12 Tool Engg

SCHEME AND SYLLABUS OF M.
Tech
IN
TOOL ENGINEERING
With effect from 2005 – 06
VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELGAUM – 590 014
(KARNATAKA)
Page 1 of 39
VISVESVARAYA TECHNOLOGICAL UNIVERSITY, BELGAUM
Scheme of Teaching and Examination for M.Tech course in Mechanical Engineering
TOOL ENGINEERING (MTE)
First Semester (18 weeks)
No. of hours / week Marks for

Duration
Name of the Practical/ Total
Sub. Code of Exam
Subject Lectures Field work/ IA Exam Marks
in hours
Assignment
Die Casting & Die
05 MTE 11 4 2 3 50 100 150
Design
Theory of
05 MTE 12 Elasticity & 4 2 3 50 100 150
Plasticity
05 MTE 13 Press Tool Design 4 2 3 50 100 150
05 MTE 14 Elective – I 4 2 3 50 100 150
05 MTE 15 Elective – II 4 2 3 50 100 150
05 MTE 16 Seminar - 3 - 50 - 50
Total 20 13 15 300 500 800
Elective – I
05 MTE 141 Gauges & Measurements
05 MTE 142 Cutting Tools
05 MTE 143 Jigs & Fixtures Design
Elective – II
05 MTE 151 CAD / CAM
05 MTE 152 Component Materials
05 MTE 153 Advanced Machining
Page 2 of 39
Second Semester (18 weeks)

Duration
Sub. Code of Exam
in hours
Assignment
Finite Element
05 MTE 21 4 2 3 50 100 150
Analysis
Plastic Moulds
05 MTE 22 4 2 3 50 100 150
Design
Composite
05 MTE 23 4 2 3 50 100 150
Materials
05 MTE 24 Elective – III 4 2 3 50 100 150
05 MTE 25 Elective – IV 4 2 3 50 100 150
05 MTE 26 Seminar - 3 - 50 - 50
Total 20 13 15 300 500 800
Elective – III
05 MTE 241 Design Analysis
05 MTE 242 Rapid Prototyping
05 MTE 243 Plastic Processing
Elective – IV
05 MTE 251 CNC Machining
05 MTE 252 Advanced Mould Techniques
05 MTE 253 Lasers in Manufacturing
Page 3 of 39
Third Semester (8 weeks)

Duration
Sub. Code of Exam
in hours
Assignment
8 weeks duration
Industrial
05 MTE 31 between 2nd & 3rd - 100 - 100
Training
Semester
05 MTE 32 Seminar - 3 - 50 - 50
Total - 3 - 150 - 150
Fourth Semester (22 weeks)

Duration
Sub. Code of Exam
in hours
Assignment
05 MTE 41 Seminar - 3 - 50 - 50
Project work
05 MTE 42 Evaluation & Viva - - - - - 200
Voce
Total - 3 - 50 - 250
Grand Total form (Ist to IVth semester) : 2000
Note:
1. The hours per week shown in the column of Practical / Field work /
Assignment are the contract hours for students, no load to be shown to the
teachers. The teachers should provide guidance.
2. Industrial Training: 8 weeks of compulsory Industrial training to be

undergone by the students as soon as the second semester examinations are
over. An extensive report on the industrial training is to be submitted by the
students and to be evaluated for 100 marks by a committee of the
Department constituted by the Head of the Department. This is to be
included in the Marks Card of III semester.
3. The seminar Marks are to be awarded by the department committee

constitute for the purpose.
4. The project evaluation and Viva-Voce will be conducted by a committee

consisting of the following.
4.1 Head of the department (Chairman)

4.2 Two examiners appointed by the university.
Page 4 of 39
DIE CASTING AND DIE DESIGN
Sub Code : 05 MTE 11 IA Marks : 50

No. of Lecture
: 04 Exam Hours : 03
Hrs/week
Total Lecture Hrs : 52 Exam Marks : 100
Practical/Field
work/Assignment : 02 First Semester : 18 weeks
Hrs/week
INTRODUCTION
Classification of Castings, Sand casting, Metal mould castings, Plastic moulds casting,
Investment casting, Gravity die casting, Pressure die casting, Advantages of Die casting,
Die casting process, vacuum casting. (04 Hrs)
DIE CASTING ALLOYS

Low fusion alloys, High fusion alloys, Properties. (02 Hrs)
DIE CASTING MACHINES

History of die casting machines, Hot chamber machine, cold chamber machine,
Horizontal machine, Vertical machine, Die locking, Toggle locking, Hydraulic locking,
Injection systems, knock out pins and plates, ejector system furnaces, loading of metal
into hot chamber. (08 Hrs)
FEED SYSTEM
Gates, Runners, Taper tangent runner system, Precession layout, Spreader, shot sleeve,
shot weight calculations etc., (04 Hrs)
DIE CONSTRUCTION
Cores, Cavities, pillars and bushes, ejectors, bolster plates. (04 Hrs)
COOLING SYSTEM
Core cooling, Cavity cooling, cooling of shot sleeve, cooling of spreader, baffles, cooling
calculations. (04 Hrs)
TYPES OF DIES
Single cavity dies, Multi cavity dies, combination dies, unit dies, trimming and finishing of
components, Inspection of components, safety, SPC & visual control techniques.
(06 Hrs)
DIES WITH SIDE CORES

Construction, Actuation of side cores. (08 Hrs)
DIE CASTING, DEFECTS AND REMEDIES

Preparation and Presentation of typical designs in the form of drawings following
1. Cold chamber die casting dies.
2. Hot chamber die casting dies.
3. Single cavity die casting dies.
4. Multi cavity die-casting dies.
5. Dies with side cores.
(12 Hrs)
Page 5 of 39
Reference Books:
1. Die casting -DO EHLER H.A. New York -McGraw Hill Book Co-Inc. International
Student Edt. 1951.
2. The Die casting Book -STREET. C. ARTHUR, Surrey, England -Portcullis Press Ltd.,
2nd Edt. 1986.
Page 6 of 39
THEORY OF ELASTICITY AND PLASTICITY
No. of Lecture
Hrs/week
Practical/Field
Hrs/week
PART – I ELASTICITY
1.1) ANALYSIS OF STRESS
Introduction -Body force, Surface force, Stress vectors, State of stress at a point, normal
and shear stress, rectangular stress components, stress components on an arbitrary
plane. Principal stresses, Stress Invariant -Mohr's circle for three-dimensional state of
stress-Differential equation of equilibrium, Surface traction, boundary condition.
(06hrs)
1.2) ANALYSIS OF STRAIN.
Introduction -normal strains and shear strain. Rectangular strain. Components -State of
strain at a point -Plane State of strain. (06hrs)
1.3) STRESS -STRAIN RELATIONS

