ad02jan2018

Section B Syllabus of AMIE examination of Mechanical Engineering

            

Compulsory Subjects

IC 402 Engineering Management
MC 403 Mechanics of Solids
MC 404 Mechanics of Fluids
MC 405 Thermal Science and Engineering
MC 406 Manufacturing Technology
MC 407 Design of Machine Elements

Optional Subjects (Any three from any one Group)

Group I Thermal Engineering

MC 411 Refrigeration and Air-conditioning
MC 412 Power Plant Engineering
MC 413 Non-conventional Energy Systems
MC 414 Internal Combustion Engines
MC 415 Turbo-machinery

Group II Engineering Design

MC 421 Design of Mechanical Systems
MC 422 Optimization — Theory and Applications
MC 423 Analysis and Synthesis of Mechanisms and Machines
MC 424 Design of Machine Tools
MC 425 Computer Aided Engineering Design

Group III Manufacturing Engineering

MC 431 Manufacturing Science
MC 432 Computer Aided Manufacturing
MC 433 Tool and Die Design
MC 434 Manufacturing Automation
MC 435 Production Management
















ENGINEERING MANAGEMENT

Group A
 Management and Organisations
Management process: Definition, planning organizing, directing, controlling, coordinating, types of management.
Organisation Definition, planning, design and development, types of organizations.
Management planning and control: Classical, new classical and modern principles. General Management, scientific management, engineering, management, systems management.
Planning: Procedures, resources and constraints, objectives, goals, policies and procedures.
Control: Setting of reference or standards, appraisal or evaluation, monitoring and controlling, types of control.
Human resource planning and management, selection, recruitment, training, retraining, skill development, competence development, promotion and career development, participative management, trade unions, and collective bargaining,
Management of Physical Resources
Plant: site selection procedures, factors affecting selection. Layout-types and relative merits and demerits, Maintenance-Objectives, different types of associated decisions, strategies for effective maintenance, computer applications.
Material : Functions, objectives, planning and control including inventory models with or without storage costs, price break ( excluding dynamic and probabilistic considerations). Different classes of inventory. Material Requirement Planning (MRP).
project, project implementation, project planning, scheduling and monitoring, project control
(PERT, CPM techniques including crashing). Project evaluation.
Information technology and management. Role of information, management information
system and decision support system, Information technology-introduction to e-business, ecommerce
and integration tools like enterprise resource planning (ERP).



Group B

Financial management: Introduction to standard forms of financial statements, ie., balance-sheet, profit and loss, and income statement. Fixed and current asset items. Fixed and current liability items. Linkage of two successive balance-sheets through income or profit and loss statement. Funds flow statement. Financial ratios and their implications.
Managerial economics: Concepts, theory of production, marginal productivity and cost. Introduction to theory of firm.
Quality management: Quality definition, quality planning, quality control and quality management, Total quality management, ISO 9000 systems, simple quality control techniques like control charts and acceptance sampling.
Marketing management consumer behavior, market research, product design and development pricing and promotion.
Project management: Introduction. Concept of a project, project management concepts, project simulation, cost or project and means of financing, economic evaluation criteria of the project, project implementation, project planning, scheduling and monitoring, project control (PERT, CPM techniques including crashing). Project evaluation.
Information technology and management. Role of information, management information system and decision support system, Information technology-introduction to e-business, e-commerce and integration tools like enterprise resource planning (ERP).
Recommended Books
• G Dieter, Engineering Design, McGraw-Hill International.
• E S Buffa. Modern Production/Operations Management. New Age International (P) Ltd., New Delhi.
• A K Gupta and J K Sharma. Management of Systems.Macmillan India Ltd., New Delhi







MECHANICS OF SOLIDS


Group A

Review of free body diagrams; Analysis of deformation unde-!" axial loading. Simple shear
and pressure.
Statically determinate and indeterminate cases. Forces and moments transmitted by simple
beams.
Mechanics of deformable solids, stress and strain, transformation of stress and, strain, Mohr
circle diagram, equilibrium equations and compatibility conditions.
Material properties and their testing: Elastic, inelastic, plastic and viscoelastic material
behaviour. Fatigue and creep. Concepts of ductility, hardness, toughness and their
quantification. Tensile and impact tests.


Group B

Stress-strain-temperature relations. Generalised Hooke's law and thermal strains.
Equations of elasticity. Solutions of thin and thick cylinders and rotating disks.
Stresses in beams. Torsion of circular shafts and thin walled sections. Deflection of helical
springs.
Yield criteria, energy methods, basic elasticity equations.





























