semester – iii - kalasalingam...

M.TECH ENGINEERING DESIGN REGULATION 2014

KALASALINGAM UNIVERSITY(Kalasalingam Academy of Research and Education)

Anand Nagar, Krishnankoil – 626 190

DEPARTMENT OF MECHANICAL ENGINEERING

CURRICULUM FOR M.Tech (Engineering Design)

SEMESTER – ICourse Code Course Name L T P C

THEORYMAT5009 Applied Mathematics 3 0 0 3MEC5701 Advanced Mechanics of Materials 3 0 0 3MEC5702 Concepts of Engineering Design 3 0 0 3MEC5703 Quality Concepts in Design 3 0 0 3MEC5704 Mechanical Vibrations 3 0 0 3MECxxxx Elective I 3 0 0 3

PRACTICALMEC5781 Vibration Lab 0 0 3 2

Total 18 0 3 20

SEMESTER – IICourse Code Course Name L T P C

THEORYMEC5007 Product Design and Development Strategies 3 0 0 3MEC5705 Finite Element Analysis in Design 3 0 0 3MEC5706 Mechanism Design and simulation 3 0 0 3MEC5015 Tribology in Design 3 0 0 3MEC5707 Machine Tool Design 3 0 0 3MECxxxx Elective II 3 0 0 3

PRACTICALMEC5782 Analysis and Simulation Lab 0 0 3 2

Total 18 0 3 20

SEMESTER – IIICourse Code Course Name L T P C

THEORYMECxxxx Elective III 3 0 0 3MECxxxx Elective IV 3 0 0 3MECxxxx Elective V 3 0 0 3

PRACTICALMEC6798 Project Work – Phase I 0 0 18 6

Total 9 0 18 15

SEMESTER – IVCourse Code Course Name L T P C

PRACTICALMEC6799 Project Work Phase II 0 0 36 12

Total Credit = 67


LIST OF ELECTIVES

M.Tech (Engineering Design)

Course Code Course Name L T P CMEC5605 Optimization techniques in Engineering 3 0 0 3MEC6020 Mechanical Testing of Materials 3 0 0 3MEC5708 Fluid Power Control and Automation 3 0 0 3MEC6514 Rapid prototyping - Principles and Applications 3 0 0 3MEC5709 Condition Monitoring and Vibration Control 3 0 0 3MEC5710 Mechanics of Fracture 3 0 0 3MEC5711 Wear Analysis and Control 3 0 0 3MEC5712 Value and Reengineering 3 0 0 3MEC6701 Composite Materials and Mechanics 3 0 0 3MEC6702 Manufacturing Considerations in Design 3 0 0 3MEC6001 Design of Materials Handling Equipments 3 0 0 3MEC6703 Experimental Stress Analysis 3 0 0 3MEC5417 Reliability engineering 3 0 0 3MEC5019 Computational Fluid Dynamics 3 0 0 3MEC6704 Plates and shells 3 0 0 3MEC6705 Surface Engineering 3 0 0 3MEC6706 Advanced Metal Forming Techniques 3 0 0 3MEC6707 Design of Pressure vessel and Piping 3 0 0 3MEC6031 Analysis and Characterization of Polymers 3 0 0 3


MEC5701 ADVANCED MECHANICS OF MATERIALS L T P C3 0 0 3

UNIT I ELASTICITY Stress-Strain relations and general equations of elasticity in Cartesian, Polar and curvilinear coordinates, differential equations of equilibrium-compatibility-boundary conditions-representation of three-dimensional stress of a tension generalized hook's law - St. Venant's principle - plane stress - Airy's stress function. Energy methods.

UNIT II SHEAR CENTER AND UNSYMMETRICAL BENDING Location of shear center for various thin sections - shear flows. Stresses and Deflections in beams subjected to unsymmetrical loading-kern of a section.

UNIT III STRESSES IN FLAT PLATES AND CURVED MEMBERS Circumference and radial stresses – deflections - curved beam with restrained ends - closed ring subjected to concentrated load and uniform load - chain links and crane hooks. Solution of rectangular plates – pure bending of plates – deflection – uniformly distributed load – various end conditions

UNIT IV TORSION OF NON-CIRCULAR SECTIONSTorsion of rectangular cross section - St.Venants theory - elastic membrane analogy - Prandtl's stress function - torsional stress in hollow thin walled tubes.

UNIT V STRESSES IN ROTATING MEMBERS AND CONTACT STRESSESRadial and tangential stresses in solid disc and ring of uniform thickness and varying thickness allowable speeds. Methods of computing contact stress- deflection of bodies in point and line contact applications.

TOTAL : 45 PERIODS

REFERENCES 1. Arthur P Boresi, Richard J. Schmidt, “Advanced mechanics of materials”,John Wiley, 2002. 2. Timoshenko and Goodier, "Theory of Elasticity", McGraw Hill. 3. Robert D. Cook, Warren C. Young, "Advanced Mechanics of Materials", Mc-millan pub. Co., 1985. 4. Srinath. L.S., “Advanced Mechanics of solids”, Tata McGraw Hill, 1992. 5. G H Ryder Strength of Materials Macmillan, India Ltd, 2007. 6. Allan F. Bower, “Applied Mechanics of Solids”, CRC press – Special Indian Edition -2012, 2010 7. K. Baskar and T.K. Varadan, “Theory of Isotropic/Orthotropic Elasticity”, Ane Books Pvt. Ltd., New Delhi, 2009

MEC5702 CONCEPTS OF ENGINEERING DESIGN L T P C3 0 0 3

FUNDAMENTALS IN DESIGN Importance of design- The design process-Considerations of Good Design – Morphology of Design –Organization fordesign– Computer Aided Engineering – Designing to codes and standards – Concurrent Engineering – Product and process cycles – Technological Forecasting – Market Identification – Competition Bench marking.DESIGN FOR CUSTOMER NEEDSIdentification of customer needs- customer requirements- Quality Function Deployment- Product Design Specifications- Human Factors in Design – Ergonomics and Aesthetics.Societal consideration - Contracts – Product liability – Protecting intellectual property – Legal and ethical domains – Codes of ethics - Ethical conflicts – Design for ecological –future trends in interaction of engineering with society.DESIGN TECHNIQUES


Creativity and Problem Solving –Creativity methods-Theory of Inventive Problem Solving(TRIZ)– Conceptualdecomposition-Generating design concepts-Axiomatic Design – Evaluation methods-Embodiment Design-Product Architecture-Configuration Design- Parametric Design. Role of models in design-Mathematical Modeling – Simulation – Geometric Modeling –Rapid prototyping- Finite Element Analysis– Optimization – Search Methods.MATERIAL SELECTION PROCESSING IN DESIGNMaterial Selection Process – Economics – Cost Vs Performance – Weighted property Index – Value Analysis – Role of Processing in Design – Classification of Manufacturing Process – Design for Manufacture – Design for Assembly – Designing for castings, Forging, Metal Forming, Machining and Welding – Residual Stresses – Fatigue, Fracture and Failure.PROBABILITY CONCEPTS IN DESIGN FOR RELIABILITY Probability – Distributions – Test of Hypothesis – Reliability Theory – Design for Reliability – Reliability centered Maintenance-Robust Design-Failure mode Effect Analysis.TOTAL: 45References1. Dieter, George E., “Engineering Design - A Materials and Processing Approach”, McGraw Hill, InternationalEditions, Singapore, 2000.2. Pahl, G, and Beitz, W.,”Engineering Design”, Springer – Verlag, NY. 1984.3. Ray, M.S., “Elements of Engg. Design”, Prentice Hall Inc. 1985.4. Suh, N.P., “The principles of Design”, Oxford University Press, NY.1990.5. Karl T. Ulrich and Steven D. Eppinger “Product Design and Development” McGraw Hill Edition 2000.

