Finite Element Methods in Engineering

Introduction-Basic Concept of FEM, Methods of weighted residual techniques-Weak Formulation, Galerkin FE formulation, Rayleigh & Ritz FEM,FEM analysis of One-dimensional problems:-Second order boundary value problem, Applications in Solid, Fluid and Heat Transfer, Bending of Beams, Euler-Bernoulli Beam, Truss/Frame analysis, Eigenvalue and Time dependent problems, MATLAB Application, Numerical Integration and Computer Implementation-Natural Co-ordinates, Interpolation Functions, Numerical Integration, Isoparametric Formulation, Computer Implementation, Applications in two-dimensional problems-Plane Stress and plane Strain, Three Dimensional Solid, Axi-symmetric Solid, Plate and Shell structures, Flow of Viscous Fluid, MATLAB Application, Special Topics, Stationary Singular elements, Quarter-Point Singular Elements, Moving singular elements, Semi-infinite elements, Buckling analysis, Non-linear analysis.

Heat Transfer

Introduction: basic concepts and modes; relationship to thermodynamics.
Conduction: mechanism; Fourier's general conduction equation in 3-D; 1-D steady state conduction with heat generation: composite plane wall and cylinders, thermal resistance network, critical thickness of insulation; extended surface heat transfer. 2-D steady state conduction: solution for simple boundary conditions. Unsteady heat conduction: lumped parameter system, semi-infinite wall with convection boundary condition. Use of Heisler charts.
Convection: Review of hydrodynamic equations of boundary layer theory. Convection boundary layers: velocity and thermal boundary layers. Laminar boundary layer analysis on flat plate. Fully developed heat transfer through smooth pipes. Relation between fluid friction and heat transfer. Turbulent boundary layer; forced convection correlations.
Free convection: laminar free convection on a vertical flat plate; empirical correlations.
Boiling and condensation: mechanism, laminar film condensation on a vertical plate
Heat exchangers: types, analysis: LMTD, effectiveness-NTU method
Radiation: physical mechanism; radiation properties. Black body radiation, gray body; spectral dependence of radiation properties, Kirchoff’s law. Wien's displacement law. View factor; radiation exchange between infinite planes, and between gray bodies; Radiation shields; re-radiating surface and 3-surface enclosures, network representation.

Casting Forming and Welding

Casting: Types of foundries, steps in making a casting; cast metals; types, materials and allowances of patterns; moulding processes and their characteristics; moulding materials; gating and risering; melting furnaces; casting defects.

Welding: Welding processes; welding energy sources and their characteristics; fluxes and coatings; weldability and welding of various metals and alloys; metallurgical characteristics of welded joints; weld testing and inspection.

Forming: Classification of metal forming processes; basic metal working concepts and plasticity; yield criterion; slip line fields; estimation of force and energy requirements; technology of bulk and sheet metal forming processes; precision forming processes; various features of different types of metal forming dies; principles of powder forming.

Principles Of Machine Design

General considerations & procedure of Machine Design: General Principle of Machine Design, Engineering materials & their mechanical properties, factor of safety, Fits & tolerances. Basic design principle of machine elements and their selection: Fasteners, fittings, Shaft, Couplings, Clutches, Brakes, Bearing Selection, Fly Wheel, Belt drive, Chain Drive, Gears, Gear Train and Gear units, Non-metallic machine elements, Fluid Power systems & components. Design and drawing of a few machine systems: Fasteners, Power Screw, Gear Units, Clutch/Brake.

 

Laser Applications In Manufacturing

Laser Fundamentals: spontaneous & stimulated emission/absorbtion, population inversion & pumping, cavity design , coherence and interference. Common industrial lasers and their output characteristics: CO2, Ruby, Nd-YAG, Nd-glass, excimer & He-Ne. Overview of laser Applications: Laser application in various fields, advantages & disadvantages, economics. Laser processing fundamentals: beam characteristics, optical components and design of beam delivery systems, absorption characteristics of materials, heat flow theory and metallurgical considerations. Cutting and drilling: Process characteristics, material removal modes, development of theoretical models and practical performance. Welding: Process mechanisms like keyhole & plasma, development of theoretical models, operating characteristics and process variation. Surface modification: heat treatment, rapid solidification, alloying and cladding, surface texturing, development of theoretical models, LCVD, LPVD. Introduction to interferometry: working principles of Michelson interferometer and Fabry-Perot interferometer and elementary holography. Special topics: detection and measurement of radiation, laser safety.
 