MECHANICS OF FLUIDS

Group A

Properties and classifications of fluids. Fluids statics, buoyancy.
Scalar and vector fields, Reynolds transport theorem.
Continuity and momentum equations, momentum theorem, Bernoulli’s equation and their
applications.
Constitutive relation for a Newtonian fluid. Navier Stokes equations, exact solutions for flow
between parallel plates, rotating cylinders, Couette flow and Poiseuille flow.
Application of viscous flows through pipes, Correlation of friction factor.
Laminar boundary layer, boundary layer equations Blasius solution over a flat plate, wall
shear stress. boundary layer thickness, boundary layer control.


Group B

Separation; momentum integral method.
Turbulent flow; mixing length models; Skin friction coefficient in a turbulent boundary layer.
Compressibility flow; Nozzles and diffusers; Shocks; Effect of friction and heat transfer.
Potential flows.
Experimental methods for flow and velocity measurements.































THERMAL SCIENCE & ENGINEERING


Group A

System, property, work and heat interactions, zeroth law, first law of thermodynamics,
application of first law to closed systems and flow processes.
Thermodynamic properties of fluids.
Second law of thermodynamics, Carnot cycle, temperature scale, Clausius inequality, entropy increase, availability.
Thermodynamic property relations. Clapeyron’s equation.
Power and refrigeration cycles. Operating principles and essential components of vapour
power cycles. IC engines and gas turbines.
Thermodynamics of mixtures, psychrometry.







Group B

System, property, work and heat interactions, zeroth law, first law of thermodynamics,
application of first law to closed systems and flow processes.
Thermodynamic properties of fluids.
Second law of thermodynamics, Carnot cycle, temperature scale, Clausius inequality, entropy
increase, availability.
Thermodynamic property relations. Clapeyron’s equation.
Power and refrigeration cycles. Operating principles and essential components of vapour
power cycles. IC engines and gas turbines.
Thermodynamics of mixtures, psychrometry.




MANUFACTURING TECHNOLOGY


Group A

Introduction. Manufacturing cycle. Manufacturing processes and their selection.
Engineering materials and their selection.
Casting: Patterns, gating system design, riser design, product design, defects, inspection
techniques. Other casting processes: investment casting, die casting, centrifugal casting and
continuous casting. Basic design considerations in casting.
Metal forming: Plastic deformation, hot and cold working. Forming operations-rolling,
extrusion, drawing processes, sheet metal operations, load estimations for homogeneous
deformation. Sheet metal die design. High velocity forming processes.
Heat treatment processes.
Processing of plastics: Extrusion, injection moulding, blow moulding, rational moulding,
thermo-forming and compression moulding. Basic design considerations, rapid prototyping,
stereo lithography technique.
Powder metallurgy processing: Production of metal powders, compaction and sintering
processes. .





Group B

Metal cutting: Tool .materials, tool geometry and nomenclature in ASA, ORS and NRS,
cutting fluids, single and multipoint cutting operations, production of gears and screw
threads, grinding and finishing processes, specification of grinding wheels.
Machine tools: Primary and secondary dnves, guideway and slideways, structure.
Introduction to NC, CNC and DNC machining.
New machining methods: Process capabilities and limitations of AJM, USM, WJM, ECM,
ECG, EDM, EBM and LBM processes.
Joining processes: Fusion welding processes, heat affected zone, testing of welded joints,
solid state welding processes, brazing and soldering. Basic design considerations in welding.
Process selection. Adhesive bonding. Mechanical fastening processes.





DESIGN OF MACHINE ELEMENTS



Group A

Mechanical systems and elements, overall design considerations, safety, ecological and
societal considerations in design. Codes for design-Bureau of Indian Standards (BIS)-codes,
design data handbook. Load, stress and critical sections in machine parts.
Materials, stress-strain curves of ductile and brittle materials, cast iron, steel, non-ferrous
alloys and plastics, hardness and surface properties of materials, material strength, factor of
safety and allowable stress. Review of axial, bending, shear and torsional loading on machine
components, combined loading, two- and three dimensional Mohr's circle. Stresses in curved
beams, thick and thin shells under pressure.
Deflection and stability, beam deflection and column buckling. Euler's formula and Johnson's
formula. Failures theories-maximum normal stress theory, maximum shear stress theory, and
maximum distortion energy theory. Application to components made of brittle and ductile
materials, stress concentration factor.
Cyclic loading and fatigue failures: Reverse bending, axial and torsion loadings, effect of
stress concentration, fatigue life prediction-Miner's rule, effect of surface treatments (shotpeening,
surface hardening) on fatigue
life of components.
Design of threaded fasteners and power screws, thread forms and threaded fastener types and
materials, power screws, bolt tightening and initial tension, static and group of bolts.
Rivets and welding: Loading, bending, direct shear, axial and bending.






