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06ME71 CONTROL ENGINEERING

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SYLLABUS
Sub code: 06ME71
Hours / Week: 5
Total Hours: 52

I A Marks: 25
Exam Hours: 3
Exam Marks: 100

1. Introduction: concept of automatic controls, open and closed loop systems, concepts of feed back
requirement of an ideal control system
03 hrs
2. Mathematical Model Mechanical System: (both translational and rotational) electrical systems (servos, dc
motors, ac motors, servomotors) hydraulic system (liquid level and fluid power systems) thermal systems,
integrating devices, hydraulic servomotor, temperature control system, error detectors
06 hrs
3. System Response: first order and second order system response to step, ramp and sinusoidal inputs, concepts
of time constant and its importance in speed of response. System of stability- Routh Hurwitz criterion 06 hrs
4. Block diagrams, signal flow graphs and transfer functions definitions of transfer function, block
representation of system elements, reduction of block diagrams, signal flow graphs, basic properties and gain
formula to block
06 hrs
5. Control action- types of controllers proportional, integral, proportional integral differential controllers.
(Basic concepts only)
03 hrs
6. Frequency Response: polar and rectangular plots for frequency response system analysis using Nyquist
diagrams relative stability concepts of gain margin and phase margin, m & n circles
04 hrs
7. System Analysis Using Logarithmic Plots: bode attenuation diagrams, stability analysis using bode diagrams
simplified bode diagrams.
04 hrs
8. Root Plots: definition of root loci, constructing of root loci, graphical relationship setting the system locus
gain.
06 hrs
9. Compensation: System series and feed back compensation, physical devices for system compensation 08 hrs
10. Introduction to state variable characteristics of linear system introduction to the state concepts state
equation to linear continuous data systems matrix representation of state equations- controllability and
observability, Kalman & Gilberts test
06 hrs
Text Books:
1. Modern Control Engineering K. Ogatta
2. Automatic Control Systems B C Kuo
3. Automatic Control Systems Raven
Reference Books:
1. Feedback Control Systems Schaums series, 2001.
2. Control Systems by I.J. Nagarath & M.Gopal, New age International Publishers, 2002.
3. Control Systems: M.Gopal, Tata McGraw Hill, New Delhi, 2e, 2002.

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LESSON PLAN
Hours / Week: 04
Total Hours: 52

Sub Code: 06ME71

Sub: Control Engineering

Hour. No

Topics to be covered

01
02
03
04

Introduction concept of automatic control system open loop system

Close loop system, feed back system & examples
Requirement of ideal control system & examples
Control action types of controllers - proportional controller integral controller
action
Proportional integral controller
Proportional integral controller - proportional integral differential controllers
Problems on control action
Transfer Function Models, Models of Mechanical System
Hydraulic servo motors
Temperature control system, error detectors
Differential equation for mechanical system transactional & rotational
Electrical system servo, dc motors & ac motors
Hydraulic system liquid level and fluid power system
Models of Pneumatic system
Thermal system, integrative device
Block diagram definition
Components of block diagrams and its benefits
Basic properties and gain formula to block diagrams
Reduction of block diagram
problems on reduction of block diagram
Signal flow graphs reduction of signal flow graphs
Masons gain Formula for signal flow graph
Problems on reduction of signal flow graphs
Problems on reduction of signal flow graphs
Time response system Introduction
Definition, time response for first order system
Time response for first order system for unit step ramp & sinusoidal signals
Time response for second order system
Time response for second order system for unit step ramp & sinusoidal
signals
Time response specification
Problems on time response specification
Problems on time response specification
Problems on time response specification
System of stability
Routh hutwtz criteria for system stability
Problems on Routh hutwtz criteria for system stability
Polar plots for frequency response & problems
Rectangular plots for frequency response
Nyquist diagram for system analysis
Relative stability concepts of gain margin and phase diagram
M & n circles problems
System analysis using logarithmic plots

05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42

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Nyquist diagram for system analysis problems

44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62

Nyquist diagram for system analysis problems

Bode attenuation diagram
Stability analysis using bode diagram
Simplified bode diagram
Problems on bode diagram
Root locus plots definition construction
General Rules for constructing Root Loci
Analysis using R-C Plots
Problems on graphical relationship
Problems on graphical relationship
Settling the system gain
System compensation series
System compensation feed back
Physical device foe system compensation description.
State variables introduction definition and description
Characterization of linear system
Introduction to the state concept-state equation
Linear continuation data system problems
Matrix representation of state equation problems

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QUESTION BANK
01
02
03
04
05
06
07

08
09
10
11
12
13
14
15

16

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Explain briefly the concept of automatic controls.

Briefly, explain open loop system with an example.
Briefly, explain closed loop system with an example.
Briefly, explain concepts of feedback.
What are all the requirements of an ideal control system? What are the qualitative
measures of these measurements?
Give an example of open loop control system? How can this be modified into a closed
loop one? Compare the performance of both the systems.
Distinguish between linear and Non-linear control system
a) Continuous and discrete data system
b) Time invariant and Time variant systems.
What is meant by feed back and what are its effects.
Briefly, explain about error detectors.
Define the following a) Servomechanism b) Regular system c) Follow-up system.
With the help of a sketch, explain the following working of a) Speed control system b)
Pressure control system c) Hydraulic control system.
Derive the differential equation and obtain the transfer for a field controlled DC
motor.
Derive the differential equation and obtain the transfer for a hydraulic system.
Derive the differential equation for R L C circuit.
Obtain the transfer function for the mechanical system as shown in figure.

Obtain the transfer for spring mass damper system. (Transactional and rotational) as
in fig a & b

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17

Obtain the transfer function for the electrical circuit as shown in figure. Mention order of
the system.

18

Define the following terms as applied to the response of a second order system
subjected to a unit step input. a) Maximum overshoot, b) Settling time c) Rise time.
Obtain an expression for response of first order system for unit step input.
In a DC position control servomechanism, a motor supplied by a constant armature
current drives the load. The field current is supplied from dc amplifier, the input to
which is the difference between the voltages obtained from input and output
potentiometers. The load and motor together have a moment of inertia, J = 0.4 kgm2 and the viscous friction constant of f = 2 Nm/rad/sec. Each potentiometer
constant of field current. The field time constant is negligible. A) Make a sketch of the
system and show how the hardware is connected. B) Also find the amplifier gain K in
amperes/volt to give an un-damped natural frequency of 10 rad/sec, after obtaining
the transfer function.
Obtain the transfer function of the system shown in the figure.

19
20

21

22

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The figure shows the Force- current analogues circuit of a transnational mechanical
system. Draw the mechanical system and explain the method employed.

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23

Derive the transfer function of the circuit shown in fig. If Vi = 5 sin 10t volts, R1=50
& R2=5 Kilo ohms. C = 1microF. Calculate the output voltage in magnitude and in
phase relative to input voltage.

24

Reduce the block diagram shown in the following figure by block diagram reduction
technique to obtain C/R

25
26
27
28

What are the advantages of a Block diagram of a control system?

VII SEMESTER

Explain briefly the types of blocks in linear control system.

Explain briefly the Rules for block diagram technique.
Obtain the overall transfer function of the block diagram by reduction technique

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29

Obtain the overall transfer function of the block diagram by reduction technique

30

Obtain the overall transfer function of the block diagram by reduction technique

31

Obtain the overall transfer function of the block diagram by reduction technique

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32

Determine C/R for the block diagram shown in fig using Masons Gain formula

33

For the signal flow graph shown in figure obtain the transfer function using Masons
formula

34
35
36
37
38
39
40
41
42
43
44

Explain Proportional plus derivative control

Explain control action.
Briefly explain a) proportional Integral differential controllers
Briefly, explain a) Integral b) proportional controllers.
List the basic classification of the controllers.
Explain briefly the Derivative control action.
Explain briefly the Proportional plus Integral plus derivative Control action.
Explain briefly the On Off controllers.
Explain briefly The Velocity feed back.
Briefly explain Nyquist stability criteria.
For the system with an open loop transfer function as given below plot the Nyquist
diagram and determine the stability of the system

G ( s) H ( S ) =
45
46
47
48

(4 s + 1)
S ( s + 1) (2 s + 1)

Explain briefly about polar plots.

