NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI - 620 015

M.Tech. DEGREE

in

MANUFACTURING TECHNOLOGY

SYLLABUS

FOR

CREDIT BASED CURRICULUM

OPERATIVE FOR STUDENTS FROM 2015 -2016 ADMISSION
4 SEMESTER PROGRAMME

CODE : PR

DEPARTMENT OF PRODUCTION ENGINEERING

 NATIONAL INSTITUTE OF TECHNOLOGY: TIRUCHIRAPPALLI - 620 015
DEPARTMENT OF PRODUCTION ENGINEERING
M. Tech. MANUFACTURING TECHNOLOGY

Department Vision
To establish a world class academy for Manufacturing and Industrial Engineering

Department Mission
 Curriculum development with state-of-the-art technologies
 Pursue research interests of Manufacturing and Industrial engineering
 Consultancy in design, Manufacturing and industrial engineering
 Industry-Institute interaction
 Equipping Laboratories with state-of-the-art equipment

Programme Educational Objectives (PEOs):

PEO 1: Graduates of the programme will be capable of integrating Engineering fundamentals
and advanced Manufacturing Engineering concepts.
PEO 2: Graduates of the programme will be professionally competent for gainful employment in
Manufacturing functions and sustain future challenges.

Programme Outcomes (POs):

Sl. Programme Outcomes (POs)
Attributes
No On successful completion of the programme the students will be able to
Acquire in depth knowledge in Manufacturing technology with an
Scholarship of
1 ability to define, evaluate, analysis and synthesize existing and new
Knowledge
knowledge.
Analyze problems critically; apply independent judgment for
Critical
2 synthesizing information to make intellectual and/or creative advances
Thinking
for conducting research.
Conceptualize and solve Manufacturing engineering problems and
Problem
3 evaluate optimal solutions considering economic and eco-friendly
Solving
factors
Develop scientific/ technological knowledge in Manufacturing
4 Research Skill
engineering through literature survey and design of experiments.
Usage of Apply of IT tools such as CAD/CAE/CAM for modeling and
5
modern tools simulation of complex Manufacturing processes.
Collaborative Perform collaborate multidisciplinary scientific Manufacturing
and multi- engineering research through self-management and team work.
6
disciplinary
work
Demonstrate knowledge and understanding of Manufacturing
Project engineering and management and apply the same to one’s own work, as
7 Management a member and leader in team, manage projects efficiently in respective
and Finance disciplines and multidisciplinary environments after consideration of
economical and financial factors.

Department of Production Engineering 2

 Communicate with the engineering community, and with society at
large, regarding complex engineering activities confidently and
8 Communication effectively, such as, being able to comprehend and write effective
reports and design documentation by adhering to appropriate standards,
make effective presentations, and give and receive clear instructions.
Recognize the need for, and have the preparation and ability to engage
Life-long
9 in life-long learning independently, with a high level of enthusiasm and
Learning
commitment to improve knowledge and competence continuously.
Acquire professional and intellectual integrity, professional code of
Ethical
conduct, ethics of research and scholarship, consideration of the impact
Practices and
10 of research outcomes on professional practices and an understanding of
Social
responsibility to contribute to the community for sustainable
Responsibility
development of society.
Independent and Observe and examine critically the outcomes of one’s actions and make
11 Reflective corrective measures subsequently and learn from mistakes without
Learning depending on external feedback.

Department of Production Engineering 3

 NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI
DEPARTMENT OF PRODUCTION ENGINEERING
M. Tech. (Manufacturing Technology)
Total minimum credits required: 66
(Operative for students from 2015-2016 admission)
CODE Semester 1 L T P C CODE Semester 2 L T P C
Advanced Machining
PR 601 3 0 0 3 PR 602 Precision Machining 3 0 0 3
Technology
Flexible Tooling and
PR 603 2 1 2 4 PR 604 Theory of Plasticity 2 1 0 3
Automated Inspection
Advanced Welding Flexible Manufacturing
PR 605 3 0 0 3 PR 606 3 0 0 3
Processes Systems
----- Elective I 3 0 0 3 ----- Elective IV 3 0 0 3
----- Elective II 3 0 0 3 ----- Elective V 3 0 0 3
----- Elective III 3 0 0 3 ----- Elective VI 3 0 0 3
Advanced Production
PR607 0 0 3 2 PR 608 Automation & CIM Lab 0 0 3 2
Process Lab
Advanced Material Process Modeling, Design &
PR609 0 0 3 2 PR 610 0 0 3 2
Processing & Tribology Lab Rapid Manufacturing Lab
Total 17 1 8 23 Total 17 1 6 22

CODE Semester 3 L T P C CODE Semester 4 L T P C

PR641 Project Work – Phase I 0 0 24 9 PR642 Project Work – Phase II 0 0 24 12
LIST OF ELECTIVES
CODE Materials & Process Stream L T P C CODE Product & System Stream L T P C
Modeling of Manufacturing
PR 611 3 0 0 3 PR 625 Manufacturing Management 3 0 0 3
Processes
Advances in Polymer matrix Computer Aided Design and
PR 612 3 0 0 3 PR 626 3 0 0 3
Composites Manufacturing
Control of Manufacturing
PR 613 Heat Treatment 3 0 0 3 PR627 3 0 0 3
Processes
Industrial Welding
PR 614 3 0 0 3 PR 628 Design for Manufacture 3 0 0 3
Applications
Industrial Automation and
PR 615 Lasers in Manufacturing 3 0 0 3 PR 629 3 0 0 3
Mechatronics
Product Design and
PR 616 Machine Tool Technology 3 0 0 3 PR 630 3 0 0 3
Development
Manufacturing of Non- Production Automation and
PR 617 3 0 0 3 PR 631 3 0 0 3
metallic Products CNC Technology
PR 618 Materials Technology 3 0 0 3 PR 632 Rapid Manufacturing 3 0 0 3
Mechanical Behaviour of
PR 619 3 0 0 3 PR 633 Robotics 3 0 0 3
Materials
Mechanics of Composite
PR 620 3 0 0 3 PR 634 Terotechnology 3 0 0 3
Materials
PR 621 Non-Destructive Testing 3 0 0 3 PR 635 Tolerance Technology 3 0 0 3
Smart Materials and MEMS: Common Electives with
PR 622 3 0 0 3
Design and Fabrication M.Tech.-Ind. Engg. & Mgmt.
PR 623 Surface Engineering 3 0 0 3 PR 654 Modeling and Simulation 2 1 0 3
Intelligent Manufacturing
PR 624 Tribology 3 0 0 3 PR 662 3 0 0 3
Systems
PR 671 Sustainable Manufacturing 3 0 0 3
PR 672 Project Management 3 0 0 3
Product Life Cycle
PR 679 3 0 0 3
Management

Department of Production Engineering 4

SEMESTER 1

PR 601 ADVANCED MACHINING TECHNOLOGY

L T P C
COURSE OUTCOMES: 3 0 0 3
1. Select suitable machining process for suitable materials
2. Select optimum parameters for the respective machining process
3. Summarizes the merits and demerits of the non-traditional manufacturing process

Metal Cutting Technology: Introduction to metal cutting - tool nomenclature and cutting forces -
thermal aspects of machining - tool materials - tool life and tool wear - traditional and
nontraditional machining – high speed machining

Mechanical Processes: Ultrasonic Machining - Water Jet Machining - Abrasive Jet Machining -
Abrasive Water Jet Machining - Ice Jet Machining - Magnetic Abrasive Finishing

Chemical and Electrochemical Processes: Chemical Milling - Photochemical Milling -

Electropolishing - Electrochemical Machining - Electrochemical Drilling - Shaped Tube
Electrolytic Machining

Thermal Processes: Electric Discharge Machining - Laser Beam Machining - Electron Beam
Machining - Plasma Beam Machining - Ion Beam Machining

Hybrid Processes: Electrochemical Grinding, Honing, Superfinishing and Buffing – Ultrasonic

and Laser Assisted ECM - Electroerosion Dissolution Machining - Abrasive Electrodischarge
Machining - EDM with Ultrasonic Assistance

References
1. Bhattacharya "Metal Cutting Theory and Practice”, New Central Book Agency (p) Ltd.,
Calcutta1984.
2. Boothroy .D.G. and Knight. W.A "Fundamentals of Machining and Machine tools", Marcel Dekker,
New York, 1989.
3. Hassan Abdel – Gawad El-Hofy "Advanced Machining Processes", McGraw, New York, 2005.
4. Wellar, E.J. "Non-Traditional Machining Processes", Society of Manufacturing Engineers
Publications, 2nd Edition, Michigan, 1984.
5. Metals Handbook. Vol. 16, Machining. Materials Park; OH: ASM International, 1995.
6. Kalpakjian, S “Manufacturing Process for Engineering Materials”, MA:Addison-Wesley, 1997.
7. Brown, J “Advanced Machining Technology Handbook”, New York: McGraw-Hill, 1998.
8. McGeough, J “Advanced Methods of Machining”, London. New York: Chapman and Hall, London,
1988.
9. Rumyantsev, E and Davydov, A “Electrochemical Machining of Metals”, Moscow:Mir Publishers,
1984.

