Beruflich Dokumente
Kultur Dokumente
Draft curriculum on
May, 2017
Contents
Contents .................................................................................................................................................. 3
1. INTRODUCTION ............................................................................................................................... 1
1.1 Background ............................................................................................................................. 1
1.2 Course Aim and Objectives ..................................................................................................... 1
1.3 Who Can Join the Program? ................................................................................................... 2
2. RATIONALE OF THE GRADUATE PROGRAM .................................................................................... 3
3. GRADUATE PROFILE ........................................................................................................................ 3
4. PROGRAM REQUIREMENTS ............................................................................................................ 4
4.1 Admission Requirements ........................................................................................................ 4
4.2 Graduation Requirements ...................................................................................................... 4
4.3 Evaluation Criteria................................................................................................................... 4
4.4 Quality Assurance and curriculum review .............................................................................. 4
5. DEGREE NOMENCLATURE ............................................................................................................... 6
6. PROGRAM DESCRIPTION................................................................................................................. 7
6.1 Modules .................................................................................................................................. 7
6.2 Structure of the Program ...................................................................................................... 10
6.3 Course Listing ........................................................................................................................ 10
7. DESCRIPTION OF THE PROGRAMS ................................................................................................ 11
7.1 Module Listing and Scheduling ............................................................................................. 11
7.1.1 Module Listing .............................................................................................................. 11
7.1.2 Module Offering Schedule ............................................................................................ 13
7.2 Descriptions of the Modules ................................................................................................. 14
7.2.1 Finite Element Methods in Manufacturing ................................................................... 14
7.2.2 Metal Cutting Analysis ................................................................................................. 16
7.2.3 Metal Joining Processes ................................................................................................ 18
7.2.4 Metal Forming Analysis................................................................................................ 21
7.2.5 Foundry Engineering..................................................................................................... 23
7.2.6 Tool and Die Design and Manufacturing ...................................................................... 25
7.2.7 Polymer and Composite Manufacturing ....................................................................... 27
7.2.8 Production and Operations Management ...................................................................... 29
7.2.9 CAD/CAM/CAE ........................................................................................................... 31
7.2.10 Applied Mechatronics/Manufacturing .......................................................................... 33
7.2.11 Computer Integrated Manufacturing ............................................................................. 35
7.2.12 Lean Manufacturing ...................................................................................................... 37
7.2.13 Industrial Robotics ........................................................................................................ 39
7.2.14 Total Quality Management ........................................................................................... 41
7.2.16 Heat Transfer................................................................................................................. 45
7.2.17 Manufacturing Systems Modeling and Simulation ....................................................... 47
7.2.18 Rapid Prototyping and Manufacturing .......................................................................... 49
Lab Component-1.............................................................................................................................. 51
Lab Component-II.............................................................................................................................. 53
1. INTRODUCTION
1.1 Background
Based on the needs of the industrial sector and the capacity building of higher educational
institutions and recommendations of the staffs of the School of Mechanical & industrial
Engineering, the school offers M.Sc. and PhD programs in three areas of specialization,
namely: Thermal Engineering, Mechanical Design and Industrial Engineering since
1998/1999. As the school aspires to develop expertise in other disciplines as well, the new
specialized PG program leads to a separate full-fledged program in Manufacturing
Engineering which increases the specializations to four. This will allow the enrollment of
manufacturing engineers with B.Sc. and M.Sc.
The program consists of three main elements, technology, systems and tools and
Management. During the program, the students will acquire the necessary skills to tackle
issues in product design, engineering and manufacturing and manage industrial systems
under financial and resource constraints. The students also deal with modern mathematical
tools for measuring systems performance techniques, quality and reliability issues.
Manufacturing industry worldwide has experienced major changes since the industrial
revolution. Dynamic changes such as globalization, mass customization, enterprise agility/
supply chain management, continuous innovation, and increasing application of computer
aided design and manufacturing, etc are exhibited in the past two decades. These
challenges require a new generation of manufacturing engineers that are highly specialized
along with other expertise.
For the engineering and academic community such as AAU and AAiT in particular, it is
essential to train and educate the next generation of Manufacturing Engineers who will be
able to work in the challenging environment where a systems approach to problem solving
is crucial.
1
to date advanced knowledge in Manufacturing Engineering and its applications, who can
meet the challenges of the manufacturing environment locally and internationally.
Towards achieving this objective, the Manufacturing Engineering graduates will be equipped
with the latest techniques in manufacturing and systems engineering in:
2
Engineering and Technology professionals/graduates from Mechanical, Industrial,
Manufacturing, Production and Material.
Recent engineering and technology professionals/graduates who have decided to
move into manufacturing and related disciplines.
The education offered by the School must cope with the current growth and development
of both engineering and technology in industries in order to meet the high-level professional
demand. Mechanical engineers with higher level of knowledge and skill than that of the
B.Sc. degree graduates are required. The postgraduate program is intended to fulfill this gap
assessed by the School in general and the chair of Manufacturing and Materials Engineering
specifically.
3. GRADUATE PROFILE
After the successful completion of the Masters in Mechanical Engineering specialization in
Manufacturing Engineering program, the graduates are in a position to:
Take up a position in Manufacturing and related industries looking after jobs like
design, production and process planning, research, production, maintenance and
management.
Take up a teaching post in Universities and in higher educational institutions.
Take up a research activities in research organizations.
Become entrepreneur.
Serve as independent consultant.
Get promotion in their respective jobs that are being held
Pursue PhD degree.
3
4. PROGRAM REQUIREMENTS
4.1 Admission Requirements
The candidates for Manufacturing Engineering program must have B.Sc./B.Tech. Degree in
Industrial, Mechanical, Production, Manufacturing Technology/ Engineering and meet other
requirements set by the School of Graduate Studies.
In addition to the requirements of Addis Ababa University, a candidate for the M.Sc. degree
is expected to successfully complete ---------- credit hours of course work and a thesis [120
ECTS].
Grade Points/Marks
Excellent Above 95
Very Good 85-95
Good 75-85
Satisfactory 60-75
Fail less than 60
The respective instructors will evaluate the final examination, project works and
assignments and finally give grades based on the following pattern. The final graduate
project will also be evaluated in the same way.
Letter
Grade Points/Marks
A 90-100
B+ 84- 89
B 75-87
C+ 69-74
C 60-68
D 50-59
F below 50
The quality of the program offered by the school is assessed by the performance of its
graduates and the impact they bear on the industrial sector of the country. The quality
assurance methods adopted by the school include the following:
4
In line with the AAU and AAiT policy, student evaluations regarding the teaching-
learning process are taken at the end of each semester;
External evaluation by experts from external university;
Feedback from employers and stakeholders is obtained through personal contacts
formally and/or informally;
Former graduates of the program and
Students who go for higher studies in foreign institutions.7
5
5. DEGREE NOMENCLATURE
After the fulfillment of the set requirements, the graduate will be awarded the
IN
MECHANICAL ENGINEERING
(MANUFACTURING ENGINEERING)
yYNS StRS !G
lM}G }V
(bn#KcNG x!N!nNG)
6
6. PROGRAM DESCRIPTION
6.1 Modules
The curriculum for Manufacturing Engineering is structured in six modules. These modules
are:
Credit ECTS %
Modules for Manufacturing Engineering
hrs.
