2nd year - Dayananda Sagar Institutions

DepartmentofCollegiateandTechnicalEducation,GovernmentofKarnataka 1

GovernmentofKarnatakaDEPARTMENTOFCOLLEGIATEANDTECHNICALEDUCATION

CurriculumStructureIIISemesterSchemeofStudies-DiplomainMechanicalEngineering

Sl.No.

CourseCategory/

Teaching

Department

CourseCode CourseName

Hoursperweek

Totalcontacthrs

/week

Credits

CIEMarks

SEEMarks

TotalM

arks

MinMarksfor

Passing(including

CIEmarks)

AssignedGrade

GradePoint

SGPAandCGPA

L T P Max Min Max Min

IntegratedCourses

BothSGPA&CGPA

1 PC/ME 20ME31P MechanicsofMaterials 3 1 4 8 6 60 24 40 16 100 40

2 PC/ME 20ME32P MachineToolTechnology 3 1 4 8 6 60 24 40 16 100 40

3 PC/ME 20ME33P ManufacturingProcesses 3 1 4 8 6 60 24 40 16 100 40

4 PC/ME 20ME34P FluidPowerEngineering 3 1 4 8 6 60 24 40 16 100 40

AuditCourse5 AU/KA 20KA31T !ಾ#ತ%&ಂಚನ-II/ಬಳ/ೆಕನ2ಡ-II 2 0 0 2 2 50 20 - - 50 20

Total 14 4 16 34 26 290 116 160 64 450 180

*PC:ProgrammeCore::AU-AuditCourse::KA:Kannada::L:Lecture::T:Tutorial::P:Practice


GovernmentofKarnataka

DEPARTMENTOFCOLLEGIATEANDTECHNICALEDUCATIONCurriculumStructure

IVSemesterSchemeofStudies-DiplomainMechanicalEngineering

Sl.No.

CourseCategory/

Teaching

Department

CourseCode CourseName

Hoursperweek

Totalcontacthrs

/week

Credits

CIEMarks

SEEMarks

TotalM

arks

MinMarksfor

Passing(including

CIEmarks)

AssignedGrade

GradePoint

SGPAand CGPA

L T P Max Min Max Min

IntegratedCourses

BothSGPA&CGPA

1 PC/ME 20ME41P OperationsManagement 3 1 4 8 6 60 24 40 16 100 40

2 PC/ME 20ME42P CNCProgrammingandMachining

3 1 4 8 6 60 24 40 16 100 40

3PC/ME

20ME43P ProductDesignandDevelopment

3 1 4 8 6 60 24 40 16 100 40

4PC/ME 20ME44P ElementsofIndustrial

Automation3 1 4 8 6 60 24 40 16 100 40

AuditCourse5 AU/ME 20ME45T IndianConstitution 2 0 0 2 2 50 20 - - 50 20

Total 14 4 16 34 26 290 116 160 64 450 180

*PC:ProgrammeCore::AU-AuditCourse::L:Lecture::T:Tutorial::P:Practice


3rdSEMESTER



DEPARTMENTOFTECHNICALEDUCATION

Programme MechanicalEngineering Semester III

CourseCode 20ME31P TypeofCourse ProgrammeCore

CourseName MechanicsofMaterials ContactHours8hours/week104hours/semester

TeachingScheme L:T:P::3:1:4 Credits 6

CIEMarks 60 SEEMarks 401.RationaleInthiscourse,Diplomaengineersarerequiredtoanalysethereasonsforfailureofcomponentsandselectthesuitablematerialsforagivenapplications.Forthispurpose,itisessentialtostudytheconcepts,principles,applicationsandpracticescoveringstress,strain,stressconcentration,weakpoints,deformations,bendingmomentandshearingforce.ThestudentswillalsostudythebasicprinciplesofFiniteElementsAnalysisandperform stress strain analysis usingAnsys software to understand and quantify the effects of real-worldconditionsonapart.Thesesimulations,willallowDiplomaengineerstolocatepotentialproblemsinadesign,includingareasoftensionandweakspots.FEAbecomesatremendousproductivitytool,helpingengineersinreducingproductdevelopment timeand cost.Hence, FEA is introduced in this course. It is expected thateffortswillbemadetoprovideappropriatelearningexperiencesintheuseofbasicprinciplestothesolutionofappliedproblemsandtodeveloptherequiredskillandcompetencies

2.CourseOutcomes:AttheendoftheCourse,thestudentwillbeableto:

CO-01 Analyse Simple Stresses and Strains on given Structuralmember that is subjected to Tensile,CompressiveandShearloadsbyusingDestructiveTest.

CO-02 Draw Shear force Diagram (SFD) and Bending moment Diagram (BMD) and Also, AnalyseBendingStressesinaBeamusingFiniteelementmethods(FEM)software

CO-03 Demonstratetheapplicationof finiteelementformulationstosolvebothOnedimensionalandTwodimensionalProblems.

CO-04 DemonstratetheapplicationofFEMsoftwareforValidationofbothOnedimensionalandTwodimensionalProblems

3.CourseContent

Week CO PO*

Lecture(Knowledge)

Tutorial(Activity)

Practice(Skill)

3hours/week 1hour/week4hours/week(2

hours/batchtwiceinaweek)

1 01 01

1. Introduction to Force-Types of Forces-Resolutionofforces

ReferTable1

Resolution of forces byGraphicalMethod

2.ProblemsonResolutionofforces-AnalyticalMethod Verification of Forces by

Lami’sTheorem3.ProblemsonResolutionofforces-AnalyticalMethod

2 01 01

1. Types of Loads-Tensile,Compression,Shear, Impact,Stress-Types-Strain-Types-- Hooks Law- Young'sModulus

ConductTensile test for thegiven Specimen andDetermine Stress- Strain-Young’s Modulus, YieldStress- Maximum Stress-


2. Stress - Strain Diagram -Elastic constants- Linearstrain, Lateral Strain,Poison’s Ratio, VolumetricStrain, Bulk Modulus,RigidityModulus ,Fatigue-EnduranceLimit

ReferTable1

Breaking Stress- %Elongation inLengthand%ReductioninAreaAlso,DrawStress-StrainDiagramfortheaboveParameters3. Stress concentration,

Factor of Safety(FOS),Concept of Temperaturestresses

3 01 01

1. Simple Problems onStress, Strain and Elasticconstants

ReferTable1

Conduct Compression testfor the given Specimen andDetermine Stress- Strain-Young’s Modulus, YieldStress- Maximum Stress- %Reduction in Length and%IncreaseinAreaAlso,DrawStress-StrainDiagramfortheaboveParameters

2.. Simple Problems onStress, Strain and Elasticconstants

3. Simple Problems onStress, Strain and Elasticconstants

4 01 01

1. Problems on Memberssubjected to combinedStresses

ReferTable1Conduct Shear test for thegivenspecimen

2. Problems on Memberssubjected to combinedStresses3. Problems on Memberssubjected to combinedStresses

5 02 02

1. Types of Beams-Types ofLoads acting on Beams-Concept of Shear force -Bendingmoment2DrawShearforceDiagram(SFD) and BendingMomentDiagram (BMD) forCantileversubjectedtoPointLoad and UniformlyDistributedloads(UDL)3.DrawShearforceDiagram(SFD) and BendingMomentDiagram (BMD) forCantileversubjectedtoPointLoad and UniformlyDistributedloads(UDL)

ReferTable1

ConductBendingtestforthegivenspecimen


6 02 02

1.DrawShearforceDiagram(SFD) and BendingMomentDiagram(BMD)foraSimplysupported beam subjectedtoPointLoadandUniformlyDistributedloads(UDL)

2.Draw SFD and BMD forSimply supported andCantileverbeamsubjectedtoPoint Load and UDL DrawShear force Diagram (SFD)and Bending MomentDiagram(BMD)foraSimplysupported beam subjectedtoPointLoadandUniformlyDistributedloads(UDL)3 Draw SFD and BMD forSimply supported andCantileverbeamsubjectedtoPoint Load and UDL DrawShear force Diagram (SFD)and Bending MomentDiagram(BMD)foraSimplysupported beam subjectedtoPointLoadandUniformlyDistributedloads(UDL)

ReferTable1

Present You tube videos inStress, Strain and BendingStresses on DifferentmechanicalmembersPrepare a report on theobservationsmadeEg:https://www.youtube.com/watch?v=C-FEVzI8oe8

7 02 02

1. Pure Bending-Assumptions- Neutral Axis-BendingEquation2. Problems on BendingEquation3. Problems on BendingEquation

ReferTable1

Present You tube videos inStress, Strain and BendingStresses on DifferentmechanicalmembersPrepare a report on theobservationsmade

8 03,04 01

1.Introduction to FiniteElement Methods (FEM),Need-BackGround2. Methods employed inFEM-StepsinFEM3. Advantages andDisadvantages, Limitations,ApplicationsofFEM-ConceptofDiscontinuity

ReferTable1 Practice on FEM software(Eg:Ansys)

9 02,03,04 01,02,04

1. Phases of FEA(FiniteElementAnalysis)2.DiscretizationProcess3.Meshing–Elementtype

ReferTable1

Validate Bending EquationProblems solved inWeek 7using FEM software (Eg:Ansys)

10 02,03,04 01,02,04

1.Stiffness Matrix of a BarElement2.Global Stiffness Matrix-Propertiesofstiffnessmatrix

ReferTable1

Validate Bending EquationProblems solved inWeek 7using FEM software (Eg:Ansys)


3. Boundary Conditions-Methods–Types

11 03,04 02,04,07 Problemson1-Delements Studythelatesttechnologicalchangesinthiscourseandpresenttheimpactofthesechangesonindustry

ValidateusingFEMsoftware(Eg:Ansys)

12 03,04 02,04,07 Problemson1-Delements ValidateusingFEMsoftware(Eg:Ansys)

13

03,04

02,04,07 Problemson2-Delements ValidateusingFEMsoftware(Eg:Ansys)

Totalinhours 39 13 52• *PO=ProgramOutcomeaslistedanddefinedinyear1curriculum

• CourseCoordinatormustpreparePO–COmappingwithstrength(Low/Medium/High)beforecourseplanning

TABLE1:SuggestiveActivitiesforTutorials:(TheListisonlysharedasanExampleandnotinclusiveofallpossibleactivitiesofthecourse.StudentandFacultyareencouragedtochooseactivitiesthatarerelevanttothetopicandontheavailabilityofsuchresourcesattheirinstitution).

Sl.No. SuggestiveActivitiesforTutorials

01 UnderstandStaticEquilibriumusingcommonexamples,trytoapplytheprinciplesanddemonstrateinclasstheimportanceofstaticequilibriumindailylife,athomeoratwork.

02StudythebehaviorofAluminumundertheactionofTensile/CompressionLoad.PlotStressStrainDiagramandDemonstrateintheclassthebehaviorofAluminumdifferentfromthatofaCastIron.

03Aseesawisoccupiedbytwochildrenofequalweight“W”N.Thecenterofgravityofeachchildisxmetersfromthefulcrum.Thelengthoftheboardis3xmeters,ymmwideandzmmthick.Determinethemaximumbendingstressandshearstressintheboard.

04

TaperedelasticbarsubjectedtoanappliedtensileloadPatoneendandattachedtoafixedsupportattheotherend.Thecross-sectionalareavarieslinearlyfromA0atthefixedsupportatx=0toA0/2atx=L.Calculatethedisplacementoftheendofthebar(a)bymodellingthebarasasingleelementhavingcross-sectionalareaequaltotheareaoftheactualbaratitsmidpointalongthelength,(b)usingtwobarelementsofequallengthandsimilarlyevaluatingtheareaatthemidpointofeach,andcomparetotheexactsolutionByFEM.

05 IdentifythetypeBeaminTrafficLightPost.DeterminethedisplacementfieldforthisbeamsubjectedtoUDLthroughoutitslength.

06 DiscussprocedureusingthecommercialpackageavailabletodayforsolvingproblemsofFEM.TakeaStructuralProblemtoDemonstratethesame.

07

In1989,Jason,aresearch-typesubmersiblewithremoteTVmonitoringcapabilitiesandweighing35200N,wasloweredtoadepthof646minanefforttosendbacktotheattendingsurfacevesselphotographsofasunkenRomanshipoffshorefromItaly.Thesubmersiblewasloweredattheendofahollowsteelcablehavinganareaof452×10–6m2andE=200GPa.Determinetheextensionofthesteelcable.Duetothesmallvolumeoftheentiresystem,buoyancymaybeneglected.

08Laboratorytestsonhumanteethindicatethattheareaeffectiveduringchewingisapproximately0.25cm2andthatthetoothlengthisabout1.1cm.Iftheappliedloadintheverticaldirectionis880Nandthemeasuredshorteningis0.004cm,determineYoung’smodulus.


4.CIEandSEEAssessmentMethodologiesSl.No

AssessmentTestWeek

Duration

InminutesMaxmarks

Conversion

1. CIE-1WrittenTest 5 80 30 Averageofthreetests

302. CIE-2WrittenTest 9 80 30

3 CIE-3WrittenTest 13 80 30

4. CIE-4SkillTest-Practice 6 180 100 Averageoftwoskilltestreducedto205 CIE-5SkillTest-Practice 12 180 100

6CIE-6PortfoliocontinuousevaluationofTutorialsessionsthroughRubrics

1-13 10 10

TotalCIEMarks 60

SemesterEndExamination(Practice) 180 100 40

TotalMarks 100

5.FormatforCIEwrittenTest

CourseName

MechanicsofMaterials Test I/II/III Sem III

CourseCode 20ME31P Duration 80Min Marks 30

Note:Answeranyonefullquestionfromeachsection.Eachfullquestioncarries10marks.

Section AssessmentQuestions CognitiveLevels(R/U/A)

CourseOutcome Marks

I1

2

II3

4

III5

6

NotefortheCoursecoordinator:Eachquestionmayhaveone,twoorthreesubdivisions.Optionalquestionsineachsectioncarrythesameweightageofmarks,cognitivelevelandcourseoutcomes.


5.(a)ForCIESkillTest-4Duration:240MinSL.No.

CO Particulars/Dimension Marks

1 01 VerificationofForcesbyLami’sTheorem• Findingtheresultantofforces-AnalyticalMethod–15Marks• VerificationofForcesbyLami’sTheorem–Practically-15Marks

30

2 02 DeterminethedeformationofagivenspecimensubjectedtoTensile/Compressive/Shearloads/BendingusingUTM• WritingobservationsandTabularcolumn--10Marks• WritingEquationsrequiredWithallnotations–-10Marks• ConductionofExperiment---20Marks• CalculationandResultwithGraphifany---20Marks

60

3 01,02 PortfolioevaluationbasedontheaverageofallPracticeSessions(1-6weeks)

10

TotalMarks 100

5.(b)ForCIESkillTest-5Duration:240MinSL.No.


