Detailed Syllabus

SEMESTER 1



04O101 COMMUNICATION SKILLS



READING: Selection of essays and short stories – to develop reading ability, Syntax and

Vocabulary.



FOCUS ON LANGUAGE: Functional Grammar – Tenses in context – Modals in context – Use of

articles and propositions – Spoken Grammar in context.



WRITING: Practice in writing - Note making – Summarizing – organizing and writing paragraphs and

essays – Writing messages – Reviews of stories and articles – Letter writing.



SPEAKING: Speech making practice – Conversation practice using Role plays – simulated activities.





04O102 MATHEMATICS I



MATRICES: Rank of a matrix, vector Space, basis, dimension. Linear transformation. Consistency

and inconsistency of a system of linear algebraic equations. Eigenvalues and Eigen vectors.

Quadratic forms – reduction to canonical form byorthogonal reduction.





APPLICATIONS OF DIFFERENTIAL CALCULUS: Curvature, circle of curvature, evolutes, involutes,

envelopes. Statement of Taylor‟s series for a function of two variables. Maxima and Minima of two

variables (Problems only). Constrained maxima and inima – Lagrange multipliers method.





MULTIPLE INTEGRALS: Evaluation of multiple integrals, change of order of integration, application

of multiple integrals to find area enclosed by plane curves and volume of solids.





BETA AND GAMMA INTEGRALS: Definition, relation connecting Beta and Gamma integrals,

properties, evaluation of definite integrals in terms of Beta and Gamma functions.





VECTOR CALCULUS: Differentiation of vectors – gradient, divergence and curl, directional

derivative. Line,Surface and Volume integrals – statements of Green‟s Theorem, Gauss Divergence

Theorem and Stoke‟s Theorem, applications.





SELF STUDY:

ALGEBRA: concept of convergence and divergence of an infinite series (No question need to be set).

Binomial, Exponential and Logarithmic series – summation of series using Binomial, Exponential and

n

Logarithmic series, finding coefficient of X in power series expansion, approximation using Binomial,

Exponential and Logarithmic series.









04O103 APPLIED PHYSICS I





ULTRASONICS: Introduction. Production – magnetostriction effect, magnetostriction generator,

inverse piezoelectric effect, piezoelectric generator. Detection of ultrasonic. Properties. Cavitation.

Industrial applications – drilling, welding, soldering and cleaning. Non Destructive Testing – pulse

echo system, through transmission, resonance system. Medical applications – cardiology,

neurology, ophthalmology, ultrasonic imaging.

LASERS: Introduction. Principle of spontaneous emission and stimulated emission. Population

inversion, pumping. Types of lasers - He-Ne, CO2, Nd YAG, Excimer, Dye lasers ,Semiconductor

laser. Spectroscopic analysis of materials. Applications - lasers in microelectronics, welding, heat

treatment, cutting, holography, defence and ranging. Applications of Excimer and Dye laser.



FIBER OPTICS AND APPLICATIONS: Principles. Modes of propagation. Fabrication technique -

crucible-crucible technique. Classification based on materials, refractive index profile. Splicing.

Losses in optical fiber. Light sources for fiber optics. Detectors. Fiber optical communication links.

Fiber optic sensors - temperature, displacement, voltage and magnetic field measurement.



QUANTUM PHYSICS: Development of quantum theory. Dual nature of matter and radiation - de

Broglie wave length. Uncertainty principle. Schrodinger‟s equation. Particle in a box. Limitations of

optical microscopy. Electron microscope. Scanning electron microscopeTransmissionelectron

microscope, STEM applications.





VACUUM SCIENCE: Introduction. Schematic diagram of a vacuum system. Applications and

scope. Pumping speed and throughput. Types of pumps - rotary pump, diffusion pump, turbo

molecular pump. Working principle and construction, operation of gauges - pressure range,

limitations and pumping characteristics, measurement of vacuum using Pirani and Penning gauge.







04O104 APPLIED CHEMISTRY I



THERMODYNAMICS: Systems and surroundings, work and heat, measurement of work and heat,

internal energy and enthalpy, temperature variation of enthalpy. Limitations of first law and need for

second law of thermodynamics, entropy and second law, entropy changes in the surroundings,

absolute entropy and third law of thermodynamics, spontaneity of chemical reactions, properties of

Gibbs free



WATER: Hardness - unit, determination (EDTA method). Softening - principles of lime soda and

zeolite processes, calculations, demineralization process. Boiler troubles and remedies, removal of

oils and silica, internal conditioning, treatment of water for municipal supply, break point chlorination,

desalination by electro dialysis and reverse osmosis, water quality standards and parameters.



POLYMER AND PLASTICS: Introduction - classification, functionality of monomers, molecular weight

of polymer. Polymerization reactions - chain, condensation, co polymerization and co-ordination

polymerizations, synthetic rubber, plastics - advantages and disadvantages, thermo plastics and

thermo set plastics, compounding of plastics, polymer processing by injection, extrusion and blow

mouldingtechniques.



ENVIRONMENTAL CHEMISTRY: Air pollution, chemicals and dust, metal toxicity, toxic materials and

gases, causes and prevention, global warming, ozone hole. Water pollution - sources, aerobic and

anaerobic oxidation, BOD and COD definitions and significance, sewage and its treatment.



CHEMISTRY OF ADVANCED MATERIALS: Organic electronic material, solid oxide materials,

memory materials, Nanomaterials, Buckminster fullerenes.

04C106 BASICS OF ENGINEERING



ELECTRICAL ENGINEERING:

ELECTRICAL CIRCUITS: Ohm‟s law and Kirchoff‟s laws – Simple problems in DC Circuits –

Alternating current and voltage – RMS and Average values of sinusoidal waveforms – Simple

problems in single-phase AC circuits – Introduction to three-phase AC circuits.



MAGNETIC CIRCUITS: Inductance – Self and Mutual, Transformer – Construction and principle of

operation of single-phase transformer, Introduction to three phase transformers.



ELECTRIC DRIVES:DC generator – Principle of operation, DC Motor – Construction, principle of

operation and characteristics, Three-phase induction motor – Principle of operation, Torque equation

and Mechanical characteristic - Types of single phase induction motor - Selection of motors for

cranes, machine tool applications, Centrifugal pump and rolling mills.



ELECTRONICS ENGINEERING:

ELECTRONIC CIRCUITS: Semi Conductor Diodes – P-N Junction, Zener Diodes and power supply,

Transistors - Bipolar Junction Transistors (BJT) and Junction Field Effect Transistors (JFET);

MOSFET‟s, RC Coupled amplifiers, Operational amplifiers – Block diagram, Applications – Inverting,

Non Inverting Amplifiers, Adder, Subtractor, Differentiator, Integrator and Comparator.



DIGITAL CIRCUITS: Number systems – Binary, Octal and Hexadecimal, Logic gates – AND, OR,

NOT, NAND, NOR, EXOR, EXNOR, Half adder, Full adder, Parallel adder/Subtractor, Flip flops - RS,

JK, Master slave, D and T types, Introduction to counters and registers.



MECHANICAL ENGINEERING:

ENERGY CONVERSION SYSTEMS: Principle of Internal and external combustion engines-auto

engine-diesel engine. Electricity generation-hydro-thermal-nuclear-solar power plants layout and

principle of operation. -energy efficiency-green house,- gas emission.



FOUNDRY TECHNOLOGY: Moulding process-properties of moulding sand-methods of moulding –

tools and equipments used. Casting-different methods-melting furnaces-cupola-defects in casting-

inspection of casting.



METAL FORMING: Hot and cold forming. Welding processes-arc & gas welding-AC & DC welding

equipments-TIG-MIG-Submerged arc-Thermit welding- resistence welding. Brazing and soldering.





04P107 ENGINEERING GRAPHICS



INTRODUCTION: Introduction to Engineering Drawing. BIS. Geometric Constructions. Principles

of dimensioning. Conic sections and special curves.



ORTHOGRAPHIC PROJECTION: Principles of orthographic projection-projection of points, straight

lines, planes and solids. Orthographic projection of simple engineering components-missing view

exercises.



PICTORIAL PROJECTIONS: Principles of pictorial views, isometric view of simple engineering

components. Free hand sketching of orthographic views from pictorial views. Free hand sketching of

isometric views from given two or there views.



INTRODUCTION TO COMPUTER GRAPHICS-Demonstration only.

SEMESTER II



04O105 C PROGRAMMING



INTRODUCTION: Need for studying Computer Programming Languages. Role of Programming

Languages. Problem definition and analysis. Developing algorithm. Procedural Programming

(modular and structural)-Top-Down approach. Program compilation, execution, debugging and testing



C LANGUAGE BASICS: C language program structure, C Character set, identifiers and keywords.

Data types – Constants, variables. Arrays. Declaration. Expression. Statements. Symbolic Constants.

Operators & Expressions – Arithmetic operators, unary operators, relational & logical operators,

assignment operators, conditional operator, comma operator. Library Functions – Data input and

output function.



CONTROL STATEMENTS: Conditional Branches- if statement, types of if statement, switch case,

break, continue go to statement. Conditional control statement - while statement, do while statement,

for loop, nested for loops.



FUNCTIONS: Defining a function, accessing a function, passing arguments to functions, function

signatures (specifying arguments data type), function prototypes, nested function call. Storage

classes – Auto, static, register and external variables.



ARRAYS: Defining an array, declaration of array, Initialization of array, assignment of array,

processing array, passing array to a function, two and multi dimensional array, array and strings.



POINTERS: Pointer variable declaration, initialization and assignment, pointers to a function, pointers

and one dimensional array and multi dimensional array, operating a pointers, array of pointers,

passing function to other functions.



STRUCTURES AND UNIONS: Definitions, processing a structure, user defined data types,

structures and pointers, passing structure to functions, self referential and nested structures. Defining

a Union, processing unions, structures and unions comparison.



FILES: Introduction to files, file access, file organization, file operations (open, close, read, write,

etc.)



Preprocessor Directives: Bit fields. Command line arguments. Bit wise operators.





LIST OF PRACTICALS:



SIMPLE PROGRAMS USING DECISION-MAKING AND LOOPING STATEMENTS



1. Write a program to calculate the simple interest, given the principle, period and rate of interest.

(Simple Interest = PNR / 100)



2. Write a program to convert the temperature from Fahrenheit to Centigrade and vice versa. ( F

= 1.8 x C +32 ; C = ( F - 32 ) / 1.8 )



3. Write a program to find the largest of 3 numbers using the minimum possible checks. (Simple

if)



4. Write a program to convert binary to decimal number using while loop.



5. Write a program to find all possible roots of quadratic equation using switch case.



6. Write a program to read a particular number and to check whether it is a prime number or not.

7. The telephone company has to print up the bills for its customers at the following rate:



st

For the 1 50 calls rate is Rs.25 (Fixed)

For the next 100 calls rate is Rs.6 (per 10 calls)

For the next 200 calls rate is Rs.7 (per 10 calls)

For more than 350 calls rate is Rs.8 (per 5 calls)



Write a program to do the above and the output should be in the following order Customer name,

Number of Calls and the Total Bill.



PROGRAMS USING FUNCTIONS



8. Write a program using function that will round a floating point number to an indicated decimal

place. For example, the number 12.758



9. would yield the value 12.76 when it is rounded off to two decimal places.



10. Write a function exchange to interchange the values of two variables say x and y.



11. Write a recursive function that will generate and print first n Fibonacci series.



PROGRAMS USING ARRAYS



12. Write a program to merge two different sized arrays and eliminate the duplicate from the

merged array.



13. Write a menu driven program for inserting an element into an array and for deleting an element

from the array. Program should also have the provision for deleting the duplicates in an array.



14. Write a program to multiply two matrices. Use separate functions to read, process and print the

data in matrix form. Also find the trace and transpose of the given matrix.



15. A list of N numbers is given. Write a program to find



Their average and standard deviation.



The number of integers, which are greater than equal to a specified number in the list.