Advanced Manufacturing and Automation
MEng 6101 Metal Cutting Analysis [4 Cr.]
MEng 6102 Metal Joining Processes [3 Cr.]
25 50 42%
MEng 6103 Metal Forming Analysis [3 Cr.]
MEng 6201 Foundry Engineering [3 Cr.]
MEng 6203 Tool and Die Design in Manufacturing [3 Cr.]
MEng 7101 CAD/CAM/CAE [3 Cr.]
I
MEng 7102 Applied Mechatronics/Manufacturing Automation
[3 Cr.]
MEng 7103 Production and Operations Management [3 Cr.]
MEng 6105 Metrology & Tolerance Technology (Advanced
Manufacturing Measurement) [3 Cr.]
MEng 6106 Computer Integrated Manufacturing [3 Cr.]
MEng 6205 Industrial Robotics [3 Cr.]
Advanced Materials and Technologies in
Manufacturing
ii 4 5 7%
MEng 6202 Polymer and Composite Manufacturing [4 Cr.]
MEng 6206 Rapid Prototyping and Manufacturing [3 Cr.]
7
Facilities and Systems Engineering 6 12 10.00%
Meng 6104 Finite Element Methods in Manufacturing [3 Cr.]
9
6.2 Structure of the Program
Total
Semester I Semester II Semester III Semester IV
Credits
4 Core Courses: 4 Core Courses: 3 Core Courses: Thesis
(1*4 + 3*3) (4*3) (2*4 + 1*3)
1 Elective: (1*3) 1 Elective: (1*3) 1 Elective: 1*3
Research Methods &
Thesis Stage I
Scientific Writing (2)
Seminar (P/F)
Total Cr. 16 17 14 15 45
10
7. DESCRIPTION OF THE PROGRAMS
7.1 Module Listing and Scheduling
Bridge Modules will be recommended based on the applicant academic background by the
chair or committee assembled during admission procedure.
11
III. Elective Modules
ELECTIVE I
MEng 6207 Production Planning & Control, Production Costing And Cost 3 6
Control
ELECTIVE I II
12
7.1.2 Module Offering Schedule
Total 17 30
Total 14
13
7.2 Descriptions of the Modules
Learning Outcome:
1. To impart knowledge in the area of finite element methods and its application in
manufacturing.
2. Understand fundamentals of one dimensional and two dimensional problems using FEA in
manufacturing.
3. Apply the procedure involved to solve a structural problem using Finite Element Methods.
4. Develop the element stiffness matrices using different approach.
5. Analyze a 2D problem using line, triangular, axi - symmetric and quadrilateral element.
6. Analyze a 3D problem using tetrahedral and hexahedral elements.
CONTENT:
INTRODUCTION
Fundamentals Initial, boundary and Eigen value problems weighted residual, Galerkin and Rayleigh
Ritz methods - Integration by parts Basics of variation formulation Polynomial and Nodal
approximation.
Shape functions for one and two dimensional elements- Three nodded triangular and four nodded
quadrilateral element Global and natural co-ordinatesNon linear analysis Isoparametric elements
Jacobian matrices and transformations Basics of two dimensional, plane stress, plane strain and
axisymmetric analysis.
14
COMPUTER IMPLEMENTATION
Pre Processing, mesh generation, elements connecting, boundary conditions, input of material and
processing characteristics Solution and post processing Overview of application packages
Development of code for one dimensional analysis and validation
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Semester project work
Assessment Strategy: Exercises
Workshop exercises
Laboratory exercises
Project
Final examination
Module Requirements:
Minimum of 75% attendance during lecture hours
100% attendance during practical work sessions, except for some unprecedented
mishaps
All exercises and project works must be submitted by the specified dead line date
Text books:
1. Reddy, J.N. An Introduction to the Finite Element Method, McGraw Hill,2005.
2. Rao, S.S., Finite Element method in engineering, Pergammon press, 2005.
3. 3. Seshu P., Textbook of Finite Element Analysis, PHI Learning Pvt. Ltd, 2004.
References:
1. Lewis R.W. Morgan, K, Thomas, H.R. and Seetharaman, K.N. The Finite Element Method in
Heat Transfer Analysis, John Wiley, 1994.
2. Bathe, K.J., Finite Element procedures in Engineering Analysis, 1990
3. Kobayashi,S, Soo-ik-Oh and Altan.T. Metal Forming and the Finite Element Methods, Oxford
University Press, 1989.
4. www.tbook.com
5. www.pollockeng.com
6. Zienkiewicz, O. C., The Finite Element Method, Butterworth Heinemann (2002).
7. Huebner, K. H., Dewhirst, D. L., Smith, D. E. and Byrom, T. G., The Finite Element Methods
for Engineers, John Wiley (2000).
8. Cook, R. D., Concepts and Applications of Finite Element Analysis, John Wiley and Sons
(2001).
9. Buchman, G. R., Finite Element Analysis, Schaums Outlines, McGraw Hill (1995).
10. Chandrupatla, T. R. and Belgundu, A. D., Introduction to Finite Elements in Engineering,
Prentice Hall of India (1997).
11. Jordan, C. Calculus of Finite Differences, American Mathematical Society (1979).
15
7.2.2 Metal Cutting Analysis
Learning Outcome:
1. Apply cutting mechanics to metal machining based on cutting force and power consumption.
2. Operate lathe, milling machines, drill press, grinding machines, etc.
3. Select cutting tool materials and tool geometries for different metals.
4. Select appropriate machining processes and conditions for different metals.
5. Learn machine tool structures and machining economics.
6. Write simple CNC programs and conduct CNC machining
CONTENT:
INTRODUCTION:
MECHANICS OF METAL CUTTING: Mechanism of chip formation, Orthogonal & Oblique
cutting, types of chips, built-up edge, Determination of shear plane angle, forces on the chips, forces in
orthogonal cutting, Merchant circle diagram and analysis, Theory of Lee & Shaffer, co-efficient of
friction, power & energy relationship, velocity relationship, shear-strain, factors affecting forces and
power, problems.
GEOMETRY OF CUTTING TOOLS: Single point and multi point cutting tools, tools nomenclature,
tool point reference systems, tool angle specifications ISO and ASA systems, conversion from one
system to another. Recommended tool angles, Effect of cutting parameters on tool geometry.