MEC5703 QUALITY CONCEPTS IN DESIGN L T P C3 0 0 3

UNIT I DESIGN FUNDAMENTALS, METHODS AND MATERIAL SELECTION Morphology of Design – The Design Process – Computer Aided Engineering – Concurrent Engineering – Competition Bench Marking – Creativity – Theory of Problem solving (TRIZ) – Value Analysis - Design for Manufacture, Design for Assembly – Design for casting, Forging, Metal Forming, Machining and Welding

UNIT II DESIGN FOR QUALITY Quality Function Deployment -House of Quality-Objectives and functions-Targets-Stakeholders-Measures and Matrices-Design of Experiments –design process-Identification of control factors, noise factors, and performance metrics - developing the experimental plan- experimental design –testing noise factors- Running the experiments –Conducting the analysis-Selecting and conforming factor-Set points-reflecting and repeating.

UNIT III FAILURE MODE EFFECT ANALYSIS AND DESIGN FOR SIX SIGMA Basic methods: Refining geometry and layout, general process of product embodiment - Embodiment checklist- Advanced methods: systems modeling, mechanical embodiment principles-FMEA method- linking fault states to systems modeling - Basis of SIX SIGMA –Project selection for SIX SIGMA- SIX SIGMA problem solving- SIX SIGMA in service and small organizations - SIX SIGMA and lean production –Lean SIX SIGMA and services

UNIT IV DESIGN OF EXPERIMENTS Importance of Experiments, Experimental Strategies, Basic principles of Design, Terminology, ANOVA, Steps in Experimentation, Sample size, Single Factor experiments - Completely Randomized design, Randomized Block design, Statistical Analysis, Multifactor experiments - Two and three factor full Factorial experiments, 2K factorial Experiments, Confounding and Blocking designs, Fractional factorial design,


Taguchi‟s approach - Steps in experimentation, Design using Orthogonal Arrays, Data Analysis, Robust Design- Control and Noise factors, S/N ratios

UNIT V STATISTICAL CONSIDERATION AND RELIABILITY Frequency distributions and Histograms- Run charts –stem and leaf plots- Pareto diagrams-Cause and Effect diagrams-Box plots- Probability distribution-Statistical Process control–Scatter diagrams –Multivariable charts –Matrix plots and 3-D plots.-Reliability-Survival and Failure-Series and parallel systems-Mean time between failure-Weibull distribution TOTAL : 45 PERIODS

REFERENCES 1. Dieter, George E., “Engineering Design - A Materials and Processing Approach”, McGraw Hill, International Editions, Singapore, 2000. 2. Product Design Techniques in Reverse Engineering and New Product Development, KEVIN OTTO & KRISTIN WOOD, Pearson Education (LPE), 2001. 3. Product Design And Development, KARL T. ULRICH, STEVEN D. EPPINGER, TATA McGRAW-HILL- 3rd Edition, 2003. 4. The Management and control of Quality-6th edition-James R. Evens, William M Lindsay Pub:son south-western(www.swlearning.com) 5. Fundamentals of Quality control and improvement 2nd edition, AMITAVA MITRA, Pearson Education Asia, 2002. 6. Montgomery, D.C., Design and Analysis of experiments, John Wiley and Sons, 2003. 7. Phillip J.Rose, Taguchi techniques for quality engineering, McGraw Hill, 1996.

MEC5704 MECHANICAL VIBRATIONS L T P C3 0 0 3

FUNDAMENTALS OF VIBRATION Differential equation, complex exponential method of solution, energy method, power relations, phase relations, Nyquist diagram– Impulse Response function – System Identification from frequency response – Transient Vibration – Laplace transformation formulation.SINGLE DEGREE OF FREEDOM SYSTEMSSimple harmonic motion, definition of terminologies, Newton’s Laws, D’Alembert’s principle, Energy methods. Free vibrations, free damped vibrations, and forced vibrations with and without damping, base excitation.MULTI-DEGREES OF FREEDOM SYSTEMSTwo degrees of freedom systems, Static and dynamic couplings, eigen values, eigen vectors and orthogonality conditions of eigen vectors, Vibration absorber, Principal coordinates, Principal modes. Hamilton’s Principle, Lagrangean equation and their applications.VIBRATION CONTROLSpecification of Vibration Limits –Vibration severity standards- Vibration as condition Monitoring tool-Vibration Isolation methods - Dynamic Vibration Absorber, Torsional and Pendulum Type Absorber- Damped Vibration absorbers-Static and Dynamic Balancing-Balancing machines-Field balancing – Vibration Control by Design Modification- - Active Vibration ControlEXPERIMENTAL METHODS IN VIBRATION ANALYSIS Vibration Analysis Overview - Experimental Methods in Vibration Analysis.-Vibration Measuring Instruments – Selection of Sensors- Accelerometer Mountings. Vibration Exciters-Mechanical, Hydraulic, Electromagnetic And Electrodynamics –Frequency Measuring Instruments-. System Identification from Frequency Response -Testing for resonance and mode shapesTOTAL: 45 + 15 = 60References :1. Timoshenko, S. “Vibration Problems in Engineering”, John Wiley & Sons, Inc., 1987.


2. Meirovitch, L. “Elements of Vibration Analysis”, McGraw-Hill Inc., 1986.3. Thomson W.T, Marie Dillon Dahleh, “Theory of Vibrations with Applications”, Prentice Hall, 1997.4. F.S. Tse., I.F. Morse and R.T. Hinkle, “Mechanical Vibrations”, Prentice-Hall of India, 1985.5. Rao.J.S. and Gupta.K. “Theory and Practice of Mechanical Vibrations”, Wiley Eastern Ltd., New Delhi,1999.6. Fung, Y.C., “An Introduction to the Theory of Aeroelasticity”, John Wiley & Sons Inc., New York, 1985.

MEC5007 PRODUCT DESIGN AND DEVELOPMENT STRATEGIES

L T P C3 0 0 3

INTRODUCTION TO PRODUCT DESIGNNature and scope of product engineering - creative thinking - organizing for product innovation criteria - product success - life cycle of a product.

MODELING AND SIMULATIONModeling and simulation - role of models in product design - mathematical modeling - similitude relations - weighted property index.

MATERIAL SELECTIONProblems of material selection-performance characteristics of materials - materials selection process - economics of materials - cost versus performance relations - weighted property index.

DESIGN CONSIDERATION Functional and production design - form design-influence of mechanical loading and material on form design - design consideration of gray castings, malleable iron castings, aluminium castings, pressure die castings, plastic moulding, welded fabrications, forging and manufacture by machining methods.

TOLERANCE AND ANALYSISInfluence of space, size, weight, etc., on form design, aesthetic and ergonomic considerations - dimensioning and tolerancing a product-functional production and inspection datum - tolerance analysis.

Text Book

1. Jones, J. C., Design Methods, John wiely and sons, 1980.

References

1. Dieter, G. E., Engineering Design, McGraw Hill, 1983.2. Robert Matouseek, Engineering Design, Blackie and Sons Ltd., 1963.3. Niebel, B. W. and Draper, A. B., Product Design and Process Engineering, McGraw Hill, 1974.4. Harry Peck, Designing for Manufacturing, Sir Issac Pitman and Sons Ltd., 1973.

MEC5705 FINITE ELEMENT ANALYSIS IN DESIGN L T P C3 0 0 3

UNIT - IIntroduction: Historical Perspective of FEM and applicability to mechanical engineering design problems. Mathematical Models and Approximations: Review of elasticity. Mathematical models for structural problems: Equilibrium of continuum-Differential formulation, Energy Approach-Integral formulation, Principle of Virtual work - Variational formulation. Overview of approximate methods for the solution of


the mathematical models, Residual methods and weighted residual methods, Ritz, Rayleigh-Ritz and Galerkin’s methods. Philosophy of solving continuum problems using Finite Element method.

UNIT IIFinite Element Formulation: Generalised FE formulation based on weighted residual method and through minimisation of potential, displacement based formulation, Concept of discretisation, Interpolation, Formulation of Finite element characteristic matrices and vectors, Compatibility conditions, Assembly and boundary considerations. Finite element Analysis for One Dimensional Structural problems: Structural problems with one dimensional geometry. Bar element: formulation of stiffness matrix, consistent and lumped load vectors. Boundary conditions and their incorporation: Elimination method, Penalty Method, Introduction to higher order elements and their advantages and disadvantages. Formulation for Truss elements, Case studies involving hand calculations with an emphasis on Assembly, boundary conditions, contact conditions and multipoint constraints.

