DR. A.P.J ABDUL KALAM TECHNICAL UNIVERSITY, LUCKNOW EVALUATION SCHEME & SYLLABUS FOR rd B. Tech. 3 Year Production Engineering ON CHOICE BASED CREDIT SYSTEM (CBCS) [Effective from session 2018-19] DR. A.P.J ABDUL KALAM TECHNICAL UNIVERSITY, LUCKNOW EVALUATION SCHEME PRODUCTION ENGINEERING and INDUSTRIAL PRODUCTION V SEMESTER Th/ Sessional Sl Subject Teachin Lab Cre Subject Name L-T-P Total No. Code g Deptt. Mar Te Assig dit ks st /Att RAS501 MANEGIRIAL Applied 1 3---0---0 70 20 10 100 3 ECONOMICS Science RAS502/ SOCIOLOGY /CYBER Applied 2 RUC501 3---0---0 70 20 10 100 3 SECURITY Science Design of Machine 3 RME504 3---0---0 70 20 10 100 3 Elements Manufacturing Science & 4 RME505 3---1---0 70 20 10 100 4 Technology-II Advance Welding 5 RME506 3---0---0 70 20 10 100 3 Technology RPI051, DEPT ELECTIVE 052 COURSE-1 RME- 6 052,055 Design and simulation 7 RME554 3---1---0 70 20 10 100 4 lab Manufacturing Science & 8 RME555 0---0---2 50 50 100 1 Technology-II lab Advance Welding 9 RME556 0---0---2 50 50 100 1 Technology lab Seminar – I 0--0--2 50 50 100 1 RPI559 10 TOTAL 1000 24 Department Elective Course –I 1.RPI051: Facility Planning and Layout Design. 2.RPI052: Tool Engineering 3.RME052: Mechetronics & Microprocessor 4.RME055: Advance Manufacturing Science DESIGN OF MACHINE ELEMENTS UNIT I I ntroduction Design requirements of machine elements, Principles of mechanical design, Modes of failures and Factor of Safety. Systematic design process, Aesthetic and Ergonomic considerations in design, Use of standards in design, Manufacturing consideration in design, Selection of preferred sizes, Indian Standards designation, Designation of carbon & alloy steels, Selection of materials for static and fatigue loads. UNIT II D esign for Static and Fluctuating Loads Cyclic stresses, Fatigue and endurance limit, Notch sensitivity, Stress concentration. Design for finite and infinite life, Soderberg, Goodman & Gerber criteria. S hafts, Keys and Couplings Materials for shaft, Stresses in shafts, Design of shafts subjected to twisting moment, bending m oment and combined twisting and bending moments, Shafts subjected to fatigue loads. Types of keys, splines, Selection of keys, Strength of keys, Design of rigid and flexible couplings. UNIT III D esign of Mechanical Drives Introduction to power transmission and drives. Classification of gears, Terminology, Gear tooth proportions, Tooth forms, System of gear teeth, contact ratio, Standard proportions of gear systems, Interference in involute gears, Backlash, Selection of gear materials, Gear manufacturing methods, Failure of gear tooth, Design considerations, AGMA and Indian standards, Beam strength and wear strength of gear tooth, Design of spur and helical gears. UNIT IV Mechanical Springs Classification of springs, Material for helical springs, End connections for compression and tension helical springs, Design of helical springs subjected to static and fatigue loading. P ower Screws Forms of threads, multiple threads, Efficiency of square threads, Trapezoidal threads, Stresses in screws, Design of screw jack. UNIT V Basic of Finite Element Method, Variational calculus, Integral formulation, variational methods: Methods of weighted residuals, Approximate solution using variational method, Modified Galerkin method, Boundary conditions. Basic Finite Element Concepts: Basic ideas in a finite element solution, General finite element solution procedure, Finite element equations using modified Galerkin method, Axis symmetric Problems, Axial bars, Torsion bars, Application in Solid Mechanic Problems, Plane truss problems using software application. Note: Design data book is allowed in the examination Text Books: 1. Design of Machine Elements,V.B. Bhandari, Tata McGraw Hill Co. 2. Design of Machine Elements, Sharma and Purohit, PHI. 3. Machine Design, Sadhu Singh, Khanna Book Publishing Co. 4. Machine Design, P C Gope, PHI Publication 5. Machine Design-R S Khurmi and J K Gupta, S Chand 6. J N Reddy “An Introduction to finite element method” Tata Mc Graw Hill 3rd edition 7. S.S. Rao, “Finite Element Method In Engineering”, Pergaman Press 8. Machine Design Data Book, Sadhu Singh, Khanna Book Publishing Co. 9. P Seshu, Finite Element Analysis, PHI publications, Delhi Design data book: Design Data Handbook for Mechanical Engineering in SI and Metric Units – by K. Mahadevan, and K. Balaveera Reddy. References: 1. Design of Machine Elements-M.F. Spott, Pearson Eductaion 2. Machine Design-Maleev and Hartman, CBS Publishers. 