16. Using arrays write a program to arrange the given set of N numbers in ascending order and

hence to pick the greatest and the smallest number. And also find the presence of a specified

number.



STRING HANDLING PROGRAMS



17. Write a program to count number of vowels, consonants, words, white spaces and other

characters in a given line of text.



18. Write a program to check whether the given string is a palindrome or not.



19. Write a program to find the occurrence of a sub string in a main string and if found replace it

with new string.



20. Write a program to sort the set of names in alphabetical order.

21. Write a program using gets () and puts () which converts a given „C‟ program typed in

uppercase to a program in lowercase.



PROGRAMS USING STRUCTURES



22. Create a structure to store the following details:



Rollno, Name, Mark1,Mark2,Mark3, Total, Average, Result and Class.



Write a program to read Rollno, name and 3 subject marks. Find out the total, result and class

as follows:



a. Total is the addition of 3 subject marks.



b. Result is “Pass” if all subject marks are greater than or equal to 50 else “Fail”.



c. Class will be awarded for students who have cleared 3 subjects



i) Class “Distinction” if average >=75



ii) Class “First” if average lies between 60 to 74 (both inclusive)



iii) Class “Second” if average lies between 50 & 59 (both inclusive)



d. Repeat the above program to manipulate 10 students‟ details and sort the

structures as per rank obtained by them.



23. Define a structure that can describe the employees with the fields Eno, Ename, Basic. Write a

program to calculate DA = 32% of Basic, HRA = 15% of Basic, CCA = 10% of BASIC, PF =

15% of Basic and print all details with Netpay. All processing should be using pointer notation.



PROGRAMS USING POINTERS



24. Write a program to count the number of consonants, vowels, digits, white spaces and other

characters in a line of text using pointers.



25. Write menu driven program to perform all string handling operations using pointers.



26. Write a program to sort a list of strings in an alphabetical order (using pointers with DMA).



27. Write a menu driven program to perform addition, subtraction and multiplication of matrices

using pointers.



28. Write a program to search for an element using binary search.



29. Write a program for encryption of a given sentence and decryption of the same sentence.



PROGRAMS ON FILE MANAGEMENT



30. Write a program to generate a file containing the list of customers and their telephone numbers.

Use a structure variable to store the information. Display the customer name if the telephone

number is specified.



31. A file named DATA contains a series of integer numbers. Code a program to read these numbers

and then write all odd numbers to a file called ODD and all even numbers to a file called EVEN

04O201 COMMUNICATION SKILLS II



LISTENING: Listening Comprehension - Listening for Specific Information - Information transferring.



SPEAKING: Speaking in Technical Context – Describing a process, mechanism and making short

speeches.

READING: Comprehending reading material for professional purposes - scanning for details and

making inferences - Practice in cloze test to enhance global reading comprehension skills and

appropriate linguistic knowledge.



WRITING: 1. Technical Composition – Definitions, Physical, Functional and process Descriptions.

2. Structure, Function and Types of Reports, Instructions – Writing Laboratory Reports.







04O202 MATHEMATICS II



ORDINARY DIFFERENTIAL EQUATIONS: Solutions of first order differential equations of the form

dy/dx = (ax + by + c) / (a‟x + b‟y + c‟), exact equation, integrating factors. Linear differential equations

of higher order with constant coefficients. Euler‟s equations with variable coefficients. Simultaneous

equations. Method of variation of parameters. Linear Equation of the 2nd order- complete solution

given one solution of homogeneous equation.



APPLICATIONS OF DIFFERENTIAL EQUATIONS: Applications to electric circuits, bending of

beams, problems on motion of a particle in a resisting medium and simple harmonic motion.

(Differential equations and associated conditions need to be given).



SPECIAL FUNCTIONS: Definition of Bessel functions, Legendre polynomials- Recurrence relations,

Generating functions, orthogonality.



FOURIER SERIES: Dirichlet‟s conditions, statement of Fourier theorem. Fourier coefficients, change

of scale, half range series, complex form of Fourier Series, root mean square value.







SELF STUDY:



THREE DIMENSIONAL GEOMETRY: Direction cosines and ratios, equation of planes, straight lines,

shortest distance between two skew lines, sphere.



04C203 APPLIED PHYSICS II



THERMAL PHYSICS: Mode of heat transfer. Coefficient of thermal conductivity. Thermal diffusivity.

Flow of heat - Rectilinear flow of heat along a bar (Derivation), Radial flow of heat - Spherical shell

method. Thermal conductivity of rubber tube. Thermal conductivity of powder materials. Conduction

through compound media. Thermal insulation in the buildings. Practical application of heat

conduction and convection – Conductivity of the earth‟s crust and age of earth, Ventilation,

Radiators, Central heating, Gas filled electric lamps.



CONDUCTING MATERIALS: Classical free electron theory of metals. Electrical conductivity

expression (derivation), Wiedmann Franz law (Derivation). Lorentz number. Drawbacks of classical

theory. Fermi distribution function. Superconducting Phenomena. Properties of superconductors -

Meissner effect, Isotope effect, Type I and Type II superconductors, High Tc superconductors.

Applications – Magnetic levitation and SQUIDS.



SEMICONDUCTING MATERIALS: Origin of band gap in solids (qualitative treatment only).

Concepts of effective mass of electron and hole. Carrier concentration in an intrinsic semiconductor

(Derivation). Fermi level, Variation of Fermi level with temperature. Electrical conductivity. Band

gap determination. Hall effect, Determination of Halloefficient.



MAGNETIC AND DIELELCTRIC MATERIALS: Properties of dia, para, ferro, antiferro and ferri

magnetic materials. Hysteresis. Hard and soft materials. Anti-ferromagnetic materials. Ferrites -

Properties, characterisation, preparation and applications. Dielectric materials – Ionic, orientational

and space charge polarization. Frequency and temperature dependence of polarization, Internal field

and deduction of Clausius-Mossotti relation. Dielectric losses. Dielectric breakdown. Classification

of insulation materials – Ferroelectric materials, Properties and applications..



NEW ENGINEERING MATERIALS: Metallic glasses – Glass formation, properties and applications.

Fibre reinforced plastics (FRP) and fibre reinforced metals (FRM). Shape memory alloys –

Characteristics, Properties of NiTi alloys, applications. Advanced ceramic materials – Processing,

Forming, Thermal treatment, Ferroelectric and ferromagnetic ceramics, Aluminum Ceramics.





04C204 APPLIED CHEMISTRY II



CHEMICAL BONDING: Types of bonding, van der Waals forces of attraction, hydrogen bonding,

coordinate bond, chelates, industrial application of co-ordination complexes, metallic bond - band

theory.



CORROSION AND CORROSION INHIBITION: Corrosion, causes of corrosion, principles of chemical

corrosion, Pilling, Bedworth rule, principles of electrochemical corrosion, factors influencing corrosion,

types of corrosion - galvanic corrosion, differential aeration corrosion, stress corrosion, soil corrosion,

pitting corrosion, water line corrosion. Corrosion control - cathodic protection, sacrificial anode,

selection of materials and proper designing, corrosion inhibitors.



PROTECTIVE COATING: Paints - constituents, functions, mechanism of drying. Varnishes and

lacquers. Special paints - fire retardants, water repellent, temperature indicating and luminous paints.



CHEMISTRY OF BUILDING MATERIALS AND COMPOSITES: Cement - chemical composition,

setting and hardening. Concrete, weathering of cement and concrete and its prevention. Special

cements - high alumina cement, sorel cement, white portland cement, water proof cement. Lime -

classification, setting and hardening. Refractories - requisites, classification, common refractory

bricks, preparation, properties and use of silica bricks, high alumina bricks, magnesite bricks, carbon

bricks, zirconia bricks and carborundum. Composites - definition of composites, characteristics,

constituents of composites, types, fibre reinforced plastics (FRP), metal matrix composites (MMC),

ceramic matrix composites (CMC), properties and applications.



CEMENT REPLACEMENT MATERIALS: Rice husk ash - chemical constituents of rice husk ash,

method of production of rice husk ash cement. Pulverized fuel ash (pfa) - classification and

characterization, specifications for pfa and their significance, influence of pfa on hydrating concrete,

durability of pfa, specific application and recent developments of pfa.







04P208TECHNICAL DRAWING

SECTION OF SOLIDS: Sections of regular solids, types of sections, BIS conventions, selection of

sectional views. Sectional views of simple engineering components.



DEVELOPMENT OF SURFACES: Development of lateral surfaces of regular solids, truncated solids

and simple engineering sheet metal components.



COMPUTER GRAPHICS: Introduction to 2D and 3D modeling packages. Drafting practices -

modeling of simple engineering components, sections and extraction of 2D drawings.









04P209 APPLIED PHYSICS LAB





1. Young‟s modulus of a material-cantilever method.



2. Magnetic hysteresis.



3. Coefficient of thermal conductivity of bad conductor Disc Method



4. Coefficient of viscosity-Poiseuille‟s Method.



5. Lattice Parameters-powder photographic technique.



6. Measurement of temperature-thermistor



7. Efficiency of solar cell



8. Electrical conductivity of metal and Alloy-Carey Foster Bridge.



9. Demonstration of optical phenomena using He-Ne Laser



10. Demonstration of determination of laser parameters.







04P210 APPLIED CHEMISTRY LAB



1. Estimation of oxalic acid.



2. Estimation of hydrogen peroxide.



3. Estimation of potassium dichromate.



4. Estimation of total hardness of water by EDTA method.



5. Conductometric estimation of a strong acid.



6. Potentiometric estimation of a strong acid.



7. Determination of hardness of water by ion-exchange method.



8. Study of viscosity of a lubricating oil using Saybolt / Redwood viscometer and determination of

flash and fire point of a lubricating oil.



9. Estimation of alkalinity in water.

10. Estimation of moisture and ash content of coal.







SEMESTER III

04P301 ENGINEERING MATHEMATICS



LAPLACE TRANSFORMS: Laplace transform, inverse transform, shifting, transforms of derivatives

and integrals, unit step functions, second shifting theorem, dirac‟s delta function, differentiation and

integration of transforms, convolution, transform of periodic functions. Solution of ordinary linear

differential equations with constant coefficients and integral equations by Laplace transform

technique.



FOURIER TRANSFORMS: Fourier transforms, finite and infinite Fourier sine and cosine transforms,

transforms of standard functions, properties, convolution theorem ( Statement only). Discrete Fourier

and Fast Fourier Transform – discrete convolution, periodic sequence and circular convolution, DTFT,

decimation-in-time algorithm, decimation-in-frequency algorithm, computation of Inverse DFT.



Z-TRANSFORMS: Z–transform of standard functions, inverse Z-transform (Partial fraction

expansions), properties of Z-transform. Solution of difference equations.



COMPLEX VARIABLES: Analytic functions - Cauchy-Riemann equations in Cartesian and Polar-

coordinates, statement of sufficient conditions, properties of analytic functions, singularities,

construction of analytic functions whose real / imaginary part is given. Complex integration - Cauchy

's fundamental theorem and formula, Taylor's series, Laurent's series, Residue theorem (statement

only), evaluation of real integrals using Contour integration along semi circle and unit circle.



LINEAR ALGEBRA : Vector Spaces. Sub spaces. Basis and Dimension, Inner product, orthogonality,

Gram – Schmidt Orthoganalization Process, Applications to linear models.



PARTIAL DIFFERENTIAL EQUATIONS: Separable partial differential equations - Classical

equations and Boundary-value problems. One dimensional wave equations. One dimensional heat

equation. Two dimensional heat equations. Laplace equations of two dimensions

(CartesianandPolar).Orthogonal series expansion.



04P302 KINEMATICS OF MACHINERY



BASICS OF MECHANISMS: Terminology and definitions, degree of freedom, mobility. Grashoff‟s

law. Kinematic inversions - 4-bar chain, slider crank chain. Mechanical advantage. Transmission

angle. Description of common mechanisms, applications of mechanisms.