UNIT III Beams and Frames: Review of bending of beams, higher order continuity (C0 and C1 Continuity), interpolation for beam elements and formulation of FE characteristics, Plane and space frames and examples problems involving hand calculations. Algorithmic approach for developing computer codes involving 1-D elements. Two dimensional Problems: Interpolation in two dimensions, natural coordinates, Isoparametric representation, Concept of Jacobian. Finite element formulation for plane stress plane strain and axi-symmetric problems; Triangular and Quadrilateral elements, higher order elements, subparametric, Isoparametric and superparametric elements. Formulation of plate bending elements using linear and higher order bending theories, Shell elements, General considerations in finite element analysis of design problems, Choosing an appropriate element and the solution strategies. Introduction to pre and post processing of the results and analysis.

UNIT IV Three Dimensional Problems: Finite element formulation for 3-D problems, mesh preparation, tetrahedral and hexahedral elements, case studies. Dynamic Analysis: FE formulation in dynamic problems in structures using Lagragian Method, Consistent and lumped mass models, Formulation of dynamic equations of motion, Modelling of structural damping and formulation of damping matrices, Model analysis, Mode superposition methods and reduction techniques.

UNIT VFEM in Heat Transfer and Fluid Mechanics problems: Finite element solution for one dimensional heat conduction with convective boundaries. Formulation of element characteristics and simple numerical problems. Formulation for 2-D and 3-D heat conduction problems with convective boundaries. Introduction to thermo-elastic contact problems. Finite element applications in potential flows; Formulation based on Potential function and stream function. Design case studies Algorithmic Approach for problem solving: Algorithmic approach for Finite element formulation of element characteristics, Assembly and incorporation of boundary conditions. Guidelines for code development. Introduction to commercial Finite Element software packages like ANSYS.

READING: 1. Seshu P, Textbook of Finite Element Analysis, PHI. 2004 2. Reddy, J.N., Finite Element Method in Engineering, Tata McGraw Hill, 2007. 3. Singiresu S.Rao, Finite element Method in Engineering, 5ed, Elsevier, 2012 4. Zeincowicz, The Finite Element Method 4 Vol set, 4th Edition, Elsevier 2007.


MEC5706 MECHANISM DESIGN AND SIMULATION L T P C3 0 0 3

INTRODUCTION Review of fundamentals of kinematics-classifications of mechanisms-components of mechanisms – mobility analysis – formation of one D.O.F. multi loop kinematic chains, Network formula – Gross motion concepts-Basic kinematic structures of serial and parallel robot manipulators-Compliant mechanisms-Equivalent mechanisms.

KINEMATIC ANALYSIS Position Analysis – Vector loop equations for four bar, slider crank, inverted slider crank, geared five bar and six bar linkages. Analytical methods for velocity and acceleration Analysis– four bar linkage jerk analysis. Plane complex mechanisms-auxiliary point method. Spatial RSSR mechanism-Denavit-Hartenberg Parameters – Forward and inverse kinematics of robot manipulators.

PATH CURVATURE THEORY, COUPLER CURVE Fixed and moving centrodes, inflection points and inflection circle. Euler Savary equation, graphical constructions – cubic of stationary curvature. Four bar coupler curve-cusp-crunode-coupler driven six-bar mechanisms-straight line mechanisms

SYNTHESIS OF FOUR BAR MECHANISMS Type synthesis – Number synthesis – Associated Linkage Concept. Dimensional synthesis – function generation, path generation, motion generation. Graphical methods-Pole technique-inversion technique-point position reduction-two, three and four position synthesis of four- bar mechanisms. Analytical methods- Freudenstein’s Equation-Bloch’s Synthesis.

SYNTHESIS OF COUPLER CURVE BASED MECHANISMS & CAM MECHANISMSCognate Lingages-parallel motion Linkages. Design of six bar mechanisms-single dwell-double dwell-double stroke. Geared five bar mechanism-multi-dwell. Cam Mechanisms- determination of optimum size of cams. Mechanism defects. Study and use of Mechanism using Simulation Soft-ware packages. Students should design and fabricate a mechanism model as term project.

REFERENCES 1. Robert L.Norton., “Design of Machinery”,Tata McGraw Hill, 2005. 2. Sandor G.N., and Erdman A.G., “Advanced Mechanism Design Analysis and Synthesis”, Prentice

Hall, 1984. 3. Uicker, J.J., Pennock, G. R. and Shigley, J.E., “Theory of Machines and Mechanisms”, Oxford

University Press, 2005. 4. Amitabha Ghosh and Asok Kumar Mallik, “Theory of Mechanism and Machines”, EWLP, Delhi,

1999. 5. Kenneth J, Waldron, Gary L. Kinzel, “Kinematics, Dynamics and Design of Machinery”, John

Wiley-sons, 1999. 6. Ramamurti, V., “Mechanics of Machines”, Narosa, 2005.

MEC5015 TRIBOLOGY IN DESIGN L T P C3 0 0 3

SURFACE, FRICTION AND WEARTopography of the surfaces - surface features, surface interaction - theory of friction - sliding and rolling friction, friction properties of metallic and non-metallic materials - friction in extreme conditions - wear, types of wear, mechanism of wear, wear resistance materials, surface treatment , surface modifications,


surface coatings.LUBRICATION THEORY Lubricants and their physical properties lubricants standards - lubrication regimes -hydrodynamic lubrication Reynolds equation - thermal, inertia and turbulent effects - Elasto hydrodynamic and Plasto hydrodynamic and magneto hydrodynamic lubrication - hydro static lubrication - gas lubrication. DESIGN OF FLUID FILM BEARINGSDesign and performance analysis of thrust and journal bearings - full, partial, fixed and pivoted journal bearings design - lubricant flow and delivery - power loss, heat and temperature rotating loads and dynamic loads in journal bearings - special bearings - hydrostatic bearing design. ROLLING ELEMENT BEARINGGeometry and kinematics - materials and manufacturing processes - contact stresses - Hertzian stress equation - stresses and deflection - axial loads and rotational effects - bearing life capacity and variable loads - ISO standards - oil films and their effects - rolling bearings failures.

TRIBOLOGY MEASUREMENTS IN INSTRUMENTATIONSurface topography measurements - electron microscope and friction and wear measurements- pin on disc, pin on roller, slurry abrasion, anti fretting - laser method – instrumentation - international standards bearings performance measurements - bearing vibration measurement.

Text Book

1. Cameron, A. "Basic Lubrication Theory", Ellis Herward Ltd. , UK,1981.

References

1. Hulling , J. (Editor), Principles of Tribology, Macmillan ,1984. 2. Williams J.A . Engineering Tribology, Oxford Univ. Press, 1994. 3. Neale M.J, "Tribology Hand Book, Butterworth Heinemann, 1995. 4. Bharat Bhushan, “Engineering Tribology”, John wiley and sons, 2002

MEC5707 MACHINE TOOL DESIGN L T P C3 0 0 3

STATIC AND DYNAMIC STIFFNESS, FORCE ANALYSISStatic stiffness and compliance- deformation caused by weight, Forces- deformation caused by cutting forces – forced vibrations, self-excited vibrations, Force distribution in different parts of Lathe, Drilling machine, Milling machine.DESIGN OF STRUCTURESBeds, columns and housing for maximum strength and rigidity – cast and welded construction – CNC machine tools - structure – main drive and feed drive- ball screws- automatic tool changers- chip conveyors- tool magazines- tool turrets.DESIGN OF SLIDE WAYS Selection of materials- integrated and attached ways- hydro-static guide ways,aero-static guide ways- antifriction guide ways- design of friction guide ways- plastic inserted guide ways and LM guide ways.DESIGN OF MACHINE TOOL SPINDLES AND DRIVESDesign requirements – standards – selection of spindle bearings- materials for spindles- typical spindle design – design consideration of Electrical, Mechanical and Hydraulic drives in machine tools.MACHINE TOOL CHATTERThe Dynamics of cutting process - physical causes of chatter- theory of machine tool chatter- the theory of chatter with several degree of freedom - chatter suppression. Design of control mechanisms – selection of standard components - dynamic measurement of forces and vibrations in machine tools - use of vibration dampers.