Group B

Design of springs: Spring materials, helical compression and extension springs, design for
fatigue, loading, leaf sprints. Design of sliding bearings, bearing materials, fluid viscosity,
hydrodynamic lubrication, Petroff's equation, Raimondi and Boyd chart. Heat
dissipation.
Rolling elements bearings: Types, catalogue information (Timken and SKF bearings),
bearing life radial and thrust loads. Selection of bearings. Spur, helical and worm gears, gear
tooth profile, gear geometry, module, contact ratio, gear train, gear tooth bending strength,
gear tooth surface fatigue analysis, gear material.
Design of shafts, keys, pins and splines, shaft couplings. Cotter and pin joints, pipe joints,
gaskets, seal and packing, cylinder joints, flanged joints.
Clutches and brakes: Single and multiple plate clutch, constant wear and constant pressure
theories for plate clutches, materials, shoe drum brakes, internal and external shoe brakes.
Power transmission elements: Belts and chain drives, design of flat and V-belts.






Group I Thermal Engineering

REFRIGEREATION AND AIRCONDITIONING


Group A
Introduction to refrigeration and air-conditioning, methods of refrigeration-conventional and
non-conventional, unit of refrigeration, COP and refrigeration efficiency.
Air refrigeration. Carnot. Bell Coleman, Brayton cycles, simple and bootstrap aircraft
refrigeration systems.
Mechanical refrigeration. Carnot vapour refrigeration compression cycle, simple vapour
compression cycle. Effect of sub-cooling and superheating on cycle performance, actual
vapour compression cycle, multistage and cascade refrigeration, industrial refrigeration
systems.
Vapour absorption refrigeration: Working principle, COP comparison between vapour
absorption and vapour compression refrigeration systems, actual ammonia
vapour refrigeration systems. Lithium bromide water absorption system, electrolux
refrigeration system.






Group B

Steam jet refrigeration system: Principle and applications, performance, actual steam jet
refrigeration. Vortex and pulse tube refrigeration, theory and operation.
Thermoelectric refrigeration: Thermoelectric elements, working principle and COP
refrigerants, desirable properties of refrigerants, primary and secondary refrigerants, various
refrigerants and their properties, alternatives to the chloro fluorocarbons.
Air-conditioning: Psychrometry, psychrometry chart and various psychometric processes,
comfort and industrial airconditioning, effective temperature and comfort chart, unitary and
central airconditioning systems.
Cooling and heating load calculations, design conditions, sensible and latent heat loads,
sensible heat ratio, structural, electrical, infiltration and ventilation heat gains, occupancy
heat gains, apparatus dew point, bypass and contact factors.



POWER PLANT ENGINEERING

Group A

Thermal power stations. Main components and working of power stations, thermodynamics
cycles, fuel handling, combustion and combustion equipment, problem of ash disposal,
circulating water schemes and supply of make up water. Choice of pressure of steam
generation and steam temperature, selection of appropriate vacuum economiser, air preheater, feedwater heaters and dust collection. Characteristics of turbo alternators, steam
power plant, heat balance and efficiency.
Boilers and steam generation, general classification, fire tube and water tube boilers, natural
circulation and forced circulation boilers, high pressure, high temperature boilers,
supercritical pressure boilers, boiler mounting and accessories, feed pumps, economisers,
superheaters, air preheaters; boiler furnaces, heat generation rates, water walls.
Gas fired and fuel fired oil furnaces, pulverised fuel fired furnaces, burners for gas fired, fuel
oil-fired and pulverised fuel fired furnaces, grate fired furnaces for solid fuels, feedwater
pumps and pipings, boiler settings, estimation of air quantity requirement and draught
systems, ID and FD fans.
Diesel power plants: Diesel engine performance and operation, plant layout, log sheets,
selections of engine size.
Gas turbine plants: Plant layout, methods of improving output and performance fuel and fuel
systems, methods of testing, open and closed cycle plants, operating characteristics-






