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M. TECH.

DEGREE IN
MANUFACTURING TECHNOLOGY

SYLLABUS
FOR
CREDIT BASED
CURRICULUM

DEPARTMENT OF MECHANICAL
ENGINEERING NATIONAL INSTITUTE OF
TECHNOLOGY AGARTALA - 799046
INDIA
1st SEMESTER

Code No. Subject Name L-T-P Cr.


PME21C05 Physics of Manufacturing Processes 3-1-0 4
PME21B03 Numerical Analysis & Computer Programming 3-1-0 4
PME21C06 Production Planning & Control 3-1-0 4
PME21C07 Advanced Material & Processing 3-1-0 4
PME21E04 Elective I 3-1-0 4
PME21P08 CAD/CAM Laboratory 0-0-3 2
PME21P10 Welding Laboratory 0-0-3 2
PME21P09 Seminar 0-0-1 1
Total 25
(PME21C05) PHYSICS OF MANUFACTURING PROCESSES: (3-1-0) 4

1. Introduction of manufacturing processes from the point of view of underlying physics.


2. Stresses and Strain: stress and strain behavior of materials, plastic and tangent modulus, work
hardening, plastic instability in tensile test, empirical stress-strain equations, effect of
pressure, strain-rate and temperature, analysis of stress tensor, eigen values, decomposition
into deviatoric and hydrostatic components, octahedral stresses, analysis of strain and strain-
rates, stress equilibrium and virtual work, objective stress rates.
3. Plasticity: the criteria of yielding, isotropic and anisotropic hardening, rules of plastic flow,
Levy-Mises and Prandtle-Reuss equations, anisotropic flow rule, Hill’s 1948 and 1979 yield
criteria for anisotropic yielding.
4. Upper bound theorem and its application in processes like rolling, wire drawing, extrusion,
forging and machining.
5. Lower bound theorem with a few applications.
6. Slab method and its application in process like asymmetric rolling, forging, wire drawing and
extrusion.
7. Elastoplastic sheet bending.
8. Analysis of autofrettaging.
9. Theory of slipline field and its application in metal forming and machining. Heat transfer
analysis in manufacturing. Workability and dynamic materials model.
(PME21B03) NUMERICAL ANALYSIS & COMPUTERPROGRAMMING
(3-1-0) 4

1. Approximations and round off errors, Truncation errors and Taylor Series.
2. Determination of roots of polynomials and transcendental equations by Newton-Raphson,
Secant and airstow's method.
3. Solutions of linear simultaneous linear algebraic equations by Gauss Elimination and Gauss-
Siedel iteration methods.
4. Curve fitting- linear and nonlinear regression analysis. Backward, Forward and Central
difference relations and their uses in Numerical differentiation and integration
5. Application of difference relations in the solution of partial differential equations.
6. Numerical solution of ordinary differential equations by Euler, Modified Euler, Runge-Kutta
and Predictor-Corrector method.
7. Introduction to computer programming in C and C++ languages.
8. Arithmetic expressions, Simple programs.
9. The emphasis should be more on programming techniques rather than the language itself.
10. The C programming language is being chosen mainly because of the availability of the
compilers, books and other reference materials. Example of some simple C program.
11. Dissection of the program line by line. Concepts of variables, program statements and
function calls from the library (printf for example)
12. C data types, int, char, float etc. C expressions, arithmetic operations, relational and logic
operations. C assignment statements, extension of assignment to the operations.
13. C primitive input output using getchar and putchar, exposure to the scant and printf
functions. C statements, conditional execution using if, else. Optionally switch and break
statements may be mentioned.
14. Concepts of loops, example of loops in C using for, while and do-while. Optionally continue
may be mentioned.
15. One dimensional arrays and example of iterative programs using arrays, 2-d arrays. Use in
matrix computations.
16. Concept of Sub-programming, functions. Example of functions. Argument passing mainly
for the simple variables.
17. Pointers, relationship between arrays and pointers. Argument passing using pointers. Array
of pointers, Passing arrays as arguments.
18. Strings and C string library. Structure and unions.
19. Defining C structures, passing structures as arguments.
20. Program examples. File I/O. Use of fopen, fscanf and fprintf routines.
(PME21C06 ) PRODUCTION PLANNING & CONTROL (3-1-0) 4

