NOTE
Theory Paper
Duration UNLESS Specified, always it will be 03 (THREE) Hours Duration
• Note:
For Seminar, a group of nine students shall be considered.
• After
the Sem. VI examinations the student shall undergo a vacational in plant
training
of four
weeks duration which will be assessed during B. E. Semester VII of next
year.
T. E.
(Production Engineering) – Semester V
1.
METALLURGY - I
Teaching
scheme: Examination scheme:
Lectures:
3 Hrs per Week Theory Paper: (3 Hrs) - 100 Marks
Practical:
2 Hrs per week per batch Term Work: 25 Marks
Course
Objective
Study of
structures, compositions, properties, applications, testing, specifications and
selection
of various Ferrous and Non Ferrous materials
SECTION
–I
1.
Introduction Of Materials: Classification
metals, alloys, ceramics, polymers and
composites
(GRP, glass cermets and cermets), types, properties and applications (2)
2.
Crystallography - Unit Cell, Bravais lattices, study of crystal structures of
S.C., B.C.C., F.C.C. and C.P.H. - Average number of atoms per unit cell, A.P.F.
coordination number, Miller indices for planes and directions (2)
3. Metals
and Alloy Systems
(a)
Nucleation and growth, dendrite structure
(b)
Concept of phases, constituents (components) and degree of freedom
(c) Phase
rule and lever rules, modification and applications
(d)
Construction of phase diagram using cooling curves
(e)
Equilibrium diagrams for isomorphous systems, eutectic system, impure
eutectic
systems (partial solubility), peritectic and intermetallic compounds.
explanations
of cooling of an alloy from liquid state to room temperature.
room
temperature structures, coring
(f) Solid
solutions : types, substitutional and interstitial, ordered/ disordered type
solid
solutions, Hume- Rothery rules for formations of substitutional solid solutions
(g)
Intermediate phases: electron compound, laves phases (interstitial compounds)
(7)
4. Study
of Ferrous Equilibrium Diagrams, Compositions, Properties, Applications and Specifications
of Important Alloys
a) Fe-Fe3C
equilibrium diagram - plain carbon steels, effect of carbon on
structure
and properties, free cutting steels
b) Alloy
steels - effect of alloying elements on Fe-Fe3C
equilibrium
Diagram
and properties of steels -tool steels, stainless steels, heat resisting steels,
HSLA steels, OHNS steel, structural steels, low temperature alloys, Invar,
Hadfield steel, spring steel
c) Cast
Irons - Fe-C Equilibrium Diagram, Factors Affecting Structure of
C.I.(graphitization),
Carbon equivalent of cast iron, grey C.I., white C.I., mottled C.I.,
malleable
iron (heat treatment cycle only), S.G.iron, meehanite, alloy C.I., Ni-Hard,
modified
Ni- Hard and Ni-Resists,.
d) Wrought
Iron (8)
SECTION
–II
5. Study
of non-ferrous equilibrium diagrams, compositions, properties, applications and
specifications of important alloys
a)
Copper-based alloys - Cu-Ni- Cupronickels, Cu-Zn- Brasses, Cu-Sn-Wrought and
Cast Tin
Bronzes, Cu-Be
b)
Aluminum-based alloys - Al-Cu: Duralumin, Al-Si: modification treatment
c)
Titanium-based alloys - Ti-Al, Ti-Mn
d)
Non-ferrous equilibrium diagrams - Pb-Sn : solders, Sn-Sb : Babbit (4)
6.
Principles of destructive testing- Introduction, purpose and importance of,
(a)
Tension test - stress-strain diagrams for ductile and brittle metals, test
procedure
and analysis of results
(b)
Hardness test - concept, various tests such as Brinell, Rockwell, Vickers,
Shore’s
Scleroscope
(c) Impact
test - Charpy and Izod tests
(d)
Fatigue test - S-N curve for ferrous and non-ferrous alloys, factors affecting
endurance
strength
(e) Creep
test - effect of temperature, creep curve (4)
7.
Pyrometry - Study of principles, construction, working, temperature ranges,
accuracy
and
applications of following pyrometers
(a)
Contact type - thermocouples and resistance pyrometers
(b)
Distant type - optical pyrometer (disappearing filament type) and total
radiation
pyrometer
(2)
8. Theory
of plastic deformation
(a)
Imperfections and defects in crystals - point defects, line defects (edge and
screw
dislocations),
plastics deformation in crystalline materials, slip and twinning
(b) Hot
and cold working of metals and alloys - effect of cold working and
annealing
on structure and properties
(c)
Fractures - Griffith’s theory of brittle fracture, ductile fracture
(d)
Fatigue and creep-mechanisms and theories (5)
9.
Selection and Specifications of engineering materials for various applications
(a)
Materials based on IS, BS/EN, ASTM, AISI/SAE standards
(b)
Various criteria for selection
(i)
Material properties –mechanical, physical and chemical (ii) manufacturing
properties -
formability,
weldability, castability, heat-treatability and machinability (iii) cost and
(iv)availability
(5)
TERM
WORK
1. Study of
Metallurgical microscope and need for microscopy
2.
Metallography – preparation of specimen and study of mounting
3. Study
of microstructure of steel
4. Study
of microstructure of cast iron
5. Study
of microstructure of Non-ferrous alloys
6.Macroscopy
and spark test of ferrous and non-ferrous alloy specimens
7.
Assignment on Selection of Steels
Specifications
Properties and applications of Steels:
a.
Structural steels-
En3 as per
B.S 970 / St 42 as per IS 1079,
En4 as per
B.S 970/ St42-S as per IS 1079 and equivalent specifications,
b. Medium
carbon/ Heat treatable steels:
En 8/ C45
as per IS 1570/ C 1042 as per AISI, En 9, En 18B as per B.S 970/ 40Cr1 as per
IS 1570/
5135 as per AISI, En36, En 42 etc and Equivalent specifications
c. Case
Hardening steels-
En32 as
per B.S 970/ C14 as per IS / C 1016 as per AISI/SAE
En 207 as
per B.S 970/15Cr65 as per IS1570 &
17 Mn1Cr
as per IS 1570/5117as per AISI
d.
Unalloyed tool steels
Ex- T 90
as per IS 1570/ W1 as per AISI
e. Cold
working alloyed tool steels (Die Steel or High C high Cr steel)
T 215 Cr
12 as per IS 1570/ D3 as per AISI
8.
Assignment on Selection of Cast Irons
Specifications
Properties and applications of Cast Irons
a.
Specifications of Grey Cast Iron- IS 210 and equivalent.
b.
Specifications of Malleable Cast Iron Black Heart Malleable (B35-12 &
B32-10) and White Heart Malleable (W 35-4 & W 40-4)
c.
Specifications of SG Iron as per IS 1865
9.
Assignment on Selection of Non Ferrous Alloys
Specifications
Properties and applications of Non Ferrous alloys
a.
Aluminum based alloys (Important Al-Si, Al-Cu as per BS/LM series/
b. Copper
based alloys (Important Cu-Sn, Cu-Zn and Cu-Be alloys)
c. Tin and
Lead based alloys (Sn-Sb Babbits/ Pb-Sn Solders)
REFERENCE
BOOKS
1.
Introduction To Physical Metallurgy, -Avner, TMH
2.
Engineering Metallurgy Vol. I And II ,- R.A.Higgins (ELBS)
3.
Engineering Metallurgy - E. C. Rollason, (ELBS)
4.
Introduction To Engineering Materials,- B.K.Agrawal (TMH )
5.
Mechanical Metallurgy(SI Units), -Dieter, (TMH)
6. Engg
Materials, Properties and Selection, Kenneth G. Budunski (PHI)
7.
Engineering Metallurgy by Lakhtin, C.B.S. Publishers & Distributors
8.
Physical Metallurgy, Vijendra Singh , Standard,Publishers Distributors, New
Delhi
9.
