ANNEXURE - A: M. TECH.

(MANUFACTURING ENGINEERING)
COURSE STRUCTURE
Course Year and
Course Title L-T-P Credits
No. Semester
ME501 Computational Methods for Engineers 3-0-2 4
ME502 Advanced Casting Technology 3-0-2 4
ME503 I Year Advanced Welding Technology 3-0-2 4
ME504 I Semester Computer Graphics and CAD 3-0-2 4
ME505 Manufacturing Systems Engineering 3-0-2 4
ME506 Non Traditional Machining 3-1-0 4
Total Credits (First Semester) 24
ME507 Quality Control and TQM 3-0-2 4
ME508 Forging Die Design and Manufacture 3-0-2 4
ME509 I Year CNC and Programming 3-0-2 4
ME510 II Semester Design of Machine Tools 3-1-0 4
----- Elective I 3-0-2/3-1-0 4
----- Elective II 3-0-2/3-1-0 4
Total Credits (Second Semester) 24
----- Elective III 3-0-2/3-1-0 4
----- Elective IV 3-0-2/3-1-0 4
II Year
ME511 Seminar ----- 1
I Semester
ME512 Industrial Training ----- 1
ME513 Project Work (Part I) ----- 5
Total Credits (Third Semester) 15
ME514 II Year Comprehensive Viva-voce ----- 2
ME515 II Semester Project Work (Part II) ----- 15
Total Credits (Fourth Semester) 17
Total Credits (All Semesters) 80

LIST OF ELECTIVES
(All these courses will have 4 credits and will be offered in 3-0-2 or 3-1-0 pattern)
S. No. Course No. Course Title
1 ME521 Finite Element Methods and Applications
2 ME522 Geometric Modeling for Manufacturing
3 ME523 Non Destructive Evaluation
4 ME524 Optimization Methods for Engineers
5 ME525 Metrology and Computer Aided Inspection
6 ME526 Advanced Metal Forming Technology
7 ME527 Advanced CAD and Computational Geometry
8 ME528 Soft Computing Techniques
9 ME529 Artificial Intelligence in Manufacturing
10 ME530 Design of Jigs and Fixtures
11 ME531 Micro and Nano Manufacturing
12 ME532 Laser Assisted Manufacturing
13 ME533 Flexible Manufacturing Systems
14 ME534 Mechatronics
15 ME535 Precision Engineering
16 ME536 Rapid Prototyping and Reverse Engineering
17 ME537 Design for Manufacture and Assembly
18 ME538 Design and Analysis of Experiments
19 ME539 Modern Casting Processes
20 ME540 Foundry Tooling and Methoding
21 ME521 Reliability Engineering
22 ME542 Rolling Technology
23 ME543 Near Net Shape Processes
24 ME544 Concurrent Engineering
25 ME545 Tool Design
 LIST OF ELECTIVES
(These courses will be offered in 3-0-2 or 3-1-0 pattern)
S. No. Course No. Course Title L-T-P Credits
1 ME521 Finite Element Methods and Applications 3-0-2 4
2 ME522 Geometric Modeling for Manufacturing 3-0-2 4
3 ME523 Non Destructive Evaluation 3-0-2 4
4 ME524 Optimization Methods for Engineers 3-0-2 4
5 ME525 Metrology and Computer Aided Inspection 3-0-2 4
6 ME526 Advanced Metal Forming Technology 3-0-2 4
7 ME527 Advanced CAD and Computational Geometry 3-0-2 4
8 ME528 Soft Computing Techniques 3-0-2 4
9 ME529 Artificial Intelligence in Manufacturing 3-0-2 4
10 ME530 Design of Jigs and Fixtures 3-0-2 4
11 ME531 Micro and Nano Manufacturing 3-1-0 4
12 ME532 Laser Assisted Manufacturing 3-1-0 4
13 ME533 Flexible Manufacturing Systems 3-1-0 4
14 ME534 Mechatronics 3-1-0 4
15 ME535 Precision Engineering 3-1-0 4
16 ME536 Rapid Prototyping and Reverse Engineering 3-1-0 4
17 ME537 Design for Manufacture and Assembly 3-1-0 4
18 ME538 Design and Analysis of Experiments 3-1-0 4
19 ME539 Modern Casting Processes 3-1-0 4
20 ME540 Foundry Tooling and Methoding 3-1-0 4
21 ME521 Reliability Engineering 3-1-0 4
22 ME542 Rolling Technology 3-1-0 4
23 ME543 Near Net Shape Processes 3-1-0 4
24 ME544 Concurrent Engineering 3-1-0 4
25 ME545 Tool Design 3-1-0 4
 CORE SUBJECTS
ME501 COMPUTATIONAL METHODS FOR ENGINEERS (3-0-2)
Approximations - Accuracy and precision - Definitions of round-off and truncation errors - Error
propagation - Algebraic equations - Formulation and solution of linear algebraic equations - Gauss
elimination - LU decomposition - Iteration methods (Gauss-Siedel) - Convergence of iteration methods
- Eigen values and Eigen vectors - Interpolation methods - Newton’s divided difference - Interpolation
polynomials - Lagrange interpolation polynomials - Differentiation and integration - High accuracy
differentiation formulae - Extrapolation - Derivatives of unequally spaced data - Gauss quadrature and
integration - Transform techniques - Continuous Fourier series - Frequency and time domains -
Laplace transform - Fourier integral and transform - Discrete Fourier transform (DFT) - Fast Fourier
transform (FFT) - Differential equations - Initial and boundary value problems - Eigen value problems -
Solutions to elliptical and parabolic equations - Partial differential equations - Regression methods -
Linear and nonlinear regression - Multiple linear regression - General linear least squares - Statistical
methods - Statistical representation of data - Modeling and analysis of data - Tests of hypothesis -
Introduction to optimization methods - Local and global minima - Line searches - Steepest descent
method - Conjugate gradient method - Quasi Newton method - Penalty functions - Solution to
practical engineering problems using software tools.