Department of Production Engineering 5

 PR 603 FLEXIBLE TOOLING AND AUTOMATED INSPECTION

L T P C
COURSE OUTCOMES: 2 1 2 4
1. State of Art in Tooling in Manufacturing and Inspection
2. Design and Develop tooling for Flexible Manufacturing
3. Design and Develop Automated Inspection Systems

Introduction to Principles of Tooling in Manufacturing-Economics of Tooling- Pre -Design

Product and Process Analysis -Automated Tooling for Machining-Tool Changers-Tool Presets

Flexible Tooling –Tooling for Forming- Evolution of Dies, Forging, Bending and Drawing and
Extrusion Processes- Tooling for Casting processes –Mechanization –Flexible tooling in Non
Traditional Manufacturing

Tooling for Micro Manufacturing-Tooling for Physical and Mechanical joining Processes-
Tooling for CMM-Tool handling Robots.

Principles of Gauging - New concepts for gaging, inspection, checking, machine vision, and
robotic testing. Smart Inspection Systems - Techniques and Applications of Intelligent Vision -
Stages of automated visual inspection (AVI) and "smart" inspection systems- examples

Application of conventional and artificial intelligence techniques in AVI. AVI process, from
illumination, image enhancement, segmentation and feature extraction, through to classification,
and includes case studies of implemented AVI systems-Robots in Automated Inspection

Tutorial: Design of Tooling Layout for Automats, Die Design, Modular Fixture Design
Practice: Exercises in CMM and Robots for Inspection

References
1. Mikell P Groover Fundamentals of Modern Manufacturing: Materials, Processes, and Systems
John Wiley and Sons 2012
2. Stephen Murphy In-Process Measurement and Control: 32 (Series Manufacturing Engineering
and Materials Processing) CRC Press 1990
3. Boothroyd, G. (2005). Assembly automation and product design (Vol. 536). Boca Raton, FL:
Taylor & Francis.
4. Stanley L. Robinson, Richard Kendall Miller Automated Inspection and Quality Assurance 1989
CRC Press
5. Duc T. Pham and R J Alcock Smart Inspection Systems: Techniques and Applications of
Intelligent Vision Academic Press
6. Black, J. Temple. The Design of the Factory with a Future. McGraw-Hill Companies, 1991

Department of Production Engineering 6

 PR 605 ADVANCED WELDING PROCESSES

L T P C
3 0 0 3
COURSE OUTCOMES:
1. Discriminate the knowledge of principles, operations and applications of different casting
and welding processes
2. Analyze the effects of process parameters on the quality of cast and weld products
3. Select the NDT techniques for the evaluation of cast and weld components

Welding processes classification, arc welding processes- solid state welding processes, plasma
arc welding and ultrasonic welding - Resistance welding process- different types weld joints,
welding positions. Brazing, soldering and adhesive bonding, process principles & applications.

Electron beam welding, laser beam welding, Hybrid welding– explosive welding – diffusion
bonding – high frequency induction welding –twin wire active TIG welding-A-TIG welding- Hot
wire TIG welding- Weld Surfacing & cladding.

Friction Surfacing, Friction stir spot welding, Explosive Welding, Welding of Ni and Ti based
alloys, Friction welding with Cu interlayer.

Magnetically impelled arc butt (MIAB) welding - under water welding -Welding of Cu, Al, Ti
and Ni alloys – processes, difficulties, microstructures, defects and remedial measures -
Hydrogen embrittlement – Lamellar tearing – Residual stress – Distortion and its control .

Heat transfer and solidification - Analysis of stresses in welded structures – pre and post welding
heat treatments – weld joint design – welding defects-Inspection & testing of weld joints - Safety
aspects in welding.

For Understanding:
Casting basics - design for moulding and casting -advanced moulding and casting processes.
Castingdefects – Inspection and testing of casting

References
1. Dr.R.S.Parmer "Welding processes and Technology" Khanna Publishers.
2. H.S.Bawa "Manufacturing Technology-I" Tata Me Graw Hill Publishers New Delhi, 2007.
3. S.V.Nadkami, Modem Arc Welding Technology, Oxford & IBH Publishing Co. Pvt. Ltd.
4. CORNU.J. Advanced welding systems – Volumes I, II and III, JAICO Publishers,1994.
5. LANCASTER.J.F. – Metallurgy of welding – George Alien & Unwin Publishers, 1980
6. Carry B., Modern Welding Technology, Prentice Hall Pvt Ltd., 2002
7. P .L. Jain “Principles of foundry Technology" Tata Mc Graw Hill Publishers.

Department of Production Engineering 7

 PR 607ADVANCED PRODUCTION PROCESS LAB
L T P C
0 0 3 2

1. Micro-turning/ milling/ drilling operation on DT-110 Multi-process micro-machining center.

2. Micro- machining operation on Micro-EDM & Micro-Wire cut EDM.
3. Exercise on Measurement of Specific cutting energy in turning Process.
4. Exercise on Temperature measurement in drilling.
5. Exercise on Stir casting of Aluminum based composites.
6. Manufacturing of PMC using injection moulding .
7. Manufacturing of PMC using compression moulding
8. Joining of Thermoplastic pipes by Resistant welding .
9. Joining of Thermoplastic composite pipes/plates/composite plates by Resistant welding.
10. Joining of Thermoplastic pipes by Fusion Welding Machine.

PR609ADVANCED MATERIAL PROCESSING AND TRIBOLOGY LAB

L T P C
1. Exercise on Weld bead performance on GMAW 0 0 3 2
2. Exercise on Measurement of temperature distribution on GTAW
process using thermocouple.
3. Exercise on Water Hammer Forming / Abrasive Machining
4. Laser marking / engraving on metals.
5. Laser micro-welding. / micro drilling / micro channeling
6. Pin-on-disc based tribological characterization of ferrous/ non-ferrous materials at
different environment.
7. Measurement of bonding strength of coating using Scratch Tester.
8. Laser transformation hardening of ferrous materials.
9. Laser surface melting of ferrous / non-ferrous materials.
10. Laser surface alloying.

Department of Production Engineering 8

Semester 2
PR 602 PRECISION MACHINING
L T P C
3 0 0 3
COURSE OUTCOMES
1. Recognize the various micro machining techniques
2. Apply various micro/nano finishing techniques for the production of required
components
3. State the metrological principles and techniques for the evaluation of precision machined
components

Micro- manufacturing- types- micromachining- classification- mechanical advanced micro-

machining processes-advanced nano finishing processes-Micro Electro Mechanical Systems
(MEMS) - Nano Electro Mechanical Systems (NEMS)

Lithography-diamond turning- micro drilling - micro milling - Electrical Discharge Micro-

Machining (EDMM) - Electro Chemical Micro-Machining (ECMM)

Wire Electrical Discharge Micro-Machining (EDMM)- Laser Micro-Machining (LMM) – Types

of Lasers

Nano finishing- magnetorheological finishing process-micro/nano finishing with flexible flow of

abrasives- Electrolytic In-process Dressing (ELID) Grinding.

Profilometers- optical microscopy- confocal laser scanning microscopy- Scanning Electron

Microscope (SEM)-Atomic Force Microscope (AFM).

References
1. M.J. Madou, “Fundamentals of Micro Fabrication”, CRC Press, 2002
2. V.K.Jain, “Introduction to Micromachining”, Narosa Publishing House, 2010
3. Mark J. Jackson, “Micro Fabrication and Nano machining”, Taylor and Francis, 2006
4. Serope Kalpakjian, “Manufacturing Engg. and Technology”, Pearson Education, 2005
5. Yi Qin, “Micro-Manufacturing Engineering and Technology”, Elsevier Publication,2010

Department of Production Engineering 9

 PR 604 THEORY OF PLASTICITY
L T P C
COURSE OUTCOMES 2 1 0 3
1. Recognize the various metal forming techniques
2. Apply the theory of plasticity and its application for analyzing various metal forming
Processes
3. Describe the advancement in forming technologies
Mohr’s Circle, Plastic instability, Tensile test, Advantages of true stress and true strain diagrams
etc., Various Yield theories and comparison - Von-Mises Yield theory, Tresca Yield theory,
Solving problems related to Yield theories

Plastic instability in biaxial tension, Plastic instability using old Hill’s Yield theory, Plastic
instability using latest Hill’s Yield theory, Plastic instability using Bassni’s yield theory

Anisotropy in sheet metals, Hill’s Anisotropic Plasticity theory, Special cases, Generalization of
Hill’s criterion, Bassani’s Yield theory, M-K analysis for imperfect sheets, Upper bound
theorem, Plane strain, Simple indendation, Compression between smooth plates, Upper bound
problems

Slab analysis, Sheet drawing, Wire/rod drawing, Direct compression in plane strain, Sticking
friction at interface, Axisymmetric compression, extrusion, Cold rolling theory of strip or plate

Slip line filed theory, Governing stress equations, Properties of SLF, Velocity equations,
Derivation of Velocity diagram, Simple stress boundary conditions, Thick walled cylinder under
internal pressure solution by SLF method, Processes, Theory of plasticity for porous materials.

