pg subjects

Promoted by

Industries Commissionerate, Government of Gujarat

Proposed By: Anchor Institute Cell (Engg & Auto) Sardar Vallabhbhai National Institute of Technology, Ichchhanath, Surat 395 007 , Gujarat, India

September 2012 AIC‐CR‐PGS1 ANCHOR INSTITUTE FOR ENGINEERING & AUTO

REPORTCourse Curriculum Development & Restructuring

Master of Engineering

Course Curriculum Restructuring & Development of Advanced Thermodynamics & Heat Transfer (ME SEM I IC Engine & Auto)

September 2012

1Anchor Institute for Engineering & Auto, SVNIT‐Surat

Course Curriculum Development & Restructuring

Contents

1.0 Anchor Institute for Engineering & Auto 6

2.0 Need of Course curriculum Restructuring & Development 4

3.0 Course Curriculum after restructuring 5

3.1 Advanced Thermodynamics & Heat Transfer 8

3.2 IC Engineering for automobile 10

3.3 Automobile Air‐conditioning 12

3.4 Instrumentation & Vehicle Testing 14

3.5 Alternate Fuels and Energy 16

3.6 Modern Vehicle Design 18

3.7 Automobile Chassis & Body Engineering 19

3.8 High Speed Diesel Engine 20

3.9 Automobile Maintenance & Pollution Control 21

3.10 Hydraulic & Pneumatic systems in Automotive Vehicles 23

3.11 Advanced Machine Design 24

3.12 Computer Aided Production Management 26

3.13 Advanced Materials and Manufacturability 28

3.14 Mechanical Engineering for Mechatronics 31

3.15 Computer Aided Manufacturing 33

3.16 Robotic Engineering 35

3.17 Machine Tool Design 37

3.18 Rapid Prototyping and Tooling 39


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Anchor Institute for Engineering & Auto, SVNIT‐Surat


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1.0 ANCHOR INSTITUTE FOR ENGINEERING & AUTO Anchor Institute (Engineering & Auto), SVNIT‐Surat is supported by Industries Commissionerate, Department of Industries and Mines, Gujarat Government, Gandhinagar

The wide industrial base in Gujarat state is expected to increase significantly in near future due to the large new investments coming in as envisaged during Vibrant Gujarat Summits. One of the issues arising due to this will be regarding availability of necessary technical manpower as realized by the Industrial Commissionerate, Government of Gujarat, Gandhinagar, in spite of sufficient technical manpower coming out of the academic institutions. This is due to the fact that large fraction of the fresh graduates coming out from ITI, Polytechnics and Degree colleges are unemployable. The need for better quality and skilled technical manpower is increasing and will continue to increase in time to come.

The Industrial Commissionerate, Gandhinagar, has decided to tackle this issue through the training and skill development programmes for technical manpower to be conducted on massive scale by academic institutes which will be provided substantial part of necessary financial support for this purpose. These programmes are to be industry responsive which should provide readily employable manpower.

It is our pleasure to mention here that our institute is selected as a State Level Anchor Institute in the Engineering & Auto sector for this purpose. The selection was based on presentation made on November 7, 2007 by the invited institutes at Udyog Bhavan, Gandhinagar. The basic motive for Anchor Institute is to take various initiatives in creating readily employable and industry responsive Man Power, at all level, across the state. This includes preparing Course curriculum and benchmarking and Training for the Trainers/Faculties. The input from industries in terms of training area needs, trained technical manpower requirements, any other suggestions and providing guest faculties as per the availability when needed for this purpose will be of immense help to make this noble effort a grand success.

Accordingly Industrial Policy, 2009 of Government has laid emphasis on the expansion of a skilled and educated manpower base. Addressing the specific objective of providing need‐based, industry responsive managerially and technically competent manpower at various levels along with the need of benchmarking the courses, Government has issued GR no. CED‐112007/2081(1)/I dated 27.2.2009 on Scheme to establish and operationalize Anchor institutes in various sectors.


September 2012



2.0 NEED FOR COURSE RESTRUCTURING & DEVELOPMENT There are global challenges before the engineering & Auto industries.

Gujarat’s excellent trade and transportation networks create better market access and trade flows for companies.

Highly industrialized state, with more than 38 % of GDP contributed by secondary sector

12 Special Investment Regions of more than 100 sq km each being planned. 40 % of the planned Delhi Mumbai Industrial Corridor route is through Gujarat. 9,607 Industrial Entrepreneurs Memoranda (IEM) filed till June 2010 with an

estimated investment of Rs 7,702 billion and employment potential of 1,941,374 Engineering products where Gujarat’s share is greater than 10% in India include:

Sponge Iron, Electric Motors, Compressors, Steel Pipes, Ball and Roller Bearings, Construction Machinery, Casting Copper Rods, Textile Machinery, Transmission line Towers, TV Picture Tubes, Submersible Pumps, Environment Control Equipment, Gears

Ahmedabad, Anand, Rajkot, Vadodara, Surendranagar, Jamnagar, Mehsana, Panchmahal and Kutch have emerged as important locations of Engineering Industries.

Hence to archive all these goals, there is an urgent need of up‐gradation of syllabus in relevance with the globalization and modernization. This will not only benefit the academics but also enhance the quality of workmanship as desired by the developers who employee these graduates.


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3.0 COURSE CURRICULUM AFTER RESTRUCTURING

3.1 ADVANCED THERMODYNAMICS & HEAT TRANSFER

This subject is offered in GTU ME Mechanical I Semester.

3.1.1 SYLLABUS

SN Course Contents Hrs.

1 Concept of Entropy:

1st & 2nd law analysis. 1st law applied to open & closed systems. 2nd law applied to open & closed system – Entropy generation, concept of energy.

11

2 Equilibrium Diagrams:

Phase equilibrium, phase rule without chemical reaction, chemical potential of ideal gases, T‐ds equations for simple compressible systems, Helmholtz and Gibbs functions, Maxwell relations; generalized relations for changes in enthalpy, entropy and internal energy, equations for specific heats; Clausius Clapeyron equation, Joule‐Thomson and Joule coefficients, and applications of thermodynamic relations.

13

3 Conduction heat transfer:

steady state one & two dimensional heat transfer with & without internal heat generation Extended surface heat transfer, Enhancement technique in heat transfer system.

