bansilal ramnath agarwal charitable trust’s vishwakarma ... · p. h. joshi, press tools design...

Vishwakarma Institute of Technology Issue 01 : Rev No. 1 : Dt. 01/07/18

Structure and syllabus of B. Tech. Production Engineering. Pattern D-18, A.Y. 2018-19 (P a g e | 1)

Bansilal Ramnath Agarwal Charitable Trust’s

Vishwakarma Institute of Technology (An Autonomous Institute affiliated to Savitribai Phule Pune University)

Structure & Syllabus of

B. Tech. (Production Engineering)

Pattern ‘D18’ Effective from Academic Year 2018-19

Prepared by: - Board of Studies in Industrial & Production Engineering



Final Year B. Tech. Production Engineering AY 2018‐19 (D18)

Subject No.

Subject Code

Subject Name Teaching Scheme (Hrs/Week)

Examination scheme Credits

Theory Lab CA MSE ESA Total

HA LAB ESE VIVA Semester-1 (Module-VII)

S1 PR4001 Process Engineering 3 2 10 30 10 30 20 100 4 S2 PR4003 Die & Mould Design 3 2 10 30 10 30 20 100 4 S3 PR4006 Modern Manufacturing Processes 3 2 10 30 10 30 20 100 4 S4 PR4074 Major Project -- 8 10 30 10 30 20 100 4 S5 PR4075 **Professional Development -- -- -- -- -- -- -- -- --

OR

S1 PR4071 Industry Internship -- -- -- -- -- -- -- --

16 PR4072 Research Internship -- -- -- -- -- -- -- --

PR4073 Global Internship -- -- -- -- -- -- -- --

Total 9 14 16



Subject No.

Subject Code

Subject Name Teaching Scheme (Hrs/Week)

Examination scheme Credits

Theory Lab CA MSE ESA TotalHA LAB ESE VIVA

Semester-2 (Module-VIII)

S1 PR4071 Industry Internship -- -- -- -- -- -- -- --

16 PR4072 Research Internship -- -- -- -- -- -- -- --

PR4073 Global Internship -- -- -- -- -- -- -- --

OR

S1 PR4001 Process Engineering 3 2 10 30 10 30 20 100 4 #PR4002 Supply Chain Analysis & Modeling

S2

PR4003 Die & Mould Design

3 2 10 30 10 30 20 100 4 #PR4004 Financial Management &

Management Accounting #PR4005 Mechatronics & Industrial Robotics

S3 PR4006 Modern Manufacturing Processes 3 2 10 30 10 30 20 100 4 #PR4007 Powder Metallurgy

S4 PR4074 Major Project -- 8 10 30 10 30 20 100 4 #PR4086 Major Project

S5 PR4075 **Professional Development -- -- -- -- -- -- -- -- --

Total 9 14 16

.(#) Courses in Second semester for those students who do not opt for Semester Internship (**) Audit Course evaluated in any semester



FF No.: 654

PR4001::PROCESS ENGINEERING Credits: 04 Teaching Scheme: 3 Hrs/Wk

SECTION-1 1) Process engineering and its functions:- Method of reading and interpreting the part print, Identification of functional surfaces, grouping of related surfaces to be machined, Identification of basic process for processing and sequence of operation from part print, 2) Geometric dimensioning and tolerance analysis, tolerance stacking, tolerance chart 3) Work-piece control - Causes of work-piece variations, variables influencing work-piece control, equilibrium theories, mechanical, geometrical and dimensional control, 4) Basic process operations - principal processes and auxiliary processes, Identification of major, critical, qualifying, re-qualifying and supporting operations. Selection of single or combined operations, Identification of finishing operations, Establishing manufacturing sequence.

SECTION-2 1) Equipment/machine selection - Factors to be considered in equipment/machine selection, determining machine up and down time. Types of tooling, Factors affecting selection of tooling, use of multi-tooling set-up, 2) Process Selection - Component of process selection, Factor affecting on process selection decisions, Deigning the process (Process flow analysis, Process Re-engineering, Product –Process Mix, Operations Strategy, Capacity utilization, 3) Capacity Planning-, Importance of capacity decisions, Defining and measuring capacity, Dimensions of capacity, Determining capacity requirements, Developing capacity alternatives, Factors determining effective capacity, 4) Process Sheet Design: Study of the part-print , logical design of process plan, stock preparation, blank size selection with material estimates, Selection of datum surfaces, identification of machining surfaces, dimension and tolerance analysis, selection of machining methods with time estimates and standard time for each operation, Preparation of process picture sheet and operation route sheet for complete manufacturing part. 5) CAPP: Generative Process Planning, Knowledge-based Process Planning, Feature Recognition in Computer Aided Process Planning List of Practicals: 1. Process parameters and machining time determination of lathe operations. 2. Process parameters and machining time determination of milling operations. 3. Dimensional and tolerance analysis of part print 4. Preliminary part print analysis of industrial component