1 02 CalculateandPlotSFDandBMDfortheGivenData• FindingShearforceandBendingMoment–(10+15)=25Marks• PlotSFDandBMD–15Marks

40

2 03,04

ApplyfiniteelementformulationstosolvethegivenOnedimensionalcasesandValidateusingAnsys

• SolvebyFEMMethod—25Marks• ValidateUsingFEMsoftware(Eg:Ansys)---25Marks

50

3 02,03,04

PortfolioevaluationbasedontheaverageofallPracticeSessions(7-12weeks)

10

TotalMarks 100

6.RubricsforAssessmentofActivity(QualitativeAssessment)

Sl.No.

Dimension Beginner Intermediate Good Advanced Expert StudentsScore

2 4 6 8 10

1 Descriptor Descriptor Descriptor Descriptor Descriptor 8




AverageMarks=(8+6+2+2)/4=4.5 5

Note:DimensionandDescriptorshallbedefinedbytherespectivecoursecoordinatoraspertheactivities

7.Reference:


Sl.No.

Description

1 SchaumOutlines,“StrengthofMaterials”,5 Edition

2 RAMAMURTHAM.S.,“StrengthofMaterials”,14thEdition,DhanpatRaiPublications,2011

3 KHURMIRS,“AppliedMechanicsandStrengthofMaterials”,5Edition,S.Chandandcompany

4 NASHW.A,“TheoryandproblemsinStrengthofMaterials”,SchaumOutlineSeries,McGraw-HillBookCo.,NewYork,1995.

5 RYDERG.H,“StrengthofMaterials”,3rdEdition,MacmillanIndiaLimited,2002.

6 BANSALR.K,“StrengthofMaterials”,LaxmiPublications,NewDelhi,2012.

7 Schaumseries,StrengthofMaterials

8 TIMOSHENKOS.P,“ElementsofStrengthofMaterials”,TataMcGraw-Hill,Delhi,

9 IntroductiontoFiniteElementsinengineeringbyTRIRUPATHIR,CHANDRUPATLA,ASHOKDBELEGUNDA,PearsonPublications.

10 PracticalFiniteElementAnalysisbyNITINSGOKHALE,SANJAYSDESHPANDE,FinitetoInfinitePublications

11ANSYSfreesoftwaretutorial((Studentversion)

https://www.google.co.in/search?biw=1024&bih=667&q=ansys+software+tutorial&sa=X&ved=0ahUKEwjm5o MndHNAhUBsI8KHbRWDhUQ1QIIXygE

8.LISTOFSOFTWARE/LEARNINGWEBSITES

1. www.nptel.iitm.ac.in/courses/.../IIT.../lecture%2023%20and%2024htm2. www.wikipedia.org/wiki/Shear and moment diagram3. www.freestudy.co.uk/mech%20prin%20h2/stress.pdf4. www.engineerstudent.co.uk/stress and strain.html5. www.ansys.com/Student6. http://www.mece.ualberta.ca/tutorials/ansys

9.SEESchemeofEvaluation Duration:180Min

SL.No.

CO

Particulars/Dimension Marks

1

01,02

DeterminethedeformationofagivenspecimensubjectedtoTensile/Compressive/ShearloadsusingUTM• WritingobservationsandTabularcolumn--10Marks• WritingEquationsrequiredWithallnotations–-10Marks• ConductionofExperiment---05Marks• CalculationandResultwithGraphifany---15MarksORCalculateandPlotSFDandBMDfortheGivenData• FindingShearforceandBendingMoment–10Marks• PlotSFDandBMD–15Marks• ValidateUsingFEMsoftware(Eg:Ansys)---15Marks

40


2

03,04

ApplyfiniteelementformulationstosolvethegivenOnedimensional/TwodimensionalcasesandValidateusingAnsys

• SolvebyFEMMethod—20Marks• ValidateFEMsoftware(Eg:Ansys)---20Marks

40

3 01,02,03,04

Vivavoce 20

TotalMarks 100

10.Equipment/softwarelistwithSpecificationforabatchof20students

Sl.No. Particulars Specification Quantity

01 Universaltestingmachine

Computerized100TonCapacityWithallattachmentstoconductshear,bending,compressionandtensiletest

01

02 Ansyssoftware 20user03 DesktopComputer Latestconfiguration 10nos



DEPARTMENTOFCOLLEGIATEANDTECHNICALEDUCATION

1. Rationale: Diploma Engineers are responsible for supervising production processes to achieveproduction targets and for optimal utilization of resources. For this purpose, knowledge about variousmachiningprocessesisrequiredtobeimparted.ThestudentsaretobetrainedandequippedwithadequatetheoreticalandpracticalknowledgeaboutMetalCuttingPhenomenonandvariousprocesses like turning,drilling,milling, grindingetc.Hence, this course is introduced toprovidehandsonexperienceonvariousmachinetoolsusedinthemanufacturingstreamandtoprovidefoundationfordiplomaengineerswhowanttofurtherspecialiseinthefieldofprecisionmanufacturing


CO-01 ListrelevantworkplaceOccupationalhealthandsafetystandardsandexplaintheimportanceoftheneedtocomplywiththem.

CO-02 ExplaintheimportanceofCuttingtoolGeometry,listvariousCuttingParameters,theroleanduseoftherightCoolantsandLubricantsforthegivenmachiningprocesses.

CO-03 Demonstrateturningoperationforagivencomponentdrawingandobject,prepareaprocesschartandestimatethecostofitsproductionasperdrawing.

CO-04Demonstratemillinganddrillingoperationneededasperagivencomponentdrawing,listallthemachine toolsneeded for theoperation,prepareaprocess chart andestimate the costof itsproductionasperthedrawing.

3.CourseContent

Week CO PO*

Lecture(Knowledge)

Tutorial(Activity)

Practice(Skill)

3hours/week 1hour/week 4hours/week(2hours/batchtwiceinaweek)

1 01 05

1.Educate about Safety standardsPracticed in the machine Shop -Importance of housekeeping andgoodShopfloorPractices(5S)2.UnderstandthePrinciplesofFirstAid.PreventivemeasurestobetakenduringFireandElectricalemergency

ReferTable1

1.Readandinterpretthesafetysigns displayed in theMachineshop

InstructorhastoshowvariousSafety sign charts andPersonnel ProtectiveEquipment(PPE)andaskthetrainees to identify andrecord in the dairy2.ReadandinterpretthePPE



CourseName MachineToolTechnology ContactHours8hours/week104hours/semester


CIEMarks 60 SEEMarks 40


TypesofFireextinguisher(ClassA,B,C,D)3.KnowledgeaboutSafetyandEnvironmentRegulations

FirstaidandbasictrainingIdentifyandSegregatewastematerial(cottonwaste,metalchips,burrsetc.)Arrangementofwasteinbins

3.Hazardsidentificationandavoidance

Preventivemeasureforelectrica accidents

Selectthefireextinguisheraccordingtotypeoffire

4.OperatetheFireextinguisherandextinguishthefire

PreventivemeasureforOilleakagesandrelatedHazardsPracticethesafetynormswhileworkingonDeferentMachineTool

2 02 01,04

1Lubrication-NeedofLubrication-SelectionofLubricantasperISOstandard.2.TheoryofmetalRemoval-Traditional&NonTraditionalmaterialremovalprocess-Chipforming&Nonchipforming3.Typesofcuttingtools-Singlepointtools-Multipointtools–SpecificationofSinglePointCuttingTool,Parting,KnurlingTool,V-tool

ReferTable1

1. InstructorhastodisplayalltheLubricantsusedinthesectionandbriefaboutitsuses

2. SelectaProperlubricantanddemonstratethelubricationofvariousmAskthestudentstorecordintheDairy

3. Instructorhastoshowall

thetools,machineriesandmeasuringinstrumentsusedinthemachineshopandbriefaboutitsuses.AskthestudentstorecordintheDairy.

4. IdentifythetypeofChips

formedandrecordinthedairy

3 02 01

1.Grinding-Abrasives-ApplicationsofNaturalabrasives-standstone(Quartz),CorundumandEmeryDiamondandGarnets-ApplicationofManufacturedAbrasives-SiliconCarbide,AluminumOxideCubicboronNitride2.Explain–Grit,Grade,Structure,Bond,TypeISODesignationofGrindingWheels3.ToolGeometry-ToolmaterialsandDesignation-Toollife&Wear

ReferTable1

1.PracticeonGrindingmachine2GrindingPracticeofSinglepointtoolaspertoolGeometry


ConceptofCuttingspeed-Depthofcut-Feed

4 03 01

1.IntroductiontoSurfaceTexture-IndicationofRoughnessSymbols-Completesurfacesymbolchart,GradeandNumbers,-Tolerances-UnilateralandBilateral2.IntroductiontoLathe-Typesoflathe-CapstoneandTurretLathe,AutomaticLatheandothers-SpecificationofaCenterLathe-.CuttingFluids-Selectionofcuttingfluids-3.ExplainWorkholdingDevices-ToolHoldingDevices

ReferTable1

1. ReadandinterprettheSurfacefinishandTolerancesinthegivenProductiondrawing.

2. IdentifythemainPartsofLatheanditsfunctions

IdentifythemovementsinLatheParts

• Carriage• CrossSlide• TailStock

3.RemovetheChuckfromSpindleNoseandagainmountonit

4.DemonstrationofholdingWorkpiecein3-Jawand4-Jawchuck

5.IdleoperationofLathe.RotationofspindleinClockwiseandCounterclockwisedirection

6.IdentifytheLubricationPartsinLathe

7.SettheSpindlespeed-Feed-LeverPosition.

5 03 01,02,04

1.ExplainPlainturning,Stepturning,KnurlingandChamferingOperations2.PreparetheProcessplanasperthegivendrawingforPlainTurning,StepTurning,KnurlingandChamfering2.EstimatetheProductioncostperPieceasperthegivendrawingforPlainTurning,StepTurning,KnurlingandChamfering(ConsiderallDirectandIndirectcosts)

ReferTable1

1.ReadandUnderstandthegivenDrawing2.SelectthesuitableRawmaterial3.FixthegivenmaterialbetweenheadstockandTailStockafterperformingFacingandCountersinking.4.SelecttheSpeedandFeed5.Selectandsettheappropriatecuttingtoolsasperthesequenceofoperations5Performalloperationsaspertheprocessplan6.Checkthedimensionsusingmeasuringinstruments7.ObserveandIdentifytheChipFormation

6 03 01,02,04

1.ExplainTaperturningoperationsbydifferentmethods-CalculateTaperanglesfor

ReferTable1 1. ReadandUnderstandthegivenDrawing


differentTaperturningcomponentDrawings2.PreparetheProcessplanasperthegivendrawingforTaperTurning3.EstimatetheProductioncostperPieceasperthegivendrawingforTaperTurning(ConsiderallDirectandIndirectcosts)

2. MarktherequireddimensionsasperthegivendrawingforTaperturning

3. FixthegivenmaterialbetweenheadstockandTailStock

4. SelectandSetthetoolstoperformTaperturning

5. SelecttheSpeedandFeed6. PerformtheTaperTurningoperationsandrecordthemachiningtime.

7. MeasuretheTaperangleinthegivenspecimenusingBevelProtractor

7 03 01,04

1.ExplainThreadcuttingMechanisma) HalfNutMechanismb) TumblerGearMechanism2.PreparetheProcessplanasperthegivendrawingforThreadcutting

3.EstimatetheProductioncostperPieceasperthegivendrawingforThreadcutting(ConsiderallDirectandIndirectcosts)

ReferTable1

1. ReadandUnderstandthegivenDrawing

2. FixthegivenmaterialbetweenheadstockandTailStock

3. SelectandSetthetoolstoperformThreadcuttingoperations

4. SelecttheSpeed,Feedandlubricant

5. PerformthethreadcuttingoperationsMeasurethePitchofthethreadforthegivenspecimenbyusingPitchGauge

8 04 01,04

1.IntroductiontoMilling–Typesofmillingmachine–SpecificationofaMillingmachine2.TypesofMillingcuttersandtheiruses-MillingCutterNomenclature-SpecificationofMillingCutter3.MethodsofMilling-UpMillingandDownMilling-Workholdingdevices

ReferTable1

1. IdentificationofMillingmachinePartsanditsUsage

2. DemonstratetheworkingPrincipleofMillingmachineandmovementsofTableandArbor

3. SettingofViceandJobontheTableofMillingMachine

4. SettheCutterontheArbor5. IllustratethesafetypointstobeobservedwhileworkingontheMillingmachine

6. IdentifyandSelectthedifferentMillingCutters

7. DemonstratetheUp-millingandDown–MillingProcess

9 04 01,02,04

1.ExplainPlainMillingOperation2..PreparetheProcessplanasperthegivendrawing(SolidBlock)forPlainMilling3.EstimatetheProductioncostperPieceasperthegivendrawingforPlainMilling

ReferTable1

1. PerformPlainMillingofSixfacesofaSolidBlock

2.ChecktheaccuracyoftheJobwithsuitableMeasuringInstruments


Operation(ConsiderallDirectandIndirectcosts)

10 04 01,02,04,07

1.ExplainKeywayandV-slotOperation2.PreparetheProcessplanasperthegivendrawingforKeywayandV-slot3. EstimatetheProductioncost

perPieceasperthegivendrawingforKeywayandV-slot

Studythelatesttechnologicalchangesinthiscourseandpresenttheimpactofthesechangesonindustry

1. PerformMillingof

KeywayandVSlot

2. CheckthedimensionalaccuracywithsuitableMeasuringInstrument

11

04

01,02,04,07

1. ExplainGearcuttingbyIndexingMethods

2. PreparetheProcessplanasperthegivendrawingforGearcutting

3. EstimatetheProduction

costperPieceasperthegivendrawingforGearcutting

1. DemonstrateIndexingHead

2. SetandAlignIndexing

HeadwithreferencetotheJobonMillingmachineTable

3. PerformGearTeethonaBlankbySimpleIndexingMethod


12 04 01,02,04,07

1.IntroductiontoDrilling–TypesofDrillingMachines-SpecificationofDrillingMachines-SpecificationofDrillBit,Reamer,DieandTaps2.NomenclatureofDrillBit,Reamer,DieandTaps-StandardsizesofDrillBitsExplainOperationsperformedinDrillingMachines-Drilling,Countersinking,Reaming,Boring,Tapping3.PreparetheProcessplanasperthegivendrawingandEstimatetheProductioncostperPieceasperthegivendrawing

1. IdentificationofDrillingmachineParts

2. DemonstratetheworkingPrincipleofDrillingmachine

3. SettheViceandJobontheTableofDrillingmachine

4. IllustratethesafetypointstobeobservedwhileworkingontheDrillingmachine

5. IdentifyandSelectthedifferentDrillBits

6. SettheDrillbitsonthespindle.

7. DrillEquallyspacedholes(Circular/Square/Rectangularplate)

8. Finishthepre-drilledholewithaReamer

13

01,02,03,04

Demonstratethemanufacturingoffollowing components usingYouTubeVideos

1. Fasteners2. PropellerShaft3. Gears4. Pistonmanufacturing

Discuss and Prepare a Report onthe videos Presented for eachmanufacturedcomponent.

Demonstrate themanufacturing of followingcomponents using YouTubeVideos1. TubeandPistonRod

Manufacturing.2. Cylinder

manufacturingetc.,3. Singlepointtool4. DrillbitsEtc.