10

4 Convection heat transfer:

Natural & Forced conduction Correlations Laminar & turbulent flow heat transfer for external & Internal flows Radiation heat transfer – principles, loss of black body radiation , concept of gray body, radiation thermal n/w analysis, Radiation through non‐absorbing media; Hottel’s method of successive reflections.

11

TOTAL 45

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3.1.2 REFERENCE BOOKS

1. Moran M.J. & Shapiro H.M., “Fundamentals of Engineering Thermodynamics”, John Wiley, 2007.

2. Gordon R. & Yon M., “Engineering Thermodynamics work and heat Transfer”, Addison‐Wesley, 2001.

3. Cengel Y.A. & Boles M.A., “Thermodynamics an Engineering Approach”, Tata McGraw‐Hill, 2007.

4. Van Wylen, G.J. & Sonntag, re., “Fundamentals of Classical Thermodynamics”, John Wiley, 1986.

5. Wark K. Jr. & Donald E.R., Thermodynamics”, McGraw Hill, 6th Edition, 1999. 6. Rohsenow and Choi, “Heat Mass and Momentum transfer”, Prentice Hall, 2010. 7. Grober, Erk and Grigull, “Fundamentals of Heat Transfer”, McGraw Hill, 2008. 8. Eckert and Drake, “Analysis of Heat and Mass Transfer”, McGraw Hill, 2007. 9. Siegel and Howell, “Thermal Radiation”, McGraw Hill, 4th Edition, 2001. 10. Jones & Dugan, “Engineering Thermodynamics”. 11. Nag P.K., “Engineering Thermodynamics”, Parmagon Press London, 2005. 12. Kalyan Annamalai & Puri I.K., “Advanced thermodynamics engineering”, CRC

Press, 2007. 13. Kreith F., “Handbook of Thermal Engineering”, CRC Press, Springer, 2000.


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3.2 IC ENGINEERING FOR AUTOMOBILE.


3.2.1 SYLLABUS


1 IC Engines:

IC Engineering system‐types & their operations, Actual cycle; air fuel cycle; combustion charts (Equilibrium); Two stroke engines; four stroke engine; characteristics of engines; air capacity of engine; and valve timing diagram.

8

2 Construction of Engines:

Engine Components, Material, construction and design aspects; piston assembly; connecting rod; crankshaft; cylinder head; cylinder block; flywheel, ports; valves; valve actuating mechanism; cams; camshaft drives; and vibration damper.

9

3 Fuel Supply in SI Engines:

Carburetion and mixture requirements; Transfer pump; Carburetors ‐ types, constructional and design aspects; Mixture distribution and inlet manifold; The concept of multipoint fuel injection system, Fuel Supply in CI Engines; Injection system components; Jerk and Distributor pumps; Mechanical and Pneumatic governors; and Injectors.

10

4 Stratified Charging:

Low heat rejection engine; four / three valve engine; OHC engine; MPFI; VVT; cam less engine; New engine technology; and recent developments in I. C. engines.

7

6 Automotive electrical system:

Basic transmission systems; suspension systems; steering systems; tyre and wheel; handling and maintenance; troubleshooting and repairs.

6

7 Automotive Electronics:

Fundamentals of Automotive Electronics, Microprocessor and micro computer applications in automobiles, Components for engine management system.

5

TOTAL 45

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3.2.2 LIST OF PRACTICALS:

1. Testing of Internal combustion engine according to Indian and International standards.

2. Study and Performance analysis of two stroke Petrol Engine. 3. Study and Performance analysis of four stroke Petrol Engine. 4. Study and Performance analysis of four stroke Diesel Engine. 5. To Study various engine components, material and design aspects. 6. Study of MPFI and CRDI systems 7. Study of ignition , cooling, lubrication systems 8. Study of clutch and Transmission systems 9. Study of automotive brakes , suspension and steering systems 10. Study of Recent developments in the field of I.C. Engine and Automobile 11. Group Discussion / Technical Debate on advanced topic.


1. Heywood John B., “Internal Combustion Engines Fundamentals “, McGraw Hill, 1988.

2. Heister H., “Vehicle and Engine Technology”. 3. Stone Richard, “Introduction to Internal Combustion Engines”, McMillan

London, 1999. 4. Taylor C. F. & Edward S. T., “IC Engines”, International text book com, 1988. 5. Obert E. F. and Harper, “IC Engine & Air Pollution”, Row Publishers, ,New York,

2011. 6. Herbert E., “Automotive Engines”, Ellinger, 1988. 7. Young, Griffitns, “Automobile Electrical & Electronic Equipments” Butterworths,

London, 2012. 8. Hilliers V.A.W., “Fundamentals of Automotive Electronics”, Hatchin, London.


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12

3.3 AUTOMOBILE AIR‐CONDITIONING.

This subject is offered in GTU ME Mechanical I Sem.

3.3.1 SYLLABUS


1 Refrigeration Systems:

Vapour compression refrigeration system for automobile AC‐ Refrigerant, Classification, properties, selection criteria, commonly used refrigerants, alternative refrigerants, eco‐friendly refrigerants, applications of refrigerants, and refrigerants used in automobile air conditioning.

9

2 Air conditioning for passengers; isolated vehicles, transport vehicles; applications related with very low temperatures.

6

3 Psychrometry:

definitions and processes; Application of psychrometric processes of summer and winter air conditioning air conditioning load calculations, factors forming the load on air conditioning systems; cooling & heating load calculations; load calculations for automobiles, effect of air conditioning load on engine performance.

10

4 Air conditioning:

AC system components, compressors, evaporators, condensers, expansion devices, fan blowers, heating systems, Automotive heaters, Control used in AC system, Air conditioning protection, Engine protection, Distribution duct system, sizing, supply / return ducts, type of grills, diffusers, ventilation, air noise level, layout of duct systems for automobiles and their impact on load calculations.

11

6 Air Conditioning Service:

Air conditioner maintenance & service; servicing heater system, removing & replacing components; trouble shooting of air conditioning system, compressor service; methods of dehydration, charging & testing, Air Conditioning Control : Common control such as thermostats, humidistat, control dampers, pressure cutouts and relay.