Materials Science And Metallurgy, -Dr. Kodgire ( Everest , Pune )
T. E. (
Production Engineering) – Semester V
2. Theory
of Machines – II
Teaching
Scheme: Examination Scheme:
Lectures:
3 Hrs. / Week Theory Paper (3 Hrs): 100 Marks
Practical:
2 Hrs. / Week/ Batch Term work: 25 Marks
Course
Objective
To
introduce the students to the kinematics and kinetics in the machines and
mechanisms.
SECTION
– I
1. GEAR:
Introduction, law of gearing, involute and cycloidal profiles,
gear terminology,
length of
path of contact, arc of contact, contact ratio, interference of involute gear
teeth,
helical
and double helical gears, (5)
2. GEAR
TRAINS: Types of gear trains, analysis of gear
trains. (4)
3. BALANCING:
Static and dynamic balancing, balancing of rotary masses, masses
in
the same
plane, masses in different planes, balancing of reciprocating masses, primary
and
secondary balancing, balancing of locomotives, balancing of multi-cylinder
inline
engines,
balancing of V-engines (6)
4. FLYWHEEL:
Crank effort, turning moment on crankshaft, turning moment
diagram,
fluctuations
of energy and speed. (4)
SECTION
– II
5. GYROSCOPE:
Introduction, Gyroscopic couple, Effect of gyroscopic couple on
motion of
aero plane, naval ship, two and four wheelers, Gyroscopic stabilization (5)
6. GOVERNORS:
Functions of governor, types of governors, characteristics of
governor,
effort and power of governor. (5)
7. VIBRATIONS:
a)
Longitudinal and transverse vibrations: Introduction, types, natural frequency
for
various
loading systems, Dunkerly’s empirical formula, critical speed of shaft, (4)
b)
Torsional vibrations: Introduction, natural frequency for single, two and three
rotor
system,
bifilar, trifler suspension system, torsionally equivalent shafts, free
torsional
vibrations
of a geared system (5)
TERM
WORK
1. At
least one industrial visit to study industrial practices related to the subject
and
submission
of the visit report.
2. One
presentation by each student for 10 minutes related to the subject and
submission of the same. (Optional)
And any
eight experiments from below,
1.
Generation of involute gear tooth profile.
2. Study
of differential gear box.
3.
Experiment on verification of static and dynamic balancing principle.
4.
Experimental verification of gyroscopic principle.
5. Determination
of the governor characteristics of Porter and Hartnell governor.
6.
Experiment on free longitudinal vibrations
7.
Experiment on trifler suspension system.
8.
Experiment on critical speed of the shaft.
9.
Experiment on forced vibration
10.
Measurement of vibrations by using vibration-measuring instrument.
(At least
one experiment should involve use of computer.)
REFERENCE
BOOKS
1. Theory
of Machines, - Thomas Bevan, CBS Publishers & Distributors
2. Theory
of Machines and Mechanisms, -Joseph Shigley, McGraw Hill Intl. Edition.
3. Theory
of Machines and Mechanisms, -P. L. Ballaney, Khanna Publications
4. Theory
of Machines, -W. G. Green, Blackie & Sons
5. Theory
of Machines, -S. S. Ratan , Tata McGraw Hill Co. Ltd.
6. Theory
of Machines, -R. S. Khurmi and J. S. Gupta, Eurasia Pub. House (Pvt.) Ltd.
7.
Mechanism and Machine Theory, -J. S. Rao & R. V. Dukipatti, Wiley Eastern
Ltd.
T. E. (
Production Engineering) – Semester V
3. Design
of Machine Elements
Teaching
Scheme: Examination Scheme:
Lectures:
3 Hrs. / Week Theory Paper (3 Hrs):
100 Marks
Practical:
1 Hrs. / Week/ Batch Term work: 25 Marks
Course
Objective
To study
the different types load considerations and design aspects of various machine members.
SECTION
– I
1.
Introduction: Concept of machine design, general design considerations, design
procedure;
factor of safety for different types of loading its significance and selection;
theories
of failures, Selection of engineering materials for a component considering
functionality,
raw material generating process, strength, cost, quantity and aesthetics, use of
IS codes (5)
2. Design
for static loading: Knuckle joint, turnbuckle, cotter joint, levers.(3)
3. Design
for fluctuating loads: Fatigue phenomena, concept of stress vs. number of
cycles
diagram and endurance limit, stress concentration and remedies, use of Goodman and
Soderberg diagram in design of machine elements like shafts, springs and
couplings. (5)
4. Design
of shafts, keys, splines and couplings: Design of solid and hollow shafts for
strength
and rigidity against pure torsion, pure bending, combined bending, torsion and axial
loads; design of keys and splines; design of rigid and flexible couplings.
(6)
SECTION
– II
5. a)
Design of pressure vessels: Classification and design of thick a thin pressure
vessels
and cylinders.
b) Design
of joints: Design of bolted, riveted, and welded joints subjected under
transverse
and eccentric loading, materials for bolts, initial tightening loads on bolts,
effect of
washer and gasket, uniform strength bolts.(5)
6. Design
of springs: Types, applications, spring materials, stress deflection equation
of helical spring, Whal’s stress factor, style of ends, design of springs for
valves, clutches, buffers etc., design considerations for leaf spring.(4)
7. Design
of power screw: Types, materials used, thread forms and their applications; types
of stresses induced, overhauling and self-locking properties, re-circulating
ball screw, design of nuts, methods of pitch error compensation for machine
tools (4)
8. Design
of gears: a) Spur gears- materials, gear tooth loads, number of teeth, face
width, strength of gear teeth, static beam strength (Lewis equation), dynamic
tooth load (Spot equation), Wear strength (Buckingham’s equation), estimation
of module based on beam strength and wear strength, gear design for maximum
power
b) Helical
gears- No. of teeth, force analysis, beam and wear strength, effective load and
design procedure
c)
Construction details of gears i.e. hub, web, arms, rim, gear Lubrication, gear
tooth
failures
and remedies. (7)
TERM
WORK
(Any Six
of the following exercises.)
(Standard
components shall be selected from relevant I.S. codes and Design Data
Handbooks
for the exercises given below.)
1) Study
of Engineering Materials, their applications and selection as per different
standards
used in practice.
2) Design,
stress analysis and working drawing of components and assembly of Cotter Joint,
Knuckle Joint and Turnbuckle.
3) Design
of Coupling and Detailed Working drawings with assembly.
4) Design
of bolted, riveted and welded joints for transverse and eccentric loading.
5) Design
of Gear Drive involving Gears, Shafts, and Keys with working drawings.
6) One
assignment using CAD package on any one of the exercises 2, 3, or 5 above.
7) Two
computer programs on any of the above exercise
REFERENCE
BOOKS
1. Design
of Machine Elements, V. B. Bhandari, (Tata McGraw-Hill Publishing
Company
Ltd.)
2.
Elements of Machine Design, N. C. Pandya and C. S. Shaha, (Charotar Publishing House)
3.
Mechanical Engineering design, J. E. Shigley, Mitchell, (McGraw-Hill Publishing
Co.Ltd)
4. Machine
Tool Design, N. K. Mehta, (Tata McGraw-Hill Publishing Company Ltd.)
5. Design
of Machine Elements, Dbrovalsky ( MIR Publisher )
6. A Text
Book of Machine Design, R. S. Khurmi, (S. Chand)
7. Design
of Machine Elements by M. F. Spoots, T.E.Shoup (PHI)
8. Machine
Design, R. K. Jain, (Khanna Publishers.)
9. Engg.
Design, a Materials & Processing Approach, G. Dieter, (Tata McGraw-Hill
Publishing
Company Ltd.)
10.
Computer Aided Analysis and Design of Machine Elements by Dukki Patti, Rao,
Bhat ,
(New Age, Delhi)
11. CMTI
Machine Tool Design Handbook (TMH)
12. Design
of Machine Elements, An Integrated Approach by Robert and Norton,
(Pearson)
13.