DiscussandPrepareaReportonthevideosPresentedforeachmanufacturedcomponent

Totalinhours 39 13 52

• *PO=ProgramOutcomeaslistedanddefinedinyear1curriculum


Table1:SuggestiveActivitiesforTutorials:(TheListisonlysharedasanExampleandnotinclusiveofallpossibleactivitiesofthecourse.StudentandFacultyareencouragedtochooseactivitiesthatarerelevanttothetopicandontheavailabilityofsuchresourcesattheirinstitution)Sl.No. SuggestiveActivitiesforTutorials

01

PresentareportonMachinesafetyGuidelinesaspertheApplicablestandardGuidelines(CSAStandardZ432-04(R2009))includinghazardsassociatedwithmachines,Powertools,MachineShop.AlsoDiscussgeneralcontrolsforreducingmachineHazards.https://ehs.utoronto.ca


02DiscussCommongrindingProblemsAndtheirRemedies.AlsodiscusstheneedforBalancingtheGrindingWheels..https://www.Euromarcconz

03Whetherit'sgraniteforyourcountertops,backsplash,orfloortiles,makingpristinecutscanbeachievedwithproperprecautions,techniques,andspecializedgranitecuttingtoolsformakingtilesandslabsofthishardrock.Discussandpresentareportonthosetools.

04PresentaReportonApplicationsofInversionsofKinematicMechanisms:With-worthquickreturnmotionmechanisminShaperDouble-slidercrankmechanism

05PresentaCaseStudyonMachinetoolchatterarisinginaninterruptedturningprocess

https://core.ac.uk/download/pdf/33663698.pdf

06

PresentaReportonInfluenceofCuttingParametersoncuttingforceandSurfacefinishinTurningoperation

https://www.sciencedirect.com

07 AnalysetolerancesinaProductionDrawing

08 AnalyseSurfacefinishsymbolsinaProductionDrawing

09 DemonstratethevariousmeasuringinstrumentsusedinMachineShop

10CollectthesamplepieceofvariousrawmaterialsusedinmachineshopandDiscusstheirmechanical,chemicalandPhysicalproperties


Assessment TestWeekDurationInminutes

Maxmarks

Conversion

1. CIE-1WrittenTest 5 80 30 Averageofthreetests30

2. CIE-2WrittenTest 9 80 303 CIE-3WrittenTest 13 80 304. CIE-4SkillTest-Practice 6 180 100 Averageoftwoskill

testreducedto205 CIE-5SkillTest-Practice 12 180 100


1-13 10 10

TotalCIEMarks 60SemesterEndExamination(Practice) 180 100 40

TotalMarks 100

5.FormatforCIEwrittenTestCourseName MachineToolTechnology Test I/II/III Sem IIICourseCode 20ME32P Duration 80Min Marks 30Note:Answeranyonefullquestionfromeachsection.Eachfullquestioncarries10marks.

Section AssessmentQuestionsCognitiveLevels(R/U/A)

CourseOutcome

Marks

I1

2

II3

4

III 5


6

NotefortheCoursecoordinator:Eachquestionmayhaveone,twoorthreesubdivisions.Optionalquestionsineachsectioncarrythesameweightageofmarks,Cognitivelevelandcourseoutcomes.



1 03 QuestiononTurningoperationswithProcessplan,ProductionCostoftheproductforaGivenparameters

• ProcessplanincludesComponentDrawing,processlistandToolselection=25marks

• CostingincludesRawmaterial,processandfindingTotalcost,sellingPriceandcostofscrap=25marks

• PerformanceofTurningandTaperturningoperations(20+15)=35marks

• Dimensionalaccuracy=05Marks

90

2 01,02,03 PortfolioevaluationbasedontheaverageofallPracticeSessions(1-6weeks)

10

TotalMarks 100



1

04

QuestiononMillingoperationswithProcessplanandProductionCostoftheproductforaGivenparameters



• PerformanceofMillingoperationsincludingKey/Slot/Gearteethcuttingoperations(20+15)=35marks


90

2 03,04 PortfolioevaluationbasedontheaverageofallPracticeSessions(7-12Weeks)

10

TotalMarks 100


Sl.No.


2 4 6 8 101 Descriptor Descriptor Descriptor Descriptor Descriptor 82 Descriptor Descriptor Descriptor Descriptor Descriptor 63 Descriptor Descriptor Descriptor Descriptor Descriptor 24 Descriptor Descriptor Descriptor Descriptor Descriptor 2

AverageMarks=(8+6+2+2)/4=4.5 5Note:DimensionandDescriptorshallbedefinedbytherespectivecoursecoordinatoraspertheactivities

7.Reference:


Sl.No. Description1 MechanicalestimationandcostingT.R.BangaandS.C.SharmaKhannapublishers2 MechanicalEstimationMalhothra

3 IndustrialOrganizationandEngineeringEconomics T.R.BangaandS.C.Sharma Khannapublishers

4 MechanicalEstimationNITTTRChennai NITTTRChennai5 MechanicalcostingandEstimation. SinghandKhan KhannaPublishers6 ProcessPlanning&CostEstimation M.Adithan NewageInternational

7 Rao,P.N.,ManufacturingTechnology,Vol I& II,TataMcgrawHillPublishingCo.,NewDelhi,1998

8 Seropekalpakjian, Steven R Schmid Manufacturing Engineering and Technology- PearsonEducation-Delhi

9Sharma,P.C.,ATextbookOfProductionTechnology–VolIAndII,S.Chand&CompanyLtd.,NewDelhi,1996

10 HMT–“ProductionTechnology”,TataMcgraw-Hill,1998

8.LISTOFSOFTWARES/LEARNINGWEBSITES:

1.http://calculatoredge.com/index.htm#mechanical2.www.nptel.ac.in/courses/112105126/363.www.youtube.com/watch?v=T5gjkYvMg8A4.www.youtube.com/watch?v=ESKoaZtoB1E5.www.freevideolectures.com9.SEESchemeofEvaluation Duration:180minSL.No.


1

03,04

QuestiononTurningoperationswithProcessplanandProductionCostoftheproductforaGivenparameters



• PerformanceofOperations=30marks• Dimensionalaccuracy=05Marks

ORQuestiononMillingoperationswithProcessplanandProductionCostoftheproductforaGivenparameters



• PerformanceofMillingoperationsincludingKey/Slot/Gearteethcuttingoperations(20+10)=30marks


80

2 01,02,03,04

Vivavoce 20

TotalMarks 100


10.EquipmentlistwithSpecificationforabatchof20students

Sl.No.

Particulars Specification Quantity

01 CenterlatheWithallaccessoriesandattachments(Geardriven)

Max50mmDiaHoldingcapacity500mmCenterdistance.Swingoverdia200mm

20

02 HSScuttingtool 20*20*150MM 4003 HSScuttingtool 10*10*150MM 2004 Cementedcarbidetippedtoolswithholderbrazed Forturning 2005 KnurlingtoolRough Standard 1006 KnurlingtoolSmooth Standard 1007 Verniercalipers 300mm 2008 Outercaliper 5ommOD 2009 Steelscale 300mm 2010 Dialgaugeforsettingofwork Standard 10

11 CountersunkDrillBit 6mmTapershank 20

12 UprightDrillingMachineUpto24mmdrillWithallattachment

01

13 SensitiveDrillingMachine Upto18mmdrill 01

14 MachineVice(ToholdJob) 120mmJawGap 05

15 DrillBitset 6mmto24mm 10set16 MarkingDivider 200mmdia 17 Markingpunch Standard 20nos18 CombinationSetSquare Standard 10nos19 Surfaceplate 300*300mm 01no

20 ColumnandKneetypeVerticalMILLINGmachineWithallattachments

.TableTravelof800mm.24mmcuttersBoredia(ID)

01no

21 PlainmillingCutter24mmID/Slabmilling StandardSizeforPractice 05

22 Keywaycutter 6mm 1023 Keywaycutter/Slotcutter 12 10

24 Gearcutter(Spurteeth) StandardSizeforPractice 10

25 ConcaveMillingcutter StandardforSizePractice 10

26 ConvexMillingcutter StandardSizeforPractice 10

27 KeywayMillingcutter 40mmdia 1028 EndMillingCutter 24mmdia 10

29 BenchGrinder300mmwheeldiaRoughandSmooth

02




1. Rationale: Diploma Engineers are responsible for supervising production processes to achieveproduction targets and for optimal utilization of resources. For this purpose, knowledge about variousmanufacturingprocessesisessential.Thisrequirestrainingthestudentsincastingandmetalformingdomainsoastoequipthemwithadequatetheoreticalandpracticalknowledgeaboutthevariousmetalcastingandforming processes like rolling, forging, drawing, extrusion, Sheet metal work etc. Hence this course isintroducedtoprovidehandsonexperienceonvariousmanufacturingprocesses.

2.CourseOutcomes:AttheendoftheCourse,thestudentwillbeableto

CO-01 Producepatterns,moulds,andcastingofagivencomponentdrawingandestimatethecostofcasting.

CO-02 Demonstrateforgingoperationforagivencomponentdrawingandestimatethecostofforging.

CO-03 Preparesheetmetaldrawing,demonstratesheetmetaloperationandestimatethecostsofSheetmetaloperation.

CO-04 Explainrollingandextrusionoperationandlistapplicationsofmetalsformingprocesses.

3.CourseContent

Week CO PO*

Lecture(Knowledge)

Tutorial(Activity)

Practice(Skill)

3hours/week 1hour/week

4hours/week(2hours/batchtwiceina

week)

1 01 01,04

1.Introductiontofoundry–YoutubevideosonfoundriesExplainthesafetyPrecautionstobetakeninfoundries2.ExplaintheneedofaPattern-TypesofPatterns—SolidorSinglePiecepattern,SplitPattern,LoosePiecePattern,MatchPlatePattern,GatedPattern,SweepPattern,Skeleton-Pattern3.Allowances-MaterialsusedforPattern

ReferTable1

1.Identifythetoolsandequipmentusedinfoundrywithapplication2.PrepareasinglePiecewoodenPatternconsideringallallowances

2 01 01,04

1.MoldingSand-Types2.IngredientsandPropertiesofMoldingSand

ReferTable11.Prepareamoldingsand2.PreparationofMoldwiththehelpofPattern



CourseName ManufacturingProcesses ContactHours8hours/week104hours/semester

TeachingScheme

L:T:P::3:1:4 Credits 6



3.ImportanceofCoreandCoreprints-Gates-Runner-Riser

3.Meltthemetal(wax)andpouringitintothemoldcavity

3 01 01,04

1.ExplainDefectsinCasting2.InspectionofCasting3.DeterminationofProductionCostofagivenmaterialconsideringRawmaterial,Processcost,Overheadsandotherexpenses

ReferTable1

1. CuttingRunnerandriserinthecastedcomponent

2. Cleaningofthecastedcomponent

3. Inspectionofthecasted

component

4. Recordthedefects,ifany

4 02 01,04

1.IntroductiontobasicMetalFormingProcessandApplications-ShowYoutubeVideo’sonMetalFormingProcess2.ExplainHotandColdWorkingProcesswithApplicationShowYoutubeVideosonHotandColdWorkingProcess3.Introductiontoforgingoperation-Typesofforging-HandforgingandPowerforging

ReferTable1

1.DemonstratesafetyprecautionstobefollowedinForging2.Identifythetoolsandequipment’susedinforging3.ForgingPractice(Hammering)

5 02 01,04

1.ExplainforgingOperations-Upsetting,drawingdown,Cutting,Bending2.ExplainPunchingandDrifting,SettingdownandFinishing,ForgeWelding3EstimationofLengthofRawmaterialrequiredtoconvertCircularrodtoSquareandCalculatetheProductionCostconsideringdirectandIndirectexpenses.

ReferTable1 ConversionofCircularrodtoSquare

6 02 01,04

1. EstimationofLengthofRawmaterialrequiredtoconvertCircularrodtoHexagonandCalculatetheProductionCostconsideringdirectandIndirectexpenses.

2. ExplaintheworkingprincipleofPowerhammer

3. ShowtheyoutubevideosoncomponentsproducedbyPowerforging

ReferTable1

ConversionofCircularrodtoHexagon

7 02 01,04

1. EstimationofLengthofRawmaterialrequiredtoconvertHexagonto”L”shapedNailandCalculatetheProductionCostconsideringdirectandIndirectexpenses

2. ExplainForginglosses-ForgingDefects

ReferTable1ConversionofHexagonto”L”Nailasperthegivendrawing


3.Showtheyoutubevideosoncomponentsproducedbyforgingoperations

8 03 01,04

1.Introductiontosheetmetal-ShowYoutubevideosonsheetmetaloperationsandApplications2.Explainsheetmetalmaterials–StandardGaugesofsheet-SpecificationofSheet3.ExplaindifferentSheetmetaloperations

ReferTable1

1. Identifyanddemonstratethevarioustoolsusedforsheetmetaloperations.

2. Measurethegaugesofsheet

3. DemonstratetheoperationsperformedonShearingmachine

9 03 01,04

1.ExplaintheDevelopmentofConeandCylinder2.ExplaintheDevelopmentofPrismandPyramid3.ExplaintheDevelopmentofFunnel

ReferTable1

1. PrepareCone,Cylinder,Prism,PyramidandFunnel

2. Joinendsurfacesby

meansofSeamJoint

10 03 01,04

1.ExplaintheDevelopmentofTray2.ExplaintheDevelopmentofTransitionpieces3.ExplaintheDevelopmentofTransitionpieces

ReferTable1

1. PrepareaTray

2. PrepareanyTransitionPiece

11 03 01,0407

1. FindthetotalProductioncostofasheetmetalcomponentslikeOpencontainer,CylindricalDrum

2. IntroductiontoPowerPress-Presssize-Presstools–DieAccessories

3. TypesofDieanditsoperations


1. PresentYoutubeVideosonPressworkoperations

2. Recordthe

observationsmadeandprepareareport.

12 04 01,07

1.IntroductiontoRolling-NomenclatureofRolledProducts-Diesusedinrollingprocess2.TypesofRollingmills-2highmill-3Highmill–4Highmill-Clustermill,TandemMill,Planetarymill,DefectsinRolling3.IntroductiontoExtrusionandDrawing–TypesofExtrusionProcess.WireandTubeDrawingProcess,DiesusedinExtrusionandDrawingProcess

Video/VirtualexposureonRollingandExtrusion

13 04 01,07

Demonstrate the manufacturing offollowing components usingYouTubeVideos1. CrankShaft2. Valves3. Wheel4. Gearcase5. Hairsprings

Demonstrate themanufacturing of followingcomponentsusingYouTubeVideos1. TMTSteels2. Channelsections3. PumpCasings4. RollingofSheets



5. Toothpastetube6. Pipes7. Tubesetc.,





01

Fromheavycastingof300Kgtosmallcastingof30kg,investmentcastingmethodisusedforaswideforhi-techindustrialapplications.Investmentcastingislargelyreliedonforcomplicateddesignsthatcannotbecastedusinganyothermethod.Discuss.Also,PresentthePreparationofPatternsfortheProcess.ComparetherelativesurfacefinishofthisprocesswithotherCastingProcesses.