9

TOTAL 45

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3.3.2 REFERENCE BOOKS:

1. “Heating & Air Conditioning Systems”, Mitchell Information Service, 2007. 2. Paul L., “Automotive Air Conditioning”, C.B.S. Publisher & Distributor, Delhi, 2003. 3. Harris, “Modern Air Conditioning”, McGraw Hill, 1983. 4. ASHRAE Handbook – 1985 Fundamentals (2nd volume application is to be included) 5. Crouse W. H. & Anglin D.L., “Automotive Air Conditioning”, McGraw Hill, 1990. 6. Mitchell Information Services, Inc., “Mitchell Automatic Heating & Air Conditioning Systems", Prentice Hall, Inc. 1989.

7. Weisler P., “Automotive Air Conditioning”, Reston Publishing Co., 1990. 8. Arora and Domkundwar, “A text book of Refrigeration and Air conditioning”.


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3.4 INSTRUMENTATION & VEHICLE TESTING.

This subject is offered in GTU ME Mechanical II Semester.

3.4.1 SYLLABUS


1 Planning of Measurement; Instrumentation; Selection of measuring instrument, precision, accuracy, errors, sensitivity, readability and reliability; Measurement of thermo‐physical properties; Devices to measure temperature and pressure of the working fluid, coolant, air and fuel flow into the engine, and Uncertainty analysis

10

2 Indicating and recording instruments:

Vibrometer, Accelerometer, vibration and pressure pickups, vibration test methods, Counters, stroboscopes, charge amplifiers, cathode ray oscillographs, and FFT analyzer.

8

3 Warning and alarm instruments:

Brake actuation warning system; traficators, flash system; oil pressure warning system, engine over heat warning system, air pressure warning system, speed warning system, door lock indicators, gear neutral indicator; horn design, permanent magnet horn, air & music horns, safety air bag and latest developments.

10

4 Data acquisition and processing:

General data acquisition system examples, storage, processing, recording and display devices.

8

5 ISI codes for testing automotive engines, Laboratory dynamometer testing systems of power train and vehicle under simulated conditions, Instrumentation for testing vehicles, road test of automobile vehicles, wheel alignment, balancing, PUC test of vehicles; preparation of test reports, EURO standards, and various Bharat stages.

9

TOTAL 45

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September 2012




1. Study of Garage layouts, Workshop management and Automotive service equipments.

2. Cleaning and Testing of a Petrol Injector on MPFI test bench. 3. Calibration and Phasing of Diesel Fuel Injection Pump on Fuel Pump test bench. 4. Study working principle and perform operation of (a) Four post hoist (b)

Electronic air inflator (c) Tyre changer (d) Car Washer. 5. Overhauling of Carburettor. 6. Overhauling of Gearbox 7. Balancing of a wheel using Wheel balancer and Alignment measurement 8. Inspection and service of an Air conditioning system of a car using AC recovery

unit and UV leak detector. 9. Tutorial :

a. Maintenance schedule chart for service of a car. b. Service procedure for any car with necessary steps.

10. Visit of well equipped Automobile workshop.


1. Doeblin E.O., “Engineering Experimentation”. 2. Holman J.P., “Experimental Methods for Engineers”, McGraw Hill Book Co, 1977. 3. Doeblin E.O., “Measurement Systems, Applications & Design”, McGraw Hill Book

Co., 1994. 4. Andrews W.G., “Applied Instrumentation in Process Industries”, Andrew Williams,

2009.


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3.5 ALTERNATE FUELS AND ENERGY.


3.5.1 SYLLABUS


1 Types OF Fuels:

Conventional fuels, Estimation of conventional fuels, advantages and disadvantages of conventional fuels, Need for Alternate fuel, Availability and Comparative properties of Alternate fuels, Use of Alcohols, LPG, Hydrogen, CNG and LNG, Vegetable oils and Biogas in Automotive Engines, Relative merits and demerits of various alternate fuels.

9

2 Processing of Alcohols:

Production of Alcohols, Properties as engine fuels Alcohols and Gasoline blends, Performance in S. I. Engines: Methanol and gasoline blends, Effect of compression ratio, Alcohols in Stratified charge engines, Combustion characteristics in engines, Reformed alcohols use in CI Engines, Ignition accelerators, Alcohol Diesel emulsions, Dual fuel systems and Engine system compatibility.

10

3 BioFuels:

Various vegetable oils for engines, Esterification Performance in engines, Biodiesel in engines, Performance and Emission characteristics, Shale oil, coal liquid and Tars and fuel, Performance and Emission characteristics and Engine system compatibility.

9

4 Availability of CNG, Properties; Modification required to use in Engines, Performance and Emission characteristics of CNG, LPG & Biogas in SI and CI Engines, Performance and Emission data for LPG, Hydrogen Production methods, Storage and handling, Performance, Safety aspects.

8

5 Layout of an electric vehicle, Advantages and limitation, specifications, System components, Electronic control system, High energy and power density batteries, Hybrid vehicles, Solar energy based vehicles, Hydrogen energy based vehicles, Latest development.

9

TOTAL 45

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1. Testing of Internal combustion engine according to Indian and International standards.

2. Study the properties of conventional fuels and Need for an alternative fuels. 3. Study of measurement technique as per ASTM and measurement of different fuel

properties. 4. Performance test on a 4 stroke 4 cylinder diesel engine with different blends of a

biodiesel. 5. Study of Hydrogen as an alternate fuel for auto vehicle. 6. Study of an Electric & Hybrid Car. 7. Case study on performance of a dual fuel engine using LPG‐Diesel fuel and study of

a LPG vehicle. 8. Study of a CNG as a substitute fuel for an I.C. engine. 9. Group Discussion or Technical quiz.


1. Bechtold R., “Alternate fuels guide book”, SAE, 1987. 2. Duffie & Beckman, “Solar Engineering of Thermal Processes”, John Wiley, 1991. 3. Bungay, “Energy, the Biomass Option”, John Wiley. 4. Lysen, “Introduction to Wind Energy Technology “, Georgia Inst., 1983. 5. Doolittle, “Energy”, Matrix Pub. 6. Fowler, “Energy & Environment”, McGraw Hill, 2004. 7. Knothe G., “Biodiesel Handbook”, 2010. 8. Dr. Thipse, “Alternate Flues” Jaico publication, 2010.


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3.6 MODERN VEHICLE DESIGN


3.6.1 SYLLABUS


1 Engine Components:

Material, construction and design aspects of engine components; Determination of engine power, Engine selection‐swept volume, stroke, bore & no. of cylinders; and arrangement of cylinders stroke to bore ratio.

