MSC Manufacturing Engineering SMIE AAiT May 15 - Endalk

ADDIS ABABA UNIVERSITY
ADDIS ABABA INSTITUTE OF TECHNOLOGY (AAiT)

SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING
Draft curriculum on
Master of Science Program in

Manufacturing Engineering
Chair: Manufacturing and Materials Engineering
May, 2017
Contents
Contents .................................................................................................................................................. 3
1. INTRODUCTION ............................................................................................................................... 1
1.1 Background ............................................................................................................................. 1
1.2 Course Aim and Objectives ..................................................................................................... 1
1.3 Who Can Join the Program? ................................................................................................... 2
2. RATIONALE OF THE GRADUATE PROGRAM .................................................................................... 3
3. GRADUATE PROFILE ........................................................................................................................ 3
4. PROGRAM REQUIREMENTS ............................................................................................................ 4
4.1 Admission Requirements ........................................................................................................ 4
4.2 Graduation Requirements ...................................................................................................... 4
4.3 Evaluation Criteria................................................................................................................... 4
4.4 Quality Assurance and curriculum review .............................................................................. 4
5. DEGREE NOMENCLATURE ............................................................................................................... 6
6. PROGRAM DESCRIPTION................................................................................................................. 7
6.1 Modules .................................................................................................................................. 7
6.2 Structure of the Program ...................................................................................................... 10
6.3 Course Listing ........................................................................................................................ 10
7. DESCRIPTION OF THE PROGRAMS ................................................................................................ 11
7.1 Module Listing and Scheduling ............................................................................................. 11
7.1.1 Module Listing .............................................................................................................. 11
7.1.2 Module Offering Schedule ............................................................................................ 13
7.2 Descriptions of the Modules ................................................................................................. 14
7.2.1 Finite Element Methods in Manufacturing ................................................................... 14
7.2.2 Metal Cutting Analysis ................................................................................................. 16
7.2.3 Metal Joining Processes ................................................................................................ 18
7.2.4 Metal Forming Analysis................................................................................................ 21
7.2.5 Foundry Engineering..................................................................................................... 23
7.2.6 Tool and Die Design and Manufacturing ...................................................................... 25
7.2.7 Polymer and Composite Manufacturing ....................................................................... 27
7.2.8 Production and Operations Management ...................................................................... 29
7.2.9 CAD/CAM/CAE ........................................................................................................... 31
7.2.10 Applied Mechatronics/Manufacturing .......................................................................... 33
7.2.11 Computer Integrated Manufacturing ............................................................................. 35
7.2.12 Lean Manufacturing ...................................................................................................... 37
7.2.13 Industrial Robotics ........................................................................................................ 39
7.2.14 Total Quality Management ........................................................................................... 41
7.2.16 Heat Transfer................................................................................................................. 45
7.2.17 Manufacturing Systems Modeling and Simulation ....................................................... 47
7.2.18 Rapid Prototyping and Manufacturing .......................................................................... 49
Lab Component-1.............................................................................................................................. 51
Lab Component-II.............................................................................................................................. 53
1. INTRODUCTION
1.1 Background
Based on the needs of the industrial sector and the capacity building of higher educational
institutions and recommendations of the staffs of the School of Mechanical & industrial
Engineering, the school offers M.Sc. and PhD programs in three areas of specialization,
namely: Thermal Engineering, Mechanical Design and Industrial Engineering since
1998/1999. As the school aspires to develop expertise in other disciplines as well, the new
specialized PG program leads to a separate full-fledged program in Manufacturing
Engineering which increases the specializations to four. This will allow the enrollment of
manufacturing engineers with B.Sc. and M.Sc.
The Manufacturing Engineering program is designed to address the challenges of modern

Manufacturing and Enterprise Systems. It covers a breadth of subjects that enable
candidates to appreciate and deal with complexities of modern industrial environments.
This program is expected to impart theoretical and practical knowledge and research skills
to the students in the latest state of the art in Manufacturing Engineering and make them
good engineer, scientist, industrialist and academicians in the area of Manufacturing
Engineering.
The program consists of three main elements, technology, systems and tools and
Management. During the program, the students will acquire the necessary skills to tackle
issues in product design, engineering and manufacturing and manage industrial systems
under financial and resource constraints. The students also deal with modern mathematical
tools for measuring systems performance techniques, quality and reliability issues.
1.2 Course Aim and Objectives
Manufacturing industry worldwide has experienced major changes since the industrial
revolution. Dynamic changes such as globalization, mass customization, enterprise agility/
supply chain management, continuous innovation, and increasing application of computer
aided design and manufacturing, etc are exhibited in the past two decades. These
challenges require a new generation of manufacturing engineers that are highly specialized
along with other expertise.
For the engineering and academic community such as AAU and AAiT in particular, it is
essential to train and educate the next generation of Manufacturing Engineers who will be
able to work in the challenging environment where a systems approach to problem solving
is crucial.
The Master of Science (M.Sc) program in Manufacturing Engineering, therefore is aimed at

producing highly skilled and competitive Engineers, academicians and researchers with up
1
to date advanced knowledge in Manufacturing Engineering and its applications, who can
meet the challenges of the manufacturing environment locally and internationally.
Towards achieving this objective, the Manufacturing Engineering graduates will be equipped
with the latest techniques in manufacturing and systems engineering in:
Design and development of highly flexible and economical global manufacturing

systems and supply chains.
Managing and providing solutions for advanced automated and semi-automated
industries.
Application of advanced computer and mathematical modeling for improved
performance, design and management of industrial systems.
Deploy the latest advanced measurement techniques and technologies for
calibration
Management and implementation of projects and operations under time and
resource constraints.
Design and development of sustainable and environmentally responsible products.
The specific objectives of this program are:
1. To produce graduates with full professional competence in Manufacturing

Engineering.
2. To have high level technical manpower who can participate in the national
development activities.
3. To enable the graduates carry out research in the areas of Manufacturing
Engineering, relevant to the societal needs of the Country.
4. To enable graduates render consultancy services to the community.
5. To provide opportunity for the working community in the field of Automobile
engineering to upgrade their knowledge to a higher level.
6. To equip the in-service candidates working in various industries, factories and
institutions with the latest technologies in the field of manufacturing Engineering to
make them competitive enough in the present day market and make them useful for
the development of the country.
1.3 Who Can Join the Program?
The program is intended to benefit a wide range of candidates, in particular:
Established manufacturing engineers working in industry and faced with the

challenge of new areas of responsibility.
Managers and product designers working in manufacturing organizations that need
to invest in their personal career development.
2
Engineering and Technology professionals/graduates from Mechanical, Industrial,
Manufacturing, Production and Material.
Recent engineering and technology professionals/graduates who have decided to
move into manufacturing and related disciplines.
2. RATIONALE OF THE GRADUATE PROGRAM

The undergraduate program School of Mechanical and Industrial Engineering in its five year
program produces Mechanical engineers with broad knowledge and spectrum. The program
allows students to gain broad background so they can fit in different industrial sectors, such
as the manufacturing industry, power generation industry, design and research institutions
and service giving industries.
The education offered by the School must cope with the current growth and development
of both engineering and technology in industries in order to meet the high-level professional
demand. Mechanical engineers with higher level of knowledge and skill than that of the
B.Sc. degree graduates are required. The postgraduate program is intended to fulfill this gap
assessed by the School in general and the chair of Manufacturing and Materials Engineering
specifically.
3. GRADUATE PROFILE
After the successful completion of the Masters in Mechanical Engineering specialization in
Manufacturing Engineering program, the graduates are in a position to:
Take up a position in Manufacturing and related industries looking after jobs like
design, production and process planning, research, production, maintenance and
management.
Take up a teaching post in Universities and in higher educational institutions.
Take up a research activities in research organizations.
Become entrepreneur.
Serve as independent consultant.
Get promotion in their respective jobs that are being held
Pursue PhD degree.
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4. PROGRAM REQUIREMENTS
4.1 Admission Requirements
The candidates for Manufacturing Engineering program must have B.Sc./B.Tech. Degree in
Industrial, Mechanical, Production, Manufacturing Technology/ Engineering and meet other
requirements set by the School of Graduate Studies.
4.2 Graduation Requirements
In addition to the requirements of Addis Ababa University, a candidate for the M.Sc. degree
is expected to successfully complete ---------- credit hours of course work and a thesis [120
ECTS].
4.3 Evaluation Criteria
The achievements of the thesis will be indicated as follows:
Grade Points/Marks
Excellent Above 95
Very Good 85-95
Good 75-85
Satisfactory 60-75
Fail less than 60
The respective instructors will evaluate the final examination, project works and
assignments and finally give grades based on the following pattern. The final graduate
project will also be evaluated in the same way.
Letter
Grade Points/Marks
A 90-100
B+ 84- 89
B 75-87
C+ 69-74
C 60-68
D 50-59
F below 50
4.4 Quality Assurance and curriculum review
The quality of the program offered by the school is assessed by the performance of its
graduates and the impact they bear on the industrial sector of the country. The quality
assurance methods adopted by the school include the following:
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In line with the AAU and AAiT policy, student evaluations regarding the teaching-
learning process are taken at the end of each semester;
External evaluation by experts from external university;
Feedback from employers and stakeholders is obtained through personal contacts
formally and/or informally;
Former graduates of the program and
Students who go for higher studies in foreign institutions.7
5
5. DEGREE NOMENCLATURE
After the fulfillment of the set requirements, the graduate will be awarded the
Degree of MASTER OF SCIENCE
IN
MECHANICAL ENGINEERING
(MANUFACTURING ENGINEERING)
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lM}G }V
(bn#KcNG x!N!nNG)
6
6. PROGRAM DESCRIPTION
6.1 Modules
The curriculum for Manufacturing Engineering is structured in six modules. These modules
are:
i. Advanced Manufacturing and Automation

ii. Advanced Materials and Technologies in Manufacturing
iii. Facilities and Systems Engineering
iv. Quality Management and Reliability
v. Qualitative and Analytical Tools
vi. Leadership and Entrepreneurship
vii. Master Thesis and Seminar
The courses in each module are presented in table below
Credit ECTS %
Modules for Manufacturing Engineering
hrs.
Advanced Manufacturing and Automation
MEng 6101 Metal Cutting Analysis [4 Cr.]
MEng 6102 Metal Joining Processes [3 Cr.]
25 50 42%
MEng 6103 Metal Forming Analysis [3 Cr.]
MEng 6201 Foundry Engineering [3 Cr.]
MEng 6203 Tool and Die Design in Manufacturing [3 Cr.]
MEng 7101 CAD/CAM/CAE [3 Cr.]
I
MEng 7102 Applied Mechatronics/Manufacturing Automation
[3 Cr.]
MEng 7103 Production and Operations Management [3 Cr.]
MEng 6105 Metrology & Tolerance Technology (Advanced
Manufacturing Measurement) [3 Cr.]
MEng 6106 Computer Integrated Manufacturing [3 Cr.]
MEng 6205 Industrial Robotics [3 Cr.]
Advanced Materials and Technologies in
Manufacturing
ii 4 5 7%
MEng 6202 Polymer and Composite Manufacturing [4 Cr.]
MEng 6206 Rapid Prototyping and Manufacturing [3 Cr.]
7
Facilities and Systems Engineering 6 12 10.00%
Meng 6104 Finite Element Methods in Manufacturing [3 Cr.]
MEng 6204 Flexible Manufacturing System [3 Cr.]

iii
MEng 6207 Production Planning and Control, Production
Costing And Cost Control [3 Cr.]
MEng 7105 Lean Manufacturing [3 Cr.]
Quality Management & Reliability

iv 3 6 %
MEng 7106 Total Quality Management and Reliability [3 Cr.]
Qualitative and Analytical Tools
MEng 6304 Research Methods & Scientific Writing [2 Cr.]
v MEng 6107 Manufacturing System Modeling & Simulation [3