02Discusstheforgingdefectscommonlyoccurringinforgings,theircausesandRemedies.PresentthemethodologyformeasuringForgingdefects.https://studentlesson.com

03 AGascylinderisproducedbySheetmetaloperations.PreparethedevelopmentandPresenttheprocedureinvolvedinmakingthegivencomponent.

04 IdentifytheformingprocessadoptedinmakingToothPasteTubes.Presenttheprocess.Listthelimitationsinvolvedandsolutionstoovercometheselimitations.

05 EstimationofLengthofRawmaterialrequiredforaforgedboltandCalculatetheProductionCostconsideringdirectandIndirectexpenses.



Maxmarks

Conversion





1-13 10 10


TotalMarks 100

5.FormatforCIEwrittenTestCourseName ManufacturingProcesses Test I/II/III Sem III/IVCourseCode 20ME33P Duration 80Min Marks 30Note:Answeranyonefullquestionfromeachsection.Eachfullquestioncarries10marks.

Section AssessmentQuestions CognitiveLevels

CourseOutcome Marks


I1 2

II3 4

III5 6




1 01 QuestiononCastingProcessWithProcessplan,CostingoftheproductforaGivenparametersincludingpattern,meltingandotherexpenses• ProcessplanincludingComponentDrawing,processlistandTool/Equipment’sselection=15marks

• PreparationofMoldbyusingPattern=25Marks• CostingincludingRawmaterial,processandfindingTotalcost,sellingPrice=25Marks

• Operationperformed=20marks• Dimensionalaccuracy=05Marks

90

2 01 PortfolioevaluationbasedontheaverageofallPracticeSessions(1-6weeks) 10TotalMarks 100



1 02 QuestiononForgingoperationwithProcessplan,CalculationofRawmaterialLength,CostingoftheproductforaGivenparametersconsideringallPossibleLosses.• ProcessplanincludingComponentDrawing,processlistandTool/Equipment’sselection=15marks• CostingincludingRawmateriallength,processtimeandfindingTotalcost,sellingPrice=25marks• OperationsPerformedwithDimensionalaccuracy=20Marks.

60

2 03 OneSkillorientedQuestiononSheetMetalwork• Developmentforagivendrawing=20Marks• SheetmetalOperationwithDimensionalaccuracy=10marks

30

3 02,03

PortfolioevaluationbasedontheaverageofallPracticeSessions(7-12weeks)

10

TotalMarks 100


Sl.No.


2 4 6 8 101 Descriptor Descriptor Descriptor Descriptor Descriptor 82 Descriptor Descriptor Descriptor Descriptor Descriptor 6


3 Descriptor Descriptor Descriptor Descriptor Descriptor 24 Descriptor Descriptor Descriptor Descriptor Descriptor 2


7.Reference:Sl.No. Description1 ElementsofWorkshopTechnology(Vols.1andII)byHajraChaudhary2 ProductionTechnologyByR.K.Jain3 FoundryTechnologyByO.P.Khanna4 EngineeringDrawingVol-2ByK.R.GopalaKrishna5 EngineeringDrawingByN.D.Bhat8.SEESchemeofEvaluationDuration:180MinSL.No.

CO


1

01,02

OneSkillorientedQuestiononCasting• ProcessplanincludingComponentDrawing,processlistand

Tool/Equipment’sselection=15marks• PreparationofMoldbyusingPattern=30Marks• OtherOperationsperformed=10marks

OROneSkillorientedQuestiononForgingoperationwithProcessplan,CalculationofRawmaterialLength,CostingoftheproductfortheGivenparametersconsideringallPossibleLosses.

• ProcessplanincludingComponentDrawing,processlistandTool/Equipment’sselection=20marks

• CostingincludingRawmateriallength,processtimeandfindingTotalcost,sellingPrice=25marks

• OperationsPerformedwithDimensionalaccuracy=10Marks.

55

2 03

OneSkillorientedQuestiononSheetMetalwork• Developmentofproduct=15Marks• PerformanceandOperationwithDimensionalaccuracy=10marks

25

4 01,02,03,04 Vivavoce 20 TotalMarks 100

9.EquipmentlistwithSpecificationforabatchof20students

Sl.No. Particulars Specification Quantity01 Mouldingbox 300*300*100mm 2002 MouldingRammer Standardsize 2003 Mouldingtoolkit Standardsize 20

04 Electricfurnaceformelting(Wax/Lowmeltingpointmetalwithcrucibleandladderforpouring) Standardsize 04

05 Portablegrinderforcleaningofcasting Standardsize 0206 SandBlaster Standardsize 0407 BallpeenHammer ½lb 0508 PatternMakingToolkit Standardsize 1009 AnvilForForging Standardsize 0510 Sledgehammer 2LB 10


11 Handhammer 1lb 1012 Flatteners Standardsize 2013 FlatTongs Standardsize 2014 RoundTongs Standardsize 2015 Steelscale 300mm 2016 GIBucketforQuenching 15ltscapacity 1017 OpenHeartFurnacewithstandandBlower Standardsize 0418 HotChisel 24mmsize 1019 SheetshearingMachine(ManualorM/ctype) Standardsize 0420 Sniperforcuttingsheet Standardsize 2021 Metalstake Standardsize 1022 Woodenmallet Standardsize 2023 PlasticHammer Standardsize 2024 BenchviceforBendingofsheet Standardsize 0525 BrazingGun Standardsize 10



DEPARTMENTOFCOLLEGIATEANDTECHNICALEDUCATION1.Rationale:Fluidpowerisoneofthebasicbuildingblocksofmodernautomationandismostwidelyusedsystem to convert fluid energy into useful work through the use of pump, compressor, control valves,actuatorsandothercontrollingelements.Thistechnologyisusedtopowerarangeof itemssuchastools,constructionequipmentandmachineries,automotiveandmachineriesinmanufacturingsectors.Fluidpowerengineeringinvolvesstudyofpropertiesoffluids,lawsgoverningflowoffluids,workingprinciplesoffluidmachineriesandknowledgeofcontrolofmachinemovements.Thiscourseallowsthestudentstodeveloptheknowledgeandunderstandingoftheoperationalrequirementsoffluidpowersystemandbeabletorecognisecircuitcomponentsandbuildthecircuitsforapplicationsneededindailylife

2.CourseOutcomes:Attheendofthiscourse,studentwillbeableto

CO-01 MeasurefluiddischargethroughChannelsandPipesusinginstrumentsandestimatethesizeofthepipeneededforagivenpopulationsize.

CO-02 Selecttherighthydraulicmachinerytobeusedinaspecificapplicationforagivenheadanddischarge.

CO-03 Listthevariouscomponentsanditsuseinagivenfluidpowersystem.

CO-04 Buildasimplefluidpowersystemforagivenapplication

3.CourseContent

Week CO PO*

Lecture(Knowledge)

Tutorial(Activity)

Practice(Skill)



1 01 01,04

1.ExplainclassificationandPropertiesoffluids-Units-ConversionofCubicmeters-Liters–Gallons-TMC

2.ExplainPascalLaw,Equationofcontinuity,ConceptofTotalEnergy

3.ExplainBernoulli’sequationanditsApplications-Venturimeter,Pitottube,Orificemeter

RefTable1

1.FindDischargeofafluidthroughVenturimeter

2 01 01,04

1.ExplainDischargethroughRectangularNotch-NumericalProblems

2.ExplainDischargethroughV-notch-NumericalProblem

3.ExplainFlowthroughPipes-MajorandMinorLosses

RefTable1

1.FindingDischargethroughRectangularNotch2.FindingDischargethroughV-Notch



CourseName FluidPowerEngineering ContactHours8hours/week104hours/semester

TeachingScheme




3 01 01,04

1.Determineco-efficientoffrictionbyusingChezy’sandDarcy’sformulae

2.DesignaPipeforagivennumberofInhabitants

3.DesignaPipeforagivendischarge

RefTable1

1.FindingCo-efficientofFrictioninPipes2.Youtubepresentationonfluidflowthroughpipesandnotches

4 02 01,02,04

1.ClassificationofPumps2.ExplaintheWorkingPrincipleofCentrifugalPumpanditsApplication

3.ExplaintheWorkingPrincipleofMonoblockanditsApplication

RefTable1

1. Findthedischarge

throughCentrifugalPump

2. ServicingandRepairofCentrifugalPumps

5 03 01,02,04

1.ExplaintheWorkingPrincipleofSubmersiblepumpanditsapplication

2.ExplaintheWorkingPrincipleofReciprocatingpumpanditsapplication

3.SelectasuitablePumpforagivenApplication

RefTable1 ServicingandRepairofSubmersiblepumps

6 02 01,04

1.ClassificationofHydraulicTurbines2.SelectasuitableTurbineforagivenHead

3.ExplaintheWorkingPrincipleofImpulseTurbineanditsApplication

RefTable1 DeterminePerformanceofPeltonwheel

7 02 01

1.ExplaintheWorkingPrincipleofReactionTurbineanditsApplication

2.ExplaintheImportanceofDrafttube,PenstockandSurgeTank

3.VideoonHydraulicPowerPlant

RefTable1

VideoonfluidflowfromsourcetoEndapplicationEg:OilRefineries,HydraulicPowerplant,Waterdistributionthroughpipelines

8 03 01

IdentifythebasiccomponentsofFluidpowerSystemswithSymbolsandApplication

• Aircompressor• AirDrier• FRLUnit• GearPump• PressurecontrolValve-PressureReducingValve,PressureIntensifier

• DirectioncontrolValves-3/2,5/2,4/2

• FlowcontrolValve• NeedleValve• CheckValve• ShuttleValve• QuickExhaustValve• TimeDelayValve

RefTable1

VideoonWorkingprinciplesofcomponentsusedinFluidPowerSystems

9 03 01

• ExplainValveActuatingmechanisms-Spring,Lever,Pushbutton,Solenoid

• ExplaintheroleofAccumulatorsinfluidpowersystems.

• ExplainworkingprincipleofActuators-SingleActing,DoubleactingAirCylinders,AirMotors

RefTable1

VideoonWorkingprinciplesofcomponentsusedinFluidPowerSystems


• ExplaintheimportanceofSealsandPackages

10 04 01,04

• BuildaFluidPowercircuittoControlSpeedofaSingleActingcylinder

• BuildaFluidPowercircuittoControlSpeedofaDoubleActingcylinder

• BuildaFluidPowercircuitforPilotcontrolDoubleActingCylinder

RefTable1

ExecutethecircuitPracticedintheClassusingTrainerKitorSimulationSoftware

11 04 01,04,07

• BuildaFluidPowercircuitfordoubleActingCylinderbeingcontrolledby4/2DCSolenoidOperatedValve

• BuildaCircuitforStampingoperationbyusing3/2DCValvewithSingleActingCylinder

• BuildaCircuitforAutomaticOpeningandClosingofDoorby/usingdoubleActingCylinderbeingcontrolledby4/2DCValve


Executeminimum2CircuitsPracticedintheClassusingTrainerKitorSimulationSoftware

12 04 01,03,07

• BuildaFluidPowercircuitforAutomaticreciprocatingmotionofadoubleactingCylinder

• Buildacircuitforfeedingastripwithfollowingsequences:

Holdingthestrip,movingthestripforwardontothetool,maintainingthestripinthatpositionandreturningthestriptoitsoriginalpositionafterworkisover.

• DesignaCircuittopressfitapintoaholewithapreconditionthatwhileactuatingofthecylinder,boththehandsoftheoperatorshouldbeengaged

Executeminimum2CircuitsPracticedintheClassusingTrainerKitorSimulationSoftware

13 04 01,07

• BuildCircuitforamachinedevicedrivenbyasingleactingcylinderwithactuationatleasttwomutuallyoperatedDCvalves(SafetycircuitwithORandANDGates)

• BuildCircuitfortheClampingDeviceofaDrillingMachineofaDrillingmachinesuchthattheclampsareactivatedbeforethedrillisfedtotheWork

• BuildaCircuitforyourOwnApplication

Executeminimum2CircuitsPracticedintheClassusingTrainerKitorSimulationSoftware,includingdevelopingyourOwnPneumaticCircuittoperformcertainfunction


• CourseCo-OrdinatormustpreparePO–COmappingwithstrength(Low/Medium/High)beforecourseplanning

Table1:SuggestiveActivitiesforTutorials:(TheListisonlysharedasanExampleandnotinclusiveofallpossibleactivitiesofthecourse.StudentandFacultyareencouragedtochooseactivitiesthatarerelevanttothetopicandontheavailabilityofsuchresourcesattheirinstitution)



01DocumentandpresenttheapplicationofPascal’sPrincipleinRealLifebyselectingHydraulicJack/HydraulicBrakes/HydraulicLifthttps://www.studiousguy.com

02 PresentareportonpossiblefailuresinSubmersiblePumpsandtroubleshootthesame.

03 DiscussandpresenttheapplicationofPneumaticsinfarmingusingcasestudy:FarminginCalifornia-TheissuesandPositivity’s

04 BuildandPresentanElectro-PneumaticBrakesystemusedinTrains.Also,documentBrakeCylinderPressureeffect.

05 PreparealineDiagramofthepipelineofyourResidenceorCollege06 PrepareawaterdistributionlinediagramfromWaterreservoirtocollege07 PreparealinediagramforrainwaterharvestingofyourResidenceorCollege08 StudyandprepareareportonwaterdistributioninDipIrrigationSystem.4.CIEandSEEAssessmentMethodologiesSl.No


Maxmarks

Conversion

1. CIE-1WrittenTest 5 80 30 Averageofthreetests302. CIE-2WrittenTest 9 80 30

3 CIE-3WrittenTest 13 80 304. CIE-4SkillTest-Practice 6 180 100 Averageoftwoskill



1-13 10 10


TotalMarks 100

5.FormatforCIEwrittenTestCourseName ManufacturingProcesses Test I/II/III Sem III/IVCourseCode 20ME33P Duration 80Min Marks 30Note:Answeranyonefullquestionfromeachsection.Eachfullquestioncarries10marks.

Section AssessmentQuestions CognitiveLevels

CourseOutcome Marks

I1 2

II3 4

III5 6




1 01 OneExperimentalQuestiononcaserelatedtoApplicationofBernoulli’stheorem(Venturimeter/Orifice/Pitottube)(Groupof5Students)

• WritingobservationsandTabularcolumn--10Marks• WritingEquationsrequiredWithallnotations–-15Marks

45


• ConductionofExperiment---10Marks• CalculationandResult---10Marks

2 01 OneExperimentalQuestiononChannels/Pipes(Groupof5Students)• WritingobservationsandTabularcolumn--10Marks• WritingEquationsrequiredWithallnotations–-15Marks• ConductionofExperiment---10Marks• CalculationandResult---10Marks

45

3 O1 PortfolioevaluationbasedontheaverageofallPracticeSessions(1-6Weeks)

10

TotalMarks 100



1 03,04

TwoSkillbasedQuestiontoDesignaPneumaticCircuitforthegivencase(IndividualExperiment)=45Markseach

• WritingCircuitDiagramwithallcomponents-25marks• BuildingCircuitontheKit-10marks• ShowingtheResult/output-10Marks

90

2 03,04 PortfolioevaluationbasedontheaverageofallPracticeSessions(7-12Weeks) 10TotalMarks 100


Sl.No.



