bearings:
Types, Static and Dynamic load Capacity, Stribeck's Equation, Concept of
equivalent load, Load life Relationship, Selection of bearing from
Manufacturer's Catalogue, Design for variable loads and Speeds, Bearings with
Probability of Survival other than 90%, Lubrication and Mounting of bearing.
Sliding
Contact Bearings:
Introduction, Classification of bearings, Hydrodynamic Lubricated Bearings,
Wedge film Journal Bearings, Squeeze film Journal Bearings, Materials used for
Sliding Contact Bearings, Lubricants.
UNIT
V
10 Hrs
Flywheel: Introduction, Coefficient of fluctuation of speed,
Fluctuation of energy, Maximum fluctuation of energy, Energy stored in
flywheel, Stresses in flywheel rim & Arms, Detail Design and construction
of flywheel.
Design
for Manufacture:
General Principles for Design for Manufacture, Principles of design for
casting, Forging, Machining, Welded Joints, etc., Design for Manufacturing
& Assembly, Aesthetic and Ergonomics aspects in design.
UNIT
VI
10 Hrs
Statistical considerations in design and Optimum Design:
Statistical
Considerations in Design: Analysis of Tolerances, Design and Natural
Tolerances, Factor of safety and reliability.
Optimum
Design:
Objectives of Johnson's Method of optimum design, design for normal
specification and redundant and incompatible specification, Lagrange
multipliers.
Term
Work:
1.
Assignments,
one each on Units I, II, IV, V& VI.
2.
Design Project: -
One design project on gear box design, consisting detail design report &
Two Full Imperial size sheets one showing the manufacturing drawing
(Preferably on C.A.D.) of assembly of Gear box and second showing details for
the same.
Oral
is based on above Term work
Text
Book:
1.
Design of Machine Elements, Bhandari V.B., Tata McGraw Hill Publication.
2.
Mechanical Engineering Design, Shigly, McGraw Hill Publication.
3.
Design of Machine Elements, M.F. Spott, Prentice Hall.
References:
1. Theory of Machine, R.S.Khurmi
& J.K.Gupta, S.Chand and Company.
2. Theory of Machine, Ratan,
Tata McGraw Hill Publication.
3. Principles of Machine Tools,
G.C. Sen & A. Bhattacharya.
4. Design Data Book, PSG College
Technology.
5. William C.Ortwein, Machine
Component Design, West Pub. Co. and Jaico Publication House.
6. R.K.Jain, Machine Design,
Khanna Publication Delhi.
7. R.S.Khurmi & Gupta J.K., A Text book of Machine Design, S.Chand and Company.
T.E.
(Production)
311083
Material forming
Teaching
scheme:
Examination scheme: I Lectures:
4 Hrs/W eek
Theory:
100 Marks Practical: 2
Hrs/Week
Oral: 50 Marks
UNIT
I
10Hrs
Fundamentals of Material Forming: Introduction of forming processes.
Strain hardening Concept of flow stress determination, Theory of plasticity,
Yield criteria for ductile materials- Von mises criteria, Tresca criteria.
Effect of temperature, strain rate, metallurgical microstructure, chemical
composition and mechanical properties, for Classification of material forming
process. Concept of Formability, formability limits s. and formability
diagram.
UNIT
II
10Hrs FORGING: Introduction,
classification of forging processes. Forging equipment- Hammers, presses,
furnaces etc. construction working capacities and selection of equipment.
Basic forging operations such as drawing, fullering edging, blocking etc. wing
Forgability tests, design of forging as a product, friction in forging.
Forging defects and r the remedies. New technologies: Liquid metal forging,
isothermal forging, No draft forging, P/M forging, Rotary swaging, roll
forging, Lubrications in forging.
UNU
III
6 Hrs WIRE AND TUBE DRA WING: Introduction rod and wire drawing machines -
construction and working. Preparation of stock for wire drawing. Wire drawing
dies, material and design. Patenting heat treatment. 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 penetration.
lubrication in tube drawing
UNIT
IV
8 Hrs ROLLING OF METALS: Scope and importance of rolling. Types of Rolling
Mills- Construction and working. Roll bite, reduction, elongation and spread.
Deformation in rolling and determination forces required. Process variables,
redundant deformation. Roll flattening, Roll camber - its effect on rolling
process, mill spring. Defects in rolling. Automatic gauge control- Roll pass
classification & design. Lubrication in rolling
UNIT
V
8
Hrs EXTRUSION: Types: Direct, reverse, impact, hydrostatic extrusion.