References
1. Hosford W.F and Caddell, R.M, “Metal Forming Mechanics and Metallurgy”, Prentice Hall, 1983.
2. Narayanasamy R., “Theory of Plasticity”, Ahuja Publications, 2000.
3. W.Johnson&P.B.Mellor “Engineering Plasticity” McGraw Hill.

Department of Production Engineering 10

 PR 606 FLEXIBLE MANUFACTURING SYSTEMS
L T P C
3 0 0 3
COURSE OUTCOMES:
1. Define the flexibilities in FMS
2. Apply the components of FMS and their integration
3. Analyze the issues related to planning for successful implementation of FMS

FMS Introduction and Description - Objectives and Benefits of FMS - Basic Components of
FMS and their integration in the data processing systems - Types of FMS - FMS Layouts –
Types of Flexibility - FMS design criteria- Group Technology – Cellular manufacturing -
Differences between FMC and FMS

FMS workstations - Machining station – CNC/DNC Features – Machine Tool applications -

Machining Centers – Automated Features and Capabilities - Wash Stations - Coordinate
Measuring Machines – Contact and noncontact inspection principles - Functions of CMM
Computer/software

Material Handling Systems - Introduction to material handling – material transport systems –

AGV’s - conveyors – storage systems - AS/RS – Automatic data capture - Industrial Robots -
Basic Configurations – Sensors in Robotics - robot cell design and control - Applications of
Industrial Robots – Robot programming

FMS Software Structure, Functions and Description - General Structure and Requirements -
Activities and Functions to be Performed by FMS Software - Requirements of FMS Software -
Types of FMS Software Modules - Computer Simulation - Functions of an FMS Host Computer
– Distributed systems in FMS – Part program preparation

System Hardware and General Functionality - Programmable Logic Controllers - Cell

Controllers - Communication Networks - FMS Installation and Implementation - Case Studies -
Just-in-Time production – CIM Technology

References
1. H.K. Shivanand, M.M.Benal, V.Koti, “Flexible Manufacturing System”, New Age International
Publishers, 2006
2. Mikell P Groover, “Automation Production systems, Computer Integrated Manufacturing”, Prentice
Hall,1987.
3. Paul Ranky, “The Design and Operation of FMS”, IFS publication. 1983.
4. David J Parrish, “Flexible Manufacturing”, Butterworth-Heinemann Ltd, 1990

Department of Production Engineering 11

 PR 608 AUTOMATION & CIM LAB
L T P C
0 0 3 2
1. Plain turning and facing operations on EMCO turning machine/Step turning on
LEADWELL machine.
2. External threading operation on LEADWELL and STC 15 machines.
3. Profile milling operation on VMC machine.
4. Circular pocketing / Rectangular pocketing / drilling operations on EMCO milling machine.
5. Mirroring operation on MTAB milling machine.
6. Simulation of hydraulic circuits in a hydraulic trainer / single and double acting cylinder
circuits.
7. Simulation of Electro-pneumatic latch circuits / Logic pneumatic circuits / electro
pneumatic sequencing circuits
8. Measurement of form tolerance (circularity, cylindricity and perpendicularity) using
CMM
9. Robot programming for pick and place of jobs with vision system / function of ASRS
10. Simulation of CIM environment

PR 610 PROCESS MODELING, DESIGN & RAPID MANUFACTURING LAB

L T P C
0 0 3 2
1. Analysis of stress strain distribution in a plate with center hole using MATLAB coding
2. Transient heat transfer analysis of a rectangular slab using a FEA package
3. Modeling & simulation of hot forging / orthogonal machining / cold rolling operation /
milling operation using a FEA package
4. Exercise on Rapid Product Development selection of Rapid Prototyping Technology
5. Exercise on development of prototypes using 3D Printer
6. Life Cycle Assessment using GaBi package
7. Analysis of Geometric Tolerance and manufacturing variation on product designs using
Pro/ENGINEER.
8. Assembly tolerance stack up analysis using the RSS Method
9. Tolerance stack up analysis for feature of size, assembly with plus and minus
Tolerancing, for floating fastener assembly and fixed fastener assembly.
10. Sustainable Product Development – Developing environmentally friendlier products

Department of Production Engineering 12

LIST OF ELECTIVES
Materials & Process Stream
PR 611 MODELING OF MANUFACTURING PROCESSES
L T P C
3 0 0 3
COURSE OUTCOMES
1. Arrange the application of numerical method for non-linear problems
2. Apply numerical methods for manufacturing processes
3. Evaluate the numerical results of manufacturing processes

Review of manufacturing processes, need for numerical solution – Review of basic concepts of
numerical methods

FE concepts – variational and weighted residual approaches – Element types – 2D elements –

plane triangular, quadrilateral, 3 dimensional axi-symmetric, plate and shell elements – mapping
of elements

FE solution for Steady state and transient problems. FE procedure for non-linear problems -
Material and geometric non-linearities – solution using implicit and explicit methods

Lagrangean and Eulerian formulations for modelling of machining, rolling, forging, drawing.
ALE elements

Thermal modeling for induction hardening, arc welding, cooling of castings – deduction of
cooling rate and metallurgical transformations.

References
1. M.Asghar Bhatti “Advanced Topics in Finite Element Analysis of Structures” John Wiley & sons,
Inc,2006.
2. Lewis R.W.Morgan, K, Thomas, H.R. and Seetharaman, K.N. The Finite Element
Method in Heat Transfer Analysis, John Wiley, 1994.
3. Edward R Champion Jr, “Finite Element Analysis in Manufacturing Engineering”, McGraw Hill,
1992.
4. Prakash M. Dixit, Uday S. Dixit”Modeling of Metal Forming and Machining Processes”, 1st Edition,
2008, Springer Verlog.
5. Lars-Erik Lindgren, “Computational welding mechanics” , 1st Edition, 2007, CRC Press,

Department of Production Engineering 13

 PR 612 ADVANCES IN POLYMER MATRIX COMPOSITES
L T P C
3 0 0 3
COURSE OUTCOMES
1. Describe manufacturing and characterization of polymer matrix composites
2. Perform joining & machining of polymer matrix composites
3. Apply polymer composites for recent industrial applications & confront environmental
issues
Polymer matrix –classification- thermoplastics and thermosetting plastics, types of matrix
material, reinforcement material- fiber- particulate- whisker, properties of reinforcements and
matrix. Composite material-Types-MMC-PMC-CMC, Advantages and Disadvantages.

Manufacturing of PMC material– Lay-up, Autoclave Molding filament Winding, Pultrusion, etc..
Machining of polymeric composite material, Forming methods for Polymers and polymeric
composite material- component design consideration.

Joining of PMC-Friction Welding of PMC, Thermal Welding of PMC, Electromagnetic Welding

of PMC-Process-Processing Parameters-Materials-Advantages& Disadvantages and
Applications. Mechanical fastening of PMC, Chemical bonding of PMC, Joint design, equipment
and application methods, Advantages and disadvantages, Applications adhesive bonding

Application of Polymers and PMC material- Automotive Industry- Marine Industry- Materials
Handling- Chemical Industry- Electrical & Electronics Industry- Aerospace Industry-
Biomedical field.

Recent advancements in polymeric materials-Blends and composites- conducting polymer -

nanofibers- Polymeric nanocomposites-Biodegradable Polymeric Nanofibers for Biomedical
Applications- nanotube based Conducting Polymer Composite- polymeric nanomaterials in
piezoelectric sensors- Biodegradable Polymers to improve new Antifouling coating etc..,
Polymer in health care, Environmental issues concerning polymers and polymer in energy
application.

References
1. Mein Schwartz., “Composite Materials Handbook”, McGraw Hill, 1984
2. “ASM Hand book on Composites”, Volume 21, 2001
3. “Handbook of Plastics Joining- A Practical Guide”, Plastics Design Library, 13 Eaton Avenue,
Norwich, New York 13815.
4. Leonard Hollaway “Handbook of Polymer Composites for Engineers”, British Plastics Federation.
5. Edward Arnold, “Process Selection from design to manufacture”, 1997.

Department of Production Engineering 14

 PR 613 HEAT TREATMENT

L T P C
COURSE OUTCOMES: 3 0 0 3
1. Identify the effect of heat treatment in alloying elements
2. Apply surface modification techniques
3. Find the defects occurring in heat treated parts

Iron - Carbon Equilibrium Diagram: Effect of alloying element on properties of steel and heat
treatments. Types and application of heat treatments in manufacturing Industries.

TTT & CCT diagram for steels-Various heating media used for heat treatment, furnaces,
Temperature and atmosphere control- Selection of furnace for heat treatment.

Heat Treatment Processes: Annealing – Normalising, Hardenability studies, Jominy end quench
test, Grossman's experiments - Tempering, Austempering and Martempering. Thermomechanical
treatments.

Surface Modification Techniques: Induction hardening, flame hardening, electron beam

hardening and Laser beam hardening. Carburising, nitriding, carbonitriding, CVD and PVD
processes, Ion implantation.