Group B

Combined working of power plants: Advantages of combined working of different types of
power plants, need for co-ordination of types of power plants in power systems, base load
stations and peak load stations.
Hydroelectric plants: Penstocks, water turbines, specific speed, turbine governors, hydroplant
auxiliaries, plant layout, automatic and remote control of hydroplants, pumped projects, cost
of hydroelectric project.
Nuclear power plants: Elements of nuclear power plants, nuclear reactor fuel moderators,
coolants, control.
Major electrical equipment in power plants: Generator and exciters, power and unit
transformers, circuit breakers, protective equipment, control board equipment, elements of
instrumentation.
Power station auxiliaries. Alternate power sources. Solar power, geothermal, tidal and wind
power.


NON CONVENTIONAL ENERGY SYSTEMS


Group A

Introduction to non-conventional sources—Solar, bio-gas, wind, tidal, geothermal.
Basic bio-conversion mechanism; source of waste; simple digester; composition and calorific
values of bio-gas.
Wind and tidal energy generation; Special characteristics; Turbine parameters and optimum
operation; Electrical power generation from wind/tidal energy.
Energy from the sun: Techniques of collection; Storage and utilisation; Types of solar
collectors; Selective surfaces; Solar thermal processes; Heating; Cooling; Drying; Power
generation, etc.







Group B

Direct energy conversion methods: Photoelectric, thermoelectric, thermionic, MHD
(magneto-hydrodynamics) and electro-chemical devices; Solar cells.
Photo voltaic; Amorphous semiconductors; Limitations of photovoltaics efficiency; Fuel
cells; Peak load demands; Developments in fuel cells and applications.
Ocean thermal energy conversion; Geothermal energy-hot springs and steam injection; Power
plant based on OTEC and geothermal springs.
Fusion energy: Control through fusion of hydrogen and helium. Energy release rates-present
status and problems. Future possibilities.
Integrated energy packages using solar, biomass, wind, etc. Comparative study of non-
conventional energy sources; Cost considerations and economics.





INTERNAL COMBUSTION ENGINES

Group A

Classification of engines according to fuels, cycle of operation and number of strokes,
construction details, value arrangements, application of IC engines, review of air standard
cycles, deviation of actual cycles from fuel-air cycles, various influencing factors.
Review of fuels for IC engines with particular reference to velocity, ignition quality and
knock rating, variable compression ratio engines.
Air-fuel ratios and mixture requirements of SI engines, stoichiometric fuel air ratio, lean and rich mixture operation, optimum conditions, carburetors-principle, types and venturi, fuel orifice sizes, charge stratification and distribution.
Fuel-air requirement in CI engines. Methods of fuel oil distribution and injection. Types of
injector systems in SI and CI engines. Flame front and normal combustion. Detonation in SI
and knocking CI engines. Factors influencing detonation and knock. Comparative analysis.
Ignition systems in SI and CI engines.








Group B

Engine friction and lubrication: Effect of engine variables, total engine friction, requirem
of lubricants and lubricating systems.
Cooling systems: Gas temperature variation, heat transfer rates, piston and cylinder
temperature, heat rejected to coolant, air and water cooling systems and components.
Two-stroke engines: Special features, scavenging systems.
Supercharging: Objects, effects on engine performance, supercharging limits, methods of
supercharging with special .emphasis on turbochargers.
Engine testing and performance: Various performance parameters and their measurements.
Air pollution from engine exhaust, its measurement and control, principle constituents of
engine, emission methods of control, modification of conventional engines, dual fuel and
multifuel engines, stratified charged engines, sterlings engines, Wankel rotary combustion
engine.




TURBOMACHINERY

Group A

Positive displacement and turbo machines. Basic principles of rotodynamic machines.
Efficiency of turbo machines.
Flow through nozzles and blade passages: Steady flow through nozzles, isentropic flow;
Effect of friction in flow passages; Converging-diverging nozzles; Flow of wet steam through
nozzles; Diffusers.
Steam and gas turbines. Pressure and velocity compounding; Velocity diagrams; Degree of
reaction; Utilisation factor; Reaction blanding; Analysis of flow through turbo machines;
Energy equation; Momentum equation.
Fluid dynamic consideration: Theoretically obtainable work head; Profile losses. Clearance
and leakage losses. Windage losses. Partial admission losses. Flow deviation, Diffuser
performance. Design of blade passages. Cavitation in turbo machines.







