PRODUCTION ENGINEERING

M 801 2+1+ 0

Module 1
Theory of metal cutting: Historical back ground –Classification of manufacturing process – Deformation
of metals (review only) – Performance & process parameters - Oblique & orthogonal cutting – Mechanism
of chip formation, types, chip curl, chip control – Tool geometry: American, British, DIN, ISO systems –
Mechanism of orthogonal cutting: Thin zone model, Merchant’s analysis, Oxley thin shear zone analysis –
Thick zone models, Palmer & Oxley analysis – shear angle relationship, Lee & Shaffer`s; relation ship etc.
– Friction process in metal cutting: nature of sliding friction, effect of increasing normal load on apparent
to real area of contact , columb`s law, yield stress at asperities, adhesion theory, ploughing, sublayer flow –
Effect of rake angle,cutting angle, nose radius etc. on cutting force and surface finish – Empirical
determination of force component.

Module 2
Thermal aspects of machining: Source of heat; temperature distribution in chip, shear plane & work
piece; effect of speed, feed & depth of cut – Tool materials: carbon steel, HSS, coated HSS, ceramics,
diamond etc.- Cutting fluids: effect of specific heat, etc on selection of liquids; effectiveness at tool chip
interface; classification of fluids – Tool wear: flank & crater [KT] wear – Tool wear mechanisms: adhesion,
abrasion, diffusion & fatigue; Taylor’s equation, application at shop floor; speed, tool material & micro
structure on tool life; allowable wear land [VB] ; rapid, steady & catatospheric wear on rough & finishing
operations – Economics of machining – Machineability index.

Module 3
Power metallurgy: Preparation metal powers – Power characteristics: properties of fine power, size, size
distribution, shape, compressibility, purity etc.- Mixing – Compaction techniques – Mechanism of sintering
of single & multi phase materials - Sintering atmosphere – Finishing operations: heat treatment, surface
treatment, impregnation treatment etc. – Impregnated bearings – Sintered oil-retaining bearing –
Economics of p/m.
Advanced materials: Super alloys - Titanium & titanium alloys – shape memory alloys –smart materials –
microstructure, properties, applications.

Module 4
Polymers: Polymerization – Structural features: Linear & net work molecular structure – Molecular wt,
degree of polymerization, branching, cross linking – co polymers & ter polymers – Molecular architecture
– effect of crystallinity – Glass transition temp: - Thrmo polymers – Thermoset polymers – Additives –
Polymer matrix composites: properties & applications. - Elastamers: Kinked structure - Mechanical,
physical & chemical properties – Vulcanization of rubber – conductive polymers, applications. – Ceramics:
Structure – Mechanical, physical properties & applications. – Glasses: Types, glass ceramics – Types,
properties and application of MMC and CMC – Honey comb structure.

Module 5
Advanced production methods: Rapid prototyping: background & definitions – Process methods:
Stereolithography, selective laser sintering, fused deposition modeling, laminated object manufacturing,
laser engineered net shaping, 3D welding – Information processing – Indirect fabrication of metals &
ceramics. – Non traditional machining: EDM, ECM, USM – principle, types, process parameters, control,
MRR, surface finish, application etc. – Electro chemical grinding, lapping, honing; process principle & Ra
only, applications – EBM, LBM, IBM, AJM, Abrasive water jet machining, LIGA process.

References

1. Armarego & Brown, The Machining of Metals, Prentice - Hall

 2. Beaman, Barlow & Bourell, Solid Free Foam Fabrication: A new direction in mafg., Kluwer Academic
Publishers
3. Brophy, Rose & Wulf, The Structure & Properties of Metals Vol.2, Wiley Eastern
4. Dixon & Clayton, Powder Metallurgy for Engineers, Machinery publishing co. London
5. HMT, Production Technology, Tata McGraw Hill
6. Kalpakjian, Manufacturing Engineering & Technology, Addison – Wesley, 4nd edn.
7. Lal G.K., Introduction to Machining Science, New Age publishers
8. Metcut research, Machinablity Data Center Vol.1 & 2, Metcut research associates, Cincinnati
9. Paul. H. Black, Theory of Metal Cutting, McGraw Hill

AUTOMOBILE ENGINEERING
M 802 3+1+0

Module 1
Engines: Types of engines in automobiles-classifications-engine components-working of various systems-
CNGengines-R&D works-present and future vehicles-frame, body and engine construction-structure and
mechanism forming components- carburetors, diesel fuel pumps, injector, single point and multi point fuel
injection-combustion chambers-lubricating oil pumps-cooling systems-Vehicle performance-resistance to
the motion of vehicle-air, rolling, and radiant resistance-power requirement-acceleration and gradeability-
selection of gear ratios.