Explain briefly about frequency domain specifications.
List out the parameters that are can be measured with the help of Nichols chart.
Draw the Nyquist plot of the system of the system whose transfer function is given
by

G ( s) H ( S ) =

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( s + 2) ( s + 3)

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The characteristic equation of a feedback control system is given by s3+5Ks2+(2K+3)

s+10=0apply Nyquist criterion to determine the value of K for the system to be in
stable closed loop

50
The open loop transfer function of a system is

51
52
53
54
55

G(s) H (S ) =

s+2
( s + 1) ( s 1)

Draw the

Nyquist plot and ascertain its stability

Explain briefly the concept of system stability.
Using RH criteria find out the range of K for which the system is stable.
S3+5KS2+(2K+3)S+10=0
Explain the importance of rouths stability criterion.
Examine the stability of a second order system whose characteristic equation is given
by q(s)=a2+s2+a1s+a0.
Construct the bode plot for a system whose open loop transfer is given by

G ( s) H (S ) =

180
s + 8s + 25s + 26
3

The sketch given shows the Bode magnitude plot

for a system. Obtain the transfer function

56

57

Sketch

the

magnitude

and

phase

k(S + 0.2)
hence
G(s) H (S) =
S(s + 0.01) (s + 2) (s +10)

plot

for

the

having

OLTF

determines the value of k for which the

8
and
s (1 + s ) (1 + 4 s )

hence determine the gain margin and phase

margin of the system. If the gain is to be doubled, what should be the new value of
gain?
Sketch the bode plot for a system characterized by the open transfer
function G ( s ) =

K (1 + 0.2 s ) (1 + 0.025s)
show
S 3(1 + 0.001s ) (1 + 0.005s )

that the system is conditionally

stable. Find the ranges of K for which the system is stable

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system

system is just stable

Draw the bode plot of a feedback control system whose loop transfer function is given
by G ( s ) h ( S )

58

bode

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59

60

the system becomes unstable?

Sketch the root locus diagram

for

K
G ( s) =
S(s + 4)(s 2 + 4s + 10.25)
61
62
63
64
65
66

K ( s + 1)
(s + 18)(s2 + 2.5s + 12)

Sketch the root locus plots of G ( s ) H ( s )

the

open

loop

for what value of k

transfer

function

find the value of k and at which the system is

marginally stable
What are the types of system compensation and explain any one briefly.
What are the advantages and disadvantages of Phase Lag compensator?
What are the advantages and disadvantages of Phase Lead compensator?
What are the advantages and disadvantages of Phase Lag - lead compensator?
Explain clearly the need for compensation in a control system.
Show the transfer function of lead compensated electrical network as shown in figure.

67
68

Explain briefly how a tachometer functions as a compensating device

Show the transfer function of lead compensated mechanical network as shown in
figure

69
70
71

Define the terms 1) State 2) State variables.

72

VII SEMESTER

Define a) State vector b) State space.

Write short notes on 1) Controllability 2) observability 3) controllability 4)
observability theorems.
Represent MIMO and SISO systems as block diagrams (state variable representation)

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73

Obtain the state space representation for the system as in given figure.

74
75

78
79
80
81
82

What are the types of state space models?

Calculate the final value of the given function F(z)=8. Obtain the state equation of
the system whose difference equation is given by y(K+2) + 4y(K+1)+6y(K) = 3U(K)
The characteristic equation of a linear discrete data control system is given by f(z) =
Z3+Z2+Z+K=0, where K is a constant. Find the range of values of K so that the
system is stable.
Solve the following difference equation by using Z transform method x(k+2) +
3x(k+1) + 2x(k) = 0 when x(0) =0, x(1)=5.
List out the properties of Z transform.
List out the properties of Starred function.
List out the applications of sampled data technique.
List out the advantages of Digital computer control.
Determine the state controllability and observability of the system described by

83

Obtain the state model of the system whose closed loop transfer function is

76

77

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QUESTION PAPERS

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06ME72 - COMPUTER INTEGRATED

MANUFACTURING

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SYLLABUS
Sub Code: 06ME72
Hrs/Week: 04
Total Hrs: 52

IA Marks: 25
Exam Hours: 3
Exam Marks: 100

UNIT 1
COMPUTER INTEGRATED MANUFACTURING SYSTEMS:
Introduction, Automation definition, Types of automation, CIM, processing in
manufacturing, Production concepts, Mathematical Models-Manufacturing lead time,
production rate, components of operation time, capacity, Utilization and availability, Workin-process, WIP ratio, TIP ratio, Problems using mathematical model equations.
8 Hrs
UNIT - 2
HIGH VOLUME PRODUCTION SYSTEM:
Introduction Automated flow
line-symbols, objectives, Work part transport-continuous,
Intermittent, synchronous, Pallet fixtures, Transfer Mechanism-Linear-Walking beam, roller
chain drive, Rotary-rack and pinion, Ratchet & Pawl, Geneva wheel, Buffer storage, control
functions-sequence, safety, Quality, Automation for machining operation.
6 Hrs
UNIT - 3
ANALYSIS OF AUTOMATED FLOW LINE & LINE BALANCING:
General terminology and analysis, Analysis of Transfer Line without storage-upper bound
approach, lower bound approach and problems, Analysis of Transfer lines with storage buffer,
Effect of storage, buffer capacity with simple problem, Partial automation-with numerical
problems, flow lines with more than two stages, Manual Assembly lines, line balancing
problem
6 Hrs
UNIT - 4
MINIMUM RATIONAL WORK ELEMENT
Work station process time, Cycle time, precedence constraints. Precedence diagram, Balance
delay methods of line balancing-largest Candidate rule, Kilbridge and Westers method,
Ranked positional weight method, Numerical problems covering above methods and
6 Hrs
computerized line balancing
UNIT - 5
AUTOMATED ASSEMBLY SYSTEMS:
Design for automated assembly systems, types of automated assembly system, Parts feeding
devices-elements of parts delivery system- hopper, part feeder, Selectors, feed back,
escapement and placement analysis of Multistation Assembly Machine analysis of single
station assembly. Automated Guided Vehicle System: Introduction, Vehicle guidance and
routing, System management, Quantitative analysis of AGVs with numerical problems and
application.
8 Hrs
UNIT - 6
COMPUTERIZED MANUFACTURING PLANNING SYSTEM:
Introduction, Computer Aided Process Planning, Retrieval types of process planning,
Generative type of process planning, Material requirement planning, Fundamental concepts
of MRP inputs to MRP, Capacity planning

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UNIT - 7
CNC MACHINING CENTERS:
Introduction to CNC, elements of CNC, CNC machining centers, part programming,
fundamental steps involved in development of part programming for milling and turning.
UNIT - 8
ROBOTICS:
Introduction to Robot configuration, Robot motion, programming of Robots end effectors,
Robot sensors and Robot applications. [This is required for CIM automation lab 06MEL77]
TEXT BOOKS:
1. Automation, Production system & Computer Integrated manufacturing, M. P. Groover
Person India, 2007 2nd edition.
2. Principles of Computer Integrated Manufacturing, S. Kant Vajpayee, Prentice Hall India.
REFERENCE BOOKS:
1. Computer Integrated Manufacturing, J. A. Rehg & Henry. W. Kraebber.
2. CAD/CAM by Zeid, Tata McGraw Hill.

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LESSON PLAN
Subject code :06ME72
Subject Name : COMPUTER INTEGRATED MANUFACTURING
Hour
No

Hours/Week : 05
Total Hours : 52

Topics to be covered

Unit-1: COMPUTER INTEGRATED MANUFACTURING SYSTEMS

01
Introduction to computer integrated manufacturing systems, Automation Definition.
02

Types of Automation, computer integrated manufacturing systems.

03

Processing in manufacturing.

04

Production concepts.

05

Mathematical models-Manufacturing lead-time., Production rate,

06

Components of operation time,. Capacity, Utilization and availability.

07

Problems related to MLT,

08

Production rate, components of operation time,. Capacity, , Utilization and availability

09

Work-in-process.-Work-in-process [WIP] Ratio, Tip Ratio

10

Problems using mathematical model equations.

Unit-2: HIGH VOLUME PRODUCTION SYSTEM

11
Introduction automated flow line-symbols.
12

Objectives, Work part transport-continuous, Intermittent, synchronous, pallet fixtures.

13

Transfer mechanism-linear-walking beam.

14

Roller chain drive, Rotary-rack and pinion.

15

Ratchet and Pawl, Geneva wheel, Buffer storage.

16

Control functions-sequence, safety, and quality

17

Automation for machining operation.

Unit-3: ANALYSIS OF AUTOMATED FLOW LINE & LINE BALANCING

General Terminology and analysis, Analysis of Transfer line without storage upper
18
bound approach.
19
Lower bound approach and problems.
20

Analysis of Transfer lines with storage buffer.

21

Effect of storage buffer, buffer capacity with simple problems.

22

Partial automation-with numerical problems.

23

Flow lines with more than two stages

24

Manual Assembly lines.

25

Line balancing problems.

Unit-4: MINIMUM RATIONAL WORK ELEMENT

26
Work station process time, Cycle time.
27

Precedence constraints, precedence diagrams.

28

Balance delay methods of line balancing-largest candidate rule.

29

Kilbridge and westers method., problems.

30

Ranked positional weight method., problems.

31

Computerized line balancing.

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Unit-5: AUTOMATED ASSEMBLY SYSTEMS

32
Design for automated assembly systems.
33

Types of automated assembly systems.

34

Parts feeding devices-elements of parts delivery system-hopper., Part feeder, selectors

& feed back.

35

Escapement and placement analysis of multi-station assembly machine.

36

Analysis of single station assembly.

37

Introduction to Automated Guided Vehicle System [AGV].