ME502 METAL CASTING TECHNOLOGY (3-0-2)

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.

ME503 ADVANCED WELDING TECHNOLOGY (3-0-2)

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.

ME504 COMPUTER GRAPHICS AND CAD (3-0-2)

Computer graphics fundamentals - Points and lines - Algorithms for generating lines,circles,
ellipsesand other conic sections - Primitives and functions- 3D concepts and object representation -
3D display methods - 2D and 3D transformations and their matrix representations - Principles of
computer aided design - Plane and space curves (Splines, Bezier and B-spline curves) -
Surface description and generation - Parametric surfaces (Splines, Bezier and B-spline surfaces) -
Implementation of parametric curves and surfaces using C++ language and OpenGL - Solid
modeling - Representation of 3D objects - Use of standard CAD software.
 ME505 MANUFACTURING SYSTEMS ENGINEERING (3-1-0)
Introduction to process planning - Process planning in integrating CAD/CAM - Approaches to process
planning: mutual, variant, generative and 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 - Basics of concurrent
engineering - Understanding interactions between design and manufacturing - Serial engineering Vs.
concurrent engineering - Benefits of concurrent 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 methods - Layout planning in cellular manufacturing - Scheduling problems in flexible
manufacturing systems.

ME506 NON TRADITIONAL MACHINING (3-1-0)

Newer processes in manufacturing - Process principles, process parameters, advantages and
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) and
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) and Ion Beam Machining (IBM) -
Introduction to micromachining.

ME507 QUALITY CONTROL AND TQM (3-0-2)

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.