5. Determination of sequence of operation and tool layout, and cost estimation of industrial component 6. Identification of locating, clamping areas on work piece and planning for jigs and fixtures List of Project areas: 1. Project 1:-Development of process sheet for prismatic component 2. Project 2:- Development of process sheet for cylindrical component 3. Project 3:- Development of process sheet for complex casting component 4. Project 4:- Development of process sheet for machining on CNC machining centre Text Books: 1. D. F. Eary, G. E. Johnson, Process engineering for manufacturing, Prentice-Hall 2. P. W. Wang, J. Kelly Computer aided process planning-Pearson 3. Nanua singh ,System approach to computer integrated design and manufacturing,

Prentice hall 4 Narayana K. L., Kannaiah P., Vankata Reddy K., Production Drawing, New age international Publishers. Reference Books: 1. H. W. Wage Manufacturing Engineering, , McGraw hill 2. Manufacturing catalogues for cutting tools and inspection equipments 3. P. Radhakrishnan , S. Subrmaniyum, V. Raju, CAD\CAM\CIM, New Age International

Pvt Ltd 4. K. Hitomi, John Willey Manufacturing Systems Engg-Pearson, 5. Groover Mikell. P. Fundamentals of modern manufacturing- materials, processes and

systems, 2nd edition, Willey 2002 Course Outcomes: The student will be able to – 1. Perform preliminary part print analysis of part 2. Understand concepts of geometric dimensioning and tolerancing in product engineering 3. Classify operations and achieve work piece control for manufacturing of industrial

products 4. Manage equipment, tools, gauges, manpower and time economically, required for

manufacture of industrial products 5. Select and plan process for manufacturing of industrial products cost effectively 6. Design process sheet for machined component



FF No.: 654

PR4003::DIE & MOULD DESIGN Credits: 04 Teaching Scheme: Th-3 Hrs/Wk+Lab-2 Hrs/Wk

SECTION-1 1) Introduction to Press Working Press working terminology, Basic operations, types of presses- mechanical, hydraulic, pneumatic and their mechanisms, elements of die sets, types of die sets, types of dies - simple, compound, progressive, combination and inverted dies, types of punches Methods of reduction of shear force, types of strip layouts, types of strippers, types of pilots, types of stoppers 2) Design of Blanking & Progressive dies Shearing force, press capacity, clearances, die & punch size types of strippers, types of pilots, types of stoppers, selection of dowel pins & allen screws., center of pressure of progressive die. Problems on progressive and blanking die design 3) Design of Drawing Dies Deep drawing mechanism, Design of deep drawing die: blank size, no of draws, drawing punch and die size, drawing force, press capacity and ironing 4) Bending Dies Types of Bending dies, developed length calculation, bending force, spring back & methods used to overcome it, press brake

SECTION-2 1)Forging Die Design :Design of forging die for multi-impression die-: selection of parting line, drafts, fillet & comer radii, ribs & webs, stock size calculation, flash & gutter, design of fullering, edging, blocking, finishing impressions, trimming dies, Die block dimensions, die inserts. Upset forging punch and die design 2) Plastic manufacturing processes, Types of plastics, Pastic manufacturing processes: Extrusion, Blow moulding, Thermo forming, Compression and Tranfer moulding, Injection moulding: Types of machines and equipment 3) Injection Mould design: Selection of plastic material for various parts, Design of mould elements: Cavity, Core, back plates, inserts, and guide pins, guide bushes. Two plate injection mould system, three plate injection mould system, runner less molds, parting lines, split molds, molds for threaded components. Feed system: Designs of various types of runners, gates, balancing of runners, positioning of gates, mould filling patterns etc. Ejection system: Pin ejection, stripper plates, valve ejection, blade ejection, air ejection, etc. Cooling & heating arrangements: Design of cooling channels, layouts etc. 4) Die and Mould Materials: Punch and die materials for sheet metal working operations, Material requirements for Forging dies, Die and moulds material for injection moulding. Die and mould manufacturing techniques and treatment of dies and tools List of Practical 1. To design Punch and die for simple blank with selection of hardware, stripper & stopper



2. To design Punch and die for progressive die with selection of pilot, hardware, stripper & stopper.

3. Deep drawing die design: Blank size, no of draws, drawing force and punch and die design.

4. To determine the developed length of bend components, bending force and die 5. Forging die design for closed die forging 6. Upsetting die design for upset forging 7. Injection mould design for the given component. List of Project areas: 1. Design of simple Blanking die set for sheet metal blanks. 2. Design of Progressive die set for multiple piercing, complicated profile of component 3. Design of Compound die for washer type components 4. Design of Combination die for shearing and forming operations together 5. Design of Deep drawing die for stainless steel cup 6. Design of bending die for bend work pieces 7. Design of multi impression closed die forging for transmission lever 8. Injection Mould design for cap of water bag Text Books 1. Donaldson, Lecain and Goold, Tool Design, Tata McGraw Hill, ISBN 0 07 099274 2. J R Paquin, Die design Fundamentals, Industrial Press Inc., ISBN 0 8311 1172 0. 3. P. N. Rao, Manufacturing Technology- Foundry, Forming & Welding, Tata McGraw Hill 4. R. G. W. Pye, Injection Mould Design (Design manual for plastic industry), EWP Reference Books 1. P. H. Joshi, Press Tools Design & Construction, Wheeler Pub 2. P. C. Sharma, Production Engineering, S. Chand 3. Dr. Surender Kumar, Production Engg. Design (Tool Design), Satya Prakashan 4. R. G. W. Pye, Injection Mould Design (Design manual for plastic industry), EWP 5. A. S. Athalye, Plastics Materials handbook, Multitech Pub. Co., ISBN 81 7671 007 6. Denton and Glanvil Injection mould design fundamentals, Industrial Press, Inc. Course Outcomes: Student will be able to 1. understand mechanism of shearing of sheet metals, elements of dies and equipment. 2. select and design appropriate die set and equipment for shearing operations of sheet