38

Vehicle guidance and routing system management.

39

Quantitative analysis of AGVs,

40

Problems and applications of AGVs.

Unit-6: COMPUTERISED MANUFACTURING PLANNING SYSTEM

41
Introduction to computerized manufacturing planning system.
42

Computer aided process planning.

43

Retrieval types of process planning.

44

Generative types of process planning.

45

Material process planning,

46

Fundamental concepts of MRP inputs to MRP

47

Capacity planning.

Unit-7: CNC MACHINING CENTERS

48
Introduction to CNC machines.
49

Elements of CNC.

50

CNC machining centers.

51

CNC part programming.

52

Fundamental steps involved in the development of CNC part programming.

53

CNC part programming for Turning.

54

Part programming for Turning models.

55

CNC part programming for Milling

56

Part programming for Milling models

Unit-8: ROBOTICS
57
Introduction to Robotics., Robot configuration.
58

Robot motion.

59

Programming of Robots end effectors.

60

Robot sensors.

61

Robot applications.

62

Introduction to CIM automation lab problems.

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QUESTION BANK
CHAPTER 1: Computer Integrated Manufacturing
1. Define the term CAD, CAM & CIM.
2. Define the term Automation and Briefly explain the different types of automation with
their salient features
3. List the various reasons for Automation.
4. Comparison between Automation and CIM?
5. Briefly explain the different types of production system with an example.
6. Enlist the functions in the Manufacturing system.
7. What are the Arguments for and against in favor of the Automation?
8. With neat sketch explain the information processing cycle in a typical manufacturing
organization.
9. Enlist the automation strategy with their effect? Briefly explain each of them.
10.

Define the following term with respect to Production concepts

Production rate
Plant capacity
Utilization
Availability
Manufacturing lead time
Work in process.

11.
Write a note on MLT? Give the expression of MLT for different types of
production.
Explain the following with respect to WIP.,
12.

WIP ratio

TIP ratio
A certain part is routed through 6 machines. The parts are made in very large
13.
quantities on a flow production line in which an automated work handling system is
used to transfer parts between the machines. The transfer time between stations is 15
seconds. The total time required to setup the entire line is 150 hrs. Operation time for
individual machines are given in the following table.,
Operation
Machine
time (min)
1
5
2
3.5
3
10
4
1.9
5
4.1
6
2.5
Determine: 1) The MLT for an average production part coming of the line
2) Production rate for operation 3
3) Theoretical production rate for the entire production line.

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14.The avg parts produced is a certain batch has to be processed through an avg of 6
machines. There are 20 new batches of parts launch each week. Other pertinent
information are,
Avg operation time = 6 min = 0.1 hrs , Avg setup time = 5 hrs
Avg batch size = 25 parts , Avg non-operation time = 10 hrs.
There are 18 work centers in the plant and the plant operates for an avg of 70 production
hrs / week.
Scrap rate is negligible. Determine 1) MLT for avg part Ans. 105 hrs
2) Plant capacity
Ans. 700 pc/week
3) Plant utilization Ans. 71.43 %
15. In certain factory an avg of 20 new orders are processed every month 50 parts are to
be processed on an avg for every order. The processing of the order is carried out through
10 machines in the factory the following data is made available for further computations,
Operation time / machines for each part = 15 min
Non operation time per order at each machines = 8 hrs
Setup time per order = 4 hrs
No of machines in factory = 25
No of hrs of plant operation / month = 160 hrs
% of machines operational at any time = 80 %
% of machines under repair and maintenance at any time =20%
You are required to computer the following,
1) MLT per product. Ans 245 hrs
2) Plant capacity per month. Ans 969.7 pc/months
3) Plant utilization. Ans 103.125%
4) WIP Ratio. Ans 98%
16. A certain part is routed to the 6 machines in a batch production plant. The setup and
operation time for each machine is given in following table. The batch size is 100 units
and the avg non-operation time per machine is 12 hrs.
Operating
Set up
Machine
cycle
time (min)
time(min)
M/C 1
4
5
M/C 2
2
3.5
M/C 3
8
10
M/C 4
3
1.9
M/C 5
3
4.1
M/C 6
4
2.5
Determine
1) MLT Ans 141 hrs
2) Production rate for operation 3 and 5. Ans Production rate for 3 & 5 is 4.055
pieces/hr and 10.1698 pieces/hr respectively
17. The average part produced in a certain Batch manufacturing plant must be processed
through an average of 6 machines. 20 new batches of parts are launched each week.
Average operation time= 6min, Average setup time = 5hrs. Average batch size = 25 parts,
Average Non operation time per batch = 10 hrs. There are 18 machines in the plant and the
plant operates an average of 70 production hrs per week. Neglecting scrap rates determine
the following.
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i. The MLT for an average Plant

ii. The plant Capacity
iii. The plant utilization &
iv. Explain how the non operation time to be affected by the plant utilization
CHAPTER 2: High Volume Production System
1. Briefly explain the Automated flow lines with their objectives.
2. Enlist the symbols used in the production system diagrams.
3. Differentiate between In-Line type and Rotary Type.
4. Briefly explain the various methods of work part transport in automated flow line.
5. Write a note on Buffer storage.
6. Briefly explain the mechanism used in the Buffer storage.
7. State the design and fabrication considerations for an automated flow line.
8. With a neat sketch explain the following transfer mechanisms

Walking beam transfer system

Chain Driven Conveyor

Rack and Pinion

Geneva Mechanism.
CHAPTER 3: Analysis of Automated flow lines and line balancing
CHAPTER 4: MINIMUM RATIONAL WORK ELEMENT
1.
An indexing machine performs 10 assembly operations at 10 specific stations. The
total cycle time including transfer time/station is 18 sec. The station breakdown with a
probability P=0.061, which can be considered equal for all the stations. When this work
stoppage occur, it takes an average of 2.5 min to correct the fault parts. Compute the
following by using both the approaches.
 Frequency of the line stop.
 Average production time.
 Average production rate.
 Proportion of down time.
 Line efficiency.
Comment on which it has the less down time.
2.
The following data apply at a 12 station in-line transfer machine. P= 0.01 ( All stations
have an equal probability of failure) Ct = 0.3 min & ADt = 3 min. Using upper bound and
lower bound approach compute the following.
 Frequency of line stops
 Average production rate
 Line efficiency
3. A 10 station transfer machine used for producing pump component has an ideal cycle
time Ct= 1 min, with an estimated breakdowns of all types occurring with a frequency of F0.10 Breakdown/cycle and an average down time per line stop is 6 min. The scrap rate for
the current conventional method is 5% and is considered a good estimate for the transfer
line. The starting casting for the component casts Rs 75 each and it will cost Rs 3000/hr to
operate the transfer line. Cutting tools are estimated to cost Rs 7.5.work part. Using these
data compute the following measures of line performance.
 Production rate
 Number of hrs required to meet the demand of 1500 units/week
 Line efficiency
 Cost per unit produced.

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4. A 20 station transfer line has an ideal cycle time Ct = 1.2 minutes. The probability of
station breakdowns per cycle is equal for all stations and P=0.005 breakdowns per cycle. The
average down time per cycle is 8 minutes. For each of the upper bound and lower bound
approaches, determine
 Frequency of the line stops
 Average actual production rate
 Line efficiency
5. The following list defines the precedence relation ships and elemental times for a new
model toy.
Immediate
Element Te (min)
Predecessors
1
0.5
2
0.3
1
3
0.8
1
4
0.2
2
5
0.1
2
6
0.6
3
7
0.4
4,5
8
0.5
3,5
9
0.3
7,8
10
0.6
6,9
1. Construct the precedence diagram for this job
2. Assign work elements to stations using different methods of line balancing.
Determine the number of stations required and the corresponding balance delay.
6. Briefly explain the basic measures of automated flow lines
7. Briefly explain the starving and blocking of the stations
8. Explain the upper bound approach and lower bound approach in analyzing transfer lines
without storage buffer.
9. Explain the upper bound approach and lower bound approach in analyzing transfer lines
with storage buffer.
10. With an example, explain precedence Diagram.
11. Define the following

Total work content

Cycle time

Zoning constraint

Position constraint

Balance delay
12. Briefly explain the different types of Line balancing methods in detail
13. Write a note on computerized Line balancing
14. Briefly explain about the Partial Automation.
15. Briefly explain the assembly process
16. What is meant by the term precedence constraints?
17. What are the steps involved in the computerized line balancing?
18. what is the difference between the largest candidate rule and the Kilbridge and
Wester method.

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CHAPTER 5: AUTOMATED ASSEMBLY SYSTEM

1.
2.
3.
4.
5.
6.
7.
8.

Briefly explain the different types of Automated assembly line.

With neat sketch briefly explain the elements of parts feeding device.
Write a note on Automated guided vehicles.
Explain the different types of guidance system used in AGV.
Define ASRS & briefly explain the basic components involved in it.
List the benefits of ASRS & Application of ASRS.
Briefly explain the analysis of single station assembly machine
Briefly explain the analysis of Multi station assembly machine.