ME508 FORGING DIE DESIGN AND MANUFACTURE (3-0-2)

Study of forging drawing and its simplification from die design point of view - Determination of stock
size, tensile strength of material at the finishing temperature while forging - Calculation of weight of
falling parts or die of a drop hammer - Mechanical press - Selection of the size of massive die blocks
or insert dies - Production of die blocks and factors controlling their quality - Location of parting line -
Selection of flash gutter - Determination of flash thickness and volume of fin - Calculation of wall
thickness and distance between two impressions - Design of edger, fuller, bender, blocker, finishing
impression, dovetail, cross, key and tapered key - Laws governing the design of dies of horizontal
forging machine - Design of punches and heading tools for upsetter (horizontal forging machine) -
Upsetting rules - Coining tool design method - Determination of capacity of trimming press - Design of
trimming and piercing tool, die clearance between punch and die - Design of stripping and clipping
tools - Assembly detail for trimming - Technical requirements for sinking, re-sinking and rectification of
dies - Die-sinking methods like copy-milling, EDM, ECM, etc. - Instruction for mounting, setting and
working of dies - Reduced roll design - Saved preform design - Die life improvement - Computer aided
design of forging dies - Optimization of die design parameters - Optimum material utilization -
Modeling and analysis of forging process using software.

ME509 CNC AND PROGRAMMING (3-1-0)

Introduction to NC/CNC/DNC - Basics elements of CNC - Introduction to part programming - Radius
and length compensation schemes - Tooling and Work-holding for CNC machine tools - Advanced
programming features and canned cycles - Geometric modeling for NC machining and machining of
freeform surfaces - NC program generation from CAD models - Introduction to APT programming -
Post processors - NC program verification and virtual NC - Recent developments in CNC machine
tools.

ME510 DESIGN OF MACHINE TOOLS (3-1-0)

Introduction to machine tool drives and mechanisms - General principles of machine tool design -
Selection of electric motor - Mechanical transmission and its elements - Devices for intermittent
motion - Regulation of speed and feed rates - Stepped regulation of speed - Design of speed and
feed boxes - Classification of speed and feed boxes - Design of machine tool structures - Basic
design principles - Process capability of machine tools - Static compliance and overall compliance of
machine tools - Design of beds, columns, housings, bases and tables - Design of cross rails, arms,
saddles and carriages - Design of rams - Design of guide ways: Slide ways and their design - Stick
slip phenomenon in slide ways - Design of hydrodynamic slide ways - Design of hydrostatic slide
ways - Design of antifriction guide ways - Design of spindles and spindle supports - Antifriction
bearings - Preloading of antifriction bearings - Sliding bearings - Sleeve bearings - Hydrodynamic
journal bearings - Vibrations in machine tools - Effects of vibrations - Sources of vibrations - Analysis
of single degree of freedom system - Chatter theory - Regenerative principle - Elimination of vibrations
- Damping - Testing of machine tools for alignment and accuracy - Standard test charts.

ELECTIVE SUBJECTS
ME521 FINITE ELEMENT METHODS AND APPLICATIONS
Introduction to FEM - Heat transfer - Coordinates and shape functions - Linear, quadratic, triangular
and axisymmetric - Euler-Lagrange equation - Galerkin 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 - Potential energy approach, Galerkin
approach - Finite element equations for one dimensional problems and treatment of boundary
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.

ME522 GEOMETRIC MODELING FOR MANUFACTURING

Geometric representation of curves, surfaces and solids - Machining of freeform surfaces from
geometric models - Geometric modeling for die and mold design - Geometric model driven process
simulation and process planning - Use of geometric models in inspection of curved geometries and
reverse engineering - Realization of freeform solids by layered manufacturing - Computational
geometry for manufacturing and inspection.

ME523 NON DESTRUCTIVE EVALUATION

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 and C scans - Eddy current testing - Image sensing
through welding arc - Thermal imaging - Image reconstruction - Non-destructive inspection of typical
components: Castings, forgings, welded components, brazed and adhesive bonded assemblies.