10

2 Design procedure and considerations:

material selection & actual design of components; cylinder block deign; Design of Piston, piston assembly, Cylinder, Cylinder liner, Cylinder head, Combustion Chamber, Connecting rod, Crank Shaft, Fly Wheel, valves, valve actuating mechanism, cams, camshaft drives, vibration damper, Gearbox design, Constant‐mesh gearboxes, synchro‐mesh gearboxes and heavy vehicle gearboxes.

11

3 Design of couplings:

design fluid couplings; torque converter, differential axle, Suspension system design, Tandem axle suspension, adaptive suspension system, shock dampers, Steering system design – power assisted steering and four wheel steering system.

12

4 Design of Brakes: Hydraulic brakes, air and endurance brake, antilock brakes; vehicle structure, chassis frames, Principle of vehicle Aerodynamics, Aerodynamic design of vehicle and latest developments.

9

5 Stress analysis on Automobile Components. 3

TOTAL 45

3.6.2 REFERENCE BOOKS 1. Reimpell J., “The Automotive Chassis – Engineering Principles”, SAE, 2011. 2. Lukin P., Gasparyarts G, Rodionov V, “Automotive Chassis – Design & Calculation”,

MIR Publishing, Moskow. 3. Heldt P. M., “Automotive Chassis”, Chilton Co. NY, 1999. 4. Heldt W., “Mechanics for Road Vehicles”, ILiffe Books Ltd., London. 5. Kolchin and Demodov, “Design of Automotive engines”, Mir Publishers, 1984. 6. Giles J.G., “Automotive design“, SAE, 1968.

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September 2012



3.7 AUTOMOBILE CHASSIS & BODY ENGINEERING

This subject is offered in GTU ME Mechanical II Sem.

3.7.1 SYLLABUS


1 Vehicle Aerodynamics:

Objects‐ vehicle drag and types; various types of forces and moments; effects of forces and moments; various body optimization techniques for minimum drag; principle of wind tunnel technology, flow visualization techniques and tests with scale models.

15

2 Details of Vehicle Body:

Types, visibility, regulation, driver’s visibility, methods of improving visibility, safety design, constructional details of roof, under floor, bonnet, boot, wings, Classification of coach work etc.

14

3 Design of Vehicle Bodies:

Vehicle body materials, Layout of the design, preliminary design, safety, Idealized structure, structural surface, shear panel method, symmetric and asymmetrical vertical loads, longitudinal loads, different loading situations, load distribution on vehicle structure, Calculation of loading cases, stress analysis of heavy vehicles body structure under bending and torsion, Design of chassis frame; Rules and regulations, Recent safety measures and Testing.

16

TOTAL 45


1. Pawloski J., “Vehicle Body Engineering “, Business Books Ltd, 1980. 2. Reimpell J., “The Automotive Chassis: Engineering Principles”. 3. Fenton J., “Vehicle Body Layout and Analysis”, Mechanical Engineering

Publications Ltd. London, 1980. 4. Giles J.G., “Body Construction and Design”, ILiffe Books, Butterworth and Co., 1971.

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3.8 HIGH SPEED DIESEL ENGINE


3.8.1 SYLLABUS


1 Thermodynamic cycles for diesel engine (Ideal and actual):

various losses, limitations; compression ratio, Combustion in diesel engine, various stages, Delay period and different factors affecting it, its influence on performance and various performance parameters.

9

2 Introduction of combustion:

Chamber in diesel engine, combustion chamber requirements, necessity and types of air motion, Swirl flow, swirl ratio, selection of method of swirl, types of swirl, Types, design and constructional features and relative merits of open, pre‐combustion, swirl, air cell and energy cell combustion chamber, M‐combustion chamber, and latest combustion chamber.

10

3 Functions of components:

Plunger and distributor pumps, pressure valves, Fuel injector, types of injection nozzle, spray characteristics, valve opening and closing pressures, quantity and duration of fuel injection, injection timing and nozzle cooling.

9

4 Supercharging and Turbo charging of diesel engine:

Necessity and limitations, supercharging methods, relative merits, turbo charging methods, turbocharger selection.

8

5 Performance and maintenance of diesel engine:

Piston cooling, Engine with different types of combustion chamber, Multi fuel engines, pilot injection, special features of agricultural and industrial engines.

9

TOTAL 45

3.8.2 REFERENCE BOOKS 1. Maleev V.L., “Diesel Engine Operation and Maintenance”, Mir Publishers, 1954. 2. Stone Richard, “Introduction to Internal Combustion Engines”, McMillan, London,

1999. 3. Heyhood J.B., “Internal Combustion Engines Fundamentals”, McGraw Hill, 1988. 4. Judge A.W., “High Speed Diesel Engines”, Chapman and Hall, 1967. 5. Heldt P.M., “high Speed Diesel Engines”, Clinton Co., 1956. 6. Lichty, “Combustion engine processes”. 7. Vincent, “Supercharging”.

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September 2012



3.9 AUTOMOBILE MAINTENANCE & POLLUTION CONTROL

This subject is offered in GTU ME Mechanical II Sem.

3.9.1 SYLLABUS


1 Engine Maintenance:

Engine troubles, effects & remedies, different major & minor services for engine, inspection and checking of components visually and dimensionally, reconditioning methods of engine components, engine tune‐up, special tools and advanced equipments.

9

2 Chassis Diveline Maintenance:

Maintenance, repair and servicing of clutches, Fluid flywheel, gear boxes, Automatic transmission, CVT unit, propeller shaft, differential unit, front axle and rear axle, suspension systems, servicing of brake systems‐ hydraulic, air systems, brake bleeding and brakes adjustments, maintenance and servicing of steering system‐Manual & Power Steering system, wheel balancing, wheel alignment, maintenance of tyres, tyre rotation, frame defects and chassis frame alignment.

11

3 Maintenance, servicing of auxiliaries:

Cooling system service, anti corrosion additives, anti freezing solutions, dry & wet liners, Petrol fuel and diesel fuel system maintenance, MPFI maintenance, lubrication system services, Chassis lubrication, lubrication chart, maintenance and care of storage batteries, battery testing methods, maintenance of ignition systems, tyre service and reconditioning.