2 4 %
Cr.]
MEng 6108 Heat Transfer [3 Cr.]
Leadership and Entrepreneurship
vi MEng 7107 Leadership (managing people and organizations) 2 4 6.67%
and Entrepreneurship [3 Cr.]
Master Thesis and Seminar 30 25.00%
MEng 7402 Seminar (Special Topics in Manufacturing
vii
Engineering)
MEng 7401 Thesis
Total 38 120 100%
The detail description of the modules follows.
i) Advanced Manufacturing and Automation Module

The objective of this module is to enable students understand the principles in designing
and controlling modern automated manufacturing systems, and employs a systems
approach in doing so. Students are equipped with a variety of industrial and factory
automation practices and selecting appropriate automation and control methods for the
equipment or process, the basic measurement theory, modern measurement techniques
and principles, capabilities of practical measuring machines and their applications in
advanced manufacturing
8
ii) Advanced Materials and Technologies in Engineering
Materials Engineering and associated technologies in manufacturing have evolved
enormously in the 21st century. Plastics and composites are competitive engineering
materials in selection during product development. Also, rapid prototyping with lithography
is a preferred modeling technique in prototype development using plastic and composites.
iii) Facilities and Systems Engineering Module

The objective of this module is to equip students with the necessary knowledge and skills for
the design of facilities such as industrial plants and systems in manufacturing and service
industries.
iv) Quality Management and Reliability Module

This module provides an in-depth understanding of the principles of modern quality control
and their applications in engineering, manufacturing and services. It also enables students
to develop advanced techniques of reliability engineering in order to improve the
maintenance and safety of manufacturing plants.
v) Qualitative and Analytical Tools Module

The objective of this module is to give to the students the required knowledge and skills of
operations research and simulation techniques which are necessary for demand forecasting,
optimizing layout of facilities and evaluation of performance of manufacturing and service
systems.
vi) Leadership and Entrepreneurship

This module enables the student to understand the skill and knowledge necessary in
managing people and organizations in small and large manufacturing organizations. The
module also provides basic skills if product development and innovations and being an
entrepreneur.
vii) Master Thesis and Seminar Module

Following the taught part of the program and reflecting individual interests, the Master
Thesis is an in-depth study of a real manufacturing problem or situation, requiring a high
standard of investigation and presentation, frequently involving a company or workplace or
expands knowledge in a particular discipline by way of advanced research, etc.
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6.2 Structure of the Program
Total
Semester I Semester II Semester III Semester IV
Credits
4 Core Courses: 4 Core Courses: 3 Core Courses: Thesis
(1*4 + 3*3) (4*3) (2*4 + 1*3)
1 Elective: (1*3) 1 Elective: (1*3) 1 Elective: 1*3
Research Methods &
Thesis Stage I
Scientific Writing (2)
Seminar (P/F)
Total Cr. 16 17 14 15 45
6.3 Course Listing

Course No. Course Name Cr. Hrs ECTS
Core Courses
MEng 6101 Metal Cutting Analysis 4 8
MEng 6102 Metal Joining Processes 3 6
MEng 6103 Metal Forming Analysis 3 6
MEng 6201 Foundry Engineering 3 6
MEng 6104 Finite Element Methods in Manufacturing 3 6
MEng 6203 Tool and Die Design in Manufacturing 3 6
MEng 7101 CAD/CAM/CAE 3 6
MEng 7102 Applied Mechatronics/Manufacturing Automation 3 6
MEng 7103 Production and Operations Management 3 6
MEng 6202 Polymer and Composite Manufacturing 4 8
MEng 6204 Flexible Manufacturing Systems, Automation in Manufacturing 3 6
MEng 7104 Research Methods & Scientific Writing 2 5
Additional Courses: Elective I
MEng 6105 Metrology & Tolerance Technology 3 6
Advanced Manufacturing Measurement
MEng 6106 Computer Integrated Manufacturing 3 6
MEng 6107 Manufacturing System Modeling & Simulation
MEng 6108 Heat Transfer
Additional Courses: Elective I I
MEng 6205 Industrial Robotics 3 6
MEng 6206 Rapid Prototyping and Manufacturing 3 6
MEng 6207 Production Planning & Control, Production Costing And Cost Control 3 6
Additional Courses: Elective I II
MEng 7105 Lean Manufacturing
MEng 7105 Total Quality Management and Reliability 3 6
MEng 7107 Leadership (managing people and organizations) and 3 6
Entrepreneurship
Final Year Seminar and Thesis
Meng 7201 Seminar: Special Topics in Manufacturing Eng /Independent study P/F
MEng 7202 Thesis
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7. DESCRIPTION OF THE PROGRAMS
7.1 Module Listing and Scheduling
7.1.1 Module Listing

I. Bridge Modules
Bridge Modules will be recommended based on the applicant academic background by the
chair or committee assembled during admission procedure.
II. Compulsory Modules
Course Code Course Name Cr. Hr. ECTS
Meng 6104 Finite Element Methods in Manufacturing 3 6

Meng 6101 Metal Cutting Analysis 4 8
Meng 6102 Metal Joining Processes 3 6
Meng 6103 Metal Forming Analysis 3 6
Meng 6201 Foundry Engineering 3 6
Meng 6202 Polymer and Composite Manufacturing 4 8
Meng 6203 Tool and Die Design in Manufacturing 3 6
Meng 6204 Flexible Manufacturing Systems, Automation in 3 6
Manufacturing
Meng 7101 CAD/CAM/CAE 3 6
Meng 7102 Applied Mechatronics/Manufacturing Automation 3 6
Meng 7103 Production and Operations Management 3 6
Meng 7104 Research Methods & Scientific Writing 2 5
Elective I 3 6
Elective II 3 6
Elective III 3 6
Meng 7201 Seminar P/F
Meng 7202 Thesis 14
60
11
III. Elective Modules
ELECTIVE I

MEng 6105 Metrology & Tolerance Technology, Advanced 3 6
Manufacturing Measurement
MEng 6106 Computer Integrated Manufacturing 3 6
MEng 6107 Manufacturing System Modeling & Simulation
MEng 6108 Heat Transfer
ELECTIVE I I

MEng 6205 Industrial Robotics 3 6
MEng 6206 Rapid Prototyping and Manufacturing 3 6
MEng 6207 Production Planning & Control, Production Costing And Cost 3 6
Control
ELECTIVE I II

MEng 7105 Lean Manufacturing
MEng 7105 Total Quality Management and Reliability 3 6
MEng 7107 Leadership (managing people and organizations) and 3 6
Entrepreneurship
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7.1.2 Module Offering Schedule
Year Semester Module No Module Name Cr. Hr ECTS
MEng 6101 Metal Cutting Analysis 4 8

MEng 6102 Metal Joining Processes 3 6
1 MEng 6103 Metal Forming Analysis 3 6
MEng 6104 Finite Element Methods in 3 6
Manufacturing
I Elective I 3 6
Total 16 30
MEng 6201 Foundry Engineering 3 6

2 MEng 6202 Polymer and Composite 4 8
Manufacturing
MEng 6203 Tool and Die Design in 3 6
Manufacturing
MEng 6204 Flexible Manufacturing Systems, 3 6
Automation in Manufacturing
Elective II 3 6
Total 17 30
MEng 7101 CAD/CAM/CAE 3 6

MEng 7102 Applied Mechatronics / 3 6
Manufacturing Automation
MEng 7103 Production and Operations 3 6
1 Management
MEng 7104 Research Methods & Scientific 2
Writing
II
Elective III 3
Total 14
MEng 7201 Seminar P/F
2 MEng 7202 Thesis 14
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7.2 Descriptions of the Modules
7.2.1 Finite Element Methods in Manufacturing
Module Title: Finite Element Methods in Manufacturing

Module Code: MEng
Module Credit: Credit Hours : 3
ESTC : 6
Pre-requisite Module: Matrix algebra and Mathematical knowledge
Co-requisite Module: None
Barred Combination Modules: None
Module Description: Introduction, boundary and Eigen value problems, One dimensional analysis,
steps in FEM discretization, Interpolation, derivation of elements characteristic matrix, shape function,
shape functions and higher order formulations, computer implementation in FEM, Analysis of
production processes.
Learning Outcome:
On successful completion of this module students would be able to:
1. To impart knowledge in the area of finite element methods and its application in
manufacturing.
2. Understand fundamentals of one dimensional and two dimensional problems using FEA in
manufacturing.
3. Apply the procedure involved to solve a structural problem using Finite Element Methods.
4. Develop the element stiffness matrices using different approach.
5. Analyze a 2D problem using line, triangular, axi - symmetric and quadrilateral element.
6. Analyze a 3D problem using tetrahedral and hexahedral elements.
CONTENT:
INTRODUCTION
Fundamentals Initial, boundary and Eigen value problems weighted residual, Galerkin and Rayleigh
Ritz methods - Integration by parts Basics of variation formulation Polynomial and Nodal
approximation.
ONE DIMENSIONAL ANALYSIS

Steps in FEM Discretization. Interpolation, derivation of elements characteristic matrix, shape
function, assembly and imposition of boundary conditions-solution and post processing One
dimensional analysis in solid mechanics and heat transfer.
SHAPE FUNCTIONS AND HIGHER ORDER FORMULATIONS
Shape functions for one and two dimensional elements- Three nodded triangular and four nodded
quadrilateral element Global and natural co-ordinatesNon linear analysis Isoparametric elements
Jacobian matrices and transformations Basics of two dimensional, plane stress, plane strain and
axisymmetric analysis.
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COMPUTER IMPLEMENTATION
Pre Processing, mesh generation, elements connecting, boundary conditions, input of material and
processing characteristics Solution and post processing Overview of application packages
Development of code for one dimensional analysis and validation
ANALYSIS OF PRODUCTION PROCESSES

FE analysis of metal casting special considerations, latent heat incorporation, gap element Time
stepping procedures Crank Nicholson algorithm Prediction of grain structure Basic concepts of
plasticity and fracture Solid and flow formulation small incremental deformation formulation
Fracture criteria FE analysis of metal cutting, chip separation criteria, incorporation of strain rate
dependency FE analysis of welding.
Teaching Strategy/Methods:
Lecture
Workshops and Laboratories
Projects
Semester project work
Assessment Strategy: Exercises
Workshop exercises
Laboratory exercises
Project
Final examination
Module Requirements:
Minimum of 75% attendance during lecture hours
100% attendance during practical work sessions, except for some unprecedented
mishaps
All exercises and project works must be submitted by the specified dead line date
Text books:
1. Reddy, J.N. An Introduction to the Finite Element Method, McGraw Hill,2005.
2. Rao, S.S., Finite Element method in engineering, Pergammon press, 2005.
3. 3. Seshu P., Textbook of Finite Element Analysis, PHI Learning Pvt. Ltd, 2004.
References:
1. Lewis R.W. Morgan, K, Thomas, H.R. and Seetharaman, K.N. The Finite Element Method in
Heat Transfer Analysis, John Wiley, 1994.
2. Bathe, K.J., Finite Element procedures in Engineering Analysis, 1990
3. Kobayashi,S, Soo-ik-Oh and Altan.T. Metal Forming and the Finite Element Methods, Oxford
University Press, 1989.
4. www.tbook.com
5. www.pollockeng.com
6. Zienkiewicz, O. C., The Finite Element Method, Butterworth Heinemann (2002).
7. Huebner, K. H., Dewhirst, D. L., Smith, D. E. and Byrom, T. G., The Finite Element Methods
for Engineers, John Wiley (2000).
8. Cook, R. D., Concepts and Applications of Finite Element Analysis, John Wiley and Sons
(2001).
9. Buchman, G. R., Finite Element Analysis, Schaums Outlines, McGraw Hill (1995).
10. Chandrupatla, T. R. and Belgundu, A. D., Introduction to Finite Elements in Engineering,
Prentice Hall of India (1997).
11. Jordan, C. Calculus of Finite Differences, American Mathematical Society (1979).
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7.2.2 Metal Cutting Analysis
Module Title: Metal Cutting Analysis