References :1. Mehta. N.K, “Machine Tool Design” Tata McGraw Hill, 1989.2. Koenisberger.F. “Design principles of Metal cutting Machine Tools”.Pergamon press, 1964.3. Acherkan.N.,”Machine Tool Design”. Vol. 3 & 4, MIR Publishers, Moscow, 1968.4. Sen.G. and Bhattacharya.A.,”Principles of Machine Tools”. Vol.2, NCB. Calcutta, 1973.5. Tobias.S.A.,”Machine tool Vibration” Blackie and Son Limited, London,1965.

MEC5605 Optimization techniques in Engineering L T P C3 0 0 3

INTRODUCTIONOptimization – Historical Development – Engineering applications of optimization – Statement of an Optimization problem– classification of optimization problems.

CLASSIC OPTIMIZATION TECHNIQUESLinear programming - Graphical method – simplex method – dual simplex method – revised simplex method – duality in LP – Parametric Linear programming – Goal Programming.

NON-LINEAR PROGRAMMINGIntroduction – Lagrangeon Method – Kuhn-Tucker conditions – Quadratic programming – Separable programming – Stochastic programming – Geometric programming

INTEGER PROGRAMMING, DYNAMIC PROGRAMMING AND NETWORK TECHNIQUESInteger programming - Cutting plane algorithm, Branch and bound technique, Zero -one implicit enumeration – Dynamic Programming – Formulation, Various applications using Dynamic Programming. Network Techniques – Shortest Path Model – Minimum Spanning Tree Problem – Maximal flow problem.

ADVANCES IN SIMULATIONGenetic algorithms – simulated annealing – Neural Network and Fuzzy systems

References:

1. R. Panneerselvam, “Operations Research”, Prentice Hall of India Private Limited, New Delhi 1, 2005 2. P.K. Guptha and Man-Mohan, “Problems in Operations Research” – Sultan Chand & Sons, 1994 3. Ravindran, Philips and Solberg, “Operations Research Principles and Practice”, John Wiley & Sons,

Singapore, 1992 4. J.K.Sharma, “Operations Research – Theory and Applications” – Macmillan India Ltd., 1997 5. Hamdy A. Taha “Operations Research – An Introduction”, Prentice Hall of India, 1997 6. N. V. S. Raju, “Optimizaiton methods for Engineers”, Prentice Hall of India Private Limited, New Delhi,

2014

MEC6020 MECHANICAL TESTING OF MATERIALS L T P C3 0 0 3

FLOW PROPERTY TESTING Tension - Engineering & true stress-strain curves, evaluation of tensile properties tensile instability, effect of strain-rate & temperature on flow properties - Compression - Comparison with tension, buckling & barreling. Bending - Pure bending & flexure formula. Torsion - Stresses for elastic & plastic strain, Torsion vs. Tension - Impact - Notched bar impact tests, transition Temperature & metallurgical factors affecting it.

FATIGUE


Fatigue - Stress cycles & S-N curve, effect of variables like mean stress, stress concentration, surface, size, metallurgical factors etc.

CREEPCreep - Creep, stress rupture & stress relaxation tests, development of creep resistant alloys, prediction of long time properties.

POLYMER TESTINGPolymer testing (sample preparation, testing standards and methods, analysis of polymer and additives) - problems of polymer (thermoxidative degradation, fire hazards, toxicity, effluent disposal, feedstock scarcity).

FAILURE ANALYSIS Modes of failures, corrosion failure, high temperature failure, Case studies in failure analysis. Prevention of failures

TEXT BOOK1. Dowling, Norman E (2006), Mechanical Behavior of Materials, Prentice Hall, 3rd Edition. 2. Marc Andre Meyers, Krishan Kumar Chawla, Mechanical Behavior of Materials, Prentice Hall, 1998

REFERENCE

1. Yung-Li Lee, Jwo Pan, Richard Hathaway, Mark Barkey (2004), Fatigue Testing and Analysis: Theory and Practice, Butterworth-Heinemann.

2. Norman E. Dowling (1998), Mechanical Behavior of Materials: Engineering Methods for Deformation, Fracture, and Fatigue, Prentice Hall; 2nd edition.

3. Jacek J. Skrzypek and Richard B. Hetnarski (1993), Plasticity and Creep: Theory, Examples, and Problems, CRC Press

4. George E. Dieter, “Mechanical metallurgy, McGraw Hill

MEC5708 FLUID POWER CONTROL AND AUTOMATION L T P C3 0 0 3

OIL HYDRAULIC SYSTEMS AND HYDRAULIC ACTUATORS Hydraulic Power Generators – Selection and specification of pumps, pump characteristics. Linear and Rotary Actuators– selection, specification and characteristics.

CONTROL AND REGULATION ELEMENTS Pressure - direction and flow control valves - relief valves, non-return and safety valves - actuation systems.

HYDRAULIC CIRCUITSReciprocation, quick return, sequencing, synchronizing circuits - accumulator circuits - industrial circuits - press circuits- hydraulic milling machine - grinding, planning, copying, - forklift, earth mover circuits- design and selection of components.

PNEUMATIC SYSTEMS AND CIRCUITSPneumatic fundamentals - control elements, position and pressure sensing - logic circuits - switching circuits - fringeconditions modules and these integration - sequential circuits - cascade methods - mapping methods - step countermethod - compound circuit design - combination circuit design.

DESIGN OF SPECIAL CIRCUITS Pneumatic equipments- selection of components - design calculations – application -fault finding - hydro pneumatic


circuits - use of microprocessors for sequencing - PLC, Low cost automation -Robotic circuits. Software for pneumatic/ hydraulic systems simulation.References :1. Antony Espossito, “Fluid Power with Applications”, Prentice Hall, 1980.2. Dudleyt, A. Pease and John J. Pippenger, “Basic fluid power”, Prentice Hall, 1987.3. Michael J., Pinches and John G.Ashby, “Power Hydraulics”, Prentice Hall, 1989.4. Bolton. W., “Pneumatic and Hydraulic Systems “, Butterworth –Heinemann, 1997.5. Joji P., “Pneumatic Controls”, Wiley India Pvt. Ltd., New Delhi, 2008.6. Andrew Parr, “Hydraulic and Pneumatics” (HB), Jaico Publishing House, 1999.7. John J. Pippenger, “Industrial Hydraulics” Mc Graw hill, 1979

MEC6514 RAPID PROTOTYPING PRINCIPLES AND APPLICATIONS

L T P C3 0 0 3

Introduction: Prototyping fundamentals, Historical development, Fundamentals of Rapid Prototyping, Advantages and Limitations of Rapid Prototyping, Commonly used Terms, Classification of RP process, Rapid Prototyping Process Chain: Fundamental Automated Processes, Process Chain.

Liquid-based Rapid Prototyping Systems: Stereo lithography Apparatus (SLA): Models and specifications, Process, working principle, photopolymers, photo polymerization, Layering technology, laser and laser scanning, Applications, Advantages and Disadvantages, Case studies. Solid ground curing (SGC): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies Solid-based Rapid Prototyping Systems: Laminated Object Manufacturing (LOM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Fused Deposition Modeling (FDM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Laser engineered net shape and laser based additive processing

Powder Based Rapid Prototyping Systems: Selective laser sintering (SLS): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Three dimensional Printing (3DP): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Rapid Tooling: Introduction to Rapid Tooling (RT), Conventional Tooling Vs RT, Need for RT. Rapid Tooling , Classification: Indirect Rapid Tooling Methods: Spray Metal Deposition, RTV Epoxy Tools, Ceramic tools, Investment Casting, Spin Casting, Die casting, Sand Casting, 3D Keltool process. Direct Rapid Tooling: Direct AIM, LOM Tools, DTM Rapid Tool Process, EOS Direct Tool Process and Direct Metal Tooling using 3DP.

Rapid Prototyping Data Formats: STL Format, STL File Problems, Consequence of Building Valid and Invalid Tessellated Models, STL file Repairs: Generic Solution, Other Translators, Newly Proposed Formats. Rapid Prototyping Software’s: Features of various RP software’s like Magics, Mimics, Solid View, View Expert, 3 D View, Velocity 2, Rhino, STL View 3 Data Expert and 3 D doctor.