Hooke's Law -Compatibility equation -formulation of Elasticity problem-Saint Venant's
principle -principle of super position -Uniqueness of solution reciprocal theorem. (06hrs)
1.4) Solution of plane elasticity problem in rectangular coordinates. Airy's stress function
-bending of a hollow cantilever beam under end-load-bending of a simply supported
beam with uniform load. (04hrs)
1.5) Solution of plane elasticity problem in polar coordinates –general equation in 2D
polar coordinates -stress distribution in axi symmetric: bodies, symmetric about an axis,
pure bending of curved bars. (04hrs)
1.6) Torsion of prismatic bars. Membrane analogy torsion of thin open sections and thin
tubes. (04hrs)
PART – II PLASTICITY
2.1) Introduction -Octahedral stress -decomposition of stress into hydrostatic and pure
shear state effective stress. (04hrs)
2.2) Strain -cubical dilation -finite coefficient octahedral stress -effective strain special
and deviator strain- strain rate tension. (06hrs)
2.3) Yield criteria -Von Mises and Tresca -yield surface for isotropic plastic materials for
an anisotropic material. (06hrs)
2.4) Stress strain relations- Prandil Reuus levy saint Venant Von Mises Equation
experimental verification of Prandil Reuss equation -yield locus. Typical --solution of
methods for plastic problem in metal working process. (06hrs)
Page 7 of 39
Reference Books:
1. Advanced Mechanics of Solids - SRINATH L.S.: Tata McGraw Hill Publication Company
Ltd., 20th 2001 Reprint.
2. Theory of Elasticity -TIMOSHENKO S. P. & GOODIER J.N.:Singapore Tata McGraw Hill
3rd print 1970.
3. Applied Elasticity -WANG C. T. Eastern: Economic Edition -2000.
Page 8 of 39
PRESS TOOL DESIGN
No. of Lecture
Hrs/week
Practical/Field
Hrs/week
INTRODUCTION
Elements of press tools, classification of press, press brakes, shearing theory, cutting
force, elements of press tool, clearance between punch and die, shut height and daylight,
press tonnage calculation. (06 Hrs)
STRIP LAYOUT
Basic rules, economic layout, bridge size, calculation of plug point/center of pressure.
(04 Hrs)
PRESS TOOL OPERATIONS
Piercing, blanking, slitting, cropping, trimming, shaving, lancing, bending, curling,
calibrating, drawing, Embossing, coining, flanging, fine blanking. (08 Hrs)
DESIGN OF PRESS TOOL ELEMENTS
Die plates, punches, punch holder plates, stripper plates, and calculation of stripping
force, bolster plates, pilots, ejectors, shedders, material s ops, pillar, bush, slender
punches, Stock guides, stock feeding device and die sets (06 Hrs)
TYPES OF PRESS TOOLS
Progressive tools, stage tools, compound tools, combination tools, cam actuated die,
horn dies, sub press dies, inverted dies, bulging dies, levering dies, trimming dies,
shaving dies, riveting dies, assembly dies, lamination dies.
(08 Hrs)
BENDING AND FORMING DIES
Theory of bending, development of bend, spring back, correcting spring back, bending
tools, U -bending, V -bending, forming tools, bending on press brake,' bending force
calculation. (06 Hrs)
DRAWING.
Theory of drawing, blank development, strain factor, calculation of number of stages of
drawing, circular draw, rectangular draw, draw force calculation, lubrication. Defects and
remedies, ironing. (06 Hrs)
EXTRUSION
Forward, backward, combined extrusion, Modem metal forming techniques.
Preparation and Presentation of typical designs in the form of drawings for the following
1. Piercing & blanking tool.
2. Progressive tool
3. Stage tool
4. Bending tool
5. Forming tool
6. Compound tool
7. Combination tool
8. Fine blanking tool (08 Hrs)
Page 9 of 39
Reference Books:
1. Die Design Fundamentals -PAQUIN J.R. & CROWLEY R.E:
New York -Industrial Press Inc. 2nd Edt. 1987.
2. Progressive Dies -DALLAS B. DANIEL
Michigan -SME 2nd Edt. 1994.
3. Die Design Hand Book -SMITH A. DAVID.SME 3rd 1990.
Page 10 of 39
GAUGES AND MEASUREMENTS

No. of Lecture
Hrs/week
Practical/Field
Hrs/week
FITS AND TOLERANCE
Limits Fits and Tolerances.

(12 Hrs)
INTRODUCTION TO GAUGES
Types of Gauges, Taylor's Principles and its application, Calculation of Dimension of limit
gauges, taper gauges, Thread gauges, Function gauges and Manufacturing process of
gauges.
(20 Hrs)
DESIGN EXERCISE
Design of Plug Gauge, Ring Gauge, Snap Gauge. Indicator Gauge, Taper plate Gauge,
Taper Plug Gauge, Thread Gauge and Position Gauge.
(20 Hrs)
Reference Books:
1. Engineering Metrology by R.K. JAIN

New Delhi -Khanna Publications -4th Edtn. -1976.
2. B.l.S. Books.
3. Dimensional Metrology and Geometric conformance by TMEH
Page 11 of 39
CUTTING TOOLS

