Manufacturing Curriculum_MTech
Tender

National Institute of Foundry & Forge Technology

Hatia, Ranchi - 834 003 (Jharkhand)
 

Name of the M.Tech. Programme

Manufacturing Engineering

Distribution of Credits

Programme Core

Programme Elective

Total Credits

60

20

80

 

Course No.

Year

Semester

Course Title

L-T-P

Credits

 

I

I

Non Traditional Machining

3-1-0

4

     

Metal Casting Technology

3-0-2

4

     

Advanced Welding Technology

3-0-2

4

     

Computer Aided Design

2-0-4

4

     

Manufacturing Systems Engineering

3-0-2

4

     

CNC & Programming

3-0-2

4

     

Total Credits

 

24

 

Course No.

Year

Semester

Course Title

L-T-P

Credits

 

I

II

Quality Control & TQM

3-0-2

4

     

Forging Die Design and Manufacture

3-0-2

4

     

Advanced Manufacturing Systems Engineering

3-1-0

4

     

Elective - I

3-1-0/

3-0-2

4

     

Elective - II

3-1-0/

3-0-2

4

     

Elective - III

3-1-0/

3-0-2

4

     

Total Credits

 

24

 

Course

No.

Year

Semester

Subject

L-T-P

Credits

 

II

I

Modelling & Simulation of Castings & Forgings

1-0-6

4

     

Elective - IV

3-0-2 /3-1-0

4

     

Seminar

 

2

     

Industrial Training (Seminar)

 

2

     

Project-Part1 (presentation)

 

3

     

Total Credits

 

15

 

Course

No.

Year

Semester

Subject

L-T-P

Credits

 

II

II

Comprehensive Viva-Voce

 

2

     

Project -Part2

 

15

     

Total Credits

 

17

 

Syllabi of Courses - MANUFACTURING ENGINEERING
 


Non Traditional Machining

Newer Processes in Manufacturing - Process Principles, Process Parameters, Advantages & Limitations and Industrial Applications of Processes such as Abrasive Jet Machining (AJM), Water Jet Machining (WJM), Abrasive Water Jet Machining (AWJM), Abrasive Flow Machining (AFM), Ultrasonic Machining (UM), Electro Chemical Machining (ECM), Electro Chemical Grinding (ECG), Electro Chemical Discharge Grinding (ECDG), Shaped-Tube Electrolytic Machining (STEM), Electro Stream Drilling (ESD), Chemical Machining (CM), Electrical Discharge Machining (EDM), Electrical Discharge Wire Cutting (EDWC), Electron Beam Machining (EBM), Laser Machining (LM), Plasma Arc Cutting (PAC), Thermal Energy Method Deburring (TEM),Ion Beam Machining (IBM),Introduction to Micro-Machining.


Metal Casting Technology

Introduction. Pattern materials and pattern allowances. Types of patterns and core boxes. Base sands and their characteristics. Clay bonded sand systems and practices. Additives and washes. Inorganic and organic binder based processes. Melting furnaces for different types of metals and alloys. Cupola melting and melt control. Introduction to gating and feeding. Fettling and salvaging of castings. Casting defects and remedies.


Advanced Welding Technology

Review of major welding processes, Heat flow in welding, Welding stresses and distortion, Weldability of specific materials, Cracks in welds, weldability tests, Weld Defects, Weld inspection, repair and ,Maintenance welding, Weld design based on static, fatigue loading and fracture toughness.


Computer Aided Design

Principles of computer aided design. Computer graphics fundamentals. Points and lines. Transformations and projections. Plane curves. Space curves – cubic splines, normalized cubic splines, Bezier curves, B-spline. Surface description and generation. Surface modeling- Coons surface, Bazier surface, B spline surface. Solid modelling, Representation of 3-D objects – B-rep, CSG; Voxelization:

Laboratory: Modelling using Solid Modeler. Part Modelling, Creating Geometry , Operations , Modifying parts, Parametric design, Surface Modelling, Designing procedure by interfacing RDBMS (design data base based on data books) and Visual Basic.


