RME6C002 Machining Science and Technology

MODULE – I 
Geometry of cutting tools in ASA and ORS, Effect of Geometrical parameters on cutting force and surface finish, Mechanics of chip formation, Merchant’s theory, Force relationship and velocity relationship, Cutting tool materials. Types of Tool Wear: Flank wear, Crater wear, Wear measurement, Cutting fluid and its effect; Machinability Criteria, Tool life and Taylor's equation, Effect of variables on tool life and surface finish, Measurement of cutting force, Lathe tool dynamometer, Drill tool dynamometer. Economics of machining.

MODULE II 
Conventional machining process and machine tools – Turning, Drilling, Shaping, Planning, Milling, Grinding. Machine tools used for these processes, their specifications and various techniques used. Principles of machine tools : Kinematics of machine tools, speed transmission from motor to spindle, speed reversal mechanism, mechanism for feed motion, Tool holding and job holding methods indifferent Machine tools, Types of surface generated, Indexing mechanism and thread cutting mechanism, Quick return mechanism Production Machine tools – Capstan and turret lathes, single spindle and multi spindlesemiautomatics, Gear shaper and Gear hobbing machines, Copying lathe and transfer machine

MODULE III 
Non-traditional Machining processes : Ultrasonic Machining, Laser Beam Machining, Plasma Arc Machining, Electro Chemical Machining, Electro Discharge Machining, Wire EDM , Abrasive Jet Machining

Books :
3. Fundamentals of Machining and Machine Tools, G.Boothroyd and W.A.Knight, CRC Press
2. Metal Cutting Principles, M.C.Shaw, Oxford University Press
1. Metal Cutting Theory and Practice, A.Bhattacharya, Central Book Publishers
4. Manufacturing Technology – by P.N.Rao, Tata McGraw Hill publication.
5. Modern Manufacturing Processes, P.C.Pandey, H.S.Shan, Tata McGraw Hill
6. Manufacturing Science, Ghosh and Mallik, East West Press.
7. Metal Cutting Theory and Practice, D.A.Stephenson and J.S.Agapiou, CRC Press
8. Machining Technology; Machine Tools and Operation, H.A.Youssef and H. El-Hofy, CRC Press
9. Machine Tools and Manufacturing Technology, Krar, Rapisarda and Check, Cengage Learning
10. Technology of Machine Tools, Krar, Gill and Smidt, Tata McGraw Hill
11. Principles of Metal Cutting, G.Kuppuswamy, Universities Press
12. Metal Cutting and Machne Tools, G.T.Reddy, Scitech
13. Fundamentals of tool Engineering Design, S.K.Basu, S.K.Mukherjee, R. Mishra , Oxford & IBH Pub Co.
14. Machine Tools, R.N.Datta, New Central Book Agency

RME6D001 Smart and Composite Materials

MODULE I 
Introduction: definitions and classifications; natural composites; role of matrix and reinforcement; factors which determine properties; the benefits of composites. Reinforcements and the reinforcement matrix interface: natural fibers; synthetic organic fibers – aramid, polyethylene; and synthetic inorganic fibers – glass, alumina, boron, carbon, silicon based fibers; particulate and whisker reinforcements, reinforcement-matrix interface – wettability, interfacial bonding, methods for measuring bond strength.

MODULE II 
Metal matrix composites: Introduction, important metallic matrices; metal matrix composite processing: solid state processing – diffusion bonding, powder metallurgy; liquid state processing – melt stirring, compocasting (rheocasting), squeeze casting, liquid infiltration under gas pressure; deposition – spray co-deposition and other deposition techniques like CVD and PVD; in situ processes. Interface reactions. Properties of MMCs – physical properties; mechanical properties like elastic properties, room temperature strength and ductility, properties at elevated temperatures, fatigue resistance. Processing, structure of multifilamentary superconductors, properties of aluminium reinforced with silicon carbide particles

MODULE III
Ceramic matrix composites: Introduction; processing and structure of monolithic materials – technical ceramics, glass-ceramics. Processing of ceramics: conventional mixing and pressing – cold pressing and sintering, hot pressing, reaction bonding processes, techniques involving slurries, liquid state processing – matrix transfer moulding, liquid infiltration, sol-gel processing, vapour deposition techniques like CVD, CVI, liquid phase sintering, lanxide process and in situ processes. Processing, properties and applications of alumina matrix composites - SiC whisker reinforced, zirconia toughened alumina; Glass-ceramic matrix composites; Carbon-carbon composites - porous carbon-carbon composites, dense carbon-carbon composites.