Non Traditional Manufacturing Processes

Needs of manufacturing industries and the concept of surface integrity. The role of newer & innovative processes for the solutions
Impact erosion and the evaluation for impregnation of foreign bodies. Theory and application of Abrasive Jet, Water Jet, Abrasive Flow, Ultrasonic, Total Form Machining and Low stress Grinding.
Theory and applications of Chemical Processing: Chemical Machining, etching of semiconductors, coating and Electroless forming and CVD.
Theory and applications of Electrochemical machining and grinding including, Electrochemical sharpening, polishing, honing and deburring, surface treatment, coating and Electroforming.
Thermal energy methods of material processing (machining, welding, cladding, alloying and heat-treatment): Electro-discharge, Laser, Electron beam, Plasma arc, Plasma spray, Ion beam and PVD.
Hybridization of processes for improving process capability and surface integrity. Explanation of some processes like ECDG, ultrasonic and Laser assisted processing, LIGA & SLIGA etc.; Generic manufacturing and introduction to rapid prototyping.
Practical-component: Experiments on EDM, ECM, laser etc.

Emerging Trends In Manufacturing Technology
 

Surface engineering and High speed grinding: Application of advanced coatings in high performance cutting tools and high performance super-abrasive grinding wheels. Application of surface coating in metal-ceramic joining. Ultra high speed grinding with monolayer CBN grinding wheel. Machining and grinding under cryogenic environment. Micro and nano machining of glasses and ceramics in ductile regime using diamond cutting tool and diamond grinding wheel.
 

Rapid prototyping: Need for Rapid Prototyping, Basic Principles and advantages of RP, Classifications of different RP techniques with examples, Introduction to three Representative RP techniques: Fused deposition modeling, Laminated Object Manufacturing and Stereo-lithography

MEMS: Introduction, history, development and need of micro-electro-mechanical systems. IC fabrication processes used for MEMS; MEMS sensors and actuators; Mechanical process techniques and process models for micro-machining; Fabrication processes and design of the process sequences; Agile prototyping; Reliability and process control of micro manufacturing processes; Introduction to nano-technology processes.

Vibration and Noise Control

Introduction to single DOF, 2-DOF and Multi degree freedom systems. Free and Forced Response. Vibration of Continuous systems: strings, bars, beams and plates. Force Transmissibility, Design of Vibration Isolators and Absorbers. Torsional Vibration, Basics of Acoustics, Solution of 1-D and 3-D wave equation, Sound Field Characterization, Principles of Noise Control, Sound Control Materials: Absorbers, Barriers and Damping Materials, Silencers, Introduction to Active Noise and Vibration Control.

Rapid Prototyping

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, layering technique (2D or 3D) and energy sources; Process Technology and Comparative study of :- Stereo-lithography (SL) with photo-polymerization, SL with liquid thermal polymerization, Solid foil polymerization, Selective laser sintering, Selective powder binding, Ballastic particle manufacturing – both 2D and 3D, Fused Deposition Modelling, Shape Melting, Laminated Object Manufacturing, Solid Ground Curing, Repetitive Masking and deposition, Beam Inference Solidification, Holographic Interference Solidification, Special Topic on RP using metallic alloys, Programming in RP, Modelling, Slicing, Internal Hatching, Surface Skin Fills, Support Structure

Machine Tool Engineering

Major techno-economical aspects of machine tools. Kinematic structure, working principle and application of semi-automatic and automatic lathes, gear teeth cutting machines and copying machines. Design principles of special purpose machine tools. Design of machine tool gear boxes, spindles and beds of machine tools. Slides and guides and selection of bearings for machine tools. Rigidity, system compliance and process capability of machine tools. Machine tool vibration and chatter. Foundation and installation of machine tools. Machine tool inspection, testing and maintenance. Flexible automation and robot application in manufacturing by machine tools. Constructional features, operational characteristics and part programming of flexibly automatic machine tools; CNC machining center and FMS and their advantageous applications.

Evolutionary Computing

Genetic Algorithms: introduction, mathematical foundation, computer implementation, genetic based machine learning, applications.
Neural Networks: introduction, multi-layer networks, recurrent networks, learning paradigms.
Fuzzy Control: an industrial perspective, knowledge based system for process control, mathematics of fuzzy control, non-linear and adaptive fuzzy control.
Chaos: complexity and simplicity, evolution of possibilities, simple models of chaos, strange attractors, deterministic chaos, self-organization, synergetics.
Evolutionary Computing: hybrid intelligent system, evolutionary dynamics, evolutionary engineering and its application.
practical-component (Manufacturing software lab): Development of software for the control of network based distributed and real time systems using techniques based on Corba, Java and XML etc. Development of software for collaboration using agents and other approaches. Development of process control software using neural network, fuzzy logic, genetics and other emerging approaches.

Process Dynamics And Adaptive Control

State space approach to control systems. State transition equations. Linear Time invariant and nonlinear systems. Controllability and Observability of systems. Pole placement design. Design of control systems. Elements of optimal control. Digital control and time delay control systems. Basic concepts of estimation and identification in automatic control systems. Adaptive control of complex process control systems as in automated machining and welding processes, energy based systems and processes. Nonlinear control and related topics using neuro, fuzzy or genetic algorithms. Case studies and descriptions for automated industrial process control applications inclusive of advanced topics in processes for the high tech industry.