metal. 3. understand principles of sheet metal forming and design of tools for deep drawing and

bending operations. 4. apply principals of forging operations and design dies for closed die and upset forging. 5. understand different plastic processing techniques and equipment. 6. design elements of injection molding dies and understand working of injection machine.



FF No.: 654

PR4006::MODERN MANUFACTURING PROCESSES Credits: 04 Teaching Scheme: 3 Hrs/Wk

SECTION-1 Introduction to nontraditional machining methods - Need for non - traditional machining - Sources of metal removal -Classification on the basis of energy sources - Parameters influencing selection of process Mechanical Processes Abrasive Jet Machining – Water Jet Machining – Abrasive Water Jet Machining (AJM, WJM and AWJM) Operating principles -Equipment -Parameters influencing metal removal - Applications -Advantages and Limitations. Ultrasonic Machining, Operating Principle and Process characteristics Thermo Electrical Energy Techniques Electrical Discharge Machining (EDM) Fundamental principle of EDM, Equipment’s required for EDM process parameters, process capabilities. Application example trouble shooting, Introduction to wire EDM, Process principle and parameters, process capacities and its applications.EDM tool design, Machine tool selection, EDM accessories / applications, electrical discharge grinding.

SECTION-2 Thermal Energy Techniques Operating principles - Equipment and sub systems - Parameters influencing metal removal- Benefits - Applications - Advantages and limitations of Electron beam machining (EBM), Plasma ARC Machining (PAM) and laser beam machining (LBM). Electron Beam Machining, EBM Principle and process characteristics Electro Chemical Machining (ECM) Background of ECM process, Classification of ECM processes. Electrochemistry of ECM, Equipment required in ECM. Process capabilities and processes parameters. Evaluation of MRR. Parameters influencing metal removal- Applications - Advantages and limitations. Electro Chemical Grinding: Process principles, process parameters, Applications Chemical Machining (CHM) Introduction, Elements of process Chemical blanking process:-Preparation of workpiece. Preparation of masters, masking with photo resists, etching for blanking, applications of chemical blanking, chemical milling (Contour machining):- Process steps – masking, Etching, process characteristics of CHM :-material removal rate accuracy, surface finish, Advantages & application of CHM. Electro-chemical Drilling and De-burring operations. List of Practicals: Student will do exercises based modeling of following processes in order to predict MRR, Surface roughness etc. and also they will study parametric correlations of the process. 1. Exercise on Ultrasonic machining (USM), Abrasive Jet Machining (AJM) and Abrasive

water jet machining (AWJM)



2. Exercise on MRR and surface roughness modeling of EDM process and wire-EDM process. Exercise on Laser Beam Machining (LBM), Plasma Arc Machining (PAM) and Electron Beam Machining (EBM)

3. Exercise on Electro Chemical Machining (ECM) and Chemical Metal removal process 4. Case study on Hybrid material Removal process (ECDM, ECG, EDG etc.) List of Project areas: Students will perform projects of following processes (Any One) for experimental investigation of the process, modeling of the process and process optimization 1. Abrasive water jet Machining 2. Electro Discharge Machining 3. Laser Beam Machining 4. Wire- Electro discharge Machining Text Books:

1. V. K. Jain Advanced Machining Processes,

Edition No.,

Allied Publishers Pvt. Ltd., New Delhi,

2007

2. P. K. Mishra Non-Conventional Machining,

Edition No.,

The Institution of Engineers (India), Text Book Series

1997

3. P. C. Pandey and H. S. Shan

Modern Machining Processes,

Edition No.,

Tata McGraw-Hill, New Delhi

2007

Reference Books:

1. G. F. Benedict, Unconventional Machining Process,

Edition No.,

Marcel Dekker Publication, New York,

1987.

2. McGeough, Advanced Methods of Machining,

Edition No.,

Chapman and Hall, London,

1998.

3. P. C. Sharma, A Text book of Production Engg

Edition No.

S Chand, New Delhi, 1995.

4. P. DeGarmo, J. T. Black, and R. A. Kohser,

Material and Processes in Manufacturing

Edition No. 8

Prentice Hall of India Pvt. Ltd., New Delhi

2001.