KINEMATICS: Displacement, velocity and acceleration analysis in simple mechanisms, graphical

method, velocity and acceleration polygons. Kinematic analysis by algebraic method, a

demonstration, vector approach, chace equation, computer applications in the kinematics analysis of

simple mechanisms.



BELTS AND ROPE DRIVES: Limiting ratio of tensions, centrifugal tensions. Condition for maximum

power transmission, corresponding speed.



KINEMATICS OF CAM: Classifications, displacement diagrams-parabolic, uniform velocity, simple

harmonic paths. Layout of plate cam profiles for different types of followers - knife - edged, roller,

mushroom, flat type, derivatives of follower motion, pressure angle and undercutting.



GEARS: Spur gear terminology and definitions. Fundamental law of toothed gearing and tooth forms.

Interchangeable gears, gear tooth action-interference and undercutting. Helical, bevel, worm, rack

and pinion gears (basics only). Gear trains, epicyclic gear trains, differentials, automotive

transmission gear trains.

GYROSCOPIC COUPLE: Gyroscopic couple and its effect in ship, car, motorcycle, aircraft and space

vehicles, gyroscopic stabilization.





04P304 MATERIALS ENGINEERING



MECHANICAL PROPERTIES AND TESTING OF METALS: Stress-strain behavior of metals-elastic

deformation. An overview of mechanical properties of materials, Hooke's law, elastic properties.

Plastic deformation, tension test, tensile properties. Hardness - Rockwell hardness test, Brinell

hardness test, Knoop and Vickers hardness tests, impact testing-Charpy and Izod tests. Fatigue-S-N

curve, fatigue tests, factors affecting fatigue life. Creep - creep curve, stress and temperature effects

on creep. Non-destructive tests - classification and comparison with mechanical tests. Description of

the following four NDT methods - liquid penetrant test, magnetic particle test, radiography test (both x-

ray and gamma ray ) and ultrasonic test.



DISLOCATION AND STRENGTHENING MECHANISMS: Dislocations, slip, slip direction and slip

planes. Strengthening of metals by grain refining, solid solution strengthening, strain hardening.

Recovery, recrystallisation and grain growth.



PHASE DIAGRAMS: Binary isomorphous systems-determination of phase composition and phase

quantities, lever rule, binary eutectic systems, development of microstructure in eutectic alloys,

eutectoid and peritectic reactions.



PHASE TRANSFORMATIONS IN IRON-CARBON ALLOYS: Iron - carbon phase diagram,

development of microstructures in iron-carbon alloys. Isothermal transformation diagrams and

continuous cooling transformation diagrams.



HEAT TREATMENT OF METALS: Process annealing, stress relief annealing, full annealing,

normalising, spheroidising, hardening, tempering, austempering, martempering. Surface hardening-

carburising, cyaniding, flame hardening, induction hardening, nitriding. Concept of hardenability - the

Jominy end quench test. Precipitation hardening - mechanism and steps.



STEELS AND CAST IRONS: Composition, structure and properties of carbon steels - low alloy

steels, stainless steels, tool steels. Composition, structure and properties of cast irons - grey iron,

ductile iron, white iron and malleable iron, commercial grades of materials.



NON-FERROUS ALLOYS: Composition, structure and properties of non-ferrous alloys - copper and

copper alloys, aluminium and aluminium alloys, magnesium and magnesium alloys, nickel and nickel

alloys and titanium and titanium alloys, commercial grades of materials.



NON-METALLIC MATERIALS: Types and applications of glasses and glass ceramics, refractories

and abrasives. Polymeric materials - thermoplastic and thermosetting polymers. Composites-particle

reinforced, fiber reinforced, laminar composites.



04P305 FOUNDRY TECHNOLOGY



INTRODUCTION: Introduction to casting process and its potential, Chronology of the art of founding



PATTERN AND MOULD MAKING: Pattern- types and materials, mould and mould materials, popular

casting processes, core and core making, importance of pattern and core on quality and economy of

the castings.



ALLOYS HANDLED BY FOUNDRIES: Discussion on foundry practices for cast iron, steel, malleable

iron, SG iron and zinc alloys, copper alloys and aluminum alloys with applications.



MELTING OF ALLOYS AND GATING: Melting practices, selection of furnaces, pouring methods,

flow of molten metal inside the mould, design of gates and types of gates.

SOLIDIFICATION OF CASTINGS: Freezing of molten metals/alloys, grain structure and effect of heat

transfer on grain structure and properties. Feeding of metals / alloys, design of feeder, Chovrinov's

rule



CASTING DEFECTS: Causes for occurrence of various casting defects and remedies



CLEANING AND TESTING: Cleaning methods for castings, Non-destructive tests and mechanical

testing for castings.



DESIGN OF CASTINGS, GENERAL PRINCIPLES, CASE STUDIES: Use of CAD-CAE and Rapid

Prototyping in foundry - A case study using CAD/CAE/CAM for developing pattern and core box for

castings.





04P306 FLUID MECHANICS AND MACHINERY



ELEMENTARY CONCEPTS: Concept of gauge and absolute pressure, measurement of pressure

using manometer of different types, types of flow, definitions and explanations of unsteady, steady,

non-uniform, uniform, laminar and turbulent flows.



ENERGY EQUATION: Derivation of general three-dimensional equation, applications in one-

dimensional steady flow, derivation of Bernoulli's energy equation and Euler's equation, examples

illustrating the use of energy equation.



FLOW METERS: Venturi meter, orifice meter, nozzle, derivation of equations for discharge, pitot

tubes.





FLOW THROUGH PIPES: Friction loss calculation, turbulent flow, Reynolds number, Darcy-

Weisbach equation, use of Moody diagram, minor losses, design and layout of piping.



HYDRAULIC TURBINES: Impact of jets, momentum equation, force on blades - plane and curved -

Pelton wheel, Francis turbine, Kaplan turbine, materials and manufacturing methods for turbines,

cavitation in turbines, performance characteristics of various turbines, specific speed, draft tubes.



PUMPS: Materials and manufacturing methods, work done by the impeller, head, efficiency, specific

speed, NPSH, different types of pumps – Gear oil pumps etc. - testing of pumps.



COMPRESSORS, FANS AND BLOWERS: Principles of operation, testing, material selection and

efficiency calculations.







WORKSHOP PRACTICE



FITTING : Fitting tools – fitting operations – measurement and checking – fitting exercise – different

types of joints.



CARPENTRY : Carpentry tools – carpentry process – carpentry exercises –different types of joints.



FOUNDRY: Foundry tools– preparation of molding sand – patters – cores – foundry exercises

preparation of simple moulds.



WELDING: Are welding tools and equipments – welding symbols – are welding exercise different

types of joints – demo of gas welding and gas cutting.

SHEET METAL WORKING AND SOLDERING : Sheet metal working tools – operations – different

types of joints – sheet metal exercises – soldering tools soldering exercises.



PLUMBING AND ELECTRICAL WIRING : Basic plumbing and electrical tools – exercises involving

house hold plumbing fittings – basic domestic wiring – demo of house electrical appliances.



04P307 MACHINE DRAWING



INTRODUCTION: Introduction to machine drawing. Importance of sectional views, simple sectional

views. Computer-aided design and

drafting.



CONVENTIONS: Code of practice for engineering drawing-methods of dimensioning, conventional

representation of details- drilled and tapped holes, countersunk and counter bored holes, internal and

external threads, undercuts, grooves, chamfers, fillet radii and keyways. Conventions to represent

standard components-bolts, nuts, washers, screws, cotters, pins, circlips, bearings, gears, springs

andflanges.





ASSEMBLY CONCEPTS: Methods and concepts of assemblies-assembly requirements, Bill of

materials. Methods of assembly-bolts, nuts, studs, screws and pins. Methods of arresting motion of a

member in an assembly.



ASSEMBLY DRAWING PRACTICE: Making free hand sketches of typical subassemblies-flange

coupling, stuffing box, journal bearings, rolling element bearings, keyed joints, cotter joints, C clamp.

Drawing of assemblies-plummer block, machine vice, stop valve, screw jack, tail stock, cylindrical

gear box, simple drill jig.



ASSEMBLY USING SOLID MODELING: Modeling and assembly using software-extracting views

and sections. Modeling of components and assemblies-plummer block, machine vice, stop valves,

screw jack, coupling.



FITS AND TOLERANCES: Limits, fits and tolerances-need, types, representation of tolerances on

drawing, calculation of minimum and maximum clearances and allowances. Geometric tolerance-

uses, types of form and position tolerances, symbols, method of indicating geometric tolerances on

part drawings. Surface finish symbols- methods of indicating the surface

roughness.







SEMESTER IV



04P205 ENGINEERING MECHANICS

STATICS OF PARTICLES: Forces in splane-Vector addition of concurrent forces in plane and space-

Problems involving the equilibrium of a particle-free body diagram-equilibrium of particle in space.



STATICS OF RIGID BODIES IN TWO DIMENSIONS: Rigid bodies-To dimensional structure-moment

of force about an axis-moment of a couple-equivalent systems of coplanar forces-Rigid body in

equilibrium-Problems involving equilibrium of rigid body-types of supports-reactions of beams and

frames.



FRICTION: Laws of friction-coefficient of friction-problems involving dry friction: wedge & ladder

friction.



APPLICATION OF STATICS: Roof trusses-method of joints & sections-Tension Coefficient.

CENTROID, CENTRE OF GRAVITY & MOMENT OF INERTIA: Centroids of areas, composite

areas, determination of moment of inertia of plane figures, polar moment of inertial-radius of gyration.



KINEMATICS OF PARTICLES: Introduction-plane, rectilinear motion-time dependent motion-

rectangular coordinates-projectile motion.



KINETICS OF PARTICLES: Equation of motion-rectilinear motion-work energy method-potential

energy-kinetic energy-conservation of energy.



IMPULSE & MOMENTUM: Impulse-Momentum principle-Concept of conservation of momentum-

Impact-Direct central impact-oblique central impact.



INTRODUCTION TO VIBRATION: Simple Harmonic Motion-mass spring system-free vibration

(elementary treatment only)

04P206 MECHATRONICS



MECHATRONICS: Definition of Mechatronics, introduction to Mechatronics systems, need and

applications, role of Mechatronics in automation, manufacturing, products and design, elements of

Mechatronics.



SENSORS AND FEED BACK DEVICES: Importance of sensors in Mechatronics. Accuracy,

repeatability, sensitivity, resolution, stability, errors and output impedance of sensors. Static and

Dynamic characteristics of sensors. Classification – transducers for measurement of displacement,

strain, position, velocity, flow, pressure, temperature, humidity, vibration, liquid level, light sensors.



CONTROL ELEMENTS AND ACTUATORS: On/off push buttons, control relays, contactors selector

switches solid, state switches. Mechanical actuators – types of motion, gear trains, belt and chain

drives, screw roads, mechanical aspects of motor selection. Electrical actuators, solenoids, AC and

DC motors, servomotors, stepper motors, Linear motors. Hydraulic and Pneumatic controls- control

valves, cylinders and hydro motors.



CONTROLLERS AND CNC: Basic concepts of control systems – open loop, closed loop, semi closed

loop control system, block diagram. Microprocessors and microcontrollers, introduction,

developments, applications, types of memory. Introduction to CNC, advantages, block diagram of a

CNC machine, elements of a CNC machine, working principle, analog and digital control systems.



PROGRAMMABLE LOGIC CONTROLLER (PLC): Introduction, definition block diagram advantages

and disadvantages, types of programming, simple programs for process control applications using

relay ladder logic (RLL)–applications of PLC.



ROBOTICS: Definition of a robot, types – Cartesian, cylindrical, spherical and articulated robots.

Industrial applications of robots. Robotic vision systems, image acquisition, illumination techniques.



FACTORY AUTOMATION: Introduction to factory automation and integration, material handling

systems, transfer lines, ASRS, introduction to MEMS and MOEMS – design of simple Mechatronics

system using low cost automation.