RP Applications: Application - Material Relationship, Application in Design, Application in Engineering, Analysis and Planning, Aerospace Industry, Automotive Industry, Jewelry Industry, Coin Industry, GIS application, Arts and Architecture. RP Medical and Bioengineering Applications: Planning and simulation of complex surgery, Customised Implants & Prosthesis, Design and Production of Medical Devices, Forensic Science and Anthropology, Visulization of Biomolecules.

REFERENCS

1. Rapid prototyping: Principles and Applications - Chua C.K., Leong K.F. and LIM C.S, World Scientific publications , Third Edition, 2010.


2. Rapid Manufacturing - D.T. Pham and S.S. Dimov, Springer , 2001 3. Wholers Report 2000 - Terry Wohlers, Wohlers Associates, 2000 4. Rapid Prototyping & Manufacturing - Paul F.Jacobs, ASME Press, 1996.

MEC5709 CONDITION MONITORING AND VIBRATION CONTROL

L T P C3 0 0 3

INTRODUCTION Review of fundamentals of single degree freedom systems – Two degree freedom systems, Multi Degree Freedomsystems, Continuous systems, Determination of Natural frequencies and mode shapes, Numerical methods in vibrationAnalysis.

VIBRATION CONTROLIntroduction – Reduction of vibration at the source – control of vibration – by structural design – Material selection –Localized additions – Artificial damping – Resilient isolation, Vibration isolation, Vibration absorbers.

ACTIVE VIBRATION CONTROLIntroductions – Concepts and applications, Review of smart materials – Types and characteristic review of smart structures– Characteristic Active vibration control in smart structures

CONDITION BASED MAINTENANCE PRINCIPLES AND APPLICTIONS Introduction – condition monitoring methods – The design of Information system, Selecting method of monitoring, Machine condition monitoring and diagnosis – Vibration severity criteria – Machine Maintenance Techniques – Machine condition monitoring techniques – Vibration monitoring techniques – Instrumentation systems – choice of monitoring parameter.

DYNAMIC BALANCING AND ALLIGNMENT OF MACHINERYIntroduction, Dynamic balancing of Rotors, Field Balancing in one plane, Two planes and in several planes, Machineryalignment, Rough alignment methods, The face peripheral dial indicator method, Reverse indicator method, shaft-to coupling spool method.

References :1. Timoshenko, S. “Vibration Problems in Engineering”, John Wiley & Sons, Inc., 1987.2. Meirovitch, L. “Elements of Vibration Analysis”, McGraw-Hill Inc., 1986.3. Thomson W.T, Marie Dillon Dahleh, “Theory of Vibrations with Applications”, Prentice Hall, 1997.4. F.S. Tse., I.F. Morse and R.T. Hinkle, “Mechanical Vibrations”, Prentice-Hall of India, 1985.5. Rao.J.S. and Gupta.K. “Theory and Practice of Mechanical Vibrations”, Wiley Eastern Ltd., New Delhi,1999.6. Fung, Y.C., “An Introduction to the Theory of Aeroelasticity”, John Wiley & Sons Inc., New York, 1985.

MEC5710 MECHANICS OF FRACTUREL T P C3 0 0 3

ELEMENTS OF SOLID MECHANICS The geometry of stress and strain, elastic deformation, plastic and elastic-plastic deformation – limit analysis.

STATIONARY CRACK UNDER STATIC LOADING Two dimensional elastic zone fields – Analytical solutions yielding near a crack front – Irwin’s approximation – Plasticzone size – Dugdaale model – J integral and its relation to crack opening development.

ENERGY BALANCE AND CRACK GROWTHGriffith analysis – Linear fracture mechanics – Crack opening displacement – Dynamic energy balance – Crack arrest.

FATIGUE CRACK GROWTH CURVE


Empirical Relation describing crack growth by fatigue – life calculations for a given load amplitude – effects of changingthe load spectrum – Effects of Environment.

ELEMENTS OF APPLIED FRACTURE MECHANICS Examples of crack- growth Analysis for cyclic loading – leak before break – crack Initiation under large scale yielding –Thickness as a Design parameter – crack instability in Thermal or Residual – Stress fields.

References :1. David Broek, “Elementary Engineering Fracture Mechanics”, Fifthoff and Noerdhoff International Publisher,1978.2. KAreHellan, “Introduction of Fracture Mechanics”, McGraw-Hill Book Company, 1985.3. Preshant Kumar, “Elements of Fracture Mechanics”, Wheeler Publishing, 1999.

MEC5711 WEAR ANALYSIS AND CONTROLL T P C3 0 0 3

INTRODUCTION TO WEAR Types of wear, Adhesive wear, two-body and three-body abrasive wear, erosive wear, cavitation wear, wear due to -surface fatigue – chemical reaction.

SURFACE ROUGHNESS AND WEAR MEASUREMENTSTribo systems and tribo-elements, Measurement of Surface roughness Ra, Rz, Experimental studies on friction on varioustribo systems using pin-on-ring (POR) and pin-on-disc (POD)machines. Sample preparation, wear measurement ofvarious tribo-elements, using POR and POD machines. Calculation of wear volume and wear coefficient, comparisonwith existing data.

WEAR IN LUBRICATED CONTACTSRheological lubrication regime, Functional lubrication regime, Fractional film defect, Load sharing in lubricated contacts, Adhesive wear equation, Fatigue wear equation, Numerical example.

DIAGNOSIS AND CONTROL OF WEARDiagnosis of wear mechanisms using optical microscopy and scanning electron microscopy,Wear resistant materials,wear resistant coatings, eco-friendly coatings designing for wear, systematic wear analysis, wear coefficients, filtrationfor wear control.

WEAR IN MECHANICAL COMPONENTSComponent wear, bushings, lubricated piston rings and cylinder bore wear, dry piston rings,rolling bearings, seal wear,gear wear, gear couplings, wear of brake materials, wear of cutting tools, chain wear.

References :1. Czichos, H., “Tribology:A system approach to the science & technology of friction,lubrication and wear”,Series 1, Elsevier Publications,1982.2. Glaeser,W. A., “Tribology series – Vol. 20,” Elsevier Publications,1992.3. Neale, M.J., “The Tribology Hand Book,” Butterworth Heinemann, London, 1995.4. Peterson, M. B., Winer, W.O., “Wear Control Handbook,” ASME, NY. 1980.5. Stolarski.T.A. “Tribology in Machine Design”Buttorworth Heinemann, Oxford, 2000.


MEC5712 VALUE AND RE-ENGINEERINGL T P C3 0 0 3

FUNDAMENTALS OF VALUE ENGINEERINGValue- Types – Organizing the value engineering study- Value Engineering concepts, Advantages, Applications, Problemrecognition, and role in productivity criteria for comparison, element of choice.

VALUE ENGINEERING TECHNIQUESSelecting products and operation for VE action, VE programmes, determining and evaluating functions assigning rupeeequivalents - developing alternate means to required functions - decision making for optimum alternative - Use of decision matrix - Queuing theory and Monte Carlo method, make or buy, Measuring profits - Reporting results - Follow up, Use of advanced technique like FAST (Function Analysis System) Tech.

ORGANISATION AND ANALYSIS OF FUNCTIONLevel of VE in the organization- Size and skill of VE staff-small plant VE activity - Unique and quantitative evaluation ofideas-Anatomy of the function, Use esteem and exchange values- Basic Vs secondary Vs. unnecessary functions.

REENGINEERING PRINCIPLES The 6 R’s of organizational transformation and reengineering – process reengineering - preparing the workforce –Methodology – PMI leadership expectation – Production and service improvement model – Process improvement.

IMPLEMENTATION OF REENGINEERINGProcess analysis techniques – Work flow analysis – Value analysis approach – Nominal group technique – Fish bonediagram – Pareto analysis – team building – Force fields analysis – Implementation.