Machine Design by Black and Adams (McGraw-Hill Publishing Company Ltd)
T. E.
(Production Engineering) – Semester V
4. METAL
CUTTING TECHNOLOGY
Teaching
Scheme: Examination Scheme:
Lectures:
3 Hrs. / Week Theory Paper (3 Hrs): 100
Marks
Practical:
1 Hr. / Week/ Batch Term work: 25 Marks
Course
Objective
Study of
metal cutting technology including the process, measurements, design and
selection
of various cutting tools and their industrial specifications.
SECTION
I
1. Theory
of Metal Cutting:
a) General
principles: Wedge action of cutting, concept of speed, feed and depth of cut, orthogonal
and oblique cutting. (2)
b)
Mechanics of metal cutting: Chip Formation and types of chips, shear plane
angle,
cutting
ratio and force relationship - velocity relationships, Merchant theory, it’s
assumptions
and limitations (4)
c) Tool
dynamometry – Requirements, types and applications (2)
d)
Machinability of metals – Cutting force, surface roughness and tool life as
measures of machinability.
(i) Cutting force - Effect of speed, feed,
depth of cut, tool materials, angles and work material on - tangential cutting
force, gross and net power requirements, concept of specific cutting force,
specific power consumption.
(ii) Tool Life - Flank and crater wear,
preliminary and ultimate failure, mechanism of wear - effect of variables such
as speed, feed, depth of cut and material on tool life,Taylor’s equation.
(iii) Surface roughness: Factors affecting
surface roughness like speed, feed and depth of cut, tool angles, tool/work
piece materials etc. built up edge, chatter and its elimination.
(iv) Metal cutting with and without
coolants, comparison, types and selection of coolants. (9)
e)
Sharpening of drills and milling cutters using tool and cutter grinder(1)
SECTION
II
2. Tool
Materials: Study of modern tool materials such as
uncoated / coated carbides, ceramics, cermets, cubic boron nitride, diamond
etc. Selection of tool grades and styles including specifications from
commercial catalogues for different processes like turning, milling, drilling,
grinding for different operations. (4)
3.
Design of Cutting tools:
a)
Single point tools - Definition of angles as per ASA
system and ORS system, tool signature,
design procedure of single point turning tool and boring bar, constructional
features of carbide tools - brazed and indexable insert, coated tips,
components of tool assembly, ISO nomenclature of cutting tools (4)
b) Form tools: Flat, tangential and
circular form tools, Constructional features-Design of flat and circular form
tool. (2)
c) Drills and Reamers: Geometry,
nomenclature, types, selection and applications (1)
d)
Milling cutters: Geometry, nomenclature, types, selection procedure(2)
e)
Broach: Types, Applications, Nomenclature - Design of broach.(3)
f) Gear cutting tools- Nomenclature, types
and selection of gear hobs and shaper cutters(2)
4. Modern cutting tools for
CNC machines, high speed machining, modular tooling, tool presetting (2)
Note:
Selection of cutting tools shall be done by using catalogs of commercial tool
manufacturers.
TERM
WORK
1.
Measurement of Cutting force with the help of Tool Dynamometer (Any Two)
a) Lathe
tool dynamometer
b) Drill
tool dynamometer
c) Milling
tool dynamometer
2.
Machining of minimum two jobs of different materials such as C.I., Steel,
Aluminium
etc. and
measurement of surface roughness to study the effect of parameters such as
feed,
tool nose
radius, depth of cut on the surface roughness.
3. Design
of form tool and broach for given components
4. Industrial visit to study applications of tools for different
metal cutting processes.
REFERENCE
BOOKS
1. Cutting
tools - P.H. Joshi - Tata McGraw Hill Publishing Co. Ltd..
2.
Production Technology - HMT Handbook (TMH)
3. Metal
Cutting Theory and Cutting Tool Design - Arshinov V. and Alekseev G., Mir
Publication.
4. Metal
cutting Theory and Practice- A. Bhattacharya, New Central Book Agency.
5. Metals
Handbook, Vol. 16 Machining, A.S.M., Metals Park, Ohio.
6. Metal
Cutting and Tool Design - Dr. Ranganath - Vikas Publishing House.
7. Metal
Cutting Principals - Shaw M.C. - Oxford Calrendon Press, 1984.
8. Theory
of Metal Forming and Metal cutting by Sinha, Prasad ( Dhanpat Rai).
9. Machine
Tool Engineering: K. R. Nagpal, Khanna Publication.
10. Tool
Engineering handbook - ASTME, Frank Wilson (Editor) (TMH)
11. Text
Book of Production Engineering (Tool Design) by K. Surendar and Umesh
Chandra.
12.
Commercial catalogues of tool manufacturers like SANDVIK, KENNAMETAL,
TAEGUTECH,
ISCAR, MITSUBISHI, Grindwell Norton, Carborundum Universal etc.
T. E.
(Production Engineering) – Semester V
5. METAL
FORMING & PLASTICS TECHNOLOGY
Teaching
Scheme: Examination Scheme:
Lectures:
3 Hrs. / Week Theory Paper (3 Hrs): 100 Marks
Practical:
2 Hrs. / Week/ Batch Term work: 25 Marks
Course
Objective
To
introduce the students to the theory and practices of metal forming and
plastics
processing.
SECTION
I
1. Theory
of Plasticity : Flow curve, Concepts of true stress and true strain, stress
tensor and strain tensor, yield criteria and their comparison., plastic
stress-strain relationships (5)
2.
Rolling: Classification of rolling processes, rolling mill types, deformation
of metal in rolling, roll bite, elongation, reduction, defects in rolling,
rolling of sheets, plates, bars, sections and tubes, applications (4)
3. Forging
: Basic operations, types of forging, forging hammers/ presses, forging stress and
force calculations, die design considerations, forging defects, applications
(4)
4.
Extrusion: Equipment and principles, types of extrusion, direct, indirect,
impact,
hydrostatic,
tube extrusion, metal flow in extrusion, defects, factors affecting extrusion load,
(3)
5.
Drawing: Types of Drawing, Rod/wire drawing, equipment and principles of
process, defects, Tube drawing, Seamless pipe manufacturing. (2)
6.
Advanced Metal forming Processes: Explosive forming, Electro-hydraulic forming,
Electromagnetic
forming, Magnetic pulse forming,. (2)
SECTION
II
7. Fine
Blanking: Process, die design considerations, equipment (1)
8. Plastic
Materials: Types, raw materials for plastic, properties, thermosetting
plastics, thermoplastics, laminated and reinforced plastics, plastisols,
additives, applications. (4)
9.
Injection Molding: Process, equipment, applications, product design for
injection
molding,
general mold construction, nozzles, runners and gates (5)
10. a) Plastic extrusion: Process,
equipment, extruders,
b) Compression molding: Process, equipment,
compression mould, transfer molding (3)
11. a) Blow molding: Principles, material
characteristics in blow molding, production of parison, b) Rotational molding
process for making hollow plastic articles (3)
12.
Thermoforming- Process, heating equipment, basic forming methods, thermoform packaging;
Calendaring- various calendaring processes, applications
(2)
TERM
WORK
1. Die
design for a simple forged component including calculations and drawing
2.
Numerical exercise on Roll Pass Design including calculations and schematic
drawing
3.
Designing layout for multi-pass wire drawing
4. Making
simple components of suitable material using the following processes /
equipment
(Any four different components for a group of maximum four students
each).
a) Hot
Forging
b) Wire
Drawing
c)
Extrusion
d) Rolling
e)
Injection Molding
f) Plastic
Extrusion
5. Industrial
visits (minimum two) for studying the metal forming and plastic
processing
and submission of reports
6. Study
of die clamping and die handling for plastic molding processes
REFERENCE
BOOKS
1.
Mechanical Metallurgy (S.I. Units) - Dieter, McGraw Hill
2.