1. Introduction; Pre-planning, market survey, machine and process capacity, capacity analysis
2. Effects of cyclic and random variations; Routing route sheets, common charts
3. Scheduling; various techniques of scheduling
4. Production order, despatching of production orders, job card Inventory control, inventory
costs, lot size models, back orders and last sales, quantity discounts, safety, stock, elementary
control under risk
5. Materials purchasing, quotations
6. Rate controls; Introduction to value analysis.
(PME21C07) ADVANCED MATERIALS AND PROCESSING (3-1-0) 4

1. Introduction of advanced materials and its manufacturing processes for engineering


applications.
2. Piezoelectric materials (PZT): piezoelectric effect, Di-electric hysterisis, piezoelectric
constants, piezoelectric charge constants, dynamic behaviour of PZT transducers,
piezoelectric materials and manufacturing techniques (stability, poling and depolarisation).
3. Shape memory alloys (SMA): Shape memory effect and the metallurgical phenomenon of
SMA, Temperature assisted shape memory effect, Visco-elastic behaviour, magnetic shape
memory effect. Various shape memory alloys. Manufacturing technology of SMAs.
4. Electro rheological (ER) and magneto-rheological (MR) materials: Characteristics of ER and
EM fluids. ER and EM materials.
5. Composite materials: Design and manufacturing of polymer matrix, metal matrix and ceramic
matrix composites. Various forms and type of reinforcements, fillers and additives. Design of
composites for structural, wear resistance and high temperature applications. Micro-electro-
mechanical (MEMS) systems. Introduction, characteristics of silicon wafers and other
materials for MEMS applications.
6. Various manufacturing techniques of MEMS components Materials for high temperature
applications: Ni-Cr alloys, ODS materials, Ni base and Co based super alloys, carbon-carbon
composites. Diffusion bond coating of high temperature materials.

7. Powder metallurgy: Introduction and feature of powder metallurgy processes. Advanced


solidification techniques: directional solidification, single crystal growth and levitation
melting.
(PME21E04) ELECTIVE- I (3-1-0) 4

METAL CASTING
1. Structure of silica and different types of clays, bonding mechanism of silica – water-clay
systems. Swelling of clays, sintering adhesion and colloidal clay; silica grain shape and size
distribution standard permeability A.F.S. clay.
2. Characteristics, Ingradients and additives of moulding sand, core sands .
3. Solidifications of Metals, nucleation, free energy concept, critical radius of nucleus. Nucleation
and growth in metals and alloys.
4. Constitutional super cooling. Columnar equiacquiesced and dendritic structures.
5. Freezing of alloys centreline feeding resistance.
6. Rate of solidification, time of solidification, mould constant.
7. Fluidity of metals, volumes redistribution.
8. Analysis of the process. Riser design shape, size and placement. Effect of appendages on
risering.
9. Effective feeding distances for simple and complex shapes. Use of chills, gating design, filling
time.
10. Aspiration of gases. Top, bottom and inside gating. Directional solidifications stresses in
castings. Metal mould reactions.
11. Expansion scale and metal penetration.
12. Analysis of the process. Various moulding and casting processes, hot box, cold box process,
investment, shell moulding, full mould process, die casting, ceramic shell mould, vaccum
moulding etc.
13. Non-ferrous Die-casting of Aluminium and its alloys, brass and bronze.