AverageMarks=(8+6+2+2)/4=4.5 5Note:DimensionandDescriptorshallbedefinedbytherespectivecoursecoordinatoraspertheactivities7.Reference:Sl.No. Description

1 Bansal.R.K.,“Fluid Mechanicsand Hydraulics Machines”, 9th Edition, LaxmiPublicationsPrivateLimited,NewDelhi.2011.

2 R.S.Khurmi,“FluidMechanicsandMachinery”,S.ChandandCompany,2ndEdition,2007.3 Hydraulics&Pneumatics–AndrewParr,JaicoPublishingHouseNewDelhi.

4HydraulicandPneumaticControlsUnderstandingMadeEasy-K.S.Sundaram,-S.chandCompanyDelhi

5Ramamrutham. S, “Fluid Mechanics, Hydraulics and Fluid Machines”,DhanpatRai&Sons,Delhi,2004.

6P.NModiandS.M.Seth,“HydraulicsandFluidMechanicsIncludingHydraulicsMachines”,19thEdition,StandardBookHouse,2013


7HydraulicandPneumaticControls-Srinivasan,R.-VijayNicoleImprintsPrivateLimited,2/e,2008

8PneumaticAndPneumaticsControls-UnderstandingMadeEasy-K.S.Sundaram,-S.chandCompanyDelhi

9 PneumaticSystems-Majumdar,S.R.-TataMcGraw-HillPublication,3/e,2013


1. www.youtube.com/watch?v=VyR8aeioQrU2. http://www.youtube.com/watch?v=R6 q5gxf4vs3. www.howstuffworks.com4. .http://nptel.iitm.ac.in/courses/Webcourse-contents/IIT-KANPUR/machine/ui/TOC.htm5. https://www.youtube.com/watch?v=F 7OhKUYV5c&list=PLE17B519F3ACF93766. https://www.youtube.com/watch?v=zOJ6gWDMTfE&list=PLC242EBB626D5FFB57. http://www.youtube.com/watch?v=0p03UTgpnDU8. http://www.youtube.com/watch?v=A3ormYVZMXE9. http://www.youtube.com/watch?v=TjzKpke0nSU10. http://www.youtube.com/watch?v=vl7GteLxgdQ11. http://www.youtube.com/watch?v=cIdMNOysMGI12. www.boschrexroth.co.in13. http://www.automationstudio.com/14. http://www.howstuffworks.com/search.php?terms=hydraulics15. http://hyperphysics.phy-astr.gsu.edu/hbase/fluid.html#flucon16. http://www.youtube.com/watch?v=FVR7AC8ExIM17. http://www.youtube.com/watch?v=iOXRoYHdCV018. http://www.youtube.com/watch?v=qDinpuq4T0U19. http://www.youtube.com/watch?v=xxoAm3X4iw020. www.festo.com21. www.boschrexroth.co.in22. www.nptel.iitm.ac.in23.http://www.howstuffworks.com/search.php?terms=pneumatics9.SEESchemeofEvaluationDuration:180MinSL.No.


1

01

OneExperimentalQuestiononcaserelatedtoApplicationofBernoulli’stheorem(Venturimeter/Orifice/Pitottube)(Groupof5Students)

• WritingobservationsandTabularcolumn--10Marks• WritingEquationsrequiredWithallnotations–-15Marks• ConductionofExperiment---10Marks• CalculationandResult---15Marks

OROneExperimentalQuestiononChannels/Pipes(Groupof5Students)

• WritingobservationsandTabularcolumn--10Marks• WritingEquationsrequiredWithallnotations–-15Marks• ConductionofExperiment---10Marks• CalculationandResult---15Marks

50

2 03,04 OneSkillbasedQuestiontoDesignaPneumaticCircuitforthegivencase(IndividualExperiment) 30


• WritingCircuitDiagramwithallcomponents-20marks• BuildingCircuitontheKitandResult-10marks

3 CO1,CO2,CO3,CO4 Vivavoce 20 TotalMarks 100

10Equipment/softwarelistwithSpecificationforabatchof20students

Sl.No. Particulars Specification Quantity

01 BenchmountedTestRigforVenturimeter --------------- 01

02 BenchmountedTestRigforNotches ……………… 0103 BenchmountedTestRigforFrictionthroughpipes ……………….. 0104 CentrifugalPumpsFORMaintainesandServicing Usedone 0205 ManoblockPumpsFORMaintenanceandServicing ………do………….. 0206 SubmersiblePumpsFORMaintenanceandServicing ………do…… 0207 PneumaticsTrainerKitwithallstandardaccessories. Standardsize

08 CompressorforPneumaticsTrainerKit6BarpressureSinglephase50Hz

01

09 HosepipesforPneumaticsTrainerKit …………….. ………..10 BenchmountedTestRigforPeltonwheel Standardsize 01


4THSEMESTER




1.Rationale:Thesuccessofanyorganisationnotonlydependsonqualityofitsproductsandservicesbutalso depends on the people within it. Thus, an operational manager has to play a prominent role in anorganisationwithhumancapitalandmachines.Therefore,managerialskillsareessentialforenhancingtheiremployabilityandcarriergrowth.Thiscourseisthereforedesignedtoprovidebasicconceptsinoperationsmanagement, forecasting techniques, capacity planning, aggregate planning,master production schedule,quality,andinventoryandsupplychainmanagementforeffectiveutilisationofresourcesandcompetitiveadvantagethroughoperationalexcellence

2.CourseOutcomes:OnCompletionofcourse,thestudentwillbeableto:

CO-01 Prepare a production capacity utilization plan based on demand forecast and availableproductioncapacityforagivenproduct.

CO-02 Prepareamasterproductionplanbasedonaproductioncapacityutilizationplanandamaterialmanagementplanforagivenproduct.

CO-03 Prepareaprocessplanusingtimestudy,motionstudyandotherappropriatemethodstoensureprocessefficiency.

CO-04 Prepareaqualityassuranceplanbasedonagivenqualitymodelwhichissuitableforeitheraproductoraserviceorganisation.

3.CourseContent

Week CO PO*

Lecture(Knowledge)

Tutorial(Activity)

Practice(Skill)



1 01 01

IntroductiontoOperationManagement1.IntroductiontoOperationManagement-OperationFunctions

RefTable1

• VirtualTourOrganization(Youtube)• ProblemsonProductivity

2.EvolutionsandHistoricalEventsinOperationalManagement3.ProductivityandCompetitiveness,Strategyandoperation

2 01 01

DEMANDFORECASTING1.DemandForecasting-DemandBehavior-TrendCycle-SeasonalBackground-StepsinForecastingProcess RefTable1

Problemson

• QualitativeForecast-Delphimethod,MarketResearchmethod• QuantitativeForecast-TimeseriesMethoda)Movingaverage(Naiveforecast,Simplemoving

2.ShortrangeandLongRangeForecast

3.QualitativeForecastmethods

Programme MechanicalEngineering Semester IV


CourseName OperationsManagement ContactHours8hours/week104hours/semester

TeachingScheme




Average,WeightedmovingAverage)

3 01 01

1.QuantitativeForecastmethodsRefTable1

Problemson

b)Exponentialsmoothing

2.SeasonalAdjustments

3.ForecastAccuracy

4 01 01

CAPACITYANDAGGREGATEPLANNING1.NeedforCapacityPlanning–CapacityexpansionStrategies–CapacityplanningModels.

RefTable1

Problemson

• CapacityPlanning,• Aggregateplanning• MasterproductionSchedule2.Aggregateplanning-Methods

3.MasterproductionSchedule

5 01 01

PROCESSPLANNING1.MakeorBuyDecisionOutsourcing-FactorsforOutsourcingdecision-ProcessSelection–Batch,Mass,Continuous RefTable1

• VirtualTouronBatch,MassandcontinuousProcess• DevelopanOperationSheetindicatingProcessPlanandProcessflowchartforagivencomponent.

Componentsofe-manufacturing

6 03 01

1.MotionStudy

RefTable1

• DevelopJobProcesschartwithProcessSymbolsforagivenProcess.• DevelopMan-MachinechartforagivenProcess.• CasestudyonTimeStudyPrinciplesforagivenprocess.

2.Man-Machinechart

3.ConceptsonTimeStudy

7 02 01

INVENTORYMANAGEMENT1.ElementsofInventoryManagement-InventoryCosts-Carrying,OrderingandShortageCosts

RefTable1

Problemson

• ABCClassificationSystem• EconomicOrderQuantityModels• TheProductionQuantityModel

2.InventoryControlSystems-ContinuousInventorySystem(Fixed-Order-QuantitySystem)PeriodicInventorySystem(Fixed-Time-PeriodSystem)3.ConceptonABCClassification,EconomicOrderQuantityModels,ProductionQuantityModel

8 02 01,02

1.OrderQuantityforAPeriodicInventorySystemOrderQuantitywithVariableDemand RefTable1

CasestudyonJIT(Eg:ToyotoProductionSystem)2.JIT-PullSystem

3Kanban’sSystem

9 02 01

SupplyChainManagement1.SupplyChainsSupplyChainsforServiceProviders RefTable1

Studyon

• TheBullwhipEffect• RiskPooling• GreenSupplyChains

2.ValueChainsTheManagementofSupplyChains3.VendorSelection-Vendor


evaluationandVendorDevelopment,Negotiations

10 02 01

1.SupplyChainUncertaintyandInventory

RefTable1

Studyon• InformationTechnology:SupplyChainEnabler• BarCodes• RadioFrequencyIdentification• Build-To-Order(BTO)

2.E-Business,ElectronicDataInterchange

3.SupplyChainIntegration-CollaborativePlanning,Forecasting,AndReplenishment

11 02 01,07

1.MaterialRequirementsPlanning(MRP)EnterpriseResourcePlanning(ERP),


CasestudyonProcurement-Outsourcing.

• E-Procurement• E-Marketplaces• ERPMODULES

2.WarehouseManagementSystemsCollaborativeLogistics,DistributionOutsourcing3.Finance/Accounting-Sales/Marketing-Production/MaterialsManagement-HumanResources

12 04 01,04,07

QUALITYMANAGEMENT1.QualityfromTheCustomer’sPerspectiveDimensionsofQualityforManufacturedProductsDimensionsofQualityforServices

PracticeonQualityTools

• ProcessFlowcharts• 5Whys,Cause-And-EffectDiagrams• ChecksheetsAndHistograms• ParetoAnalysis• ScatterDiagrams

2.QualityfromTheProducer’sPerspectiveAFinalPerspectiveOnQualityTheCostofQualityTheCostofAchievingGoodQuality3.TheCostofPoorQualityTheQuality–ProductivityRatioQualityManagementSystem

13 04 04,05,07

1.TQMandQMSTheFocusofQualityManagement—Customers Practiceon

TheDemingWheel(PDCACycle)• ProcessControlCharts• StatisticalQualityControl• ISO9000• ISO14000

2.QualityManagementinTheSupplyChainTheRoleofEmployeesinQualityImprovementKaizenandContinuousImprovementQualityCircles3.ProcessImprovementTeamsSixSigmaTheBreakthroughStrategy:DMAIC






01

Belowaremonthlysalesoflightbulbsfromthelightingstore.Forecastsales forJuneusingthefollowing

• Naivemethod• Three-monthsimplemovingaverage• Three-monthweightedmovingaverageusingweightsof0.5,0.3and0.2• Exponentialsmoothingusinganalphaof0.2andaMayforecastof350.

MONTH Jan Feb March April May JuneSALES 50 200 80 40 360

02

DelphManufacturingCompanyisgoingtopurchaseanautopartscomponentfromoneoftwocompetingsuppliers.Delphisgoingtobaseitsdecision,inpart,onthesupplychainperformanceofthetwosuppliers.Thecompanyhasobtainedthefollowingdataforaveragerawmaterials,work-in-process,andfinishedgoodsinventoryvalue,aswellascostofgoodssoldforthesuppliers

Items Supplier1 Supplier2Costofgoodssold Rs8,360,000 14,800,000Rawmaterials 270,000 870,000Work-In-Progress 62,000 550,000Finishedgoods 33,000 150,000

Eachcompanyoperates52weeksperyear.Determinewhichsupplierhasthebestsupplychainperformanceaccordingtoinventoryturnsandweeksofsupply.Whatotherfactorswouldthecompanylikelytakeintoaccountinselectingasupplier?

03

Themaintenancedepartmentforasmallmanufacturingfirmhasresponsibilityformaintaininganinventoryofsparepartsforthemachineryitservices.Thepartsinventory,unitcost,andannualusageareasfollowsThedepartmentmanagerwantstoclassifytheinventorypartsaccordingtotheABCsystemtodeterminewhichstocksofpartsshouldmostcloselybemonitored

Part UnitCost(Rs) AnnualUsage

1 100 902 350 403 30 1304 20 1805 320 50

04

Thedesigncapacityforenginerepairinourcompanyis80trucks/day.Theeffectivecapacityis40engines/dayandtheactualoutputis36engines/day.Calculatetheutilizationandefficiencyoftheoperation.Iftheefficiencyfornextmonthisexpectedtobe82%,whatistheexpectedoutput?

05

Countyschoolbusesareinspectedeverymonthfor“defects.”Inarecentmonthlyinspection,27wornortornseatswerefound,22buseshaddirtyfloors,therewere14casesofexteriorscratchesandchippedpaint,therewere8crackedorbrokenwindows,theengineson4buseshadtroublestartingorwerenotrunningsmoothly,and2buseshadfaultybrakes.DevelopaParetochartforthebusinspectionsandindicatethemostsignificantquality-problemcategories.WhatdoesthistellyouaboutthelimitationsofapplyingParetochartanalysis?HowmighttheselimitationsbeovercomeinParetochartanalysis

06 StudyandprepareareportonInventorymanagementinASuperBazaar07 CasestudyonSupplychainManagementinAmazon,Flikartetc08 CasestudyonuseofERPinAnEducationInstitution(FromAdmissiontoAwardofDegree)09 CasestudyonlogisticsmanagementinSwiggy,Zomoto,Dunzoetc


4.CIEandSEEAssessmentMethodologies

Sl.No Assessment TestWeekDuration

Inminutes Maxmarks Conversion


2. CIE-2WrittenTest 9 80 303 CIE-3WrittenTest 13 80 304. CIE-4SkillTest-Practice 6 180 100 Averageoftwo

skilltestreducedto205 CIE-5SkillTest-Practice 12 180 100


1-13 10 10


TotalMarks 100

5.FormatforCIEwrittenTestCourseName OperationManagement Test I/II/III Sem IVCourseCode 20ME41P Duration 80Min Marks 30Note:Answeranyonefullquestionfromeachsection.Eachfullquestioncarries10marks.