Module Code: MEng
ESTC : 8
Pre-requisite Module: Material Science and Mechanics of materials
Module Description:
An overview of metal cutting machine tools, survey of various methods of metal removal, mechanics
of orthogonal cutting, nature of contact between chip and tool, stress distribution, at chip-tool interface,
controlled contact tools, mechanics of oblique cutting, thermal aspects of metal cutting, cutting fluids,
method of selection of fluids, dry cutting, tool wear, wear theories, experimental methods, tool life,
machinability, machining economics, dynamometry, abrasive machining processes, mechanics of
grinding process, grinding wheel wear , high speed machining , ultra-precision machining and hard
turning.
Learning Outcome:
1. Apply cutting mechanics to metal machining based on cutting force and power consumption.
2. Operate lathe, milling machines, drill press, grinding machines, etc.
3. Select cutting tool materials and tool geometries for different metals.
4. Select appropriate machining processes and conditions for different metals.
5. Learn machine tool structures and machining economics.
6. Write simple CNC programs and conduct CNC machining
CONTENT:
INTRODUCTION:
MECHANICS OF METAL CUTTING: Mechanism of chip formation, Orthogonal & Oblique
cutting, types of chips, built-up edge, Determination of shear plane angle, forces on the chips, forces in
orthogonal cutting, Merchant circle diagram and analysis, Theory of Lee & Shaffer, co-efficient of
friction, power & energy relationship, velocity relationship, shear-strain, factors affecting forces and
power, problems.
GEOMETRY OF CUTTING TOOLS: Single point and multi point cutting tools, tools nomenclature,
tool point reference systems, tool angle specifications ISO and ASA systems, conversion from one
system to another. Recommended tool angles, Effect of cutting parameters on tool geometry.
TOOL MATERIALS AND THEIR PROPERTIES: Characteristics of tool materials, types of tool
materials carbon tool steels, high speed steels, cast alloys, cemented carbides, ceramics, diamonds,
SIALON, CBN, UCON, recommended cutting speeds for the above tools, discussion on steels, air,
water, oil hardening of tools and their applications.
Measurement of Cutting Forces: Reasons for measuring cutting forces, Classification of cutting force
dynamometers mechanical, hydraulic, pneumatic, optical, inductance, piezoelectric, and strain gage
type dynamometers, Dynamometers for lathe, drilling, and milling, Calibration of dynamometers.
Tool Wear, Tool Life: Mechanisms of tool wear, Sudden & gradual wear, crater wear, flank wear, tool
failure criteria, tool life equations, effect of process parameters on tool life, tool life tests, conventional
& accelerated tool wear measurement, machinability index
Thermal Aspects in Metal Cutting: Heat sources in metal cutting, temperature in chip formation,
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temperature distribution, experimental determination of tool temperatures.
Cutting fluids: Basic actions of cutting fluids, properties of cutting fluids, selection of cutting fluids,
application of cutting fluids, filtration of fluids, recommended cutting fluids.
Economics of Machining: Introduction, elements of total production cost, optimum cutting speed and
tool life for minimum cost, optimum cutting speed and tool life for maximum production, problems.
Lecture
Projects
Assessment Strategy:
Exercises
Workshop exercises
Project
Final examination
Teaching Support and Inputs:
Lectures
Workshop and laboratory exercises
Project
mishaps
Text books:
Metal cutting Principles - M.C. Shaw - Oxford Publication 1985.
Fundamentals of metal cutting & Machine Tools - by B.L.Juneja & G.S Sekhar - Wiley Eastern.
Metal Cutting - V.C.Venkatesh & S.Chandrasekhanan - Pantice Hall 1991.
Metal Cutting - Dr. B.J.Ranganath -Vikas Publications
References:
1. Geoffrey Boothroyd and Knight. W.A "Fundamentals of Machining and Machine tools", Crc Press,
New York, 2006.
2. Bhattacharya. - " Metal Cutting Theory and Practice ", New central Book Agency pvt. Ltd., Calcutta,
2000.
Attendance Requirement:
Minimum of 75% attendance during lecture hours;
100% attendance during practical work sessions, except for some unprecedented mishaps; and
Presence during industrial visit/visits.
Evaluation:
Assignments and mini project work 20%,
Mid-semester Examination 30%, and
Final Examination 50%.
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7.2.3 Metal Joining Processes
Module Title: Metal Joining Processes

Module Code: MEng
ESTC : 6
Pre-requisite Module: Knowledge of material science and physics of metallurgy
Module Description:
Introduction to joining technology, general survey and classification of welding processes, safety and
hazards in welding, physics of the welding, arc and arc characteristics, metal transfer and its importance
in arc welding, various forces acting on a molten droplet and melting rates, power sources for arc
welding, welding consumables; fluxes, gases and filler materials, SMAW, SAW, GTAW and related
processes, GMAW and variants, PAW, Gas Welding, Soldering, Brazing, and diffusion bonding,
Thermal cutting of metals, Surfacing and spraying of metals, Resistance welding processes: spot, seam,
butt, flash, projection percussion etc, Thermit welding, Electro-slag and electro-gas welding, Solid-state
and radiant energy welding processes such as EBW, LBW, USW, Explosive welding; Friction welding,
etc., welding of plastics, advances, challenges and bottlenecks in welding.
Learning Outcome:
1. Acquire knowledge of various welding processes.
2. Select the appropriate metal joining process.
3. Decide the process parameters suitable for the material & processes.
4. Interpret weld plan as per WPS / PQR.
5. Apply knowledge of Friction stir techniques for material joining and processing
6. Evaluate the welding defects & suggest their remedies.
7. Decide the thermal treatments necessary for the weldments.
8. Apply knowledge of various Mechanical testing of welded joints.
9. Apply knowledge of various NDT testing of welded joints.
CONTENT:
INTRODUCTION OF METAL JOINING PROCESSES,

Joining process as a manufacturing route. Relevance of joining process to metallurgy. Classification of
joining process. Safety aspects in Metal joining processes.
FUSION WELDING: welding procedure, Joint design and edge preparation, welding codes for weld
position. Welding symbols. Selecting groove geometry, fillet weld, bead weld, dilution, stress
concentration, plug weld, weld bead geometry, Welding parameters, welding process, welding
consumable, cleanliness, flux, electrode diameter.
CHARACTERISTICS OF POWER SOURCES: Review of Power Sources for Fusion Welding
Processes. Nature of Heat sources, Electrical characteristic of arc, Machine Characteristics of Arc,
Different modes of metal transfer.
PHYSICAL METALLURGY OF WELDS: Weld CCT diagrams, Role of Carbon equivalent. Heat
flow - temperature distribution-cooling rates, Phase transformations during heating & Cooling Gas-
metal and slag-metal reactions, evolution of gases, formation of porosity, inclusions in weld metal,
weld pool solidification, residual stresses, , Role of preheating and post heating on metallurgy of
weldments.
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FUSION WELDING: SMAW: Function of coatings, based on slag metal, gas metal reactions- Coding
Method (Specification) of consumable electrode & their functions. Selection Criteria for electrodes;
AC, DCRP, DCSP configurations, Electrode shapes, polarity and its effects; Submerge arc welding,
Electro -slag welding Processes
FUSION WELDING: GTAW, GMAW, FCAW PROCESSES: GTAW Welding Equipment, Non
Consumable electrode, Inert Gases Process Parameters. Plasma Welding, type of guns;
GMAW-Welding Equipment, Shielding gases, Process Parameters & different metals welded. FCAW-
Welding equipment, Flux cored electrode wire & its functions.
INTRODUCTION TO MODERN WELDING PROCESSES
Electron beam welding. Laser beam welding, Submerged arc welding, Explosive Welding, Atomic
Hydrogen Welding. Thermit Welding, Ultrasonic welding, Under water welding, Industrial applications
of Modern Welding Processes, Friction stir techniques for material processing as; Friction Stir
Welding, Friction stir processing, Friction stir Surfacing, Friction stir channeling etc. Uses of Friction
stir processing to increase Fatigue Resistance of Fusion Welds.
Advanced soldering and brazing processes, different types welding of plastics
INSPECTION OF WELD : destructive test like tensile bend and nick test , Impact and hardness test,
Non destructive techniques like x-ray, ultrasonic, magnetic particl, dye penetrate test, Gamma ray
inspection
WELDING SYMBOLS: Need for, Representing the welds, Basic weld symbols, Location of
Weld, Supplementary symbols, Dimensions of welds, Examples
WELDING DESIGN - Introduction, Principles of sound welding design, Welding joint
design. Welding positions, Allowable strengths of welds, under steady loads
QUALITY CONTROL IN WELDING - Introduction, Quality assurance v/s Quality control, Weld
quality, Discontinuities in welds, their causes and remedies and Quality conflicts
COMPUTER AIDED WELDING DESIGN: Introduction, principles of sound welding design,
welding joint design, welding positions, Allowable strength of welds,1D steady loads, weld throat
thickness , solved and unsolved examples
A.S.M.E. SEC IX FOR WELDING: Interpret ASME Sec-IX codes applicable for welding.
Understanding of WPS, PQR, WPQ Format. Cost calculations in welding. Welding procedure,
qualification of operators, testing and inspection during and after welding. Welding defects
Lecture
Projects
Exercises
Workshop exercises
Project
Final examination
Lectures
Project
19
mishaps
Text books:
1. The Metallurgy of Welding, Brazing and Soldering J.F. Lancaster, George Alien and
Unwin Ltd., London.
2. S V Nadkarni, Modern Arc Welding Technology, Ador Welding Limited, 2010, New Delhi.
3. Welding handbook, American Welding Society, 1987, 8th edition, volume 1 & 2, USA
4. Manufacturing Technology (Foundry, Forming and Welding)-P.N.Rao, Tata Mc-Graw Hill.
5. The Physics of Welding- L.F.Lancaster, Pergamon Press.
6. Principles of Welding- R.S. Parmar.
7. Welding Technology- O.P. Khanna, Khanna Pub.,
8. Friction Stir Welding and Processing, Editors Rajiv S. Mishra & Murray W. Mahoney,
ASM International, 2007
9. Welding Engineering Rossi-Mcgraw Hill Publications
10. Advanced welding processes-Nichodosco and shansky-MIR Publications
11. Welding for Engineers-Udin Funk and wulf
References: List of Open Source Software/learning website:
1. www.gowelding.com
2. http://www.iws.org.in/
3. http://www.asme.org
4. http://www.aws.org
5. http://www.ewf.be
6. http://www.astm.org
Evaluation:
20
7.2.4 Metal Forming Analysis
Course Number: Credit Hours: 3 , 6 ECTS
Course Title: Metal Forming Analysis Contact Hours: 2 Lecture hrs and 3 Tutorial hrs
Course Objectives:
The course enables students to analyze:

Describe isotropic and anisotropic materials characteristics
select appropriate work piece and tool materials for metal forming
calculate strains, strain rates and temperatures during deformation
calculate resulting properties such as flow stress and hardness distribution of metal formed
components
determine limits of formability
design and dimension tools for metal forming
select appropriate forming processes for specific components
measure some of the parametric process variables in forming process
Course Description:
Stress-strain relations in elastic and plastic deformations, Yield criteria for ductile metals, Work
hardening and Anisotropy in yielding, Flow curves, Elements of theory of plasticity, formulation of
plastic deformation problems, application of theory, application of theory of plasticity for solving metal
forming problems using slab method, upper bound and lower bound methods, slip line field theory,
extremium principles, effect of temperature and strain rate in metal working, friction and lubrication in
cold and hot working, technology and analysis of important metal forming processes Forging, Rolling,
Extrusion, Wire Drawing, Sheet metal forming processes like deep drawing, Stretch forming, Bending,
Introduction to finite Element Analysis of metal forming processes.
The goal of the course is to give understanding about Mechanical behavior associated to forming
processes; Analyze Bulk and Sheet metal forming Processes: Flat and shape rolling, Dimensional
controls of rolling mills and gauging system; Forging processes, Design of hammers & presses and
engineering design of components manufactured by forming; Extrusion process; Bend and Deep
drawing, blanking and tool design; and Measurement techniques in forming processes.
CONTENT:
MECHANICAL BEHAVIOUR OF MATERIALS ASSOCIATED TO FORMING /

DEFORMATION
Structure and deformation in materials; Plastic deformation and yield criteria; Engineering aspects of
fracture; High temperature behavior of metals; Review of selected topics from mechanical behavior of
materials; Analysis of metal behavior during metal forming process, forming limit; Fundamental
metallurgical concepts for punch and die materials.
BULK DEFORMATION/FORMING PROCESSES

Ideal Work and Actual Work in Metal Forming
Rolling: Rolling mills for flat products (Two High, Three High, Four High, Cluster, Tandem mills);
Analysis of rolling parameters; Strip profile and flatness control; Analysis of selected topics on steel
21
rolling technology
Forging: Upsetting, Impression and Flash-less Forgings; Hot forging ; Design of Upsetting tools;
Design, construction, properties and operation of drop, single, double hydraulic hammers; percussion
presses.
Extrusion: Cold and Hot Extrusions Analysis (Direct/Forward and Indirect/Backward); Hot impact
extrusion; Presses, tools and machinery for hydrostatic extrusion.
SHEET METAL FORMING PROCESSES

Bending and Deep Drawing processes Analysis; Blanking process; Numerical Simulation and Data
processing for sheet metal forming; Punch-Die Design for sheet metal operation.
MEASUREMENT TECHNIQUES IN METAL FORMING:

Differential transformer, measurements of stresses and forces, measurements of temperatures, and
temperature distribution under extreme conditions.
Teaching Methods:
Lectures supported by tutorials,
Assignments, and
Laboratory exercises.
Laboratory Exercises:
1. Mechanical Behavior of metals study/Testing
2. Bulk and sheet metal forming
3. Measurement of stress and force
Attendance Requirement:
Minimum of 75% attendance during lecture hours;
100% attendance during practical work sessions, except for some unprecedented mishaps; and
Presence during industrial visit/visits.
Evaluation:
Textbook: Metal Forming Analysis, R.H. Wagoner & J.L. Chenot, 2001; ISBN: 9780521642675
Mechanical metallurgy: George E Dieter
References:
1. Metal Forming: Mechanics and Metallurgy, WilliamF. Hosford, Robert M. Caddell, CUP 2007;
ISBN: 0521881218, 9780521881210
2. Sheet Metal Forming Processes: Constitutive Modeling and Numerical Simulation, Dorel
Banabic, 2010 ISBN: 978354881124
3. Sheet Metal Forming and Die Design, Vukato Boljanovic, 2004; ISBN: 0831131829,
9780831131821
4. Plasiticity for structural engineers -Chen
5. Principles of Metal Working - R.Rowe - Amold London 1965.
22
7.2.5 Foundry Engineering
Module Title: Foundry Engineering

Module Code: MEng
ESTC : 6
Pre-requisite Module: Material science knowledge and physics of metals
Module Description: Solidification, Principles of casing and risering, Design of casting and casting
quality control, Furnace technology for castings, Foundry practice for grey cast iron, Malleable cast
iron, Ductile cast iron, Steel casting, Aluminum and copper foundry practice, Foundry mechanization
and modernization.
CONTENT:
SOLIDIFICATION OF CASTING: Concept of solidification of metals. Homogenous and

heterogeneous nucleation. Growth mechanism. Solidification of pure metals and alloys.
Mechanism of columnar and dendritic growth. Coring or Segregation. Solidification time and
Chvorinov's rule. Concept of progressive and directional solidifications.
PRINCIPLES OF CASTING AND RISERING: Purpose of the gating system. Components

of the gating System and its functions. Design of the gating System. Different types of gates.
Gating ratio and its functions. Definition and functions of the riser. Types of risers and their
application. Design of the riser - its shape. Size and location. Use of insulating material and
exothermic compounds in risers.
DESIGN OF CASTING: Factors to be considered in casting design, Design considerations in

pattern making, molding techniques and core making and assembly. Cooling stresses and hot spots
in castings and modification in casting geometry to overcome them.
CASTING QUALITY CONTROL: Casting defects and factors responsible for them. Different
inspection and testing methods to evaluate casting quality, Quality control activity in foundry
activities, salvaging methods of defective castings
FURNACE TECHNOLOGY: Study of various furnaces used in foundry, construction method of

crucible and hearth furnaces. Resistance, Arc and Induction furnaces-their construction, operation and
application. Heat treatment furnaces and drying ovens used in foundry.
GRAY CAST - IRON FOUNDRY PRACTICE: Chemical Composition and structure of gray cast
iron. Moulding, gating and risering techniques. Melting of gray cast iron in Cupola and induction
furnace. Inoculation of gray cast iron. Application of gray cast iron castings
MALLEABLE CAST IRON: Chemical composition and structure of white-heart and black heart
malleable cast iron, Melting malleabilisation heat treatment and application of malleable cast iron.
DUCTILE CAST IRON: Chemical composition and structure of ductile cast iron Melting and
spherodisation treatment. Inoculation of 'ductile iron. Properties and application of ductile cast iron.
23
STEEL CASTING PRACTICE: Common steel casting, their composition, structure and properties.
Smelting and refining of steel. Gating and risering of steel casting. Cleaning of steel casting.
ALUMINIUM FOUNDRY PRACTICE: Composition, properties and application of common

aluminum alloy casting. Melting and casting of AI-alloys. Gating and risering of AI-alloy
casting.
COPPER ALLOY FOUNDRY PRACTICE: General characteristics of common cast copper alloys.
Melting and casting of copper alloys. Gating and risering of cu-alloy castings.
FOUNDRY MECHANIZATION AND MODERNIZATION: Introduction to modernization.

Mechanization of foundry and its advantages. Mechanization of sand plant, moulding and core
making mechanization in melting, pouring and shakeout units. Material handling equipments and
conveyor systems. Brief sketches and description of layouts of job. Captive and mechanized
foundries.
Lecture
Projects
Exercises
Workshop exercises
Project
Final examination
Lectures
Project
mishaps
Text books:
1. Principle of metal casting - Heine, et. al - Tata-McGraw-HiII Publication - 2003.
2. A test book of Foundry Technology - Lal, M. Khanna, P.O - DhanpatRai & Sons Publication.
3. Foundry Technology - Beelely, P.R. Butterworth
Evaluation:
24
7.2.6 Tool and Die Design and Manufacturing
Module Title: Tool and Die Design and Manufacturing

Module Code: MEng
ESTC : 6
Pre-requisite Module: Metal cutting Theory, Mechanics of materials
Module Description:
CONTENT:
TOOL-DESIGN METHODS: Introduction, the design procedure, drafting and design techniques in
tooling drawing
TOOL-MAKING PRACTICES: Introduction, tools of the tool maker, hand finishing and polishing,
screws and dowels, hole location, jig-boring practice, installation of drilling bushings, punch and die
bushings, punch and die manufacture, EDM, EDM for cavity applications, tracer and duplicating mills
for cavity applications, low
TOOLING MATERIALS AND HEAT TREATMENT: Introduction, properties of materials,

ferrous tooling - materials ,non ferrous tooling materials, non-metallic tooling materials, heat
treatment and tool design.
DESIGN OF CUTTING TOOLS: Introduction, the metal cutting process, revision of metal cutting
tools-single point cutting tools, milling cutters, drills and drilling, reamers, taps. Selection of carbide
tools, determining the insert thickness for carbide tools.
DESIGN OF TOOLS FOR INSPECTION AND GAUGING: Introduction, work piece quality
criteria, principles of gauging, types of gages and their applications, amplification and magnification
of error, gage tolerances, selection of material for gages, indicating gages, automatic gages, gauging
positional tolerance parts, problems.
DESIGN OF TOOLS FOR INSPECTION AND GAUGING: Introduction, workpiece quality

criteria , principles of gauging, types of gages and their applications, amplification and magnification
error, gage tolerance, selection of material for gages, indicating gages, automatic gages, gauging
positional tolerance part, problems
LOCATING AND CLAMPING METHODS: Introduction basic principle of location, locating
methods and devices, basic principle of clamping.
DESIGN OF DRILL JIGS: Introduction, types of drill jigs , general considerations in the design of
drill jigs, drill bushings, methods of construction, drill jigs and modern manufacturing
DESIGN OF FIXTURES: Introduction and types of fixtures and economics of fixtures
DESIGN OF PRESS WORKING TOOLS: Power presses, cutting operations, types of die-cutting
operations - and their design, evolution of blanking and progressive blanking
DESIGN OF SHEET METAL BENDING, FORMING AND DRAWING DIES: Introduction,

bending dies, forming dies, and drawing dies. Evolution of a draw die, progressive dies and
25
selection of progressive dies. Strip development for progressive dies, evolution of progressive dies,
examples of progressive dies. Extrusion dies, drop forging dies and auxiliary tools, problems.
TOOL DESIGN FOR JOINING PROCESSES: Introduction, tooling for physical joining
processes, tooling for soldering and brazing, tooling for mechanical joining processes, problems.
TOOLING FOR CASTING: Introduction, tooling for sand casting, shell molding, metal
molding and die-casting, problems.
TOOL DESIGN FOR NC MACHINE TOOLS: Revision of NC control, fixture design for NC
machine tools, cutting tools and tool-holding methods, automatic tool changers and tool petitioners.
PLASTICS AS TOOLING MATERIALS: Introduction, Plastics commonly used as tooling
materials, Application of Epoxy plastic tools, construction methods, metal forming operations with
urethane dies, Calculation of forces for urethane pressure pads, problems
Lecture
Projects
Exercises
Workshop exercises
Project
Final examination
Respective Role of Instructors and Students:
Lectures
Project
mishaps
Text books:
1. Tool Design - Cyril Donaldson, GH Lecain and VC Goold - TMH Publishing Co Ltd., New
rd
Delhi, - 3 editions, 2000.
2. Fundamentals of Tool Design ASTME - PHI (P) Ltd., New Delhi -1983.
References:
1. Cutting Tool Design - Rodin - Mir publications -1968.