Module 2
Transmission: prime movers-clutch-principle-friction-helical spring and conical spring clutches –
centrifugal clutches and fluid couplings-Gear box-principle and necessity of manual gear box- constant
mesh, sliding mesh and synchromesh gear boxes-epicyclic gearbox-overdrives-hydraulic torque
converters-semi and automatic transmission-Final drive-front wheel, rear wheel and four wheel drives-
transfer case-Hotchkiss and torque tube drives-universal joints-constant velocity universal joint-
differential-non-slip differential-rear axles-types of rear axles.

Module 3
Steering and Suspension: Different steering mechanisms-steering gear boxes-power steering –types-
suspension systems-front axle, rigid axle and independent suspensions-anti-roll bar-coil spring and leaf
spring-torsion bar-Macpherson strut-sliding pillar-wish bone-trailing arm suspensions-front axle types-
front wheel geometry-castor, camber, king pin inclination, toe-in toe-out. Shock absorbers-hydraulic and
gas charged shock absorbers-air suspensions.

Module 4
Chassis and Body: Types of chassis and body constructions-crumble zones, air bags and impact beams-
automotive air conditioning-braking mechanism and convectional brakes- booster, hydraulic and power
brakes, components and attachments-mechanical, hydraulic and pneumatic brakes-anti-lock braking
systems-Wheels and Tyres:tube-less tyres-ply ratings- radial tyres-hybrid vehicles-vintage cars-racing cars-
automated roads-coach works-materials- safety provisions- motor vehicle act.

Module 5
Electrical systems Battery, charging and ignition systems-electronic ignition-dynamos and alternators-
voltage regulators-light and horn relays-circuit diagrams-starting motor-bendix and follow through drives-
power windows-electronic engine control unit for fuel injection- automotive lighting, accessories and
dashboard instruments-Preventive and breakdown maintenance-engine testing, servicing-overhaul- engine
tuning- wheel balancing-trouble shooting-garage tools and equipments-noise, vibration, and performance
tests.

References
 1. Automobile Engineering (Vol. 1 & 2) - K.M.Guptha
2. Automotive Mechanics - Joseph Heitner
3. Automobile Engineering - Harbans Singh Reyd
4. Automotive Mechanics - William H. Course

PRODUCTION PLANNING AND CONTROL

M 803 2+1+0

Module 1
Introduction to PPC: need for PPC, effect, advantages, functions and problems of PPC.
Forecasting: methods of sales forecasting-forecasting for new products-forecasting for established
products-time series analysis for sale forecasting – long term forecasting – methods of estimating Sales
trend- problems- correlation analysis.

Module 2
Production planning: objectives-characteristics-process planning. Capacity planning- factors affecting-
Master production scheduling-material requirement planning – BOM and product structure.
Production control: objectives- production control systems- principle and procedure of production
Control.
Routing: objectives- procedure – route sheets.

Module 3
Sequencing assumptions: solution of sequencing problems-processing n jobs through two machines
Processing n jobs through three machines – processing n jobs through m machines – processing two
Jobs through m machines-problems

Module 4
Materials management: Components of integrated material management Purchasing management- stores
management. Supply chain management – ERP-Role of I.T.

Module 5
Loading and scheduling: aim- reasons for scheduling- master scheduling or aggregate scheduling
Estimating shop loads- short term scheduling – mathematical loading and scheduling- problems-
Scheduling through PERT / CPM problems.
Despatching- duties- procedure- rules.
Follow up and reporting- types-report preparation and presentation.