Manufacturing Systems Engineering

Introduction of Group Technology, Coding and Classifications, Selection of Coding Systems, Examples of Coding Systems, Benefits of Group Technology, Cell formation approaches; Rank order clustering algorithm, Cluster identification algorithm, Similarity coefficient- based methods, Mathematical Programming based methods, and graph theoretic-method, Layout planning in cellular manufacturing, Scheduling problems in flexible manufacturing systems.

Introduction to process planning, Process planning in integrating CAD/CAM, approaches to process planning: mutual, variant, generative, feature based systems. Some examples of process planning systems. Introduction to Just-in-Time manufacturing systems. Describing three M’s, Pull vs Push, Types of Kanbans, and Kanban planning and control models, Basic of Concurrent Engineering, Understanding interactions between design and manufacturing, Serial Engineering vs Concurrent. Engineering, Benefits of Concurrent Engineering.


CNC & Programming

Introduction to NC/CNC/DNC, Basics elements of CNC, Introduction to Part Programming, Radius and Length Compensation Schemes, Tooling & Work-holding for CNC machine tools, Advanced Programming Features & Canned Cycles, Geometric Modeling for NC machining & Machining of Free-form Surfaces, NC program generation from CAD models, Introduction to APT programming, Post processor, NC Program verification and Virtual NC, Recent developments in CNC machine tools.


Quality Control and TQM

Probability and statistics; Statistical parameters for quality assurance; Prediction of process or product quality using normal distribution; sampling inspection, selection of sampling schemes for attributes and variables; Use of control charts for attributes and variables; interpretation of control charts. Seven QC tools and their applications, Quality Function Deployment. Quality Circles,Quality Audits. TQM in manufacturing and services. Tools and improvement cycle (PDCA). Life cycle approach to quality costs-Prevention; Appraisal and Failure costs. Basics of ISO-9000 and ISO 14000:Relevance and misconceptions, Six-sigma philosophy. Implementation barriers to TQM practices.


Forging Die Design & Manufacture

Job analysis, study of component drawing, development of forging drawing, allowances and tolerances; Die design considerations- parting line selection, design of rib and web dimensions, draft angle, fillet and corner radii, etc; design of flash and gutter, preform design, blocker and finisher design, insert design. Estimation of equipment capacity like press, hammer etc.

Upsetting rules; Coining tool design method; Design of trimming and piercing tools; Computer aided design of forging dies; Optimization of die design parameters; Optimum material utilization; Use of simulation software. Reducer roll design & sheared perform design.

Die sinking method like copy milling, EDM,ECM etc., re-sinking of dies, die life improvement.


Advanced Manufacturing Systems Engineering

Key characteristics of manufacturing systems, transfer lines and general serial systems, Introduction to Flexible Manufacturing Systems (FMS), Types of flexibilities and their measurement, FMS types, Layout of FMS, Design problems of FMS, Operational problems in FMS, and Control problems of FMS. Introduction to CIM, Integration concepts, CIM wheel, Fundamentals of networking, Developing a successful CIM strategy: Guidelines and examples.


Modelling & Simulation of Casting & Forgings

3-D modelling of molds & forging dies using solid modeller; Simulation and analysis of close die forging of forged components, such as gear blank connecting rod, crank shaft, rocker arm using FEM based software packages. Simulation of metal flow in moulds, solidification pattern analysis, microstructure and stress distribution in castings using industry standard FEM based software packages.


ELECTIVES


Concurrent Engineering

Concurrent Engineering- meaning and need. Review of Engineering Problem Solving methods. Description of methods of Analysis, Decision Making, Creativity and Information processing and their role in engineering. Discussion of Emerging engineering strategies of Total Design, Design for Manufacturing and Assembly, Quality Function Deployment, and Constraint networks. Integrating concurrent approaches with those of conventional. Implementation of concurrent engineering in industrial environment especially those of IT and high speed computation.


Micro- and Nano-Manufacturing

An overview of micro and nano mechanical systems and their applications in Mechanical Engineering, MEMS Micro-fabrication methods, Silicon Micromachining methods, Laser Micromachining methods, Mechanical Micromachining techniques, Nano-manufacturing methods, CAD/CAM Tools for Micro- and Nano-manufacturing processes.