Manufacturing Processes – Begman, Amstead etc.( John Wiley)
3. Rowe,
Principles of Industrial Metal working Processes,
4. ASM
Handbook on Forming.
5. Forging
and Forging Die Design - Sharan, Prasad, Saxena.
6. Rolling
of Metals: Ivankove and Chaturvedi (Yantrik Publications, Mumbai)
7.
Extrusion - Pearson (McGraw Hill)
8.
Manufacturing Technology: Foundry, Forming and Welding by P.N. Rao (TMH)
9. Plastic
Technology: Theory, Design & Manufacture – William J. Patton
10.
Plastics-6/e, J. Harry DuBOIS, Frederick W. John, Van Nostrand Reinhold Co.
11.
Manufacturing Engineering Technology by Kalpakjian (Addison Wesley )
12.
Manufacturing Processes for Engineering Materials by Kalpakjian (Addison Wesley
)
13.
Injection Mold Design, R.G.W. Pye 4/e, Affiliated East West Press Pvt. Ltd. New
Delhi.
14. Plasic
Manufacture: Properties & Applications – N. J. Miss, ELBS
15.
Plastics for Industrial Use- Sasse John
T. E. (
Production Engineering) – Semester V
6.
METROLOGY
Teaching
Scheme: Examination Scheme:
Lectures:
3 Hrs. / Week Theory Paper (3 Hrs): 100 Marks
Practical:
2 Hrs. / Week/ Batch Term work: 25 Marks
Practical
examination:25 Marks
Course
Objectives
To
understand principles of measurement and its techniques.
To study
design, construction and accuracy features of various instruments.
To acquire
hands-on skills of measurement by using different instruments and gauges.
SECTION
– I
1.
Fundamental Principles and Measurement System Analysis:
Definition
and scope of metrology, definition of measurement, primary, secondary
tertiary
and working standards, line and end standards, advantages of optical standard
as a primary standard sources of errors in measurement, precautions to minimize
errors, measurement system and its characteristics: accuracy, precision,
repeatability, reproducibility, linearity and stability of a measurement
system, maintenance & calibration of instruments (4)
2.
Instruments and Accessories
Vernier
calipers, micrometers, height and depth gauges, - types, design considerations,
specifications, applications, sources of errors and handling precautions,
selection and general care of measuring instruments
Slip gauge
box - Grades, materials, wringing, setting to sizes, precautions while use and storage
Accessories
- Bench centers, surface plates, V-blocks, angle plates - types, applications Principle
of digital measurement instruments and examples, Instrument-computer interface,
Introduction to coordinate measuring machines (CMM), (6)
3. Gauges
and Gauge Design
Concept of
limit gauging, Taylor’s principle, various types of plug, ring and snap gauges for
plain and taper dimensions, gauge design for a given dimension for workshop, inspection
and general grade gauges (IS:919, Part 1, 1993-ISO system for limits, fits and tolerances,
is to be used for gauge design) (4)
4.
Magnification and Comparators
Need for
comparators, comparison of principles, sensitivity, repeatability and
magnification
of mechanical, pneumatic, optical and electrical and electronic instruments, dial
indicator, bore gauges and master rings, optical profile projector, toolmakers microscope,
electrical and electronic comparators, differential pneumatic comparator, and applications
of pneumatic gauging (6)
SECTION
– II
5.
Measurement of Angles, Tapers and Radius
Bevel
protractor, clinometer, sine bar, angle dekor, angle slip gauges, optical
dividing
head,
measurement of taper, angle and radius with the help of simple inspection
set-ups using standard pins and balls (3)
6.
Geometrical Features and Alignment Tests
Measurement
of straightness, flatness, parallelism, squareness, circularity, roundness, concentricity,
symmetry, distance between axes and other geometrical features Straight edge,
level beam comparator, autocollimator, fixtures and gauges for measurement of pitch
circle diameter, center distance between holes, positioning of holes and
surfaces, various alignment tests on machine bed, spindle and slides of lathe,
milling machine and drilling machine (8)
7.
Measurement of surface properties
Waviness
and roughness, causes of variation in surface quality, different parameters for
assessment of surface roughness, methods of calculation, instruments for
surface roughness measurement (3)
8.
Measurement of Screw Threads
Basic
terminology, measurement of major, minor and effective diameter, Screw thread micrometer,
floating carriage diameter measuring machine, two wire and three wire method,
measurement of pitch and pitch error, thread pitch gauges, limit gauges for thread
measurements (3)
9.
Measurement of gears
Basic
terminology, measurement of pitch, lead, run out, back lash and tooth
thickness, constant chord and base tangent method, gear tooth vernier caliper,
David Brown tangent comparator, errors in gear geometry, measurement of
composite error, Parkinson gear tester (3)
Note:
Students shall use IS:919, Part 1, 1993-ISO system for Limits, Fits and
Tolerances,
for designing of gauges during the theory examination.
TERM
WORK
1. One
industrial visit to study inspection practices and submission of the report
In
addition, any seven experiments from
the following.
2.
Measurement of linear dimensions using vernier, micrometer and bore gauge
3.
Measurement of height and steps by using dial indicator and slip gauge box
4.
Measurement of angle by using bevel protractor and sine bar
5.
a)Measurement of radius by using inspection setup like rollers and pins b)
Dimensional measurement by using pneumatic comparator
6.
Measurement of effective diameter of a screw thread by using floating carriage
diameter
measuring machine
7.
a)Measurement of roundness and concentricity by using dial indicator
b)Measurement of gear tooth thickness by using gear tooth vernier caliper
8. a)
Measurement of roughness of machined surface b)Assessment of profile of a
component
by using profile projector
9.
Alignment tests on lathe/ drilling machine/ milling machine (any one)
Practical
Examination: Each candidate shall perform individually,
one assigned
experiment
from the above list and submit the result, followed by an oral examination.
REFERENCE
BOOKS
1.
Engineering Metrology, -K. J. Hume, McDonald London
2.
Engineering Metrology, -D. M. Anthony, Oxford University Press (I)
3. The
Quality Technician’s Handbook,- Garry Griffith, Prentice Hall
4.
Engineering Metrology,- I. C. Gupta, Dhanpat Rai Publications
5.
Principles of Machine Tool Design, -Sen, Gupta, New Central Book Agency
6. Basic
Machine Technology, -C. Thomas Olivo, Bobbs-Merrill Educational Publishing
7. Machine
Tool Practices,- Kibbe, Neely, Meyer, White, Prentice Hall
9.
Engineering Metrology, -R. K. Jain, Khanna Publishers, Delhi
8. Testing
of Machine Tools, -Dr. George Schlesinger, Pergamon Press
9. Basic
Rules on using Measuring Tools, -Mitutoyo Metrology Institute
10. A
Manual of Measurement System Analysis, Ford, General Motors, Chrysler
Corporation
11.
Metrology Laboratory Manual, -R. Bahl, M. Adithan, Technical Teacher’s Training
Institute,
Chandigarh
12. A Text
Book of Metrology, -M. Mahajan, Dhanpat Rai and Co.
T. E.
(Production Engineering) - Semester V
7. BASIC
CNC LABORATORY
Teaching
Scheme: Examination Scheme:
2
Hrs/batch/week Term Work: 25 Marks
Course
Objective
To
introduce the student to the practical CNC technology followed in the industry.
The Term
Work shall consist of following exercises.
1. a)
Selection of cutting parameters including tool specifications for various
operations
on CNC machines for at least one job on each of the machine type –
Turning
Center and Machining Center.
b) Study
of the features of the controller of the CNC machines (e.g. FANUC,
SINUMERIC,
MAZAK etc.)- including Tool offsets, Wear Compensation etc.
2. Manual
CNC Part Programming for (using cutter radius compensation)
a) Lathe –
at least two parts (using fixed cycles) along with selection of cutting
parameters
/ tools.
b)
Machining Center – at least four parts involving operations like milling,
drilling,
boring etc. (using fixed cycles) along with selection of cutting parameters
/ tools.