No. of Lecture
Hrs/week
Practical/Field
Hrs/week
PRINCIPLES OF METAL CUTTING

Types of Tools, Single point tool, milling cutter, Drills, Broaches, Form Tools, Thread
cutting tools, Geometry of single point and multi point cutting tools, tool wear and tool
life, relation between effective setting and geometric angles of the cutting edges, role or
coolants. (12 Hrs)
TOOL MATERIALS
HSS, Cemented carbides, coated carbides, Ceramics, CBN, Diamond, Polycrystalline
Diamonds. (08 Hrs)
TURING TOOLS
Index able Inserts, Chip breakers, ISO classification of inserts and tool holders. (06
Hrs)
MILLING CUTTERS
Standardization, geometry, Face Mills, Shoulder Mills, End Mills, Deep shoulder Mills, T-
Slot cutters. (06 Hrs)
DRILLING
Drills with index able inserts, Deep hole drills, carbide tipped drills, Core drills, Counter
pores, and Counter sinks. (06 Hrs)
BORING
Types of boring tool, Boring heads, Cartridges. (06 Hrs)
REAMER
Types of reamers, Geometry of flutes.
TOOLS FOR CNC
DESIGN EXERCISE
Design of Single point tool, Drill, Broach, Form tools, Reamer. (08 Hrs)
Page 12 of 39
Reference Books:
1. Metal cutting theory and Cutting tool design – ARSHINOV M I R Publications,
2. All about machine tools – HEINRICH GERLING
3. Production technology – HMT
4. Tool design POLACK
5. Metal cutting tool handbook – USCTI
Page 13 of 39
JIGS AND FIXTURES DESIGN

No. of Lecture
Hrs/week
Practical/Field
Hrs/week
INTRODUCTION:
Definition of Jigs and Fixtures, Difference between jigs and fixtures, Advantages, Steps
for design. (06 Hrs)
LOCATION
Degree of freedom, 3-2-1 principles, Choice of location, redundant location, Diamond pin
calculation, Locating methods and chip control. (06 Hrs)
LOCATING DEVICES
Surface location, Rest blocks, pins, V-blocks, Equalizers, Profile locators. (06 Hrs)
CLAMPING
Basic principles, cutting forces, Rigid clamping, wedge clamping, Cam clamping, quick
action clamps, Toggle clamps, simultaneously acting clamps. (06 Hrs)
GUIDING ELEMENTS
Jig bushes, Standards, Setting gauges. (06 Hrs)
INDEXING JIGS & FIXTURES

Indexing methods, Linear, Rotary, Indexing jigs, Indexing fixtures. (06 Hrs)
DESIGN OF JIGS AND FIXTURE BODIES AND OTHER ELEMENTS

TYPES OF JIGS AND FIXTURES
Plate jigs, Box jigs, Indexing jigs, Milling fixtures, and Indexing-milling fixtures, turning
fixtures, Grinding fixtures, Universal jigs and fixtures, welding fixtures, Broaching
fixtures.
1. Drill Jig
2. Drilling and Reaming Jigs
3. Milling Fixtures
4. Indexing Jigs
5. Indexing Milling Fixtures.
6. Turning Fixtures
7. Welding Fixtures
8. Turning Mandrel
9. Grinding Mandrel
10.Broaching Fixtures. (16
Hrs)
Page 14 of 39
Reference Books:
1. An Introduction to Jig and Tool Design -KEMPSTER M.H.A.- Bristol- ELBS 3 rd Edt.
1974.
2. Jigs & Fixtures -JOSHI P .H.- New Delhi -Tata McGraw Hill Pub. Co. Ltd., 11th print
1999.
3. Jigs. & Fixtures & Gauges -BOYES E. WILLIAM-Michigan -SME 1st Edt. 1986.
Page 15 of 39
CAD/CAM

No. of Lecture
Hrs/week
Practical/Field
Hrs/week
Overview of CAD/CAM System in brief: Introduction, CAD/CAM contents and tools,

Market trends, Industrial applications, Hardware. (06 Hrs)
CAD/CAM Software:
Graphics standards, Data Structure, DBNIS, Co-ordinate systems, Modes of graphics
operations, User interface, Software modules, Modeling and Viewing, Documentation,
Software Trends. (12 Hrs)
Geometric Modeling:
Mathematical representation of curves, surfaces and solids -Wire frame models, entities
analytic curves, synthetic curves, manipulation, surface entities, analytic, synthetic
surfaces, solid entities, representation, manipulations, applications. (08 Hrs)
Geometric Transformation:
Transformation of geometric models, mapping, inverse transformations, projections of
geometric models, engineering applications. (08 Hrs)
Computer Aided Manufacturing:

Introduction, computer aided process planning, MRP, Capacity planning, Computer
-process control-types, programming, CAD/CAM integration, implementation, Computer
Integrated Manufacturing. (08 Hrs)
Materials handling and storage systems in brief:

Automated materials handling, storage systems, robot applications in material handling.
(08 Hrs)
Reference Books:
1. CAAD/CAM Theory & Practice -Ibrahim Zeid

2. CAD/CAM - Groover
3. CAD/CAM/CIM-P. Radhakrishnan & S. Subramanian, -New Delhi – New Age
international (P) Ltd. 2nd Edtn, 2000.
4. Computer graphics -Joseph Harrington.
Page 16 of 39
COMPONENT MATERIALS

No. of Lecture
Hrs/week
Practical/Field
Hrs/week
TOOL STEELS &ITS CLASSIFICATION:

Water hardening, oil hardening, air hardening, hot work tool steels. Effect of alloy
additions, properties, selection, application commercial names of tool steels, material IS
testing.
(08 Hrs)
HEAT TREATMENT:
I-C equilibrium diagram, T T T diagram, Quenching. Quenching media, Heat treatment
Process, Annealing, Normalizing, case hardening, Nitriding, Subzero treatment, Design
construction, Heat treatment defects and remedies, equipments, furnace and
accessories.
(10 Hrs)
PLASTIC MATERIALS:
History, source and manufacture of raw material, basic chemistry, methods of
manufacturing, flow behavior, additives, processing behavior, general properties and
applications.
(08 Hrs)
GENERAL PURPOSE PLASTICS:
Olefin polymers and co-polymers, Poly vinyl chloride and its co-polymers, Polystyrene
and styrene co-polymers, celluloses, Acrylics.
(08 Hrs)
ENGINEERING THERMOPLASTICS: .
Nylons, Polyacetal, Ultrahigh molecular weight HDPE, Saturated polyester, Floine-
containing Polymers, Polycarbonate, Polyphenyle sulfide, Polyphenyl oxide, Polysulphone,
Poly Ether EtherKetone (PEEK), Plastic alloying and Blending, Composite Polymeric
material.
(10 Hrs)
THERMOSETTING PLASTICS:
Phenol formaldehyde, Urea formaldehyde, Melamine formaldehyde, unsaturated
polyester, Epoxy, Polyurethane, Silicones, Thermo set composite materials.
(08 Hrs)
Page 17 of 39
Reference Books:
1. Properties of Engineering Materials -R.A. HIGGINS.