10

4 Air Pollution due to Automobile Exhaust:

Sources of Emission, Exhaust gas constituents & analysis, Ingredients responsible for air pollution, Smoke, odor, Smog formation and sources of pollution,

7

5 Exhaust Emission Control:

Basic method of emission control, catalytic converter, After burners, diesel particulate trap (DPT), reactor manifold, air injection, crank case emission control, evaporative loss control, Exhaust gas recirculation, Fuel additives. Pollution Norms: European pollution norms, Indian pollution norms as per Central Motor Vehicle Rules (C.M.V.R.) and Real world emission.

8

TOTAL 45

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1. W. Steed, “Mechanics of Road Vehicles”, ILiffe Books Ltd. London, 1960. 2. Heldt P. M., “Automotive Chassis”, SAE, 1952. 3. Litchy, “I. C. Engine”. 4. Richard Stone, “Introduction to Internal Combustion Engines”, McMillan, London,

1999. 5. Hein H., “Advance Vehicle Technology”, Edward Arnold, 2002. 6. Fisher C.A., “S. I. Engine – Fuel Injection Development”, Chapman & Hall, 2001. 7. Herbert E., “Automotive Engines”, Ellinge, 1974. 8. American Technical Society, “Automobile Engineering Volume – I”, Chicago, 2009. 9. Heyhood J.B., “Internal Combustion Engines Fundamentals”, McGraw Hill, 1988. 10. Peavy H.S., Rowe D.R., “Environmental Engineering”, McGraw Hill Book Company,

New York, 2009. 11. Masters G., “Introduction to Environmental Engineering and Science”, Prentice‐

Hall International Editions, 2004. 12. Environmental Considerations in Energy Development, Asian Development Bank

(ADB) Manila.


September 2012



3.10 HYDRAULIC & PNEUMATIC SYSTEMS IN AUTOMOTIVE VEHICLES

This subject is offered in GTU ME Mechanical IV Semester.

3.10.1 SYLLABUS


1 Fluid Power:

Its nature, advantages and disadvantages, Hydrostatic transmission systems, working principle, construction and Characteristics of positive displacement pumps, linear and rotary actuators. Comparison between mechanical, electrical, hydraulic and pneumatic power transmission

16

2 Properties and selection of hydraulic fluids, Hydraulic symbols, Filtration, hydraulic reservoirs

12

3 Working principle and construction of flow Control Valves:

Directional control, pressure control, flow control, electro‐hydraulic servo valves, and proportional valves. Hydraulic accessories like accumulators, Intensifiers in hydraulic control systems. Design considerations of hydraulic power transmission systems. Systems and their dynamic performances. Pneumatic drives, Fluidics, Fluidic elements and their industrial applications in automobiles.

17

TOTAL 45


1. Mc Cloy D., ‘Control of Fluid Power Analysis and Design” Ellis Horwood Ltd., 1980. 2. Goodwin A. B., “Fluid Power Systems”, McMillan Pub. Co., 1999. 3. Anderson B. W., “The Analysis & Design of Pneumatic Systems”, John Wiley, 1971.

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24

3.11 ADVANCED MACHINE DESIGN


3.11.1 SYLLABUS


1 Design Concepts:

General design procedure for design problems, design concepts, product design and development, Product design specifications, Product life cycle, Protection of intellectual property, Bench marking, Brainstorming, Ethics in Engineering design and whistle blowing.

7

2 Design Considerations:

Design for strength & rigidity, Design based on ‐ Fatigue, Fracture, Creep criteria, and safe life v/s fail safe design.

3

3 Dynamic design of Mechanical equipments:

Modeling of machine tools, Aircraft and Automobiles etc. for determining dynamic characteristics and extraction of Modal parameters for dynamic design.

4

4 Reliability in Design:

Design for manufacturing including assembly aspects & other aspects, and reliability based design of mechanical components.

4

5 Pressure Vessel Design:

Recent developments in pressure vessel design, testing of pressure vessels as per standards, Computer aided design of pressure vessels.

3

6 Rotating disc and rotating cylinder:

Disc with uniform thickness – disc for uniform strength – stresses in rotating cylinders with and without internal pressure.

6

7 Creep:

Thermal stress, creep and stress rupture; Dynamic and fatigue behavior.

2

8 Material Handling:

Recent trends in materials handling equipment design, basic principles of design, main girder design, structure analysis , loading patterns, service factors and environmental conditions, testing as per BIS, etc.

7

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September 2012



9 Gear Design:

Advances in gear design, gear materials, corrective gear design, gear rating calculation as per BIS, etc.

5

10 Quality Aspects:

Quality Function Deployment – Concurrent engineering.

4

TOTAL 45


1. Robert L.N., “Machine Design”, an Integrated Approach, Pearson Education, 2000. 2. Haidery F., “Mechanical System Design” 3. George E.D., “Engineering Design”, McGraw Hill, 2008. 4. Rudenko P., “Material handling equipment”, MIR Publication, 1967. 5. Maitra G.M., “Handbook of Gear design”, Vol. –I & II, Tata McGraw Hill, 2001. 6. Burr and Cheatham, “Mechanical analysis & design”. 7. Rao S.S., “Mechanical Vibrations”. 8. Bednar, “Pressure Vessel Design”, 2009. 9. Joshi, “Process Equipment Design”, 2004.


September 2012



26

3.12 COMPUTER AIDED PRODUCTION MANAGEMENT


3.12.1 SYLLABUS


1 Computer Aided Forecasting:

Nature and use of forecast, sources of data, demand patterns, forecasting methods – Delphy’s method, Time series method, exponential smoothing, linear regression, Box Jerkin’s method, selection of forecasting technique, measurement of forecast Accuracy‐ MAD, and Adoptive methods.

6

2 Layout Planning:

Computerized relative allocation of facility technique, automated layout design program and computerized relationship layout planning for facility location and layout.

4

3 Group Technology:

Introduction, objectives part families, algorithms and models for G.T. ‐ Rank order clustering, Bond energy, mathematical model for machine – component cell formation. Design and manufacturing attributes. Parts classification and coding, concept of composite job machine group, cell group tooling, design rationalization, CAD/CAM and GT benefits.

7

4 Computer Aided Process Planning:

Generative and variant types, backward and forward approach, feature based and CAD based CAPP, and Operation Management.

4

5 MRP:

Introduction, Objective, Input, Computational procedure, information provided by the system. Aggregate planning, Detailed capacity planning, manufacturing resources planning, MRP‐II and master production schedule.