Heat Treatment of Non-Ferrous Metals and Specific Alloy steels: Heat treatment of gray irons,
white irons (malleabilising) and S.G.irons. Austempering of S.G.Iron. Defects: Defects in heat
treated parts, causes and remedy Design for heat treatment.

References
1. Rajan and Sharma "Heat Treatment Principles and Techniques" – Prentice Hall of India (P) Ltd, New
Delhi, 2004.
2. Prabhudev, K H., "Handbook of Heat Treatment of Steels", Tata - McGraw Hill Publishing Co., New
Delhi, 2000.
3. VijendraSingh,"Heat Treatment of Metals", Standard Publishers Distributors, Delhi, First edition 1998.
4. American Society for Metals, "Metals Handbook Vol.4", ASM Metals Parks, Ohio, USA, 2001.
5. Karl-Erik Thelning, "Steel and its Heat Treatment", Butterworths London, second edition 1984.
6. Novikov I, "Theory of Heat Treatment of Metals", MIR Publishers, Moscow, 1978.

Department of Production Engineering 15

 PR 614 INDUSTRIAL WELDING APPLICATIONS

L T P C
COURSE OUTCOMES: 3 0 0 3
1. Apply the knowledge of welding in Heavy Engineering
2. Apply the knowledge of welding in Automotive Industries
3. Apply the knowledge of welding in Nuclear Power

Application of welding in heavy engineering: Boiler manufacture - boiler drum, water wall
panels, headers, economizers. Heat exchangers.

Application of welding in oil & gas industries: orbital pipe welding, welding consumables,
fabrication codes, inspection &testing, acceptance criteria.

Application of welding in Nuclear Power: Materials, processes, fabrication codes, inspection &
testing, reasons for stringent quality control measures.

Application of welding in automotive industries: Thin sheet welding, selection of materials and
welding processes, inspection and testing procedure, acceptance criteria.

Application of welding in shipbuilding & Aerospace Industry: Materials involved, welding

processes, fabrication code, inspection & testing, acceptance criteria.

References
1. American Welding Society, 'Guide for Steel Hull Welding', 1992
2. Gooch T. S; 'Review of Overlay Welding Procedure for Light Water Nuclear Pressure Vessels',
American Welding Society, 1991
3. Winter Mark H, 'Materials and Welding in Off-Shore Constructions', Elsevier, 1986
4. Welding Institute Canada, 'Welding for Challenging Environments', Pergamon Press, 1996.
5. Mishra, R.S and Mohoney, M W, Friction stir welding and processing, ASM 2007.

Department of Production Engineering 16

 PR 615 LASERS IN MANUFACTURING
L T P C
3 0 0 3
COURSE OUTCOMES
1. Compare the types of lasers and its applications.
2. Employ laser for surface engineering, welding, cutting and drilling.
3. Analyze the micro machining processes by Laser

Fundamentals of laser –lasing action- properties - spectrum and wavelength –wave length chart-
types of laser- modes of operation-continuous mode-pulsed mode-laser components - interaction
of laser radiation with materials-long pulse and short pulse interaction.

Laser surface treatment –forms of laser surface treatment-laser transformation hardening -

advantages - laser surface melting - laser alloying - laser cladding-co-axial powder feeding-
lateral powder feeding-laser texturing-case examples-.

Laser welding-process arrangement - mechanisms - applications –modes of welding- conduction

limited welding-key hole welding-heat flow theory - one dimensional heat flow - model for
stationary and moving point source - simulation of laser welding.

Laser cutting –process characteristics-theoretical models of cutting - practical performance-

applications - process variations - drilling –single pulse drilling-percussion drilling- trepanning-
applications.

Fiber Laser and UV Laser based marking - micromachining solutions - laser shock loading -
basics - applications - laser safety - danger - safety limits - eye and skin - class four safety
arrangements - electric hazards - fume hazards.

References

1. William M. Steen, “Laser Material Processing”, Springer Verlag, 2003.

2. M.Young, “Optics and Lasers”, Springer, 1993.
3. K.Thyagarajan, AjoyK.Ghatak, “Lasers, Theory and Applications”, Plenum Press, 1981.
4. J.F. Reddy, “Industrial Applications of Lasers”, Academic Press, New York, 1978.
5. S. S. Charschan, “Lasers in Industry”, Wiley & Sons Inc., 1974.
6. Michael Bass, “Laser Materials Processing”, Elsevier Science, 1983.

Department of Production Engineering 17

 PR 616 MACHINE TOOL TECHNOLOGY

L T P C
COURSE OUTCOMES 3 0 0 3
1. Identify various parts of machine tools
2. Apply various design aspects of spindles and bearings
3. Reduce vibration and chatter developing on machine tools

Metal cutting machine tools and their specifications - machine beds and columns - relative
merits of different types of beds and columns - design of beds and columns -force on cutting
tool.

Types of slideways and design of slideways - wear adjustments in slideways, surface treatment
for slideways.

Design of spindles – example for lathe, drilling machine and milling machine, Design of bearing-
example for lathe, drilling machine and milling machine, choice of bearings.

Types of drives for machine tool – step and stepless – speed and feed mechanisms – kinematic
diagrams. Typical examples for drives in advanced machine tools.

Machine tool vibration – types - effect of undeformed chip thickness variations, rake and
clearance angle variations - stability of cutting operation - regenerative chatter - testing of
machine tools for alignment and accuracy - standard test charts.

References
1. Sen and Bhattacharya, “Principles of Machine Tools”, New Central Book Agencies, 1975.
2. Boothroyd,G., “Fundamentals of Metal Machining and Machine Tools”, McGraw Hill, 1985.
3. Acherkan,, “Machine Tool Design”, Vol. 2 & 3, MIR Pub, 1973

Department of Production Engineering 18

 PR 617 MANUFACTURING OF NON-METALLIC PRODUCTS
L T P C
3 0 0 3
COURSE OUTCOMES
1. Describe the types of polymers and its manufacturing techniques
2. Describe the application, types of glass and ceramics and their manufacturing methods
3. Knowledge in types of composites and their manufacturing techniques

Polymers - classification - Thermoplastics and thermosetting plastics - Thermoforming processes

- compression and transfer molding - injection molding - extrusion - blow molding - calendaring
- lamination and pultrusion.

Rubber - additives - applications. Stages in raw rubber and latex rubber technology - Processing
of rubbers –Manufacturing techniques - tires - belts - hoses - foot wears - cellular products -
cables. Manufacture of latex based products

Glass - characteristics - application - glass making - Glass forming machines - hollow wares flat
glasses, fiberglass, bulbs, bottles, heat absorbing glasses, amber glass and their manufacturing
methods, general plant layouts for manufacture of different types of glasses.

Ceramics - classification - traditional ceramics - structural ceramics - fine ceramics - bio

ceramics - ceramic super conductors. Ceramic processing techniques - hot pressing - hot isostatic
pressing (HIP) - Sintering - injection molding - slip casting - tape casting - gel casting -
extrusion.

Composites - requirements of reinforcement and matrix - Manufacturing of composites - casting

- solid state diffusion - cladding - HIP - liquid metal infiltration - liquid phase sintering -
preparation of molding compounds and prepregs - hand layup method - autoclave method -
filament winding method - compression molding - reaction injection molding - knitting -
braiding.

References
1. Ghosh, Polymer Science and Technology – Plastics, Rubber, Blends, and Composites, Tata-Mcgraw
hill, 1989.
2. J.L.White, Rubber Processing Technology, Materials and Principles, Hanser
Publishers, 1995.
3. E. B. Shand, Glass Engineering Handbook, McGraw-Hill, 2nd Edition, 1958.
4. Kingery, w d &etc Introduction to ceramics 2ndedtion, John Wiley & Sons publ 2004
5. ASM Handbook, Vol. 21 Composites, 2001 Lubin, Handbook of Composites, Springer, 1st Edition,
1982.

Department of Production Engineering 19

 PR 618 MATERIALS TECHNOLOGY

L T P C
COURSE OUTCOMES 3 0 0 3
1. Classify the mechanical properties of materials
2. Relate the various forming process
3. Apply the knowledge in formability

Crystal structure, Slip planes, Slip systems and Formability, Close packed planes and directions,
Tensile test, Yielding behavior, True stress, strain, Strain hardening, Dislocations, Tensile
instability, Constitutive material relationships, Strain rate and sensitivity, Volume constancy
principle, Mass constancy principle

Effect of Mohr’s circle on Formability, Formability of low carbon steels, Automobile grade
steels
Effect of grain size on Formability, Effect of second phase particles on formability

Formability of Carbon - Manganese steels, Micro alloy steels, HSLA steels, I.F steels, Dual
phase steels, etc., Formability of Stainless steels

Diffused necking and localized necking in tensile test, Super plasticity and its applications, Deep
drawing and deep drawability of sheet metals, Defects in deep drawing

Cold working, Hot working and Warm working, Recrystallization, Forming Limit Diagram,
Workability of materials.