3.
Simulation of the above programs using any suitable CNC simulation software.
4.
Preparing a simple CNC part program and executing it on a CNC machine for a
given part
(One job for Lathe and One job for Machining Center) in a group of
four
students each.
The
journal shall consist of the printouts and report of the above exercises.
Reference
Books:
1. CAD /
CAM, Principles & Applications by P. N. Rao ( TMH )
2.
Programming Manuals of various CNC machines (Lathes and Machining Centers)
e.g.
FANUC, SINUMERIC, MAZAK etc.
3.
Catalogs of Commercial Tool Manufacturers e.g. SANDVIK, KENNAMETAL,
ISCAR,
TAEGUTECH, MITSUBISHI etc.
4. Manuals
of CNC Simulation Software
T.
E. ( Production Engineering) – Semester V
8.
WORKSHOP PRACTICE – V
Teaching
Scheme: Examination Scheme:
Practical:
2 Hrs. / Week/ Batch Term work: To
be assessed During
Semester
VI
Course
Objective
To train
the students to plan and work on various metal cutting machines.
Contents One
composite job assembly consisting of 5 to 6 parts requiring the machining processes
like turning, drilling, threading, tapping, milling, grinding etc. is to be completed
under Workshop Practice - V and VI by each student
Note
:
1. The
composite job assembly is to be carried on to Semester VI under Workshop
Practice
VI.
2.
The practical examination of 50 marks based on Workshop Practice
- V and VI will be conducted at the end of Semester VI
3. The
student shall maintain a diary of the work consisting of the process plan and work
done.
Semester-
VI
T. E.
(Production Engineering) – Semester VI
1.
METALLURGY - II
Teaching
scheme: Examination scheme:
Lectures:
3 Hrs per Week Theory Paper: (3 Hrs) - 100 Marks
Practical:
2 Hrs per week per batch Term Work: 25 Marks
Course
Objective:
Study of
various heat treatment processes for different engineering materials,
thermomechanical and surface treatments and powder metallurgy.
SECTION
I
1.
Introduction to Heat Treatment: Definition of heat treatment,
process variables,
purposes. (1)
2.
Principles of heat treatment of steels:
a)
Formation of austenite on heating - mechanism
and kinetics of austenite formation, austenite grain size - important factors
affecting austenite grain size, inherent and actual grain size, methods of
determination of austenite grain size, ASTE grain size specifications.
b)
Isothermal transformation of austenite - TTT
curves, kinetics and mechanism of
austenite
to pearlite, bainite and martensite transformations.
c)
Transformation on continuous cooling - CCT
curves
d) Effect
of carbon, alloying elements and grain size on phase transformations, effect on
TTT diagrams. (5)
3. Heat
treatment process of steels and cast irons:
a)
Annealing and Normalizing - Classification of annealing process, types of
annealing process and applications. normalizing process and applications,
comparison between annealing and normalizing, patenting.
b)
Hardening - Hardening process, factors affecting hardening process,
hardenability - definition, factors affecting hardenability, determination of
hardenability, Grossman’s and Jominy end quench test, characteristics of
martensitic transformation, retained austenite, preparation of articles for
hardening; hardening methods - continuous cooling, cooling in two media,
stepped quenching, austempering, martempering, sub- zero treatment, mechanism
of heat removal during quenching, quenching stresses, quenching media used in
hardening, properties required.
c)
Tempering - Purposes of tempering, types of tempering, structural changes
during
tempering
, secondary hardening, temper brittleness
d) Cast
Irons - Stress relief annealing, normalizing, hardening, surface, hardening and
malleablising, annealing. (6)
4. Surface
and case hardening processes:
a)Case
Hardening- Introduction, steels used for case hardening,
b)Carburizing:-
Pack , liquid and gas carburizing, post carburizing heat treatments, case depths
obtained and applications.
c)
Nitriding - Liquid and gas nitriding, plasma nitriding, case depths obtained,
white layer , elimination of white layer, applications.
d) Surface
Hardening :- Steels used for surface hardening, flame hardening, induction hardening,
electron beam hardening and laser hardening, comparison of surface hardening
processes, advantages and limitations, case depths obtained and applications.
e) Case
depth measurement - hardness method, chemical method, microstructure method.
f)
Metallizing :- Types - aluminizing ( calorizing ), silicon-diffusion,
chromizing, boron diffusion, applications,
comparison of case hardening processes, advantages and
limitations
(6)
SECTION
II
5. Heat
treatment furnaces, atmospheres, defects and energy economy
a) Heat
treatment furnaces, control systems, equipments, furnace atmospheres.
b) Heat
treatment defects: - causes and remedies.
c) Energy
economy in heat treatment through change in material, heat treatment practice and
processes. (3)
6. Heat
Treatment of non-ferrous metals and alloys: introduction to heat treatment
processes
carried out on copper, aluminum, magnesium and titanium metals and alloys (1)
7.
Precipitation Hardening:
a) Basic
requirements of alloys that can be precipitation hardened, precipitation
hardenable
ferrous and non-ferrous alloys and their applications.
b) Steps
in the process of precipitation hardening - Solutionizing, quenching, aging
c) Effect
of variables like- aging time, temperature, cold working, impurity, alloy
composition
on the properties of precipitation hardened alloys.
d)
Mechanism of precipitation hardening:- coherent lattice theory and G.P. Zone
theory (4)
8.
Thermomechanical Treatments - a) Classification of TMT, b) Controlled rolling
and
cold
rolling c)Ausforming and isoforming. d) Marstraining and cryoforming,
thermomechanical annealing e)TMT of non-ferrous alloys. (2)
9.
Strengthning Mechanisms
(a) Cold
Worked Structures - Strain hardening, strain aging
(b)
Strengthening by alloying - Solid solution strengthening,
(c)
Strengthening from fine particles - dispersion hardening
(d) Grain
refinement, micro-alloyed steels
(e)
Transformation hardening - martensitic hardening (2)
10. Powder
Metallurgy.
(a)
Importance of powder metallurgy as a manufacturing technique, advantages and
limitations
of powder metallurgy
(b)
Methods of powder manufacture, characteristic and testing of metal powders,
powder conditioning - heat treatment, blending and mixing.
(c) Powder
compaction - Methods of compaction, compaction pressures, types of
compaction,
property changes during compaction.
(d) Sintering
- Types of sintering, structure and property changes during sintering,
sintering
atmospheres and their importance.
(e)
Finishing operations - Sizing, heat treatment, surface treatment,
electroplating and impregnation treatments.
(f)
Applications - Self lubricating (porous) bearings, electric contact materials,
filters,
magnets,
sintered friction materials, cutting tools and cermets, flow charts for
manufacturing
of above components. (5)
TERM
WORK
1. Study
of grain size measurement
2. Study
of annealing heat treatment
3. Study
of Normalizing heat treatment
4. Study
of hardening and Tempering heat treatment
5. Study
of heat treatment furnaces
6. Study
of micro structure of Carburized, Nitrided, Induction Hardened and Welded
steels
7. One
presentation of 10 minutes by each student related to the subject and
submission of the write up on the presentation. (Optional)
8.
Industrial visits (minimum two) for observing various heat treatment processes,
furnaces,
control systems and equipment carrying out heat treatment of ferrous &
nonferrous metals and alloys and powder metallurgical processes.
REFERENCE
BOOKS
1. Heat
treatment principles and technique - Rajan Sharma & Sharma.
2.
Introduction to Physical Metallurgy, -Avner, TMH
3.
Engineering Metallurgy Vol. I & II - R.A.Higgins (ELBS)
4.
Engineering Metallurgy - E. C. Rollason, (ELBS)
5.
Introduction to Engineering Materials - B.K.Agrawal (TMH )
6.
Mechanical Metallurgy (S I Metric ed.), Dieter, (TMH)
7. Engg
Materials, Properties and Selection, Kenneth G. Budunski (PHI)
8.