References :1. S.S.Iyer, “Value Engineering”, New Age Information, 1996.2. Del L. Younker, “Value Engineering” Marcel Dekker, Inc. 20033. M.S.Jayaraman and Ganesh Natarajan, “Business Process Reengineering”, Tata McGraw Hill, 1994.4. Dr.Johnson, A.Edosomwan, “Organizational Transformation and Process reengineering”, British LibraryCataloguing in publication data, 19965. Miles, “Techniques of Value Analysis and Engineering”, Tata McGraw Hill Publications

MEC6701 COMPOSITE MATERIALS AND MECHANICSL T P C3 0 0 3

INTRODUCTIONDefinition – Need – General Characteristics, Applications. Fibers – Glass, Carbon, Ceramic and Aramid fibers.Matrices – Polymer, Graphite, Ceramic and Metal Matrices – Characteristics of fibers and matrices.Smart materials –Types and Characteristics.

MECHANICS AND PERFORMANCECharacteristics of fiber – reinforced lamina – Laminates – Interlaminar stresses – Static Mechanical Properties –Fatigue and Impact Properties – Environmental effects – Fracture Behavior and damage Tolerance.

MANUFACTURINGBag Moulding – Compression Moulding – Filament winding – Other Manufacturing Processes – Quality Inspectionmethods.

ANALYSIS Stress Analysis of Laminated composites Beams, Plates and Shells – Vibration and Stability Analysis – Reliability ofComposites – Finite Element Method of Analysis – Analysis of Sandwich Structures.

DESIGN


Failure Predictions – Laminate Design Consideration – Bolted and Bonded Joints design Examples.

References :1. Mallick, P.K., Fiber – “Reinforced Composites: Materials, Manufacturing and Design”, Maneel DekkerInc, 1993.2. Halpin, J.C., “Primer on Composite Materials, Analyis”, Techomic publishing Co., 1984.3. Agarwal, B.D., and Broutman L.J., “Analysis and Performance of Fiber Composites”, John Wiley andSons, New York, 1990.4. Mallick, P.K. and Newman, S., (edition), “Composite Materials Technology: Processes and Properties”,Hansen Publisher, Munish, 1990.

MEC6702 MANUFACTURING CONSIDERATIONS IN DESIGNL T P C3 0 0 3

INTRODUCTION General design principles for manufacturability –Factors influencing design-Types of problems to be solved-, evaluationof customer’s requirements-Systematic working plan for the designer-Types of problems to be solved-Possible solutions-Evaluation method- Process capability - Feature tolerances -Geometric tolerances - Assembly limits -Datum features -Tolerance stacks-Interchangeable part manufacture and selective assembly.

FACTORS INFLUENCING FORM DESIGNMaterials choice - Influence of basic design, mechanical loading, material, production method, size and weight on formdesign- form design of welded members and forgings

COMPONENT DESIGN – CASTING CONSIDERATIONForm design of grey iron, steel, malleable iron and aluminium castings. Redesign of castings based on parting line considerations - Minimizing core requirements, machined holes, redesign of cast members to obviate cores.

COMPONENT DESIGN - MACHINING CONSIDERATIONDesign features to facilitate machining - drills - milling cutters - keyways - Doweling procedures, counter sunk screws -Reduction of machined area- simplification by separation - simplification by amalgamation - Design for machinability -Design for economy - Design for clampability - Design for accessibility - Design for assembly. Identification of uneconomical design - Modifying the design - group technology -Computer Applications for DFMA.

DESIGN FOR ENVIRONMENTIntroduction – Importance of DFE -Environmental objectives – Global issues – Regional and local issues– Design guidelines for DFE –Lifecycle assessment – EPS system - AT&T’s environmentally responsible product assessment – Weighted sum assessment method –Techniques to reduce environmental impact – Design to minimize material usage –Design for disassembly – Design for recyclability – Design for remanufacture –Design for energy efficiency – Design to regulations and standards.

References :1. Boothroyd, G, “ Design for Assembly Automation and Product Design”, New York, Marcel Dekker.19802. Bralla, “Design for Manufacture handbook”, McGraw hill, 1999.3. Boothroyd, G, Heartz and Nike, “Product Design for Manufacture”, Marcel Dekker, 1994.4. Dickson, John. R, and Corroda Poly, “Engineering Design and Design for Manufacture and Structural Approach”, Field Stone Publisher, USA, 1995.5. Fixel, J. “Design for the Environment”, McGraw hill. 1996.7. Kevien Otto and Kristin Wood, “Product Design”, Pearson Publication, 2004.8. Dr.ING.RobertMatouslk,”Engineering Design”.Blackie& son limited,1962.9. Harry peck, “Designing for manufacture”, Pitman publishing.


MEC6001 DESIGN OF MATERIAL HANDLING EQUIPMENTS L T P C3 0 0 3

(Use of Approved Data Book is permitted)

MATERIAL HANDLING EQUIPMENTSIntroduction – Material Handling - Types, selection and applications

DESIGN OF HOISTDesign of hoisting elements- welded and roller chains, hemp and wire ropes, design of ropes, pulleys, pulley systems, sprockets and drums, load handling attachments - design of forged hooks and eye hooks, crane crabs lifting magnets, grabbing attachments, design of arresting gear, brakes - shoe, band and cone types.

DRIVES OF HOISTING GEARHand and power drives - travelling gear, rail traveling mechanism , cantilever and monorail cranes, slewing, jib and luffing gear, cogwheel drive, selecting the motor ratings.

CONVEYORSTypes - description - design and applications of belt conveyors, apron conveyors and escalators pneumatic conveyors, screw conveyors and vibratory conveyors.

ELEVATORSBucket elevator design - loading and bucket arrangements - cage elevators - shaft way, guides, counter weights, hoisting machine, safety devices - design of form lift trucks.

Text Book

1. Spivakovsy, A.O. and Dyachkov, V.K., L Conveying Machines, Volumes I and II, MIR Publishers, 1985.

References

1. Alexandrov, M., Materials Handling Equipments, MIR Publishers, 1981.2. Boltzharol, A., Materials Handling Handbook, The Ronald Press Company, 1958.

MEC6703 EXPERIMENTAL STRESS ANALYSISL T P C3 0 0 3

FORCES AND STRAIN MEASUREMENTStrain gauge, principle, types, performance and uses. Photo elasticity – principleand applications - Moire Fringe – Hydraulic jacks and pressure gauges –Electronic load cells – Proving Rings – Calibration of Testing Machines.

VIBRATION MEASUREMENTSCharacteristics of Structural Vibrations – Linear Variable Differential Transformer (LVDT) – Transducers for velocityand acceleration measurements. Vibration meter – Seismographs – Vibration Analyzer – Display and recording of signals– Cathode Ray Oscilloscope – XY Plotter – Chart Plotters – Digital data Acquisition systems.

ACOUSTICS AND WIND FLOW MEASURESPrinciples of Pressure and flow measurements – pressure transducers – sound level meter – venturimeter and flowmeters – wind tunnel and its use in structural analysis – structural modeling – direct and indirect model analysis

DISTRESS MEASUREMENTSDiagnosis of distress in structures – crack observation and measurements – corrosion of reinforcement in concrete –Half-cell, construction and use – damage assessment – controlled blasting for demolition.


NON DESTRUCTIVE TESTING METHODSResidual stress analysis – Mechanisms, methods of measuring, effect of RS on components, residual stress reliabiligy methods– acoustic emission – ultrasonic testing principles and application – Holography – use of laser for structural testing – Brittle coating

REFERENCES:1. Sadhu Singh – “Experimental Stress Analysis”, Khanna Publishers, New Delhi, 1996.2. JW Dalley and WF Riley, “Experimental Stress Analysis”, McGraw Hill Book Company, N.Y. 19913. L.S.Srinath et al, “Experimental Stress Analysis”, Tata McGraw Hill Company, New Delhi, 19844. R.S.Sirohi, HC Radhakrishna, “Mechanical Measurements”, New Age International (P) Ltd. 19975. F.K Garas, J.L. Clarke and GST Armer, “Structural assessment”, Butterworths, London, 1987

MEC5417 RELIABILITY ENGINEERING L T P C3 0 0 3

RELIABILITY CONCEPT Reliability function – failure rate – mean time between failures (MTBF) – mean time to failure (MTTF) – A priori and a posteriori concept - mortality curve – useful life – availability – maintainability – system effectiveness. FAILURE DATA ANALYSIS Time to failure distributions – Exponential, normal, Gamma, Weibull, ranking of data – probability plotting techniques – Hazard plotting. RELIABILITY PREDICTION MODELS Series and parallel systems – RBD approach – Standby systems – m/n configuration – Application of Bayes’ theorem – cut and tie set method – Markov analysis – Fault Tree Analysis – limitations. RELIABILITY MANAGEMENT AND RISK ASSESSMENT Reliability testing – Reliability growth monitoring – Non-parametric methods – Reliability and life cycle costs – Reliability allocation – Replacement model. Definition and measurement of risk – risk analysis techniques – risk reduction resources – industrial safety and risk assessment.