New Delhi -Viva Low priced student Edtn, -6th -1982
2. Plastic Materials -J .A. Brydson.
London -British Library Cataloging in Publication data -4th Edtn. 1982.
3. Plastic Materials Hand Book -ATHALYE
Bombay -Multi print, Byculla -1992.
5. Hand Book of Thermo set Plastics –GOODMAN
Page 18 of 39
ADVANCED MACHINING
No. of Lecture
Hrs/week
Practical/Field
Hrs/week
INTRODUCTION
Process selection, classification, and comparative study of different processes. (04 Hrs)
MECHANICAL PROCESS
Ultrasonic machining, definition, Mechanism of metal removal, elements of the process,
Tool feed mechanism, Theories of mechanics of cutting, Effect of parameters,
Applications. (06 Hrs)
ABRASIVE JET MACHINING
Principles, parameters of the process, applications, advantages and disadvantages.
(04 Hrs)
THERMAL METAL REMOVAL PROCESSES
Electric discharge machining, principle of operation, mechanism of metal removal basic
EDM circuitry spark erosion generators, analysis of relaxation type of circuit, material
removal rate in relaxation circuits, critical resistance, parameters in Ro circuit, die electric
fluids, electrodes for spark erosion, surface finish, applications. (06 Hrs)
ELECTROCHEMICAL AND CHEMICAL PROCESSES
Electro chemical machining, classification of ECM process, principle of ECM, chemistry of
ECM process, parameters of ECM process, Determination of the metal removal rate,
dynamics of ECM process, hydro dynamics of ECM process, polarization, tool design,
advantages & disadvantages, applications., Electro chemical grinding, Electro chemical
honing, electro chemical de-burring. (06 Hrs)
CHEMICAL MACHINING:
Introduction, fundamental principal, types of chemical machining, maskants, Etch ants,
advantages, disadvantages, applications. (04 Hrs)
PLASMA ARC MACHINING:
Introduction, plasma, generation of plasma & equipments, mechanism of metal removal,
PAM parameters, process characteristics, types of torches, applications. (06 Hrs)
ELECTRON BEAM MACHINING (EBM):
Introduction, equipment for production of electron beam, theory of electron beam.
Machining, thermal & non-thermal type, process characteristic, applications. (06 Hrs)
LASER BEAM MACHINING:
Introduction, principle of generation process, selection, comparison of conventional &
high velocity forming methods, types of high velocity forming methods, explosion
forming process, Electro hydraulic forming, magnetic pulse forming. (06 Hrs)
HIGH VELOCITY FORMING PROCESS:
Introduction, development of specific process, selection, comparison of conventional,
explosion forming process, Electro hydraulic forming, magnetic pulse forming. (04 Hrs)
Page 19 of 39
Reference Books:
1. 'New technology' Institution of Engineers, India -BHATTACHARYA
2. 'Production Technology' Tata Mc Graw Hill- HMT
New Delhi, TATA Mc Graw Hill Pub, 1993. :
3. 'High velocity forming of metals' -ASTME Prentice Hall:
4. HMT Production Technology -Tata Mc Graw Hill. 1
Page 20 of 39
FINITE ELEMENT ANALYSIS
No. of Lecture
Hrs/week
Practical/Field
Second
work/Assignment : 02 : 18 weeks
Semester
Hrs/week
1. Calculus of variation, Introduction to calculus of variations, Introduction to

equilibrium equations in elasticity, Euler's Lagrange’s equations, Principal of virtual
work, virtual displacements, Principles of minimum potential energy, boundary
value, initial value problems, Flexibility approach, Displacement approach, Different
problems in structural analysis. (08 Hrs)
2. FEM Procedure, Derivation of FEM equations by variation principle polynomials,
Concept of shape functions, Derivation for linear simplex element, Need for integral
forms, Interpolation polynomials in global and local coordinates. (06 Hrs)
3. Weighted residual Methods: Concept of weighted residual method, Derivation of FEM
equations by Galerkin's method, Solving cantilever beam problem by Galerkin’s
approach, Derivation of shape functions for CST triangular elements, Shape
functions for rectangular elements, Shape functions for quadrila1.eral elements.
(08 Hrs)
4. Higher order Elements: Concept of iso-parametric elements, Concept of sub-
parametric and super -parametric elements, Concept of Jacobin matrix. (06 Hrs)
5. Numerical Integration: Numerical Integration, one point formula and two point
formula for 2D formula, Different problems of numerical integration evaluation of
element stiffness matrix, Automatic mesh generation schemes, Pascal's triangle law
for 2D shape functions polynomial, Pascal's triangle law for 3D shape function
polynomials, Shape function for beam elements, Hermition shape functions.
(08 Hrs)
6. Convergence: Convergence criteria, Compatibility requirements, Geometric isotropy
invariance, Shape functions for iso-parametric elements, Special characteristics of
stiffness matrix, Direct method for deriving shape functions using Langrage's
formula, Plane stress problems. (08 Hrs)
7. Analysis of structures: Truss elements, Analysis of truss problems by direct stiffness
method. Analysis of frames and different problems, Different axi-symmetric truss
problems. (06 Hrs)
Text Book:
1. The Finite Element method -ZIENKIEWICZ.O.C.Tata McGraw Hill Pub. New Delhi, 2000
Page 21 of 39
Reference Books:
1. Finite Elements in Engineering:- Chandrupatta, et. AI. Prentice Hall of India Pvt. Ltd.,
New Delhi, 2000
2. Concepts and Applications of Finite Element Analysis: COOK. D. Robert.
Malus.S.David, Plesha E. Michel, John wilely & sons 3rd Edn. New York, 2000
3. Finite Element Analysis -C.S. Krishnanmoorthy, Tata McGraw Hill Publishing Co. Ltd,
New Delhi, 1995
4. Introduction to the Finite Element method -Desai / ABEL-C.B.S. Publishers &
Distributors, New Delhi 2000
Page 22 of 39
Page 23 of 39
PLASTIC MOULDS DESIGN