Course Outcomes: Students will be able to: 1. Understand need of advanced machining processes and select process for any industrial

job based on its complexity, cost and specifications required. 2. Apply the working principles and processing characteristics of mechanical type advanced

machining processes such as USM, AJM, WJM and Develop experimental, regression based, mathematical and physics based models for the advanced machining processes and predict MRR and surface roughness.

3. Apply the working principles and processing characteristics of electro-thermal type advanced machining processes such as EDM, wire-EDM and Develop experimental,



regression based, mathematical and physics based models for the advanced machining processes and predict MRR and surface roughness.

4. Apply the working principles and processing characteristics of thermal type advanced machining processes such as PAM, LBM, EBM machining to the production of precision components.

5. Apply the working principles and processing characteristics of chemical type advanced machining processes such as Electrochemical Machining to the production of precision micro and macro components.

6. Apply the working principles and processing characteristics of chemical type advanced machining process for production of precision components.



FF No. : 654

PR4074::MAJOR PROJECT

Credits: 04 Teaching Scheme:- 8 Hr/Wk The project work could be of the following nature: 1. Manufacturing /Fabrication of a prototype machine' including selection, concept, design,

material, manufacturing the components, assembly of components, testing and performance evaluation.

2. Improvement of existing machine / equipment / process. 3. Design and fabrication of Jigs and Fixtures, dies, tools, special purpose equipment,

inspection gauges, measuring instruments for machine tools. 4. Computer aided design, analysis of components such as stress analysis. 5. Problems related to Productivity improvements. 6. Problems related to value engineering. 7. Problems relating to material handling system. 8. Energy Audit of organization, Industrial evaluation of machine devices. 9. Design of a test rig for performance evaluation of machine devices. 10. Product design and development. 11. Analysis, evaluation and experimental verification of any engineering problem

encountered. 12. Quality systems and management. Total Quality Management. 13. Quality improvements, In-process Inspection, Online gauging. 14. Low cost automation, Computer Aided Automation in Manufacturing. 15. Time and Motion study, Job evaluation. 16. Ergonomics and safety aspects under industrial environment 17. Management Information System. 18. Market Analysis in conjunction with Production Planning and Control.

OR Fabrication of models, machines, prototypes based on new ideas, robots and machine based on hitech systems and automation, experimental set-up, fabrication of testing equipment, renovation of machines, etc. Computer based design / analysis or modeling / simulation of product(s), mechanism(s) or system (s) and its validation or comparison with available benchmarks / results. Modelling/simulation of product(s), mechanism(s) or system(s) and its validation or comparison with available bench marks / results. Design/development and Fabrication of models, machines, and prototypes based on new ideas, robotic and automation systems, Experimental set ups, test rigs/ equipments. The project work shall be taken up individually or in a group consisting of not more than 4 students.



A report containing maximum 30 pages shall be submitted based on the background, need and scope of the project, project specifications, activities involved in the project and activity plan, study of literature and basic theory, and work completed (if any). Guidelines:

Report shall be typed or printed.

Figures and tables shall be on separate pages and attached at respective positions.

Project title and approval sheets shall be attached at the beginning of the report followed by index and synopsis of the project.

References shall be mentioned at the end followed by appendices (if any).

When a group of students is doing a project, names of all the students shall be included on every certified report copy.

Each group of students shall submit two copies of reports to the institute and one copy shall be prepared for each individual student. Course Outcomes: Students will be able to: 1. Survey literature for problem identification 2. Cultivate the habit of working in a team, communicate effectively and attempt a problem

solution in a right approach 3. Correlate the theoretical and experimental/simulations results and draw the proper

inferences. 4. Apply engineering knowledge in carrying out project starting from design, drafting,

process planning, project management, costing, manufacturing, QC and inspection, down to assembly, testing and evaluation.

5. To practice data collection and analysis using different measurement equipment’s and software packages.

6. Prepare project report as per guideline and present it effectively



FF No. : 654

PR4002::SUPPLY CHAIN ANALYSIS & MODELING

Credits: 04 Teaching Scheme:- 3Th + 2 Lab Hrs/Wk

SECTION-1

Basics of Supply Chain Management: Concept, Objective. Decision Phases in Supply Chain. Process View of Supply Chain – Cycle View, Push/Pull view, Supply Chain Performance – Achieving Strategic Fit. Types of Supply Chain – Responsive, Efficient, Achieving Strategic Fit. Supply Chain Drivers – Facilities, Inventory, Transportation, Information, Pricing and Sourcing. Logistics - Logistics Function: Transportation–Significance in SCM, Modes of Transportation– Rail, Road, Pipelines, Water, Air, Multimodal – Advantages & Disadvantages, Concept of TL, LTL, FTL. Selection of Appropriate Modes of Transportation. Warehouse Management: Warehousing – Objectives, Functions, Types. Concept of SKUs, Warehousing Principles & Best Practices in Receiving, Shipping, Order Picking, Storage & Put away, Warehouse Activity Profiling, Warehouse Layout Planning, Order Processing – Role of IT, Material Handling, Warehouse Management Systems Network Design in Supply Chain - Factors Influencing Distribution Network Design – Response time, Product variety, Product availability, Customer experience, Order visibility, Return ability. Transportation Modeling & Optimization: Transportation Model: Vogel’s Approximation Method, UV Method, Stepping Stone Method, Transshipment problems, Shortest Path Problem, Minimal Spanning Tree, Maximal Flow Problem, Traveling Salesman Problem, Vehicle Routing Problem. Managing Supply and Demand: Managing Capacity – time flexibility of workforce, seasonal workforce, subcontracting, use of dual facilities, and design product flexibility into production processes. Managing Inventory – use common components across multiple products; build inventory of high demand of predictable demand products Managing Demand: Variable pricing, Forward buying. Collaborative Planning Forecasting & Replenishment