CUTTING TOOL DESIGN


1. Introduction, system of Tool nomenclature, Tool Geometry, Mechanism of Chip, formation and
forces in orthogonal cutting, Merchant’s force diagram.
2. Oblique Cutting: Normal chip reduction coefficient under oblique cutting, true shear angle,
effective rake, influx region consideration for deformation, direction of maximum elongation,
effect of cutting variables on chip reduction co-efficent, forces system in oblique cutting, effect of
wear land on force system, force system in milling, effect of helix angle.
3. Fundamentals of Dynamometry, Theoretical determination of forces, angle relations, heat and
temperature during metal cutting; distribution, measurement, analysis, theoretical estimation of
work piece temperature, hot machining. Fundamental factors, which effect tool forces
4. Correlation of standard mechanised test. (Abuladze – relation), nature of contact and stagnant
phenomenon, rates of strains, shear strain and normal strain distributions, cutting variables on
cutting forces.
5. Cutting Tools: Tools materials analysis of plastic failure (from stability criterion), Analysis failure
by brittle fracture, wear of cutting tools, criterion, flank and crater wear analysis, optimum tool
life, tool life equations, (Taylor’s woxen etc) Tool life test,
6. Machining optimisation, predominant types of wear; abrasive, adhesive, diffusion wear models,
wear measurements and techniques, theory of tool wear oxidative mathematical modelling for
wear, test of machinability and influence of metallurgy on machinability.
7. Economics of Metal machining. Abrasive Machining: Mechanics of grinding, cutting action of
grit, maximum grit chip thickness, energy and grit force temperature during grinding, wheel wear,
grinding, process simulation, testing of grinding wheels, mechanics of lapping and honing, free
body abrasion.

WELDING TECHNOLOGY
1. Introduction: Basic classification of welding processes, weldability, weld thermal cycle,
metallurgy of fusion welds, solidification mechanism and microstructural products in weld metal,
epitaxial,cellular and dendritic solidification, metallurgical changes in weld metal, phase
transformation during cooling of weld metal in carbon and low alloy steel, prediction of
microstructures and properties of weld metal. Heat affected zone, re-crystallization and grain
growth of HAZ, gas metal reaction, effects of alloying elements on welding of ferrous metals.
2. Welding Arc: Arc efficiency, temperature distribution in the arc; arc forces, arc blow, electrical
characteristics of an arc, mechanism of arc initiation and maintenance, role of electrode polarity
on arc behaviour and arc stability, analysis of the arc.
3. Coated Electrodes: Electrode coatings, classification of coatings of electrodes for SMAW, SAW
fluxes, role of flux ingradients and shielding gases, classification of solid and flux code wires.
4. Fusion Welding reviews: Critical reviews of manual metal arc welding (MMAW) GTAW,
GMAW FCAW and CO welding processes, plasma arc, submerged arc welding, electro gas and
electro slag welding, analysis of the process.
5. Welding power sources: Arc welding power sources basic charters tics of power sources for
various arc welding processes, duty cycles, AC, DC welding power source, DC rectifiers, thyristor
controlled rectifiers, transistorised units, inverter systems. Arc length regulation in mechanised
welding processes
6. Metal Transfer and Melting Rate: Mechanism and types of metal transfer, forces affecting metal
transfer, modes of metal transfer, metal transfer in various welding processes, effective of polarity
on metal transfer and melting rate.
7. Solid State welding: Theory and mechanism of solid sate welding. Techniques and scope of
friction welding, diffusion welding, cold pressure welding and ultrasonic welding. High energy
rate welding. Analysis of the Process.

8. Welding Techniques using Radiation energy: Technique, scope and application of the electron
beam and laser welding processes.

ENTREPRENEURSHIP

1. Introduction: Factors leading to Industrial development Entrepreneur definition and various


concepts, self awareness.
2. Motivational aspects, attitude development, creativity, copying with uncertainties, resilience.
Information: Industrial potential, environmental scanning,
3. Identification of opportunities, dynamics of an opportunity, business opportunities
recognition. Government policy for Industrial development.
4. Choice of Technology Research for patents, product development.
5. Planning: Planning of an Industrial unit, project planning, identification of market and demand
for product, role of significant variables, execution of projects legal aspects, financial aspects
and labour laws, feasibility studies, sectoral, Industrial and unit level feasibility, exposure to
past, present and future.
6. Entrepreneurial Management: Business finance Management through elementary
conceptbreak even, working capital knowledge of various institutions and their mode of
assistance. Elements of Production processes, quality control, Inspection methods. Production
planning group dynamics.
2nd SEMESTER

Code No. Subject Name L-T-P Cr.