HUMAN RELIABILITY ANALYSISDevelopment of HRA – Approaches and trends in HRA – Human reliability methods – Human reliability data – Human actions – Interdisciplinary analysis of human reliability – Probabilistic Safety Analysis

References 1. Srinath L.S, Reliability Engineering, Affiliated East-West Press Pvt Ltd, New Delhi, 1998. 2. Modarres, Reliability and Risk analysis, Maral Dekker Inc.1993. 3. John Davidson, The Reliability of Mechanical system, Institution of Mechanical Engineers, London,

1988. 4. Smith C.O., Introduction to Reliability in Design, McGraw Hill, London, 1976.

MEC5019 COMPUTATIONAL FLUID DYNAMICS L T P C3 0 0 3

GOVERNING DIFFERENTIAL EQUATION AND FINITE DIFFERENCE METHOD


Classification, initial and boundary conditions, initial and boundary value problems - finite difference method, central, forward, backward difference, uniform and non-uniform grids, numerical errors, grid independence test.

CONDUCTION HEAT TRANSFERSteady one-dimensional conduction, two and three dimensional steady state problems, transient one-dimensional problem, two-dimensional transient problems

INCOMPRESSIBLE FLUID FLOWGoverning equations, stream function – verticity method, determination of pressure for viscous flow, simple procedure of Patankar and spalding, computation of boundary layer flow, finite difference approach.

CONVECTION HEAT TRANSFER AND FEMSteady one-dimensional and two-dimensional convection – diffusion, unsteady one-dimensional convection – diffusion, unsteady two - dimensional convection – diffusion – introduction to finite element method – solution of steady heat conduction by fem – incompressible flow – simulation by FEM. TURBULENCE MODELSAlgebraic models – one equation model, K - models, standard and high and low Reynolds number models, prediction of fluid flow and heat transfer using standard codes.

Text Book

1. Muralidhar, K., and Sundararajan, T., Computational Fluid Flow and Heat Transfer, Narosa Publishing House, New Delhi, 1995.

References

1. Ghoshdasdidar, P.S., Computer Simulation of flow and heat transfer, Tata McGraw-Hill Publishing Company Ltd., 1998.

2. Subas, V.Patankar Numerical heat transfer fluid flow, Hemisphere Publishing 3. Corporation, 1980.4. Taylor, C and Hughes, J.B. Finite Element Programming of the Navier Stock 5. Equation, Pineridge Press Limited, U.K., 1981.6. Anderson, D.A., Tannehill, J.I., and Pletcher, R.H., Computational fluid Mechanics and Heat

Transfer “ Hemisphere Publishing Corporation, Newyork, USA, 1984.7. Fletcher, C.A.J. Computational Techniques for Fluid Dynamics 1” Fundamental and General

Techniques, Springer – Verlag, 1987.8. Fletcher, C.A.J. Computational Techniques for Fluid Dynamics 2, Specific Techniques for

Different Flow Categories, Springer – Verlag, 1987.9. Bose, T.X., Numerical Fluid Dynamics Narosa Publishing House, 1997.

MEC6704 PLATES AND SHELLS L T P C3 0 0 3

INTRODUCTION Review of equations of elasticity- kinematics, compatibility equations, stress measures- equations of motions- constitutive relations- transformation of stresses, strains and stiffness-energy principles and variational methods in elasticity- virtual work-external and internal virtual work- variational operator- functionals- Euler Lagrange equations- energy principles- Hamilton‟s principle- principle of minimum total potential- applications

CLASSICAL THEORY OF PLATES Plates as structural elements- stress and moment resultants- assumptions made in the classical theory- displacement fields and strains- equations of equilibrium in Cartesian coordinates and in polar coordinates-


boundary conditions – bending of rectangular plates with various boundary conditions and loading- symmetrical and asymmetrical bending of circular plates-limitations of classical theory- finite element analysis(elementary treatment only; discussion of various elements used and their capabilities- not for examination)

BUCKLING ANALYSIS OF RECTANGULAR PLATES Buckling of simply supported plates under compressive forces- governing equations- the Navier solution- biaxial compression of a plate- uniaxial compression of a plate- buckling of plates simply supported on two opposite edges- Levy‟s solution- buckling of plates with various boundary conditions- general formulation- finite element analysis(elementary treatment only; discussion of various elements used and their capabilities- not for examination)

VIBRATION OF PLATES Governing equations for natural flexural vibrations of rectangular plates- natural vibrations of plates simply supported on all edges- vibration of plates with two parallel sides simply supported- Levy‟s solution- vibration of plates with different boundary conditions- Rayleigh-Ritz method- Natural vibration of plates with general boundary conditions- transient analysis of rectangular plates- finite element analysis(elementary treatment only; discussion of various elements used and their capabilities- not for examination)

ANALYSIS OF THIN ELASTIC SHELLS OF REVOLUTION Classification of shell surfaces- geometric properties of shells of revolution- general strain displacement relations for shells of revolution- stress resultants- equations of motion of thin shells- analytical solution for thin cylindrical shells- membrane theory- flexure under axisymmetric loads- shells with double curvature- geometric considerations- equations of equilibrium- bending of spherical shells- vibration of cylindrical shells- finite element analysis(elementary treatment only; discussion of various elements used and their capabilities- not for examination)

REFERENCES 1. Reddy,J.N., “Theory and Analysis of Elastic Plates & Shells”, C.R.C.Press,NY,USA, 2nd Edition 2. Szilard, R., Theory and Analysis of Plates, Prentice Hall Inc., 1995 3. Timoshenko, S. and Krieger S.W. Theory of Plates and Shells, McGraw Hill Book Company, New York 1990. 4. Wilhelm Flügge, stresses in shells, Springer - Verlag 5. Timoshenko, S. Theory of Plates and Shells, McGraw Hill, 1990 6. Ramasamy, G.S., Design and Construction of Concrete Shells Roofs, CBS Publishers, 1986 7. Dr.N.Subramanian, Principles of Space Structures , Wheeler Publishing Co. 1999 8. K. Baskar and T.K. Varadan, “Plates- Theories and Applications”, Ane Books Pvt. Ltd., New Delhi, 2013

MEC6705 SURFACE ENGINEERING L T P C3 0 0 3

FRICTIONTopography of Surfaces – Surface features – Properties and measurement – Surface interaction – Adhesive Theory of Sliding Friction – Rolling Friction – Friction properties of metallic and non metallic materials – Friction in extreme conditions – Thermal considerations in sliding contact

WEAR Introduction – Abrasive wear, Erosive, Cavitation, Adhesion, Fatigue wear and Fretting Wear- Laws of wear – Theoretical wear models – Wear of metals and non metals - International standards in friction and wear measurements


CORROSION Introduction – Principle of corrosion – Classification of corrosion – Types of corrosion – Factors influencing corrosion – Testing of corrosion – In-service monitoring, Simulated service, Laboratory testing – Evaluation of corrosion – Prevention of Corrosion – Material selection, Alteration of environment, Design, Cathodic and Anodic Protection, Corrosion inhibitors

SURFACE TREATMENTS Introduction – Surface properties, Superficial layer – surface modification – Wear resistant coatings and Surface treatments – Techniques – PVD – CVD – Physical CVD – Ion implantation – Surface welding – Thermal spraying – Laser surface hardening and alloying,– Characteristics of Wear resistant coatings – New trends in coating technology – DLC –Thick coatings – Nano-engineered coatings – Other coatings, Corrosion resistant coatings

ADVANCED CHARACTERIZATION TECHNIQUESSurface characterization: SEM, TEM, EDAX, AFM, XRD, Quantitative Phase Analysis, small angle scattering, grazing incidence.Thermal Charaterization: DTA, TGA, DSC, Dilometry, Spectroscopy: AAS, UV-VIS, FTIR, Electrical and Dielectric Characterization, Electrical Conductivity and Dielectric permittivitySample preparation for characterization: Optical, SEM, TEM, XRD