6

6 ERP:

Introduction, main features, generic model of ERP system, selection of ERP, proof of concept approach, analytic hierarchy approach and ERP implementation.

5

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September 2012



7 Job Allocation:

Job Sequencings, scheduling.

2

8 Shop Floor Control:

Data collection, source of data, computer generated time standard, Priority Sequencing, and Machine Allocation and Data information sources.

3

9 Computer Aided Inspection & Quality Control:

Computer Aided Testing, Contact and non‐contact type measurements.

2

10 Simulation:

Major activities, purpose, simulation process, types methodology, simulation packages, process quality simulator, computer requirements trends and applications simulation of machine shop.

6

TOTAL 45

3.12.2 REFERENCE BOOKS 1. Chien Chang and Richard A.W., “Computer Aided Manufacture”, Prentice Hall,

1987. 2. Groover M.P. & Zimmers, “CAD / CAM”, Pearson Education, 1980. 3. Burbridge, “G.T in the engineering industry”. 4. Buffa & Sarin, “Modern Production Management”. 5. Mahapatra P.B., “Computer Aided Production Management”. 6. Adam E., “Production Operation Management”, 1992. 7. Radhakrishnan P., Subramanyan S, “CAD / CAM / CIM”, New Age International,

Second Edition, 2008.


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28

3.13 ADVANCED MATERIALS AND MANUFACTURABILITY


3.13.1 SYLLABUS


1 ADVANCED MATERIALS:

Piezoelectric materials, Advanced magnetic materials, Advanced engineering polymer materials, Advanced ceramic and composite materials, photo conducting and photovoltaic materials, electro‐optic materials, Lasers and smart materials.

4

2 PROCESSING OF MATERIALS:

Conventional processing techniques for advanced materials, special processing techniques and use of computers in metal processing.

2

3 DESIGN:

Introduction to design philosophy – steps in design process – General design rules for manufacturability – basic principles of designing for economical production – creativity in design.

3

4 MATERIALS:

Selection of Materials for design – Developments in Material technology –criteria for material selection – Material selection interrelationship with process selection – process selection charts.

2

5 MACHINING PROCESS:

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 and general design recommendations for machined parts

3

6 METAL CASTING:

Appraisal of various casting processes, selection of casting process, ‐ general design considerations for casting – casting tolerances – use of solidification simulation in casting design – product design rules for sand casting and die‐casting.

4

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7 METAL JOINING:

Appraisal of various traditional & newer welding & joining processes, selection approaches , Factors in design of weldments – general design guidelines – pre and post treatment of welds – effects of thermal stresses in weld joints and design of brazed joints

4

8 FORGINGS:

Design factors for Forging – Closed die forging design – parting lines of dies – drop forging die design and general design recommendations.

3

9 EXTRUSION & SHEET METAL WORK:

Design guidelines for extruded sections ‐ design principles for Punching, Blanking, Bending, Deep Drawing – Keeler Goodman Forming Line Diagram and Component Design for Blanking

3

10 PLASTICS:

Viscoelastic and creep behavior in plastics – Design guidelines for Plastic components – Design considerations for Injection Moulding – Design guidelines for machining and joining of plastics

2

11 STRUCTURE – PROPERTY RELATIONSHIP:

Atomic structure & Chemical bonding, Crystalline & Network structure, Grain structure, Grain deformation & Anisotropic properties, Properties of material, Physical, Chemical, Electrical, Thermal and Mechanical properties.

3

12 THERMAL PROPERTIES OF MATERIALS :

Specific Heat: Classical, Einstein‐Debye theory, Inharmonic crystal imperfections, Electronic specific heat, Thermal Expansion, Hypothetical & Actual Energy Curves. Thermal Conductivity and Wridemann – Franz ratio.

3

13 PERFORMANCE OF MATERIALS IN SERVICE:

Performance based on – static properties, dynamic properties and temperature effect, methods of testing and interpretation of test results.

2

14 THEORY OF ELASTICITY AND PLASTICITY:

Fundamentals‐ Methods – Yield surface.

1


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15 ADVANCED MATERIALS:

Super alloys, Ferro electric and piezoelectric materials, Advanced magnetic materials, Advanced engineering polymer materials, Advanced ceramic and composite materials, photo conducting and photovoltaic materials, electro‐optic materials, Lasers, smart materials. Biomaterials – Determining mechanical properties and their applications and Recent trends in Bio‐Material Characterization.

4

16 PERFORMANCE OF MATERIALS IN SERVICE:

Service performance, corrosion and its control, Delayed fracture, Performance of materials at High and low temperatures, Radiation damage and recovery

2

TOTAL 45


1. Cobert J., “Wesley Design for Manufacture”, Adisson 1995. 2. ASM Handbook, Vol.20, 2003. 3. Chitale A.K. and Gupta R.C., “Product design and Manufacturing”. Prentice – Hall of

India, New Delhi, 2003. 4. Surender K. & Sutradhar G., “Design and Manufacturing”, Oxford & IBH Publishing

Co. Pvt. Ltd., New Delhi, 1998. 5. Shackelford J.F. & Madanapalli K., “Material Science for engineers”, Muralidharan,

Pearson Education, 2007. 6. Laurence H., Van Vlack, ”Elements of Material Science”, Sixth edition, Pearson

Education, 6th edition, 2002. 7. George E.D., “Engineering Design‐ A Material and Processing Approach”, McGraw

Hill Intl., 2nd Edition, 2000. 8. Timoshenko, “Theory of Elasticity and Plasticity”, PDF edition, 2007. 9. Flinn R. A. & Trojan P. K., “Engineering Materials & Their Applications”. 10. Degarmo E.P. & Black J.I., “Materials & Process in Manufacturing”. 11. Newey C. & Weaver G., “Materials, Principles & Practice”. 12. Callister W.D., “Material Science & Engineering”, Prentice Hall, New Delhi, 2009.


September 2012



3.14 MECHANICAL ENGINEERING FOR MECHATRONICS


3.14.1 SYLLABUS


1 Introduction to Mechatronics:

Origin and evaluation, definition, multidisciplinary scenario, need in industry, objectives, design of Mechatronics systems, modules in the system, Mechatronics technology, Mechatronics and engineering skills, overview, system and Mechatronics, measurement system, microprocessor based controllers, engine management system, automatic camera, automatic washing machine and automatic bathroom scale.