Engineering Physical Metallurgy - Lakhtin, C.B.S. Publishers & Distributors
9.
Physical Metallurgy - Vijendra Singh , Standard,Publishers Distributors, New
Delhi
10.
Materials Science & Metallurgy - Dr. Kodgire (Everest, Pune )
11. Powder
Metallurgy - A.K.Sinha, ( Dhanapat Rai & Co. )
T.E.
(Production Engineering) – Semester VI
2.
INDUSTRIAL MANAGEMENT
Teaching
Scheme: Examination Scheme:
Lectures:
3 Hrs./Week Theory Paper (3 Hrs.): 100 Marks
Course
Objective
To study
various functions of management essential for efficient working of industrial
organization
SECTION
– I
1.
INTRODUCTION: Management – meaning, definition, scope,
importance, functions of management, development of management thought,
contribution by Fayol, Taylor, Drucker, different approaches to management –
scientific, operational, human and system approach, role and social
responsibilities of a manager (3)
2.
PLANNING: Meaning, definition, scope, importance,
objectives of planning, steps in planning, decision making, strategic planning,
management by objectives (MBO) (3)
3.
ORGANIZING: Meaning, definition, principles of
organization, delegation of
authorities
and decentralization, span of management, types of organization – line, staff, project,
functional and informal organizations (3)
4.
STAFFING: Definition, functions of staffing,
selection process, training and
development,
performance appraisal (2)
5.
DIRECTING: Definition, principles of direction,
importance motivation, theories of
motivation
– theory X and theory Y, Maslow’s hierarchical needs, Herzberg theory,
leadership
– meaning, styles of leadership, types of leaders, trait theories, behavioral
theories –
managerial grid, Rensis Likert’s leadership systems communication –
importance,
types of communication, barriers to effective communication, methods to
overcome
barriers (5)
6.
CONTROLLING: Definition, steps in control process,
requirements of effective
control
process, various control techniques (2)
SECTION
– II
7. FORMS
OF ORGANIZATION: Proprietor, partnership firms, private
limited, public
limited,
co-operative organizations, joint stock and public sector undertakings –
structure of management, advantages and limitations, authorities and
liabilities of owners (3)
8. HUMAN
RESOURCE MANAGEMENT: evolution, objectives, functions,
organization,
introduction to industrial relations, trade unions and their functioning,
significance
of labor laws, human behavior at work, supervisor’s role (3)
9. FINANCE
MANAGEMENT: Objectives, functions, kinds of capital,
sources of
capital,
financial planning and control, profit planning, basic terms in financial
accounting,
reading and interpretation of balance sheet and profit and loss account (4)
10.
MARKETING MANAGEMENT: Objectives, functions, difference between
marketing
and selling, introduction to marketing mix, product planning, pricing policies,
channels of distribution, advertising, market research (3)
11.
PRODUCTION AND MATERIALS MANAGEMENT: Primary and
secondary
objectives,
functions, organization, types and procedure of purchasing (3)
12.
INDUSTRIAL PSYCHOLOGY: Basic concepts of psychology, industrial
psychology,
scope, causation of behavior, individual differences, differences in
psychological
characteristics – intelligence, interest, physique, learning ability,
perception,
concept of psychological test (2)
REFERENCE
BOOKS
1.
Management by James A. F. Stoner, R. Edward Freeman, PHI
2.
Management Today: Principles and Practice by Gene Burton and Manab Thakur, TMH
3.
Essentials of Management by Koontz and O’Donell, TMH
4.
Organizational Behavior by Keith Davis, TMH
5.
Management (Tasks, responsibilities and Practices) by Peter Drucker, Harper
Business
6.
Production Management by Lockyer, ELBS
7. Modern
Production Management by E. S. Buffa ( John Wiley )
8.
Financial Management by Vanhorne, PHI
9.
Financial Management (Theory and Practice) by Prasanna Chandra, TMH
10.
Marketing Management by Philip Kotler, Pearson Edition
11.
Marketing Management by Rajan Saxena, TMH
12.
Personnel Management by Edward Flippo, TMH
13.
Managing Human Resources by Gorrez, Balkin, Candy, PHI
T. E.
(Production Engineering) – Semester VI
3.
INDUSTRIAL HYDRAULICS AND PNEUMATICS
Teaching
Scheme: Examination Scheme:
Lectures:
3 Hrs. / Week Theory Paper (3 Hrs): 100
Marks
Practical: 2 Hrs. / Week/ Batch Term work: 25 Marks
Practical
examination: 25 Marks
Course
Objective
To study
of fundamental concepts, components, circuits and applications in industrial
hydraulics
and pneumatics
SECTION
– I
1.
Fundamental concepts of fluid mechanics: Classification of fluids, derivation
of
Pascal’s
law, continuity equation and Bernoulli’s equation
(3)
2.
Introduction to fluid power: Types, advantages and applications, ISO symbols
for
hydraulic
and pneumatic systems; hydraulic fluids- functions, desirable properties and technical
specification for selection, conditioning of fluids, study of reservoirs,
strainers, filters, heat exchangers (3)
3.
Hydraulic system elements: pumps – types, working, characteristics and
applications; types of conductors and connectors, their selection, seals and
packing – types, materials, applications, hydraulic actuators – linear and
rotary - types, working, cushioning effect, mounting, calculation of force and
velocity of piston, system components: accumulators, intensifiers, their types,
working, applications. (5)
4. Control
Elements: a)construction and working of pressure control valves – direct
acting
type, pilot operated, sequence, counterbalancing, unloading, pressure reducing,
b)Direction
control valves – types, construction and working, spool actuation methods, spool
center positions, c)Flow control valves – compensated and non compensated types,
construction and working. (4)
5.
Hydraulic circuits and their applications: Speed control circuits,
regenerative,
sequencing,
counterbalancing, interlocking, synchronizing circuits, use of accumulator and
intensifier, methodology to design hydraulic circuits. (3)
SECTION
– II
6.
Pneumatics: Basic principle, applications, comparison with hydraulic system.(1)
7.
Pneumatic system elements: Piping, materials and pressure ratings, piping
layout,
calculation
of pressure drop in pneumatic line; air compressors, types, selection criteria;
FRL unit- construction and working; pneumatic cylinders and air motors-
construction, working and types, calculation of force and air consumption,
comparison of air, hydraulic and electric motors. (5)
8.
Pneumatic system control elements: Direction control valves- types and working,
flow control valves, working of variable flow control, quick exhaust, time
delay and shuttle valve. (4)
9.
Pneumatic circuits: Basic circuit, impulse operation, speed control,
sequencing, time delay circuits and their applications, pneumatic clamping
systems, pneumatic power tools (3)
10. Hydro
pneumatic systems: concept, working and applications (descriptive treatment only)
(2)
11.
Fluidics: Concept, study of logic gates and applications. (2)
12. Fluid
power maintenance, troubleshooting and safety. (1)
TERM
WORK
1.
Verification of Bernoulli’s Theorem on Bernoulli’s apparatus.
2. Study
of pressure, direction and flow control valves in hydraulics and pneumatics
using cut
section models
3. Speed
control circuits on hydraulic trainer (Meter-in, Meter-out and Bleed-off)
4.
Construction and operation of Sequencing, Counterbalancing, Synchronizing,
Interlocking,
pressure reducing circuits on hydraulic trainer.
5. Manual
/ automatic forward and reverse and sequencing circuit on pneumatic trainer.
6.
Operations of basic logic and sequencing circuits on pneumatic trainer.
7. Design
of a hydraulic circuit for a given application and selection of components from
commercial catalogs.
8. At
least one industrial visit to study industrial applications of hydraulics and
pneumatics
with submission of the relevant report.
Note:
Practical examination will consist of performing an actual experiment by a
group of
maximum two students, from the above list (Sr. Nos. 3 to 6) and to show
working /
results by the candidates, followed by oral examination.