References
1. George Krauss, “Steels; Processes, Structure& Performance”, ASM International, The Materials
Information Society, 2005
2. Narayanasamy R., “Metal Forming Technology”, Ahuja publications, New Delhi, 2000.
3. S.Kalpakjian, “Manufacturing Processes for Engineering Materials”, Addison Wesley Pub. Co.,
1997.

Department of Production Engineering 20

 PR 619 MECHANICAL BEHAVIOUR OF MATERIALS

L T P C
COURSE OUTCOMES 3 0 0 3
1. Identify the crystal structure of various materials
2. Analyse the type of fracture in materials
3. Categorize the behavior of creep and fatigue in materials

Introduction, Stress and strain relations, mechanical testing, Elements of plasticity, the flow
curve, Strain hardening, Strain rate and temperature dependence of flow stress.

Plastic deformation, slip in crystals, dislocations, and dislocation motion. Twins, strengthening
mechanisms, grain boundaries, solid solution strengthening and strain hardening.

Fracture, types of fracture, brittle fracture, Griffith theory of brittle fracture of material, ductile
fracture, notch effects, and fracture mechanics.

Fatigue, the S-N curve, low and high cycle fatigue, structural features, surface effects, Creep,
stress rupture test, structural changes, creep mechanisms and super plasticity

Embrittlement, residual stresses, mechanical behavior of Ceramics, glasses, polymeric materials,

and composite materials.

References
1. Dieter, G. E., “Mechanical Metallurgy”, 3rd Ed., McGraw Hill. 1988
2. Courtney, T.H., “Mechanical Behavior of Materials”, 2nd Ed., McGraw Hill. 1990
3. Meyers, M.A. and Chawla, K.K., “Mechanical Behavior of Materials”, Prentice Hall. 1999
4. R.W.K., “The Plastic Deformation of Metals”, Edward Arnold..

Department of Production Engineering 21

 PR 620 MECHANICS OF COMPOSITE MATERIALS

L T P C
COURSE OUTCOMES 3 0 0 3
1. Classify the composite materials
2. Categorize the properties of composite materials
3. Apply the knowledge of matrix in composite materials

Classification, Types, characteristics and selection of composites, prepegs, sandwich

construction.

Micro and Macro mechanics of a lamina: four elastic moduli – Rule of mixture, ultimate
strengths of unidirection lamina - Hooke’s law - number of elastic constants - Two – dimensional
relationship of compliance & stiffness matrix.

Macro Mechanical analysis of laminate - Kirchoff hypothesis – CLT, A,B,& D matrices -

Engineering constants - Special cases of laminates, Failure criterion.

Manufacturing processes and Quality assurance of composites.

Metal matrix composites, Application developments - future potential of composites.

References
1. Mein Schwartz, “Composite Materials Hand Book”, McGraw Hill, 1984.
2. Autar K. Kaw, “Mechanics of Composite Materials”, CRC Press, 1994.
3. Rober M Joness, “Mechanics of Composite Materials”, McGraw HIll,1982.

Department of Production Engineering 22

 PR 621 NON-DESTRUCTIVE TESTING

L T P C
COURSE OUTCOMES 3 0 0 3
1. Select appropriate non-destructive techniques
2. Apply surface modification techniques
3. Compare the merits of various non-destructive techniques

Visual Inspection : Fundamentals of Visual Inspection - metallic materials, raw materials and
welds - Inspection objectives, inspection checkpoints, sampling plan, inspection pattern etc.
classification of indictions for acceptance criteria - Codes, Standards and Specifications
(ASME,ASTM,AWS etc.)-Capabilities, Limitation and Applications

Liquid Penetrant Testing: Principles - types and properties of liquid penetrants - developers -
advantages and limitations of various methods - Control and measurement of penetrant process
variables - Limitation and Applications

Magnetic Particle Testing: Theory of magnetism - ferromagnetic, Paramagnetic materials -

advantages - Circular magnetisation techniques, Limitation and Applications

Ultrasonic Inspection Methods, Equipment/Materials: Principle of pulse echo method, through

transmission method, resonance method - Advantages, limitations - Focussing Techniques
(SAFT), Time of Flight Diffraction (TOFD), Signal Analysis. Capabilities, Limitation and
Applications

Characterization: X-ray Diffraction(XRD) - SEM, Photoluminescence(PL) – Raman

Spectroscopy, UV-Vis-IR Spectrophotometer –AFM.

References
1. American Metals Society, "Non-Destructive Examination and Quality Contro!"Metals Hand Book,
Vol. I 7, 9th Ed, Metals Park, OH, 1989.
2. Krautkramer, Josef and Hebert Krautkramer, "Ultrasonic Testing of Materials", 3rd Ed, Newyork,
Springer-verlag, 1983.
3. A. Goswami, "Thin film fundamentals", New age international (P) Ltd. Publishers, New Delhi, 1996.
4. Birchan, D, "Non Destructive Testing", Oxford University Press, 1977.

Department of Production Engineering 23

 PR 622 SMART MATERIALS AND MEMS: DESIGN AND FABRICATION
L T P C
3 0 0 3

COURSE OUTCOMES:
1. Describe the overview of different kinds of smart materials and their applications
2. Describe the various fabrication processes of smart materials and MEMS
3. Deliberate the fundamentals of mechanics for design of smart materials

Introduction to smart materials and MEMS: an overview- scaling issues in MEMS -Micro
sensors, some examples –Micro actuators, some examples– Micro systems – Examples of smart
systems.

Smart composites - piezoelectric materials, shape memory alloys, magnetic materials -Electro
and magneto-statics, Electro active polymers and electrostrictive materials - measurement
techniques for MEMS.

Fabrication processes - Structure of silicon and other materials Silicon wafer processing; Thin-
film deposition, Lithography, Etching, LIGA, Micromachining, Thick-film processing, Smart
material processing.

Mechanics of materials- Stresses and deformation: bars and beams - Micro device suspensions:
lumped modeling -Residual stress and stress gradients - Thermal loading; bimorph effect -
Vibrations of bars and beams - Gyroscopic effect

Electronics and packing - Semiconductor devices - Signal conditioning for microsystems

devices-Vibration control of a beam - Integration of microsystems and microelectronics -
Packaging of microsystems.

References
1. Engineering analysis of smart material systems, Donald J. Leo, John Wiley Sons.
2. Smart material systems: model development, R.C. Smith, SIAM.
3. S.D. Senturia, Microsustem Design, Kluwer Academic Publishers, 2001.
4. Tai-Ran Hsu, MEMS & Microsystems Design and Manufacture, McGraw Hill, 2002.
5. V.K. Varadan, K.J. Vinoy, and S. Gopalakrishnan, Smart Material Systems and MEMS: Design and
Development Methodologies, Wiley, 2006.

Department of Production Engineering 24

 PR 623 SURFACE ENGINEERING
L T P C
COURSE OUTCOMES 3 0 0 3
1. Compare the use of different surface engineering techniques
2. Select appropriate thermal process to alter the material surface
3. Apply laser for surface modification

Introduction- Significance of surface engineering- Solid surface- Surface energy-Superficial

layer- Physico-chemical parameters- Properties of the superficial layer-Surface coating-
Classification.

Physical vapor deposition (PVD): Ion plating- Sputter deposition- Reactive deposition-
Magnetron sputtering- Chemical vapor deposition (CVD)- Ion implantation- Electron beam
technology- Applications.

Thermal Spraying Techniques- Flame Spraying, Atmospheric Plasma Spraying (APS), Vacuum
Plasma Spraying (VPS), Detonation-Gun Spraying (D-GUN), High-Velocity Oxy-Fuel (HVOF)
Spraying-Applications.

Laser surface engineering- Laser transformation hardening - Laser remelting- Laser alloying-
Laser cladding- Laser ablation- Pulsed laser deposition- Laser doping - Laser crystallization-
Laser surface texturing- Laser shock peening.

Methods of characterization-Microstructure- Mechanical: Adhesion-Hardness-micro hardness-

Residual stress-Friction-Wear- Physical: Porosity-Density- Electrical: Conductivity- Magnetic-
Chemical.

References
1.Tadeusz Burakowski, Tadeusz Wierzchon, “Surface Engineering of Metals-Principles, equipment and
technologies”, CRC Press, 1999.
2. Lech Pawlowski, "The Science and Engineering of Thermal Spray Coatings", 2nd Edition, John Wiley
& Sons, 2008.
3. William M. Steen, Jyotirmoy Mazumder, “Laser Material Processing”, 4th Edition, Springer Verlag,
2010.

Department of Production Engineering 25

 PR 624 TRIBOLOGY

L T P C
COURSE OUTCOMES 3 0 0 3
1. Apply the knowledge of tribology in industries
2. Identify the friction and its effect
3. Identify the surface textures

Industrial significance of tribology - Strength and deformation properties of solids - physio-

chemical characteristics of solid surfaces –fracture-modes of fracture- ductile-brittle-Analysis of
surface roughness - measurement.

Friction - classification - Adhesion theory of friction - Elastic, plastic and visco - elastic effects
in friction - rolling friction - friction of materials - alloys - ceramics - polymers - Interface
temperature of sliding surfaces - measurement.