TOOL MATERIALS AND THEIR PROPERTIES: Characteristics of tool materials, types of tool
materials carbon tool steels, high speed steels, cast alloys, cemented carbides, ceramics, diamonds,
SIALON, CBN, UCON, recommended cutting speeds for the above tools, discussion on steels, air,
water, oil hardening of tools and their applications.
Measurement of Cutting Forces: Reasons for measuring cutting forces, Classification of cutting force
dynamometers mechanical, hydraulic, pneumatic, optical, inductance, piezoelectric, and strain gage
type dynamometers, Dynamometers for lathe, drilling, and milling, Calibration of dynamometers.
Tool Wear, Tool Life: Mechanisms of tool wear, Sudden & gradual wear, crater wear, flank wear, tool
failure criteria, tool life equations, effect of process parameters on tool life, tool life tests, conventional
& accelerated tool wear measurement, machinability index
Thermal Aspects in Metal Cutting: Heat sources in metal cutting, temperature in chip formation,
16
temperature distribution, experimental determination of tool temperatures.
Cutting fluids: Basic actions of cutting fluids, properties of cutting fluids, selection of cutting fluids,
application of cutting fluids, filtration of fluids, recommended cutting fluids.
Economics of Machining: Introduction, elements of total production cost, optimum cutting speed and
tool life for minimum cost, optimum cutting speed and tool life for maximum production, problems.
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Assessment Strategy:
Exercises
Workshop exercises
Laboratory exercises
Project
Final examination
Teaching Support and Inputs:
Lectures
Workshop and laboratory exercises
Project
Semester project work
Module Requirements:
Minimum of 75% attendance during lecture hours
100% attendance during practical work sessions, except for some unprecedented
mishaps
All exercises and project works must be submitted by the specified dead line date
Text books:
Metal cutting Principles - M.C. Shaw - Oxford Publication 1985.
Fundamentals of metal cutting & Machine Tools - by B.L.Juneja & G.S Sekhar - Wiley Eastern.
Metal Cutting - V.C.Venkatesh & S.Chandrasekhanan - Pantice Hall 1991.
Metal Cutting - Dr. B.J.Ranganath -Vikas Publications
References:
1. Geoffrey Boothroyd and Knight. W.A "Fundamentals of Machining and Machine tools", Crc Press,
New York, 2006.
2. Bhattacharya. - " Metal Cutting Theory and Practice ", New central Book Agency pvt. Ltd., Calcutta,
2000.
Attendance Requirement:
Minimum of 75% attendance during lecture hours;
100% attendance during practical work sessions, except for some unprecedented mishaps; and
Presence during industrial visit/visits.
Evaluation:
Assignments and mini project work 20%,
Mid-semester Examination 30%, and
Final Examination 50%.
17
7.2.3 Metal Joining Processes
Learning Outcome:
1. Acquire knowledge of various welding processes.
2. Select the appropriate metal joining process.
3. Decide the process parameters suitable for the material & processes.
4. Interpret weld plan as per WPS / PQR.
5. Apply knowledge of Friction stir techniques for material joining and processing
6. Evaluate the welding defects & suggest their remedies.
7. Decide the thermal treatments necessary for the weldments.
8. Apply knowledge of various Mechanical testing of welded joints.
9. Apply knowledge of various NDT testing of welded joints.
CONTENT:
Exercises
Workshop exercises
Laboratory exercises
Project
Final examination
Teaching Support and Inputs:
Lectures
Workshop and laboratory exercises
Project
Semester project work
Module Requirements:
Minimum of 75% attendance during lecture hours
19
100% attendance during practical work sessions, except for some unprecedented
mishaps
All exercises and project works must be submitted by the specified dead line date
Text books:
1. The Metallurgy of Welding, Brazing and Soldering J.F. Lancaster, George Alien and
Unwin Ltd., London.
2. S V Nadkarni, Modern Arc Welding Technology, Ador Welding Limited, 2010, New Delhi.
3. Welding handbook, American Welding Society, 1987, 8th edition, volume 1 & 2, USA
4. Manufacturing Technology (Foundry, Forming and Welding)-P.N.Rao, Tata Mc-Graw Hill.
5. The Physics of Welding- L.F.Lancaster, Pergamon Press.
6. Principles of Welding- R.S. Parmar.
7. Welding Technology- O.P. Khanna, Khanna Pub.,
8. Friction Stir Welding and Processing, Editors Rajiv S. Mishra & Murray W. Mahoney,
ASM International, 2007
9. Welding Engineering Rossi-Mcgraw Hill Publications
10. Advanced welding processes-Nichodosco and shansky-MIR Publications
11. Welding for Engineers-Udin Funk and wulf
References: List of Open Source Software/learning website:
1. www.gowelding.com
2. http://www.iws.org.in/
3. http://www.asme.org
4. http://www.aws.org
5. http://www.ewf.be
6. http://www.astm.org
Evaluation:
Assignments and mini project work 20%,
Mid-semester Examination 30%, and
Final Examination 50%.
20
7.2.4 Metal Forming Analysis
Course Title: Metal Forming Analysis Contact Hours: 2 Lecture hrs and 3 Tutorial hrs
Course Objectives:
Stress-strain relations in elastic and plastic deformations, Yield criteria for ductile metals, Work
hardening and Anisotropy in yielding, Flow curves, Elements of theory of plasticity, formulation of
plastic deformation problems, application of theory, application of theory of plasticity for solving metal
forming problems using slab method, upper bound and lower bound methods, slip line field theory,
extremium principles, effect of temperature and strain rate in metal working, friction and lubrication in
cold and hot working, technology and analysis of important metal forming processes Forging, Rolling,
Extrusion, Wire Drawing, Sheet metal forming processes like deep drawing, Stretch forming, Bending,
Introduction to finite Element Analysis of metal forming processes.
The goal of the course is to give understanding about Mechanical behavior associated to forming
processes; Analyze Bulk and Sheet metal forming Processes: Flat and shape rolling, Dimensional
controls of rolling mills and gauging system; Forging processes, Design of hammers & presses and
engineering design of components manufactured by forming; Extrusion process; Bend and Deep
drawing, blanking and tool design; and Measurement techniques in forming processes.
CONTENT:
Rolling: Rolling mills for flat products (Two High, Three High, Four High, Cluster, Tandem mills);
Analysis of rolling parameters; Strip profile and flatness control; Analysis of selected topics on steel
21
rolling technology
Forging: Upsetting, Impression and Flash-less Forgings; Hot forging ; Design of Upsetting tools;
Design, construction, properties and operation of drop, single, double hydraulic hammers; percussion
presses.
Extrusion: Cold and Hot Extrusions Analysis (Direct/Forward and Indirect/Backward); Hot impact
extrusion; Presses, tools and machinery for hydrostatic extrusion.