Dies for extrusion, stock penetration. Extrusion ratio Force equipment (with
and without friction), metal flow in extrusion, defects. Role of friction and
lubricants. Manufacture of seam-less tubes.
UNIT
VI
10Hrs
ADVANCED METAL FORMING PROCESSES: High
velocity forming- principles, comparison of high velocity and conventional
Forming processes. Explosive forming, Magnetic pulse forming, Electro
hydraulic Forming.Microforming, Microcoinig, microextrusion, Microbending
Stretch
forming, coining embossing, curling spinning, flow forming advantages,
limitations and application of the process
Term
work;
Term
work shall consist of
1.
Assignment based on each topic of syllabus
2.
Study of roll pass design for two structural shapes -Round & Square.
3.
A report on factory visit, comprising of product range, processes, plant
layout. AuxilIary equipment, process parameters etc.
Text
Books:
1.
Dieter, Mechanical Metallurgy
2.
P.N. Rao, Manufacturing Technology, TataMcGrawHill
3.
G.W. Rowe, Principles of industrial metal working process, Edward Arnold
References:
1.
Dr. R. Narayanswamy, Metal Forming Technology, Ahuja Book Co.
2.
Surender Kumar, Principles of Metal Working.
3.
ASM Metal hand book Vol: 4 forming.
T
.E. (Production Engineering)
311084
PRODUCTION PLANNING AND CONTROL
Teaching
Scheme:
Examination Scheme:
Lectures:
4Hrs / Week
Theory:
1 00 Marks Practical: 2Hrs / Week
Term
work: 50
UNIT-I
6 Hrs
Introduction
to PPC:
Role and stages of PPC, PPC as an integrated function, Product Life Cycle
Analysis, Types of Production systems.
UNIT-ll
8Hrs
Forecasting
Techniques:
Use and types of forecasting, Methods of forecasting and comparison,
Verification and control.
UNIT-III
10Hrs
Scheduling Techniques And Production Control: Process sheet, Routing,
Scheduling- Gantt Chart, Machine Loading Chart, Line of Balance, Line
Balancing, Dispatching rules, Sequencing - Johnson's rule, Loading, Follow-
up, Evaluation.
UNIT-IV
10 Hrs
Materials
Planning And Purchasing: Scope and requirement of MRP, MRP I and MRP II,
Master Production Schedule, Bill of Materials, Capacity Requirement Planning,
Introduction to ERP, Purchasing - Documentation, Make or Buy decisions, Vendor
Development.
Inventory
Control: Types of Inventory Cost of Inventory, EOQ, Selective Inventory
Control, Replenishment Systems.
UNIT-VI
6 Hrs
Stores
Management:
Types of stores, Storage layout and storage systems, Stores Documentations,
Stores Control and Control of Wastage and surplus, JIT, Value Stream Mapping.
Text Book:
1.
J.L. Riggs, "Production Systems - Planning Analysis and Control ",
JhonWiley & Sons.
2.
J.B. Dilworth, "Operations Management - Design, Planning &
Control for
Manufacturing
and Services ", McGraw Hill.
3.
S N Charry, "Production and Operation Management" Tata McGraw- Hill
Reference Books:
1. Samuel Elion, Elements of PPC
", Universal Book Company.
2. Martand Telsang,
"Industrial Engineering and Production Management" S. Chand and Co.
Ltd.
3. Moore, "Production
Control ".
4. Mager and Boodman,"
Production Planning And Inventory Control"
5. Martin Star, "
Production Management ".
6. Erry Johnson, " Process
Engineering ".
7. E. EL. Buffa, "
Production Management ".
8. A. K. Bewoor,
"Production Planning and Control" Satya Publication.
TE
Production Engineering
311085
Metal Cutting and Tool Design
Teaching
scheme:
Examination scheme: Theory :
4 Hrs/W eek
Paper:
100 Marks Practical: 2 Hrs/Week
Oral
: 50 Marks
UNIT
I
10 Hrs
Theory
of metal cutting:
Cutting tools, tool geometry, concept of speed, feed, depth of cut &
cutting action & effect of these on cutting forces, types of chips,
Merchant circle of forces. Estimation of cutting forces. Empirical relations.
Tool force dynamometers. Measurement of d cutting forces and power required.
Cutting
tool standards and materials:
Tool signature ORS & ASA methods, tool standards: Single point cutting
tool, drills, broach, reamer, milling cutters. Cutting tool materials, heat
treatment of tools. Non-conventional tool geometry: Koleshov, Gussian tools,
Anti chatter tools, Advance tool materials, coating on tool, throwaway
inserts.