2. Metal cutting & Tool Design - Arshinov - Mir Publishers , Moscow 1970.
3. Press working of metals Hinman - McGraw Hill 1950.
26
7.2.7 Polymer and Composite Manufacturing
Module Title: Polymer and Composite Manufacturing

Module Code: MEng
ESTC: 8
Pre-requisite Module: Material science
Module Description:
Plastics as an Engineering material, Physical, Mechanical and Thermal properties of thermoplastics and
thermosetting plastics, injection molding, compression molding, rotational molding, low molding, and
thermo forming, principles of Injection molding, Injection molding machine and types, capacity &
clamping tonnage, mold size, plasticating extruder concepts, molding properties and control
parameters, molding cycle. FRP Composites, fiber types, fiber forms and properties, matrices type and
properties, lamina, laminate, composites, macro and micro-mechanical analysis & properties, failure
theories, primary and secondary manufacturing, Layup, Filament winding, Pultrusion, Compression
molding, RTM, Processing of Metal Matrix composites.
Learning Outcome:
1. Understand on types, physical properties and processing of polymer matrix composites, metal
matrix composites and ceramics matrix composites.
2. Learn about matrix material, reinforcements of polymer matrix composites, MMC and ceramic
matrix composites.
3. To develop knowledge on processing, interfacial properties and application of composites.
CONTENT:
PROCESSING OF POLYMERS
Chemistry and Classification of Polymers Properties of Thermo plastics Properties of
Thermosetting Plastics - Extrusion Injection Moulding Blow Moulding Compression and Transfer
Moulding Casting Thermo Forming. General Machining properties of Plastics Machining
Parameters and their effect Joining of Plastics Thermal bonding Applications.
INTRODUCTION TO COMPOSITE MATERIALS: Definition, Classification, Types of matrices
& reinforcements, characteristics & selection, Fiber composites, laminated composites, particulate
composites, prepegs, sandwich construction.
FIBERS AND MATRIX MATERIALS
Fibers Fabrication, Structure, properties and applications Glass fiber, Boron fiber, carbon fiber,
organic fiber, ceramic and metallic fibers - whiskersFabrication of Matrix materials polymers,
metals and ceramics and their properties interfaces Wettability Types of bonding at the interface
Tests for measuring interfacial strength - Physical and chemical properties.
MICRO MECHANICAL ANALYSIS OF A LAMINA: Introduction, Evaluation of the four elastic
modules Rule of mixture, Macro mechanics of a lamina: Hookes law for different types of materials,
number of elastic constants, Laminate code, Failure criterion.
MACRO MECHANICAL ANALYSIS: Hooke's law for different types of materials, Number of
elastic constants, Derivation of nine independent constants for orthotropic material, Two - dimensional
relationship of compliance and stiffness matrix. Hooke's law for two-dimensional angle lamina,
engineering constants - Numerical problems. Invariant properties. Stress-Strain relations for lamina of
arbitrary orientation, Numerical problems.
27
PROCESSING OF POLYMER MATRIX COMPOSITES
Thermoset matrix composites: hand layup, spray, filament winding, Pultrusion, resin transfer molding,
autoclave molding - bag molding, compression molding with Bulk Moulding Compound and sheet
Moulding Compound thermoplastic matrix composites film stacking, diaphragm forming,
thermoplastic tape laying, injection molding interfaces in PMCs - structure, properties and application
of PMCs recycling of PMCs.
PROCESSING OF METAL MATRIX COMPOSITES
Metallic matrices: aluminum, titanium, magnesium, copper alloys processing of MMCs: liquid state,
Solid state, in situ fabrication techniques diffusion bonding powder metallurgy techniques-
interfaces in MMCs mechanical properties machining of MMCs Applications.
PROCESSING OF CERAMIC MATRIX COMPOSITES AND CARBON-CARBON
COMPOSITES
Processing of CMCs: cold pressing, sintering, reaction bonding, liquid infiltration, lanxide process in
situ chemical reaction techniques: chemical vapor deposition, chemical vapor impregnation, sol-gel
interfaces in CMCs mechanical properties and applications of CMCs Carbon-carbon Composites
applications.
Lecture
Projects
Exercises
Workshop exercises; Laboratory exercises
Project
Final examination
Lectures
Project
100% attendance during practical work sessions, except for some unprecedented mishaps
Text books:
1. Krishnan K Chawla, Composite Materials: Science and Engineering, International Edition,
Springer, 2012, ISBN:978-0-387-74364-6.
2. Mallick P.K., Fiber Reinforced Composites: Materials, Manufacturing and Design, CRC press,
New Delhi, 2010, ISBN:0849342058.
3. Jamal Y. Sheikh-Ahmad, Machining of Polymer Composites, Springer, USA, 2009. ISBN: 978-
0-387-35539-9.
4. Mallick, P.K. and Newman.S., Composite Materials Technology, Hanser Publishers, 2003.
5. Harold Belofsky, Plastics, Product Design and Process Engineering, Hanser Publishers
6. Seamour, E.B. Modern Plastics Technology, Prentice Hall, 2002
7. Mechanics of composite materials Autar K Kaw-CRC Press
8. Composite Materials Handbook - Mein Schwartz - Mc Graw Hill Book Company
References:
1. Said Jahanmir, Ramulu M. and Philp Koshy, Machining of Ceramics and Composites, Marcel
Dekker Inc., New York, 1999, ISBN: 0-8247-0178-x.
2. ASM Handbook Composites, Vol-21, 2001, ISBN: 978-0-87170-703-1.
28
7.2.8 Production and Operations Management
Module Title: Production and Operations Management

Module Code: MEng
ESTC : 6
Pre-requisite Module:
Module Description:
Learning Outcome:
1. Demonstrate an understanding of production as a process of converting or transforming
resources into products;
2. Demonstrate an understanding of the manager's concern in planning, organizing, directing, and
controlling productive operations to meet organizational objectives;
3. Demonstrate an understanding of productivity measures, quality and costs both, direct and
indirect; and
4. Use a variety of problem-solving techniques to aid in effective decision making.
CONTENT:
INTRODUCTION:
OPERATIONS PLANNING CONCEPTS: Introduction, Operations Functions in Organizations,

Historical development, Framework for managing operations, The trend: Information and
Non-manufacturing systems, Operations management, Factors affecting productivity, International
dimensions of productivity, The environment of operations, Production systems decisions- a look
ahead.
OPERATIONS DECISION MAKING : Introduction, Management as a science, Characteristics of

decisions, Framework for decision making, Decision methodology, Decision Tree Pr System
Design and Capacity : Introduction, Manufacturing and service systems, Design oblems, Economic
models-Break Analysis in operations, P/V ratio, Statistical models.Design and system capacity,
capacity planning
FORECASTING DEMAND: Forecasting objectives and uses, Forecasting variables,Opinion

and judgemental methods,Time series methods,moving average methods,Exponential smoothing
techniques,Trend adjusted exponential smoothing,Regression and correlation metods,Application
and control offorecasst,MEAN, absolute deviation,BIAS, Tracking signal
AGGREGATE PLANNING AND MASTER SCHEDULING: Introduction- planning and

scheduling, Objectives of aggregate planning, Three Pure Strategies, Aggregate planning methods,
Master scheduling objectives, Master scheduling methods.
MATERIAL AND CAPACITY REQUIREMENTS PLANNING: Overview: MRP and CRP,
MRP: Underlying concepts, System parameters, MRP logic, System refinements, Capacity
29
management, CRP activities.
SCHEDULING AND CONTROL OF PRODUCTION ACTVITIES: Introduction to PAC

objective and dat requirement,Loading Finite and Infinite scheduling methodology, Priority
sequencing, capacity control,
SINGLE MACHINE LOADING: Concept and measure of performance, SPT rule,

Weighted SPT rule, EDD rule.
FLOW SHOP SCHEDULING: Introduction, Johnsons rule for n jobs on 2 and 3

machines, CDS heuristic.
JOB SHOP SCHEDULING: Types of schedules, Heuristic procedure, scheduling

2 jobs on m machines.
Lecture
Projects
Exercises
Project
Final examination
Lectures
Project
mishaps
Text books: Text Books:
1. Monks, J.G., Operations Management, McGraw-Hill International Editions, 1987.
2. Productions & operations management by Adam & Ebert.
3. Pannerselvam. R., Production and Operations Management, PHI.
4. Chase Jacobs Aquilano, Operations Management for Competitive Advantages,10 th Edition,
TMH
References:
1. Buffa, Modern Production/Operations Management, Wiely Eastern Ltd.
2. Chary, S.N., Production and Operations Management, Tata-McGraw Hill.
3. Operations management by James Dilworth.
4. Lee J Karjewski and Larry P Ritzman, Operations Management strategy and Analysis, 6th
Edn, Pearson Education Asia
5. B J Ranganath , System Dynamics by - I K International Publishing house Pvt. Ltd
6. Production and Operations Management, William J Stevenson, 9th Ed., Tata McGraw Hill.
30
7.2.9 CAD/CAM/CAE
Module Title: CAD/CAM/CAE

Module Code: MEng
ESTC : 6
Learning Outcome:
1. Create the different wireframe primitives using parametric representations.
2. Create surface primitives using parametric modeling.
3. Create the different solid primitives using the different representation schemes.
4. Apply geometric transformations on the created wireframe, surface and solid models
5. Apply the concepts of machining for the purpose of selection of appropriate machining centers,
machining parameters, select appropriate cutting tools for
6. CNC milling and turning equipment, set-up, program, and operate CNC milling and turning
equipment.
7. 7.Create and validate NC part program data using manual data input (MDI) and automatically using
standard commercial CAM package for manufacturing of required component using CNC milling
or turning applications.
8. Produce an industrial component by interpreting 3D part model/ part drawings using Computer
Aided Manufacturing technology through programming, setup, and ensuring safe operation of
Computer Numerical Control (CNC) machine tools.
9. Create and demonstrate the technical documentation for design/ selection of suitable drive
technologies, precision components and an overall CNC machine tool system for automation of
machining operations using appropriate multi-axis CNC technology.
CONTENT:
INTRODUCTION: Definition and scope of CAD/CAM, Introduction to design process and role of
computers in the design process.
TRANSFORMATIONS: 2D and 3D transformations.
CURVES AND SURFACES: Analytical, Synthetic curves with advantages, Disadvantages,
Comparison with parametric curves, Geometric modeling curves and surfaces, Representation, Wire
frame models, Parametric representations, Parametric curves and surfaces, Manipulations of curves and
surfaces, DDA, Bresenhams /Mid-point line, circle, ellipse algorithms.
SOLID MODELING: Solid models, Fundamentals of solid modeling, Different solid representation
schemes, Half -spaces, Boundary representation (B-rep), Constructive solid geometry (CSG), Sweep
representation, Analytic solid modeling, Perspective, Parallel projection, Hidden line removal
algorithms.
CAD/CAM DATA EXCHANGE FORMATS: Types of file formats & their exchange, Graphics
standards.
NEED OF NC TECHNOLOGY, FUNDAMENTAL CONCEPTS IN NUMERIC CONTROL:

structure and functions of NC System, advantages of NC technology over conventional manufacturing.
NC MACHINE TOOLS: Types, Definition and designation of control axes, Special constructional
and design characteristics of NC machine tools, Standard tooling used for NC turning and milling
centers.
NC PART PROGRAMMING: Work holding and tool setting procedure for NC turning and milling
31
centers, Tool zero presetting, Block formats and introduction to ISO based G & M codes for NC part
programming, Concepts of tool length and radius compensation, Standard canned cycles used in CNC
turning and milling centers, Introduction to automatic NC part program generation from CAD models
using standard CAD/CAM software for machining of surfaces, moulds and dies etc.
COMPUTER NUMERICAL CONTROL OF MACHINE TOOLS: Types and functions of
computer numeric control (CNC), Types and functions of direct numeric control (DNC), Need of
adaptive control types, functions and types of adaptive control, its uses & benefits, Advantages of
combined CNC/DNC systems.
SYSTEM DEVICES: Drives, Feedback devices, Interpolator systems, Control loop circuit elements in
point to point (PTP) and contouring system, Interpolation schemes for linear and circular interpolations.
Lecture
Projects
Exercises
Project
Final examination
Lectures
Project
100% attendance during practical sessions, except for some unprecedented mishaps
Text books:
1. Zeid, I., CAD/CAM, McGraw Hill (2008)
2. Rogers, D. F. and Adams, J. A., Mathematical Elements for Computer Graphics, McGraw Hill
(1989).
3. Rogers, D. F., Procedural Elements for Computer Graphics, McGraw Hill (2008).
4. Rooney, J. and Steadman, P., Principles of Computer Aided Design, prentice Hall (1988).
5. Rooney, J. and Steadman, P., Computer Aided Design, Pitman/Open University (1987).
6. Mallineuse, G., Computational Concepts and Methods, Kogan Page Ltd. (1986).
7. Manuals & Tutorials on CAD/CAE packages like Pro/Engineer, Pro/Mechanica, ANSYS, etc
latest available in the lab.
8. Kelley David S., Pro/ENGINEER Wildfire 5.0 Instructor, Tata McGraw Hill (2011).
9. Shih Randy H., Introduction to Finite Element Analysis Using Creo Simulate 1.0, SDC
Publications, USA (2011, ISBN: 978-1-58503-670-7, ISBN (Book + Software on Disk): 978-1-
58503-731-5
10. Toogood Roger Ph.D., P. Eng., Zecher Jack P.E., Creo Parametric 1.0 Tutorial and MultiMedia
DVD, SDC Publications, USA (2012), ISBN: 978-1-58503-692-9, ISBN (Book + Software on
Disk): 978-1-58503-730-8
11. Shih Randy H., Parametric Modeling with Creo Parametric 1.0-An Introduction to Creo
Parametric 1.0, SDC Publications, USA (2011) ISBN: 978-1-58503-661-5, ISBN (Book +
Software on Disk): 978-1-58503-729-2
32
7.2.10 Applied Mechatronics/Manufacturing
Module Title: Applied Mechatronics/Manufacturing Automation