Teaching Methods:
Lectures supported by tutorials,
Assignments, and
Laboratory exercises.
Laboratory Exercises:
1. Mechanical Behavior of metals study/Testing
2. Bulk and sheet metal forming
3. Measurement of stress and force
Attendance Requirement:
Minimum of 75% attendance during lecture hours;
100% attendance during practical work sessions, except for some unprecedented mishaps; and
Presence during industrial visit/visits.
Evaluation:
Assignments and mini project work 20%,
Mid-semester Examination 30%, and
Final Examination 50%.
Textbook: Metal Forming Analysis, R.H. Wagoner & J.L. Chenot, 2001; ISBN: 9780521642675
References:
1. Metal Forming: Mechanics and Metallurgy, WilliamF. Hosford, Robert M. Caddell, CUP 2007;
ISBN: 0521881218, 9780521881210
2. Sheet Metal Forming Processes: Constitutive Modeling and Numerical Simulation, Dorel
Banabic, 2010 ISBN: 978354881124
3. Sheet Metal Forming and Die Design, Vukato Boljanovic, 2004; ISBN: 0831131829,
9780831131821
4. Plasiticity for structural engineers -Chen
5. Principles of Metal Working - R.Rowe - Amold London 1965.
22
7.2.5 Foundry Engineering
Module Description: Solidification, Principles of casing and risering, Design of casting and casting
quality control, Furnace technology for castings, Foundry practice for grey cast iron, Malleable cast
iron, Ductile cast iron, Steel casting, Aluminum and copper foundry practice, Foundry mechanization
and modernization.
CONTENT:
CASTING QUALITY CONTROL: Casting defects and factors responsible for them. Different
inspection and testing methods to evaluate casting quality, Quality control activity in foundry
activities, salvaging methods of defective castings
GRAY CAST - IRON FOUNDRY PRACTICE: Chemical Composition and structure of gray cast
iron. Moulding, gating and risering techniques. Melting of gray cast iron in Cupola and induction
furnace. Inoculation of gray cast iron. Application of gray cast iron castings
MALLEABLE CAST IRON: Chemical composition and structure of white-heart and black heart
malleable cast iron, Melting malleabilisation heat treatment and application of malleable cast iron.
DUCTILE CAST IRON: Chemical composition and structure of ductile cast iron Melting and
spherodisation treatment. Inoculation of 'ductile iron. Properties and application of ductile cast iron.
23
STEEL CASTING PRACTICE: Common steel casting, their composition, structure and properties.
Smelting and refining of steel. Gating and risering of steel casting. Cleaning of steel casting.
COPPER ALLOY FOUNDRY PRACTICE: General characteristics of common cast copper alloys.
Melting and casting of copper alloys. Gating and risering of cu-alloy castings.
24
7.2.6 Tool and Die Design and Manufacturing
CONTENT:
TOOL-DESIGN METHODS: Introduction, the design procedure, drafting and design techniques in
tooling drawing
TOOL-MAKING PRACTICES: Introduction, tools of the tool maker, hand finishing and polishing,
screws and dowels, hole location, jig-boring practice, installation of drilling bushings, punch and die
bushings, punch and die manufacture, EDM, EDM for cavity applications, tracer and duplicating mills
for cavity applications, low
DESIGN OF CUTTING TOOLS: Introduction, the metal cutting process, revision of metal cutting
tools-single point cutting tools, milling cutters, drills and drilling, reamers, taps. Selection of carbide
tools, determining the insert thickness for carbide tools.
DESIGN OF TOOLS FOR INSPECTION AND GAUGING: Introduction, work piece quality
criteria, principles of gauging, types of gages and their applications, amplification and magnification
of error, gage tolerances, selection of material for gages, indicating gages, automatic gages, gauging
positional tolerance parts, problems.
25
selection of progressive dies. Strip development for progressive dies, evolution of progressive dies,
examples of progressive dies. Extrusion dies, drop forging dies and auxiliary tools, problems.
TOOL DESIGN FOR JOINING PROCESSES: Introduction, tooling for physical joining
processes, tooling for soldering and brazing, tooling for mechanical joining processes, problems.
TOOLING FOR CASTING: Introduction, tooling for sand casting, shell molding, metal
molding and die-casting, problems.
TOOL DESIGN FOR NC MACHINE TOOLS: Revision of NC control, fixture design for NC
machine tools, cutting tools and tool-holding methods, automatic tool changers and tool petitioners.
PLASTICS AS TOOLING MATERIALS: Introduction, Plastics commonly used as tooling
materials, Application of Epoxy plastic tools, construction methods, metal forming operations with
urethane dies, Calculation of forces for urethane pressure pads, problems
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Assessment Strategy:
Exercises
Workshop exercises
Laboratory exercises
Project
Final examination
Respective Role of Instructors and Students:
Teaching Support and Inputs:
Lectures
Workshop and laboratory exercises
Project
Semester project work
Module Requirements:
Minimum of 75% attendance during lecture hours
100% attendance during practical work sessions, except for some unprecedented
mishaps
All exercises and project works must be submitted by the specified dead line date
Text books:
1. Tool Design - Cyril Donaldson, GH Lecain and VC Goold - TMH Publishing Co Ltd., New
rd
Delhi, - 3 editions, 2000.
2. Fundamentals of Tool Design ASTME - PHI (P) Ltd., New Delhi -1983.
References:
26
7.2.7 Polymer and Composite Manufacturing
Learning Outcome:
On successful completion of this module students would be able to:
1. Understand on types, physical properties and processing of polymer matrix composites, metal
matrix composites and ceramics matrix composites.
2. Learn about matrix material, reinforcements of polymer matrix composites, MMC and ceramic
matrix composites.
3. To develop knowledge on processing, interfacial properties and application of composites.
CONTENT:
PROCESSING OF POLYMERS
Chemistry and Classification of Polymers Properties of Thermo plastics Properties of
Thermosetting Plastics - Extrusion Injection Moulding Blow Moulding Compression and Transfer
Moulding Casting Thermo Forming. General Machining properties of Plastics Machining
Parameters and their effect Joining of Plastics Thermal bonding Applications.
INTRODUCTION TO COMPOSITE MATERIALS: Definition, Classification, Types of matrices
& reinforcements, characteristics & selection, Fiber composites, laminated composites, particulate
composites, prepegs, sandwich construction.
FIBERS AND MATRIX MATERIALS
Fibers Fabrication, Structure, properties and applications Glass fiber, Boron fiber, carbon fiber,
organic fiber, ceramic and metallic fibers - whiskersFabrication of Matrix materials polymers,
metals and ceramics and their properties interfaces Wettability Types of bonding at the interface
Tests for measuring interfacial strength - Physical and chemical properties.