CHAPTER 6: COMPUTERIZED MANUFACTURING PLANNING SYSTEM

1.
2.
3.
4.

Define GT? Explain the part Families in GT.

What is process planning? With neat flow chart explain the retrieval type CAPP.
List and explain the benefits of CAPP systems
Explain the following automated process planning system

CAM-I CAPP

MULTI CAPP

MIP LAN

AUTAP
5. Briefly explain generative CAPP systems
6. Explain the typical activities in a production planning and control system.
7. Briefly explain the objectives of MRP.
8. Define MRP? Explain fundamental concepts of MRP
9. Differentiate between MRP Versus Order point systems
10. Briefly explain the structure of an MRP system with neat block diagram
11. List the benefits & limitations of MRP
12. Briefly explain various elements involved in MRP implementation
13. Briefly explain the Misconception about MRP.
14. Briefly explain the capacity planning.
15. Write short notes on

Capacity planning

Bill of Materials

MPS

Inventory record files.
CHAPTER 7: CNC MACHINING CENTERS
1.
2.
3.
4.
5.
6.

Define CNC and explain the basic components in CNC system.

what are the advantages of CNC systems over NC system.
write a short notes on CNC machining centers.
what are the steps involved computer assisted part programming.
what are the steps involved in development of part programming for milling?
what are the steps involved in development of part programming for turning.?

CHAPTER 8: ROBOTICS
1. Explain about different Robot configurations.
2. write a brief note on End effectors.
3. write a brief note on Robot sensors
4. Write short notes on Industrial applications of robot?
5. Explain the different methods of programming a robot.

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QUESTION BANK

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06ME73 MANUFACTURING PROCESS - III

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SYLLABUS
Subject Code: 06ME73
No. of Lecture Hrs./ Week: 04
Total No. of Lecture Hrs.: 62

IA Marks: 25
Exam Hours: 03
Exam Marks: 100
PART A

UNIT - 1
INTRODUCTION AND CONCEPTS: Classification of metal working processes,
characteristics of wrought products, advantages and limitations of metal working
processes.Concepts of true stress, true strain, triaxial & biaxial stresses. Determination of
flow stress. Principal stresses, Tresca & Von-Mises yield criteria, concepts of plane stress &
plane strain.
7 Hrs
UNIT - 2
EFFECTS OF PARAMETERS: Temperature, strain rate, friction and lubrication, hydrostatic
pressure in metalworking, Deformation zone geometry, workability of materials, Residual
stresses in wrought products.
6 Hrs
UNIT - 3
FORGING: Classification of forging processes. Forging machines & equipment. Expressions
for forging pressures & load in open die forging and closed die forging by slab analysis,
concepts of friction hill and factors affecting it. Die-design parameters. Material flow lines in
forging. Forging defects, Residual stresses in forging. Simple problems.
7 Hrs
UNIT - 4
ROLLING: Classification of Rolling processes. Types of rolling mills, expression for RoIling
load. Roll separating force. Frictional losses in bearing etc, power required in rolling, Effects
of front & back tensions, friction, friction hill. Maximum possible reduction. Defects in rolled
products. Rolling variables, simple problems.
6 Hrs
PART - B
UNIT - 5
DRAWING: Drawing equipment & dies, expression for drawing load by slab analysis, power
requirement. Redundant work and its estimation, optimal cone angle & dead zone formation,
drawing variables, Tube drawing, classification of tube drawing, simple problems. 7 Hrs
UNIT - 6
EXTRUSION: Types of extrusion processes, extrusion equipment & dies, deformation,
lubrication & defects in extrusion. Extrusion dies, Extrusion of seamless tubes. Extrusion
variables, simple problem
6 Hrs
UNIT - 7
SHEET & METAL FORMING: Forming methods, dies & punches, progressive die, compound
die, combination die. Rubber forming. Open back inclinable press (OBI press), piercing,
blanking, bending, deep drawing, LDR in drawing, Forming limit criterion, defects of drawn
products, stretch forming. Roll bending & contouring, Simple problems
6 Hrs

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UNIT - 8
HIGH ENERGY RATE FORMING METHODS: Principles, advantages and applications,
explosive forming, electro hydraulic forming, Electromagnetic forming.
POWDER METALLURGY: Basic steps in Powder metallurgy brief description of methods of
production of metal powders, conditioning and blending powders, compaction and sintering
application of powder metallurgy components, advantages and limitations.
7 Hrs
TEXT BOOKS:
Mechanical metallurgy (SI units), by G.E. Dieter, Mc Graw Hill pub.2001
Manufacturing Engineering and Technology by Serope Kalpakjian and Stevan R.
REFERENCE BOOKS:
1. Materials and Processes in Manufacturing by E.paul, Degramo, J.T. Black, Ronald,
A.K. Prentice -hall of India 2002
2. Principles of Industrial metal working process - G.W. Rowe, CBSpub. 2002
3. Manufacturing Science, hy Amitabha Ghosh & A.K. Malik - East -Westpress 2001
4. Theory of plasticity by Dr. Sadhu Sing

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LESSON PLAN
Sub Code: 06ME73
Sub: Manufacturing Process-III
Hours
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49

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Hours/week: 5
Total Hours: 62

Topics Proposed to be Covered

Unit1: Introduction and Concepts: Classification of metal working
processes.
Wrought Products, Characteristics of wrought products.
Advantages and Limitations of metal working processes.
Concepts of true stress, true strain, triaxial and biaxial stresses.
Methods for the determination of flow stress.
Principal stresses.
Tresca and Von-mises yield criteria.
Concepts of plane stress and plane strain.
Brief description of methods of metal deformation analysis.
Simple Problems.
Unit 2 Effect of Parameters: Effects of temperature, strain rate.
Friction and lubrication, Hydrostatic pressure in metalworking.
Deformation zone geometry, workability of materials.
Residual stresses in wrought products.
Unit 8 High Energy Rate Forming Methods: Introduction, Classification
of Energy Rate Forming processes.
Principles of Energy Rate Forming processes, advantages and applications.
Explosive forming. Electro hydraulic forming.
Electromagnetic forming.
Powder metallurgy: Introduction, Basic steps in powder metallurgy,
Advantages and Limitations of Powder metallurgy
Brief description of methods of production of metal powders,
Brief description of methods of production of metal powders, Continued..
Conditioning and Blending of powders.
Compaction and Sintering.
Applications of powder metallurgy components.
Unit 7 Sheet Metal Forming: Introduction, Advantages and Limitations of
Sheet Metal Forming.
Forming methods dies and punches.
Progressive die, compound die, combination die.
Rubber forming, open back inclinable press (OBI press).
Piercing, blanking, bending and stretch forming.
Roll bending and contouring.
Applications of Sheet Metal Forming.
Unit 4 Rolling: Introduction, Advantages and Limitations of rolling
processes.
Classification of rolling processes.
Types of rolling mills.
Expressions for rolling load.
Roll separating force.
Frictional losses in bearing etc, power required in rolling,
Effects of front and back tensions, frictions, & friction hill.
Maximum possible reduction. Defects in rolled products.
Simple Problems.
Unit 6 Extrusion: types of extrusion processes.
Extrusion equipment and dies.
Deformation and lubrication.
Defects in extruded products.
Extrusion of seamless pipes and tubes.
Extrusion of seamless pipes and tubes. Continued..
Unit 3 Forging: classification of forging processes.
Forging machines and equipment.

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52
53
54
55
56
57
58
59
60
61
62

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Expressions for forging pressure and load in open die forging by slab
analysis.
Expressions for forging pressure and load in and closed die forging by slab
analysis.
Concepts of friction hill and factors affecting it.
Die- design parameters. Material flow lines in forging.
Forging of a connecting Rod.

Forging defects, residual stresses in forging.

Simple Problems.
Unit 5 Drawing: Drawing equipment and dies,
Expression for drawing loads by slab analysis, power requirement.
Redundant work and its estimation.
Optimal cone angle and dead zone formation.
Drawing Variables & Tube Drawing.
Classification of tube Drawing & Simple problems.

Text books:
1. Materials and processes in manufacturing by E.paul, Degramo, J.T Black, Ronald, A.K. Prentice
hall of India 2002.
2. Manufacturing Engineering and Technology by Serope Kalpakjian and Stevan.R.Schmid, Pearson
Educational Aisia, 4th Edition, 2002.
Reference book:
1. Mechanical Metallurgy by G.E.Dieter, Mc Graw Hill pub.2001.
2. Manufacturing Science by Amitabha Ghosh and A K Malik East west press 2001.
3. deformation processing by W A Backofen, Addissen Weslay, 1973.

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QUESTION BANK
UNIT 1:
INTRODUCTION & CONCEPTS OF METAL FORMING PROCESS
1.
2.
3.
4.
5.
6.