Module Code: MEng
ESTC : 6
Module Description:
Modern developments in automation in manufacturing and its effect on global competitiveness, Need
and implications of automation in Manufacturing, different types of production systems and
automation, hard/fixed automation including process automation, Rapid prototyping and tooling,
Hydraulic and pneumatic actuators their design and control devices, sequence operation of
hydraulic/pneumatic actuators, designing of complete systems with hydraulic, electro-hydraulic and
digital control devices, applications in manufacturing, material handling systems, feeders, orienting and
escapement devices, their analysis and design, Automatic assembly machines, designing for automatic
assembly.
Learning Outcome:
1. Construct the block diagram of any physical Mechatronics device used in day-to-day life.
2. Calculate the output to input relation of any physical model in the form of a transfer function.
3. Evaluate the performance of any physical system in terms of its performance parameters.
4. Develop the mathematical model of any physical model from any engineering domain.
5. Interface the sensors and actuators of a Mechatronics device to the computer/laptop.
6. Recognize the key features of different type of controllers and develop a suitable controller to
obtain the desired performance from the system.
CONTENT:
INTRODUCTION: Modern developments in automation in manufacturing and its effect on global

competitiveness, Need and implications of automation in Manufacturing, different types of production
systems and automation, hard/fixed a
INTRODUCTION TO MECHATRONICS: Integration of mechanical, electronics, control and

computer science engineering, Elements of mechatronics system, Open-loop and closed-loop system.
PHYSICAL AND MATHEMATICAL MODELING OF DYNAMIC SYSTEMS: Equations of

motion of mechanical, electrical, pneumatic and hydraulic systems, Transforming physical model to
mathematical model, Linearization, Frequency response. Modeling of different motors and generators
utomation including process automation, Rapid prototyping and tooling,
CONTROL SYSTEMS: Laplace transformations, Block diagram reduction, Signal flow graph, and
Performance specifications, transfer functions, Stability, Sensitivity of the open-loop and closed-loop
systems, Types of controller, Controller design using frequency domain and Laplace domain methods.
SENSORS: Displacement, Position and Proximity sensors, Flow sensors, Pressure and force sensors,
Motion sensors, Optical, Mechanical and Thermal sensors.
33
ACTUATORS IN MECHATRONICS SYSTEM: Electric actuators, Stepper motors, DC motors, and
AC motors.
ELECTRONIC ELEMENTS IN MECHATRONIC SYSTEM: Analog to digital and digital to

analog converters, Operational amplifiers, Introduction to Microcontrollers and Microprocessors
DESIGN OF HYDRAULIC AND PNEUMATIC ACTUATORS: Hydraulic and pneumatic

actuators their design and control devices, sequence operation of hydraulic/pneumatic actuators,
designing of complete systems with hydraulic, electro-hydraulic and digital control devices,
applications in manufacturing, material handling systems, feeders, orienting and escapement devices,
their analysis and design, Automatic assembly machines, designing for automatic assembly.
DESIGN PROCESS-STAGES OF DESIGN PROCESS: Traditional and Mechatronics design

concepts Case studies Engine management system, Automatic camera, Automatic wishing machine,
Pick and place robots.
Lecture
Projects
Exercises
Project
Final examination
Lectures
Project
Text books:
1. Mikell P. Groover (2002) Automation, Production Systems and CIM.
2. Michael B.Histand and David G. Alciatore, "Introduction to Mechatronics and Measurement
Systems", McGraw-Hill International Editions, 1999.ISBN: 0070648142
3. W.Bolton, Mechatronics Pearson Education Limited, 2004
4. Dr. Appukuttan, Introduction to Mechatronics, Oxford University Press, India, ISBN:
5. 0195687817
References:
1. R.K.Rajput.A Text Book of Mechatronics, Chand &Co, 2007

2. M.A. Mazidi & J.G. Mazidi, 8051 Micrcontroller and embedded systems, 2002
3. Devadas shetty, Richard A. Kolk, Mechatronics System Design, PWS Publishing
Company, 2001.
34
7.2.11 Computer Integrated Manufacturing
Module Title: Computer Integrated Manufacturing

Module Code: MEng
ESTC : 6
Module Description: Production Development Through CIM, Computer Aided Quality Control,
Computer Integrated Manufacturing Detroit type of Automation, Analysis of Automated flow lines
Automated Material Handling Storage Computer Process Monitoring
CONTENT:
PRODUCTION DEVELOPMENT THROUGH CIM: Computers in Industrial manufacturing,

Product cycle & Production development cycle, Introduction of CAD/CAM & CIM, sequential and
concurrent engineering, soft and hard prototyping.
Process control methods, direct digital control, supervisory computer control, steady state optimal
control, on line search strategies, adaptive control.
COMPUTER AIDED QUALITY CONTROL: The computer in Q.C, automated inspection

principles and methods, Contact inspection methods, non-contact inspection methods, machine vision
system, optical inspection method, sensors, coordinate, measuring machine, Computer-Aided testing,
Integration of CAQL with CAD/CAM.
COMPUTER INTEGRATED MANUFACTURING: Fundamentals of CAD/CAM, Computerized

Manufacturing planning systems, shop floor control & automatic identification techniques. Computer
Network for manufacturing and the future automated factor.
DETROIT TYPE OF AUTOMATION: Flow lines, Transfer Mechanisms, work pattern transfer,
Different methods, & Problems.
ANALYSIS OF AUTOMATED FLOW LINES: Analysis of transfer lines without storage with
storage buffer single stage, Double stage, Multistage with problems, Automated assembly systems,
Design for automated assembly, parts feeding devices,
analysis of Multi station assembly machine, Analysis of Single stage assembly machine,
AUTOMATED MATERIAL HANDLING STORAGE: Material functions, types of material

handling equipment, analysis of material handling systems, design of system, conveyor system,
automated guided vehicle systems, automated storage/retrieval systems, caroused storage systems work
in process storage, interfacing handling & storage with manufacturing
Lecture
Projects
Exercises
Project
Final examination
35
Lectures
Project
Text books:
1. CAD/ CAM : Zimmers and Groovers-PHI
2. CAD/CM/CIM; P. Rsdhakrishna - newage International-2 Edition
3. Automation, Production systems & Computer Aided Manufacturing - M.P. Grover -
Prentice Hall - 1984
References:
1. CAD/CAM - Zeid Mc-Graw Hill - 2005.
2. CAD/CAM - P.N.Rao - TMH.- 2 nd edition, 2004.
3. Robotics for Engineering - Koren.Y - Mc-Graw Hill - 1985.
4. Robert vision & Sensory Controls - Rooks B. - North Holland. - (ed) vol-3
36
7.2.12 Lean Manufacturing
Module Title: Lean Manufacturing

Module Code: MEng
ESTC : 6
Module Description: INTRODUCTION TO LEAN MANUFACTURING, CELLULAR
MANUFACTURING, JIT, TPM,SET UP TIME REDUCTION, TQM, 5S, VSM, SIX SIGMA,
CASE STUDIES
Learning Outcome:
1. Understand the concepts of Lean Manufacturing

2. Learn about various tools of Lean Manufacturing
3. Apply LM tools in an organization
CONTENT:
INTRODUCTION TO LEAN MANUFACTURING
Conventional Manufacturing versus Lean Manufacturing Principles of Lean Manufacturing Basic

elements of lean manufacturing Introduction to LM Tools.
CELLULAR MANUFACTURING, JIT, TPM
Cellular Manufacturing Types of Layout, Principles of Cell layout, Implementation. JIT Principles
of JIT and Implementation of Kanban. TPM Pillars of TPM, Principles and implementation of TPM.
SET UP TIME REDUCTION, TQM, 5S, VSM
Set up time reduction Definition, philosophies and reduction approaches. TQM Principles and
implementation. 5S Principles and implementation - Value stream mapping - Procedure and principles.
SIX SIGMA Six Sigma Definition, statistical considerations, variability reduction, design of
experiments Six Sigma implementation
CASE STUDIES Various case studies of implementation of lean manufacturing at industries.
Lecture
Projects
Exercises
Project
Final examination
37
Lectures
Project
Text books:
1. Design and Analysis of Lean Production Systems, Ronald G. Askin & Jeffrey B. Goldberg,
John Wiley & Sons, 2003
2. Mikell P. Groover (2002) Automation, Production Systems and CIM.
References:
1. Rother M. and Shook J, 1999 Learning to See: Value Stream Mapping to Add Value and
Eliminate Muda , Lean Enterprise Institute, Brookline, MA.
38
7.2.13 Industrial Robotics
Module Title: Industrial Robotics

Module Code: MEng
ESTC : 6
Module Description:
Introduction to robotics, classification of robots, pneumatic hydraulic and electric actuators, position,
velocity, acceleration, force, and vision sensors; coordinate transformation and DH parameters; forward
and inverse kinematics; statics; Euler-Lagrange and Newton Euler equations of motion; Dynamics
algorithms; Basics of robot control; trajectory planning; robot programming
Learning Outcome:
1. Apply the concepts of coordinate transformations for development of arm equation and
subsequently the inverse kinematics model for given serial manipulator.
2. Apply the concepts of robotic workspace analysis for design of robotic manipulator for
required work cell applications.
3. Design and analyze the workcell environment for given robotic manipulator configuration and
workcell devices for required integrated industrial application.
4. Develop and analyze the mathematical model for trajectory planning, resolved motion rate
control and dynamics model for a given serial robotic manipulator.
5. Develop the algorithms for design of robotic work cell controller and its programming for
given serial robotic manipulator.
CONTENT
FUNDAMENTAL CONCEPTS OF ROBOTICS: History, present status and future trends, Robotics.
Robot, Definition. Robotics Systems and Robot Anatomy, Specification of Robotics. Resolution,
Repeatability and Accuracy of a Manipulator
ROBOT DRIVES: Power transmission systems and control Robot drive mechanisms, hydraulic-
electric-pneumatic drives. Mechanical transmission method Rotary-to-Rotary motion conversion.
Rotary-to-linear motion conversion end effectors types-grip pind problem Remote-Centered
compliance Devices-Control of Actuators in Robotic
Mechanisms.
SENSORS AND INTELLIGENT ROBOTS: Sensory devices Non-optical-Position sensors