3. Mechanical Engineering Design, 9e – Joseph E. Shigely, McGraw Hill Education. 4. Design of Machine Elements, Gope PHI. 5. Finite Element Method with Applications in Engineering Y M Desai, Pearson Publication 6. Introduction to Finite Element Analysis by Tirupathi R.Chandrupatla & Ashok D Belegundu, Pearson Publication 7. V.Ramamurti “Finite Element Method in Machine Design”Norosa Publishing House MANUFACTURING SCIENCE TECHNOLOGY-II UNIT I Introduction: Classification of machine tools based on application and production rate: General purpose and Special purpose machines, Classification based on-types of machine tools and the processes. Metal Cutting: Mechanics of metal cutting. Geometry of tool and nomenclature .ASA system Orthogonal vs. oblique cutting. Mechanics of chip formation, types of chips. Shear angle relationship. Merchant’s force circle diagram. Cutting forces, power required. Heat generation and cutting tool temperature, Cutting fluids/lubricants.Tool materials. Tool wear and tool life. Machinability. Dynamometer. Economics of metal cutting. UNIT II Lathe: Various types of lathe: Centre lathe, facing lathe, gap-bed lathe, capstan and turret lathe, NC, CNC and DNC lathe, major difference between CNC lathe and conventional lathe. Major sub- assemblies of a lathe: Bed, headstock, tail stock, carriage consisting of saddle, cross-slide, compound slide, tool post and apron. Work holding devices: self centering three jaw chuck, independent four jaw chuck, collets, face plates, dog carriers, Centers and mandrels, Rest(Steady and Moving). UNIT III Lathe Contd..: Driving mechanisms, apron mechanism, thread cutting mechanism and calculations, features of half-nut engagement – disengagement, indexing dial mechanism. Operations on lathe: taper turning, related calculations, thread cutting, facing, under-cutting, drilling, boring, parting-off, knurling, chamfering. Reciprocating Type Machine Tools: Shaper, Planer and Slotter: Constructional features, basic machines and kinematics and related calculations. UNIT IV Drilling Machines: Constructional features of bench drilling machine, radial drilling machine, multi- spindle drilling machine, feed mechanism, work holding devices, Tool – holding devices. Different drilling operations: Drilling, reaming, counter boring and countersinking etc. estimation of drilling time. Milling Machines: Types of general purpose milling machines: horizontal, vertical, universal and their principal parts. Types of milling cutters and their applications, different milling operations, work-holding devices: vice, clamps, chucks, dividing head and its use, simple, compound and differential indexing. Indexing calculations and machining time calculations. Introduction to machining centers. UNIT V Grinding Machines: Different types of grinding machines: cylindrical, surface and centre-less grinding machines, basic constructional features and mechanisms, specifications, different grinding operations, honing, lapping and super-finishing processes. Gear Manufacturing Machines: Gear forming, gear generation, gear shaping and gear hobbing. Reference Books: 1. B.S. Raghuwanshi, “Workshop Technology”, Vol.2, Dhanpat Rai & Sons, 2003. 2. S.F. Krar Stevan F. and Check A.F., “Technology of M/C Tools”, McGraw Hill Book Co., 1986 3. Hazra Chandhari S.K., “Elements of Workshop Technology”, Vol.2, Media Promoters, 2003. 4. P.C. Sharma, “A Text Book of Production Engineering”, S. Chand, New Delhi, 2004. 5. Bawa H.S., “Workshop Technology”, Vol.2, Tata McGraw Hill, 2004. 6. Juneja & Shekhon, “Fundamental of Metal Cutting”, New Age Publications 7. Fundamentals of Metal Machining and Machine Tools – Geoffrey Boothroyd, CRC Press 8. Manufacturing Science – A. Ghosh and A.K. Mallik,Affiliated East-West Press ADVANCED WELDING TECHNOLOGY Unit-I Introduction : Importance and application of welding, classification of welding process. Selection of welding process. Brief review of conventional welding process : Gas welding, Arc welding, MIG, TIG welding. Resistance welding. Electroslag welding, Friction welding etc. Welding of MS.CI, Al, Stainless steel & Maurer/Schaefflar Diagram. Soldering & Brazing. Unit-II Advanced welding Techniques- Principle and working and application of advanced welding techniques such as Plasma Arc welding, Laser beam