No. of Lecture
Hrs/week
Practical/Field
Second
Semester
Hrs/week
INTRODUCTION TO PLASTICS
Monomer, Polymer, Degree of Polymerisation, Classification of Plastics, General review of
Properties, Application and Processing, Behaviors of various plastics PE, PP, PYC, PMMA,
ABS, NYLON, Polyacetal, Polycarbonate, PTFE, PF, UF & MF.
(04 Hrs)
PLASTIC PROCESSING TECHNIQUES
Injection moulding, Extrusion, Blow moulding, Compression and Transfer molding,
Rotational molding, calendaring, Casting etc.
(04 Hrs)
MOULD CONSTRUCTION
Injection mould elements, cores, cavities, and inserts, fitting core and cavity inserts,
pillars and bushes.
(04 Hrs)
FEED SYSTEM
Gates, Runners, Impressions, Layout, Sprues, sprue pullers, mould shrinkage.
(04 Hrs)
EJECTOR SYSTEM
Ejector grids, ejection methods, Ejector Pin, Sleeve ejection, plate ejection, Blade
ejection, Air ejection, Ejection from fixed half, Double ejection, Delayed ejection.
(06 Hrs)
COOLING SYSTEM
Need for cooling, cooling solid cores and cavities, insert cooling, cooling long cores,
cooling elements, baffles, bubblers etc., and cooling calculation.
(06 Hrs)
PARTING SURFACES
Straight, stepped, curved parting surface.
(04 Hrs)
MOULDS WITH EXTERNAL UNDER CUTS
Split moulds, Actuation of splits, Guiding of splits, side cores.
Page 24 of 39
(04 Hrs)
MOULDS WITH INTERNAL UNDER CUTS
Form pins
(02 Hrs)
MOULDS FOR THREADED COMPONENTS
External threads, internal threads, Moulds with loose cores, Automatic unscrewing type
of moulds.
(02 Hrs)
UNDER FEED MOULDS
3 Plate moulds, hot runner moulds (Runner less moulds)
(02 Hrs)
MULTI COLOR MOULDING TOOLS
DEFECTS IN MOULDING AND ITS REMEDIES
COMPRESSION MOULDING TOOLS
TRANSFER MOULDING TOOLS
1. Two plate moulds with pin ejection and edge gate.
2. Two plate moulds with sleeve ejection and submarine gate
3. Two plate moulds with stripper plate ejection
4. Two plate moulds with internal undercut
5. Two plate moulds with spilt mould and mould with side core
6. Two plate moulds for threaded parts (loose core and automatic rack & pinion design).
7. Three plate moulds with multi impressions
8. Compression moulds
9. Transfer moulds
(10 Hrs)
Reference Books:
1. Injection Mould Design-PYE R.G.W.
New-York -John Wiley &. Sons 12th Edt. 1989.
2. Injection Moulding Theory & Practice -RUBIN. J. IRVIN
New York-John Wiley & Sons 1976.
3. Injection Mould 108 Proven design -Gastro.
London -Applied Science Pub. 9th Edt. 1982.
Page 25 of 39
COMPOSITE MATERIALS
(Common to 05 MDE 23 / 05 MMD 23)
No. of Lecture
Hrs/week
Practical/Field
Second
Semester
Hrs/week
1. Introduction to composite materials:
Definition, Classification, Types of matrices & reinforcements, characteristics &
selection, Fiber composites, laminated composites, particulate composites, prepegs,
sandwich construction.
(06 Hrs)
2. Micro mechanical analysis of a lamina :
Introduction, Evaluation of the four elastic moduli – Rule of mixture, ultimate
strengths of unidirectional lamina.
(04 Hrs)
3. Macro mechanics of a lamina :
Hooke’s law for different types of materials, number of elastic constants, Two –
dimensional relationship of compliance & stiffness matrix. Hooke’s law for two
dimensional angle lamina, Engineering constants – angle lamina, Invariants,
Theories of failure.
(10 Hrs)
4. Macro Mechanical analysis of laminate :
Introduction, code, Kirchoff’s hypothesis – CLT, A,B,& D matrices, Engineering
constants, Special cases of laminates, Failure criterion.
(10 Hrs)
5. Manufacturing :
Lay up and curing – open and closed mould processing – Hand lay –up techniques –
Bag moulding and filament winding. Pultrusion, pulforming, Thermoforming,
Injection moulding, Cutting, Machining and joining, tooling, Quality assurance –
Introduction, material qualification, types of defects, NDT methods.
(12 Hrs)
6. Application developments - aircrafts, missiles, space hardware, automobile,
electrical and electronics, marine, recreational and sports equipment-future
potential of composites.
(02 Hrs)
7. Metal matrix composites: Re-inforcement materials, types, Characteristics &
selection, base metals- selection, applications.
(08 Hrs)
Text Books:
1. Mein Schwartz “Composite Materials handbook” Mc Graw Hill Book Company, 1984.
2. Autar K. Kaw “Mechanics of composite materials” CRC Press New York.
Page 26 of 39
Reference Books:
1. Rober M. Joness “Mechanics of composite materials” Mc-Graw Hill Kogakusha
Ltd.
2. Michael W, Hyer “Stress analysis of fiber Reinforced composite materials” Mc-
Graw Hill International.
3. Krishan K. Chawla “Composite material science and Engineering” Springer.
4. P.C. Mallik “Fibre reinforced composites” Marcel Decker.
Page 27 of 39
Page 28 of 39
DESIGN ANALYSIS

No. of Lecture
Hrs/week
Practical/Field
Second
Semester
Hrs/week
INTRODUCTION:
Modeling, meshing, Boundary conditions, Loads, Optimization.