What are the main characteristics of hot working as compared to cold working?
Write the difference between Hot, Cold and Worm Metal Working Process.
How are metal forming processes classified. Explain with neat sketches.
Explain the characteristics of wrought products?
Write the advantages and disadvantages of metal forming processes.
What is the concept of True stress and True Strain? Write the advantages of using the True stress and True
Strain.
7. Establish the relationship between the True stress and True Strain with nominal Stress and Strain.
8. Explain Triaxial and Biaxial Stresses.
9. Explain the concept of Plane Stress and Plane Strain.
10. Define Principal stress and derive an equation for the determination of principal stresses on an oblique
plane.
11. What is Yield Criteria? Describe the Von-mises and Trescas Yield Criteria for a Three Dimensional Stress
Field.
12. Define Flow stress? List and explain different Experiment Conducted to Determine the Flow Stress.
13. Flow stress of a material is given by 0=Kn MPa, Where K= Strength Co-efficient = 140, n = strain
hardening effect = 1.2, = true Strain. If a plate having a thickness 20mm is reduced to a thickness 15mm
by a suitable metal working process, find the value of mean Flow Stress.
14. A tensile specimen with a 12mm initial diameter and 50mm gauge length reaches a maximum load at 90KN
and fractures at 70KN. The maximum load (i.e. ultimate tensile system) and the fracture stress. What is
the engineering strain at fracture?
15. An aluminum alloy having 0 (uniaxial flow stress) as 500 MPa is subjected to three principal stresses: x as
200 MPa (tensile), y = 100 MPa (tensile), z = 50 MPa (compressive) and shear stress = 50 MPa (xy).
Will the material exhibit yielding? If not, what is the safety factor?
16. List the different methods of Metal Deformation Analysis and Explain the Slab Method.
17. Explain the FEM used in analyzing the deformation process.

UNIT 2:
EFFECTS OF PARAMETERS
1. What are the effects of Residual Stresses in metalworking? How do you relieve the Residual stresses?
2. Explain the different methods of lubrication in metalworking?
3. Discuss the importance of the following in designing successful forming process (a) Deformation Zone
geometry (b) Friction & Lubrication.
4. Explain the effect of Strain Rate in metalworking?
5. Explain what do you mean by workability of materials.
6. Explain the Residual Stress in the wrought Products.
7. Explain the effect of Strain Rate in metalworking?
8. Explain the different mechanisms of friction during metalworking?

UNIT 3:
FORGING
1. What do you mean by forging? Give detailed classification of different forging processes.
2. With a help of a neat diagram explain different forging equipments.
3. List the difference between open and closed forging.
4. Give the difference between mechanical and hydraulic presses.
5. List the difference between open and closed forging.
6. Give the difference between mechanical and hydraulic presses.
7. Explain with the help of a neat sketch Steam hammer used in forging.
8. What do you mean by forging? Give detailed classification of different forging processes.
9. Explain with the help of a neat sketch Heavy Hydraulic press in detail.
10. Explain with the help of a neat sketch Board Drop hammer used in forging.
11. Sketch and explain step-by-step procedure of drop forging of connecting rod.

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UNIT 4:
ROLLING
1.
2.
3.
4.
5.
6.
7.

Explain the classification of rolling processes.

With the help of neat sketch explain different Types of rolling mills.
Explain the Advantages and Limitations of rolling processes.
Derive an Expression for rolling load.
Define & Explain Roll separating force.
List & Explain Defects in rolled products.
Explain the Following
Frictional losses in bearing
Effects of front and back tensions
Friction in rolling & Friction Hill
Maximum possible reduction

UNIT 5
DRAWING
1. Derive Expressions for drawing loads by slab analysis & power required for drawing.
2. List & Explain different Drawing Dies.
3.
4.
5.
6.

List & Explain the Drawing Variables.

Define Tube Drawing & give the Classification of tube Drawing.
Explain redundant work and its estimation.
Optimal cone angle and dead zone formation in drawing

UNIT 6:
EXTRUSION
1.
2.
3.
4.
5.
6.

Explain with the help of a neat sketch Different equipments used in Extrusion.
Explain with the help of a neat sketch Extrusion Forging and Impact Extrusion.
List and Explain the Defects in the Extruded Products.
Explain with the help of a neat sketch Direct Extrusion and Indirect Extrusion.
Explain with the help of a neat sketch Hydrostatic Extrusion.
List and explain the different methods of Extrusion of Seamless Tubes.

UNIT 7:
SHEET & METAL FORMING
9. With the help of neat sketch classify and explain sheet metal presses in detail.
10. With the help of neat sketch, explain different dies used in sheet metal work.
11. List and explain the different press driving mechanisms.
12. Write the classification of dies and explain with the help of neat sketches.
13. With the help of neat sketch explain fly ball and power press.
14. With the help of neat sketch Explain shearing, blanking and related operations in detail.
15. With the help of neat sketch Explain in detail bending operations.
16. What do you mean by spring back effect? How to overcome it?
17. Give the difference between mechanical and hydraulic presses.

UNIT 8:
HIGH ENERGY RATE FORMING & POWDER METALLURGY
1. Write the detailed Classification of Energy Rate Forming processes.
2. Explain the Principles of Energy Rate Forming processes?
3. With the help of neat sketch explain Explosive forming?
4. With the help of neat sketch explain Electro hydraulic forming?
5. With the help of neat sketch explain Electromagnetic forming?
6. What are the advantages of powder metallurgy forming over conventional forging?
7. Explain briefly basic steps of powder metallurgy process?
8. Mention the applications of powder metallurgy?
9. What are the different factors that influence powder metallurgy process? Explain briefly.
10. What are the various finishing operations carried out on powder metallurgy products after sintering?
Explain any two of them.
11. Briefly explain cold iso static pressing in powder metallurgy with a suitable diagram.
12. What do you mean by pre sintering and sintering? Explain
13. Explain various methods of powder metallurgy production.
14. Draw the outline of processes and operations involved in making powder metallurgy parts.

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06ME74 - OPERATIONS RESEARCH

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SYLLABUS
Subject Code: 06ME74
Hours./ Week : 05
Total Hours. : 62

IA Marks
: 25
Exam Hours : 03
Exam Marks : 100

PART - A
UNIT - 1
INTRODUCTION: Linear programming, Definition, scope of Operations Research (O.R) approach and
limitations of OR Models, Characteristics and phases of OR Mathematical formulation of L.P. Problems.
Graphical solution methods.
7Hrs
UNIT - 2
LINEAR PROGRAMMING PROBLEMS: The simplex method - slack, surplus and artificial variables. Concept
of duality, two phase method, dual simplex method, degeneracy, and procedure for resolving degenerate cases.
8Hrs
UNIT - 3
TRANSPORTATION PROBLEM: Formulation of transportation model, Basic feasible solution using different
methods, Optimality Methods, Unbalanced transportation problem, Degeneracy in transportation problems,
Applications of Transportation problems. Assignment Problem: Formulation, unbalanced assignment problem,
Traveling salesman problem.
9 Hrs
UNIT - 4
SEQUENCING: Johnsons algorithm, n - jobs to 2 machines, n jobs 3machines, n jobs m machines without
passing sequence. 2 jobs n machines with passing. Graphical solutions priority rules.
7Hrs
PART - B
UNIT - 5
QUEUING THEORY: Queuing system and their characteristics. The M/M/1 Queuing system, Steady state
performance analysing of M/M/ 1 and M/M/C queuing model.
7Hrs
UNIT - 6
PERT-CPM TECHNIQUES: Network construction, determining critical path, floats, scheduling by network,
project duration, variance under probabilistic models, prediction of date of completion, crashing of simple
networks.
9Hrs
UNIT - 7
GAME THEORY: Formulation of games, Two person-Zero sum game, games with and without saddle point,
Graphical solution (2x n, m x 2 game), dominance property.
8Hrs
UNIT - 8
INTEGER PROGRAMMING: Gommorys technique, branch and bound lgorithm for integer programming
problems, zero one algorithm
7 Hrs
TEXT BOOKS:
1. Operations Research and Introduction, Taha H. A. Pearson
Education edition
2. Operations Research, S. D. Sharma Kedarnath Ramnath & Co
2002.
REFERENCE BOOKS:
1. Operation Research AM Natarajan, P. Balasubramani, A
Tamilaravari Pearson 2005
2. Introduction to operation research, Hiller and liberman, Mc Graw
Hill. 5th edition 2001.
3. Operations Research: Principles and practice: Ravindran, Phillips
& Solberg, Wiley India lts, 2nd Edition 2007
4. Operations Research, Prem Kumar Gupta, D S Hira, S Chand Pub,
New Delhi, 2007

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LESSON PLAN
Sub code: 06ME74
Sub: OPERATION RESEARCH
Hours

Hrs/Week : 05
Total Hours : 62
Topics to be covered
PART-A

Unit-1:

INTRODUCTION

01

Introduction to operation research.

02

Definition to Linear programming,

03

Scope of Operations Research

04

Approach and limitations of OR Models

05

Characteristics and Phases of OR

06

Mathematical formulation of L.P. Problems

07

Graphical solution methods

Unit-2: LINEAR PROGRAMMING PROBLEMS

08
Introduction to linear programming problems
09

The simplex method

10

Slack, Surplus and artificial variables.