ME524 OPTIMIZATION METHODS FOR ENGINEERS

Optimization problem formulation - Design variables, constraints, objective functions and variable
bounds - Single variable optimization algorithms: Bracketing methods, Exhaustive search method and
bounding phase method - Region elimination methods: Fibonacci search and golden search methods,
gradient based methods, Newton-Raphson method, bisection method, secant method and cubic
search methods - Computer programs for bounding phase method and golden selection search
method - Multi-variable optimization algorithms: Direct search method, simplex search method and
Hooke-Jeeves pattern search method - Gradient based methods - Cauchy’s (steepest descent)
method and Newton’s method - Constrained optimization algorithms: Kuhn-Tucker conditions -
Penalty function method - Method of multipliers - Cutting plane method - Generalized reduced
gradient method - Computer program for penalty function method - Integer programming - Penalty
function method - Global optimization using steepest descent method, genetic algorithms and
simulated annealing.
 ME525 METROLOGY AND COMPUTER AIDED INSPECTION
Principles of dimensional and form measurements - Errors in measurement - Linear and angular
measurements - Description, merits and demerits of some common types of comparators - Limits, fits
and tolerances - Disposition of tolerances and deviations - Gauges and design of gauges -
Measurement and evaluation of straightness, flatness and roundness - Introduction to metrology of
gears and screw thread: Measurement of gears using constant chord and base tangent methods -
Measurement of screw thread using wire methods - Best size wire - Measurement of surface finish:
Various parameters - Measuring instruments - Interferometers: Types of light sources - Types of
scales and gratings - Optical flats - Use of interferometers for calibration of height standards, etc. -
Laser metrology: Laser light source - Laser interferometer - Laser alignment telescope - Laser
micrometer - Online and in-process measurements of diameter and surface roughness - Micro-holes
and topography measurements - Coordinate measuring machines (CMMs): Types and major
elements of CMMs - Hard probing and soft probing - Construction and working of touch trigger probe -
CMM software - Performance evaluation - Environmental control - Accuracy enhancement -
Applications of CMMs - Image processing: Shape identification - Edge detection techniques -
Normalization - Grey scale correlation - Template techniques - Applications of vision systems for the
measurement of surface roughness, tool wear, lengths and diameters - Sorting and counting of
objects - Interfacing robot and image processing systems - Computer integrated inspection -
Statistical evaluation of data using computers - Integration of CMM and data logging in computers.

ME526 ADVANCED METAL FORMING TECHNOLOGY

Elements of theory of plasticity - Formulation of plastic deformation problems and different methods of
solution - Applications of upper bound method for solving metal forming problems, such as forging,
rolling, extrusion and 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 - Superplastic forming.

ME 527 ADVANCED CAD AND COMPUTATIONAL GEOMETRY

NURBS (Non-Uniform Rational B-Splines): Definition and properties of NURBS curves and surfaces -
Implementations using C++ and OpenGL - Geometric algorithms for knot and degree manipulation,
point inversion and projection, transformations and projections, etc. - Applications of NURBS for
representation of conic sections - NURBS curve and surface fitting - Shape modification.

Computational geometry: Introduction and applications - Polygon triangulation and partitioning -

Convex hulls - Algorithms for generating convex hulls in 2D and 3D - Voronoi diagrams - Delaunay
triangulations - Search and intersection algorithms - Motion planning - Some applications of
computational geometry in manufacturing and metrology.
 ME 528 SOFT COMPUTING TECHNIQUES
Introduction to soft computing - Need for soft computing - Genetic algorithms: Introduction,
mathematical foundation, computer implementation, applications - Neural networks: Introduction -
Neurons and neural networks - Basic models of neural networks, such as single-layer and multi-layer
networks, recurrent networks, radial basis function networks - Training of neural networks and
learning paradigms - Fuzzy analysis: Introduction to fuzzy set theory, mathematical foundation,
applications - Combined techniques: Genetic algorithms and fuzzy logic, Genetic Algorithms and
neural networks, Neural networks and fuzzy logic - Chaos: complexity and simplicity, evolution of
possibilities, simple models of chaos, deterministic chaos and self-organization - Applications of soft
computing techniques in manufacturing engineering.