Geometric Modelling for Manufacturing

Geometric representation of curves, surfaces and solids, Machining of free-form surfaces from geometric models, geometric modeling for die/mold design, geometric model driven process simulation and process planning, use of geometric models in inspection of curved geometries and reverse engineering, realization of free-form solids by layered manufacturing, computational geometry for manufacturing and inspection.


Non Destructive Testing

Scope of non-destructive evaluation; Liquid-penetrant and magnetic particle inspection techniques; X-ray and gamma-ray radiography; Ultrasonic inspection:- principle of wave propagation through solids, surface waves, pulse echo technique, A,B,C scan; Eddy current testing; Image sensing through welding arc; Thermal imaging; Image reconstruction; Inspection of typical components:- castings, forgings, welded components, brazed and adhesive bonded assemblies.


Finite Element method and Applications

Introduction to FEM Modelling

Heat Transfer: Coordinates and Shape Functions – Linear, Quadratic, Triangular, Axisymmetric, Euler – Langrange Equation, Galerkins Approach, Assembly of the Global Stiffness Matrix, Boundary Conditions such as Convection, Radiation etc., Unsteady State Heat Transfer Problems using Finite Difference Time Stepping Techniques like Euler, Crank – Nicolson’s and Implicit Methods, Point Sources, Torsion of Shafts.

Solid Mechanics: The Potential Energy Approach, Galerkin Approach, The Finite Element Equations for One Dimensional Problems and Treatment of Boundry Conditions, Temperature Effects, Plane Trusses, Two Dimensional Problems using Constant Strain Triangles, Beams.

Introduction to Mass Transfer, Fluid Flow and Plate Bending.

Local Coordinate System: Shape Functions in Local Coordinate System and Evaluation of Element Characteristic Matrices and Element Characteristic Vectors


Flexible Manufacturing System

Technology & Management: mid volume/ mid variety production, CIM, manufacturing cell, special manufacturing systems and FMS, FMS benefits.

FMS technology: NC,CNC,DNC; Material handling systems, hierarchical FMS computer networking 7 control, automated inspection & storage .

Management: setting goals and objectives, analysis of products for selecting production techniques, selection of machine tools, CAPP, automated material handling & storage, As/Rs vs. Just-in-Time.

Control System for FMS- MRP II - production planning, forcasting, scheduling and MPC.

FMS cost justification


Laser Assisted Manufacturing

Overview of laser Applications: Laser application in various fields, advantages & disadvantages, economics. Laser processing fundamentals: beam characteristics, absorption characteristics of materials, heat flow theory and metallurgical considerations. Cutting and drilling: Process characteristics, material removal modes, development of theoretical models and practical performance. Welding: Process mechanisms like keyhole & plasma, development of theoretical models, operating characteristics and process variation. Surface modification: heat treatment, rapid solidification, alloying and cladding, surface texturing, development of theoretical models. Introduction to interferometry:

 

Manufacturing of Plastics and Ceramic Products

General properties of engineering plastics, Structural features, Behavior of reinforced plastics and common fabrication techniques, Common fabrication processes and their analysis (Extrusion, Injection molding, thermoforming etc.), Flow analysis of polymer melt, Typical defects in plastic components and their prevention

Classification of ceramics, historical development, technologic and economic significance, structural features, physical properties, engineering processing: the sintering process; powder pressing and sintering fabrication processes; sintering defects; slip casting, ceramic injection moulding, tape casting; refractory; single crystal processing

 


Advanced Metal Forming Theory& Applications

Elements of theory of plasticity, Formulation of plastic deformation problems and different methods of solution, Application of upper bound method for solving metal forming problems- forging, rolling, extrusion, wire drawing. Slip line theory and its applications. Friction and lubrication in cold and hot working, Advances in sheet metal forming, Concept of Formability and its evaluation, Hydro-forming of sheets and tubes. Super plastic forming.

 


Design for Manufacturing and Assembly

An overview of three stages of product design, generating and evaluating conceptual alternatives from manufacturability point of view, selection of materials and processes, Evaluating part configurations for manufacturability, parametric designs for manufacturability, DFM analysis for various manufacturing processes, Product design for manual assembly, product design for high-speed automatic assembly.