MODULE IV 
Polymer matrix composites: Introduction; polymer matrices – thermosetting, thermoplastic, rubbers. Processing of PMCs: Hand methods – hand lay-up, spray-up methods; Moulding methods – matched die moulding, bag moulding processes (autoclave moulding), resin transfer moulding, pultrusion; Filament winding; Injection moulding. Processing, properties and applications of fibre-reinforced epoxies, PEEK matrix composites, rubber matrix composites. Damping characteristics. Environmental effects in polymer matrix composites. Recycling of PMCs.

MODULE V 
Sandwich structures, foam core type arrangements; Honey comb structures. Micromechanics of unidirectional composites: micromechanics models for stiffness – longitudinal stiffness, transverse stiffness, shear modulus, poisson’s ratio. Micromechanics models for strength – longitudinal tensile strength, longitudinal compressive strength, transverse tensile strength, transverse compressive strength, inplane shear failure, thermal and moisture effects. Short fibre composites: reasons for using short fibre composites, fibre length, fibre orientation, stress and strain distribution at fibres, critical fibre length and average fibre stress, stiffness and
strength: stiffness of aligned systems, non-aligned systems and variable fibre orientation, strength of aligned systems, 2-D composites, variable fibre orientation.

Books:
[1] Composite Materials: Engineering and Science, by Matthews and Rawlings, CRC Press.
[2] An Introduction to composite material, by D.Hull and T.W. Clyne, Cambridge University press.
[3] Metal Matrix Composites, Thermomechanical Behaviour by M.Taya, and R.J.Arsenault, Pergamon Press, Oxford.
[4] Fundamentals of Metal Matrix Composites by S.Suresh, A.Martensen, and A.Needleman, Butterworth, Heinemann
[5] Mechanics of composite materials, R. M. Jones, Mc Graw Hill Book Co.

[6] Mechanics of composite materials and structures, M Mukhopadhay, Universities Press.
[7] Fiber-Reinforced composite materials, Manufacturing & Design, P. K. Mallick, Marcel Dekken, Inc. New York & Basel.
[8] F.L. Matthews and R.D. Rawlings, Composite Materials: Engineering and Science, Chapman Hall, London, 1994.
[9] Weinheim, Structure and Properties of Composites, Materials ScienceTechnology, Vol. 13, VCH, Germany, 1993.

Optimization in Engineering

Module I: 
Idea of Engineering optimization problems, Classification of optimization algorithms, modeling of problems and principle of modeling. Linear Programming: Formulation of LPP, Graphical solution, Simplex method, Big-M method, Revised simplex method, Duality theory and its application, Dual simplex method , Sensitivity analysis in linear programming.

Module II: 
Transportation problems: Finding an initial basic feasible solution by Northwest Corner rule, Least Cost rule, Vogel’s approximation method, Degeneracy, Optimality test, MODI method, Stepping stone method. Assignment problems: Hungarian method for solution of Assignment problems. Integer Programming: Branch and Bound algorithm for solution of integer programming problems.

Module III: 
Non-linear programming: Introduction to non-linear programming. Unconstraint optimization: Fibonacci and Golden Section Search method. Constrained optimization with equality constraint: Lagrange multiplier, Projected gradient method. Constrained optimization with inequality constraint: Kuhn-Tucker condition, Quadratic programming.

Module IV: 
Queuing models: General characteristics, Markovian queuing model, M/M/1 model, Limited queue capacity, multiple server, Finite sources, Queue discipline.

Design of Machine Elements

Module - I 
1. Mechanical engineering design: Introduction to design procedure, Stages in design, Code and Standardization, Interchangeability, Preferred numbers, Fits and Tolerances, Engineering materials: Ferrous, Non-ferrous, Non-metals, design requirements – properties of materials, Material selection, Use of Data books.
2. Fundamentals of Machine Design: Types of load, Modes of failure, factor of safety concepts, Theories of Failure, concept and mitigation of stress concentration, Fatigue failure and curve, endurance limit and factors affecting it, Notch sensitivity, Goodman, Gerber and Soderberg criteria.

Module – II  
3. Machine Element Design: Design of Joints: Rivets, welds and threaded fasteners based on different types of loading, Boiler joints, cotter joints and knuckle joints.

Module – III 
4. Design of Keys, Shaft and Couplings: Classification of keys and pins, Design of keys and pins, Theories of failure, Design of shafts: based on strength, torsional rigidity and fluctuating load, ASME code for shaft design, Design of couplings: Rigid coupling, Flexible coupling.
5. Design of Mechanical Springs: Types of helical springs, Design of Helical springs, bulking of spring, spring surge, end condition of springs, Design of leaf springs: nipping.

Module – IV
6. Bearings: Types and selection of ball and roller bearings, Dynamic and static load ratings, Bearing life, Design of sliding contact bearings, Journal bearing, foot step bearing.