Wear - forms of wear-abrasive wear –adhesive wear-erosive wear-cavitation wear-corrosive

wear-oxidative wear-fatigue wear-melting wear-diffusive wear-mechanisms-wear of non-
metallic materials.

Lubrication –types of lubrication-hydro dynamic lubrication - Reynolds equation - hydrostatic

lubrication - bearing analysis – elastohydrodynamic lubrication - solid lubrication - boundary
lubrication.

Micro/nano tribology - Measurement techniques - Surface Force Apparatus (SFA) - Scanning

Probe Microscopy - Atomic Force Microscopy (AFM)-Nano-mechanical Properties of Solid
Surfaces and Thin Films - Computer Simulations of Nanometer-Scale Indentation and Friction.

References
1. I.M. Hutchings, “Tribology: Friction and Wear of Engineering Materials”, Elsevier Limited, 1992.
2. G. W. Stachowiak, A. W. Batchelor, “Engineering Tribology”, Elsevier Limited, 2005.
3. K.C. Ludema, “Friction, wear, lubrication: A text book in tribology”, CRC Press, 1996.
4. Bharat Bhushan, “Principles and applications of tribology”, John Wiley & Sons, 1999.
5. Bharat Bhushan, “Nanotribology and Nanomechanics: An Introduction”, Springer, 2008.

Department of Production Engineering 26

Product & System Stream
PR 625 MANUFACTURING MANAGEMENT

L T P C
3 0 0 3
COURSE OUTCOMES:

1.Understand the methods for strategic and operational decision making

2.Define and plan manufacturing problems within the business and sustainability
constraints
3.Develop and analyze quantitative models for manufacturing problems

Nature of production- Strategic, Tactical and Operational decisions considering values and
ethics- General discrete location-allocation problems - features and formulations. Facility
location models - Median model - Distribution model - Brown and Gibson model, Min-max
algorithm, Gravity location algorithm.

Aggregate production planning - ways to absorb demand fluctuations - costs relevant to

aggregate production planning - aggregate production planning models, heuristics, transportation
and linear models – Inventory management –Inventory control policies- EOQ models-models
with price breaks

Operations scheduling - Flow shop - n jobs –Johnson's rule, N-Jobs M machine, CDS heuristics,
Palmer heuristics- Assembly Line Balancing- Project Scheduling-CPM-PERT-crashing of
project network with cost trade off

Material Requirement Planning (MRP) - working of MRP - master production scheduling - Lot
sizing in MRP system-rough cut capacity planning -capacity requirement planning, Introduction
to ERP and softwares.

Concept of supply management and SCM, Flow in supply chains, Key issues in supply chain
management, Decision phases in supply chain, concept of quality management – standards for
quality management - Taguchi method of quality control.

References

1. Buffa, Sarin “Modern Production Management”, 8th Edition, John Wiley, 1987.
2. Sunil Chopra, Peter Meindl, “Supply Chain Management: Strategy, Planning and Operations”,
Prentice Hall India, 3rd Edition, 2007
3. Douglas C.Montgomery, “Introduction to Statistical Quality Control”, 2nd Edition , John Wiley
& sons, 1991

Department of Production Engineering 27

 PR 626 COMPUTER AIDED DESIGN AND MANUFACTURING

L T P C
COURSE OUTCOMES 3 0 0 3
1. Define the principles of optimum design
2. Apply surface modelling techniques
3. Analyze production systems at operation level

Basic concepts of CAD - CAD workstation - principles of computer graphics - graphics

programming - mechanical drafting package.

Advanced modeling techniques - surface modeling - solid modeling, rendering methods.

Graphics and data exchange standards, CAD/CAM data base development and data base
management systems.

Principles of optimum design - CAD optimization techniques, design for manufacture and
assembly, principles of computer aided engineering, application of CAD, rapid prototyping,
concurrent engineering.

Computer aided manufacturing, programming and interface hardware – computer aided process
monitoring - adaptive control, on-line search strategies, computer-aided process planning.

Production systems at the operation level - computer generated time standards -

machinability data systems - cutting conditions optimization - production planning - capacity
planning - shop floor control - computer integrated manufacturing systems, application.

References
1. Radhakrishnan P & Kothandaraman C.P, “Computer Graphics and Design”, Dhanpat Rai& Sons,
1990.
2. Groover M P, “Automation, Production System and Computer Aided Manufacture”, Prentice Hall,
1984.
3. William M Newman & Robert Sproul, “Principle of Interactice Computer Graphics”, McGraw Hill,
1984.
4. Ibrahim Zeid, “CAD/CAM Theory and Practice”, McGraw-Hill, 1991

Department of Production Engineering 28

 PR627 CONTROL OF MANUFACTURING PROCESSES

L T P C
3 0 0 3

COURSE OUTCOMES
1. Apply and interfere the application of statistical methods in manufacturing processes.
2. Identify the causes of process variation through statistical process control.
3. Apply the experimental design concepts in manufacturing process for problem solving

Review of probability and statistic distributions used in manufacturing processes.

Statistical process control and process capability analysis

Mechanical process variation – analyzing the causes and interpreting data

Alternate SPC methods for manufacturing process control

Application of experimental design in manufacturing

Full factorial models, Response surface modeling and process optimization, Analysis of Process
robustness, Case studies

References
1. Montgomery, Douglas C. Introduction to Statistical Quality Control. 5th Ed. New York, NY: Wiley,
2004.
2. Montgomery, Douglas C. Design and Analysis of Experiments. 5th Ed. New York, NY: Wiley, 2004.

Department of Production Engineering 29

 PR 628 DESIGN FOR MANUFACTURE

COURSE OUTCOME: L T P C
1. Apply various design rules in manufacturing processes 3 0 0 3
2. Evaluate the process by design guidelines for optimum design
3. Analyze design alternatives in the manufacture of components

Design process - General Design rules for manufacturability – DFX - basic principles for
economical production - creativity in design. Materials: Selection of materials for design
developments in material technology - criteria for material selection.

Review of various casting processes, selection of casting process, - general design considerations
for casting - casting tolerances - use of simulation in casting design – product design rules for
sand casting.

Review of various welding processes, Factors in design of weldments - General design

guidelines - effects of thermal stresses in weld joints - design of brazed joints. Forging - Design
factors - general design recommendations. Extrusion & Sheet Metal Work: Design guidelines for
extruded sections - design principles for forming operations.

Overview of various machining processes - general design rules for machining - Dimensional
tolerance and surface roughness - Design for machining - Ease - Redesigning of components for
machining ease with suitable examples. General design recommendations for machined parts.

Redesign for manufacture and case studies: Identification of uneconomical design - Modifying
the design. Design for assembly fits in the design process, general design guidelines for manual
assembly, development of the systematic DFA methodology

Reference:
1. Assembly Automation and Product Design/ Geoffrey Boothroyd/ Marcel Dekker Inc., NY, 1992.
2. Engineering Design - Material & Processing Approach/ George E. Deiter/McGraw Hill Intl. 2nd
Ed. 2000.
3. Product Design for Manufacturing and Assembly/ Geoffrey Boothroyd, Peter Dewhurst & Winston
Ansthony Knight/CRC Press/2010.
4. James G. Bralla, "Hand Book of Product Design for Manufacturing", McGraw Hill Co, 1986.
5. Design for Manufacturing-Carrado poli-Elsevier Science and Technology Books-2001.

Department of Production Engineering 30

 PR 629 INDUSTRIAL AUTOMATION AND MECHATRONICS
L T P C
COURSE OUTCOMES 3 0 0 3
1. Identify the various types of control valves
2. Apply PLCs in circuits
3. Select appropriate hydraulic and pneumatic circuits

Need for Automation, Hydraulic & Pneumatic system Comparison – ISO symbols for fluid
power elements, Hydraulic, pneumatics system – Selection criteria. Hydraulic system
components selection and specification-characteristics – Linear actuator– construction. Reservoir
capacity, heat dissipation, accumulators - standard circuit symbols, circuit (flow) analysis.
Direction, flow and pressure control valves-operating-characteristics-electro hydraulic servo
valves-types, characteristics and performance.

Typical industrial hydraulic circuits-Design methodology – Ladder diagram-cascade, method-

truth table-Karnaugh map method-sequencing circuits-combinational and logic circuit.

Electrical control of pneumatic and hydraulic circuits-use of relays, timers, counters, Ladder
diagram.

Programmable logic control of Hydraulics and Pneumatics circuits, Sensors, PLC ladder diagram
for various circuits, motion controllers, use of field busses in circuits. Electronic drive circuits
for various Motors.

Semi automats-automats-transfer lines - automatic assembly - transfer devices and feeders-

classifications and applications-job orienting and picking devices- setting of automats and
transfer lines.