 


Rapid Prototyping and Reverse Engineering

Basic Principal of RP processes, Classification of RP Processes, Various Industrial RP Systems like Sterolithography, Fused Deposition Modeling, Selective Laser Sintering, Laminated Object Manufacturing, 3D Printing, Ballistic particle modeling etc., Role of Rapid Prototyping and Rapid Tooling in Product Development. Process planning for rapid prototyping, STL file generation Defects in STL files and repairing algorithms, Slicing and various slicing procedures, Accuracy issues in Rapid Prototyping, Strength of RP Parts, Surface roughness problem in Rapid Prototyping, Part deposition orientation and issues like accuracy, surface finish, build time, support structure, cost etc., Rapid tooling techniques such as laminated metallic tooling, direct metal laser sintering. Introduction to reverse engineering. Point cloud data generation methods and processing techniques. Integration of reverse engineering and rapid prototyping.


Foundry Tooling and Methoding

Pattern Equipment for quality production of castings : Pattern plates: types, materials used; design and constructional features suiting to various moulding machines. Special design features for high pressure moulding machines.

Core Boxes: type , materials used, design and constructional features for core blowing and shooting machines. Special features for shell core shooters .Core print. Gravity Die casting: Die-Types, and design features. Pressure Die-casting: die- design features.

Gating : Elements of the gating system. Design of Gating system for cast iron & steel.

Fluidity and its significance in casting.

Risering : Solidification of iron and steel with reference to Fe-C diagram. Riser classification. Design of riser. Methods to achieve directional solidification.


Metrology & Computer Aided Inspection

Introduction: Principles of Dimensional and Form measurements. Basic standards of Length and Angle. Industrial standards. Errors in Measurement.

Linear and Angular Measurements: Vernier caliper, Micrometer, Dial indicator, Slip gauges, Angle gauges, Height gauges, Height gauges, Sine Bar, Interferometers.

Comparators: Mechanical, Pneumatic, Electrical, Electronic and Optical Comparators Description, Merits and Demerits.

Projectors and Microscopes: Abbe’s comparator, Autocollimator, Tool Maker’s microscope, Alignment Telescope – Applications.

Limits, Fits and Tolerances: Basic principles – Terminologies used – Maximum and Least material conditions – Disposition of Tolerances and deviations.

Gauges: Types of Gauges. Taylor’s Principle, Design of Gauges.

Straightness and Flatness: various methods of measuring Straightness and Flatness, Surface Plates.

Metrology Of Gears And Screw Thread: Measurement of various errors in gears – various instruments – Constant chord method – Base tangent method. Measurement of screw thread using 2- and 3- wire methods. Best size wire. Compensation for errors in these methods.

Surface Measurement: Various parameters – Analysis and Evaluation on these parameters – Surface Measuring Instruments.

Interferometers: Types of light sources and Interferometers, Types of scales and gratings, Optical flats, Use of different interferometers for calibration of height standards etc.

Coordinate Measuring Machines: CMMs, Applications, Types, Constructions, Probing, Hard Probing and Soft probing, Construction and Working Principle of Touch Trigger Probe, Alignment, Programming, Types of errors.

Principles of automatic inspection: vision systems; on-line inspection systems.

 

Rolling Technology

Hot Rolling – types of hot rolled products; behaviour of steels during deformation at elevated temperature, friction effects; basic principles of rolling and pass design; reheating of ingots and conditioning of semi-finished products; reheat furnaces; mills for blooming, slabbing, billet; Mills for bar, rod, structural, tube, plate, hot strip; rolling of rails, wheels& rings; cooling and de-scaling of products; instrumentation & computer control of hot mills; further processing.

Cold Rolling- various types of cold mills, components of cold mills; mill rolls; lubrication & thermal aspects; deformation behaviour of material - torque, load equations; instrumentation and automatic control of mills; strip shapes- its measurement & control; properties of rolled strips and further processing.

Principles of modeling in hot & cold rolling; Microstructural evolution & control; Galvanizing process & control of coating.

    
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