8

2 Overview of Sensors and Transducers:

Definitions, classification, performance parameters, pressure sensors and flow sensors, Hall effect sensors, light sensors, proximity sensors, optical sensor and desirable features of sensors and transducers and machine Vision.

6

3 Hydraulic System:

Actuators, Hydraulic Cylinders and their types, Hydraulic Motors and their types, Valves and their types, symbols for Hydraulic System Components, general hydraulic circuit, different types of hydraulic circuits and hydrostatic transmission.

7

4 Pneumatic Systems:

Introduction to pneumatics, gas laws, compressed air generation and contamination control, pneumatic actuators, valves and control circuits, multiple‐actuators circuits, pneumatic applications, maintenance, trouble shooting and safety.

8

5 System Models:

Elements of mechanical systems, spring mass damper system, an unconventional Approach, arrangement and application of mechanical elements, elements of Electrical Engineering, unconventional solution to RLC circuit, application of DC Servomotor, Hydraulic System Modeling, Modeling of actuators and control valves and Thermal Systems and their Modeling.

11

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6 MECHATRONICS:

Digital Logic and Logic Families, Micro‐controllers and Programming, Parallel I/O and Interrupt Mechanism, Sensors and their Interface.

5

TOTAL 45

3.14.2 LIST OF PRACTICALS

1. Introduction to Mechatronics. 2. Knowledge of mechanical engineering required for Mechatronics. 3. Overview of sensors and transducers. 4. Hydraulic system and its components. 5. Prepare hydraulic circuit for given application. 6. Pneumatic system and its components. 7. Prepare pneumatic circuit for given application. 8. Preparation of system models. 9. Machine Tools and their components. 10. Design of machine tool component.


1. Hegde G.S., “Mechatronics”, Published, University Science Press (An imprint of Laxmi Publication Private Limited), 2008.

2. H.M.T., Ltd., “Mechatronics”, Tata McGraw Hill Publication Co. Ltd, 2007. 3. Joji P., “Pneumatic Controls”, Wiley India Private Limited, 2008. 4. “Mechatronics‐ Integrated Technologies for Intelligent Machines”, Pandit E‐

Library.


September 2012



3.15 COMPUTER AIDED MANUFACTURING


3.15.1 SYLLABUS


1 NC / CNC Machines: Numerical Controls, types, evolution of controllers, Programmable Logic Controllers, components of NC/CNC system, specification of CNC system. Classification of NC /CNC machines, transducers used, salient features, axis designation, NC/CNC tooling ‐Fundamentals of manual part programming , types of format, word address format manual part programming for drilling, lathe and milling machine operations, subroutines, do loops, canned cycles, parametric sub routines, and Macros.

Computer assisted part programming:

Need, list of computer assisted programming languages, Automated Programmed Tools language‐ types of statement, command and programming‐CAD based CNC programming using CAM software.

16

2 Flexible Manufacturing System:

FMS definition and description need of FMS. General FMS Considerations, objective, management commitment and planning, types of FMS, main elements of FMS, flexibilities, their measurements, various mathematical techniques for flexibility measurements.

Manufacturing cells , cellular v/s flexible manufacturing. Systems planning, physical planning –human resources, Concepts of Quality, JIT and GT as applied to FMS.

Processing and Quality assurance equipments‐ Turning centre, Machining centre, Cleaning and deburring equipment, co ordinate measuring machines‐ their types‐ working, capabilities etc...

System support equipment‐Automated material movement and Automated Storage and Retrieval Systems (ASRS), scheduling of AGVs, cutting tools and tool management, work holding considerations.

FMS computer hardware & software‐general structure and requirements. FMS installation and implementation–acceptance testing, maintenance concern.

15

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3 Computer Integrated Manufacturing Systems:

Introduction to CIMS, nature, types of manufacturing system, evaluation, CIMS hardware and software, benefits, scope and needs, CIMS wheel, elements of CIMS and their role, computer technology and manufacturing, database requirement, fundamentals of communication, data base management, database models, DBMS architecture, SQL ‐Steps to implement CIM, its management, personnel, emerging technologies like expert systems, computer vision, lasers in manufacturing (machinery and metrology), laser meets CNC, concurrent engineering, multimedia communications, best people practices.

CIM specification, application, development of experiments and facilities needed, economics, justification, case studies.

Expert systems and AI based scheduling in CIM environment. CAD/CAM Integration: ‐ Activities involved, case studies, software requirements, hardware requirements, factory automation, implementation issues economic justification, CMM, Introduction to Rapid Prototyping.

14

TOTAL 45


1. Kundra T.K., Rao P.N. and Tewari N.K., “Numerical control and computer aided manufacturing”, Tata McGraw Hill, Publishing company Ltd, 2012.

2. Yorem Koran, “CNC Programming”, 2011. 3. Radhakrishnan P., “Computer numerical control machines”, New Central Book

Agency, 2009. 4. Dr. Sinha S.K., “CNC programming”, Galgotia publications, 2007. 5. William. W., “Flexible Manufacturing Cells and System”, Luggen Prentice Hall,

England Cliffs, NJ, 2011. 6. Radhakrishan P., Subramaniyam S., “CAD, CAM and CIM”, New Age International,

2001. 7. Smalli, Mrad, “Mechatronics Integrated Technologies for Intelligent Machines”, Oxford press, 2008. 8. Rao P.N., “CAD/CAM Principles and Applications”, McGraw Hill, 2002.


September 2012



3.16 ROBOTIC ENGINEERING


3.16.1 SYLLABUS


1 INTRODUCTION:

Automation and Robotics, Robot anatomy, robot configuration, motions joint notation work volume, robot drive system, control system and dynamic performance and precision of movement.

5

2 CONTROL SYSTEM AND COMPONENTS:

Basic concepts and models controllers, control system analysis, robot activation and feedback components. Positions sensors, velocity sensors, actuators sensors and power transmission system.

4

3 MOTION ANALYSIS AND CONTROL:

Manipulator kinematics, position representation forward transformation, homogeneous transformation, manipulator path control, robot dynamics and configuration of robot controller.

4

4 END EFFECTORS:

Grippers‐types, operation, mechanism, force analysis, tools as end effectors consideration in gripper selection and design.

5

5 SENSORS:

Desirable features, tactile, proximity and range sensors and uses sensors in robotics.