MICRO MECHANICAL ANALYSIS OF A LAMINA: Introduction, Evaluation of the four elastic
modules Rule of mixture, Macro mechanics of a lamina: Hookes law for different types of materials,
number of elastic constants, Laminate code, Failure criterion.
MACRO MECHANICAL ANALYSIS: Hooke's law for different types of materials, Number of
elastic constants, Derivation of nine independent constants for orthotropic material, Two - dimensional
relationship of compliance and stiffness matrix. Hooke's law for two-dimensional angle lamina,
engineering constants - Numerical problems. Invariant properties. Stress-Strain relations for lamina of
arbitrary orientation, Numerical problems.
27
PROCESSING OF POLYMER MATRIX COMPOSITES
Thermoset matrix composites: hand layup, spray, filament winding, Pultrusion, resin transfer molding,
autoclave molding - bag molding, compression molding with Bulk Moulding Compound and sheet
Moulding Compound thermoplastic matrix composites film stacking, diaphragm forming,
thermoplastic tape laying, injection molding interfaces in PMCs - structure, properties and application
of PMCs recycling of PMCs.
PROCESSING OF METAL MATRIX COMPOSITES
Metallic matrices: aluminum, titanium, magnesium, copper alloys processing of MMCs: liquid state,
Solid state, in situ fabrication techniques diffusion bonding powder metallurgy techniques-
interfaces in MMCs mechanical properties machining of MMCs Applications.
PROCESSING OF CERAMIC MATRIX COMPOSITES AND CARBON-CARBON
COMPOSITES
Processing of CMCs: cold pressing, sintering, reaction bonding, liquid infiltration, lanxide process in
situ chemical reaction techniques: chemical vapor deposition, chemical vapor impregnation, sol-gel
interfaces in CMCs mechanical properties and applications of CMCs Carbon-carbon Composites
applications.
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Assessment Strategy:
Exercises
Workshop exercises; Laboratory exercises
Project
Final examination
Teaching Support and Inputs:
Lectures
Workshop and laboratory exercises
Project
Semester project work
Module Requirements:
Minimum of 75% attendance during lecture hours
100% attendance during practical work sessions, except for some unprecedented mishaps
All exercises and project works must be submitted by the specified dead line date
Text books:
1. Krishnan K Chawla, Composite Materials: Science and Engineering, International Edition,
Springer, 2012, ISBN:978-0-387-74364-6.
2. Mallick P.K., Fiber Reinforced Composites: Materials, Manufacturing and Design, CRC press,
New Delhi, 2010, ISBN:0849342058.
3. Jamal Y. Sheikh-Ahmad, Machining of Polymer Composites, Springer, USA, 2009. ISBN: 978-
0-387-35539-9.
4. Mallick, P.K. and Newman.S., Composite Materials Technology, Hanser Publishers, 2003.
5. Harold Belofsky, Plastics, Product Design and Process Engineering, Hanser Publishers
6. Seamour, E.B. Modern Plastics Technology, Prentice Hall, 2002
7. Mechanics of composite materials Autar K Kaw-CRC Press
8. Composite Materials Handbook - Mein Schwartz - Mc Graw Hill Book Company
References:
1. Said Jahanmir, Ramulu M. and Philp Koshy, Machining of Ceramics and Composites, Marcel
Dekker Inc., New York, 1999, ISBN: 0-8247-0178-x.
2. ASM Handbook Composites, Vol-21, 2001, ISBN: 978-0-87170-703-1.
28
7.2.8 Production and Operations Management
Learning Outcome:
On successful completion of this module students would be able to:
1. Demonstrate an understanding of production as a process of converting or transforming
resources into products;
2. Demonstrate an understanding of the manager's concern in planning, organizing, directing, and
controlling productive operations to meet organizational objectives;
3. Demonstrate an understanding of productivity measures, quality and costs both, direct and
indirect; and
4. Use a variety of problem-solving techniques to aid in effective decision making.
CONTENT:
INTRODUCTION:
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Assessment Strategy:
Exercises
Workshop exercises; Laboratory exercises
Project
Final examination
Respective Role of Instructors and Students:
Teaching Support and Inputs:
Lectures
Workshop and laboratory exercises
Project
Semester project work
Module Requirements:
Minimum of 75% attendance during lecture hours
100% attendance during practical work sessions, except for some unprecedented
mishaps
All exercises and project works must be submitted by the specified dead line date
Text books: Text Books:
1. Monks, J.G., Operations Management, McGraw-Hill International Editions, 1987.
2. Productions & operations management by Adam & Ebert.
3. Pannerselvam. R., Production and Operations Management, PHI.
4. Chase Jacobs Aquilano, Operations Management for Competitive Advantages,10 th Edition,
TMH
References:
1. Buffa, Modern Production/Operations Management, Wiely Eastern Ltd.
2. Chary, S.N., Production and Operations Management, Tata-McGraw Hill.
3. Operations management by James Dilworth.
4. Lee J Karjewski and Larry P Ritzman, Operations Management strategy and Analysis, 6th
Edn, Pearson Education Asia
5. B J Ranganath , System Dynamics by - I K International Publishing house Pvt. Ltd
6. Production and Operations Management, William J Stevenson, 9th Ed., Tata McGraw Hill.
30
7.2.9 CAD/CAM/CAE
CONTENT:
INTRODUCTION: Definition and scope of CAD/CAM, Introduction to design process and role of
computers in the design process.
TRANSFORMATIONS: 2D and 3D transformations.
CURVES AND SURFACES: Analytical, Synthetic curves with advantages, Disadvantages,
Comparison with parametric curves, Geometric modeling curves and surfaces, Representation, Wire
frame models, Parametric representations, Parametric curves and surfaces, Manipulations of curves and
surfaces, DDA, Bresenhams /Mid-point line, circle, ellipse algorithms.
SOLID MODELING: Solid models, Fundamentals of solid modeling, Different solid representation
schemes, Half -spaces, Boundary representation (B-rep), Constructive solid geometry (CSG), Sweep
representation, Analytic solid modeling, Perspective, Parallel projection, Hidden line removal
algorithms.
CAD/CAM DATA EXCHANGE FORMATS: Types of file formats & their exchange, Graphics
standards.
NC MACHINE TOOLS: Types, Definition and designation of control axes, Special constructional
and design characteristics of NC machine tools, Standard tooling used for NC turning and milling
centers.
NC PART PROGRAMMING: Work holding and tool setting procedure for NC turning and milling
31
centers, Tool zero presetting, Block formats and introduction to ISO based G & M codes for NC part
programming, Concepts of tool length and radius compensation, Standard canned cycles used in CNC
turning and milling centers, Introduction to automatic NC part program generation from CAD models
using standard CAD/CAM software for machining of surfaces, moulds and dies etc.