Optical position sensors velocity sensors proximity sensors: Contact and non-contact type-Touch
and slip sensors Force and Torque Sensors AI and Robotics.
COMPUTER VISION FOR ROBOTICS SYSTEMS: Robot vision systems Imaging components
Image representation Hardware aspects-Picture coding Object Recognition and Categorization-
Visual inspection software considerations applications commercial Robotic vision systems.
COMPUTER CONSIDERATIONS FOR ROBOTIC SYSTEMS: Computer architecture for robots,

hardware, Computational elements in robotic applications Robot programming sample programs
path planning Robots computer system.
39
TRANSFORMATIONS AND KINEMATICS: Homogeneous Co-ordinates Co-ordinate Reference
Frames Homogeneous Transformations for the manipulator the forward and inverse problem of
manipulator kinematics Motion generation Manipulator dynamics Jacobian in terms of D.H.
Matrices controller architecture.
ROBOT CELL DESIGN AND CONTROL: Specifications of Commercial Robots Robot Design
and Process specifications motor selection in the design of a robotic joint Robot Cell layouts
Economic and Social aspects of robotics.
APPLICATIONS OF ROBOTS: Capabilities of Robots Robotics Applications Obstacle

avoidance Robotics in India The future of Robotics
Lecture
Projects
Exercises
Project
Final examination
Lectures
Project
mishaps
Text books:
1. 1.Robotics Engineering An integrated approach - Richard D Klafter, Thomas A
Chmielewski, Michael Negin Prentice Hall of India Pvt. Ltd. - Eastern Economy Edition,
1989.
2. Robotics: Control Sensing, Vision, intelligence - Fu KS Gomaler R C, Lee C S G - McGraw
Hill Book Co. - 1987.
References:
1. Handbook of Industrial Robotics - Shuman Y. Nof - John Wiley & Sons, New York - 1985.
2. Robotics Technology and Flexible Automation - Deb SR - McGraw Hill BookCo. 1994
3. Schilling, R.J., Fundamentals of Robotics Analysis and Control, Prentice Hall of India (2006)
4. Fu, K.S., Gonzalez, R.C. and Lee, C.S.G., Robotics: Control, Sensing, Vision, and Intelligence,
McGraw Hill (1987)
5. Craig, J.J., Introduction to Robotics: Mechanics and Control, prentice Hall (2004)
6. Deb, S.R., Robotics and Flexible Automation, McGraw Hill (2004)
7. Saha, S.K., Introduction to Robotics, McGraw Hill (2008)
8. Niku, S.B., Introduction to Robotics: Analysis, system, application, Dorling kingsley (2006)
40
7.2.14 Total Quality Management
Module Title: Total Quality Management

Module Code: MEng
ESTC : 6
Pre-requisite Module: None
Module Description: quality, total quality, evolution of TQM: leadership and quality costs:
continuous improvement: tools and techniques in TQM: quality function deployment and failure
modes effects analysis quality management systems, product acceptance control:
CONTENT:
QUALITY, TOTAL QUALITY, TQM: Introduction-Definition, Basic Approach, TQM framework,

Historical Review, Benefits of TQM.
EVOLUTION OF TQM: Contribution of Quality Gurus- Edward Deming, 14 points, PDSA cycle,
Joseph Juran, Quality trilogy, Crosby & quality treatment, Ishikawa and companywide quality control,
Taguchi & his quality loss function.
LEADERSHIP AND QUALITY COSTS: Characteristics of quality leaders, Quality statement,
strategic planning, Introduction to quality costs, prevention costs, Appraisal costs, failure costs,
Management of quality costs, economics total of quality costs and its reduction.
CONTINUOUS IMPROVEMENT: Improvement as problem solving process W-V Model of CI,
process control, Reactive Improvement
Standard steps & 7 tools of quality, seven steps, management diagnosis of seven steps, reactive
improvement. Proactive Improvement Introduction, standard steps, 7 management tools, applying
proactive improvement, to develop new product- three stages & nine step.
TOOLS AND TECHNIQUES IN TQM: Kaizen, Re-engineering, Six Sigma, Benchmarking
Definition, Process of benchmarking, 5S, 3M, Poka-Yoke.
QUALITY FUNCTION DEPLOYMENT AND FAILURE MODES EFFECTS
ANALYSIS: Introduction to QFD and QFD process, Quality by design, Rationale for implementation
of quality by design, FMEA, Design FMEA and process FMEA.
QUALITY MANAGEMENT SYSTEMS: Introduction to different standards Quality management
systems, Bureau of Indian standards (BIS), Institute of Standards Engineers (SEI), ISO-9000 series of
standards, Overview of ISO-14000, Overview of TS 16959.
PRODUCT ACCEPTANCE CONTROL: Product acceptance control through IS 2500 part 1 and
part 2.
Lecture
Projects
Exercises
41
Project
Final examination
Lectures
Project

mishaps
Text books:
1. Total Quality Management: Dale H. Bester field, Publisher - Pearson Education India, ISBN:
8129702606, Edition 03/e Paperback (Special Indian Edition)
2. Total Quality Management for Engineers: M. Zairi, ISBN: 1855730243, Publisher: Wood head
Publishing
References:
1. A New American TQM, four revolutions in management, Shoji Shiba, Alan Graham, David
Walden, Productivity press, Oregon, 1990
2. Methods for Total Quality Management: Gopal K. Kanji and Mike
Asher, ISBN: 0803977476, Publisher: Sage Publications, Inc.; Edition 1
3. Organizational Excellence through TQM, H. Lal, New age pub, 2008
42
7.2.15 Tolerance Technology
Module Title: Metrology & Tolerancing Technology

Module Code: MEng
ESTC : 6
Module Description: Tolerance Analysis, Tolerance allocation, GD and T, Tolerance charting,
Manufacturing guidelines
CONTENT:
TOLERANCE ANALYSIS Introduction Concepts, definitions and relationships of tolerancing

Matching design tolerances with appropriate manufacturing process manufacturing process capability
metrics Worst care, statistical tolerance Analysis Linear and Non-Linear Analysis Sensitivity
Analysis Taguchis Approach to tolerance design.
TOLERANCE ALLOCATION Tolerance synthesis Computer Aided Tolerancing Traditional

cost based analysis Taguchis quality loss function Application of the Quadratic loss function to
Tolerancing Principles of selective Assembly Problems.
GD&T Fundamentals of geometric dimensioning and Tolerancing Rules and concepts of GD&T
Form controls Datum systems Orientation controls Tolerance of position Concentricity and
symmetry controls Run out controls Profile controls.
TOLERANCE CHARTING Nature of the tolerance buildup structure and setup of the tolerance
chart piece part sketches for tolerance charts Arithmetic ground rules for tolerance charts
Determination of Required balance dimensions Determination of Mean working Dimensions
Automatic tolerance charting Tolerance charting of Angular surfaces.
MANUFACTURING GUIDELINES DFM guidelines for casting, weldments design Formed metal
components Turned parts Milled, Drilled parts Non metallic parts Computer Aided DFM
software Boothroyd and Dewhurst method of DFMA DCS Vis/VSA 3D Dimensional control
Statistical tolerance Analysis Software Applications.
Specifications.
Lecture
Projects
Exercises
Project
Final examination

Lectures
43
Project

mishaps
Text books:
1. C.M. Creveling, Tolerance Design A handbook for Developing Optimal Specifications,

Addison Wesley, 1997.
2. James D. Meadows, Geometric Dimensioning and Tolerancing, Marcel Dekker Inc., 1995.
3. Alex Krulikowski, Fundamentals GD&T, Delmar Thomson Learning, 1997.
4. Oliver R. Wade, Tolerance Control in Design and Manufacturing, Industrial Press, NY,
1967.
5. James G. Bralla, Handbook of Product Design for Manufacturing, McGraw Hill, 1986.
References:
1. Harry Peck , Designing for Manufacturing, Pitman Publications, 1983.

2. Dieter , Machine Design - McGraw-Hill Higher Education, -2008
3. R.K. Jain, "Engineering Metrology", Khanna Publishers, 1986
4. Product design for manufacture and assembly - Geoffrey Boothroyd, Peter dewhurst, Winston
Knight, Merceldekker. Inc. CRC Press,
5. Third Edition
6. Material selection and Design, Vol. 20 - ASM Hand book
44
7.2.16 Heat Transfer
Module Title: Heat Transfer

Module Code: MEng
ESTC : 6
Pre-requisite Module: None
Module Description:
CONTENT:
INTRODUCTORY CONCEPTS AND DEFINITIONS: Modes of heat transfer: Basic laws

governing conduction, convection, and radiation heat transfer; Thermal conductivity; convective heat
transfer coefficient; radiation heat transfer; combined heat transfer mechanism. Boundary conditions of
1st, 2nd and 3rd kind
CONDUCTION: Derivation of general three dimensional conduction equation in Cartesian coordinate,

special cases, discussion on 3-D conduction in cylindrical and spherical coordinate systems (No
derivation). One dimensional conduction equations in rectangular, cylindrical and spherical coordinates
for plane and composite walls. Overall heat transfer coefficient. Thermal contact resistance.
VARIABLE THERMAL CONDUCTIVITY: Derivation for heat flow and temperature distribution
in plane wall. Critical thickness of insulation without heat generation, Thermal resistance concept & its
importance. Heat transfer in extended surfaces of uniform cross-section without heat generation, Long
fin, and short fin with insulated tip and without insulated tip and fin connected between two heat
sources. Fin efficiency and effectiveness. Numerical problems.
ONE-DIMENSIONAL TRANSIENT CONDUCTION: Conduction in solids with negligible internal

temperature gradient (Lumped system analysis), Use of Transient temperature charts (Heislers charts)
for transient conduction in slab, long cylinder and sphere; use of transient temperature charts for
transient conduction in semi-infinite solids. Numerical Problems.
CONCEPTS AND BASIC RELATIONS IN BOUNDARY LAYERS: Flow over a body velocity
boundary layer; critical Reynolds number; general expressions for drag coefficient and drag force;
thermal boundary layer; general expression for local heat transfer coefficient; Average heat transfer
coefficient; Nusselt number. Flow inside a duct- velocity boundary layer, hydrodynamic entrance
length and hydro dynamically developed flow; flow through tubes (internal flow discussion only).
Numerically based on empirical relation given in data handbook.
FREE OR NATURAL CONVECTION: Application of dimensional analysis for free convection-

physical significance of Grashoff number; use of correlations of free convection in vertical, horizontal
and inclined flat plates, vertical and horizontal cylinders and spheres, Numerical problems.
FORCED CONVECTIONS: Applications of dimensional analysis for forced convection. Physical

significance of Reynolds, Prandtl, Nusselt and Stanton numbers. Use of various correlations for hydro
dynamically and thermally developed flows inside a duct, use of correlations for flow over a flat plate,
over a cylinder and sphere. Numerical problems.
HEAT EXCHANGERS: Classification of heat exchangers; overall heat transfer coefficient, fouling
and fouling factor; LMTD, Effectiveness-NTU methods of analysis of heat exchangers. Numerical
problems.
45
CONDENSATION AND BOILING: Types of condensation (discussion only) Nusselts theory for
laminar condensation on a vertical flat surface; use of correlations for condensation on vertical flat
surfaces, horizontal tube and horizontal tube banks; Reynolds number for condensate flow; regimes of
pool boiling, pool boiling correlations. Numerical problems. Mass transfer definition and terms used in
mass transfer analysis, Ficks First law of diffusion (no numerical).
RADIATION HEAT TRANSFER: Thermal radiation; definitions of various terms used in radiation
heat transfer; Stefan-Boltzman law, Kirchoffs law, Plancks law and Weins displacement law.
Radiation heat exchange between two parallel infinite black surfaces, between two parallel infinite gray
surfaces; effect of radiation shield; intensity of radiation and solid angle Lamberts law; radiation heat
exchange between two finite surfaces configuration factor or view factor. Numerical problems.
Lecture
Projects
Exercises
Project
Final examination
Lectures
Project

mishaps
Text books:
1. Heat & Mass transfer, Tirumaleshwar, Pearson education 2006
2. Heat transfer-A basic approach, Ozisik, Tata McGraw Hill 2002
References:
1. Heat transfer, a practical approach, Yunus A- Cengel Tata Mc Graw Hill

2. Principles of heat transfer, Kreith Thomas Learning 2001
3. Fundamentals of heat and mass transfer, Frenk P. Incropera and David P. Dewitt, John
Wiley and sons.
4. Heat transfer, P.K. Nag, Tata McGraw Hill 2002.
46
7.2.17 Manufacturing Systems Modeling and Simulation
Module Title: Manufacturing Systems Modeling and Simulation

Module Code: MEng
ESTC : 6
Module Description:
Learning Outcome: On successful completion of this module students would be able to:
1. Use parametric 3D CAD software tools in the correct manner for making geometric part
models, assemblies and automated drawings of mechanical components and assemblies.
2. Use CAD software tools for assembly of mechanism from schematic or component drawing
and conduct position/ path/ kinematic / dynamic analysis of a mechanism in motion.
3. Evaluate design, analyze and optimize using commercial CAD, CAE software as black box for
required mass properties/ stress, deflection / temperature distribution etc. Under realistic
loading and constraining conditions.
4. Redesign in CAD and evaluate a mechanical product by making components in the mechanical
workshop for design validation, using measured relevant materials properties.
CONTENT:
PRINCIPLE OF COMPUTER MODELING AND SIMULATION: Monte Carlo simulation.