ME 529 ARTIFICIAL INTELLIGENCE IN MANUFACTURING

Definitions of intelligence and artificial intelligence - Human mental capabilities: Association,
stereotyping, reasoning and vision - Artificial intelligence: Components, scope and application areas -
AI languages: Introduction to PROLOG and LISP - Knowledge-based or expert systems: Definition,
structure, characterization and justification - Knowledge sources - Expert - Knowledge acquisition and
representation - Knowledge base - Interference strategies: Forward and backward chaining - Expert
system languages - Expert system building tools or shells - Typical examples of shells - Expert
system software for manufacturing applications in CAD, CAPP, MRP, adaptive control, robotics,
process control, fault diagnosis, failure analysis, process selection, group technology, etc. -
Introduction to artificial neural networks and genetic algorithms - Manufacturing applications of neural
networks and genetic algorithms - Case studies of typical applications in tool selection, process
selection, part classification, inventory control, process planning, etc.

ME 530 DESIGN OF JIGS AND FIXTURES

Introduction to jigs and fixtures - Need for development of jigs and fixtures - Potential benefits,
advantage and limitations of jigs and fixtures - Principles of location - Examples of locations using
different types of surfaces - Locating devices - Principles and purposes of clamping - Different types
of clamping devices and their merits and demerits - Automatic clamping devices - Design principles
common to jigs and fixtures - Design principles specific to jigs and fixtures - Indexing in jigs and
fixtures - Drilling jigs: Drill bushes and their design principles - Types of drilling jigs: Template jig, plate
type jig, open type jig, swinging leaf jig, box type jig, channel type jig, etc. - Jig feet - Milling fixtures -
Essential features of milling fixtures - Milling machine vice - Design principles for milling fixtures -
Design of fixtures for grinding, boring, welding, assembly, measurements and inspection, etc. -
Development of jigs and fixtures for typical engineering components.

ME 531 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 manufacturingmethods - CAD/CAM tools
for micro and nano manufacturing processes.

ME 532 LASER ASSISTED MANUFACTURING

Laser fundamentals: Spontaneous and stimulated emission or absorption, population inversion and
pumping, cavity design, coherence and interference - Common industrial lasers and their output
characteristics: CO2, Ruby, Nd-YAG, Nd-glass, Excimer and He-Ne - Overview of laser applications in
manufacturing: application areas, economics, advantages and disadvantages - 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 and plasma, development of theoretical models, operating characteristics and process
variation - Surface modification: Heat treatment, rapid solidification, alloying and cladding, surface
texturing and development of theoretical models - Introduction to interferometry - Working principles of
some popular interferometers - Elementary holography - Detection and measurement of radiation -
Laser safety.

ME 533 FLEXIBLE MANUFACTURING SYSTEMS

Technology and management - Mid-volume and mid-variety production - CIM - Manufacturing cell -
Special manufacturing systems and FMS - FMS benefits - FMS technology - NC, CNC and DNC -
Material handling systems - Hierarchical FMS computer networking and control - Automated
inspection and storage - Management - Setting goals and objectives - Analysis of products for
selecting production techniques - Selection of machine tools - CAPP - Automated material handling
and storage - ASRS - Just-in-time - Control system for FMS - MRP II - Production planning,
forecasting, scheduling and MPC - FMS cost justification.