Recommended
Books
1.
Industrial Hydraulics by J. J. Pipenger, Hicks (McGraw Hill)
2.
Hydraulics and Pneumatic Power for Production by H. L. Stewart (Industrial
Press)
3. Fluid
Power with Applications by A. Esposito (Pearson)
4. Fluid
mechanics by R.K.Bansal, Laxmi publications. New Delhi.
5.
Engineering Fluid Mechanics by Gadre, Mirajgaonkar (Nem Chand and Brothers)
6.
Mechanics of Fluids by Shames, Irving H. (McGraw Hill)
7. Oil
Hydraulic Systems by S. R. Majumdar (TMH)
8.
Industrial Hydraulics Manual by Vickers Sperry
9.
Pneumatic Systems-Principles and Maintenance by S. R. Majumdar (TMH)
10. ABCs
of hydraulic Circuits by H. L. Stewart and J. M. Storer ( Taraporwala)
11. ABCs
of Pneumatic Circuits by H. L. Stewart and J. M. Storer ( Taraporwala)
12.
Hydraulic Text Book Basic Level (Festo Controls Pvt. Ltd. Bangalore, (Part No.
93281)
13.
Pneumatic Text Book Basic Level (Festo controls Pvt. Ltd. Bangalore) (Part No.
93131)
14.
Pneumatics and Hydraulics by H. L. Stewart (Taraporwala)
15.
Hydraulics and Pneumatics, A Technician’s and Engineer’s Guide by Andrew Parr (JAICO
)
T. E.
(Production Engineering) – Semester VI
4. DESIGN
OF JIGS, FIXTURES & DIES
Teaching
Scheme: Examination Scheme:
Lectures:
3 Hrs. / Week Theory Paper (4 Hrs): 100 Marks
Practical:
2 Hrs. / Week/ Batch Term work: 25 Marks
Oral
examination: 25 Marks
Course
Objective
To
introduce the students to the design practices of toolings (Jigs and Fixtures)
and die
design for presswork.
SECTION
– I
1.
Introduction to Jigs and Fixtures : Necessity, applications and types, basic
concept of jigs and fixtures for different manufacturing processes, dependency
of jig and fixture design on operation sequence, (3)
2.Location
and clamping system : Principles, types, applications, locating pins, pads,
diamond
pins, adjustable supports, Vee and post locators, clamping system -
principle,
types, screw clamp, strap, lever, hinge type, cam operated, toggle clamps,
centralizer
and equalizer clamp, multiple clamping, quick acting clamps,
pneumatically
operated clamps. (5)
3. Design
of Jigs: Principles of jig design, types of jigs- plate, template, box,
channel,
sandwich,
latch, tumble, turn-over, tumble jig etc., types of bushes, selection of
bushes and
liners, construction of jig and fixture bodies, use of standard parts. (5)
4. Design
of fixtures: Principles of fixture design, types of fixtures- gang, straddle,
vertical,
slot, string milling fixture etc, selection of the suitable type, design of milling
fixtures,
use of setting block, tennons, T-bolts etc, design of turning fixture for lathe
(5)
5.Indexing
System: Necessity, different indexing systems for jigs and fixtures. (2)
Section
– II
6.Introduction
to press tools: Dies, punches, types of presses, types of dies, simple,
compound,
combination and progressive dies, press tools for operations like blanking,
piercing,
drawing, shaving, trimming, etc.
(4)
7.Design
of die set for cutting operations : Theory of metal cutting, cutting force and
lank
holding force estimation, punch and die clearance, scrap strip layout, design
of
punches,
design of dies, pilots, strippers, stock stops, finger stops, auto stops,
center
of
pressure, selection of die set (6)
8.Design
of drawing die: blank size determination, no. of draws, stage wise
achievement
of drawn component, stage wise component drawings, drawing radii and clearance,
drawing forces, defects in drawing, (6)
9.Miscellaneous
dies like- cut off dies, trimming, shaving, bulging, rubber, lancing,
slitting,
horn type, side cam dies, bending, forming, curling dies etc. (theoretical
treatment
only) (3)
TERM
WORK
Note: All
standard components shall be selected using relevant IS codes in the
following
exercises.
1. At
least one industrial visit to study industrial practices related to the subject
and
submission
of the visit report.
2. Study
of various elements of jigs and fixtures
3. Design
and drawing of two drilling / reaming jigs. (Details of at least one sheet
showing
manufacturing drawing with tolerances, material specification and heat
treatment.)
4. Design
and drawing of two milling fixtures. (Details of at least one sheet showing
manufacturing
drawing with tolerances, material specification and heat treatment.)
5. Design
and drawing of one progressive die.
6. Design
and drawing of one drawing die.
REFERENCE
BOOKS
1. Tool
Design, Donaldson, (TMH)
2. Tool
Design, Pollock, Reston Pub. Co. Inc.
3. An
Introduction to Jig & Tool Design, M.H.A. Kempster, (ELBS)
4.
Fundamentals of Tool Design, Ed. Frank Wilson, ASTME ( TMH )
5. Jigs
and Fixture Design Manual, Henirkson (Industrial Press, NY)
6. A Text
Book of Prod. Engineering, P. C. Sharma, S. Chand
7.
Handbook of Die Design- Suchy, (McGraw Hill)
8. Die
Design Fundamentals, J. R. Paquin, R. E. Crowley, Industrial Press Inc.
9. Jigs
and Fixture, P. H. Joshi, Tata Mc-Graw Hill Pub. Co
10.
Techniques of Press Working of Metals by Eary and Reed
11. CMTI
Machine Tool Design Handbook, (TMH)
12. Design
Data Handbook –PSG College of Tech., Coimbtore
T. E. (
Production Engineering) – Semester VI
5. QUALITY
MANAGEMENT
Teaching
Scheme: Examination Scheme:
Lectures:
3 Hrs. / Week Theory Paper (3 Hrs): 100 Marks
Practical:
2 Hrs. / Week/ Batch Term work: 25 Marks
Course
Objective
• To
familiarize the student to the core concepts and the emerging trends in Quality
Management.
• To
develop hands-on-skills on tools and techniques of Quality Management for
industrial
problem-solving.
1.
Introduction to quality management, historical background, contribution by
quality
gurus (2)
2. Quality
Planning: Designing for quality, capturing voice of customer, quality function deployment,
quality loss function, parameter design and optimization, tolerance design, Poka-yoke.
(9)
3.
Organizing for quality: Quality line function and staff function, quality
systems: ISO
9001 and
TS 16949, certification requirements, introduction to ISO 14000. (3)
4. Quality
Control: Stages of inspection, control of non-conforming products, sampling plans,
product vs. process control, statistical quality control, variable (Xbar –R)
and attribute (p, np, c and u) charts, tools of quality control. (10)
5. Quality
Improvement: Process approach, single parameter experiments, statistical
inferences,
analysis of means, analysis of variance-ANOVA (one-way), process
capability,
variance reduction, correlation analysis, linear regression models
(10)
6.
Introduction to Six Sigma methodology, D-M-A-I-C approach. (2)
TERM
WORK
Any eight
assignments using suitable software like MS-EXCEL, MINITAB, SYSTAT
etc. on
following topics.
1. Quality
loss function
2.
Parameter design and tolerance design
3. Case
study of quality function deployment
4.
Variables control charts
5.
Attributes control charts
6.
Industrial case study on quality audit
7. Process
capability study
8. Single
parameter experiment and statistical inferences using one-way ANOVA
9.
Correlation and regression analysis
REFERENCE
BOOKS
1. Armand
V. Feigenbaum, Total Quality Control, McGraw Hill Inc. New York
2. J. M.
Juran, F. M. Gryna, Quality Planning and Analysis, Tata McGraw Hill
Publishing
Co., New Delhi
3. E.
Grant, R. Leavenworth, Statistical Quality Control, McGraw Hill International
Book Co.