CourseOutcome Marks

I1 2

II3 4

III5 6




1 01 OneQuestion-Problems/CasestudyonDemandforecasting/MasterScheduling/CapacityPlanning

45

2 01,03 BasedonthegivenCaseStudy,PrepareaJobProcesschartwithProcessSymbols/DevelopaMan-Machinechart

45

3 01,03 PortfolioevaluationbasedontheaverageofallPracticeSessions(1-6Weeks) 10TotalMarks 100



1 O2 OneQuestiononInventoryManagementandSupplyChainManagement(JIT/KanbanSystem/E-Business/)

45

2 O4 Forthegivencasestudy,PreparetheCostofachievinggoodQualityusinganyqualityTools

45

3 02,04 PortfolioevaluationbasedontheaverageofallPracticeSessions(7-12weeks) 10TotalMarks 100



Sl.No.





7.Reference:Sl.No. Description

1 ProductionandOperationsManagement–CreatingValuealongtheSupplyChainByRusselandTaylor,WileyPublications,7 Edition

2 ModernProductionandOperationManagementByBuffaandSarin,WileyPublications,8 edition3 ProductionandOperationsManagementByChary,TataMcGrawHillPublications

4 ProductionandOperationsManagement-Concepts,ModelsandBehaviourByAdamandEbert,PrenticeHallPublications


1. www.youtube.com/watch?v=SF53ZZsP4ik2. www.youtube.com/watch?v=iPZlQ3Zx5zc

9.SEESchemeofEvaluationDuration:180MinSL.No.


1

O1,02,03

OneQuestion-Problems/CasestudyonDemandforecasting/MasterScheduling/CapacityPlanningORBasedonthegivenCaseStudy,PrepareaJobProcesschartwithProcessSymbols/DevelopaMan-Machinechart

40

2

O3,O4

OneTheoryQuestiononInventoryManagementandSupplyChainManagement(JIT/KanbanSystem/E-Business/)ORForthegivencasestudy,PreparetheCostofachievinggoodQualityusinganyqualityTools

40

3 01,0203,04 Vivavoce 20 TotalMarks 100

10.Tools/Equipment/Software’sRequired

1.ERPSoftware




1.Rationale:Inrecentyearsthemanufacturingenvironmenthasundergonedramaticchange.Forachievingmarketgoals,itisessentialtoproducequalitypartsinlesstime.Evolutionofinformationtechnology,varietymanufacturingconceptswithzeroleadtimedemandandqualityconsciousnesshavesupportedfastadaptionofcomputerizednumericalcontrol (CNC)machines.As inhumanbeings’mentalability isbecomingmoreimportantthanphysicalabilitytodothemanualwork,similarlyCNCprogramminginthesamewayhasmoreimportancealongwithselectionanduseofCNCtooling.Inthiscoursethereforeanattempthasbeenmadetodevelopskillsrequiredforprogramming,toolingetcforCNCmachine.CNCmachinesnormallyarenotlimitedtomachine toolsonlybut realmofCNChaswidened in almost all areasofmanufacturing,processes andsupportactivities.ItisthereforeveryimportantforDiplomamechanicalengineerstomasterCNCtechnology.

2.CourseOutcomes/SkillSets:Attheendofthiscourse,studentwillbeableto:

3.CourseContent

Week CO PO*

Lecture(Knowledge)

Tutorial(Activity)

Practice(Skill)



1 01 01

1.IntroductiontoCNCMachines-AdvantagesofCNCmachinesoverConventionalmachines2.ExplaintheConstructionfeaturesofCNCmachine-MachineStructure,bed,spindlemotoranddrive,axesmotorandballscrewsusingMultimedia3.ExplainGuideways,LMguides,console,controlswitches,coolantsystem,hydraulicsystemusingMultimedia

RefTable1

1.DemonstratePersonal,Conduct,ShopetiquettesandgeneralsafetypracticesinCNCmachineComplysafehandlingofCNCmachines,toolsandEquipment.2.DemonstrationofCNCmachineanditsparts-bed,spindlemotoranddrive,axesmotorandballscrews,guideways,LM



CourseName CNCProgrammingandMachining ContactHours8hours/week104hours/semester

TeachingScheme



CO-01 IdentifyvariouscomponentsofaCNCmachineandlisttheuseofthosecomponentsforanygivenCNCoperation.

CO-02 Studyagivenproductiondrawingandlisttherighttoolsneededtoproduceaproductasperthedrawing.

CO-03 Write a CNC turning and milling program for a given production drawing, simulate theprogramandexecutetheprograminproductionmode.

CO-04 Develop and/or import a 3-D model of a given component drawing, generate the CNCprogrammingcodesusingCAMsoftwareandexecutetheprograminproductionmode.


guides,console,controlswitches,coolantsystem,hydraulicsystem,3.Identificationofsafetyswitches,machineovertravellimitsandemergencystop.Machinestarting&operatinginReferencePoint,JOGandIncrementalModes

2 01,02 01

1.ExplainAxisconventionofCNCmachine2.ExplainCuttingtoolmaterials,cuttingtoolgeometry–inserttypes,holdertypes,insertcuttingedgegeometry.3.ISOnomenclatureforturningtoolholders,boringtoolholders,indexableinserts.-Toolholdersandinsertsforradialgrooving,facegrooving,threading,drilling

RefTable1

1.ConductapreliminarycheckofthereadinessoftheCNCmachineviz.,cleanlinessofmachine,referencing–zeroreturn,2.Functioningoflubrication,coolantlevel,correctworkingofsub-system

3 01,02 01,04

1.ExplainAutomatictoolexchangerusingMultimedia2.ExplaintheimportanceofToollengthcompensation,ToolnoseRadiuscompensationandToolWearcompensation.3.ExplainMachineZeroandWorkZero

RefTable1

1.PerformWorkandtoolsetting:-Jobzero/workcoordinatesystemandtoolsetupandlivetoolsetup2.CNCmachiningcentreoperationinvariousmodes:JOG,EDIT,MDI,SINGLEBLOCK,AUTO3.Settingthetooloffsets,entryoftoolnoseradiusandorientationinCNCconsole

4 03 01,04

1.ExplainProgrammingsequenceandformat-AbsoluteandIncrementalSystem2.ExplainGcodesandMcodes3.ExplainLinearinterpolationandCircularInterpolation

RefTable1

1.GeometryWearCorrection.GeometryandwearoffsetcorrectioninCNCConsole2.Programcheckingindryrun,singleblockmodes

5. 03 01

1.ExplaincuttingParameters–Feed,Speedanddepthofcutw.r.tCNCmachineasperCatalogue2.ExplainCannedCycle,MirroringandSubroutines

RefTable1

1.Learnvariousnumericalkeys,AddressKeys,functionalKeysofoperationalconsole

6. 03 01,04

WritethePartProgramforFacing,Turning,StepturningandTaperturning(WriteProgramfor3modelsandexecuteanyoneonthemachine)

RefTable1

1.InputtheProgramintotheSimulatorandoperatetheSimulator2.TransferthesimulatedProgramtomachine


3.SetthemachinewithnecessarytoolsandJob4.ExecutethePrograminAutomodetoproducetheJob.

7. 03 01,04

WritethePartProgramforTurning,ProfileturningandThreadcutting(WriteProgramfor3modelsandexecuteanyoneonthemachine)

RefTable1

1.InputtheProgramintotheSimulatorandoperatetheSimulator2.TransferthesimulatedProgramtomachine3.SetthemachinewithnecessarytoolsandJob4.ExecutethePrograminAutomodetoproducetheJob

8. 03 01,04

WriteaCNCmillingprogramforPocketmachining(WriteProgramfor3modelsandexecuteanyoneonthemachine)

RefTable1


9 03 01,04

Writeapartprogramfordrilling4holesinaplateSixholesalongPCDonacircularplate

RefTable1


10. 03 01,04,07WriteaProgramusingMirroringWriteaProgramusingSubroutines

RefTable1



11 04 01,04,07

GeneratethePartProgramforComponentrequiringTurning,StepturningProfileturningandThreadcuttingbyusingCAMsoftware(Programfor3modelsandexecuteanyoneonthemachine)


1.TransferthesimulatedProgramtomachine2.SetthemachinewithnecessarytoolsandJob3.ExecutethePrograminAutomodetoproducetheJob

12 04 01,04,07

GenerateaCNCprogramforcomponenthavingPocketmachiningusingCAMsoftware(Programfor3modelsandexecuteanyoneonthemachine)

1.TransferthesimulatedProgramtomachine2.SetthemachinewithnecessarytoolsandJob3.ExecutethePrograminAutomodetoproducetheJob

13

Demonstrate the manufacturing offollowing components on CNCmachinesusingYouTubeVideos1. CNCTurning2. Rollers3. Spacers4. Brackets


DemonstratethemanufacturingoffollowingcomponentsonCNCmachinesusingYouTubeVideos

1. Spindles2. Frames3. EngineBlock4. BallBearings






01

DiscussthestepsforchoosingtheRightCNCmachinetoolusingvariousparameterslikeoperatorexperience,Materialtobecut,Partdifficultyandcomplexity,LMguides,Controlsystems,Costperpart,Availabilityofspace.www.hwaheonasia.com

02PresentationonMacrosandParametricProgramminginCNCbydiscussingbasicmacroskill-Macrocapability,commonfeaturesandapplications-Macrostructurewww.thomasnet.com

03

DiscussandpresentareportoninfluenceofcoolantinCNCbyexplainingPurpose-deliverymethodsofcoolants-Typesofcoolants-Healthandsafetyissues-Properties-Recyclinganddisposalofcuttinglubricantswww.Industr.com

04 EachstudenthastoPresentminimum5CNCProgrammingonMachininginvolvingTurning,MillingandDrilling.(CoursecoordinatorhastoensurenorepetitionofthePrograms)




Maxmarks

Conversion



testreducedto20ltests20

5 CIE-5SkillTest-Practice 12 180 100


1-13 10 10


TotalMarks 100

5.FormatforCIEwrittenTestCourseName OperationManagement Test I/II/III Sem IVCourseCode 20ME41P Duration 80Min Marks 30Note:Answeranyonefullquestionfromeachsection.Eachfullquestioncarries10marks.


CourseOutcome Marks

I1 2

II3 4

III5 6


5.(a)CIESkillTest-4Duration:240MinSL.No.


1 02,04 OneQuestiononWritingCNCprogramForTurningModel,SimulationandPreparationoftheMODELonCNCMachine

• WritingCNCprogram—30Marks• Editingtheprogram—30Marks• SimulationandPreparationoftheMODELonCNCMachine-30

Marks

90


10

TotalMarks 100

5.(b)CIESkillTest-5Duration:240MinSL.No.



1 02,03 OneQuestiononWritingCNCprogramForMillingModel,SimulationandPreparationoftheMODELonCNCMachine

• WritingCNCprogram—25Marks• EditingtheProgram—15Marks• SimulationandPreparationoftheMODELonCNCMachine-10Marks

50

2

02,04

OneQuestiononGeneratingCNCTurningProgram/MillingProgram,UsingCAMSoftware,SimulationandPreparationoftheMODELonCNCMachine.

• PreparationofSolidModelforagivenDrawingusingsoftware-25marks

• GenerateTurningProgram/MillingProgram,UsingCAMSoftware-05Marks

• InterfacewiththeCNCmachineandproducethemodel-10Marks

40

3 02,03,04 PortfolioevaluationbasedontheaverageofallPracticeSessions(7-12Weeks)

10

TotalMarks 100


Sl.No.




7.Reference:Sl.No. Description

1Automation,ProductionSystems,andComputer-AidedManufacturingbyMikellP.GrooverPrentice-HallInternationalpublication

2 CAD/CAMPrinciplesandApplicationsPNRaoMcGrawHillEducation3 CNCMachines.PablaB.S.,AdithanM.NewAgeInternational,NewDelhi,2014(reprint)4 ComputerNumericalControl-TurningandMachiningcenters.QuesadaRobertPrenticeHall20148.LISTOFSOFTWARES/LEARNINGWEBSITES:

1. http://www.nptel.ac.in2. http://www.youtube.com/watch?v=M3eX2PKM1RI3. http://www.youtube.com/watch?v=EHQ4QIDqENI&list=PLBkqkLQO2nAt5MNLo4. http://www.youtube.com/watch?v=hJFLcvtiNQI5. http://www.youtube.com/watch?v=BIM1AyxfYkw.6. http://www.mtabindia.com7. http://www.swansoftcncsimulator.com

9.SEESchemeofEvaluationDuration:180MinSL.No.



1

02,03

OneQuestiononWritingCNCprogramForTurningModel,SimulationandPreparationoftheMODELonCNCMachine

• WritingCNCprogram—30Marks• SimulationandPreparationoftheMODELonCNCMachine-20Marks

OROneQuestiononWritingCNCprogramForMillingModel,SimulationandPreparationoftheMODELonCNCMachine

• WritingCNCprogram—30Marks• SimulationandPreparationoftheMODELonCNCMachine-20

Marks

50

2 02,04 OneQuestiononPreparingaSolidModelandGeneratingCNCTurningProgram/MillingProgram,UsingCAMSoftware,

• PreparationofSolidModelforagivenDrawingusingsoftware–20marks

• GenerateCNCTurningProgram/MillingProgram,UsingCAMSoftware-10Marks

30

3 01,02,03,04 Vivavoce 20TotalMarks 100


Sl.No.

Particulars Specification Quantity

01CNCTurningCentre(TutororProductive)

Minimumdiameter25mm,Length120mmwithATC.(Approximate)

01

02

CNCMillingCentre(TutororProductive)Xaxistravel-225mm,Yaxistravel-150mm,Zaxistravel-115mm,WithATC.(Approximate)

Xaxistravel-225mm,Yaxistravel-150mm,Zaxistravel-115mm,WithATC.(Approximate)

01

03Simulationsoftwarelikes:CNCSimulatorPro,SwansoftCNC,etc.

20user

04 LatestversionofCAD/CAMintegrationsoftwarelikeMASTERCAM,NXCAMOREDGECAM

20user

05 Desktopcomputer Latestconfiguration 20no




1. Rationale: Design department of industry is one of the major job areas for Diploma engineers. ThefundamentalknowledgeofStrengthofMaterials,EngineeringMaterials,andComputerAidedDesignandDraftingisessentialtomeetjobrequirementinthissector.Toenableastudenttoworkhere,theyshouldknowhowtodesignasimplemachineelement,usualproceduresindevelopmentofproduct,fundamentalknowledgeindesignof simplemachineelements suchas shafts, springs, couplingsetc, codes,norms, standardsandguidelines forselectionofappropriatematerial.Inadditiontothis,Diplomaengineersarerequiredtoreadandinterpretthedrawings.Therefore,itisessentialthattheyhavecompetencyinpreparingdrawingsofmachineparts.Thiscourseaimsatdevelopinganalyticalabilitiesinthestudenttogivesolutionstosimpleengineeringdesignproblemsusingstandardprocedures.Hencethiscoursehasbeenintroducedwiththeexpectationsthateffortswillbemadetoprovideappropriatelearningexperiencesintheuseofbasicprinciplestothedesignsolutionforappliedproblemstodeveloptherequiredskillandcompetencies.

2.CourseOutcomes/SkillSets:AttheendoftheCourse,thestudentwillbeableto:CO-01 ExplainthekeyprinciplesofproductdesignconsideringStrength,AestheticandErgonomic

CO-02 Design simple machine elements like shafts, springs, couplings and knuckle joints usingstandarddata.