References
1. Antony Esposito, Fluid Power Systems and control Prentice-Hall, 1988
2. Herbert R. Merritt, Hydraulic control systems, John Wiley & Sons, Newyork, 1967
3. Dudbey.A.Peace, Basic Fluid Power, Prentice Hall Inc, 1967
4. Peter Rohner, Fluid Power logic circuit design. The Macmillan Press Ltd.,London, 1979
5. E.C.Fitch and J.B.Suryaatmadyn. Introduction to fluid logic, McGraw Hill, 1978.
6. W.Bolton, Mechatronics, Electronic control systems in Mechanical and ElectricaEngineering Pearson
Education, 2003.
7. Peter Rohner, Fluid Power Logic Circuit Design, Mcmelan Prem, 1994.

Department of Production Engineering 31

 PR 630 PRODUCT DESIGN AND DEVELOPMENT
L T P C
3 0 0 3

COURSE OUTCOMES
1. Understand the challenges and advancements of product development process
2. Execution of various phases of product development
3. Development of environmentally friendly products/processes

Product development process – various phases, Reverse engineering and redesigning product
development process, Illustrations of product development process, S-curve, new product
development.

Gathering customer needs, organizing and prioritizing customer needs, establishing product
function, FAST method, establishing system functionality. Tear Down and Experimentation-
Tear down method, post teardown report, benchmarking and establishing engineering
specifications, product portfolios.

Generating Concepts- Information gathering, brain ball, C-sketch/6-3-5 method, morphological

analysis, concept selection, technical feasibility, ranking, measurement theory.
Robust design, Design for Manufacture and Assembly, Axiomatic design, TRIZ, Value
Engineering, Industrial design, Poka Yoke – Lean principles – Six sigma concepts.

Design for the Environment: DFE methods, life cycle assessment, weighted sum assessment
method, techniques to reduce environmental impact – disassembly, recyclability,
remanufacturing regulations and standards.

References
1. Kevin Otto and Kristin Wood, ―Product Design – Techniques in Reverse Engineering and New
Product Development‖, Pearson Education, 2004.
2. Karl T Ulrich and Steven Eppinger, ―Product Design and Development‖, McGraw Hill, 2011, Fifth
Edition.

Department of Production Engineering 32

 PR 631 PRODUCTION AUTOMATION AND CNC TECHNOLOGY
L T P C
3 0 0 3
Numerical Control (NC) - input media - design considerations of NC
machine tools - functions of MCU- controls and system devices - CNC.

CNC programming- manual part programming – preparatory, miscellaneous functions –

computed aided part programming - post processors - APT programming- programming for CNC
turning center, machining center and CNC EDM.

Feedback devices– interpolators - tooling for CNC– point-to-point and contouring systems –
DNC-Adaptive Control – ACO and ACC systems- graphical numerical control.

Automation – principles – strategies – levels of automation – automated manufacturing systems

– devices, drives and control circuits in automation - semi-automats, automats and transfer lines.

Part families-classification and coding-cellular manufacturing- production flow analysis-

automated material handling systems- automated storage systems-automatic data capture-
automated assembly systems-industrial robots – configurations- applications.

References
1. YoramKoren, "Computer Control of Manufacturing Systems", McGraw Hill Book Co.
New Delhi, 1986.
2. Mikell P. Groover, “Automation, Production Systems and Computer Integrated Manufacturing”,
Prentice Hall of India, 2009.
3. Radhakrishnan P., "Computer Numerical Control Machines", New Book Agency, Calcutta, 1991
4. Kundra T. K., Rao P. N., and Tiwari N. K., "CNC and Computer Aided Manufacturing", Tata
McGraw Hill, New Delhi, 1991.
5. Fitzpatric.M., “Machining and CNC Technology”, McGraw Hill, 2004

Department of Production Engineering 33

 PR 632 RAPID MANUFACTURING

L T P C
COURSE OUTCOMES 3 0 0 3
1. Understand the importance of time compression technologies
2. Selection of appropriate technology for the application
3. Exposure to RP software packages
Introduction- Need for the compression in product development, History of RP systems, Survey
of applications, Growth of RP industry, Classification of RP systems.

Principle, process parameters, process details and applications of various RP processes - Stereo
lithography systems, Laser Sintering, Fused Deposition Modeling, Laminated Object

Manufacturing, Solid Ground Curing, Laser Engineered Net Shaping, 3D Printing, Laser
Melting, Cladding.

Rapid Tooling: Indirect rapid tooling Direct rapid tooling , soft tooling Vs hard tooling, Rapid
Manufacturing Process Optimization- Factors influencing accuracy, data preparation errors, part
building errors, errors in finishing, influence of part build orientation.

Software for RP: STL files, overview of solid view, magics, mimics, magics communicator, etc.,
internet based softwares, collaboration tools.

RP Technology selection, Decision Making, Life Cycle Assessment of RP processes,

Sustainability issues.

References
1. Pham D T and Dimov S S, "Rapid Manufacturing", Verlag, 2001.
2. Paul F Jacobs, "Stereo lithography and other RP&M Technologies", SME, 1996.
3. Terry Wohlers, "Wohlers Report 2001", Wohlers Associates, 2008.
4. Prasad H and Badrinarayanan, K S, “Rapid Prototyping and Tooling”, SPI-Pageturners, Bangalore,
India, 2013.

Department of Production Engineering 34

 PR633 ROBOTICS
L T P C
COURSE OUTCOMES 3 0 0 3
1. Identify the components of a robot
2. Program robots for different applications
3. Introduce robots in various in various manufacturing techniques

Fundamentals of robotics – wrists design - end effectors – actuators - modular robots.

Robot and its peripherals - sensors, machine vision - image processing & analysis - application
of artificial intelligence, voice communication - robot control units - motion controls.

Robot kinematics - homogeneous transformations - forward & inverse kinematics - problems of

dynamics - differential relationships - motion trajectories - dynamics of a robot control of
single & multiple link robot - static force analysis.

Robot Programming - different languages - expert systems.

Robot applications in manufacturing - material transfer & machine loading/unloading -

processing operations – inspection - automation - robot cell design – control – recent
developments and special applications-Micro & Bio robotics.

References
1. Richard D Klafter, Thomas A Chmielewski & Michael Negin, “Robotic Engineering – An
Integrated Approach”, Prentice Hall, 1994.
2. Deb, S.R., “Robotic Technology and Flexible Automation”, Tata McGraw Hill, 1994.
3. Fu & Gonzales, “Industrial Robotics”, Tata McGraw Hill, 1988.

Department of Production Engineering 35

 PR 634 TEROTECHNOLOGY
L T P C
3 0 0 3
COURSE OUTCOMES
1. Increase the reliability of a system
2. Conduct reliability analysis
3. Identify appropriate models for reliability measurement

Basic Concepts of reliability –Reliability and Quality –Failures and Failure modes – Causes of
failures and unreliability- Maintainability and Availability- Mathematical Expressions - Laplace
Transform application in reliability.

Reliability analysis – Mathematical models – Designing for higher reliability– Reliability and
Cost - Failure Data Analysis –MTTF in integral form- Numerical analysis.

Component reliability and Hazard Models – Nonlinear hazard model

Redundancy Techniques in System Design- Vibration analysis.

System reliability – Types, Fault Tree Analysis.

References
1. Srinath.L.S, "Reliability Engineering", Affiliated East West Press Pvt. Ltd., 1991.
2. Collacott,R.A. "Mechanical Fault Diagnosis & condition monitoring", Chapman and Hall London,
1977.
3. Balagurusamy.E, "Reliability Engineering", Tata McGraw- Hill Publishing Company Limited, New
Delhi, 1984.
4. Birolini.A, "Reliability Engineering: Theory and Practice", Springer-Verlag Publishers, Germany,
2004, Fourth Edition.

Department of Production Engineering 36

 PR 635 TOLERANCE TECHNOLOGY
(Use of approved design data book is permitted in the examination)

L T P C
3 0 0 3
COURSE OUTCOMES
1. Identify the general dimensioning techniques
2. Apply the principles of tolerencing in Manufacturing
3. Calculate the optimum material requirement

Introduction to Geometric Dimensioning and Tolerancing, Scope, Definitions, and General

Dimensioning, General Tolerancing and Related Principles, Symbology, Datum Referencing,
Tolerances of Location, Form, Profile, Orientation, and Runout

Properties of the surface , Principles for tolerancing and geometrical tolerancing- Symbols-
Definitions of geometrical tolerances-Tolerance zone-Form of the tolerance zone- Location and
orientation of the tolerance zone-Width of the tolerance zone-Length of the tolerance zone-
Common tolerance zone- Datums- Axes and median faces- Screw threads, gears and splines -
Angularity tolerances and angular dimension tolerances-Twist tolerance.

Profile tolerancing, Tolerancing of cones, Positional tolerancing, projected tolerance zone,

Substitute elements, Maximum material requirement, Envelope requirement, least material
requirement

Tolerancing of flexible parts, Tolerance chains (accumulation of tolerances), Statistical

tolerancing, respecting geometrical tolerances during manufacturing- Manufacturing influences-
Recommendations for manufacturing,

General geometrical tolerances, Tolerancing principles, Inspection of geometrical deviations,

Function-, manufacturing-, and inspection-related geometrical tolerancing, Examples of
geometrical tolerancing, Tolerancing of edges, ISO Geometrical Product Specifications (GPS).