ME 534 MECHATRONICS
Introduction to mechatronics - Definition - Mechatronics in manufacturing, products and design - Key
elements - Advanced approaches in mechatronics - Basics of fuzzy logic, neural networks and
artificial intelligence - Review of electronics fundamentals - Introduction to mechatronics devices -
Data conversion devices - Motion and position sensors - Force and tactile sensors - Flow and
temperature sensors - Ultrasonic sensors - Range sensors - Vibration control using magneto structure
transducers - Fiber optic devices in mechatronics - Signal processing devices - Output devices -
Microprocessors and controllers - Actuating devices - DC and AC drives - Stepper motors - Servo
motors - Piezoelectric actuators - Mechanical devices, such as ball screws, linear motion bearings,
cams, systems controlled by camshafts, indexing mechanisms, hoppers, magazines, chutes and
transfer systems - Hydraulic actuators - Design of hydraulic circuits - Pneumatic actuators - Design
and selection of actuating devices - Signals, systems and controls - Introduction - System
representation - Linearization of non-linear systems - Time delays - Measures of system performance
- Root locus and Bode plots - Applications in Mechatronics - Sensors for condition monitoring -
Mechatronic control in automated manufacturing - Artificial intelligence and fuzzy logic applications in
mechatronics - Micro sensors and case studies.

ME535 PRECISION ENGINEERING

Concepts of accuracy - Accuracy of machine tools - Spindle and displacement accuracies -
Accuracies of NC systems - Numerical interpolation errors - Displacement measurement system and
velocity lags - Geometric dimensioning and tolerancing (GD&T) - Tolerance zone conversions -
Surface, features and features of size, datum features - Datums - Oddly configured and curved
surfaces as datum features - Equalizing datums - Datum feature of size representation - Form and
orientation controls - Logical approach to tolerancing - Foundations of nanotechnology and measuring
systems - Processing systems for nanometer accuracies - Mechanism of metal processing - Nano
physical processing of atomic bit units - Nano chemical and electrochemical atomic bit processing -
In-process measurement of position of processing unit - Post process and on-machine measurement
of dimensional features and surface mechanical and optical measuring systems - Nano positioning
systems - Guide systems for moving elements - Servo control systems for tool positioning - Computer
aided digital and ultra-precision position control - Applications and future trends in nano technology -
Nano grating systems - Nano lithography, photo lithography and electron beam lithography -
Machining of soft metals - Diamond turning - Mirror grinding of ceramics - Development of intelligent
products - Nano processing of materials for super high density ICs - Nano mechanical parts and
micro-machines.

ME536 RAPID PROTOTYPING AND REVERSE ENGINEERING

Basic principles of RP processes - Classification of RP processes - Various industrial RP systems like
stereolithography, 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 and direct metal laser sintering - Introduction to
reverse engineering - Point cloud data generation methods and processing techniques - Integration of
reverse engineering and rapid prototyping.

ME537 DESIGN FOR MANUFACTURE 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 - Evaluating parametric mechanical engineering designs for
manufacturability - DFM analysis for various manufacturing processes - Product design for manual
assembly - Product design for high-speed automatic assembly - Product design for robot assembly.
 ME538 DESIGN AND ANALYSIS OF EXPERIMENTS
Overview and basic principles - Simple designs and analysis of variance (ANOVA) - Block designs,
Latin squares and related designs - Full factorial designs - 2-level full factorial and fractional factorial
designs - Overview of response surface methods and designs - Designs with random factors, nested
designs and split plot designs - Examples of scientific and engineering applications - DOE software.

ME539 MODERN CASTING PROCESSES

Process details, ingredients used, process variables and economy of processes using sodium silicate
as binder and organic binder processes, e.g. hot box, cold box, ABC, silicate-ester, catalyzed no-bake
and warm box - Fluid sand, full mold, magnetic molding, investment casting, frozen mold, vacuum
sealed molding, high pressure molding, impact molding, explosion molding and squeeze casting
processes - Centrifugal casting and continuous casting processes.

ME540 FOUNDRY TOOLING AND METHODING

Gating - Elements of the gating system - Design of gating system for cast iron and steel - Fluidity and
its significance in castings - Risering - Solidification of iron and steel with reference to Fe-C diagram -
Riser classification - Design of riser - Methods to achieve directional solidification - Pattern equipment
for quality production of castings - Pattern plates - Types and materials used - Design and
constructional features suiting to various molding machines - Special design features for high
pressure molding machines - Core boxes - Type, materials used, design and constructional features
for core blowing and shooting machines - Special features for shell core shooters - Core prints -
Gravity die-casting - Die-types and design features - Pressure die-casting - Die-design features.