CO-03 PrepareCADPartandAssemblydrawingsforcouplingsandknucklejointsbasedondesignedparameter.

CO-04 ProduceComponentbasedondesignedParametersusing3-DPrintingTechniques

3.CourseContent

Week CO PO*

Lecture(Knowledge)

Tutorial(Activity)

Practice(Skill)

3hours/week 1hour/week

4hours/week(2hours/batchtwice

inaweek)

1 01 01

Product Development andDesign:1.Explain Product Development-Stages of Product Development-NeedandFeasibilitystudy2.Explain Development of design-SelectionofMaterialsandProcess3.Explain Protype –launching ofproduct–Productlifecycle

RefTable1DiscusscasestudiesofProduct developmentbyusingVideo

2

01

01

Generalconsiderationindesign:Basedon• Functionalrequirement• Effectonenvironment• Life,Reliability,Safety

RefTable1 Casestudy

Programme MechanicalEngineeringDiploma Semester IV


CourseName ProductDesignandDevelopment ContactHours8hours/week104hours/semester




• PrinciplesofStandardization• AssemblyFeasibility• Maintenance-Cost-Quantity• LegalissuesandPatents• AestheticandErgonomicfactors• ChoiceofMaterials• FeasibilityofManufacturingProcesses

3 01 01

AestheticandErgonomicconsiderationinDesign:• ExplainAestheticconsiderations-Basictypesofproductforms,Designingforappearance,shape,Designfeatures,Materials,Finishes,proportions,SymmetryContrastetc.• Morgan’scolorcode.• Ergonomicconsiderations-Relationbetweenman,machineandenvironmentalfactors.Designofdisplaysandcontrols.

RefTable1

CaseStudyonErgonomicsandAestheticdesignprinciples.

4 02 03,04

TorsionofShaft:1.AssumptionsinShearstressinashaftsubjectedtotorsion–StrengthandRigidity(SolidandHollowshaft)2.PowerTransmittedbySolidandHollowshaft-ASMEandBISCodeforpowerTransmission3.ProblemsonShaftssubjectedtoonlyShearbasedonRigidityandStrength

RefTable1

1.ValidatetheProblemsonShaftsforStrengthandRigidityusingAnsys(OneeachonStrengthandRigidity)

5 02 03,04

1.ProblemsonShaftssubjectedtoonlyShearbasedonRigidityandStrength2.ProblemsonShaftsubjectedtoonlyBending3.ProblemsonShaftsubjectedtoonlyBending

RefTable1

1.RecapofCADcommands

2.PracticeonSectionofSolids-a)Prismsb)Pyramid

6 02 03,04

1ProblemsonShaftsubjectedtocombinedShearandBending.2.ProblemsonShaftsubjectedtocombinedShearandBending3.ProblemsonShaftsubjectedtocombinedShearandBending

RefTable1

1.PracticeonSectionofSolids-a)Cylinderb)Cone

7 02,03 03,04

Springs:1.Classificationofsprings-Applicationofsprings-Leafsprings–Application

RefTable1

SectionsonSimpleMachineElements(CAD)a)Sectionalfrontview,Frontviewwith


2.TerminologyofHelicalspring-MaterialsandSpecificationofsprings3.Designofhelicalspring

RighthalfinSection,FrontviewwithLefthalfinSectionb)SectionalTopViewc)SectionalSideView

8 02,03 03,04 Designofhelicalspring RefTable1

SectionsonSimpleMachineElements(CAD)a)Sectionalfrontview,FrontviewwithRighthalfinSection,FrontviewwithLefthalfinSectionb)SectionalTopViewc)SectionalSideView

9 02,03 03,04

Coupling:DesignofMuffcoupling

RefTable1

UsingCAD,preparePartModelsforMuffcouplingbasedondesignedparameterandassemblethesame.ExtracttheSectionalviewsfortheabovemachineelementindicatingSurfaceTextureandBillofMaterials

10 02,03 03,04DesignofProtectedtypeFlangeCoupling

RefTable1

UsingCAD,preparePartModelsforProtectedtypeFlangeCouplingbasedondesignedparameterandassemblethesame.ExtractSectionalviewsfortheabovemachineelementindicatingSurfaceTextureandBillofMaterials

11 02,03, 03,04,07 DesignofKnuckleJoint

UsingCAD,preparePartModelsforKnuckleJointbasedondesignedparameterandassemblethesame.ExtractSectionalviewsfortheabovemachineelementindicatingSurfaceTextureandBillofMaterials

12 04 03,04,073DPrinting1. Introduction,Process,Classifications,Advantagesof


additiveoverconventionalManufacturing,Applications,ModellingforAdditiveManufacturing2.AdditiveManufacturingTechniques,3DPrintingMaterialsanditsforms,PostProcessingRequirementandTechniques.

3. ProductQuality,InspectionandTesting,Defectsandtheircauses,AdditiveManufacturingApplicationDomains


Preparationof3DPrinterforprinting–Modelling,SavingCADfileintoSTLfile,Slicing,Materialloadingandprintingparameterselection

13 04 03,04,07

1.WorkingofFusedDepositionModelling(FDM)Machine-SingleandMultiNozzleprinters,MachineConfiguration-Cartesian,Delta,Polarandroboticarmconfiguration3Dprinters

2.CommonFDMmaterials-PLA,ABS,PA,TPU,PETG,PEEKandPEI,PrinterParameters-Temperatureofthenozzleandtheplatform,thebuildspeed,thelayerheight,Warping,LayerAdhesion,SupportStructure,In-fill&ShellThickness

3.Benefits&LimitationsofFDM,SoftwareTools-3Dmodelling,Slicers&3DPrinterHosts

PrintingofDesignedandModelledcomponent(flangecouplingandknucklejoint)onanyavailable3Dprintingmachineandcarryoutpostprocessingofadditivelymanufacturedproduct(Inspectionanddefectanalysis).





01

PresentationondesignofBicyclesforIndianchildrenfocusingonAestheticandErgonomicsbyExplainingmarketanalysis-userstudy–Problemidentification–Productdesignandspecification-Conceptgeneration-MaterialandManufacturingProcesses-Finalconceptselectionwww.sastechjournal.com

02PresentationontypesofsuspensionspringsusedinAutomobilevehiclesbyexplainingleaf-spring,Coilspring,TorsionSpring,Airbags,RubberSpringswww.theengineerspost.com

03PresentationondifferenttypesofKeysusedinTransmissionsystemandimportancesuchasparallelkey,Saddlekey,SunkKey,Gibheadedkey,FeatherKey,WoorruffKeywithAdvantagesandapplications

04 PresentationonAntifrictionBearingbyexplainingrollingcontact-journalballbearingconstruction-Cylindricalbearing–Needlebearing–FootstepBearing–PlumberBearing


05 PresentationonFrictionClutchesusedinAutomobilesbyexplainingparts-Singleplate-Multiplate-Purpose–Application

06 The Role of Additive Manufacturing in the Era of Industry 4.0 07 Application of Additive Manufacturing in health care industry 4.CIEandSEEAssessmentMethodologiesSl.No


Maxmarks

Conversion

1. CIE-1WrittenTest 5 80 30 Averageofthreetests302. CIE-2WrittenTest 9 80 30

3 CIE-3WrittenTest 13 80 304. CIE-4SkillTest-Practice 6 180 100 Averageoftwoskilltest

reducedto205 CIE-5SkillTest-Practice 12 180 100


1-13 10 10


TotalMarks 100

5.FormatforCIEwrittenTest

CourseName Production Design andDevelopment

Test I/II/III Sem IV

CourseCode 20ME43P Duration 80Min Marks 30Note:Answeranyonefullquestionfromeachsection.Eachfullquestioncarries10marks.


CourseOutcome Marks

I1 2

II3 4

III5 6

Note for theCoursecoordinator:Eachquestionmayhaveone, twoor threesubdivisions.Optionalquestions ineachsectioncarrythesameweightageofmarks,Cognitivelevelandcourseoutcomes.



1

02

OneQuestiononDesignofShaftSubjectedtoStrengthandRigidity• FixingtheDiameterofShaftafterdesign---30Marks• ValidatetheDesignedparametersofShaftforStrengthand

TwistingusingAnsys-30Marks

60

2 03 OnequestiononSectionofSolids(Prism/Pyramid/Cone/Cylinder)• PlacingtheSectionplaneanddrawingthesection–20Marks• ExtractingtheTrueshapeoftheSection–10Marks

30


10

TotalMarks 100




1

03,04

OneQuestiononDesignandAssemblydrawingofSimpleMachinepartslikeMuffCoupling/FlangeCoupling/KnuckleJoint

• DesignofSimpleMachinepartbyusingDataHandBook--35Marks• PreparationofPartModelsfortheDesignedvaluesbyusingCAD

Software--35Marks• AssemblyofPartModelsusingCADsoftwareWithBillofMaterials-

-20Marks

90


10

TotalMarks 100


Sl.No.




7.Reference:Sl.No. Description1 ATextbookofMachineDesignR.S.Khurmi&J.K.GuptaS.Chandpublication2 MachinedesignSGKulkarniMcGrawHillEducationPublications3 IntroductiontoMachinedesignVBBhandariMcGrawHillEducationPublications4 DesignOfMachineElementsVolI,VolIIJ.B.K.Das,P.L.SrinivasMurthySapnaPublication5 MachineComponentDesignWilliamOrthweinJaicopublication

6 Design Data Hand Book forMechanical Engineers KMahadevan & K Balaveera Reddy CBSpublications

7 Khanna Editorial, “3D Printing and Design”, Khanna Publishing House, Delhi.

8 J.D. Majumdar and I. Manna, “Laser-Assisted Fabrication of Materials”, Springer Series in Material Science, 2013

9D.T. Pham and S.S. Dimov, “Rapid manufacturing: The technologies and applications of rapid prototyping and rapid tooling”, London-New York, Springer, 2001

10 Lan Gibson, David W. Rosen and Brent Stucker, “Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing”, Springer, 2010

11Andreas Gebhardt, “Understanding Additive Manufacturing: Rapid Prototyping, Rapid Tooling, Rapid Manufacturing”, Hanser Publisher, 2011.

12 CK Chua, Kah Fai Leong, “3D Printing and Rapid Prototyping- Principles and Applications”, World Scientific, 2017


13 L. Lu, J. Fuh and Y.S. Wong, “Laser-Induced Materials and Processes for Rapid Prototyping”, Kulwer Academic Press, 2001

14 Zhiqiang Fan And Frank Liou, “Numerical Modelling of the Additive Manufacturing (AM) Processes of Titanium Alloy”, InTech, 2012

8.LISTSOFTWARES/WEBSITES

1.http://nptel.ac.in/courses/Webcourse-contents/IIT%20Kharagpur/Machine%20design1/left home.html2http://nptel.ac.in/courses/Webcourse-contents/IIT%20Kharagpur/Machine%20design1/left mod4.html

9.SEESchemeofEvaluationDuration:180Min

SL.No.


1

02,03

OneQuestiononDesignandAssemblyofSimpleMachinepartslikeMuffcoupling/FlangeCoupling/KnuckleJoint

• DesignofSimpleMachinepartbyusingDataHandBook-----35Marks

• PreparationofPartModelsfortheDesignedvalvesByusingCADSoftware—25Marks

• AssemblyofPartModelsByusingCADSoftwareWithBillofMaterials---20Marks

80

2 01,02,03,04 Vivavoce 20

TotalMarks 100


Sl.

No.Particulars Specification Quantity

01 LatestversionofCADsoftware ------------ 20user

02 Desktopcomputer Latestconfiguration 20no’s

03 Laserprinter ----------------- 02no’s04 3-DPrintingMachine 01no


GovernmentofKarnatakaDEPARTMENTOFCOLLEGIATEANDTECHNICALEDUCATION

1.Rationale:Inpresentscenario,Manufacturingindustriesaremovingtowardscompleteautomation.SmallandmediumindustriesareinaphaseofswitchingtoPLCandSCADAtechnologyfordataacquisitionandcontrol. Industrialautomationsystemsareused tocontrolandmonitoraprocess,machineordevice inacomputerized manner that usually fulfils repetitive functions or tasks. They are intended to operateautomaticallyinordertoreduceandimprovehumanworkintheindustry.Advantagesofthistechnologyiscommonlyattributedtohigherproductionratesandincreasedproductivity,moreefficientuseofmaterials,better product quality, improved safety, shorter workweeks for labour, and reduced factory lead times.TheAutomation Engineerwill design, program, simulate and commissionautomatedmachines and plant-wideprocessestoperformmanyjobfunctions.Dependingonthesizeoftheorganization,theengineerwillperform some or all of these responsibilities. Therefore, it is necessary for diploma engineers to haveknowledgeofbothPLCandSCADAtechnology.Thiscourseattemptstoprovidebasictheoreticalandpracticalaspectsofautomationtechnologiestodevelopoperationalcompetency.Hencethiscourseisthefoundationfordiplomaengineerswhowanttofurtherspecialiseinthefieldofindustrialautomation2.CourseOutcomes:Attheendofthiscourse,studentwillbeableto

3.CourseContent

Week CO PO*

Lecture

(Knowledge)

Tutorial(Activity)

Practice

(Skill)



1 01 01 Introduction: RefTable1 Study the followingappliances/ automation



CourseName ElementsofIndustrialAutomation ContactHours8hours/week104hours/semester

TeachingScheme



CO-01 Selecttherightsensorand/oractuatorforautomatingagivenapplicationanddemonstrateprocessvariablesusingsensorsand/ortransducers.

CO-02 PerformspecifiedcontrolfunctionsusingaProgrammableLogicController(PLC)andlistvariousapplicationsofembeddedsystems.

CO-03 Designandtestanautomationsystemforarequiredoperationalspecificationandtroubleshoottoresolveanygivenissue(s).

CO-04 ExplaintheconceptsofSCADA,HMIandDCSandlisttheirvariousapplications


1. Need and benefits ofIndustrial Automation,Automation Hierarchy, Basiccomponents of automationsystem, description of eachcomponent

2. Automation technology as apart of engineering sciences,Keydevelopmentmilestones inthe history of automationtechnology, Effects ofautomationonpeople.

3.Typesofautomationsystem:-RelaylogicandPLC

systems and identifyvarious elements used andtheirfunction

1. AirconditioningSystem2. Automatic water levelcontrol3. Elevator( for ThreeFloor)4. WashingMachine

Write the Block DiagramForeachandexplainwithaMultimediaPresentation

2 01 01

Programmable logiccontroller:

1. Introduction, CompareRelayLogicControlandPLCLogic Control, InternalArchitectureofPLC

2. I/O Modules (Interfaces),Memoryorganization.

Inputdevices:

• MechanicalSwitches• ProximitySwitches

3.Inputdevices:

• PhotoelectricSensorsandSwitches• Encoders• TemperatureSensors• Position/DisplacementSensors

RefTable1

DemonstratetheworkingofbelowshownSwitches/Sensor.

a. VariousindustrialSwitches(PushButton,ON/OFF,Toggle,Emergency,RotarySwitchesetc.)

b. Proximity-Inductive,CapacitiveandOpticalSensor

c. TemperatureSensordFloatSensors

Note: Connect each

sensor directly to the

LED/Lamp with

appropriate power

supply

3 01 01

1.Inputdevices:

• StrainGauges• PressureSensors• Liquidleveldetectors2.Inputdevices:

• Fluidflowmeasurement• SmartSensors3.OutputDevices:

• Relay• Directional controlValve

RefTable1

You tube presentation onInputandOutputdevices


4 01 01

1. ADCandDAC

2.Motors- DC motor,Synchronous motor, Servomotor,

3.Induction motor, Steppermotor

RefTable1

Demonstrate the Forwardand Reversal of Stepper,Servo and DCMotors withthehelpofDrivers.