PME22C08 Manufacturing Automation 3-1-0 4
PME22C09 Non-Conventional Machining Processes 3-1-0 4
PME22C10 Product Design & Development 3-1-0 4
PME22E05 Elective II 3-1-0 4
PME22P10 Robotics & Mechatronics Laboratory 0-0-3 3
PME22P11 NTM Laboratory 0-0-3 3
PME22P14 Project Preliminary 0-0-4 4
PME22P13 Comprehensive Viva-Voce 0-0-1 1
Total 27

Elective II:
1. Metal Cutting.
2. Machine tool Design.
3. Ergonomics & Industrial Manufacturing.
4. Robotics

st
N.B: The Welding Laboratory is kept in the 1 semester for the temporary arrangement so that
total credit for the 1st & 2nd semester is 50 for the ongoing batch. For the batch admitting on
2011, for them Welding Laboratory will be taught in 1st semester.

(PME22C08) MANUFACTURING AUTOMATION (3-1-0) 4

1. Automation strategies, flow lines, automated assembly systems


2. Transfer systems.
3. Vibratory bowl feeders, non-vibratory feeders.
4. Part orienting, feed track, part placing and part escapement systems
5. Programmable automation, industrial robotics
6. Flexible manufacturing systems; Automation equipment.
(PME22C09)NON - CONVENTIONAL MACHINING PROCESSES (3-1-0) 4

1. New Technology, Introduction, Mechanical Processes, Abrasive jet Technology, Ultrasonic


machining, whirling jet machining.
2. Fundamental principles, process parameters, characteristics,
3. Tool design, Metal removal rate-analysis, important part design, Analysis of the Process.
4. Chemical and Electro-chemical machining –Introduction. Principles & scheme,
5. Process parameters, metal removal rate, dynamic and hydro-dynamic & hydro-optimization,
electrolytes.

6. EDM: Introduction-basic principles & scheme, circuitry controls, metal removal rate, machining
accuracy,
7. Optimization, selection of tool material and tool design, Di-electric, Analysis.
8. Laser Beam Machining & Electron beam machining back ground, production of Laser, machining
by Laser and other applications,

9. Electron beam action, Dimensionless analysis to establish correlation, behavior EBM parameters.
High Velocity forming of metals, explosive forming principles and applications, Electro-hydraulic
and other applications, Analysis of the process.

(PME22C10) PRODUCT DESIGN AND DEVELOPMENT (3-1-0) 4


1. Importance of product design in industry. Principal requirements of good product design.
2. Factors and considerations affecting product design. Ergonomic factor in product design.
3. Product design methodology and techniques. Basic elements and concepts of visual design.
4. Materials, forms, function and color relationships.

5. Product graphics, product development and testing. Packaging materials their characteristics
and applications.

6. Packaging design considerations Value engineering, concept, advantage and applications.


Value, types of values.

7. Analysis of function, using and evaluating functions. Value engineering techniques. Value
control.
(PME22E05) ELECTIVE-II (3-1-0) 4

METAL CUTTING

1. Introduction, system of Tool nomenclature, Tool Geometry, Mechanism of Chip, formation and
forces in orthogonal cutting, Merchant’s force diagram.

2. Oblique Cutting: Normal chip reduction coefficient under oblique cutting, true shear angle,
effective rake, influx region consideration for deformation, direction of maximum elongation,
effect of cutting variables on chip reduction co-efficent, forces system in oblique cutting, effect of
wear land on force system, force system in milling, effect of helix angle.

3. Fundamentals of Dynamometry, Theoretical determination of forces, angle relations, heat and


temperature during metal cutting; distribution, measurement, analysis, theoretical estimation of
work piece temperature, hot machining. Fundamental factors, which effect tool forces: Correlation
of standard mechanised test. (Abuladze – relation), nature of contact and stagnant phenomenon,
rates of strains, shear strain and normal strain distributions, cutting variables on cutting forces.