(08 Hrs)
SHEET METAL ANALYSIS:
Metal Flow Analysis, Heat analysis, Micro structure analysis, Stress analysis, Thermo
mechanic processing, Heat transfer analysis, Residual stress analysis, Static analysis,
Contact analysis, Buckling analysis, Bending analysis, Natural frequency.
(14 Hrs)
MOLD ANALYSIS:
Shrinkage analysis, Warpage analysis, Flow analysis.

(06 Hrs)
DIE CASTING ANALYSIS:
3D -mesh generation, Heat flow, fluid flow, Stress and Strain, Microstructure modeling,
inverse modeling, die life estimation.
(12 Hrs)
SOFTWARE USED:
Mold flow, Pro-cast; Pro-Mechanica, De-form.

(12 Hrs)
REFERENCES:
1. Operating Manuals of mold flow, PSG-cast, PSG Mechanica, Deform.
Page 29 of 39
RAPID PROTOTYPING

No. of Lecture
Hrs/week
Practical/Field
Second
Semester
Hrs/week
INTRODUCTION: Need for the compression in product development, history of RP

systems, Survey of applications, Growth of RP industry, and classification of RP systems.
(03 Hrs)
STEREO LITHOGRAPHY SYSTEMS: Principle, Process parameter, Process details, Data
preparation, data files and machine details, Application.
(05 Hrs)
SELECTIVE LASER SINTERING: Type of machine, Principle of operation, process
parameters, Data preparation for SLS, Applications.
(04 Hrs)
FUSION DEPOSITION MODELLING: Principle, Process parameter, Path generation,
Applications.
(03 Hrs)
SOLID GROUND CURING: Principle of operation, Machine details, Applications.
(03 Hrs)
LAMINATED OBJECT MANUFACTURING: Principle, of operation, LOM materials.
Process details, application.
(04 Hrs)
CONCEPTS MODELERS: Principle, Thermal jet printer, Sander's model market, 3-D
printer. Genisys Xs printer HP system 5, object Quadra systems.
(06 Hrs)
LASER ENGINEERING NET SHAPING (LENS)
RAPID TOOLING: Indirect Rapid tooling -Silicone rubber tooling –Aluminum filled epoxy
tooling Spray metal tooling, Cast kirksite, 3Q keltool, etc >Direct Rapid Tooling Direct.
AIM, Quick cast process, Copper polyamide, Rapid Tool, DMILS, Prometal, Sand casting
tooling, Laminate tooling soft Tooling vs. hard tooling.
(10 Hrs)
SOFTWARE FOR RP: STL files, Overview of Solid view, magics, imics, magic
communicator, etc. Internet based software, Collaboration tools.
(06 Hrs)
RAPID MANUFACTURING PROCESS OPTIMIZATION: factors influencing accuracy.
Data preparation errors, Part building errors, Error in finishing, influence of build
orientation.
(10 Hrs)
ALLIED PROCESSES: vacuum casting, surface digitizing, surface generation from point
cloud, surface modification-data transfer to solid models.
(04 Hrs)
Page 30 of 39
Text Books:
1. Paul F. Jacobs: "Stereo lithography and other RP & M Technologies", SME, NY 1996.
2. Flham D.T & Dinjoy S.S "Rapid Manufacturing" Verlog London 2001.
3. Rapid automated by Lament wood . Indus press New York
Reference Books:
1. Terry Wohlers "Wohler's Report 2000" Wohler's Association 2000.

2. Rapid prototyping materials by Gurumurthi, IISc Bangalore.
NOTE: To cover syllabus by referring to the following books and websites for the
respective chapters.
Chapter
Topic Book Name / Web Site
no.
• www.cadcamnet.com
• Introduction • www.home.att.net.castelisland
1
• Classification of RP system • Rapid Manufacturing by D.T.Pham & S.S.
Dimov.
• Rapid Manufacturing by D.T.Pham & S.S.
Dimov.
2 • Stereolithography
• Stere lithography & other RP & M Technologies
by aul F. Jacobs.
3 • Selective Laser Sintering • www.cadcamnet.com
• www.cadcamnet.com
• Rapid Manufacturing by D.T. Pham & S.S.
4 • Fusion Deposition Modeling Dimov
• A Brief Introduction: Rapid Prototyping by
Amitabh gosh.
5 • Solid Ground Curing
Dimov
• Laminated Object Dimov
6
Manufacturing • A Brief Introduction: Rapid Prototyping by
Amitabh gosh.
7 • Concept Modelers
Dimov
• Laser Engineering Net • www.optomee.com
8
Shaping (LENS)
• Rapid Manufacturing by D.T.Pham & S.S.
• Rapid Tooling Dimov.
9 • Quick Cast • Stere lithography & other RP & M Technologies
• Direct aim & Keltool by aul F. Jacobs.
• www.3dsystems.com
10 • Software for PP • www.materalise.com
• Process Optimisation • Rapid Manufacturing by D.T.Pham & S.S.
11 • Introduction to Taguchi’s Dimov.
method for optimization
12 • Allied Process • Stere lithography & other RP & M Technologies
• Vacuum casting by aul F. Jacobs.
Page 31 of 39
• www.mep-group.co.uk
Question Paper Pattern:

Chapter No.1 to 8  60%  05 Questions.
Chapter No.9 & 12  30%  02 Questions.
Chapter No.10 & 11  10%  01 Questions.
Sl. No. Q. No. From Chapter No. & Topic Book Name / Web Site
1 2 1. Introduction Rapid Manufacturing by
2. Stereolithography D.T.Pham & S.S. Dimov.
2 1 3. Selective Laser Sintering www.cadcamnet.com &
4. Fusion Deposition Modeling Rapid Manufacturing by
D.T.Pham & S.S. Dimov.
3 1 5. Solid Ground Curing Rapid Manufacturing by
6. Laminated Object Manufacturing D.T.Pham & S.S. Dimov.
& A Brief Introduction:
Rapid Prototyping by
Amitab gosh
4 1 7. Concept Modelers Rapid Manufacturing by
8. Laser Engineering Net Shaping D.T.Pham & S.S. Dimov.
(LENS) & www.optomee.com
5 2 9. Rapid Tooling Rapid Manufacturing by
12. Allied Process D.T.Pham & S.S. Dimov.
&
Stere lithography & other
RP & M Technologies by aul
F. Jacobs.
www.mep-group.co.uk
6 1 10. Software for RP Rapid Manufacturing by
11. Rapid Manufacturing Process D.T.Pham & S.S. Dimov.
Optimization &
www.materalise.com
Page 32 of 39
PLASTIC PROCESSING