Note: Demonstrate the

above without using any

controllers

5 02 02

PLCProgramming:

1. Programming standards,List Different PLCProgramming, Ladderdiagram,

2. Standard IEC 1131-3Symbols used for I/ODevices

3. Ladder diagram for logicgates.AND,OR,NOT,NAND,NOR,XOR,XNOR

RefTable1

• Execute energizedmotor or bulb usingSwitches in series orParallel• Write ladderdiagram to testdigitallogicgatesandExecute/Simulatethesame.

6 02 01

1. Writing Equivalentladderdiagramfor

Electric Switch,Belt drive ,motorcircuit

Latching,SequentialO/P

2.

IntroductiontoTimerfunctions.Applicationsoftimingfunctionsinprocesscontrol--OnDelayTimerFunction,Off-delayTimerFunction

RefTable1

• There are 3 mixingdevices on a processingline A,B ,C. After theprocessbeginmixer-Aistostart after 7 secondselapse, nextmixer-B is tostart 3.6 second after A.Mixer-C is to start 5secondsafterB.Allofthenremain ON until amasterenableswitchisturnedoff.Develop PLC ladderdiagram, timing diagramandsimulatethesame• Write a LadderProgram to count thenumber of Items moving


3. PLC counter functions,ApplicationsofPLCcounterfunctioninprocesscontrol

on a conveyor Belt andExecute/Simulate thesame

7 03 02

1) Relay, Jumps andSubroutines

2) DevelopLadderProgramfor relay based motorcontrol automation suchthat the motor reversesits direction when thelimit switches areactivated

3) Develop a PLC ladderdiagram to construct an alarmsystem which operates asfollows.

- IfoneinputisONnothinghappens.- IfanytwoinputsareON,aredlightgoesON.- If any three inputs areON,analarmsirenssound.- If all are ON, the firedepartmentisnotified.

RefTable1

• Execute the LadderProgram for relay basedmotor control automationsuch that the motorreversesitsdirectionwhenthe limit switches areactivated and alsoDemonstratebyinterfacingwithPLC

• Simulate the PLCladder diagram developedfor an alarm system andalso Demonstrate byinterfacingwithPLC

8 03 02

1 & 2) Develop PLC programfor the following applicationa)TrafficLight

3)DevelopPLCprogramforthefollowing application b)WaterLevelIndicator

RefTable1

ExecuteaPLCprogramforthefollowingapplications

i) Trafficlightcontrolling

ii)Waterlevelcontrolling

9 03 02

1 & 2) Develop automaticdoor system using opticalsensorandlinearactuator

3) Develop Automatic Elevatorcontrol

RefTable1

• Execute automaticdoorsystemusingopticalsensor and linearactuator• Design ladderdiagram for an AutomaticElevatorcontrolAlso,Testandsimulatetheladder diagram designedtooperateandcontrolthe


Automatic Elevatorcontrol

10 03 02

1 & 2) Design ladderdiagram for car parking.(Hint: car is tobedetectedandentertheparkingspaceto a particular location ifspaceisavailable.Ifthereisno space, a lamp shouldindicatethatparkingisfull)

3) Design ladder diagramfor operating andcontrollingtheLift.

RefTable1

• Simulate a ladderdiagramforcarparking.• Test and simulate aladder diagramdesigned to operateandcontroltheLift

11 02 02,07

1)EmbeddedSystem-BlockDiagram of EmbeddedSystem

2)Applications ofEmbeddedSystem

• RoboticsDrones• BrakingSystem• Air conditioning,

Refrigerator• EnginecontrolSystem,

3)Applications of EmbeddedSystem

• Automatic Washingmachine

• MicrowaveOven• Keyless entry in

Automobiles.

Study the

latest

technologica

lchangesin

this course

and present

the impact

of these

changes on

industry

You tube Presentationon Applications ofEmbeddedSystem

12 04 01,07

1)Concepts on DistributedcontrolSystem,

2)ConceptsonHMI

3)IntroductionstoSCADA

• MultimediaExposuretoDCSsystem• Demonstrate the HMIinterfacetocontrolLightinAND/ORLogic

13 04 01,07

1)Typical SCADA blockdiagram,

2)BenefitsofSCADA,

3)ApplicationsofSCADA

• MultimediaExposuretoSCADAsystemOR• Makecasestudyvisitingany nearby industry(Packaging/MilkDairy/Processing) usingHMI, SCADA/DCSsystems.







01 WriteaPLCLadderProgramtoSwitchingon/offtheLampwhethertheyareatthebottomorthetopofthestaircase.

02

Theproductionlinemaybepoweredoffaccidentallyorturnedofffornoonbreak.TheprogramistocontrolthecountertoretainthecountednumberandresumecountingafterthepoweristurnedONagain.Whenthedailyproductionreaches500,thetargetcompletedindicatorwillbeONtoremindtheoperatorforkeepingarecord.PresstheClearbuttontoclearthehistoryrecords.Thecounterwillstartcountingfrom0again.WriteaPLCLadderProgramtoperformthisoperation.

03WriteaPLCLadderProgramProvidinglubricantforthegearboxbeforethelathespindlestartstorunwhichaimstoensurethattheoilpumpmotorstartsfirstandthemainmotorstartssubsequently.

04WriteaPLCLadderProgramsuchthatOncethephotoelectricsensordetects10products,theroboticarmwillbegintopackup.Whentheactioniscompleted,theroboticarmandthecounterwillbereset.

05

DevelopPLCProgrammingExamplesonIndustrialAutomationaccordingtothelogicgivenbelow,

• ASaw,FanandoilpumpallgoONwhenastartbuttonispressed.• Ifthesawhasoperatedlessthan20s,theoilpumpshouldgooffwhenthesawis

turnedoffandthefanistorunforanadditional5saftertheshutdownofthesaw.

• Ifthesawhasoperatedformorethan20s,thefanshouldremainonuntilresetbyaseparatefanresetbuttonandtheoilpumpshouldremainonforanadditional10safterthesawisturnedoff.

06 DevelopandSimulateaPLCLadderDiagramforBottleFillingPlant

07 StudyandpresentaReportonhomeAutomation

08 StudyandpresentaReportonEmbeddedsystemsinAutomation

09 StudyandpresentaReportonAutomationinProcessingIndustries



Maxmarks

Conversion






1-13 10 10


TotalMarks 100

5.FormatforCIEwrittenTestCourseName ElementsofAutomation Test I/II/III Sem IVCourseCode 20ME44P Duration 80Min Marks 30Note:Answeranyonefullquestionfromeachsection.Eachfullquestioncarries10marks.


CourseOutcome Marks

I1 2

II3 4

III5 6

Note for theCoursecoordinator:Eachquestionmayhaveone, twoor threesubdivisions.Optionalquestions ineachsectioncarrythesameweightageofmarks,Cognitivelevelandcourseoutcomes.



1 02 SelectasuitableSensor/SwitchforagivenProcessVariableandactivate

• SelectionofSensor/Transducer–05Marks• ActivationandResult–15Marks

20

2 02 Selectasuitablemotorforthegivencaseandenergize• SelectionoftheMotor–10Marks• EnergizeandResult–20Marks

30

3 03 DevelopandSimulateasimpleladderdiagramforagivenCase• WritingLadderProgram–20Marks• SimulateandTroubleshoot-20Marks

40


10

TotalMarks 100



1 03 DeviceandSimulatealadderdiagramforthegivenCaseStudy(PLCBased)

• WritingLadderProgram–40Marks• SimulateandTroubleshoot-20Marks

60

2 04 PrepareaSCADABlockDiagramforthegivenCase 303 03,04 PortfolioevaluationbasedontheaverageofallPracticeSessions(7-12

Weeks)10

TotalMarks 100



Sl.No.





7.Reference:Sl.No. Description1 ProgrammablelogicControllersByW.BOLTON2 DigitalelectronicsByFLYOD3 ExploringPLCwithapplicationsByPRADEEPKUMARSRIVATSAVA

4 Automation , Production systems and Computer integrated Manufacturing By MIKELLGROOVER

5 SensorsHandbook-SABRIESOLOMAN-MC-GRAWHILLpublications

6 HandbookofModernSensors”Physics ,DesignsandApplications- JACOBFRADEN-SpringerPublications

7 ElectricMotorsandDrivesBYAUSTINHUGHESandBILLDRURY

8.LISTOFSOFTWARE/LEARNINGWEBSITES

1.http://www.vlab.com2.http://www.mtabindia.com3.http://www.nptel.ac.in

9.SEESchemeofEvaluationDuration:180Min


Sl.

No.Particulars Specification Quantity

01 PLCTrainerKitwiththefollowingModules 05No

SL.No.

CO


1

02

SelectasuitableSensor/SwitchforagivenProcessVariableandactivate• SelectionofSensor/Transducer–10Marks• ActivationandResult–20MarksOR

Selectasuitablemotorforthegivencaseandenergize• SelectionoftheMotor–10Marks• EnergizeandResult–20Marks

30

3 03 DeviceandSimulatealadderdiagramforthegivenCaseStudy• WritingLadderProgram–30Marks• SimulateandTroubleshoot–20Marks

50

4 01,02,03,04 Vivavoce 20

TotalMarks 100


• DoorController• CarParkingApplication• WaterLevelController• ConveyorControllerApplication• LiftcontrolApplication

WithdifferentLengthPatchCords

02

Switches• MechanicalSwitches• ProximitySwitches• PhotoelectricSensorsandSwitches

05Noeach

03

Sensors• TemperatureSensors• Position/DisplacementSensors• StrainGauges• PressureSensors• Liquidleveldetectors• Fluidflowmeasurement• SmartSensors• ProximitySensors

05Noeach

04 InductionMotorwithDOLStarter 3PhaseAc50Hz 0105 SynchroniseMotorwithDOLStarter 3PhaseAc50Hz 0106 StepperMotor Standardsize 0107 Relays Standardsize 1008 CounterandTimers Standardsize 10


GovernmentofKarnatakaDepartmentofCollegiateandTechnicalEducation

Programme AuditCourse Semester IV

CourseCode 20ME45T TypeofCourse Audit

CourseName IndianConstitution ContactHours2hours/week26hours/semester


CIEMarks 50 SEEMarks Nil


CO-01 CO1 UnderstandPreamble,salientfeaturesandimportanceofIndianConstitution.

CO-02 CO2 UnderstandFundamentalrights,dutiesandDirectiveprinciplesofstatepolicy.

CO-03

CO3

Understand Parliamentary system of governance, Structure, Functions, Power ofCentral,stategovernments(Legislative,Executive)andJudiciary.

CO-04 CO4 Understand Panchayat Raj Institutions and Local self-governments, UPSC, KPSC,NHRC,Statusofwomen,RTEetc.

2.CourseContent

Week CO DetailedCourseContentContactHours

1 1IntroductiontoconstitutionofIndia-FormationandCompositionoftheConstituentAssembly-SalientfeaturesoftheConstitution-PreambletotheIndianConstitution

2

2 1,2 FundamentalRights-Definition,Therighttoequality,Therighttofreedom,Therightagainstexploitation,Therighttofreedomofreligion. 2

3 1,2 CulturalandeducationalrightsandTherighttoconstitutionalremedies.FundamentalDuties,Directiveprinciplesofstatepolicy. 2

4 1,3Parliamentarysystemofgovernance-StructureofParliament-LokSabhaandRajyaSabha.Functionsofparliament-Legislative,Executive,FinancialFunctionPowersofLokSabhaandRajyaSabha.

2

5 1,3Procedurefollowedinparliamentinmakinglaw,Annualfinancialstatement(Budget)–procedureinparliamentwithrespecttoestimates,Appropriationbill,Supplementary,additionalgrants,Voteonaccount,votesoncreditandexceptiongrant,specialprovisions,rulesofprocedure.

2

6 1,3 Structureofunionexecutive,PowerandpositionofPresident.VicePresident,Primeministerandcouncilofministers. 2

7 1,3 Structureofthejudiciary:JurisdictionandfunctionsofSupremeCourt,highcourt,andsubordinatecourts. 2

8 1,3FederalismintheIndianconstitution-DivisionofPowers:Unionlist,Statelistandconcurrentlist.Structureofstatelegislation,LegislativeassemblyandLegislativecouncil.

2

9 1,3Functionsofstatelegislature,Structureofstateexecutive-PowersandpositionsofGovernor,Speaker,DeputySpeaker,ChiefMinisterandcouncilofminister.

2

10 4Localself-government-meaning-Threetiersystem,VillagePanchayat-TalukpanchayatZillapanchayat,Localbodies-MunicipalitiesandCorporations,BruhathMahanagaraPalike,FunctionsofElectioncommission,UPSC,KPSC.

2


11 4

Amendmentoftheconstitution,HumanRights-Definition-constitutionalprovisions-righttolifeandliberty-HumanRightsofWomen-DiscriminationagainstwomenstepsthataretobetakentoeliminatediscriminationagainstwomeninEducation,employment,healthcare,Economicandsociallife,

2

12 4

StatusofWomeninIndia-Womeninruralareas,ConstitutionalSafeguards-DowryProhibitionact1961-Domesticviolenceact2005-Sexualharassmentatworkplacebill2006.HumanRightsofChildren-Whoisachild-listtheRightsoftheChild-Righttoeducation,ProtectionofChildrenfromSexualOffencesAct(POCSO)-2012-

2

13 1,4

NationalHumanRightsCommissionConstitution-PowersandfunctionoftheCommission-Employeerights-Provisionsmade,Contractual-Noncontractualemployeerights-Whistleblowing-definition-Aspects-IntellectualPropertyRights(IPR)–Meaning-Needforprotection-Brieflydescriptionofconceptofpatents,Copyright,Trademark

2

TotalinHours 26Hrs

REFERENCES

1. IntroductiontotheConstitutionofIndia-Dr.DurgaDasBasu2. EmpowermentofruralwomeninIndia-HemalathaH.MandRameshwariVarma,HemaPrakashana.


AssessmentTestWeek

Duration

Inminutes

Maxmarks

Conversion

1. CIE-1WrittenTest 5 80 30 Averageofthreetests

302. CIE-2WrittenTest 9 80 30

3 CIE-3WrittenTest 13 80 30

4. CIE-4MCQ 6 60 20 AverageoftwoCIE=205 CIE-5OpenBookTest 12 60 20

TotalCIEMarks 50

SemesterEndExamination(Practice) - - -

TotalMarks 50

2nd year - Dayananda Sagar Institutions

Documents

Transcript of 2nd year - Dayananda Sagar Institutions