4. Cutting Tools: Tools materials analysis of plastic failure (from stability criterion), Analysis
failure by brittle fracture, wear of cutting tools, criterion, flank and crater wear analysis, optimum
tool life, tool life equations, (Taylor’s woxen etc)

5. Tool life test, machining optimisation, predominant types of wear; abrasive, adhesive, diffusion
wear models, wear measurements and techniques, theory of tool wear oxidative mathematical
modelling for wear, test of machinability and influence of metallurgy on machinability.

6. Economics of Metal machining. Abrasive Machining: Mechanics of grinding, cutting action of


grit, maximum grit chip thickness, energy and grit force temperature during grinding, wheel wear,
grinding, process simulation, testing of grinding wheels, mechanics of lapping and honing, free
body abrasion.
MACHINE TOOL DESIGN

1. Introduction, Classification of machine tools, elements of machine tools, selection of speed


and feed, gear box design various types of clutch systems, Sohopke and Report drives, double
bond gears analysis, Lohr criterion for optimising double bond gear. Stepless drives,
mechanical stepless drive analysis, hydraulic step less drive & circuit analysis, design
features, throttle valves, tracer controlled hydraulic circuit, hydraulic servo controls, electrical
stepless drive circuits and charters tics.

2. Strength and rigidity consideration, process capability and compliance, design of lathe bed,
use of stiffness in bed, design of radial drill column and milling machine column.

3. Analysis of spindle bearings, slides and guides, design of spindle/arbor, antifriction and
journal bearings, hydro-dynamic action in slides, analysis of hydrostatic bearings, roller
guides, recirculating ball analysis, stick slip motion in guides-models, force analysis of lathe
guide ways.

4. Vibrations of machine tools and dynamic rigidity: Effects of vibrations, source of vibrations,
self excited vibration, single degree of freedom chatter, velocity principle and related models,
regenerative principles, chatter in lathe, drilling milling and grinding. Tlusty and palace
model, Peters model, elimentation of machine tool structures matrix, finite elements and
lumped constant models.

5. Automation: Automation drives for machine tools, degree of automation, semi-automatics,


analysis of collect action, design, of collet, bar feeding mechanism, tooling layout, single
spindle, multispindle automatic, transfer machine, indexing Geneva mechanism, analysis,
Swiss type automatic machine loading and unloading. Transfer-devices, modular –design
concept in process gauging.

6. Control system of machine tools : Control: Mechanical, electrical, hydraulic, numerical,


fluidic, basic principle of cam control, hydraulic controls, fluid controls, numerical controls,
feedback systems, primary systems programming. Basic Devices, adaptive control.
ERGONOMICS OF INDUSTRIAL MANUFACTURING
1. Ergonomics/Human factors fundamentals; Human-machine-environment interface
2. Application of ergonomics principles and criteria in industrial manufacturing; occupational
health, safety and stress at workplace with specific reference to industrial manufacturing
3. VDU workstation; Engineering anthropometry and posture
4. Ergonomics of machine tool and systems design
5. Information processing and human error prediction; Users interface evaluation.

ROBOTICS
1. Automation & Robotics; Spatial Descriptions & Transformations.
2. Manipulator Kinematics – Forward and Inverse; Jacobians: Velocities & Static Forces.
3. Robot Arm Dynamics: Lagrange- Euler formulation of manipulator dynamics. Trajectory
Planning: Joint-interpolated trajectories, Geometric problems with Cartesian paths, Collision-
free path planning.
4. Robot Control Systems: Feedback and Closed-loop control, Transfer Functions
5. Control of Second-order systems, Nonlinear & time varying systems, Adaptive Control.
6. Robotic Prehension: Dexterous manipulation; ANN approach in prehension, Sensors in
Robotics: Machine vision, Force & Torque sensors.
7. Robot programming: simulators and languages. Tele-robotics and virtual interfaces for task
specification and programming.
8. Concept of nanorobotics; Performance analysis of industrial robots and their manufacturing
applications; Economics of robotics. Social issues & future of robotics.

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