04C007/04E401/ 04T401 PROBABILITY AND STATISTICS



PROBABILITY AND CONCEPT OF RANDOM VARIABLE : Axiomatic approach to probability, law of

addition of probability, conditional probability, multiplication law of Probability, Baye‟s theorem.

Discrete and continuous random variables - probability distributions, joint probability distributions,

marginal and conditional density functions, statistical independence, mathematical expectation.

PROBABILITY DISTRIBUTIONS AND APPLICATIONS: Discrete distributions – Binomial, Poisson

and Geometric distribution. Continuous distributions – Uniform, Normal, Exponential and Weibull

distributions. moment generating functions, mean and variance.



STOCHASTIC PROCESSES: Introduction, classification of stochastic processes. Markov Chains -

discrete time Markov chain, computation of n-Step transition probabilities, state classification and

limiting probabilities.



CORRELATION AND REGRESSIONS: Simple linear correlation and regression, multiple regression

analysis, multiple and partial Correlation Coefficients.(No derivation).



THEORY OF ESTIMATION: Point estimation – properties of estimation. Interval estimation –

estimates of mean, standard deviation and properties .(No Derivation)



TESTS OF HYPOTHESES : Level of significance, type I and type II errors. Large sample tests -

tests for mean, standard deviation, proportions. Small sample tests - tests based on t, F and Chi-

square distributions.



ANALYSIS OF VARIANCE : Introduction to design of experiments, Analysis of variance - CRD and

RBD models.



STATISTICAL QUALITY CONTROL: Statistical basis for control charts, control limits. Control charts

for variables - R charts. Charts for defectives – p and np charts. Charts for defects – c chart.



04P402 DYNAMICS OF MACHINERY





STATIC FORCE ANALYSIS OF MECHANISM: Free Body diagram-conditions of equilibrium, two,

three and four force members, effect of friction.



DYNAMIC FORCE ANALYSIS OF MECHANISM: Inertia force and D Alembert‟s principle. Dynamic

force analysis of mechanisms including slider crank mechanism.



FLYWHEEL: Turning moment diagram-fluctuation of energy and speed, weight of flywheel required.



BALANCING: Balancing of revolving, reciprocating masses in single plane and several planes-

primary and secondary forces and couples, balancing of multicylinder inline engine. Balancing of V

type of engines, direct and reverse crank technique. Balancing machines- field balancing, single and

two planes.



FREE VIBRATION: Basic features of vibratory systems-elements, degrees of freedom, single

degree of freedom system. Un damped free vibration-equation of motion, natural frequency.

Damped free vibration, equation of motion, logarithmic decre-ment. Critical speed of shaft.



FORCED VIBRATION: Response to periodic forcing-forcing by unbalance, support motion, force and

amplitude transmissibility, force transmissibility, vibration isolation.



TORSIONAL VIBRATION: Torsional vibration of two and three rotor systems, geared systems,

critical speed, signature analysis, two degrees of freedom system.



04P405 MACHINING TECHNOLOGY



MECHANICS OF METAL CUTTING: Cutting tool angles, tool signature, tool materials, orthogonal

cutting, tool wear, tool life, machinability, cutting fluids.

(7)

PRODUCTION OF AXI - SYMMETRICAL PARTS: Turning machines-lathes, turret lathe, automats

and CNC lathes, examples of cylindrical components - pins and shafts, long shafts machining and

disc type component machining - hub and wheels.

(6)

PRODUCTION OF PRISMATIC COMPONENTS: Shaping, planing and milling machines, types,

application, production of housing type parts, lathe beds, machine columns, surface machining, slots.



INTERNAL MACHINING: Drilling, boring, taper machining, production of accurate hole - micro boring,

deep hole drilling and jig boring, accuracy and finish of drilled holes, broaching.



GEAR MACHINING: Gear cutting machines - gear hobbing and gear shaping, process description,

tooling and selection of cutting parameters, gear finishing operations.



ABRASIVE MACHINING: Selection, specification of grinding wheels, selection of different types of

grinding machines - surface, cylindrical, internal and centerless grinder, lapping, honing, super

finishing process parameters.



ECONOMICS OF MACHINING: Calculation of machining time for turning, drilling, shaping, milling

and grinding, general principles of economics of machining, economic tool life, optimum cutting speed

for maximum production, comparison of machining costs involved in conventional, CNC and SPMs –

process parameter comparison.



04P207 / 04A207 ELECTRICAL AND ELECTRONICS ENGINEERING LAB







1. Verification of Ohm‟s law and Krichhoff‟s laws.

2. Load test on 3 phase induction motor

3. Programming of PLC

4. Study of LVDT

5. Study of servo motor characteristics

6. Study of half wave and full wave rectifiers

7. R.C. coupled transistor amplifier

8. Applications of operational amplifier

9. Study of logic gates and implementation of Boolean functions

10. Implementation of binary adder / subtractor



04P408 MANUFACTURING PROCESS LAB I







1. Study of construction features materials and manufacturing methods – Head stock, tail stock,

carriage, cross slide, compound rest, belt, guide ways, feed gear box, apron gear box.

2. Turning – Step turning and knurling

3. Turning – Taper turning and

Grooving

4. Turning – Thread cutting

5. Turning – Drilling

6. Drilling, counter boring, counter sinking and taping

7. Pocket milling

8. Spur gear cutting

9. Keyway slotting

10. Shaping a „V‟ block



SEMESTER V

04P403 STRENGTH OF MATERIALS





STRESSES AND STRAINS: Stress and strain due to axial force-elastic limit-Hooke's law-factor of

safety - stepped bars, uniformly varying sections, stresses in composite bar due to axial force and

temperature. Strain Energy due to axial force- proof resilience, stresses due to gradual load, sudden

load and impact load.



CHANGES IN DIMENSIONS AND VOLUME: Lateral strain - Poisson's ratio, volumetric strain,

changes in dimensions and volume, shear stress, shear strain, relationship between elastic constants.

Hoop and Longitudinal stresses in thin cylindrical and spherical shells under internal pressure-

changes in dimensions and

volume.



BENDING MOMENT AND SHEAR FORCE: Relationship between load, shear force and bending

moment - shear force and bending moment diagrams for cantilever, simply supported and

overhanging beams under concentrated loads, uniformly distributed loads, maximum bending

moment and point of contraflexure.





04P502 METAL CUTTING THEORY AND CUTTING TOOL DESIGN



MECHANISM OF MATERIAL REMOVAL: Introduction, importance of metal removal, classification of

material removal operations, overview of the cutting process, plastic deformation and fracture, chip

formation, basic single point tool geometry and its significance.



ANALYSIS OF MACHINING: Analysis of machining with single point tool, orthogonal and oblique

cutting, forces. Merchant circle, relation between angles, forces - theoretical value of shear angles.



CUTTING TOOL MATERIALS: Requirements, different types of cutting tool materials, processes to

develop cutting tool materials, coated tools and inserts.



MEASUREMENT OF CUTTING FORCES: Dynamometers, measurement of temperature,

calorimetry, tool wear, tool life, Taylor's equation, machinability, cutting fluids and their applications.



DESIGN OF SINGLE POINT CUTTING TOOLS: Design of general purpose lathe tools, tool strength

and rigidity calculations, construction of carbide tipped single point tools, ceramic tools, diamond

tools, form tools, chip breakers, tools for boring, planing and shaping operations, tool selection and

tools for CNC machine tools.



MULTI-POINT CUTTING TOOLS AND THEIR DESIGN: Nomenclature of twist drills, milling cutters,

broaches, gear hob and gear shaper cutters, classification and selection, design and manufacture of

drills, reamers, taps, dies, thread chasers, milling cutters, broaches, gear hobs and gear shaper

cutters.



GRINDING OF METAL: Grinding wheel specification, surface topography of machined components,

lapping, honing and superfinishing, effect of grinding conditions on wheel behaviour, analysis of the

grinding process, grinding wheel wear, selection of grinding wheels.



FLEXURE IN BEAMS: Theory of simple bending and assumptions - derivation of equation, section

modulus, normal stresses due to

flexure.



04M503/04P503 MEASUREMENT AND QUALITY CONTROL

TRANSDUCER VARIABLES AND MEASUREMENT SIGNALS: Three stages generalised

measurement system - error analysis and classification, sources of error, frequency response,

displacement and velocity transducers, potentiometer strain gauge LVDT, variable reluctance

transducers, capacitance transducers. Tacho generator-measurement of torque on rotating elements.



VIBRATION MEASUREMENT: Elementary accelerometer and vibrometer - seismic instrument for

absolute displacement, velocity seismic accelerometer, piezo electric accelerometer .



TEMPERATURE MEASUREMENT: Liquid in glass thermometer - pressure thermometer.

Resistance temperature detector - themocouples and thermopiles, thermistor - total radiation

pyrometer, optical pyrometer - temperature measuring problem in flowing fluid.



PRESSURE AND FLOW MEASUREMENT: Manometer, elastic transducer, elastic diaphragm

transducer, pressure cell, bulk modulus pressure gauge- machine load gauge, thermal conductivity

gauges, calibration of pressure guage. Turbine type meter - hotwire anemometer, magnetic flow

meter.

BASICS OF MEASUREMENT AND DEVICES: Accuracy, precision, sensitivity, standards of

measurements. Errors in measurement. Linear measurements - limit gauges (types and design),

Taylor's principle. Comparators (mechanical, electrical, optical and pneumatic), slip gauges, optical

projector.

GEOMETRICAL MEASUREMENT: Instruments for angular measurement - vernier and optical

protractors, sine bar. Laser measuring instruments. Flatness, parallelism and roundness

measurement. Checking the dimensional accuracy of slip gauges with interference microscope.

Measurement of surface finish-direct and indirect methods. Tomilson surface meter, importance of

surface finish.

METROLOGY OF MACHINE ELEMENTS: Screw thread terminology-measurement of major,

minor and effective diameters, best wire size, two wire and three wire methods, pitch measurement.

Gear metrology (spur gear)-runout checking with concentricity tester, composite errors with gear roll

tester, base pitch measurement.

MACHINE INSTALLATION AND TESTING: Equipment erection, commissioning, testing procedures

for lathe, milling, continuous process line. First aid, safety precautions in installation of equipments,

protocol for repair and testing and inspection check list.



TORSION: Theory of torsion and assumptions-derivation of the equation, polar modulus, stresses in

solid and hollow circular shafts, power transmitted by a shaft, close coiled helical spring with axial

load.



PRINCIPAL STRESSES AND STRAINS: (Two dimensional only) State of stress at a point - normal

and tangential stresses on a given plane, principal stresses and their planes, plane of

maximum shear stress, analytical method, Mohr's circle method, application to simple

problems.





DEFLECTION OF DETERMINATE BEAMS: Governing differential equation - Macaulay's method-

moment area method, application to simple

problems.



04P504 PROCESS PLANNING AND COST ESTIMATION







ESTIMATING AND COSTING: Concepts, differences, different costing methods – classification of

costs – cost grid-problems.

LABOUR AND MATERIAL COSTS: Labour cost–direct, indirect–estimation–labour norms–time

study rating-labour cost variances; material cost–direct, indirect–estimation–material issue valuation –

material cost variances–problems.



OVERHEAD COST: Elements in overhead cost–factory, administrative, sales and distribution

expenses–methods of absorbing overheads – DL, DM, DLH, MHR methods – depreciation – methods

–accounting for service department expenses – problems.



COST CALCULATIONS: Machined components–welded components, forged components, powder

metallurgy parts, calculation of sales cost, case studies, use of computers in cost estimation, cost of

rejection.

OPTIMUM MACHINING CONDITIONS: Taylor‟s equation, deriving the equation for optimum

economic cutting velocity– selection of cutting speed for optimum cost, problems process capability

analysis.

BREAK EVEN ANALYSIS: Concept, assumptions, merits and demerits of break even analysis.

Applications. Linear, multi product break-even analysis.

GROUP TECHNOLOGY AND PRODUCTIVITY: Group technology, objectives, steps, methods of

grouping, codification system; productivity– concepts, labour, machine and material based

productivities.