No. of Lecture
Hrs/week
Practical/Field
Second
Semester
Hrs/week
PLASTIC PROCESSING
Basic principle of processing, shape and size, processing parameters, their effect and
behavior, Rheology of ideal fluids, and real polymers, Effects of melt behavior on
processing and product performance.
(04 Hrs)
INJECTION MOULDING:
Principles, process variables, moulding cycle, machinery used, parts and function,
specification, construction and maintenance of injection moulding machine, start up and
shut down procedure, cylinder, nozzles, interaction of moulding variables, press capacity,
projected area, shot weight, concepts and their relationship to processing, trouble
shooting in injection moulding, microprocessors controlled injection moulding machines.
(06 Hrs)
EXTRUSION:
Basic principles of extruders, and extrusion process, different types of extrudes i.e.
barrel, screw, drive mechanics, head, constructional features of dies, sizing and haul-off
equipment for extruders of mono filaments and tubes, blown film lines, wire and cable
covering system, pipe profile extrusion, co-extrusion, process variables in extrusion like
heating, temperature control, dies well, and melt fracture, spacing and orientation,
treating, printing and sealing, quality of extruder products, fault, causes and remedy.
(06 Hrs)
COMPRESSION AND TRANSFER MOULDING:
Techniques, various types of compression moulds, machinery used, and common
moulding faults and remedies. Transfer moulding, its advantage over compression
moulding, equipment used, press capacity, integral mold, and auxiliary mould, moulding
cycle, ram pressure, clamping pressure, faults and remedies.
(06 Hrs)
Page 33 of 39
BLOW MOULDING:
Blow moulding process, processing parameter, materials used, hand operated and
automatic blow moulding machine, extrusion blow moulding, moulding cycle, faults and
remedies.
(04 Hrs)
THERMO FORMING:
Basic principles, types of thermoforming, thermoforming moulds, processing parameters,
faults and remedies
(04 Hrs)
ROTATIONAL MOULDING:
Basic principle, charge size, wall thickness, temperature control, fault causes and
remedies.
(04 Hrs)
CALENDARING:
Basic principle, process variable, end product properties and applications, secondary
processing techniques like powder coating, casting, machining, and joining of plastics,
metalizing, printing, post moulding operations.
(06 Hrs)
COMPOUNDING:
Single screw and twin screw compounding techniques, processing of engineering plastics,
precautions, and start up procedure, preheating, shutdown procedure, quality control,
and waste management.
(06 Hrs)
RAM EXTRUSION OF PTFE:
Processing of reinforced plastics, like filament winding, Hand-lay-up, spray moulding,
SMC, DMC, Centrifugal casting, pultrusion, resin transfer moulding.
(06 Hrs)
Page 34 of 39
Reference Books:
Injection Mould Design -PYE R.G. W. - New York-John Wiley & Sons l2th Edt.1989
1. Injection Moulding Theory & Practice -RUBIN. J. IRVIN - New York -John Wiley & Sons
1976.
2. Blow moulding Hand Book –ROSATO - New York -Oxford University -Hanser
Publishers -1989.
3. Principles of rotational moulding process -BRUINS
4. Rotational Moulding of Plastics -R.J. CRAWFORD I New York -Research studies press
Ltd. -1992.
Page 35 of 39
CNC MACHINE

No. of Lecture
Hrs/week
Practical/Field
Second
Semester
Hrs/week
INTRODUCTION
(04 Hrs)
CNC MACHINE PROGRAMMING:
TURNING
Ways of Turning, Pans of CNC Machine, Working method of CNC, Co-ordinate system,
CNC Co-ordinate System, Dimensioning System, Datum point & Reference point,
Movement Instruction, Machine Instruction, Tool Instruction, Dimension Instruction,
Datum point shift, Basic Programming in Turning, Introduction to G & M Codes, ISO
Program format, Sample Program, Create Programming for Step Turning, Contour
Program, Taper Turning, Drilling, Grooving, Boring, Threading & Parting, Measuring Tool
offset & length, Load Program, Check tool management, Safety regulation in turning
(20 Hrs)
MILLING
Ways of Milling, Parts of CNC machine, working method of CNC, Co-ordinate System, CN
C Co-ordinate system, Dimensioning System, Datum point & Reference point, Movement
Instruction, Machine Instruction, Tool Instruction, Dimension Instruction, Datum point
shift, Basic Programming in Milling, Sample Program, Create Programming for
Components, Tests, Simulation, Contour Program Using ATC, Standard Milling, Pocket
Milling, 'Slot milling, Circular Pocketing, drilling (Pecking), mirror Image, Datum Shift,
Rotation, Label Function, Measuring Tool offset & length, Load Program, Check tool
management, Documenting the program, Safety Regulation in Milling.
(20 Hrs)
CASE STUDIES
Trail on Sinumerik 2100 Lathe Machine, Trail on Heidenhain Control Milling Machine, Trail
on Fanuc Control Turning Machine
(08 Hrs)
Reference Books:
1. CNC -A first look -LUGGIN
2. Advances NC -GROOVER
Page 36 of 39
ADVANCED MOULDS TECHNIQUES

No. of Lecture
Hrs/week
Practical/Field
Second
Semester
Hrs/week
INJECTION MOULDING TECHNOLOGY:

Microprocessor control injection moulding machine, close loop control, open loop control,
CNC control, multi color injection moulding, rotary injection moulding, structural foam
moulding, sandwich injection moulding, metal injection moulding, contact injection
moulding, moulding of cellular product like EPS, steam chest moulding, future trends in
injection moulding like external & internal inter locking alignment of large moulds,
processing of specialty polymers.
(12 Hrs)
EXTRUSION:
General consideration during extrusion process like specific heat, latent heat, internal
conductivity, shape & size of granular hygroscopic nature over temperature, effect of flow
property like relaxation time & defects like shark skin, elastic turbulence, influence of TG,
TM & crystal growth rate, cooling rate, impact strength, manufacturing of woven sacks
etc. co extrusion, co extruded pipe, muilt layer pipe, foam pipe, biaxial oriented pipe.
(08 Hrs)
LAMINATES
Lamination by extrusion coating, twin screw extrusion, co-rotating & counter rotating,
feeding mechanism in twin screw extruder, roll of side feeder & injection feeder,
principles of compounding, mixing mechanism etc.
(06 Hrs)
BLOW MOULDING:
Micro processor / CNC controlled blow moulding machine, injection stretch blow moulding
of PET, precut moulding, multi layer blow moulding, Parission programming.
(06 Hrs)
REACTION INJECTION MOULDING (RIM):
RIM of Polyurethane, material for RIM, liquid RIM & its advantages over conventional
injection moulding, RRIM:
(06 Hrs)
PTFE MOULDING:
Processing techniques used for PTFE, Material consideration, sintering, Ram extrusion,
and Paste extrusion, lso statistic. Moulding and skewing technique for PTFE processing.
(06 Hrs)
ADVANCEMENT IN OTHER PROCESSING TECHNIQUE:
New techniques like Resin transfer moulding, Pultrusion. Filament winding, multi layer
rotation moulding, Electro plating and printings, Centrifugal casting, Shrink film, Clink
film.
(08 Hrs)
Reference Books:
Page 37 of 39
1. Injection moulding -RUBIN
2. Extrusion -BERlN
3. Extrusion die design -M. V. JOSHI.
4. Polymer Chemistry -GOWRIKER
5. Plastic Extrusion Technology - New York -Hanser Publications.
Page 38 of 39
LASERS IN MANUFACTURING
No. of Lecture
Hrs/week
Practical/Field
Second
Semester
Hrs/week
An overview of Applications of high power lasers in various manufacturing activities.

(08 Hrs)
Gas-CO2 solid state ND- YAG and other typical lasers in continuous wave and pulsed
modes lasing principles and lasers in measurement.
(08 Hrs)
Lasers marking, engraving and holographic imagery.
(06 Hrs)
Laser cutting and drilling of various metallic, ceramics and non metallic-wood & fiber.
(06 Hrs)
Lasers caving- (Lasers die sinking).
(06 Hrs)
Laser assisted machining (LAM).
(06 Hrs)
Lasers joining -including dissimilar materials.
(06 Hrs)
Laser material processing, alloying and cladding.
(06 Hrs)
Reference Books:
1. Laser hand Book publishers.
2. BL.Mordike Laser Treatment of materials: DGM Information.

Gesellsahaft. Verlag 1992 Germany.
3. Laser & Electron Beam Material Processing

N.R YKALIN, A. UGLOV, I.ZUEV, A.KOKORA, MIR Publishers 1999.
Page 39 of 39

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SCHEME AND SYLLABUS OF M.

VISVESVARAYA TECHNOLOGICAL UNIVERSITY

No. of hours / week Marks for

No. of hours / week Marks for

No. of hours / week Marks for

Fourth Semester (22 weeks)

No. of hours / week Marks for

Grand Total form (Ist to IVth semester) : 2000

2. Industrial Training: 8 weeks of compulsory Industrial training to be

3. The seminar Marks are to be awarded by the department committee

4. The project evaluation and Viva-Voce will be conducted by a committee

4.1 Head of the department (Chairman)

Sub Code : 05 MTE 11 IA Marks : 50

DIE CASTING ALLOYS

DIE CASTING MACHINES

DIES WITH SIDE CORES

DIE CASTING, DEFECTS AND REMEDIES

1.3) STRESS -STRAIN RELATIONS

Sub Code : 05 MTE 141 IA Marks : 50

FITS AND TOLERANCE

Limits Fits and Tolerances.

1. Engineering Metrology by R.K. JAIN

Sub Code : 05 MTE 142 IA Marks : 50

PRINCIPLES OF METAL CUTTING

Sub Code : 05 MTE 143 IA Marks : 50

INDEXING JIGS & FIXTURES

DESIGN OF JIGS AND FIXTURE BODIES AND OTHER ELEMENTS

Sub Code : 05 MTE 151 IA Marks : 50

Overview of CAD/CAM System in brief: Introduction, CAD/CAM contents and tools,

Computer Aided Manufacturing:

Materials handling and storage systems in brief:

1. CAAD/CAM Theory & Practice -Ibrahim Zeid

Sub Code : 05 MTE 152 IA Marks : 50

TOOL STEELS &ITS CLASSIFICATION:

1. Properties of Engineering Materials -R.A. HIGGINS.

1. Calculus of variation, Introduction to calculus of variations, Introduction to

Sub Code : 05 MTE 22 IA Marks : 50

Sub Code : 05 MTE 241 IA Marks : 50

Modeling, meshing, Boundary conditions, Loads, Optimization.

Shrinkage analysis, Warpage analysis, Flow analysis.

Mold flow, Pro-cast; Pro-Mechanica, De-form.

1. Operating Manuals of mold flow, PSG-cast, PSG Mechanica, Deform.

Sub Code : 05 MTE 242 IA Marks : 50

INTRODUCTION: Need for the compression in product development, history of RP

1. Terry Wohlers "Wohler's Report 2000" Wohler's Association 2000.

Question Paper Pattern:

Sub Code : 05 MTE 243 IA Marks : 50

Sub Code : 05 MTE 251 IA Marks : 50

1. CNC -A first look -LUGGIN

Sub Code : 05 MTE 252 IA Marks : 50

INJECTION MOULDING TECHNOLOGY:

An overview of Applications of high power lasers in various manufacturing activities.

1. Laser hand Book publishers.

2. BL.Mordike Laser Treatment of materials: DGM Information.

3. Laser & Electron Beam Material Processing

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