Group B

Centrifugal compressors: Description and operation, energy transfer and relations, losses,
adiabatic efficiency, effect of compressibility, performance characteristics, pressure
coefficient, slip factor, surging, surge lines and stall line.
Axial compressor: Introduction, stage characteristics, blade efficiency, design coefficients,
blade loading, cascade characteristics, three-dimensional flow considerations, supersonic
axial flow compressor, performance characteristics.
Wind turbines: Power, energy and torque of wind turbines, coefficient of performance,
energy production and capacity factor, turbine shaft power, torque at variable speeds.
Hydraulic turbomachines: Hydraulic turbines (Pelton wheel and Kaplan turbines), centrifugal
and axial flow pumps, characteristics of hydraulic turbomachines.
Fans: Classification, fan laws.
Power transmitting turbomachines; Hydraulic coupling; Torque converters





Group II Engineering Design


DESIGN OF MECHANICAL SYSTEMS

Group A

The essential inputs to a design engineer. Stages in design. Creative and evolutionary design.
Problem formulation. Preliminary design and analysis.
Conceptual design: Alternative designs, feasibility analysis and design space, best design
constraints, system integration, rational design.
Design process and design cycle. Design morphology.
Design data bases and design standards.
Selection of materials and processes. Accuracy, surface finish, tolerances, statistical nature of
loads, part dimensions. Probabilistic design, factor of safety.
Detailed design of simple systems involving pressure vessels, fasteners, pins and welds.







Group B

Optimal design of machine elements and systems. Minimum weight and minimum cost
design rigidity and strength.
Reliability of systems, failure rate and component life, MTBF, reliability considerations in
design.
Static and dynamic analysis of engineering systems involving shafts, linkages, couplers,
transmission devices, toothed elements, etc.



OPTIMIZATION - THEORY AND APPLICATIONS

Group A

Introduction to optimisation: Historical development. Engineering applications. Statement of
an optimisation problem, classification and formulation of optimisation problems,
optimisation techniques.
Classical optimisation methods: Single variable optimisation, multivariable optimisation with and without constraints.
Linear programming: Standard form of a linear programming problem (LPP), geometry of
LPPs, related theorems, linear simultaneous equations, pivotal reduction, simplex method,
revised simplex method, duality, decomposition, transportation and assignment problems.
Nonlinear programming (unconstrained): Uni-modal function, exhaustive search, bi-section
and golden section methods, interpolation methods, random search methods, univariate
method, gradient of a function, conjugate gradient, quasi-Newton and variable metric
methods.







Group B

Nonlinear programming (constrained): Complex method* cutting plane method, method of
feasible directions, transformation techniques, penalty function methods, convergence
checks.
Geometric programming: Introduction to geometric programming, polynomial, unconstrained
and constrained problems.
Dynamic programming: Introduction to dynamic programming, multistage decision
processes, computational procedures, calculus and tabular methods.


ANALYSIS AND SYNTHESIS OF MECHANISMS AND MACHINES


Group A

Mechanisms and machines, kinematic pair, elements, chains and inversions, degree of
freedom, movability, Grubler's criterion, four-link mechanisms,. Grashof's criteria.
Kinematic analysis, instantaneous centres, Kennedy theorem, velocity analysis using velocity
difference and instantaneous centres, acceleration analysis, velocity and acceleration images.
Kinematic synthesis, graphical method using inversion and overlay, three-point synthesis
problems, motion, path and function generation. Freudenstein's method of three point
synthesis of four link mechanisms.
Dynamic force analysis of four-bar and slider crank mechanisms, turning moment and
flywheel analysis.
Types of governors, characteristics of centrifugal governors, stability control of speed
hunting of governors.








Group B

Balancing of rotating masses: Two balancing masses in two planes for complete dynamic
balance. Determination of balancing masses, balancing of rotors, balancing of internal
combustion engines, balancing of multicylinder inline engines, V-twin cylinder, multi-row
W-engine and radial engine. Lanchester technique for balancing internal combustion engines
with rotating eccentric weights.
Types of cam followers, selection of motion, displacement diagrams, cam profiledetermination.
Gears and gear trains, fundamental law of gearing, involute tooth profile, undercutting and
interference. Minimum number of teeth, types of gears, simple, compound and epicyclic gear
trains.