4. John
Hardesky, Total Quality Management Handbook, McGraw Hill Inc.
5. D. H.
Besterfield, Total Quality Management, Pearson Education
6.
Logothetis, Managing for Total Quality, PHI Publication
7. Gregory
Hutchins, Introduction to Quality, Maxwell McMillan International
8. Genichi
Taguchi, Quality Engineering in Production Systems, McGraw Hill
9. John M.
Ryan, Total Quality Control, Tata McGraw Hill Publishing Co.
10. P. F.
Wilson, L.D. Dell & L.F. Anderson, Root Cause Analysis, A Tool for Total
Quality
Management, Tata McGraw Hill Publishing Co.
11.
Montgomery D (2004). Introduction to Statistical Quality Control, 5/e, (John
Wiley & Sons)
12. Ross,
Phillip J. (1996) – Taguchi Techniques for Quality Engineering, 2/e. (New
York,
McGraw Hill)
13.Montgomery
D (2001). Design and Analysis of Experiments, 5/e, (New York, John
Wiley
& Sons)
14.
Montgomery D, Peck E, Geoffrey Vining G (2003). Introduction to Linear
Regression
Analysis, 3/e, (New York, John Wiley & Sons)
15.
Phadke, M (1989). Quality Engineering using Robust Design, (Prentice Hall.)
T. E. (
Production Engineering) – Semester VI
6. MACHINE
TOOLS AND PRODUCT DESIGN
Teaching
Scheme: Examination Scheme:
Lectures:
3 Hrs. / Week Theory Paper (3 Hrs): 100 Marks
Practical:
2 Hrs. / Week/ Batch Term work: 25 Marks
Course
Objective
Study of
procedure to design various machine tool members under different loading
conditions
and study of concept of product design.
Section
– I
1.
Introduction to Machine & Machine Tool: Types,
capabilities, features of
construction
like working and auxiliary motions in machine tools, parameters defining
the
working motions of a machine tool, machine tool drives, general requirements of
machine
tool design, methodology for machine tools design considering quality, quantity
of production and economic aspects (4)
2.
Principle of Machine Tool Design from the point of
view of quality, production rate,
strength,
rigidity, assembly, ergonomics, aesthetics, maintenance and inter-changeability
(2)
3.
Analysis of forces affecting machine tool elements,
determination of motive power for different operating conditions. use of
handbooks. (2)
4.
Kinematics of Machine Tools: Classification of various
driving systems, basic
considerations
in the design of drives, aims of speed and feed regulations, stepped
regulations
of speeds, design of gear box, laws of stepped regulations, selection of range ratio,
G.P. ratio, break up of speed steps, structural diagram and speed chart, design
of feed box, machine tool drives using multiple speed motors, general
recommendations for developing gearing diagram, determining number of teeth of
gears, step less regulations of speed and feed rates. (8)
5. Design
Considerations and Selection of Standard Components: Drives
systems
with
pulleys, belts, ropes and chains; selection of oil seals, gaskets and electric
motors from standard catalogues. (3)
Section
II
6. Design
of Spindle & Spindle Support: Functions of
spindle unit and requirements,
materials
and construction, spindle ends, spindle support, design calculations, mounting arrangements
of spindle bearings, spindle bearing lubrication. (3)
7.
Selection of Machine Tool Bearing: Journal, rolling
and hydrostatic bearings: basic
principles,
assembly, mounting and maintenance, procedure for selection of bearings
from
manufacturer’s catalogue based on load and life considerations. (4)
8. Design
of Machine Tool Structures: Functions and their
requirements, design
criteria,
materials, static and dynamic stiffness, profiles of machine tool structures,
basic design procedure, design of beds, columns, housings, rams etc., causes of
vibration in machine tools and methods of elimination. (4)
9. Design
of Guide ways Functions and types of guide ways, materials,
design criteria and calculations of slide ways based on wear and accuracy,
design of anti-friction guide ways, hydrostatic and hydrodynamic lubrication of
guide ways. (4)
10.
Product Design and Development: Product design by
evolution and innovation,
essential
factors of product design, analysis of the product, product characteristics, 3
S’ssimplification, standardization and specialization, basic design
considerations, functional design practice, product value, design for safety,
reliability and environmental conditions, ergonomic design of controls and
displays, introduction to rapid prototyping. (3)
TERM
WORK:
1) Design
of a gear box for speed and feed drive, Design of shafts and gears with
assembly
drawing.
2)
Selection of bearings from manufacturer’s catalogues for different given
applications
(Minimum
four).
3) Study
of different machine tools from the point of view of types of machine parts
4)
Exercise on design of machine tools from ergonomics aspects suitable in India.
5) One
case study on product design and development. (Report to be submitted)
RECOMMENDED
BOOKS:
1. Machine
Tool Design, N. K. Mehta, ( TMH )
2. Machine
Tool Design Handbook, C.M.T.I. Bangalore, (TMH )
3.
Principles of Machine Tools, Gopal Chandra Sen and Amitabha Bhattacharayya (New
Central Book Agency )
4. Design
Data Handbook –PSG College of Tech., Coimbtore
5. Design
of Machine Elements, Dobrovalsky
6. Design
of Machine Tool, Dr. S. K. Basu ( Oxford IBH )
7. Engg.
Design, a Materials & Processing Approach, G. Dieter, (Tata McGraw-Hill
Publishing
Company Ltd.)
8. Design
of Machine Elements, V. B. Bhandari, Tata McGraw-Hill Publishing Company Ltd.
9.
Elements of Machine Design, N. C. Pandya and C. S. Shaha, Charotkar Publishing House
10. Design
Data HandBook, K. Mahadevan and K. Balveera Reddy, C.B.S. Publishers & Distributors
11.
Product Design and Manufacturing, (3/e), A. K. Chitale and R. C. Gupta,
Prentice- Hall of India Pvt. Ltd.
12.
Catalogues of Bearings Manufacturers e.g. SKF, NACHI, TIMKEN, NRB etc.
T.
E. (Production Engineering) – Semester VI
7.
WORKSHOP PRACTICE – VI
Teaching
Scheme: Examination Scheme:
Practical:
2 Hrs. / Week/ Batch Term work: 25
Marks for the total
Work done
under Workshop Practice V and VI
Practical
Examination: 25 marks (6 Hours)
Course
Objective
To train
the students to plan and work on various metal cutting machines and assembly of
parts.
Contents:
One
composite job assembly consisting of 5 to 6 parts requiring the machining
processes like Turning, drilling, threading, tapping, milling, grinding etc.
carried on from Semester V under Workshop Practice-V is to be completed and
assembled under Workshop Practice - VI.
Note
:
1. The
student shall maintain a diary of the work consisting of the process plan and
work done.
2. The
term work will be assessed on the basis of total work done during Workshop
Practice-V
and VI.
3. The
practical examination shall be conducted at the end of Semester VI (duration
– six
hours). It will be based on the work prescribed for Workshop Practice V and VI.
T. E.
(Production Engineering) – Semester VI
8. SEMINAR
Course
Objective
To train
the students to the techniques of compiling specific information and presenting
it in front of a group.
Teaching
Scheme: Examination Scheme:
Practical:
2 Hr. / Week Term work: 25 Marks
Contents:
Before the
end of Semester VI, each student will deliver a seminar on a subject related to
production engineering. The seminar topic should be latest
and ahead of the scope of curriculum. The Seminar guide
shall help the student in topic selection.
The
student, as a part of the term work, shall submit the write-up of the seminar
topic in duplicate, typed on A4 size sheet in a prescribed format and bound.
The report should be compiled and edited for continuity and mere
copying-and-pasting should be avoided.
The
student shall present the seminar in front of the class. The performance of the
student shall be judged by the seminar guide along with one more colleague
appointed by the Head of Department, for awarding term work marks, on the basis
of the contents, the presentation and discussions during the seminar talk.