COMPUTER NUMERICAL CONTROL OF MACHINE TOOLS: Types and functions of
computer numeric control (CNC), Types and functions of direct numeric control (DNC), Need of
adaptive control types, functions and types of adaptive control, its uses & benefits, Advantages of
combined CNC/DNC systems.
SYSTEM DEVICES: Drives, Feedback devices, Interpolator systems, Control loop circuit elements in
point to point (PTP) and contouring system, Interpolation schemes for linear and circular interpolations.
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Assessment Strategy:
Exercises
Workshop exercises; Laboratory exercises
Project
Final examination
Respective Role of Instructors and Students:
Teaching Support and Inputs:
Lectures
Workshop and laboratory exercises
Project
Semester project work
Module Requirements:
Minimum of 75% attendance during lecture hours
100% attendance during practical sessions, except for some unprecedented mishaps
All exercises and project works must be submitted by the specified dead line date
Text books:
1. Zeid, I., CAD/CAM, McGraw Hill (2008)
2. Rogers, D. F. and Adams, J. A., Mathematical Elements for Computer Graphics, McGraw Hill
(1989).
3. Rogers, D. F., Procedural Elements for Computer Graphics, McGraw Hill (2008).
4. Rooney, J. and Steadman, P., Principles of Computer Aided Design, prentice Hall (1988).
5. Rooney, J. and Steadman, P., Computer Aided Design, Pitman/Open University (1987).
6. Mallineuse, G., Computational Concepts and Methods, Kogan Page Ltd. (1986).
7. Manuals & Tutorials on CAD/CAE packages like Pro/Engineer, Pro/Mechanica, ANSYS, etc
latest available in the lab.
8. Kelley David S., Pro/ENGINEER Wildfire 5.0 Instructor, Tata McGraw Hill (2011).
9. Shih Randy H., Introduction to Finite Element Analysis Using Creo Simulate 1.0, SDC
Publications, USA (2011, ISBN: 978-1-58503-670-7, ISBN (Book + Software on Disk): 978-1-
58503-731-5
10. Toogood Roger Ph.D., P. Eng., Zecher Jack P.E., Creo Parametric 1.0 Tutorial and MultiMedia
DVD, SDC Publications, USA (2012), ISBN: 978-1-58503-692-9, ISBN (Book + Software on
Disk): 978-1-58503-730-8
11. Shih Randy H., Parametric Modeling with Creo Parametric 1.0-An Introduction to Creo
Parametric 1.0, SDC Publications, USA (2011) ISBN: 978-1-58503-661-5, ISBN (Book +
Software on Disk): 978-1-58503-729-2
32
7.2.10 Applied Mechatronics/Manufacturing
CONTENT:
CONTROL SYSTEMS: Laplace transformations, Block diagram reduction, Signal flow graph, and
Performance specifications, transfer functions, Stability, Sensitivity of the open-loop and closed-loop
systems, Types of controller, Controller design using frequency domain and Laplace domain methods.
SENSORS: Displacement, Position and Proximity sensors, Flow sensors, Pressure and force sensors,
Motion sensors, Optical, Mechanical and Thermal sensors.
33
ACTUATORS IN MECHATRONICS SYSTEM: Electric actuators, Stepper motors, DC motors, and
AC motors.
34
7.2.11 Computer Integrated Manufacturing
CONTENT:
DETROIT TYPE OF AUTOMATION: Flow lines, Transfer Mechanisms, work pattern transfer,
Different methods, & Problems.
ANALYSIS OF AUTOMATED FLOW LINES: Analysis of transfer lines without storage with
storage buffer single stage, Double stage, Multistage with problems, Automated assembly systems,
Design for automated assembly, parts feeding devices,
analysis of Multi station assembly machine, Analysis of Single stage assembly machine,
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Assessment Strategy:
Exercises
Workshop exercises; Laboratory exercises
Project
Final examination
35
Teaching Support and Inputs:
Lectures
Workshop and laboratory exercises
Project
Semester project work
Module Requirements:
Minimum of 75% attendance during lecture hours
100% attendance during practical sessions, except for some unprecedented mishaps
All exercises and project works must be submitted by the specified dead line date
Text books:
1. CAD/ CAM : Zimmers and Groovers-PHI
2. CAD/CM/CIM; P. Rsdhakrishna - newage International-2 Edition
3. Automation, Production systems & Computer Aided Manufacturing - M.P. Grover -
Prentice Hall - 1984
References:
1. CAD/CAM - Zeid Mc-Graw Hill - 2005.
2. CAD/CAM - P.N.Rao - TMH.- 2 nd edition, 2004.
3. Robotics for Engineering - Koren.Y - Mc-Graw Hill - 1985.
4. Robert vision & Sensory Controls - Rooks B. - North Holland. - (ed) vol-3
36
7.2.12 Lean Manufacturing
CONTENT:
Cellular Manufacturing Types of Layout, Principles of Cell layout, Implementation. JIT Principles
of JIT and Implementation of Kanban. TPM Pillars of TPM, Principles and implementation of TPM.
Set up time reduction Definition, philosophies and reduction approaches. TQM Principles and
implementation. 5S Principles and implementation - Value stream mapping - Procedure and principles.
SIX SIGMA Six Sigma Definition, statistical considerations, variability reduction, design of
experiments Six Sigma implementation
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Assessment Strategy:
Exercises
Workshop exercises; Laboratory exercises
Project
Final examination
Teaching Support and Inputs:
37
Lectures
Workshop and laboratory exercises
Project
Semester project work
Module Requirements:
Minimum of 75% attendance during lecture hours
100% attendance during practical sessions, except for some unprecedented mishaps
All exercises and project works must be submitted by the specified dead line date
Text books:
1. Design and Analysis of Lean Production Systems, Ronald G. Askin & Jeffrey B. Goldberg,
John Wiley & Sons, 2003
2. Mikell P. Groover (2002) Automation, Production Systems and CIM.
References:
1. Rother M. and Shook J, 1999 Learning to See: Value Stream Mapping to Add Value and
Eliminate Muda , Lean Enterprise Institute, Brookline, MA.
38
7.2.13 Industrial Robotics
1. Apply the concepts of coordinate transformations for development of arm equation and
subsequently the inverse kinematics model for given serial manipulator.
2. Apply the concepts of robotic workspace analysis for design of robotic manipulator for
required work cell applications.
3. Design and analyze the workcell environment for given robotic manipulator configuration and
workcell devices for required integrated industrial application.
4. Develop and analyze the mathematical model for trajectory planning, resolved motion rate
control and dynamics model for a given serial robotic manipulator.
5. Develop the algorithms for design of robotic work cell controller and its programming for
given serial robotic manipulator.
CONTENT
FUNDAMENTAL CONCEPTS OF ROBOTICS: History, present status and future trends, Robotics.