Nature of computer- modeling and simulation. Limitations of simulation, areas of applications.
SYSTEM AND ENVIRONMENT: Components of a system -discrete and continuous systems,

Models of a system -a variety of modeling approaches.
DISCRETE EVENT SIMULATION: Concepts in discrete event simulation, manual simulation using
event scheduling, single channel queue, too server queue, simulation of inventory problem.
STATISTICAL MODELS IN SIMULATION: Discrete distributions, continuous distributions.
RANDOM NUMBER GENERATION: Techniques for generating random numbers- Mid square
method -the mod product method -Constant multiplier technique -Additive congruential method -Linear
congruential method -Tests for random numbers -The Kolmogorov-Smimov test -the Chi-square test.
Ivica Cmkovic, Ulfaskluna and Annita borsen Dohlgvist Publisher Artechhouse.
RANDOM VARIABLE GENERATION: Inversion transforms technique-exponential distribution.

uniform distribution, weibul distribution, continuous distribution, generating approximate normal
variates - Erlang distribution.
EMPIRICAL DISCRETE DISTRIBUTION: Discrete uniform -distribution Poison distribution -

geometric distribution - acceptance -rejection technique for Poisson distribution gamma distribution.
DESIGN AND EVALUATION OF SIMULATION EXPERIMENTS: variance reduction

techniques -antithetic variables, variables verification and validation of simulation models.
47
SIMULATION SOFTWARE: Selection of simulation software, simulation packages.
Lecture
Projects
Exercises
Project
Final examination
Lectures
Project
mishaps
Text books:
1. Descre Event system simulation :Jerry Banks & .John S Carson II - Prentice Hall Inc.-1984.
2. Systems Simulation - Gordan. G. - Prentice Hall India Ltd - 1991.
References:
1. System Simulation with Digital Computer - Nusing Deo - Prentice Hall of India - 1979.
2. Computer Simulation and Modeling - Francis Neelamkovil - John Wilely & Sons - 1987.
3. Simulation Modeling with Pascal - Rath M.Davis & Robert M O Keefe - Prentice Hall Inc. -
1989.
48
7.2.18 Rapid Prototyping and Manufacturing
Module Title: Rapid Prototyping and Manufacturing

Module Code: MEng
ESTC : 6
Module Description:
Learning Outcome:

1. Apply solid modeling concepts and techniques in RP.
2. Analyze and implement the different algorithms associated with STL file errors.
3. Calculate the layer thickness in different layering techniques and carry out design
manipulations for the generation of support structure.
4. Identify, characterize and select the ideal materials for a given Rapid Prototyping system.
CONTENT:
INTRODUCTION: Classification of manufacturing processes, Different manufacturing systems,

Introduction to Rapid Prototyping (RP), Need of RP in context of batch production, FMS and CIM and
its application; Basic Principles of RP, Steps in RP, Process chain in RP in integrated CAD-CAM
environment, Advantages of RP.
CLASSIFICATIONS OF DIFFERENT RP TECHNIQUES: Based on raw material, Based on

layering technique (2D or 3D) and energy sources.
PROCESS TECHNOLOGY IN RP: Comparative study of stereo-lithography (SL) with photo-

polymerization, Solid foil polymerization, Selective laser sintering, Selective laser melting, Ballastic
particle manufacturing, Fused deposition modeling, Shape melting, Laminated object manufacturing,
Solid ground curing, Repetitive masking and deposition, Beam inference solidification, Laser
engineered net shaping (LENS), 3D Printing,
CAD DATA AND PROGRAMMING TECHNIQUES FOR RP: Transformations, Solid modeling
for RP, Surface modeling, STL file generation, Defects in STL files and repairing algorithms, Interface
formats, Slicing methods, Design of support structures, Internal hatching and surface skin fills.
MATERIALS FOR RP: Materials used for different RP processes, Selection criterions for materials
for different processes, The advantages and limitations of different types of materials.
REVERSE ENGINEERING: Introduction to reverse engineering and its integration with rapid
prototyping.
RESEARCH ASSIGNMENT: The students will be given different assignments to write their codes in
MATLAB for constant slicing, adaptive slicing, transformations, parametric curves and surfaces
involved in Rapid Prototyping.
Lecture
49
Projects
Exercises
Project
Final examination
Lectures
Project
mishaps
Text books:
1. Chua, C.K., Leong, K.F., Rapid Prototyping: Principles and Applications in Manufacturing,
John Wiley and Sons Inc., 2000
2. Pham, D.T., Demov, S.S., Rapid Manufacturing: The Technologies and Applications of Rapid
Prototyping and Rapid Tooling, Springer-Verlag London Limited, 2001
3. Noorani, R., Rapid Prototyping: Principles and Applications, John Wiley & Sons, Inc., New
Jersey, 2006
4. Patri, K. V., Weiyin, Ma, Rapid Prototyping - Laser-based and Other Technologies, Kluwer
Academic Publishers, U.S.A., 2003
5. Saxena, A., Sahay, B., Computer Aided Engineering Design, Anamaya Publishers, New Dehi,
2005
6. Zeid, I., Mastering CAD/CAM, Tata McCraw Hill, 2006
References:
50
Lab Component-1
Module Title: Lab Component-1

Module Code: MEng
Module Credit: Credit Hours : X
ESTC : X
Pre-requisite Module: Metal cutting
Module Description:
Learning Outcome:
1. Understand practically chip reduction,

2. measurement of forces during cutting,
3. estimation of power during orthogonal cutting
CONTENT:
Perform Eight / Ten experiments :
1. Determination of Chip reduction co-efficient (reciprocal of chip thickness ratio) during single
point turning.
2. Forces measurements during orthogonal turning.
3. Estimation of Power required during orthogonal turning.
4. Torque and Thrust measurement during drilling.
5. Determination of cutting forces during milling using Milling tool dynamometer
6. Measurement of Chip tool Interface temperature during turning using thermocouple technique.
7. Study the variation of surface roughness with different speed and feed during plain milling
operation on flat surface.
8. Study of capstan lathe and its tooling and prepare a tool layout & job as per given drawing.
9. Prepare metallic samples for metallographic examination and to study the principle &
construction of Metallurgical Microscope.
10. Study of Microstructure and Hardening of steel in different medium and cooling rates; Effect of
Carbon percentage on the hardness of Steel.
11. CNC milling- Writing and execution of part program for contour milling.
Lecture
Projects
51
Exercises
Project
Final examination
Lectures

mishaps
Text books:
52
Lab Component-II
Module Title: Lab Component-Ii

Module Code: MEng
Module Credit: Credit Hours : X
ESTC : X
Module Description:
Learning Outcome:
CONTENT:
1. Study pick and place Robot- basic components, configuration, work volume
2. Experiments with Robot. Kit for minimum four assembly activities and programming
3. Programming of robots by manual, lead through and off line methods
4. Programming languages for stacking of objects in increasing or decreasing size. Palletizing
operations, assembly and inspection operation etc.
5. Become acquainted with the operation of a revolute - type 6 DOF robots; to program a robotic
system using a teaching pendant and a high level programming language.
Emphasis is made on the constraints associated when positioning and orienting an object within a 3-D
space. The practical includes point-to-point tasks and continuous robot motion.
Lecture
Projects
Exercises
Project
Final examination
Lectures
mishaps
Text books:
53
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ADDIS ABABA UNIVERSITY

ADDIS ABABA INSTITUTE OF TECHNOLOGY (AAiT)

Master of Science Program in

Chair: Manufacturing and Materials Engineering

The Manufacturing Engineering program is designed to address the challenges of modern

1.2 Course Aim and Objectives

The Master of Science (M.Sc) program in Manufacturing Engineering, therefore is aimed at

Design and development of highly flexible and economical global manufacturing

The specific objectives of this program are:

1. To produce graduates with full professional competence in Manufacturing

1.3 Who Can Join the Program?

The program is intended to benefit a wide range of candidates, in particular:

Established manufacturing engineers working in industry and faced with the

2. RATIONALE OF THE GRADUATE PROGRAM

4.2 Graduation Requirements

4.3 Evaluation Criteria

The achievements of the thesis will be indicated as follows:

4.4 Quality Assurance and curriculum review

Degree of MASTER OF SCIENCE

i. Advanced Manufacturing and Automation

MEng 6204 Flexible Manufacturing System [3 Cr.]

MEng 7105 Lean Manufacturing [3 Cr.]

Quality Management & Reliability

v MEng 6107 Manufacturing System Modeling & Simulation [3

The detail description of the modules follows.

i) Advanced Manufacturing and Automation Module

iii) Facilities and Systems Engineering Module

iv) Quality Management and Reliability Module

v) Qualitative and Analytical Tools Module

vi) Leadership and Entrepreneurship

vii) Master Thesis and Seminar Module

6.3 Course Listing

7.1.1 Module Listing

II. Compulsory Modules

Course Code Course Name Cr. Hr. ECTS

Meng 6104 Finite Element Methods in Manufacturing 3 6

Course Code Course Name Cr. Hr. ECTS

Course Code Course Name Cr. Hr. ECTS

MEng 6206 Rapid Prototyping and Manufacturing 3 6

Course Code Course Name Cr. Hr. ECTS

Year Semester Module No Module Name Cr. Hr ECTS

MEng 6101 Metal Cutting Analysis 4 8

MEng 6201 Foundry Engineering 3 6

MEng 7101 CAD/CAM/CAE 3 6

MEng 7201 Seminar P/F

2 MEng 7202 Thesis 14

7.2.1 Finite Element Methods in Manufacturing

Module Title: Finite Element Methods in Manufacturing

On successful completion of this module students would be able to:

ONE DIMENSIONAL ANALYSIS

SHAPE FUNCTIONS AND HIGHER ORDER FORMULATIONS

ANALYSIS OF PRODUCTION PROCESSES

Module Title: Metal Cutting Analysis

On successful completion of this module students would be able to:

Module Title: Metal Joining Processes

INTRODUCTION OF METAL JOINING PROCESSES,

Course Number: Credit Hours: 3 , 6 ECTS

The course enables students to analyze:

MECHANICAL BEHAVIOUR OF MATERIALS ASSOCIATED TO FORMING /

BULK DEFORMATION/FORMING PROCESSES

SHEET METAL FORMING PROCESSES

MEASUREMENT TECHNIQUES IN METAL FORMING:

Mechanical metallurgy: George E Dieter