welding, Electron beam welding, Ultrasonic welding etc. Unit-III Advanced welding Techniques (continued) : Principle and working and application of advanced welding techniques such as explosive welding/ cladding, Underwater welding, Spray-welding / Metallising, Hard facing. Unit-IV Weld Design : Welding machines/equipments and its characteristics and arc-stability, Weld defects and distortion and its remedies, Inspection/testing of welds, Weld Design, Welding of pipe-lines and pressure vessels. Life predication. Unit-V Thermal and Metallurgical consideration.: Thermal considerations for welding, temperature distribution, Analytical/Empirical analysis/formulae, heating & cooling curves. Metallurgical consideration of weld, HAZ and Parent metal, micro & macro structure. Solidification of weld and properties. Books 1. Welding Hand Book 2. Metal Casting and Joining - John.K.C- PHI Publications 3. Welding & Welding Technology- Richard L Little. Mc Graw Hill th 4. Welding Principles and Practices – EdwardR. Bohnart , Mc Graw Hill, 4 Edition. DESIGN AND SIMULATION LAB 1 . Design & Modeling of Cotter joint. 2. Design & Modeling of Knuckle joint 3. Design & Modeling of riveted joint applied to boiler joints. 4. Study of a FEA package and modeling stress analysis of a. Bars of constant cross section area, tapered cross section area and stepped bar b.Trusses, c. Beams – Simply supported, cantilever, beams with UDL, beams with varying load etc 5.Mini Project: Will take up problems from real life applications and optimize using modeling and analysis software Each student will be given a real life problem for the complete design of a subsystem/system using either manual calculation with the help of design handbook or through computer programme or through software tools. This assignment should be done in groups, which will be submitted at the end of the semester. Text Books: 1. Design of Machine Elements,V.B. Bhandari, Tata McGraw Hill Co. 2. Design of Machine Elements, Sharma and Purohit, PHI. 3. Machine Design, Sadhu Singh, Khanna Book Publishing Co. 4. Machine Design-R S Khurmi and J K Gupta, S Chand 5. J N Reddy “An Introduction to finite element method” Tata Mc Graw Hill 3rd edition 6. S.S. Rao, “Finite Element Method In Engineering”, Pergaman Press 7. Machine Design Data Book, Sadhu Singh, Khanna Book Publishing Co. 8. P Seshu, Finite Element Analysis, PHI publications, Delhi Design data book: Design Data Handbook for Mechanical Engineering in SI and Metric Units – by K. Mahadevan, and K. Balaveera Reddy References: 1. Design of Machine Elements-M.F. Spott, Pearson Eductaion 2. Machine Design-Maleev and Hartman, CBS Publishers. 3. Mechanical Engineering Design, 9e – Joseph E. Shigely, McGraw Hill Education. 4. Design of Machine Elements, Gope PHI. 5. Finite Element Method with Applications in Engineering Y M Desai, Pearson Publication 6. Introduction to Finite Element Analysis by Tirupathi R.Chandrupatla & Ashok D Belegundu, Pearson Publication 7. V.Ramamurti “Finite Element Method in Machine Design”Norosa Publishing House MANUFACTURING SCIENCE & TECHNOLOGY LAB -II Minimum eight experiments out of the following along-with study of the machines / processes 1.Shear-angle determination (using formula) with tube cutting (for orthogonal) on lathe machine. 2.Bolt (thread) making on Lathe machine 3.Tool grinding (to provide tool angles) on tool-grinder machine. 4.Gear cutting on Milling machine. 5.Machining a block on shaper machine. 6.Finishing of a surface on surface-grinding machine. 7.Drilling holes on drilling machine and study of twist-drill. 8.Study of different types of tools and its angles & materials. 9.Experiment on tool wear and tool life. 10.Experiment on jigs/Fixtures and its uses 11.Gas welding experiment 12.Arc welding experiment 13.Resistance welding experiment. 14.Soldering & Brazing experiment ADVANCE WELDING TECHNOLOGY LAB 1. Making of welded joints using conventional welding processes - arc welding. 2. Making of welded joints using conventional welding processes -gas welding. 3. Making of at least one joint using TIG welding techniques 4. Making of at least one joint using MIG welding techniques. 5. Testing of welded joints as per BIS 6. Microstructure study of welded joints 7. Inspection of welded joints by dye penetration ultrasonic method. 8. study of different techniques used for inspection of welds 9. study of HAZ of welded joint