References

1. Modern Production Management - E.S.Buffa

2. Principles of Production Management - J.Apple
3. Production management principles - Mcycss
4. Production Planning and Control - K.C.jani& L.N.Aggarwal
5. Manufacturing Planning &Control - Volfman, Berry, Whybark systems
6. Production and operations management - R.Paneerselvam
7. Modeling the supply chain - Jeremy F Shapiro

MACHINE DESIGN AND DRAWING - II

M 804 2+0+2
Module 1
 Gears: Types of gears –spur gear, helical gear, bevel gear, worm and worm wheel- strength of gear teeth –
gear forces and their effects – formative number of teeth – lead – lead angle-basic geometry and
nomenclature of meshed spur gear set-dynamic load – endurance load-wear loads – AGMA standards –
Lewis equation for strength design and Lewis form factor – design for wear – design of gears such as spur
gear, helical gear, bevel gear, worm and worm wheel.

Module 2
Bearings: Bearing materials – introduction to lubrication – minimum film thickness – hydrodynamic
theory of lubrication – viscosity of oil – oil seals – selection of lubricants – viscosity index – measurement
of viscosity – effect of temperature on viscosity – clearance ratio – summer feld number – specifications
and selection of bearing – anti friction bearing – bearing life – rating life – dynamic load capacity –
equivalent dynamic load – design of journal bearing – design of rolling contact bearing such as ball and
roller bearing.

Pumps: Design of centrifugal pump (Simple problems)

References

1. Mechanical Engineering Design – Joseph Shigley

2. Machine Design – Mubeen
3. Machine Design – Black
4. Principles of Lubrication – Cameron A.
5. Mechanical Seals – Mayer E.
6. Design of Machine Elements – Bhandari V. B.
7. Machine Design – Pandya and Shah
PROJECT MANAGEMENT (ELECTIVE - II)
M 805-5 3+1+0

Module 1
Project feasibility Analysis- Marketing, Technical, and financial feasibilities- report preparation-case
studies.

Module 2
Project Management- nature and scope- PERT and CPM techniques, Estimates-time, cost, resources
(man, material, tool).

Module 3
Forecasting Methods-Time series analysis-method pf least square, moving average, curvilinear,
correlation analysis.

Module 4
Risk Analysis-risk in economic analysis-measuring risk in investment; risk profiles, decision trees,
formulation of discounted decision trees, simulation.

Module 5
MS Project: (Software Practice) Creation of task, sequencing of task, assignment of resources, finding
critical path, ABC activities (discuss), breaking the activities, colouring techniques, resource balancing,
allocating overtime, using different calendars (Like 8 or 12 hours shift, Friday/Sunday holiday, Special
public holidays etc), cost estimates, assignment of blank fields, creation of different views on screen.
Reports: Daily reports for completed activity, lagging activities, overall progress review, Management
high-level reports, individual Departmental reports.

References

1. Corter, Mastering MS Project 2000, BPB Publishers.

 2. Harvey Maylor, Project Management, Pearson Education.
3. PrasannaChandra, Project Management, Tata McGraw Hill.
4. Prasanna Chandra, Projects, Tata McGraw Hill.

TOTAL QUALITY MANAGEMENT (ELECTIVE - III)

M 806-7 3+1+0

Goal
To give the detailed information on TQM Tools and Techniques for TQM will be known.

Module 1
Introduction – Leadership Concepts – Customer Satisfaction – employee involvement

Module 2
Continuous Process Improvement – Kaizen, Reengineering, PDSA cycle, Juran Trilogy – Supplier
Partnerships – Quality Cost

Module 3
Statistical Process Control (SPC) – Pareto Diagram, Cause – and – Effect diagram, check sheet, histogram.
Benchmarking – Quality Function Development – Failure mode and Effect Analysis (FMEA)
Module 4
Total Quality Control (TQC) – Quality Circles – Poka – Yoke- Just–in-Time (JIT)- KANBAN - ‘5-5’

Module 5
Implementing procedure of TQM - case studies

Learning Objective

1. Student will clear principles and practices of TQM

2. Student will learn tools and Techniques used in TQM.
3. Students will learn the procedure of implementation of TQM

References

1. Besterfield, Total quality Management, Person Education

2. Besterfield, Quality Control, Prentice - Hall
3. Arora K.C, TQM & 1S0 14000, S K Kataria & Sons
4. Jain & Chitale, Quality assurance and Total quality management, Khanna Publishers.
5. Mitra, Quality control & improvement, Person Education