SECTION-2 Inventory Management in Supply Chain - Managing Economies of Scale: Cycle Inventory- Role in SC - Lot sizing for single product, multiple products or customers, Aggregating multiple products in single order Managing Uncertainty: Safety Inventory – Role in SC – Determine appropriate level of safety inventory. Pipeline/ In-transit Inventory, Seasonal Inventory, Transportation & Inventory Cost Trade-off: Choice of Transportation Mode, Inventory Aggregation. Transportation cost and customer-responsiveness trade-off; Pricing & Revenue Management in Supply Chain: Role, Revenue Management for Multiple Customer Segments, Seasonal Demand, Bulk & Spot Customers,



Outsourcing & Co-ordination in Supply Chain: Procurement Process, Sourcing, 3PL, 4PL, Vendor Managed Inventory. Co-ordination in Supply Chain: Lack of SC Coordination & Bullwhip Effect. Obstacles to SC Coordination. Manager Levers to Achieve Coordination. IT and Technology in Supply Chain: Role of IT in Supply Chain IT Framework. E-business & Supply Chain, EPR Solutions, Future of Supply Chain. Cases on E-business and supply chains, Recent Technologies in SCM – Blockchain, Artificial Intelligence Special Cases in Supply Chain : Sustainable -Green SCM, Reverse Logistics, Global Supply Chain Management – Case studies, Cold & Liquid Supply Chain, List of Practicals: 1. Detailed Study of Supply Chain of any one company in an Industry of your choice 2. Study of Industry or Sector Based on Economics Times Intelligence Group 3. Single Facility Location Models- 4. Multiple Facility Location Models- 5. Allocation Models – Transportation, Transshipment model 6. Application of Travelling Salesman Problem 7. Application of Vehicle Routing Problem 8. Design/ Develop Inventory policy 9. Selective Inventory Control – ABC, FSN, VED etc. 10. Computerized Simulation Games – Bullwhip Effect 11. Supply Chain Optimization and Integration 12. Application of Recent Technologies in SCM 13. Excel – Solver based modeling List of Project areas: 1. Distribution Network Design 2. Inventory Management 3. Supply Chain Optimization 4. Logistics Modelling 5. Application of Recent Technologies in SCM 6. Outsourcing 7. Sustainable Supply Chains – Green, Reverse Text Books: 1. Sunil Chopra & Peter Meindl, Supply Chain Management - Strategy, Planning &

Operation –Pearson Education Reference Books: 1. Bowersox , Logistical Management - The Integrated Supply Chain Process 2. Christopher, Logistics & Supply Chain Management, Pearson Education 3. Logistics & Supply Chain Management – Raghuram 4. Business Logistics / Supply Chain Management – Ronald Ballou, Peason Education.



Course Outcomes: The student will be able to – 1. Identify the key elements and processes in a supply chain and their interaction 2. Understand and analyze the designing, planning and operational decisions of SCM. 3. Identify the techniques used in management of critical components of supply chain 4. Analyze, design and optimize supply chain networks for manufacturing organizations 5. Design and optimize inventories across the supply chain 6. Explain the likely future development of logistics and supply chain management



FF No. : 654

PR4004::FINANCIAL MANAGEMENT AND MANAGEMENT ACCOUNTING

Credits: 04 Teaching Scheme: Th-3 Hrs/Wk+Lab/Project-2 Hrs/Wk

SECTION I - FINANCIAL MANAGEMENT 1. Financial Statement Analysis - Nature and Scope of Finance Function; Financial goal profit vs. wealth, Maximization; Scope and Functions of Financial Management, Financial Planning and Forecasting. Budgets & Budgetary Control: Types of Budget, Preparation of Budgets: Operational & Financial Budgets, Financing and Dividend decisions. Operating & Financial Leverage, Types of accounts, Profit and Loss Account and Balance Sheet, Cash Flow Statement 2. Capital Budgeting and ratio Analysis - Ratio Analysis Classification, Ratio Analysis and its limitations. Types of Ratios, Activity Turnover, Profitability, Liquidity, etc., B: Common Size Statement, Index Statement, Capital Budgeting - Nature of Investment decisions; Investment evaluation criteria - Non-DCF & DCF Techniques, PBP, Discounted PBP, PI, ARR, Annual Worth, 3. Working Capital Management - Meaning, significance and types of working capital; calculating operating cycle period and estimation of working capital requirements; sources of working capital, NPV and IRR comparison; Capital rationing. Various committee reports on bank finance; Dimensions of working capital management