DESIGN OF MACHINE TOOLS

Group A

Conceptualisation of mechanical systems for prescribed scheme; Layout of machine tool
elements; Introduction to machine tool drives and mechanisms; General principles of
machine tool design.
Design of drive systems; Regulation of speed and feed; Kinematic structure of machine tool
gear box; Hydraulic, mechanical and electrical speed regulation.
Design of machine tool structures: Material selection; Welded vs. cast structure; Static and
dynamic stiffness; Choice of element sections and their design.









Group B

Analysis of spindles, bearings, slides and guides.
Control systems for machine tools.
Dynamics of machine tools: Machine tools as a closed loop system. Dynamic stability.
Forced vibration and chatter in machine tools.
Concept of modular design; Concepts of aesthetic and ergonomics applied to machine tools;
Acceptance tests and standardisation of machine tools.





COMPUTER AIDED ENGINEERING DESIGN

Group A

Computer aided design of engineering systems. Applications in modelling, analysis, design
and manufacturing.
Computer graphics, raster graphics and interactiveness, pixels and graphic display in
computers, windows and view-ports, lines and circles, graphic data storage and manipulation,
hardware display, input and output devices.
Geometric transformations-two, three-dimensional and homogeneous transformations,
rotation, translation, mirror, perspective, projections, etc.
Computer aided drafting. Introduction to Auto CAD-use of menus and icons, twodimensional
drawings using auto CAD lines, circles,
tangents, simple machine drawings, dimensioning, blocks and layers, editing
and adding text to a drawing. Advanced auto CAD-three-dimensional drawings. Curves, surfaces and solid models, customizing. Auto CAD, auto LISP.









Group B

Computer aided design of engineering systems. Applications in modelling, analysis, design
and manufacturing.
Computer graphics, raster graphics and interactiveness, pixels and graphic display in
computers, windows and view-ports, lines and circles, graphic data storage and manipulation,
hardware display, input and output devices.
Geometric transformations-two, three-dimensional and homogeneous transformations,
rotation, translation, mirror, perspective, projections, etc.
Computer aided drafting. Introduction to Auto CAD-use of menus and icons, twodimensional
drawings using auto CAD lines, circles, tangents, simple machine drawings, dimensioning,
blocks and layers, editing and adding text to a drawing.
Advanced auto CAD-three-dimensional drawings. Curves, surfaces and solid models,
customizing. Auto CAD, auto LISP.














Group III Manufacturing Engineering

 

MANUFACTURING SCIENCE

Group A

Deformation of metals, stress-strain curves, temperature and strain rate effects, ductility and
toughness, plane-strain deformation, mechanism of plastic deformation, control of material
properties—alloying and heat treatment.
Sand casting: Pattern materials and allowances, moulding materials, properties ol moulding
sand, effects of moulding ingredients on mould properties, estimation of pouring time,
mechanism of solidification, rate of solidification in an insulating mould, riser design and
placement, residual stresses.
Elements of plasticity—yield criteria and flow rule, plastic instability. Analysis of forming
processes—forging, rolling, extrusion, wire and strip drawing, using slab method, deep
drawing, blanking and piercing. Lubrication and friction in metal forming.










Group B

Metal cutting: Mechanics of orthogonal cutting, chip formation in turning, shaping, planning,
milling and drilling, evaluation of surface roughness in machining, heat generation,
estimation of average tool temperature, tool wear mechanism and tool life testing, variables
affecting tool life machining economics—estimation of cost and optimum cutting conditions.
Metal grinding: Basic mechanics of grinding process, forces and specific energy, grinding
temperature—heat sources and estimation of average temperature, wheel wear mechanism,
estimation of surface roughness.
Non-conventional machining: Classification of processes, mechanism of material removal
and effects of process parameters in AJM, USM, ECM, EDM, LBM, EBM and PAM.
Welding and allied processes: Bonding process in welding, principles of solid-state welding,
fusion welding, soldering and brazing, effects of process parameters, metallurgy of welding
stress distribution and heat affected zone.














COMPUTER AIDED MANUFACTURING


Group A

Basic definitions of manufacturing systems: Definitions, design, planning and control.
Part design and CAD: Engineering design, design drafting and its interpretation, inspection
and measurement. A brief history of CAD, CAD hardware and software. Fundamentals of
geometric modeling. CAD data exchange.
Process engineering: Experience-based planning, process capability analysis, basic machining
and other manufacturing process calculations, process optimisation.
Hard automation: Introduction to automated manufacturing, fixed automated manufacturing
systems, workpiece handling hardware for automation and economics of automation.
Programmable logic controllers: Function of controllers, control devices, programmable logic
controllers.
Data communication and local area networks in manufacturing: Fundamentals of data
communication and local area networks.