11

Concept of duality

12

Two phase method

13

Dual simplex method

14

Degeneracy problems

15

Procedure for resolving degenerate cases

Unit-3: TRANSPORTATION PROBLEM
16
Formulation of transportation model,
17

Basic feasible solution using different methods

18

Optimality Methods

19

Unbalanced transportation problem

20

Degeneracy in transportation problems.

21

Applications of Transportation problems.

22

Assignment Problem.

23

Formulation of unbalanced assignment problem.

24

Traveling salesman problem.

Unit-4: SEQUENCING
25

Introduction to Job sequencing.

26

Johnsons algorithm.

27

n - jobs to 2 machines.

28

n jobs 3machines.

29

n jobs m machines without passing sequence.

30

2 jobs n machines with passing.

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Graphical solutions priority rules.

PART-B
Unit-5: QUEUING THEORY
32

Introduction to queuing theory.

33

Queuing system and their characteristics

34

The M/M/1 Queuing system

35

Steady state performance

36

Analyzing of M/M/ 1

37

M/M/C queuing model.

38

Problems on queuing models

Unit-6: PERT-CPM TECHNIQUES

39

Introduction PERT-CPM techniques.

40

Network construction

41

Determining critical path

42

Determining floats

43

Scheduling by network

44

Project duration

45

Variance under probabilistic models

46

Prediction of date of completion

47

Crashing of simple networks

Unit-7:

GAME THEORY

48

Introduction to Game Theory

49

Formulation of games

50

Two person-Zero sum game

51

Games with saddle point

52

Games without saddle point

53

Graphical solution (2 x n) game

54

Graphical solution (m x 2) game

55

Dominance property

Unit-8: INTEGER PROGRAMMING

56

Introduction to Integer Programming.

57

Gommorys technique.

58

Branch logarithm for integer programming problems.

59

Bound logarithm for integer programming problems.

60

Zero one logarithm.

61

Applications of integer programming.

62

Problems.

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QUESTION BANK

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06ME753 - PRODUCT DESIGN AND

MANUFACTURING

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SYLLABUS
Subject Code:06ME753
Hours./ Week:05
Total Hours.:52

IA Marks: 25
Exam Hours: 03
Exam Marks: 100

PART - A
UNIT - 1
INTRODUCTION TO PRODUCT DESIGN: Asimows model: Definition of product design, Design by
Evolution, Design by Innovation, Essential Factors of Product design, Production-Consumption Cycle, Flow and
Value Addition in the Production-Consumption Cycle, The Morphology of Design ( The seven phases), Primary
Design Phases and Flowcharting, Role of Allowance, Process Capability and Tolerance in Detailed Design &
Assembly.
9 Hrs
UNIT - 2
PRODUCT DESIGN PRACTICE AND INDUSTRY: Introduction, Product Strategies, Time to Market, Analysis
of the Product, The Ss Standardization, Renard Series, Simplification, Role of Aesthetics in Product Design,
Functional Design Practice.
8 Hrs
UNIT - 3
REVIEW OF STRENGTH, STIFFNESS AND RIGIDITY CONSIDERATIONS IN PRODUCT DESIGN:
Principal Stress Trajectories (Force-Flow Lines), Balanced Design, Criteria and Objectives of Design, Material
Toughness: Resilience Designing for Uniform Strength, Tension vis-a-vis Compression. Review of Production
Process: Introduction, Primary Processes, Machining Process, Non-traditional Machining Processes. 8 Hrs
UNIT - 4
DESIGN FOR PRODUCTION METAL PARTS: Producibility requirements in the Design of machine
Components, Forging Design, Pressed components Design, Casting Design, and Design for Machining Ease,
The Role of Process Engineer, Ease of Location Casting and Special Casting. Designing with Plastic, rubber,
ceramics and wood: Approach to design with plastics, plastic bush bearings, gears in plastics, rubber parts,
design recommendations for rubber parts, ceramic and glass parts.
8 Hrs
PART - B
UNIT - 5
OPTIMIZATION IN DESIGN: Introduction, Siddals Classification of Design Approaches, Optimization by
Differential Calculus, Lagrange Multipliers, Linear Programming (Simplex Method), Geometric Programming,
Johnsons Method of Optimum Design.
7 Hrs
UNIT - 6
ECONOMIC FACTOR INFLUENCING DESIGN: Product Value, Design for Safety, Reliability and Environmental
Considerations, Manufacturing Operations in relation to Design, Economic Analysis, Profit and Competitiveness,
Break even Analysis, Economic of a New Product Design.
7 Hrs
UNIT - 7
HUMAN ENGINEERING CONSIDERATIONS IN PRODUCT DESIGN: Introduction, Human being as Applicator
of Forces, Anthropometry; Man as occupant of Space, The Design of Controls, of controls, the Design of
Displays, Man/Machine Information Exchange.
7 Hrs
UNIT - 8
VALUE ENGINEERING AND PRODUCT DESIGN: Introduction, Historical Perspective, What is Value? Nature
and Measurement of Value, Normal Degree of Value, Importance of Value, The Value analysis Job Plan,
Creativity, Steps to Problems-solving and Value Analysis, Value Analysis Test, Value Engineering Idea
Generation Check-list Cost Reduction through value engineering case study on Tap Switch Control Assembly,
Material and Process Selection in Value Engineering
Modern Approaches to Product Design: Concurrent Design and Quality Function Deployment (QFD). 9Hrs
TEXT BOOKS:
th
1. Product Design and Manufacturing, A.C. Chitale and R.C. Gupta, PHI 4 edition 2007.
2. Product Design & Development, Karl T. Ulrich & Steven D, Epinger, Tata Mc. Graw Hill, 3

rd

Edition,

2003
REFERENCE BOOKS:
1. New Product Development, Tim Jones, Butterworh Heinmann, Oxford, mc 1997.
2. New Product Development: Design & Analysis by Roland Engene Kinetovicz, John Wiley and Sosn
Inc., N.Y. 1990

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LESSON PLAN
Semester: VII
Subject: Product Design & Manufacturing
Sub. Code: 06ME753

No.of Periods:62
Hrs/Week:04
Total Hours: 52

Hour.
TOPICS TO BE COVERED
No
1. INTRODUCTION TO PRODUCT DESIGN: Asimows model: Definition of
product design, Design by Evolution,
2. Design by Innovation, Essential Factors of Product design
3. Production-Consumption Cycle
4. Flow and Value Addition in the Production-Consumption Cycle,
5. The Morphology of Design ( The seven phases)
6. Primary Design Phases
7. Flow charts
8. Role of allowance, process capability, tolerance in detailed design & assembly
9. PRODUCT DESIGN PRACTICE AND INDUSTRY: Introduction, Product
Strategies
10. Time to Market, Analysis of the Product
11. The Ss Standardization,
12. Renard Series, Simplification,
13. Role of Aesthetics in Product Design
14. Functional Design Practice.
15. Role of Functional Design Practice
16. REVIEW OF STRENGTH, STIFFNESS AND RIGIDITY CONSIDERATIONS IN
PRODUCT DESIGN: Principal Stress Trajectories (Force-Flow Lines
17. Balanced Design, Criteria and Objectives of Design
18. Material Toughness: Resilience Designing for Uniform Strength
19. Tension vis-a-vis Compression.
20. Review of Production Process: Introduction
21. Primary Processes
22. Machining Process
23. Non-traditional Machining Processes
24. DESIGN FOR PRODUCTION METAL PARTS: Producibility requirements in the
Design of machine Components
25. Forging Design, Pressed components Design
26. Casting Design, and Design for Machining Ease
27. The Role of Process Engineer, Ease of Location Casting and Special Casting
28. Designing with Plastic, rubber, ceramics and wood.
29. Approach to design with plastics, plastic bush bearings, gears in plastics, rubber
parts
30. Design recommendations for rubber parts
31. ceramic and glass parts
32. OPTIMIZATION IN DESIGN: Introduction, Siddals Classification of Design
Approaches
33. Optimization by Differential Calculus
34. Lagrange Multipliers
35. Linear Programming (Simplex Method)
36. Geometric Programming.
37. Johnsons Method of Optimum Design
38. ECONOMIC FACTOR INFLUENCING DESIGN: Product Value, Design for Safety
39. Reliability and Environmental Considerations
40. Manufacturing Operations in relation to Design
41. Economic Analysis
42. Profit and Competitiveness
43. Break even Analysis
44. Economic of a New Product Design

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45. HUMAN ENGINEERING CONSIDERATIONS IN PRODUCT DESIGN:

Introduction
46. Human being as Applicator of Forces
47. Anthropometry; Man as occupant of Space
48. The Design of Controls, of Displays
49. The Design of Displays
50. Man Information Exchange
51. Machine Information Exchange
52. VALUE ENGINEERING AND PRODUCT DESIGN: Introduction
53. Historical Perspective, What is Value? Nature and Measurement of Value.
54. Normal Degree of Value, Importance of Value, The Value analysis Job Plan
55. Creativity, Steps to Problems-solving and Value Analysis
56. Value Analysis Test
57. Value Engineering Idea Generation Check-list
58. Cost Reduction through value engineering case study on Tap Switch Control
Assembly
59. case study on Tap Switch Control Assembly
60. Material and Process Selection in Value Engineering
61. Modern Approaches to Product Design
62. Concurrent Design and Quality Function Deployment (QFD).