UNIT
III
8 Hrs
Heat
generation, tool life & Economic of cutting tools:
Heat generation in cutting, cutting fluid, tool wear, Tool life-modified
Taylor's equation. Factors affecting tool life, Machinability and its rating,
criteria for Machinability. Economics of tooling. Criteria for minimum cost & maximum production.
Design
of cutting tools:
Single point cutting tool, Form tool, drills, reamers, milling cutters, and
Broaches. Manufacturing of Cutting tools.
UNIT
V
8 Hrs
Fundamentals
of Jigs and fixtures: Significance and purpose of jigs and fixtures and
their functions in manufacturing processes. Classifications of jigs and
fixtures. Designs features of main elements of Jigs and fixtures such as
locating, clamping and guiding elements and their integrations. Indexing,
locking and auxiliary elements. Bodies and bases or frames of Jigs and
fixtures. Economics of Jigs and fixtures, Pneumatics & Hydraulics for jig
& fixtures.
UNIT
VI
10 Hrs
Design
of jigs & fixtures: General guidelines & procedures for design of
Jigs and fixtures. Design & selection of standard elements, Analysis of
number of clamping forces required & their magnitude, concept of modular
fixtures & tool presetting fixtures.
Text
Book:
1. Wilson, fundamentals of tool
design, A.S.T.M.E.
2. M.H.A. Kempster, Introduction
to Jigs and fixtures design.
3. Dolyle, Manufacturing
processes and material for engineers.
Reference:
1. P C Sharma, Production Engg.
, Khanna publishers.
2. P.C. Sharma, Machine tools
& Tool Design
3. Richard Kibbe, John E.Neely,
Meyer, White, Machine tool practices
4. Dolalson, Lecain and Goold,
Tool design, Tata McGrawhill.
5. Hoffman, Introduction to Jigs
and fixtures.
6. Tool Engineering Handbook,
A.S.T.M.E.
7. Basu, Mukherjee and Mishra,
Fundamentals of tool engineering and design, Oxford and ffiH publishing.
8. R. K. Jain, production
technology, Khanna Publishers
9. Milton Shaw, Metal cutting
principle
10. P .H. Joshi, Jigs &
Fixtures.
11.
Dr. Surender Kumar, Production Engineering Design
List
of Experiments:
1. Experiments on chip
formation.
2.
Verification of Metal cutting Theories.
3.
Measurement of cutting forces (anyone)
4.
In Turning / Milling / Drilling.
5.
Effect of tool geometry, cutting speed, feed, depth of cut on cutting
parameters.
6.
Design and working drawing of any three of following cutting tools:
7.
Single point tools, Form tool, Reamer, Milling cutter, Broaches, Drills.
8.
Design and Working drawing of one jig. (Drilling, Reaming, Tapping)
9.
Design and Working drawing of one fixture. (Turning, Milling, Broaching)
T.E
Production
311086
Production Practice-1
Teaching
Scheme:
Examination Scheme: Practical: 2 Hrs/W eek
Practical: 50 Marks
Each
candidate shall be required to complete and submit the following term work.
Composite
job involving different machining operations.
Part
A:-
1)
Lathe: external and internal threading (Vee, Square or Acme threads),
taper turning,
grooving, knurling, drilling operations on lathe.
2)
Milling: helical or bevel gear cutting on a milling machine.
Part
B:- Journal consistin2 of :
1)
Preparation of journal consisting of calculation and procedure for
above gear cutting on
milling machine.
2)
Safety aspects used in the machine shop:- Precautions and care to be taken
while working on various machine tools
e.g. lathe, milling, drilling, grinding etc.
Note:
- A practical examination of 12 hours duration shall be conducted at the end
of semester based on the part A.
Teaching
Scheme: -
Examination Scheme: -
Theory:
4 hrs /week
Paper:
100 Marks
UNIT
I
6Hrs
Machine
Tool Automation:
Automation Concepts, Automatic and Semiautomatic Machine Tools and their
Classification, Turret and Capstan Lathes. Single Spindle and Multi-spindle
Automats, setup of automatics and semiautomatics. Tooling Layout and Operation
Sheet, Cam Tool Layout for Single spindle automat. Concepts of Transfer
Machines/Lines.
UNIT
II
10 Hrs
NC/CNC/DNC Machining: NC/CNC Machining: Introduction to NC,CNC,DNC Machines, Comparison between NC and Conventional Machine Tools, Basic Principles of NC Machines, its Advantages, Tooling Requirements, Introduction to Turning and Machining Center.