ME541 RELIABILITY ENGINEERING

Elements of probability - Density and distribution functions for uniform, exponential, Weibull and
normal distributions - Reliability definition - Measures of reliability - Failures - Classification of failures -
Failure data Analysis - Availability - Criticality matrix - Event tree analysis - Utilization factor - Factors
affecting reliability - Analysis of reliability data - Weibull analysis - Design and manufacture for
reliability - Reliability of parts and components - Design for system reliability - Economics of standby
or redundancy in a production system - System effectiveness mission reliability design adequacy,
operational readiness serviceability performance indices, their evaluation, uses and limitations -
Reliability models of maintained systems, fundamental definitions, relationship between reliability and
maintainability single equipment systems parallel stand by k-out-of-n configuration - Steady state
availability - Non-maintained systems - Reliability definition and its importance - Method of improving
reliability redundancy techniques - Reliability models - Reliability testing - Types - Maintenance
systems and economics of reliability - Maintenance and spares management - Preventive
replacement - Condition monitoring and analysis.
 ME542 ROLLING TECHNOLOGY
Hot rolling: Types of hot rolled products - Behavior 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 and billeting -
Mills for bar, rod, structural, tube, plate and hot strips - Rolling of rails, wheels and rings - Cooling and
de-scaling of products - Instrumentation and computer control of hot mills - Further processing.

Cold rolling: Various types of cold mills - Components of cold mills - Mill rolls: Lubrication and thermal
aspects - Deformation behavior of materials - Torque and load equations - Instrumentation and
automatic control of mills - Strip shapes and their measurement and control - Properties of rolled
strips and further processing.

Principles of modeling hot and cold rolling processes - Microstructural evolution and control -
Galvanizing process and control of coating.

ME543 NEAR NET SHAPE PROCESSES

Concept of shape, size, accuracy, tolerances and surface roughness - Economical and technological
factors - Improved material and energy efficiency - Dimensional accuracy, product integrity and
reduced manufacturing cost through near net processing - Foundry processes - Shell process,
investment casting, ceramic molding, plaster mound process, V-process, squeeze casting, rheo-
casting, permanent mound casting, low pressure die casting and pressure die casting processes -
Plastic deformation processes - Warm forging, flashless forging, cold forging - Superplastic forming,
powder metal forging, liquid forging, rheo-forging and isothermal forging processes - Electro forming -
Principles of electro deposition, production of dies and molds by electro-forming.

ME544 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 - Product information systems and their
architecture - Information environment for suppliers, management, testing and inspection, design
engineering, purchasing, process control, manufacturing, support plans, operators, quality control,
servicing and maintenance - Product information modeling - Integration of information models and
end users applications - Computer aided simultaneous engineering systems - Integrated concurrent
design and product development - Constraint networks - Integrating concurrent approaches with
those of conventional approach - Implementation of concurrent engineering in industrial environment,
especially those of IT and high speed computation.
 ME545 TOOL DESIGN
Tooling for traditional material removal process: Design of single point turning, parting and boring
tools - Design of form tools - Design of internal and external broaches - Design of milling cutter and
drill bit of milling cutters - Design of twist drills, reamers and taps - Design of gear cutting tools.

Tooling for CNC machines: Interchangeable tooling system - Preset and qualified tools - Coolant fed
tooling system - Modular fixtures - Quick change tooling system - Automatic head changers - Tooling
requirements for turning and machining centres - Tool holders - Tool assemblies - Tool magazines -
ATC mechanisms - Tool management.

Tooling for automats - Tooling for nontraditional material removal processes - Design of press tools -
Tooling for forming processes - Tooling for metal casting and metal joining processes - Design of
welding fixtures - Tooling for inspection and gauging - Design and manufacture of gauges - CAD
methods in tool design.