SECTION II – MANAGEMENT ACCOUNTING 4. Introduction to concept of Cost and Overheads - Cost, Cost Centre, Cost Unit, Elements of Cost: Material Cost. Different methods of pricing of issue of materials Labour Cost: Direct & Indirect cost, Different methods, Direct Expenses: Constituents and Significance, Prime Cost, Classification: Production, Office & Administration, Selling & Distribution. Treatment of Overheads: Collection of Overheads - Primary and Secondary Distribution of Overheads: Absorption of Overheads: Machine hour, Labour hour rate, Under and Over Absorption of Overheads, Preparation of Cost Sheet 5. Costing Methods - Job Costing, Unit Costing, Contract Costing, Process Costing, Activity Based Costing Simple numerical on various methods of costing to enable ascertains cost of product. Standard costing: Concept, Standard Cost, Standard costing. Calculation of Variance Numerical on calculation of variances, Variance – Variance Analysis, Material variance, Labour Variance, Overhead Variance 6. Marginal Costing and Break Even Analysis - Fixed & Variable (Marginal) Cost, Marginal Cost. Applications of Marginal Costing in Decision-making: Product Mix, Profit Planning, Make or Buy Decisions. Limiting Factor, Cost Volume Profit Analysis, Concept of Break-Even, P/V Ratio and Margin of Safety Text Books: 1.Prasanna Chandra, Financial Management – Theory and Practice, Edition 8, 2011, TataMc Graw Hill Education,



2. B. K. Bhar, Cost Accounting – Methods and Problems, Edition No., Academic Publishers, 1980 3. M.Y. Khan and P K Jain, Financial Management: Text, Problems and Cases, Edition 5 2011, TataMc Graw Hill Education, 4. Amitabha Mukherjee, and Mohammed Hani, Modern Accountancy, Edition 2, 2002, TataMc Graw Hill Education Reference Books: 1. Paresh P. Shah, Financial Management, Reprint No. 2 2011, Biztantra, New Delhi, 2. S. N. Maheshwari, Introduction to Accountancy, Edition No. 11, 2013, Vikas Publishing House P Ltd. 3. M. Y. Khan, P. K. Jain, Management Accounting – Text, Problems, Cases, Edition No. Tata McGraw Hill Publishers, 2013 List of Practicals: 1. Case study on sources of capital and working capital 2. Studying and understanding Financial Statements 3. Studying and understanding various financial ratios used in practice 4. Case study on Analysis of published results of an organisation 5. Prepare a cost sheet to estimate cost of any product or process 6. Case study on use Marginal Costing to determine Break Even Point and profitability List of Project areas: 1. Budgeting including sources of capital and working capital 2. Preparation of Journal entries, Ledgers, Profit and Loss Account and Balance Sheet 3. Ratio Analysis based on real life data from project on Profit and loss and Balance sheet 4. Compare Analysis of published results of organisations to enable investment decision 5. Apply Product Costing to estimate cost of any process used in practice 6. Apply Service Costing to estimate cost of any process used in practice 7. Apply Process Costing to estimate cost of any process used in practice 8. Apply Marginal Costing to determine Break Even Point and profitability Course Outcomes: The student will be able to – 1. Understand and analyze functions of financial management and budgeting, interpret financial statements through accounting ratios 2. Understand the concepts of Capital Budgeting and Working Capital management for effective financial management 3. Understand the mechanics of financial accounting for preparation of financial statements to ascertain the performance and financial position of a business 4. Classify and apply different types of costs and overheads to ascertain costs of a product or a process 5. Apply different types of costing methods and techniques according to the suitability for various production processes and services. 6. Develop an ability of decision making about optimum product mix, profit planning, make or buy, limiting factors based on marginal costing concept



FF No.: 654

PR4005::MECHATRONICS & INDUSTRIAL ROBOTICS Credits: 04 Teaching Scheme: 3 Hrs/Wk

SECTION-1

1 Mechatronics Definition of mechatronics. Mechatronics in manufacturing, products and design. Review of fundamentals of electronics. Data conversion devices, sensors, microsensors, transducers, signal processing devices, relays, contactors and timers. Microprocessors controllers and PLCs. Description of PID controllers. Drives: stepper motors, servo drives. Ball screws, linear motion bearings, cams, systems controlled by camshafts, electronic cams, indexing mechanisms, tool magazines, transfer systems. Hydraulic systems: flow, pressure and direction control valves, actuators, and supporting elements, hydraulic power packs, pumps. Design of hydraulic circuits. Pneumatics: production, distribution and conditioning of compressed air, system components and graphic representations, design of systems. CNC machines and part programming. 2 Basic Concepts in Robotics Automation and robotics, robot anatomy, robot specifications, Development of industrial Robots and manipulators, basic structure of robots, resolution, accuracy and repeatability. Classification, Configuration of robots, arm and body motions, wrist motions, Mechanical, hydraulic and pneumatic Manipulators 3 Robot Arm Kinematics Orientations and frames, Mappings: Changing descriptions from frame to frame, Operators: Translations, Rotations and Transformations - Transformation Arithmetic - D-H Representation - Forward and inverse Kinematics Of Six Degree of Freedom Robot Arm – Robot Arm dynamics 4 Static and dynamic analysis of manipulator arm Statics of planer arm robot, Mass and inertia of links, Lagrangian formulation for equations of motion for serial manipulators.