COST OPTIMIZATION: Cost optimization techniques – analytical, graphical, incremental methods for

single and multi variable situations; Learning curves, product life cycle cost analysis.

COST MANAGEMENT: Tools and techniques–value analysis– steps in selection, analysis and

implementation; cost/benefit analysis; activity based costing - concepts, cost drivers; introduction to

target costing - need and applications.



04P506 WELDING TECHNOLOGY



INTRODUCTION: Comparison between casting and welding processes, definition of welding as per

AWS, weldability, heat affected zone, weld decay, basic welding positions and joint types.



GAS AND ARC WELDING: Gas welding, principle and equipment, applications and selection, arc

welding, principle, electrodes, energy source characteristics.



SPECIAL WELDING PROCESSES (FUSION): TIG and MIG welding processes, ESW, discussion on

LBW, EBW, PAW, Carbon arc welding and Atomic Hydrogen welding, applications and selection.



SPECIAL WELDING PROCESSES (NON-FUSION): Resistance welding, friction and ultrasonic

welding processes, comparison of the processes with the objective of welding, applications and

selection.



INSPECTION AND TESTING OF WELDMENTS: Welding defects, remedies, pre and post heat

treatments, destructive test methods, NDT of weldments.



DESIGN OF WELDED JOINTS: Basic principles, distortion, weld symbols.



CAE IN WELDING: Introduction to the use of CAE in modeling welding and temperature distributions.



04M408/04P308/04A408 METALLURGY AND STRENGTH OF MATERIALS LAB



Metallurgy

1. (a) Specimen preparation for metallographic inspection

(b) Study of metallurgical microscope

2. (a) Study of grey cast iron and SG iron in unetched condition

(b) Study of grey and SG irons in the etched condition.

(c) Study of white cast iron and malleable cast iron

3. (a) Study of low carbon and medium carbon steel

(b) Study of high carbon steel

4. (a) Study of quenched and tempered steel

(b) Study of case carburised steel

5 (a) Study of Aluminium alloys

(b) Study of Copper alloys



Strength Of Materials

1. (a) Tension test on metals-stress strain characteristics, ductility, resilience, toughness.

(b) Cupping test on metal sheets-load deformation characteristics, cupping load, cupping

number

2. Hardness test on metals-Brinell, Vicker and Rockwell Hardness tests.

3. (a) Impact test on metals-Charpy, Izod impact tests.

(b) Shear test on metals-direct shear strength, single shear, double shear

(c) Compression test-compressive strength, concrete, brick

4. (a) Tests on helical springs-compression, tension springs-load deformation characteristics,

stiffness, shear stress , modulus of rigidity, energy.

(b) Torsion test on beams-torque and angle of twist characteristics, shear stress, modulus of

rigidity, energy.

5. (a) Tests on wood-tension, compression and bending-load deformation characteristics,

Young‟s modulus, modulus of rupture.

(b) Deflection test on beams-load deformation characteristics, Young‟s modulus, Maxwell‟s

reciprocal law verification.









04P508 INSTRUMENTATION AND METROLOGY LAB







1. Angular measurement, use of sine bar and slip gauges.

2. Optical profile projector - study of profile of gear tooth, screw threads.

3. Tool maker's microscope - to study tool geometry, screw threads.

4. Gear Inspection.

5. Vibration study of machine tools using FFT analyzer.

6. Measurement of cutting force in drilling using dynamometer.

7. Measurement of cutting force in turning using dynamometer.

8. Tool wear measurement.

9. Speed and torque measurement.

10. Noise and surface roughness measurement.



SEMESTER VI



04P403 THERMAL SYSTEMS AND HEAT TRANSFER







THERMODYNAMICS: Zeroth law, first and second laws of thermodynamics, applications, steady flow

energy equation, ideal gas processes - calculation for work done, heat transfer and entropy changes,

carnot cycle.

POWER PLANTS: Diesel power plant, Brayton cycle, gas turbine power plant, Rankine cycle, steam

power plant – energy conservation and energy audit.



IC ENGINES: Otto, diesel cycles - principles of operation, valve and port timing diagrams, indicator

diagrams, carburetors, diesel fuel pump and injector, need for cooling and lubrication of IC engines,

conventional and electronic ignition systems, calculation of fuel consumption, mechanical, brake,

thermal and indicated thermal efficiencies, heat balance performances characteristics.



REFRIGERATION AND AIR CONDITIONING: Refrigerant - types - properties, vapor compression

and absorption refrigeration, COP and capacity. Psychrometry - requirements for comfort and

industrial air-conditioning, air washer, summer and winter air conditioning systems.



HEAT TRANSFER: Heat conduction through planes, cylinder and spherical geometry, transient

conduction, critical thickness of insulation, non uniform conductivity, natural and forced convection,

empirical relations for heat transfer coefficients - estimation of heat transfer.



04P404 METAL FORMING PROCESSES







INTRODUCTION: State of stress, components of stress, symmetry of stress tensor, principal

stresses, stress deviator, Von Mises, Tresca yield criteria, comparison of yield criteria, Octahedral

shear stress and shear strain, forming load calculations.



FUNDAMENTALS OF METAL FORMING: Flow stress determination, temperature in metal forming,

hot, cold and warm working, strain rate effects, metallurgical structures, friction and lubrication,

deformation zone geometry, hydrostatic pressure, workability, residual stresses.



FORGING: Forging – types of presses and hammers, defects and remedies, classification, open die

forging, forging of disks, closed die forging, die design, calculation of forging loads, defects, causes

and remedies.



ROLLING: Rolling of blooms, billets, slabs and sheet, types of rolling mills, rolling defects, forces and

geometrical relationship in rolling, analysis of rolling load, torque and power, forward slip and position

of neutral point, maximum possible reduction, gauge control, factors which determine rolling load,

minimum thickness and spread, defects, causes and remedies.



EXTRUSION: Direct and Indirect extrusion, equipments, port hole extrusion die, hydrostatic extrusion,

defects and remedies simple. Analysis of extrusion, tube extrusion and production of seamless pipe

and tube, hydrostatic extrusion, defects causes and remedies.



DRAWING OF RODS, WIRES AND TUBES: Simple analysis of wire and tube drawing, residual

stress in rod, wire and tubes.



SPECIAL FORMING METHODS: Explosive forming, electro magnetic forming, electro hydraulic

forming, peen forming, high velocity forging, super plastic forming, requirement and process

description, applications, orbital forming.



POWDER METALLURGY: Process fundamentals, production of metal powders, characteristics,

power blending, compacting, P/M product design, sintering, secondary operations, special P/M

processes.



04P406 ENGINEERING DESIGN



INTRODUCTION: Preferred numbers – basic and derived series – mechanical properties of

materials – concurrent engineering – introduction stress analysis: Types of stresses – stress-

strain diagram in tension – static stress equation in axial, bending and torsional loading – criteria

for failure – factor of safety.

COMBINED STRESSES: Combination of normal stresses - eccentric loading of members -

combination of normal and shear stresses - principal stresses - theories of failure – maximum shear

stress, maximum principal stress, maximum strain energy, maximum distortion energy.



VARIABLE LOADS: Mechanism of fatigue failure (in brief), fatigue limit and fatigue strength, S-N

curves, types of stress variations - terminology - Soderberg, Goodman and Gerber equations - stress

raisers - stress concentration factor, notch sensitivity factor, factors affecting fatigue limit, finite life,

equivalent stress, combined variable stress.



DESIGN OF SHAFTS AND COUPLINGS: Forces on shafts due to gears, belts and chains,

estimation of shaft size based on strength and critical speed, couplings, types and applications,

design of square keys, use of standards, rigid couplings, flexible flange couplings, selection.



SPRINGS: Helical springs and leaf springs, stresses and deflection in round wires, helical springs,

accounting for variable stresses, concentric springs, design of leaf springs - stress and deflection

equations.



RIVETED AND BOLTED JOINTS: Strength equations, efficiency, design of riveted joints, joints of

uniform strength, eccentrically loaded riveted joints, types of welded joints, weld symbols, strength of

welds, centrally loaded, unsymmetrical sections, axially loaded and eccentrically loaded joints.

Thread forms, initial stress, stresses due to external loads, elastic analysis of bolted joints for

pressure vessel flanges, eccentrically loaded joints.



BEARING SELECTION: Static and dynamic load capacity, cubic mean load, variable load, probability

of survival, selection of bearings - (deep groove, angular contact ball bearings and taper roller

bearings). Hydrodynamic and hydrostatic bearings - (theory, applications, advantages and

limitations), Sommerfield number, dimensionless parameters, optimum bearings, newer bearing

materials, design of hydrodynamic bearings.



SELECTION OF V-BELTS AND CHAINS: V-belts for given power and velocity ratio, selection of

roller chain for power and speed ratio



04P602 INDUSTRIAL ENGINEERING AND OPERATIONS RESEARCH





INTRODUCTION: Evolution of industrial engineering, fields and functions of industrial engineering.

Methods engineering process charts, motion study, work sampling and work measurement.



PRODUCTION PLANNING AND CONTROL: Introduction, objectives, components of PPC,

manufacturing systems, plant layout, types of layouts, forecasting, product planning, loading and

scheduling, dispatching, production control, material handling principles, case studies.



HUMAN ENGINEERING: Ergonomics, design of controls and displays, heating, ventilation, glare,

airflow, influence of factory environment on productivity, industrial safety.



COST ANALYSIS: Cost structure of a product-labor, material, overhead. Overhead absorption,

machine hour rate, cost computation for simple machined components, learning curve, „Make-or-Buy‟

decision.



LINEAR PROGRAMMING TECHNIQUES: Operations research and decision-making, types of

mathematical models and constructing the model. Role of computers in operations research,

formulation of linear programming problem, applications and limitations, simplex method, variants in

simplex method (analytical and graphical).



DISTRIBUTION METHODS: Vogel‟s approximation method, modified distribution method,

optimization models, unbalance and degeneracy in transportation model.

ASSIGNMENT MODELS: Hungarian algorithm, traveling salesman problem, routing problems,

processing „n‟ jobs through two machines and three machines, processing two jobs through „m‟

machines.



INVENTORY CONTROL: Variables in inventory problems, inventory models with penalty, storage and

quantity discount, safety stock, inventory models with probability, lead time, demand, multi item

deterministic model.





04P605 MACHINE TOOL ENGINEERING



OVERVIEW OF MACHINE TOOLS: Types of machine tools – general purpose – special purpose,

CNC, multitask machines.



STRUCTURES, GUIDES AND BEARINGS: Mechanical drives for rotational movement – stepped

and stepless O/P – typical layout of speeds –gear boxes – gear drive for feed motion – machine tool

bearings, types of structures, types of guideways.



DRIVES: Selection of motors, A/C variable drives, feed drives, spindle drives, integral motors,

clutches.



FLUID POWER SYSTEMS: Pumps, valves, cylinders, design of hydraulic circuits, functional diagram,

Hydraulic power pack.



MACHINE TOOL ELEMENTS: Belts, circlips, keys, pulleys, oil seals, ball screws, LM guide ways,

tool magazine, pallet changer, curvic coupling, linear motors.



MACHINE TOOL DYNAMICS: Self excited and forced vibration, vibration analysis of machine tool

structures, isolation of machine tools.



MECHATRONICS: Selection of CNC controls, feed back devices, electrical, limit switches, sensors,

PLC.



MACHINE TOOL TESTING: Geometrical alignment test, national and international test charts, testing

of CNC machine tools.



MACHINE TOOL ACCESSORIES: Types of coolant pumps, filtering equipments, chip conveyor, dust

extraction air conditioning for control panels, automatic lubrication, door closing, mist control.