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QUESTION BANK
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

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Define Product Design. Explain Design by evolution and design by innovation.

Explain the Essential factors to be considered for product design.
Explain Asimovs model
Explain with a neat sketch the production consumption cycle for a product.
Explain the morphology of a design process
Define allowance and explain its role in PDM
Define process capability, tolerance and their relationship with PDM
What is the product strategy of an organization and how does it affect the design of
the product?
How do you analyse the market and when do you think will be the right time to
market?
Explain with example Renard series
Explain the role of a designer
Define industrial design organization
Explain the basic design considerations
List and explain the problems faced by industrial designers
Explain the various models developed by industrial designers
Explain the role of aesthetics in PDM
With a neat sketch explain principal stress and strain
Define a balanced design
Explain the importance of toughness, resilience in PDM
List the objectives of design
Explain the Producibility requirements in PDM
Explain the design of a forged component
Explain the design of a welded component
Explain the design of a pressed component
Explain the location of clamps when designing a product
Explain the design of a casting
Explain the design of a expanded or wire component
Explain the design consideration for a plastic component
Explain the design consideration for a ceramic component
Explain the design consideration for a rubber component
Explain the design consideration for a wooden component
Explain the dimensional factors in PDM
How are optimization techniques applied to design of a product? Give suitable
examples
Define product value
Explain Design for safety
Explain Design for reliability
Explain Design for environment
Explain the manufacturing operations with respect to PDM
Explain economic analysis of a PDM with example
Define Anthropometrics in PDM
Explain the design of various controls devices in PDM
Define Value Engineering
How is value engineering applied to PDM
How do you measure the value of a product?
What is normal degree of value of a product?
Explain value analysis
Explain the steps of value analysis
Explain the reduction process through value engineering
Explain the case study on value engineering on Tap Switch Assembly
How do you select material and through value engineering
Define concurrent Engineering?
What are the advantages of Con current engineering
Explain Rapid Prototyping with example
Explain Quality Function Deployment (QFD)

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QUESTION PAPERS

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06ME766 ROBOTICS

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SYLLABUS
Subject Code : 06ME766
No. of Lecture Hrs./ Week : 05
Total No. of Lecture Hrs. : 62

IA Marks : 25
Exam Hours : 03
Exam Marks : 100

PART - A
UNIT - 1
INTRODUCTION AND MATHEMATICAL REPRESENTATION OFROBOTS:
History of Robots, Types of Robots, Notation, Position and Orientation of a Rigid Body, Some Properties of
Rotation Matrices, Successive Rotations, Euler Angles For fixed frames X-Y-Z and moving frame ZYZ.
Transformation between coordinate system, Homogeneous coordinates, Properties of T A B , Types of Joints:
Rotary, Prismatic joint, Cylindrical joint, Spherical joint, Representation of Links using Denvit- Hartenberg
Parameters: Link parameters for intermediate, first and last links, Link transformation matrices, Transformation
matrices of 3R manipulator, PUMA560 manipulator, SCARA manipulator
7 Hrs
UNIT - 2
KINEMATICS OF SERIAL MANIPULATORS:
Direct kinematics of 2R, 3R, RRP, RPR manipulator, puma560 manipulator, SCARA manipulator, Stanford arm,
Inverse kinematics of 2R, 3R manipulator, puma560 manipulator.
6 Hrs
UNIT - 3
VELOCITY AND STATICS OF MANIPULATORS:
Differential relationships, Jacobian, Differential motions of a frame (translation and rotation), Linear and angular
velocity of a rigid body, Linear and angular velocities of links in serial manipulators, 2R, 3R manipulators,
Jacobian of serial manipulator, Velocity ellipse of 2R manipulator, Singularities of 2R maipulators, Statics of
serial manipulators, Static force and torque analysis of 3R manipulator, Singularity in force domain. 7 Hrs
UNIT - 4
DYNAMICS OF MANIPULATORS:
Kinetic energy, Potential energy, Equation of motion using Lagrangian, Equation of motions of one and two
degree freedom spring mass damper systems using Lagrangian formulation, Inertia of a link, Recursive
formulation of Dynamics using Newton Euler equation, Equation of motion of 2R manipulator using Lagrangian,
Newton- Euler formulation.
6 Hrs

PART - B
UNIT - 5
TRAJECTORY PLANNING: Joint space schemes, cubic trajectory, Joint space schemes with via points, Cubic
trajectory with a via point, Third order polynomial trajectory planning, Linear segments with parabolic blends,
Cartesian space schemes, Cartesian straight line and circular motion planning
7 Hrs
UNIT - 6
CONTROL: Feedback control of a single link manipulator- first order, second order system, PID control, PID
control of multi link manipulator, Force control of manipulator, force control of single mass,Partitioning a task
for force and position control- lever, peg in hole Hybrid force and position controller
8 Hrs
UNIT - 7
ACTUATORS: Types, Characteristics of actuating system: weight, powerto- weight ratio, operating pressure,
stiffness vs. compliance, Use of reduction gears, comparision of hydraulic, electric, pneumatic actuators,
Hydraulic actuators, proportional feedback control, Electric motors: DC motors, Reversible AC motors, Brushles
DC motors, Stepper motors- structure and principle of operation, stepper motor speed-torque characteristics
6 Hrs
UNIT - 8
SENSORS: Sensor characteristics, Position sensors- potentiometers, Encoders, LVDT, Resolvers, Displacement
sensor, Velocity sensorencoders, tachometers, Acceleration sensors, Force and Pressure sensors piezoelectric,
force sensing resistor, Torque sensors, Touch and tactile sensor, Proximity sensors-magnetic, optical,
ultrasonic, inductive, capacitive, eddy-current proximity sensors.
5 Hrs

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TEXT BOOKS:
1. Fundamental Concepts and Analysis, Ghosal A., Robotics,
Oxford,2006
2. Introduction to Robotics Analysis, Systems, Applications, Niku,
S. B., Pearso Education, 2008
REFERENCE BOOKS:
1. Introduction to Robotics: Mechanica and Control, Craig, J. J.,
2nd Edition, Addison-Welsey, 1989.
2. Fundamentals of Robotics, Analysis and Control, Schilling R. J.,
PHI, 2006

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LESSON PLAN
Semester: VII
Subject: Robotics
Sub. Code: 06ME766
Hour
No
1

No.of Periods:62
Hrs/Week:04
Total Hours: 52
Topics to be covered

Introduction and mathematical representation of robots: History of robots,

Types of Robots

Notation, position and orientation of a rigid Body

Some properties of rotation Matrices, Successive Rotations

Euler Angles for fixed frames X-Y-Z and moving frame ZYZ

Transformation between coordinate system

Homogeneous coordinates, Types of joints: Rotary, Prismatic joint,

Cylindrical joint, Spherical joint

8
9
10

Representation of links using Denvit-Hartenberg Parameters: Link parameters for

intermediate, first and last links
Link transformation matrices
Transformation matrices of 3R manipulator, PUMA560 manipulator, SCARA
manipulator

11

Kinematics of Serial manipulators: Direct Kinematics of 2R, 3R

12

RRP, RPR manipulator

13

PUMA560 manipulator

14

SCARA manipulator

15

Standard arm

16

Inverse kinematics of 2R, 3R manipulator

17

Inverse kinematics of PUMA560 manipulator

18

Velocity and Statics of Manipulators: Differential relationships

19

Jacobean, Differential motions of a frame (translation & rotation)

20

Linear and Angular velocity of a rigid body

21

Linear and Angular velocities of links in Serial manipulators, 2R, 3R manipulators

22

Jacobian of serial manipulator

23

Velocity ellipse of 2R manipulator

24

Singularities of 2R manipulators

25

Statics of Serial manipulators, Static force and torque analysis of 3R manipulator,

Singularities in force domain

26

Dynamics of Manipulators: Kinetic energy, potential energy,

27

Equation of motion using Lagrangian

28
29

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Equation of motions of one & two degree freedom spring mass damper systems using
Lagrangian formulation
Inertia of a link

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30

Recursive formulation of dynamics using Newton Euler equation

31

Equation of motion of 2R manipulator using Lagrangian

32

Newton-Euler formulation

33

Trajectory planning: Joint Space Schemes, cubic trajectory

34

Joint Space Schemes with via points

35

Cubic trajectory with a via point

36

Third order polynomial trajectory planning

37

Linear segments with parabolic bends

38

Cartesian space schemes

39

Cartesian straight line and circular motion planning.