4

6 MACHINE VISION:

Functions, Sensing and Digitizing‐imaging, Devices, Lighting techniques, Analog to digital single conversion, Image storage, Image processing and Analysis‐image data reduction, Segmentation feature extraction. Object recognition, training the vision system and Robotics application.

6

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7 ROBOT PROGRAMMING:

Lead through programming, Robot programming as a path in space, Motion interpolation, WAIT, SINGNAL AND DELAY commands, Branching capabilities and Limitations.

4

8 ROBOT LANGUAGES:

Textual robot languages, Generation, Robot language structures and Elements in function.

3

9 ROBOT CELL DESGIN AND CONTROL:

Robot cell layouts‐Robot centered cell, In‐line robot cell, Considerations in work design, Work and control, Inter locks, Error detection and Work cell controller.

4

10 ROBOT APPLICATION:

Material transfer, Machine loading/unloading. Processing operation, Assembly and Inspection, future Application and selecting a robot for manufacturing applications.

4

11 RECENT TRENDS IN ROBOTICS:

Multi‐axis robots, intelligent robots.

2

TOTAL 45


1. Saeed B.N., “Introduction to Robotics Analysis, Systems, Applications”, PHI, 2010. 2. Moshen S., “A Robot Engg text book”, Harper and Row Publishers, NY, 1999. 3. Robert J.S., “Fundamentals of Robotics Analysis and Control”, PHI, 1990. 4. Werner G.H., “Robotic technology, Principles and practice “, Van Nostrand Reinhold Co., NY, 2011.

5. Richard D.K., Thomas A.C., Michael N., “Robotic Engineering”, an Integrated Approach by – PHI, 2011.

6. Mark W.S., Vidyasagar M., “Robot Dynamics and Control”, Wiley India, 2008. 7. Craig J.J., “Introduction to Robotics, Mechanics and Control”, Pearson Education, 2011.

8. Rawadu S.K., “Modelling and Control of Vehicular and robotic systems”, Narosa publishing house, 2010.

9. Hegde G.S., “Industrial Robots”, Laxmi Publications, 2011.


September 2012



3.17 MACHINE TOOL DESIGN


3.17.1 SYLLABUS


1 Design Requirements:

Design requirements of machine tools. A design approach for machine tools. Identification and quantification of objectives and constraints in machine tool design.

7

2 Power Calculations:

Estimation of power requirements and selection of motor for metal cutting machine tool spindles.

6

3 Gear Box Design:

Design of gearbox, stepped and step less regulation of speed, Principles of design of structural components, namely, head stock, tail stock, carriage, table, knee, column and over arms to achieve desired static & fatigue strength, stiffness, dynamic characteristics and other requirements.

9

4 Software packages:

Exercises on the design of machine tools using existing CAD software packages.

5

5 Machine Tool Design:

Design aspects of Modern CNC machine tools, CNC structures, Design/selection of linear motion systems, ball screws, CNC feedback devices, CNC spindles, bearings, feed drives and servomotors for CNC machine tools.

8

6 Elements of Machine Tools:

Structure, design considerations for structures, guide ways, their requirements and classification, slide ways, stick‐slip phenomena, antifriction ways, shapes and types slide ways, re‐circulation ball screw and nut, planetary roller screw, spindle and spindle bearings, types of loads on spindles, types of bearings, bearing material selection, antifriction bearings, preloading and its methods for re‐circulating ball screw and antifriction bearing and frictionless bearings.

10

TATAL 45

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1. Malfred W., “Handbook of Machine Tools”, John‐Wiley publication, Vol. 1 to 4, 1984.

2. “CMTI Handbook of Machine tool design”, Tata McGraw Hill, 2004. 3. Mehta N.K., “Principle of Machine Tool Design”, Tata McGraw Hill, 2004. 4. Basu S.K., “Principle of Machine Tool Design”.


September 2012



3.18 RAPID PROTOTYPING AND TOOLING

This subject is offered in GTU ME Mechanical IV Semester.

3.18.1 SYLLABUS


1 Product Development Cycle:

Influence of Innovations on Product Development, Impact on economy, export competitiveness, design as a strategy to win international market and Innovation process.

7

2 Rapid Product DevelopmentAs Overview:

Virtual prototyping and testing technology, Physical Prototyping and Rapid Manufacturing technologies and Synergic Integration Technologies.

6

3 Virtual Prototyping and Testing:

Geometric Modeling:

Types of Geometric models and Solid Models.

Reverse Engineering:

Acquiring Point Data, Constructing 3D model and Applications. Virtual augmented reality: Requirement of devices and technologies and applications.

Computer Aided Engineering:

Application of FEA in Engineering, the concept of discritization, steps in FEA and automatic mesh generation.

Design for X:

Design for manufacture and design for assembly and other facets of DFX.

10

4 Rapid Manufacturing:

Computer Numerical Control:

Comparison between NC and conventional machines features of CNC Machine Tool and programming.

Robotics:

Classification, programming, sensors and applications.

7

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5 Synergic Integration in Concurrent Engineering:

Benefits, methodology, integration and transactions.

Product Data Management:

Product data classifications, Process Management and benefits.

6

6 Stereo lithography, Fused‐deposition modeling, Selective laser sintering, Laminated‐object manufacturing, Ballistic particle Manufacturing, Solid‐base curing and Direct manufacturing and rapid tooling.

Rapid Prototyping:

Dawn of slice age, benefits, applications, important issues and popular RP process.

Rapid Tooling:

Indirect rapid tooling process.

9

TOTAL 45


1. Study of Layered Manufacturing (LM). 2. Study of Laminated Object Manufacturing (LOM). 3. Study of Selective Laser Sintering (SLS). 4. Study of Three Dimensional Printing (3DP). 5. Study of Fused Deposition Moulding (FDM). 6. Study of Shape Deposition Manufacturing (SDM). 7. Study of Stereo lithography (SLA). 8. Study of Solid Ground Curing (SGC). 9. Study of Metal Rapid & Prototyping


1. Karunakaran K. P., Bapat V. P., Akula S.B., Solanki P. D., Gupta G., Prasanth V.R., Saket A., Sarkar A. and Venkatkrishnan S., “Rapid Product Development‐ Synergic integration of time‐compression technologies”.

2. Schmid R., Kalpakjion S. and Steven, “Manufacturing Processes for Engineering Materials” Pearson Education, 2008.

pg subjects

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