Robot, Definition. Robotics Systems and Robot Anatomy, Specification of Robotics. Resolution,
Repeatability and Accuracy of a Manipulator
ROBOT DRIVES: Power transmission systems and control Robot drive mechanisms, hydraulic-
electric-pneumatic drives. Mechanical transmission method Rotary-to-Rotary motion conversion.
Rotary-to-linear motion conversion end effectors types-grip pind problem Remote-Centered
compliance Devices-Control of Actuators in Robotic
Mechanisms.
COMPUTER VISION FOR ROBOTICS SYSTEMS: Robot vision systems Imaging components
Image representation Hardware aspects-Picture coding Object Recognition and Categorization-
Visual inspection software considerations applications commercial Robotic vision systems.
39
TRANSFORMATIONS AND KINEMATICS: Homogeneous Co-ordinates Co-ordinate Reference
Frames Homogeneous Transformations for the manipulator the forward and inverse problem of
manipulator kinematics Motion generation Manipulator dynamics Jacobian in terms of D.H.
Matrices controller architecture.
ROBOT CELL DESIGN AND CONTROL: Specifications of Commercial Robots Robot Design
and Process specifications motor selection in the design of a robotic joint Robot Cell layouts
Economic and Social aspects of robotics.
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Assessment Strategy:
Exercises
Workshop exercises; Laboratory exercises
Project
Final examination
Teaching Support and Inputs:
Lectures
Workshop and laboratory exercises
Project
Semester project work
Module Requirements:
Minimum of 75% attendance during lecture hours
100% attendance during practical work sessions, except for some unprecedented
mishaps
All exercises and project works must be submitted by the specified dead line date
Text books:
1. 1.Robotics Engineering An integrated approach - Richard D Klafter, Thomas A
Chmielewski, Michael Negin Prentice Hall of India Pvt. Ltd. - Eastern Economy Edition,
1989.
2. Robotics: Control Sensing, Vision, intelligence - Fu KS Gomaler R C, Lee C S G - McGraw
Hill Book Co. - 1987.
References:
1. Handbook of Industrial Robotics - Shuman Y. Nof - John Wiley & Sons, New York - 1985.
2. Robotics Technology and Flexible Automation - Deb SR - McGraw Hill BookCo. 1994
3. Schilling, R.J., Fundamentals of Robotics Analysis and Control, Prentice Hall of India (2006)
4. Fu, K.S., Gonzalez, R.C. and Lee, C.S.G., Robotics: Control, Sensing, Vision, and Intelligence,
McGraw Hill (1987)
5. Craig, J.J., Introduction to Robotics: Mechanics and Control, prentice Hall (2004)
6. Deb, S.R., Robotics and Flexible Automation, McGraw Hill (2004)
7. Saha, S.K., Introduction to Robotics, McGraw Hill (2008)
8. Niku, S.B., Introduction to Robotics: Analysis, system, application, Dorling kingsley (2006)
40
7.2.14 Total Quality Management
CONTENT:
1. Total Quality Management: Dale H. Bester field, Publisher - Pearson Education India, ISBN:
8129702606, Edition 03/e Paperback (Special Indian Edition)
2. Total Quality Management for Engineers: M. Zairi, ISBN: 1855730243, Publisher: Wood head
Publishing
References:
1. A New American TQM, four revolutions in management, Shoji Shiba, Alan Graham, David
Walden, Productivity press, Oregon, 1990
2. Methods for Total Quality Management: Gopal K. Kanji and Mike
Asher, ISBN: 0803977476, Publisher: Sage Publications, Inc.; Edition 1
3. Organizational Excellence through TQM, H. Lal, New age pub, 2008
42
7.2.15 Tolerance Technology
CONTENT:
GD&T Fundamentals of geometric dimensioning and Tolerancing Rules and concepts of GD&T
Form controls Datum systems Orientation controls Tolerance of position Concentricity and
symmetry controls Run out controls Profile controls.
TOLERANCE CHARTING Nature of the tolerance buildup structure and setup of the tolerance
chart piece part sketches for tolerance charts Arithmetic ground rules for tolerance charts
Determination of Required balance dimensions Determination of Mean working Dimensions
Automatic tolerance charting Tolerance charting of Angular surfaces.
MANUFACTURING GUIDELINES DFM guidelines for casting, weldments design Formed metal
components Turned parts Milled, Drilled parts Non metallic parts Computer Aided DFM
software Boothroyd and Dewhurst method of DFMA DCS Vis/VSA 3D Dimensional control
Statistical tolerance Analysis Software Applications.
Specifications.
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Assessment Strategy:
Exercises
Workshop exercises; Laboratory exercises
Project
Final examination
Module Requirements:
44
7.2.16 Heat Transfer
CONTENT:
VARIABLE THERMAL CONDUCTIVITY: Derivation for heat flow and temperature distribution
in plane wall. Critical thickness of insulation without heat generation, Thermal resistance concept & its
importance. Heat transfer in extended surfaces of uniform cross-section without heat generation, Long
fin, and short fin with insulated tip and without insulated tip and fin connected between two heat
sources. Fin efficiency and effectiveness. Numerical problems.
CONCEPTS AND BASIC RELATIONS IN BOUNDARY LAYERS: Flow over a body velocity
boundary layer; critical Reynolds number; general expressions for drag coefficient and drag force;
thermal boundary layer; general expression for local heat transfer coefficient; Average heat transfer
coefficient; Nusselt number. Flow inside a duct- velocity boundary layer, hydrodynamic entrance
length and hydro dynamically developed flow; flow through tubes (internal flow discussion only).
Numerically based on empirical relation given in data handbook.
HEAT EXCHANGERS: Classification of heat exchangers; overall heat transfer coefficient, fouling
and fouling factor; LMTD, Effectiveness-NTU methods of analysis of heat exchangers. Numerical
problems.
45
CONDENSATION AND BOILING: Types of condensation (discussion only) Nusselts theory for
laminar condensation on a vertical flat surface; use of correlations for condensation on vertical flat
surfaces, horizontal tube and horizontal tube banks; Reynolds number for condensate flow; regimes of
pool boiling, pool boiling correlations. Numerical problems. Mass transfer definition and terms used in
mass transfer analysis, Ficks First law of diffusion (no numerical).
RADIATION HEAT TRANSFER: Thermal radiation; definitions of various terms used in radiation
heat transfer; Stefan-Boltzman law, Kirchoffs law, Plancks law and Weins displacement law.
Radiation heat exchange between two parallel infinite black surfaces, between two parallel infinite gray
surfaces; effect of radiation shield; intensity of radiation and solid angle Lamberts law; radiation heat
exchange between two finite surfaces configuration factor or view factor. Numerical problems.