40

Control: Feedback control of a single link manipulator- first order system

41

Feedback control of a single link manipulator- Second order system

42

PID control

43

PID control of multi link manipulator

44

Force control of manipulator

45

Force control of single mass

46

Partitioning a task for force and position control- lever

47

Peg in hole Hybrid force and position controller.

48

Actuators: Types, Characteristics of Actuating System: weight, power-to-weight

ratio, Operating pressure, stiffness vs. compliance

49

Use of reduction gears, comparison of hydraulic

50

electric, pneumatic actuators

51

Hydraulic actuators, proportional feedback control,

52

Electric motors: DC motors, Reversible AC motors

53

Brushles DC motors, Stepper motors- structure and principle of operation, Stepper

motor speed-torque characteristics.

54

Sensors: Sensor characteristics, position sensors- potentiometers

55

Encoders, LVDT, Resolvers

56

Displacement sensor, Velocity sensor- encoders

57

Tachometers, Acceleration sensors

58

Force and pressure sensors-piezo electric, force sensing resistor

59

Torque sensors, touch and tactile sensor

60

Proximity sensors-magnetic, Optical, ultra-sonic

61

inductive, capacitive

62

eddy-current proximity sensors

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QUESTION BANK
1.
2.
3.
4.
5.
6.

Define a Robot
Explain the history of Robotics
Explain automation and Robotics
How Robot is different from mechanical manipulator
State and explain various aspects that justify the needs of Robots in industry
A cylindrical coordinated robot has a vertical reach of 500mm and a stroke of 320mm what is the
minimum height of the work table to able the robot to reach the object kept on the table?
7. Enumerate the complete robot classification.
8. Define a robot with ad with a diagram explain the anatomy of robot.
9. With a neat sketch differentiate and highlight the four common types of robot configurations
10. Explain robot specifications.
11. Define repeatability resolution and accuracy
12. Explain the properties of rotation matrices
13. Explain the types of joints Rotary,prismatic,cylindrical and spherical.
14. Write a short note on DH convention
15. List the steps involved in DH convention
16. Explain the coordinate frame assignment of DH representation
17. Define and illustrate link and joint parameters .Explain their uses
18. Give the Euler angle representation for the RPY system and derive the rotation matrix
19. Explain the homogeneous transformation matrix and interpret the partitioning with application
20. Get Euler angles for system I representation by applying inverse kinematic solution
21. Derive kinematic equation for the SCARA robot giving coordinate frame diagram and kinematic
parameters.
22. Derive the kinetic equation for the elbow manipulator with coordinate frame
Diagram and kinematic parameters.
23. Explain the geometric solution of inverse kinematic with an example of two
degree
system
manipulator.
24. Explain the kinematics of PUMA 560 manipulator
25. Derive the equation of motion for a single link manipulator given the mass and length of the link.
26. Explain the Linear and angular velocities of links in serial manipulators
27. Explain the statics of serial manipulator
28. Explain the static force and torque analysis of 3R manipulator
29. Explain the singularity in force domain
30. Discuss Lagrange-Euler formulations for a robotic manipulator
31. Explain Lagrange-Euler formulations for a robot arm
32. Explain the following briefly as applied to robot arm dynamic analysis
1.Kinetic Energy
2.Potential energy
3.Joint velocities
33. Derive the equation of motion for a single link manipulator given the mass and length of the link
34. What is Lagrangian .Give the Lagrange-Euler formulations for the joint force /torque
35. Derive the dynamic equation of motion for a Revolute-Prismatic (RP) robot arm manipulator.
36. Explain the following as applied to a robot arm and also discuss their importance
1.Inertia Terms
2.Coupling inertia
3 Centrifugal force
4.Coriolis component
5.Gravity term
37. It is given that a two link manipulator has to exert a force of f=10i+5j at its tool tip. The jacobian for
-l2S12,(l1C1+l2C12),
the manipulator is given by J=[-(l1 S1 +l2S12)
l2C12 ]
Given that l1=12 l2=10 1=30 and 2=45
Determine the joint torques
38. Describe any 4 controllers used in robotic systems mentioning their respective transfer functions
39. Draw block diagram and obtain the transfer function that corresponds to spring mass-damper system
suspended from a fixed wall.
40. Explain the responses of second order systems
41. Explain the transient response of second order system
42. Explain the control concept of robotic manipulator system
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43. With the block diagram and transfer function explain the following
1. Proportional control
2. Derivative control
3. Integral control
44.Explain the advantages of the following controllers
1. PD controller
2. PID controller
45.Explain the use of damping factor and the natural frequency in deciding the response of a robotic joint
described by a differential equation
46. Develop a model ofr transfer function of a dc motor diving a robot joint.
47. For a
pring mass damper system with stiffness k=4.mass m=2 and the damping coefficient
c=4.The system is known to possess unmodeled response at w resonant =8.0 rad/sec. Determine the
velocity gain kv and the positional gain kp of the critically damped system with reasonably high stiffness.
48. Explain trajectory planning and show how t trajectory planning is done in case of PTP robot having
constant maximum velocity and finite acceleration and deceleration
49. Discuss trajectory planning for PTP robot considering modified constant velocity motion of joint.
50. What are the various forms of input required to be provided as constraints to the robot path planning.
51. Describe various path control modes in robotics
52. Discuss advantages and disadvantages between joint space scheme and Cartesian space schemes
53. Enumerate trajectory generation polynomial types
54. Explain the parameters involved in path planning with 3rd degree polynomial.
55. Write a short notes on object recognition technique
56. Enlist desirable sensor and transducer features
57. Give the classification of sensors with examples.
58. With neat sketch explain the tactile sensors and the range sensors.
59.Sketch and explain a 6 component wrist sensor based on strain gauge element for force/ torque
sensing.
60. Describe desirable engineering features of sensors and transducers.
61. Explain various velocity sensors with sketch
62.Explain various touch and tactile sensors, proximity sensors.
63.What are the advantages of Hall effect transducer?
64.Explain with diagram components of digital image processing.
65. Explain the principle and working of Inductive type, ultrasonic and optical proximity sensors.
66.Give the performance specifications for the force sensors.
67. Explain the piezo electric force and pressure sensors.
68.Explain various types and their characteristics of actuating systems
69.Explain the use of reduction gears.
70.Compare hydraulic,pneumatic,electric actuators.
71.Describe a stepper motor used in actuating systems
72.Explain the speed-torque characteristics of a stepper motor

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06MEL77 - CIM & AUTOMATION LAB

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SYLLABUS
Subject Code : 06MEL77
No. of Practical Hrs./ Week : 03
Total No. of Practical Hrs. : 42

IA Marks : 25
Exam Hours : 03
Exam Marks : 50

PART - A
CNC part programming using CAM packages. Simulation of Turning, Drilling, Milling operations. 3 typical
simulations to be carried out using simulation packages like Master- CAM, or any equivalent software.
PART - B
(Only for Demo/Viva voce)
1. FMS (Flexible Manufacturing System): Programming of Automatic storage and Retrieval system (ASRS) and
linear shuttle conveyor Interfacing CNC lathe, milling with loading unloading arm and ASRS to be carried out
on simple components.
2. Robot programming: Using Teach Pendent & Offline programming to perform pick and place, stacking of
objects, 2 programs.
PART - C
(Only for Demo/Viva voce)
Pneumatics and Hydraulics, Electro-Pneumatics: 3 typical experiments on
Basics of these topics to be conducted.

Scheme of Examinations
Two questions from Part A 40 Marks (10 Write up +30)
Viva Voce 10 Marks
Total 50 Marks

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06MEL78 - DESIGN LABORATORY

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SYLLABUS
Subject Code : 06MEL78
No. of Practical Hrs./ Week : 03
Total No. of Practical Hrs. : 42

IA Marks : 25
Exam Hours : 03
Exam Marks : 50

PART - A
1. Determination of natural frequency, logarithmic decrement, damping
ratio and damping coefficient in a single degree of freedom vibrating
systems (longitudinal and torsional)
2. Balancing of rotating masses.
3. Determination of critical speed of a rotating shaft.
4. Determination of Fringe constant of Photoelastic material using.
a) Circular disc subjected to diametral compression.
b) Pure bending specimen (four point bending )
5. Determination of stress concentration using Photoelasticity for simple
components like plate with a hole under tension or bending, circular disk
with circular hole under compression, 2D Crane hook.
PART - B
6. Determination of equilibrium speed, sensitiveness, power and effort of
Porter/Prowel /Hartnel Governor. (only one or more)
7. Determination of Pressure distribution in Journal bearing.
8. Determination of Principal Stresses and strains in a member subjected to
combined loading using Strain rosettes.
9. Determination of stresses in Curved beam using strain gauge.
10. Experiments on Gyroscope (Demonstration only)
Scheme of Examination:
One question from Part A - 20 Marks (05 Write up +15)
One question from Part B - 20 Marks (05 Write up +15)
Viva - Voce - 10 Marks
-----------Total: 50 Marks

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