Group B

Fundamentals of numerical control: Historical developments and principles of NC,
classification of NC, NC part programming, manual and computer-assisted part
programming.
Introduction to industrial robots: Power sources, actuators and transducers. Robot
applications. Economic considerations of robotic systems.
Group technology: Introduction, coding and classification, benefits of group technology.
Process planning: Introduction, manual process planning, computer aided process planning,
variant and generative approaches, simple examples.



TOOL AND DIE DESIGN

Group A

Influence of tools and dies on quality, productivity and environment, tool design methods and
procedures, tool making practices, tooling materials and treatment.
Jigs and fixtures. Basic principles of locating and clamping, development of fixture using
locating, clamping, indexing tool setting elements, force analysis, standardisation of
elements, illustrative examples of machining, welding, assembly and inspection fixtures.
Design of cutting tools and special tools (form cutters and broachers), tooling for CNC,
introduction to modular fixtures and tools.

  
Group B

Die design: Design of sheet metal blanking, piercing, bending and deep drawing dies.
Progressive die design.
Mould design. Introduction to die casting and injection mould design. General mould
construction. Design of ejection, feed and cooling systems. Parting surface design. Side cores
and side cavities. Product design for die casting and injection molding.
Cost estimation and cost benefit analysis.



MANUFACTURING AUTOMATION

Group A

Definition of automation, reasons for automating, pros and cons of automation.
Fundamentals of manufacturing and automation: Manufacturing operations and automation
strategies, production economics.
High volume production systems: Detroit type automation, analysis of automated flow lines,
assembly and line balancing, automated assembly systems.
Numerical control production systems: CNC, DNC and adaptive control.



Group B

Industrial robots: Robotics technology, robot applications.
Material handling and storage: Automated materials handling, automated storage and
retrieval systems.
Flexible manufacturing systems (FMS): FMS workstations, material handling and storage
systems, computer control systems, planning the FMS, analysis methods for FMS,
applications and benefits.
Automated inspection and testing: Inspection and testing, statistical quality control,
automated inspection principles and methods, sensor technologies for automated inspection,
coordinate measuring machines, other contact inspection methods, machine vision and other
optical inspection methods, and non-contact inspection methods.



PRODUCTION MANAGEMENT

Group A

Introduction. Concept of management, concept of a system, production system, production
functions.
Organisation fundamentals. Guidelines for good practice, organisation structures,
organisation charts, span of control, number of levels, number of executives, management
functions.
Production economics: Kinds of costs, evaluation of capital investments. Capital budgeting,
break-even analysis, make or buy decisions, evaluation of alternatives, discounted cash flow,
equivalent comparison methods, depreciation.
Aggregate planning. Planning time horizons, inputs to aggregate planning systems, single and multistage aggregate planning systems, decision processes for aggregate planning—graphical method, linear decision rule, and linear programming method-Demand management. Time span for forecasts, forecasting system, forecasting methods-time series, casual and predictive forecasting methods, selection of a forecasting method.


Group B

Scheduling. Scheduling process scheduling for a multistage production system, sequencing
production operations, Johnson's rule.
Facilities management. Plant location—factors influencing plant location, cost factors, plant
location decision process, selection of a location for new facilities, evaluation of alternative
regions and sub-regions. Plant layout-objectives, decision process, types of layouts,
comparison of layouts. Line balancing and sequence analysis concepts. Materials handlingdevices
for materials handling, basic considerations in the selection of materials handling system.
Human factor engineering: Methods analysis and works measurement, methods study,
process analysis, operation process chart, operator process chart, motion study, principles of
motion economy, motion analysis. Time study-types of studies, procedure for job time study,
physical environment.
Quality management: Three aspects of quality, functional responsibility for quality in a
manufacturing system, economics of quality assurance, quality control, QC decision
variables, process control, control charts, acceptance sampling, single, double and sequential
sampling plans, concept of total quality control (TQC).
Maintenance management: Maintenance functions, concept of reliability engineering,
reliability improvement, preventive maintenance, preventive maintenance policy, repair
policy, replacement decisions, queuing theory and its applications in maintenance.
Introduction to PERT/CPM.
.





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