SECTION-2 1 Robot Grippers Classification, types, Design consideration, Materials for hostile operation. Cylindrical Cam type; Grippers using pneumatic, Vacuum Grippers, ultrasonic grippers 2 Sensors in Robotics Sensors - functioning, types, analysis and fields of applications – position, velocity and acceleration sensors, Tactile sensors, temperature sensors, Variable Pressure Light Converting Sensor, High Resolution Compliance, Range & Proximity Sensors, Electro- optical Sensors. Pneumatic tactile Sensor, Slip type Sensors Vision system: Median filtering, thresholding, discretization, smoothening of binary image. Recognition Procedure. CCD Camera. 3 Robot Drives, Control and Robot Programming



DC servo motors, basic control systems concepts and models, control system analysis, robot activation and feed back components. Positional and velocity actuators. Methods of Programming the robot, Languages, Robographics, Introduction to Artificial Intelligence, Hydraulic systems, Power transmission systems, robot joint control design List of Practicals: 1) problems on accuracy, precision and repeatability, resolution 2) Problem on axis rotation by matrix transformation 3) problem on forward kinematics-Cartesion 4) problem on forward kinematics-cylindrical 5) problem on forward kinematics-polar 6) problem on forward kinematics-jointed arm. List of Project areas: 1. Robotic Work Cell Design Text Books: 1. Deb S.R., Robotics, Tata McGraw Hill Publications, New Delhi. 2. Yoram Koren, Robotics for Engineers, McGraw Hill Book Co. 3. Groover M.P., Weiss M., Nagel R.N., Odrey N.G., Industrial Robotics Technology - Programming and Applications, McGraw Hill Book Co. 4. Fu K.S., Gonzalex R.C., Lee C.S.G., Robotics Control Sensing, Vision and intelligence, McGraw Hill Book Co Reference Books: 1. Hartenberg and Denavit, Kinematics and Synthesis of Linkages, McGraw Hill Book Co. 2. Hall A.S., Kinematics and Linkage Design, Prentice Hall. 3. Hirchhorn J., Kinematics and Dynamics of Machinery, McGraw Hill Book Co. 4. Todd D.J., Fundamentals of Robot Technology, Wiley Publications 5. Paul R., Robots - Manipulators, Mathematics, Programming and Control, MIT Press. 6. Janakiraman P.A., Robotics and Image Processing, Tata McGraw Hill 1995. Course Outcomes: The student will be able to – 1. Understand robot system and Select type of robot for industrial applications 2. Solve direct and inverse kinematic problem for Cartesian, polar, cylindrical and articulated arm robot. 3. Understand concept of static and dynamics of manipulator arm 4. Understand various types of end effectors used in industrial robots. 5. Understand concepts and applications of sensors used in industrial robots. 6. Study and Select appropriate drives and robot programming method for industrial robots



FF No.: 654

PR4007::POWDER METALLURGY Credits: 04 Teaching Scheme: 03 Hrs/Wk

SECTION-1

Historical development, Basic principles of Powder Metallurgy. Powder production methods: Classification of metal powder production methods. Reduction, Atomization & developments in it. Electrolysis etc. Characterization of powder and properties - Production methodology and quality control. Testing of powders. Particle size distribution, surface conditions, purity, flow properties, porosity, true and apparent density, Green compact strength. Preparation of powder: grading, sizing, blending, handling and storage. Compaction: Fundamentals of compaction, presses used, selection of presses, Automation and Handling of powder, tool clearances, Die design principles, wear reclamation, Die and punch materials selection and heat treatment, surface treatment of dies, compact density variations, effect of blending powders, lubricants and lubrication in process. Pressure less powder shaping. Improvement of press tool life Sintering: Principle, time temperature effects, Theories of sintering mechanism. Sintering methods, sintering furnaces-characteristics and selection. Dimensional and property changes after sintering, Rapid sintering processes, impregnation. Liquid phase sintering, Activated sintering. Dimensional changes during sintering, Sintering atmosphere and its impact on process performance.