References
1. Gene R. Cogorno “Geometric Dimensioning and Tolerancing for Mechanical Design”, McGraw-
Hill,2006
2. Georg Henzold “Geometrical Dimensioning and Tolerancing for Design, Manufacturing and
Inspection-A Handbook for Geometrical Product Specification using ISO and ASME Standards”,
Elsevier, Second edition
3. Bryan R. Fischer “Mechanical Tolerance Stackup and Analysis” Advanced Dimensional
Management, Sherwood, Oregon, U.S.A., Marcel Dekker,Inc.
4. ASME “Dimensioning and Tolerancing”, Y14.5M-1994 [REVISION OF ANSI Y14.5M-1982
(RI98811)]

Department of Production Engineering 37

COMMON ELECTIVES WITH M.Tech. (IE&M)
PR654 MODELING AND SIMULATION
L T P C
2 1 0 3

COURSE OUTCOMES:
1.Develop Manufacturing Models of Discrete event systems
2.Generation of Uncertainty using Random numbers and Random Variates
3. Perform Input, Output Analysis: Verification & Valediction of Models and Optimization

Introduction to systems and modeling - discrete and continuous system - Monte Carlo
Simulation. Simulation of Single Server Queuing System. Simulation of manufacturing shop
Simulation of Inventory System

Random number generation Properties of Random Numbers –Generation of Pseudo Random

Numbers –Techniques –Tests for Random Numbers

Random variates-Inverse Transform Technique –Direct Transform Techniques Convolution

Method Acceptance Rejection Technique– Routines for Random Variate Generation

Testing -Analysis of simulation data-Input modeling – verification and validation of simulation

models – output analysis for a single model.

Simulation languages and packages-Case studies in WITNESS; FLEXSIM, ARENA,

SIMQUICK-Simulation based optimization-Modeling and Simulation with Petrinets-case studies
in manufacturing systems

References

1. Jerry Banks & John S.Carson, Barry L Nelson, “Discrete event system simulation” ,Prentice Hall
2. Law A.M, “Simulation Modelling and Analysis”, Tata Mc Graw Hill
3. NarsinghDeo, “ System Simulation with Digital Computer”, Prentice Hall
4. Pidd, M, “Computer Simulation in Management Science”, John Wiley & Sons, Inc.

Department of Production Engineering 38

 PR662 INTELLIGENT MANUFACTURING SYSTEMS

L T P C
3 0 0 3

COURSE OUTCOMES:

1. Apply various knowledge based techniques

2. Practice diagnosis and trouble shooting
3. Adopt intelligent system

Basic concepts of Artificial intelligence and expert systems - System Components - System
architecture and Data flow – System Operations.

Knowledge based systems - knowledge representation – knowledge acquisition and optimization

- Knowledge based approaches to design mechanical parts and mechansims and design for
automated assembly.

Knowledge based system for material selection – Intelligent process planning system. Intelligent
system for equipment selection - Intelligent system for project management & factory
monitoring.

Scheduling in manufacturing – scheduling the shop floor – Diagnosis & trouble shooting.

The role of Artificial Intelligence in the factory of the future – Intelligent systems.

References
1. Kenneth R.Baker, “Introduction to sequencing and scheduling”, John Wiley & Sons, New York,
2000.
2. Richard W. Conway, William L.Maxwell and Louis W. Miller,“Theory of Scheduling”, Dover
Publications, 2003.
3. Andrew Kussiak, “Intelligent Manufacturing Systems”, Prentice Hall, 1990.
4. Simons, G.L, “Introducing Artificial Intelligence”, NCC Pub, 1990.
5. Rich,E., “Artificial Intelligence”, McGraw Hill, 1986.

Department of Production Engineering 39

 PR 671 SUSTAINABLE MANUFACTURING
L T P C
3 0 0 3
COURSE OUTCOMES:
1. Explain the importance of sustainable development
2. Exhibit competence on the usage and applicability of sustainability tools
3. Compute sustainability performance through the indicators

Concepts of sustainability and sustainable development – Need for sustainable development -

Components of sustainability- Social, Economic, Environmental dimensions - Linkages between
technology and sustainability - Sustainable Manufacturing –Scope, Need and Benefits.

Tools and Techniques of Sustainable Manufacturing – Environmental Conscious Quality

Function Deployment, Life cycle assessment, Design for Environment, R3 and R6 cycles,
Design for Disassembly -Sustainable Product Development – Various Phases.

EIA Methods –CML, EI 95 and 99, ISO 14001 EMS and PAS 2050 standards, Environmental
Impact parameters - Interactions between energy and technology and their implications for
environment and sustainable development.

Design for recycling – Eco friendly product design methods – Methods to infuse sustainability in
early product design phases – Multi-Criteria Decision Making in Sustainability.

Frameworks for measuring sustainability- Indicators of sustainability – Environmental,

Economic, Societal and Business indicators - Concept Models and Various Approaches, Product
Sustainability and Risk/Benefit assessment– Corporate Social Responsibility.

LAB EXERCISES
Life Cycle Assessment of products using GaBi package
Sustainable Product Development – Developing environmentally friendlier products
References
1. G. Atkinson, S. Dietz, E. Neumayer, ― “Handbook of Sustainable Manufacturing”. Edward Elgar
Publishing Limited, 2007.
2. D. Rodick, “Industrial Development for the 21st Century: Sustainable Development Perspectives”, UN
New York, 2007.
3. Rogers, P.P., Jalal, K.F. and Boyd, J.A., “An Introduction to Sustainable Development”, Earthscan,
London, 2007.
4. P. Lawn, “Sustainable Development Indicators in Ecological Economics”, Edward Elgar Publishing
Limited.
5. S. Asefa, “The Economics of Sustainable Development”, W.E. Upjohn Institute for Employment
Research, 2005.

Department of Production Engineering 40

 PR672 PROJECT MANAGEMENT

L T P C
3 0 0 3
COURSE OUTCOMES:

1. Explain the methods for project identification & appraisal

2. Define and plan a project within the constraints of the environment
3. Develop & analyze quantitative models for project selection & scheduling

Introduction - Project Management: An Overview – Types, Characteristics of Projects – Project

life cycle. Identification of investment opportunities - Screening and Selection, Project
Appraisal,

Market and demand analysis- market survey-demand forecasting methods-Technical analysis –

manufacturing process, materials-product mix, plant location-project charts and layouts.

Financial analysis – cash flows for project appraisal- Investment evaluation using capital
budgeting techniques - net present value, profitability index internal rate of return, payback
period, accounting rate of return

Mathematical Techniques for project evaluation – Linear programming, goal programming,

Network technique for Project Management – CPM, PERT, Multiple projects and constraints,
scheduling.

Organization systems for project implementation- Work Breakdown-coordination and control-

Project Management Softwares

References

1. Prasanna Chandra, “Projects – Planning, Analysis, Financing, Implementation and Review”, Tata
McGraw Hill,4th Ed, 1997
2. S.Choudry “Project Management”, Tata McGraw Hill,27th Ed, 2006
3. John M Nicholas, “Project Management for Business and Technology”, 2nd edition, Pearson
Education Asia, 2001

Department of Production Engineering 41

 PR679 PRODUCT LIFE CYCLE MANAGEMENT
L T P C
3 0 0 3

COURSE OUTCOMES:
1. Recognize the importance of Product Life Cycle Management
2. Realize potential for Collaborative Product Development and digital manufacturing in
contemporary manufacturing applications
3. Competence to develop PLM strategy and conduct PLM assessment

Introduction to Product Life Cycle Management(PLM)- Definition, PLM Lifecycle model, Need
for PLM, Opportunities and benefits of PLM, Components and Phases of PLM, PLM feasibility
study

PLM Concepts, Processes and Workflow - Characteristics of PLM, Environment driving

PLM,PLM Elements, Drivers of PLM, Conceptualization, Design, Development, Validation,
Production, Support of PLM.

Collaborative Product Development- Engineering vaulting, product reuse, smart parts,

engineering change management, Bill of materials and process consistency, Digital mock-up and
prototype development, design for environment, virtual testing and validation, marketing
collateral

Digital Manufacturing – PLM Digital manufacturing, benefits manufacturing, manufacturing the

first-one, Ramp up, virtual learning curve, manufacturing the rest, production planning

Developing a PLM strategy and conducting a PLM assessment- Strategy, Impact of strategy,
implementing a PLM strategy, PLM initiatives to support corporate objectives. Infrastructure
assessment, assessment of current systems and applications

References
1. Antti Saaksvuori, Anselmi Immonen, “ Product Lifecycle Management”, Springer, 2005
2. John Stark, “Product lifecycle management: 21st century paradigm for product realization”,
Springer 2006 London, 3rd printing -2006. 441 pp., ISBN: 1-85233-810-5.
3. Michael Grieves, “Product lifecycle management: Driving the next generation of Lean thinking”,
McGraw-Hill, 2006
4. Kari Ulrich and Steven D. Eppinger, “Product Design & Development”, McGraw Hill
International Edition, 1999

Department of Production Engineering 42