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Assessment Strategy:
Exercises
Workshop exercises; Laboratory exercises
Project
Final examination
Respective Role of Instructors and Students:
Lectures
Workshop and laboratory exercises
Project
Semester project work
Module Requirements:
References:
46
7.2.17 Manufacturing Systems Modeling and Simulation
Learning Outcome: On successful completion of this module students would be able to:
1. Use parametric 3D CAD software tools in the correct manner for making geometric part
models, assemblies and automated drawings of mechanical components and assemblies.
2. Use CAD software tools for assembly of mechanism from schematic or component drawing
and conduct position/ path/ kinematic / dynamic analysis of a mechanism in motion.
3. Evaluate design, analyze and optimize using commercial CAD, CAE software as black box for
required mass properties/ stress, deflection / temperature distribution etc. Under realistic
loading and constraining conditions.
4. Redesign in CAD and evaluate a mechanical product by making components in the mechanical
workshop for design validation, using measured relevant materials properties.
CONTENT:
DISCRETE EVENT SIMULATION: Concepts in discrete event simulation, manual simulation using
event scheduling, single channel queue, too server queue, simulation of inventory problem.
RANDOM NUMBER GENERATION: Techniques for generating random numbers- Mid square
method -the mod product method -Constant multiplier technique -Additive congruential method -Linear
congruential method -Tests for random numbers -The Kolmogorov-Smimov test -the Chi-square test.
Ivica Cmkovic, Ulfaskluna and Annita borsen Dohlgvist Publisher Artechhouse.
47
SIMULATION SOFTWARE: Selection of simulation software, simulation packages.
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Assessment Strategy:
Exercises
Workshop exercises; Laboratory exercises
Project
Final examination
Respective Role of Instructors and Students:
Teaching Support and Inputs:
Lectures
Workshop and laboratory exercises
Project
Semester project work
Module Requirements:
Minimum of 75% attendance during lecture hours
100% attendance during practical work sessions, except for some unprecedented
mishaps
All exercises and project works must be submitted by the specified dead line date
Text books:
1. Descre Event system simulation :Jerry Banks & .John S Carson II - Prentice Hall Inc.-1984.
2. Systems Simulation - Gordan. G. - Prentice Hall India Ltd - 1991.
References:
1. System Simulation with Digital Computer - Nusing Deo - Prentice Hall of India - 1979.
2. Computer Simulation and Modeling - Francis Neelamkovil - John Wilely & Sons - 1987.
3. Simulation Modeling with Pascal - Rath M.Davis & Robert M O Keefe - Prentice Hall Inc. -
1989.
48
7.2.18 Rapid Prototyping and Manufacturing
Learning Outcome:
CONTENT:
CAD DATA AND PROGRAMMING TECHNIQUES FOR RP: Transformations, Solid modeling
for RP, Surface modeling, STL file generation, Defects in STL files and repairing algorithms, Interface
formats, Slicing methods, Design of support structures, Internal hatching and surface skin fills.
MATERIALS FOR RP: Materials used for different RP processes, Selection criterions for materials
for different processes, The advantages and limitations of different types of materials.
REVERSE ENGINEERING: Introduction to reverse engineering and its integration with rapid
prototyping.
RESEARCH ASSIGNMENT: The students will be given different assignments to write their codes in
MATLAB for constant slicing, adaptive slicing, transformations, parametric curves and surfaces
involved in Rapid Prototyping.
Teaching Strategy/Methods:
Lecture
49
Workshops and Laboratories
Projects
Assessment Strategy:
Exercises
Workshop exercises; Laboratory exercises
Project
Final examination
Respective Role of Instructors and Students:
Teaching Support and Inputs:
Lectures
Workshop and laboratory exercises
Project
Semester project work
Module Requirements:
Minimum of 75% attendance during lecture hours
100% attendance during practical work sessions, except for some unprecedented
mishaps
All exercises and project works must be submitted by the specified dead line date
Text books:
1. Chua, C.K., Leong, K.F., Rapid Prototyping: Principles and Applications in Manufacturing,
John Wiley and Sons Inc., 2000
2. Pham, D.T., Demov, S.S., Rapid Manufacturing: The Technologies and Applications of Rapid
Prototyping and Rapid Tooling, Springer-Verlag London Limited, 2001
3. Noorani, R., Rapid Prototyping: Principles and Applications, John Wiley & Sons, Inc., New
Jersey, 2006
4. Patri, K. V., Weiyin, Ma, Rapid Prototyping - Laser-based and Other Technologies, Kluwer
Academic Publishers, U.S.A., 2003
5. Saxena, A., Sahay, B., Computer Aided Engineering Design, Anamaya Publishers, New Dehi,
2005
6. Zeid, I., Mastering CAD/CAM, Tata McCraw Hill, 2006
References:
50
Lab Component-1
Learning Outcome:
On successful completion of this module students would be able to:
CONTENT:
1. Determination of Chip reduction co-efficient (reciprocal of chip thickness ratio) during single
point turning.
2. Forces measurements during orthogonal turning.
3. Estimation of Power required during orthogonal turning.
4. Torque and Thrust measurement during drilling.
5. Determination of cutting forces during milling using Milling tool dynamometer
6. Measurement of Chip tool Interface temperature during turning using thermocouple technique.
7. Study the variation of surface roughness with different speed and feed during plain milling
operation on flat surface.
8. Study of capstan lathe and its tooling and prepare a tool layout & job as per given drawing.
9. Prepare metallic samples for metallographic examination and to study the principle &
construction of Metallurgical Microscope.
10. Study of Microstructure and Hardening of steel in different medium and cooling rates; Effect of
Carbon percentage on the hardness of Steel.
11. CNC milling- Writing and execution of part program for contour milling.
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
51
Assessment Strategy:
Exercises
Workshop exercises; Laboratory exercises
Project
Final examination
Respective Role of Instructors and Students:
Teaching Support and Inputs:
Lectures
Workshop and laboratory exercises
Module Requirements:
52
Lab Component-II
Learning Outcome:
CONTENT:
1. Study pick and place Robot- basic components, configuration, work volume
2. Experiments with Robot. Kit for minimum four assembly activities and programming
3. Programming of robots by manual, lead through and off line methods
4. Programming languages for stacking of objects in increasing or decreasing size. Palletizing
operations, assembly and inspection operation etc.
5. Become acquainted with the operation of a revolute - type 6 DOF robots; to program a robotic
system using a teaching pendant and a high level programming language.
Emphasis is made on the constraints associated when positioning and orienting an object within a 3-D
space. The practical includes point-to-point tasks and continuous robot motion.
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Assessment Strategy:
Exercises
Workshop exercises; Laboratory exercises
Project
Final examination
Respective Role of Instructors and Students:
Teaching Support and Inputs:
Lectures
Workshop and laboratory exercises
Module Requirements:
Minimum of 75% attendance during lecture hours
100% attendance during practical work sessions, except for some unprecedented
mishaps
All exercises and project works must be submitted by the specified dead line date
Text books:
53
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
54