SECTION-2 Special P. M. Processes: Special PM processes like Hot Compaction, Iso static pressing, Hot Iso static compaction merits, demerits and typical applications. Powder metal products with polymer blends, Powder roll compaction. P.M. Forging, Powder Extrusion, Powder Injection molding, Hot powder forging, Hot powder extrusion, Comparison between various special PM processes. Composites & ceramics - Types, Processing, Typical examples, Applications. Production of nano composites with typical applications. Secondary Operations & Economics of Powder Metallurgy: Secondary operations like Sizing, Coining Oil impregnation, Heat treatments, Steam treatment, Economics, Quality assurance, Manufacturing Competitiveness due to conservation of energy, Materials, Operations, Durability, rigidity, near net – shape, surface finish and machining. Advantages and limitations of Powder Metallurgy. Powder Metallurgy Applications Production details of common PM structural parts like gears, levers, ratchets, etc. lamp filament and filament support, refractory metal components, electrical contact material, Cemented Carbide tools and wear parts, brakes and clutch lining material, porous bearings and filters, catalytic components etc.



List of Practicals: 1. Study the effect of cold compaction pressure on density 2. Characterization of metal powder 3. Study of effect of sintering temperature on properties. 4. Study of defects in P/M parts 5. Composite manufacturing 6. Characterization of composite. List of Project areas: 1. Comparison of P/M part, cast, machined & wrought part. 2. Design die for cold powder compaction for simple P/M parts. 3. Study the effect of various powder characteristics on strength of P/M part. Text Books: 1. A.K Sinha, A Textbook of Power Metallurgy, D.P.Tai 2. A. F. Thummler and R. Oberacker, An Introduction to Powder Metallurgy, The Institute of Materials, London. 3. Anish Upadhyaya & G.S. Upadhyaya, Powder Metallurgy Science, Technology & Materials, Universities Press-IIM (2011) Reference Books:

1. Powder Metallurgy ASM Handbook Vol.VII Course Outcomes: The student will be able to – 1. Select most appropriate powder manufacturing technique for cost effective manufacturing of powder component & characterize metal powder. 2. Select & apply different compaction techniques 3. Sintering techniques to obtain near net shape powder metallurgy parts. 4. Understand various special powder metallurgy techniques and secondary operations 5. Understand advantages, limitations and economics of powder metallurgy process 6. Understand typical applications of Powder Metallurgy



FF No. : 654

PR4086::MAJOR PROJECT Credits: 04 Teaching Scheme:- 8 Hr/Wk The project work could be of the following nature: 1. Manufacturing /Fabrication of a prototype machine' including selection, concept, design,

material, manufacturing the components, assembly of components, testing and performance evaluation.

2. Improvement of existing machine / equipment / process. 3. Design and fabrication of Jigs and Fixtures, dies, tools, special purpose equipment,

inspection gauges, measuring instruments for machine tools. 4. Computer aided design, analysis of components such as stress analysis. 5. Problems related to Productivity improvements. 6. Problems related to value engineering. 7. Problems relating to material handling system. 8. Energy Audit of organization, Industrial evaluation of machine devices. 9. Design of a test rig for performance evaluation of machine devices. 10. Product design and development. 11. Analysis, evaluation and experimental verification of any engineering problem

encountered. 12. Quality systems and management. Total Quality Management. 13. Quality improvements, In-process Inspection, Online gauging. 14. Low cost automation, Computer Aided Automation in Manufacturing. 15. Time and Motion study, Job evaluation. 16. Ergonomics and safety aspects under industrial environment 17. Management Information System. 18. Market Analysis in conjunction with Production Planning and Control.

OR Fabrication of models, machines, prototypes based on new ideas, robots and machine based on hitech systems and automation, experimental set-up, fabrication of testing equipment, renovation of machines, etc. Computer based design / analysis or modeling / simulation of product(s), mechanism(s) or system (s) and its validation or comparison with available benchmarks / results. Modelling/simulation of product(s), mechanism(s) or system(s) and its validation or comparison with available bench marks / results. Design/development and Fabrication of models, machines, and prototypes based on new ideas, robotic and automation systems, Experimental set ups, test rigs/ equipments. The project work shall be taken up individually or in a group consisting of not more than 4 students.



A report containing maximum 30 pages shall be submitted based on the background, need and scope of the project, project specifications, activities involved in the project and activity plan, study of literature and basic theory, and work completed (if any). Guidelines:

Report shall be typed or printed.

Figures and tables shall be on separate pages and attached at respective positions.

Project title and approval sheets shall be attached at the beginning of the report followed by index and synopsis of the project.

References shall be mentioned at the end followed by appendices (if any).

When a group of students is doing a project, names of all the students shall be included on every certified report copy.

Each group of students shall submit two copies of reports to the institute and one copy shall be prepared for each individual student. Course Outcomes: Students will be able to: 1. Survey literature for problem identification 2. Cultivate the habit of working in a team, communicate effectively and attempt a problem

solution in a right approach 3. Correlate the theoretical and experimental/simulations results and draw the proper

inferences. 4. Apply engineering knowledge in carrying out project starting from design, drafting,

process planning, project management, costing, manufacturing, QC and inspection, down to assembly, testing and evaluation.

5. To practice data collection and analysis using different measurement equipment’s and software packages.

6. Prepare project report as per guideline and present it effectively

bansilal ramnath agarwal charitable trust’s vishwakarma ... · p. h. joshi, press tools design...

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