04P407 THERMAL ENGINEERING AND FLUID MACHINERY LAB







1. Valve timing and port timing diagram

2. Heat balance and A/F mixture determination on a variable speed diesel engine

3. Performance test on a variable speed diesel engine

4. Determination of drag and lift co-efficient using wind tunnel

5. Performance test on reciprocating compressor

6. Performance study on axial flow fan and centrifugal

compressor

7. Calibration of flow meters – venturimeter – orifice meter

8. Performance test on Pelton and Francis

turbines

9. Performance test on Refrigeration and air-conditioning

tutors

10. Performance test on centrifugal pump



04P608 INDUSTRIAL ENGINEERING AND SIMULATION LAB



1. Solving linear programming problem

2. Solving transportation problem

3. PERT/CPM analysis

4. Facilities layout analysis

5. Materials requirement planning

6. Inventory analysis

7. Quality assurance using control charts

8. Simulation of process capability study of machines for the determination of C pk value

9. CAM simulation

10. Planning of experiments for process improvement using DoE software







SEMESTER VII

04P501 NUMERICAL METHODS







ERRORS AND APPROXIMATIONS: Different types of errors.



TRANSCENDENTAL AND POLYNOMIAL EQUATIONS: Newton Raphson method, Modified Newton

Raphson method Method of false position, Graffe‟s root squaring method, Bairstow‟s method.





SYSTEM OF LINEAR EQUATIONS: Gauss elimination, Gauss - Jordan elimination, Cholesky

method, Crout‟s method, Gauss - Jacobi method, Gauss – Seidel method. Solution of tridiagonal

equations. Matrix Inverse by Gauss – Jordan elimination.



EIGENVALUES AND EIGENVECTORS: Power method for finding dominant eigenvalue and inverse

power method for finding smallest eigenvalue, Jacobi method for symmetric matrices.



FINITE DIFFERENCES AND INTERPOLATION: Finite difference operators - E,

.Difference table. Interpolation- Newton-Gregory forward and backward interpolation,

Lagrange's interpolation formula, Newton divided difference interpolation formula. Solution of linear

second order difference equations with constant coefficients.



DIFFERENTIATION AND INTEGRATION : Numerical differentiation using Newton–Gregory forward

and backward polynomials. Numerical integration – Gaussian quadrature, Trapezoidal rule and

Simpson‟s one third rule.



ORDINARY DIFFERENTIAL EQUATIONS: Taylor series method, Euler and Modified Euler method,

(Heun‟s method). Runge-Kutta method, Milne‟s method, Adams–Moulton method, Solution of

boundary value problems of second order by finite difference method.



PARTIAL DIFFERENTIAL EQUATIONS: Classification of partial differential equations of second

order. Liebmann‟s method for Laplace equation and Poisson equation. Explicit method and

Crank - Nicolson method for parabolic equations. Explicit method for hyperbolic equations.



MATLAB : MATLAB - Tools Kits – 2D Graph plotting, 3D Graph plotting, Data analysis.

04P505 JIGS, FIXTURES AND PRESS TOOLS







TOOL DESIGN: Tool design objectives, tool design in manufacturing, planning the design, challenges

to the tool designer, production devices - Inspection devices.



PRINCIPLES OF SUPPORTING AND LOCATING ELEMENTS: Referencing, basic rules of locating,

planes of movement, locating from a flat surface, locating from a internal diameter, locating from a

external diameter, locating from external profile, ejectors.



PRINCIPLES OF CLAMPING AND WORK HOLDING: Principles of work holders, basic rules of

clamping, types of clamps, chucks and vises, non mechanical clamping, clamping accessories.

Materials used in Jigs and Fixtures.



DESIGN OF JIGS: Drill bushes – different types of jigs-plate latch, channel, box, post, angle plate,

angular post, turnover, pot jigs-Automatic drill jigs-Rack and pinion operated, air operated jigs

components, design and development of jigs for given components.



DESIGN OF FIXTURES: General principles of boring, lathe, milling and broaching fixtures- Grinding,



planning and shaping fixtures, assembly, Inspection and welding fixtures- Modular fixtures. Design



and development of fixtures for given component.



PRESS TOOLS: Press working terminology, presses and press accessories, computation of

capacities and tonnage requirements, shearing action.



ELEMENTS OF PROGRESSIVE COMBINATION AND COMPOUND DIES: Design and development

of progressive and compound dies for blanking and piercing operations. Die block-die shoe. Bolster

plate-punch plate-punch holder-guide pins and bushes, strippers, knockouts, stops, pilots, selection of

standard die sets strip lay out-strip lay out calculations.



DESIGN OF BENDING DIES: Design and development of bending dies, forming dies and drawing

dies. Development of drawing dies.



DESIGN OF FORGING DIES: Design considerations in forging, extrusion, design of thermoplastic

injection molds



ENVIRONMENT SCIENCE



INTRODUCTION TO ENVIRONMENTAL STUDIES AND NATURAL RESOURCES: Definition, scope

and importance – Forest resources: Use and overexploitation, deforestation. Water resources: Use

and over-utilization of surface and ground water, dams-benefits and problems – Energy resources:

Growing energy needs, renewable and non renewable energy sources, use of alternate energy

sources.– Land resources: land degradation – Role of an individual in conservation of natural

resources – Equitable use of resources for sustainable lifestyles.



ECOSYSTEMS AND BIODIVERSITY: Ecosystem – Structure and function of an ecosystem –

Energy flow in the ecosystem – Ecological succession –Structure and function of Forest ecosystem,

Grassland ecosystem and Aquatic ecosystems. Introduction to Biodiversity – Definition: genetic,

species and ecosystem diversity – Threats to Biodiversity and its impacts – endangered and endemic

species of India – Conservation of Biodiversity.



ENVIRONMENTAL POLLUTION: Definition – Causes, effects and control measures of: Air pollution,

Water pollution, Soil pollution, Marine pollution, Noise pollution, Thermal pollution, Nuclear hazards.



SOLID WASTE AND DISASTER MANAGEMENT: Causes, effects an control measures of urban

and industrial wastes – Disaster management: floods, earthquake, cyclone and landslides.



SOCIAL ISSUES AND THE ENVIRONMENT: From Unsustainable to Sustainable development –

Urban problems related to energy – Water conservation, rain water harvesting, watershed

management. Environmental Issues and possible solutions – Climate change, global warming, acid

rain, ozone layer depletion, nuclear accidents and holocaust – Environment Protection Act – Air

(Prevention and Control of Pollution) Act – Wildlife Protection Act - Forest Conservation Act. .

Population growth, variation among nations – Population explosion - Environment and human health

– Role of Information Technology in Environment and human health





04P702 AUTOMATION, CNC AND ROBOTICS

FUNDAMENTAL CONCEPTS: Fundamental concepts in manufacturing and automation-definition of

automation, reasons for automating. Types of production and types of automation, automation

strategies, levels of automation. Detroit type automation-automated flow lines, methods of work parts

transport, transfer mechanism, buffer storage, product design for transfer machine automation.

Transfer machines-transfer machines for housing type parts, transfer machines for shaft production

and gear production. Continuous rotary transfer lines - layout and output.

ANALYSIS OF AUTOMATED FLOW LINES: General terminology and analysis, analysis of transfer

lines without storage, partial automation. Automated flow lines with storage buffers, computer

simulation of automated flow lines. Automated assembly-design for automated assembly, types of

automated assembly systems, part feeding devices, analysis of multi-station assembly machines.

Flow line balancing - manual and computerized line balancing.

PNEUMATIC CONTROL: Components, constructional details, filter, lubricator, regulator,

constructional features, types of cylinders, control valves for direction, pressure and flow-air motors-

air hydraulic equipments.

PNEUMATIC CONTROL SYSTEM: General approach to control system design, symbols and

drawings, schematic layout, travel step diagram, circuit, control modes, program control sequence

control, cascade, Karnaugh-Veitch mapping method, air hydraulic control, fringe condition modules,

start, emergency, start restriction, typical application circuits.

PROGRAMMABLE AUTOMATION: Computer Numerical Control-basic theory, advantages of

numerical control. Open and closed loop systems information flow and coding theory. Classification

of CNC machine tools. Special design features of CNC systems and features for lathes and

machining centers. DNC, FMS, CIM.

DRIVE SYSTEM FOR CNC MACHINE TOOLS: Drives for spindles, servo drives for axes feed.

Principles of displacement measurement-digital, linear and rotary displacement transducers, analog

measuring systems.

CNC PART PROGRAMMING: Manual and computer aided part programming-G and M functions,

canned cycles. Programming in APT. Generation using CAM software. Feature of CAM software.

ROBOTIC SYSTEMS: Basic structure of a robot–robot end effectors. Classification of robots–

accuracy, resolution and repeatability of a robot. Drives and control systems–mechanical components

of robots–sensors and vision systems. Transducers and sensors-tactile sensors, proximity sensors

and range sensors, vision systems. Robot motion control and robot programming: Introduction to

manipulator kinematics, homogeneous transformations and robot kinematics, robot dynamics,

configuration of robot controller. Social and economical aspects of robots, typical layouts of robots in

industries, material transfer, machine loading and unloading, processing operations, assembly and

inspection.

04P704 ADVANCED MACHINING TECHNOLOGY



INTRODUCTION TO ADVANCED MACHINING TECHNOLOGY: Need for advanced machining

processes, types of advanced machining processes, hybrid processes, applications and limitations.



ULTRASONIC MACHINING (USM): Applications, advantages and comparison of the processes.

Ultrasonic Machining: Process description of ultrasonic machining, process principles, equipments,

effect of process parameters, processes capabilities, applications and limitations.



ABRASIVE MACHINING PROCESSES: Description of the apparatus, nozzles, metal removal rate

and application of abrasive jet machining, water jet machining, abrasive water jet machining, abrasive

flow machining.



ELECTRON BEAM MACHINING (EBM): Production of electron beam, description of the apparatus,

application of electron beam machining, electron beam welding, process principles, equipments,

effect of process parameters, processes capabilities.



PLASMA ARC MACHINING (PAM): Generation of plasma arc, description of the equipment, process

parameters, applications and limitations.



LASER BEAM MACHINING (LBM): Laser beam production, description of the apparatus, thermal

features, cutting speed, accuracy, three dimensional machining, applications, laser beam welding.



ELECTRICAL DISCHARGE MACHINING (EDM): Description of the EDM equipment, electrical

circuits, electrolytes, electrode materials, metal removal rate, applications, EDWC, process principles,

equipments, effect of process parameters, process capabilities, applications in die making.



ELECTRO CHEMICAL MACHINING (ECM): Description of the equipment, chemistry of the process,

electrolytes, metal removal rate, accuracy and surface finish obtained. Electro chemical grinding

equipment, application, electro chemical deburring and honing, chemical etching process,

applications.







04P507 MANUFACTURING PROCESS LAB II



1. Spur gear shaping

2. Helical gear cutting

3. Surface grinding

4. Plastic injection moulding

5. Square hole making using spark erosion

6. External shaft grinding

7. Boring of cylindrical Hole

8. Grinding of single point cutters

9. Grinding of multi point cutters

10. Study of super finishing process



04E509 TECHNICAL SEMINAR



The students are expected to make presentations throughout the semester under the supervision of a

team of respective department faculty. The students are to be grouped appropriately so that each

student makes a minimum of two different presentations on engineering topics of current interest.

Every student has to submit an approved technical report prior to his presentation. Evaluation will be

made based on the reports, the presentations and the interactions during the question answer

sessions.

04P309 INDUSTRIAL / FIELD TRAINING I





1. Shaft for pump / motor – Machining

a) Study of machine tools used

b) Study of processes



2. Preparing a component drawing and process planning chart

(Machine tools involved: SPM: Centering and facing, HMT S-pilot copy turning lathe, thread

rolling machine, automatic

keyway milling, HMT cylindrical grinding.)



3. Motor body – machining

a) Study of machine tools used

b) Study of process



4. Preparing a component drawing and process planning chart.

(Machine tools involved; base milling, SPM: twin head boring machine, drilling of foot mounting

holes; study of fixtures

used)



5. Study of vertical turning lathe (VTL) and HMT mini chucking lathe

a) Study and write specifications of machine

b) Study of hydraulic systems in mini chucker and drawing of hydraulic circuit diagram

c) Drawing of kinematic diagram of VTL



6. Study of broaching machine and balancing machine

a) Study of machines

b) Drawing for the broach

c) Principles of balancing machine



7. Assembly of submersible pump

Assembly drawing of submersible pump and describing the functions of parts.