REFERENCES 1. G.W.Stachowiak & A.W .Batchelor , “Engineering Tribology”, Butterworth-Heinemann, UK, 2005 2. Rabinowicz.E, “Friction and Wear of materials”, John Willey &Sons ,UK,1995 3. Halling, J. (Editor) – “Principles of Tribology “, Macmillian – 1984. 4. Williams J.A. “Engineering Tribology”, Oxford Univ. Press, 1994. 5. S.K.Basu, S.N.Sengupta & B.B.Ahuja ,”Fundamentals of Tribology”, Prentice –Hall of India Pvt Ltd , New Delhi, 2005 6. Fontana G., “Corrosion Engineering”, McGraw Hill, 1985

MEC6706 ADVANCED METAL FORMING TECHNIQUES L T P C3 0 0 3

INTRODUCTION TO THEORY OF PLASTICITY AND FORMING Theory of plastic deformation – Yield criteria – Tresca and Von-mises – Distortion energy – Stress-strain relation – Mohr‟s circle representation of a state of stress – cylindrical and spherical co-ordinate system – upper and lower bound solution methods – thermo elastic Elasto plasticity – elasto visco plasticity

THEORY AND PRACTICE OF BULK FORMING PROCESSES Analysis of plastic deformation in Forging, Rolling, Extrusion, rod/wire drawing and tube drawing – Effect of friction – calculation of forces, work done – Process parameters, equipment used – Defects – applications – Recent advances in Forging, Rolling, Extrusion and Drawing processes – Design consideration in forming - Formability of laminated sheet - Overview of FEM applications in Metal Forming analysis.

SHEET METAL FORMING Formability studies – Conventional processes – H E R F techniques – Superplastic forming techniques – Hydro forming – Stretch forming – Water hammer forming – Principles and process parameters – Advantage, Limitations and application

POWDER METALLURGY AND SPECIAL FORMING PROCESSES Overview of P/M technique – Advantages – applications – Powder preform forging – powder rolling – Tooling, process parameters and applications. - Orbital forging – Isothermal forging – Hot and cold isostatic pressing – High speed extrusion – Rubber pad forming – Fine blanking – LASER beam forming


ELECTROMAGNETIC FORMING AND ITS APPLICATIONSElectromagnetic Forming Process – Electro – Magnetic Forming Machines – Process Variables – Coils and Dies – Effect of Resistivity and Geometry – EM tube and sheet forming, stamping, shearing and welding – Applications – Finite Element Analysis of EM forming.

REFERENCES 1. 1. Dieter G.E., Mechanical Metallurgy (Revised Edition II) McGraw Hill Co., 2004 2. P. M. Dixit & U. S. Dixit, Plasticity: Fundamentals and application, CRC press, 2014 3. Rahulkumar Shivajirao Hingole, Advances in Metal Forming, Springer, 20144. G. K. Lal, P. M. Dixit and N. V. Reddy, Modelling Tecniniques for Metal forming, Narosa

Publications, 20115. Proceedings of International Workshop on EMFT 2010, Anna University 6. Altan T., Metal forming – Fundamentals and applications – American Society of Metals, Metals park,

2003. 7. ASM Hand book, Forming and Forging, Ninth edition, Vol – 14, 2003 SHIRO KOBAYASHI, SOO-

IK-oh-ALTAN, T,Metal forming and Finite Element Method, Oxford University Press, 2001. 8. ALTAN.T, SOO-IK-oh, GEGEL, HL – Metal forming, fundamentals and Applications, American

Society of Metals, Metals Park, Ohio, 1983. 9. Marciniak,Z., Duncan J.L., Hu S.J., „Mechanics of Sheet Metal Forming‟, Butterworth-Heinemann

An Imprint of Elesevier, 2006 10. Proc. Of National Seminar on “Advances in Metal Forming” MIT, March 2000 11. SAE Transactions, Journal of Materials and Manufacturing Section 5, 1993-2007

MEC6707 DESIGN OF PRESSURE VESSEL AND PIPING L T P C3 0 0 3

INTRODUCTION Methods for determining stresses – Terminology and Ligament Efficiency – Applications.

STRESSES IN PRESSURE VESSELS Introduction – Stresses in a circular ring, cylinder – Membrane stress Analysis of Vessel Shell components – Cylindrical shells, spherical Heads, conical heads – Thermal Stresses – Discontinuity stresses in pressure vessels.

DESIGN OF VESSELS Design of Tall cylindrical self supporting process columns –Supports for short, vertical and horizontal vessels – stress concentration – at a variable Thickness transition section in a cylindrical vessel, about a circular hole, elliptical openings. Theory of Reinforcement – pressure vessel Design. Introduction to ASME pressure vessel codes

BUCKLING OF VESSELS Buckling phenomenon – Elastic Buckling of circular ring and cylinders under external pressure – collapse of thick walled cylinders or tubes under external pressure – Effect of supports on Elastic Buckling of Cylinders – Buckling under combined External pressure and axial loading.

PIPING Introduction – Flow diagram – piping layout and piping stress Analysis.

REFERENCES 1. John F. Harvey, Theory and Design of Pressure Vessels, CBS Publishers and Distributors, 1987. 2. Henry H. Bedner, “Pressure Vessels, Design Hand Book, CBS publishers and Distributors, 1987.


3. Stanley, M. Wales, “Chemical process equipment, selection and Design. Buterworths series in Chemical Engineering, 1988. 4. William. J., Bees, “Approximate Methods in the Design and Analysis of Pressure Vessels and Piping”, Pre ASME Pressure Vessels and Piping Conference, 1997.

IDENTIFICATION AND ANALYSISIdentification of rubbers and plastics by simple physical methods & by chemical analysis.

Introduction to application of instrumental techniques for identification of polymers and additives. Raw materials characterization, Thermoplastics – melting point, density, viscosity, melt flow index, K-value. Thermosets – moisture analysis, particle size, apparent density, spiral flow test, cup flow test, gel time and peak exothermic temperature. Resins – acid value, hydroxyl value, isocyanate index, epoxy equivalent

SPECIFICATIONS, QUALITY CONTROL AND PROCESSABILITY TESTS Rubber latex and dry rubber – cup viscosity, TOTAL alkalinity, TOTAL solids, dry rubber content, volatile matter, KOH number & mechanical stability, Plasticity, plasticity retention index (PRI), scorch time and cure characteristics (plastimeter, Mooney viscometer, oscillating disc rheometer)

MOLECULAR CHARACTERIZATION OF POLYMERS Determination of molecular weight, viscometry, end group analysis, colligative property,

osmometry, light scattering technique. Determination of molecular weight and molecular weight distribution using gel permeation chromatography.

THERMAL ANALYSIS OF POLYMERSDifferential thermal analysis (DTA), differential scanning calorimetry (DSC), thermogravimetric

analysis (TGA), thermomechanical analysis (TMA), dynamic mechanical analysis (DMA).

PHYSICAL METHODS OF ANALYSISX-ray diffraction (Wide angle and small angle), Infrared spectroscopy (IR & FTIR), Nuclear

magnetic resonance spectrometer (NMR), GC – Mass spectrometer, optical microscopy, scanning electron microscopy, transmission electron microscopy.TEXT BOOKS :

1. Chermisinoff, Polymer Characterization – Laboratory Techniques and Analysis, Chapman and Hall, London, 1993.

2. Hunt & James, Polymer Characterization, Chapman & Hall, London, 19933. Kampf, Characterization of Plastics using physical methods, Experimental techniques and practical

applications, Hanser Gardner Publications, 1987.

REFERENCES :

1. Hoffman, Rubber technology Handbook, Hanser Publishers, Munich 19962. ASTM - 9.01 & 9.02; 8.01 & 8.04, 20003. D. Campbell & J.R. White, Polymer Characterization, Chapman & Hall, London 1989

MEC6031 ANALYSIS AND CHARACTERIZATION OF POLYMERS L T P C3 0 0 3

semester – iii - kalasalingam...

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