UNIT
III
8 Hrs
Surface Coating Processes: Electroplating, Electroless plating, Phosphating, Galvanizing, Metal spraying, Anodising. Plasma coating, physical and chemical vapour deposition, Ion implantation-influence of process parameters on coating.
Micro
and Nano Machining: Concepts, introduction and applications of the process and
machines.
UNIT
IV
8 Hrs
High
Volume Manufacturing System:
Analysis of automated flow lines, Analysis of transfer line without storage
buffe, partial automation, flow lines with storage buffer, computer
simulation, assembly line balancing, automated material handling and
inspection methods.
Unit
V
10 Hrs .
FMS
and Robot Technology:
Concept of manufacturing systems and automation, automation strategies, group
technology, concept of machine cell and CMS, Building blocks of FMS Planning
and implementations of FMS, Computer integrated manufacturing (CIM). Elements
of robot, robot controller unit, manipulators, end effectors, robot joints,
and degrees of freedom, Robot axes and configuration, robot sensors, robot
cells layout and applications Simulation Of Manufacturing Systems -
Introduction, Concept of System and their Nomenclature, Types of Models,
Applications.
UNIT
VI
6 Hrs
Controls/
Installation/Chip Disposal! Cutting Tool Machines:
Machine
Tool Operator's Control Systems: Need of Standardization, Classification,
Controls in Conventional and NC/CNC Machines, Adaptive Control.
Machine
Tool Installation and Maintenance, Selection of Machine Specification, Chip
Disposal Systems, Recovery of Material from Disposal.
Cutting
Tool Manufacturing Machines, Cutting Oil/Coolant Type and Selection.
Text
Book:
1. HMT Production Technology
2. Chapman; Workshop Technology
3. P.N.Rao-manufacturing technology Tata McGraw
hill publication.
Reference Books: -
1
Degarmo,
Black and Kohser; Material and Processes in Manufacturing
2 PC Sharma; Production Technology (Manufacturing Processes)
3 Roy Lindberg; Processes and Materials of Manufacture
4 Kalpakjian;
-Manufacturing Engineering and Technology,- Manufacturing Processes for
Engineering Materials
5. Pabla Adithan;
CNC Machines
6. Kundra Rao Tiwari;
Numerical Control and Computer Aided Manufacturing
7. Mikell P. Groover;
Automation, Production Systems and Computer Integrated Manufacturing
8
G
C Sen. and A.Bhattacharya; Principles Of Machine Tools
9 PH Joshi; - Cutting Tools, - Tooling Data
10
Pande Shan; Modern Machining Processes
11. Ghosh Malik;
Manufacturing Science
12. Surenderkumar and Umeshchandra; Production Engineering Design
13.
P.N.Rao-
CAD/CAM/CIM Tata McGraw hill publication.
14.
Khire
and Kulkarni CAD/CAM/CIM
TE
(Production)
311082
MANUFACTURING PROCESS-II
Teaching
Scheme
Examination Scheme:
Lectures:
4 Hrs /Week
Theory:
100 Marks
Classification of welding processes, Surface and edge preparation, fundamentals of heat and fluid flow in fusion welding. Arc welding processes-Carbon arc, submerged arc, tungsten inert Gas (TIG), metal inert gas (MIG), Electro slag, plasma arc & stud welding process- theory, comparison on merits, limitations and applications. Classification of arc welding processes with reference to BIS, ASTM, IS standards. Fluxes used in arc welding.
UNIT
II
8 Hrs
Gas
welding - processes and equipment used, types of flame, adjustment of flame,
oxy Acetylene welding, gas cutting - merits, limitations and applications of
above processes. Electric resistance welding - processes and equipment used,
spot, seam, projection, Butt, Percussion welding, resistance tube welding,
merits, limitations and applications.
UNIT
III
8 Hrs
Pressure welding, diffusion,
ultrasonic, friction, explosive, forges, Thermit welding, laser,
electron beam welding - equipment used - merits, limitations and applications of above processes.
Brazing, braze welding and
soldering processes types of flames, filler metals fluxes used merits,
limitations and applications of above processes.
UNIT
IV
8 Hrs
Solidification
of casting, theory and its applications. Chvornov's Rule. Principles of
gating, risering and their design methods. Progressive and directional
solidification casting design considerations. Segregations, shrinkage,
porosity, cellular structure, hot tear problems in casting. Computer
applications in casting design& software’s.