8. Pressure die casting

a) Study of the machine

b) Drawing of a die used

c) Visit to generator room, weld and press shop



9. Marketing survey (External field)

Students should select a product and visit various places for market survey and submit a report.



10. Study of casting process

a) Pattern and core making

b) Mould making

c) Casting process





SEMESTER VIII



04O601 ENGINEERING ECONOMICS AND FINANCIAL MANAGEMENT



FUNDAMENTALS OF ENGINEERING ECONOMICS: Introduction to Engineering Economics –

Definition and Scope – Significance of Engineering Economics.



DEMAND AND SUPPLY ANALYSIS: Definition – Law of Demand – Elasticity of Demand – Demand

Forecasting. Supply – Law of supply – Elasticity of Supply – Market Mechanism.

COST ANALYSIS: Basic cost concepts – FC, VC, TC, MC – Cost output in the short and long run.



FINANCIAL MANAGEMENT: Objectives and functions of financial management – financial

statements, working capital management – factors influencing working capital requirements –

estimation of working capital.



CAPITAL MARKET: Stock Exchanges – Functions – Listing of Companies – Role of SEBI – Index

Numbers – Capital Market Reforms.



MONEY AND BANKING: Money – Functions – Value of Money – Inflation and deflation –

Commercial Bank and its functions – Central bank and its functions.



NEW ECONOMIC ENVIRONMENT: Economic systems, Economic Liberalization –Privatization –

Globalization. An overview of International Trade – World Trade Organization – Intellectual Property

Rights.



CAPITAL BUDGETING: Need for Capital Budgeting – Project Appraisal Methods - Payback Period –

ARR – Time Value of Money – DCF Techniques – Feasibility Report.



DEPRECIATION: Meaning – Causes for Depreciation – Methods of Computing Depreciation.





BREAK EVEN ANALYSIS: Meaning – Break Even Chart – Simple Problems – Managerial uses of

BEA.



04P603 DESIGN FOR MANUFACTURE AND ASSEMBLY





DFM APPROACH, SELECTION AND SUBSTITUTION OF MATERIALS IN INDUSTRY: DFM

approach, DFM guidelines, standardisation, group technology, value engineering, comparison of

materials on cost basis, design for assembly, DFA index, Poka - Yoke principle; 6s concept; design

creativity.





TOLERANCE ANALYSIS: Process capability, process capability metrics, Cp, Cpk , cost aspects,

feature tolerances, geometric tolerances, surface finish, review of relationship between attainable

tolerance grades and different machining process, cumulative effect of tolerances, sure fit law, normal

law and truncated normal law.





SELECTIVE ASSEMBLY: Interchangeable and selective assembly, deciding the number of groups-

model-I: group tolerances of mating parts equal; model-II: total and group tolerances of shaft, control

of axial play-introducing secondary machining operations, laminated shims, examples.





DATUM SYSTEMS: Degrees of freedom, grouped datum systems-different types, two and three

mutually perpendicular grouped datum planes, grouped datum system with spigot and recess, pin and

hole, grouped datum system with spigot and recess pair and tongue-slot pair-computation of

translational and rotational accuracy, geometric analysis and applications.





TRUE POSITION THEORY: Comparison between co-ordinate and convention method of feature

location, tolerancing and true position tolerancing, virtual size concept, floating and fixed fasteners,

projected tolerance zone, assembly with gasket, zero true position tolerance, functional gauges,

paper layout gauging, compound assembly, examples.

FORM DESIGN OF CASTINGS AND WELDMENTS: Redesign of castings based on parting line

considerations, minimising core requirements, redesigning cast members using weldments, use of

welding symbols.





TOLERANCE CHARTING TECHNIQUE: Operation sequence for typical shaft type of components,

preparation of process drawings for different operations, tolerance worksheets and centrality analysis,

examples, design features to facilitate machining, datum features - functional and manufacturing,

component design-machining considerations, redesign for manufacture, examples.

LEAN MANUFACTURING: Need for lean concepts, different types of waste, metrics of

manufacturing, an overview of value stream mapping- present state map, future state map, evaluation

of benefits.





04P604 FINITE ELEMENT APPLICATIONS IN MANUFACTURING



INTRODUCTION: Relevance of mathematical modeling and solutions in manufacturing processes,

Introduction to FEA, Basic principles and concepts, simple examples.



FEA FOR METAL FORMING: Elements of theory of plasticity applied to metal forming, processes,

stress-strain formulations, elastic-plastic formulations, rigid plastic formulations, thermal formulation,

equations of velocity and temperatures.



FORGING: Modelling of forging, case studies, FEM solutions, hot die upsetting, closed die forging.



ROLLING AND DRAWING: Modelling of rolling and drawing processes.



MODELLING OF HEAT TREATMENT PROCESSES: Simple case studies and solutions using

modelling of heat treatment processes.



MATHEMATICAL MODELLING: Mathematical modelling of casting processes, boundary conditions,

solutions by FEM - simple case studies, mathematical modeling of arc welding, boundary conditions,

solutions by FEM (ANSYS), modelling temperature distribution in metal cutting (single point tool) use

of ANSYS / IDEAS.



INJECTION MOULDING: Modelling for thermo-plastic injection molding. Use of mold flow.









04M025 MANUFACTURE AND INSPECTION OF GEARS







INTRODUCTION TO GEARS: Types of gears-classification, application of gears, gearboxes,

drawings for gears, gear production method an overview.



PRODUCTION OF CYLINDRICAL GEARS: Procedure of cutting gears and obtainable quality in

milling, hobbing and gear shaping, cutter selection and work holding methods, setting calculations.

Rack type gear shaping machine description and application. Internal gear cutting methods, CNC

gear hobbing and gear shaping machines.



PRODUCTION OF CONICAL GEARS: Production of straight bevel gears by milling and bevel gear

generator, duplex rotary cutter method, Gleason Reva cycle method, spiral and hybrid bevel gear

generation. Description of machine, cutter and machine setting.



GEAR MATERIAL SELECTION AND HARDENING METHODS: Properties of gear materials-non-

metallic, non-ferrous and plastic gears, selection of material for power transmission, high speed

application. Hardening by through hardening, case hardening, induction hardening, flame hardening,

nitriding and tuftriding, hardening defects.



GEAR FINISHING METHODS: Gear finishing advantages, finishing of gears by grinding, shaving,

lapping and honing methods, cold rolling of gears - description of process, machine, cutters and

process parameters setting.



GEAR INSPECTION: Type of gear errors-gear quality standards and allowable limits-tooth thickness,

base tangent length measurement, pitch error, radial run out, involute profile error measurements

methods and analysis, composite error measurement, computerized gear inspection, gear failure

reasons and remedies.



MODERN GEAR PRODUCTION METHODS: Gear production by stamping, die casting, powder

metal process, injection and compression moulding of plastic gears, cold and hot rolling. Mass

production methods, shear speed shaping, gear broaching, Gleayson G-TRAC – gear generation

methods.



ECONOMICAL AND QUALITY PRODUCTION OF GEARS: Gear production systems – batch

production, gear production cells, lean and agile production practices, automobile gear and gear

boxes, heavy engineering gear production, gear parts instruments and appliances, process and cutter

selection for quantity, cost and quality criteria.





04M009 AUTOMOBILE ENGINEERING





TYPES OF AUTOMOBILES: The scope for automobile industries in India. General classification of



vehicles. Subsystems of automobile-front, rear and four wheel drives. Frame construction-integral



chassis, hybrid vehicles.



ENGINES: Multi valve engines-petrol injection, single point, multi point and direct injection systems.

Diesel injection, common rail diesel injection-supercharging and turbo charging, waste gate method.

Alternate fuels-ethanol and ethanol blend, compressed natural gas, liquefied nitrogen gas, hydrogen.

Catalytic converters. Fuel Cells.



CLUTCH: Need for a clutch. Diaphragm and coil spring type-single plate and multi plate clutch

design, centrifugal clutch. Variator drive.



GEAR BOX: Need for a gear box, rolling, air and gradient resistances, sliding, constant and

synchromesh gearbox. Epicyclic gear box clutches and bands-servo and solenoid controls.

Continuously variable transmission.



TRANSMISSION LINE: Propeller shaft, universal joints, constant velocity joints. Rear axle, types-two

speed axles, hub reduction axles, tandem axles. Differential and differential lock .



WHEELS AND TYRES: Types of wheels and brake drums, cross ply and radial ply tyres-

specifications. Tyre wear and maintenance. Wheel balance.



FRONT AXLE AND STEERING SYSTEM : Front axle, types of stub axle, principle of steering,

Ackerman steering, steering geometry and wheel alignment, caster, camber, kingpin inclination, toe-in

and toe-out. Types of steering gear boxes, conventional and electronic power steering, tiltable and

collapsible steering, four wheel steering.

04O607 PROFESSIONAL COMMUNICATION





INTRODUCTION: Communication – Definition – Types of communication – Verbal –Nonverbal.



SCIENTIFIC AND TECHNICAL STYLE: Clarity – Simplicity – Exactness – Brevity-Unity-Coherence

and Objectivity.



FORMAL TECHNICAL REPORT: Gathering data – Literature Search – Questionnaires and

interviews- Creating a formal –Technical Report.



BUSINESS CORRESPONDENCE: Business letters – Structural elements – Styles of presentation –

Letters of acceptance and refusal – Electronic communication – Techniques for writing effective E-

mail.



INTERVIEW: Planning, Preparation and performance in interview.



MEETINGS: A psychologist‟s view of better meetings – Features – Problems – Notice and agenda

preparation - Minutes documentation.



PRACTICALS: Group Discussions –



Presentations –



Mock interview –

04P609 CAD/CAM LAB

0032



1. Two dimensional drafting

2. Three dimensional modeling

3. Three dimensional assembly of CAD models

4. Finite element analysis and components - static problems

5. Finite element analysis and components - dynamic problems

6. Production drawing generation with suitable tolerance details

7. Data exchange of geometrical models

8. Automated NC code generation

9. Exercise on production planning using CAPP

10. Exercise on modeling, analysis for standard machine elements like gear box, screw jack, etc.





04P409 / 04A409 INDUSTRIAL / FIELD TRAINING II

0031



1. Visit to CNC (I) center

Study / specifications of DMG horizontal and universal CNC 4/5 axis machining centers.

Study and specification of Makino CNC machining centre



2. Visit to CNC (II) center

a) Study and specification of LMW, Toyoda and Hart Ford machining centers.

b) Study of gear grinding, Learning DIN class accuracies



3. Study of SIP jig boring machine and various tool holders and tools.



4. Visit to Rapid Prototyping Centre, study of SLS and FDM machines.



5. Study of process capability / accuracy / cost estimation

a) Horizontal boring machine

b) Rapid radial drilling machine

c) Slide way grinding machine

d) Study and sketch of machines.



6. Study of process capability / accuracy / cost estimation

a) Gear hobbing machine (HMT)

b) Gear shaping machine (HMT)

c) Gear tooth rounding machine

d) Rack cutting machine

e) Engraving machine

f) Drawing of kinematic diagram of hobbing and shaping machine



7. Assembly of electrical motors

a) Winding

b) Rotor assembly

c) Rotor balancing



8. Study of exhibited jigs and fixtures

a) Plate jig

b) Box jig

c) Pump jig etc.

d) Design of jig / fixture for any component under production



9. Purchase exercise (External Field)

Students should make a mock-up purchase exercise in the field for a product

10. Study of Arc welding, TIG welding, Gas welding, Ultrasonic welding









SEMESTER IX



04P703 APPLIED HYDRAULICS AND PNEUMATICS





INTRODUCTION: Introduction to fluid power, properties - hydraulic fluids, air. Selection of hydraulic fluids, comparison

between hydraulics and pneumatics.

(5)

ELEMENTS OF HYDRAULIC SYSTEMS: Pumps and motors- types, characteristics. Cylinders, types, typical construction

details. Valves for control of direction, flow and pressure, types, typical construction details.

(5)

HYDRAULIC SYSTEM DESIGN: Power pack–elements, design. Pipes- material, pipe fittings. seals and packing.

maintenance of hydraulic systems. Selection criteria for cylinders, valves, pipes. Heat generation in hydraulic system.

(5)

TYPICAL INDUSTRIAL APPLICATION OF HYDRAULIC SYSTEMS: Circuits for deceleration, regenerative circuits, differential

circuits, feed circuits, sequencing circuits, synchronizing circuits, fail-safe circuits.

(5)

ELEMENTS OF PNEUMATIC SYSTEMS: Compressors- types, selection. Symbols of pneumatic elements. Cylinders - types,

typical construction details. Valves – direction control, flow, pressure, types, typical construction details.

(5)

PNEUMATIC SYSTEMS DESIGN: General approach, travel step diagram. Types - sequence control, cascade, step counter

method. K.V.Mapping for minimization of logic equation.

(6)

TYPICAL INDUSTRIAL APPLICATIONS OF PNEUMATIC SYSTEMS: Metal working, handling, clamping, application with

counters.

(6)



ADVANCED TOPICS IN HYDRAULICS AND PNEUMATICS: Electro pneumatics, ladder diagram. Servo and Proportional

valves - types, operation, application. Hydro-Mechanical servo systems. PLC-construction, types, operation, programming.

(5)

04P003 MICRO ELECTROMECHANICAL SYSTEMS





MEMS AND MICROSYSTEMS: MEMS and microsystem products, evaluation of micro fabrication,

microsystems and microelectronics, applications of Microsystems, working principles of

Microsystems, microsensors, microactuators, MEMS and microactuators, microaccelerometers



SCALING LAWS IN MINATURIZATION: Introduction, scaling in geometry, scaling in rigid body

dynamics, the trimmer force scaling vector, scaling in electrostatic forces. Electromagnetic forces,

scaling in electricity and fluidic dynamics, scaling in heat conducting and heat convection.



MATERIALS FOR MEMS AND MICROSYSTEMS: Substrates and wafers, silicon as a substrate

material, ideal substrates for MEMS, single crystal silicon and wafers crystal structure, mechanical

properties of Si, silicon compounds, SiO2, SiC, Si3N4 and polycrystalline Silicon, silicon piezoresistors,

gallium aresenside, quartz, piezoelectric crystals, polymers for MEMS, conductive polymers.



ENGINEERING MECHANICS FOR MICROSYSTEMS DESIGN: Introduction, static bending of thin

plates, circular plates with edge fixed, rectangular plate with all edges fixed and square plates with all

edges fixed. Mechanical vibration, resonant vibration, microaccelerometers, design theory and

damping coefficients. Thermomechancis, thermal stresses. Fracture mechanics, stress intensity

factors, fracture toughness and interfacial fracture machines



BASICS OF FLUID MECHANICS IN MACRO AND MESO SCALES: Viscosity of fluids, flow patterns

Reynolds number. Basic equation in continuum fluid dynamics, laminar fluid flow in circular conduits,

computational fluid dynamics, incompressible fluid flow in micro conducts, surface tension, capillary

effect and micropumping. Fluid flow in submicrometer and nanoscale, rarefield gas, kundsen and

mach number and modeling of microgas flow, heat conduction in multilayered thin films, heat

conduction in solids in submicrometer scale. Thermal conductivity of thin films, heat conduction

equation for thin films.



MICROSYSTEM FABRICATION PROCESS: Photolithography, photoresist and applications, light

sources. Ion implantation, diffusion process, oxidation, thermal oxidation, silicon diode, thermal

oxidation rates, oxide thickness by colour. Chemical vapour deposition, principle, reactants in CVD,

enhanced CVD physical vapour deposing, sputtering, deposition by epitaxy etching, chemical and

plasma etching



MICROMANUFACTURING AND MICROSYSTEM PACKAGING: Bulk micromachining, isotropic and

etching, wet etchants, etch stops, dry etching comparison of wet and dry etching. Surface

micromachining, process in general, problems associated surface micromachining. The LIGA

process, description, materials for substrates and photoresists, electroplating, the SLIGA process.

Microsystem packaging, general considerations. The thee levels of microsystem packaging, die

level, device level and system level, essential packaging technologies, die preparation, surface

bonding wire bonding and sealing. Three dimensional packaging, assembly of Microsystems,

selection of packaging materials.





SUSPENSION SYSTEM: Objectives and characteristics, leaf spring, coil spring, torsion bar, air

spring and control, rigid axle suspension system, independent suspension, roll centre and kinematic

analysis necessity and construction of dampers. Active suspension.

BRAKING SYSTEM: Single and dual line braking system, tandem master cylinder, brakes

proportioning and adhesion utilisation. Materials for brake components, air operated braking system,

leading and trailing shoe lay out, anti lock braking system, anti spin regulation- regenerative braking.



04P004 TOTAL QUALITY MANAGEMENT



INTRODUCTION: Definitions of the terms - quality, quality planning, quality control, quality assurance,

quality management, Total Quality Management (TQM) as per ISO 8402 - overview on TQM - The

TQM axioms - Commitment - Scientific knowledge - Involvement - Consequences of total quality.



THE DEMING APPROACH TO TQM: Deming's fourteen points on quality management - five DDs -

implementing the Deming philosophy - action plan - the Deming cycle - questions and opinions of

Deming.



JURAN ON QUALITY: Developing a habit of quality - Juran quality trilogy - the universal break

through sequence - comparison Juran and Deming approaches.



CROSBY AND THE QUALITY TREATMENT: Crosby's diagnosis of a troubled company - Crosby's

quality vaccine - Crosby's absolutes for quality management - Crosby's fourteen steps for quality

improvement.



KAIZEN: Meaning - Kaizen and innovation - the Kaizen management practices - total quality

control (TQC) - approaches of Faigenbaum, Ishikawa - Kaizen and TQC - Kanban systems - small

group activities - quality control circles - suggestion systems - comparison of Kaizen and Deming's

approach.



SUPPORTING TOOLS, ACTIVITIES AND TECHNIQUES IN TQM PROJECTS : Affinity diagram -

bar chart - block diagram - brainstorming - cause and effect analysis - customer-supplier relationship

checklist - decision analysis - flow charts - force field analysis - line graph/run charts - Pareto analysis

- quality costing - Quality Function Deployment (QFD) - quality project approach and the problem

solving process.



ISO 9000 SERIES QUALITY SYSTEM STANDARDS: The structure of ISO 9000 series quality

system standards - certification process - action plan development for cases.



STRATEGIC QUALITY MANAGEMENT : Integrating quality into strategic management - Quality and

the management cycle - Resources for Quality activities - Training for Quality - Self Managing

Teams - Role of the Quality Director - Obstacles to achieving successful Strategic Quality

Management.





SAFETY SYSTEMS: Seat belt, air bags, crumble zones, accident and injury analysis, vehicle impact,

general dynamics and crush characteristics, structural collapse and its influence upon safety.







04P019 INDUSTRIAL MARKETING AND MARKET RESEARCH





ROLE OF MARKETING IN ORGANISATIONS: Core concepts of marketing, product concept, selling

concept and marketing concept, marketing process, analyzing market opportunities, designing

marketing strategies, planning marketing programmes, organizing, implementing and controlling the

marketing effort, marketing planning, current marketing situation, opportunity and issue analysis,

action programmes, profit and loss statement.

MEASURING AND FORECASTING MARKET DEMANDS: Concepts in demand measurement,

estimating current demand, estimating future demand, market segmentation, general approach to

segmenting a market, patterns of market segmentation, market segmentation procedures, base for

segmenting customer markets and industrial markets, market targeting - evaluating the market

segments, selecting the market segments.

LAUNCHING NEW PRODUCTS AND SERVICES: New product development, effective

organisational arrangements, idea generation, idea screening, concept development and testing,

product development, market testing, commercialisation, consumer adoption process, product life

cycle - introductory stage, growth stage, marketing stage and decline stage.

PLANNING MARKETING PROGRAMMES: Managing product lines, brands and packaging, product

mix decisions, product line decisions, brand decisions, packaging and labeling decisions, managing

service businesses and ancillary services - classification of services, marketing strategies for service

firms, managing product support services, pricing strategies and programs - setting the price,

adapting the price, initiating and responding to price changes.

MANAGING MARKETING CHANNELS: Nature of marketing channels, channel design decision,

channel management decisions, channel dynamics, channel co-operation, conflict and competition,

retailing, wholesaling and distribution systems, nature and importance of retailing, types of retailers,

wholesaling, physical distribution.

COMMUNICATION AND PROMOTION-MIX STRATEGIES: The communication process, steps in

developing effective communication, measuring promotion results, managing the sales force,

designing the sales force, principles of personal selling.





04O001 HUMAN VALUES AND PROFESSIONAL ETHICS







MANAGEMENT : Meaning, Definition, Significance, Functions – Planning, Organizing, Staffing,

Directing and Controlling, Principles of Management



SOCIAL RESPONSIBILITY AND ETHICS: Concept of Social Responsibility, Views of Social

Responsibility - Economic Objectives Vs Social Objectives – Business Ethics



PROBLEM SOLVING METHODS: SWOT Analysis of a Traditional Engineer - Kaizen Strategy and

Values - Kaizen Approach for Problem Solving.– Process Oriented Management Vs Result Oriented

Management



HUMAN VALUES: Value Crisis in Contemporary Indian Society, Aesthetic Values, Moral and Ethical

Values, Spiritual Values, Values in the Work Place



INTERPERSONAL RELATIONSHIPS: Managing Emotions, Emotional Intelligence, Building Better

Interpersonal Relations, Managing the Boss, Dealing with Subordinates – Case Study



CREATIVITY: Creativity and Problem Solving – Creativity Process – Creative Individuals and their

Characteristics – Techniques for Creative Problem Solving.



HUMAN RESOURCE MANAGEMENT: Importance, Objectives, Functions, Job Analysis and

Recruitment, Selection and Placement



HUMAN RESOURCE DEVELOPMENT: Training and Learning, Determining Training Needs and

Priorities, Formal Employee Training Methods, Management Development , Methods for Developing

Managers, Evaluating Training Effectiveness - Case Study.



LEADERSHIP: Definition, Characteristics of Leadership, Leadership styles, Theories of Leadership –

Tannenbaum – Schmidt Leadership Continuum – Managerial Grid Theory

MOTIVATION – Meaning and Definition – Mechanism of Motivation – Maslow‟s Need Hierarchy

Theory, Mc Gregor‟s Theory X and Y- Herzberg‟s Two Factor Theory









04P707 PRODUCT DESIGN AND DEVELOPMENT LAB







1. Study of reverse engineering concepts

2. Demonstration of 3D scanning

3. Study of rapid prototyping machines

4. Demonstration of FDM (RP)

5. Demonstration of SLS (RP)

6. Demonstration of Vacuum casting

7. Demonstration of VR

8. Exercise on Failure Mode and Effect Analysis (FMEA)

9. Exercises / Assignment on modification of an existing engineering components using CAD, CAE

& CAM

10. Exercises / Assignment on modification of an existing domestic plastic products using CAD, CAE

& CAM









04P708 AUTOMATION AND CNC LAB

1. Design and simulation of multiple actuator systems using Pneumatic elements.

2. Design and simulation of multiple actuator systems with start selection and emergency modules.

3. Design and simulation of multiple actuator circuits using Electro Pneumatic elements.

4. Design and simulation of PLC based multiple actuator systems.

5. Microprocessor based stepper motor control.

6. Velocity measurement of a pneumatic piston using virtual instrumentation software

7. Design and simulation of hydraulic system – regenerative circuit, meter-in and meter-out circuit

8. Design and simulation of hydraulic system using PLC

9. Programming and machining in CNC Lathe

10. Programming in CNC machining centre