06me71 – control engineering · modern control engineering – k. ogatta 2. automatic control...

DEPT.OF MECHANICAL ENGINEERING MVJCE

VII SEMESTER 1

06ME71 – CONTROL ENGINEERING


VII SEMESTER 2

SYLLABUS

Sub code: 06ME71 I A Marks: 25 Hours / Week: 5 Exam Hours: 3 Total Hours: 52 Exam Marks: 100

1. Introduction: concept of automatic controls, open and closed loop systems, concepts of feed back requirement of an ideal control system 03 hrs

2. Mathematical Model Mechanical System: (both translational and rotational) electrical systems (servos, dc motors, ac motors, servomotors) hydraulic system (liquid level and fluid power systems) thermal systems, integrating devices, hydraulic servomotor, temperature control system, error detectors 06 hrs

3. System Response: first order and second order system response to step, ramp and sinusoidal inputs, concepts of time constant and its importance in speed of response. System of stability- Routh Hurwitz criterion 06 hrs

4. Block diagrams, signal flow graphs and transfer functions definitions of transfer – function, block representation of system elements, reduction of block diagrams, signal flow graphs, basic properties and gain formula to block 06 hrs

5. Control action- types of controllers – proportional, integral, proportional integral differential controllers. (Basic concepts only) 03 hrs

6. Frequency Response: polar and rectangular plots for frequency response – system analysis using Nyquist diagrams relative stability concepts of gain margin and phase margin, m & n circles 04 hrs

7. System Analysis Using Logarithmic Plots: bode attenuation diagrams, stability analysis using bode diagrams – simplified bode diagrams. 04 hrs

8. Root Plots: definition of root loci, constructing of root loci, graphical relationship – setting the system locus gain. 06 hrs

9. Compensation: System series and feed back compensation, physical devices for system compensation 08 hrs

10. Introduction to state variable characteristics of linear system – introduction to the state concepts – state equation to linear continuous data systems matrix representation of state equations- controllability and observability, Kalman & Gilberts test 06 hrs

Text Books:

1. Modern Control Engineering – K. Ogatta 2. Automatic Control Systems – B C Kuo 3. Automatic Control Systems – Raven

Reference Books: 1. Feedback Control Systems – Schaum’s series, 2001. 2. Control Systems by I.J. Nagarath & M.Gopal, New age International Publishers, 2002. 3. Control Systems: M.Gopal, Tata McGraw Hill, New Delhi, 2e, 2002.


VII SEMESTER 3

LESSON PLAN

Sub Code: 06ME71 Hours / Week: 04 Sub: Control Engineering Total Hours: 52

Hour. No Topics to be covered

01 Introduction concept of automatic control system open loop system

02 Close loop system, feed back system & examples

03 Requirement of ideal control system & examples

04 Control action – types of controllers - proportional controller integral controller

action

05 Proportional integral controller

06 Proportional integral controller - proportional integral differential controllers

07 Problems on control action

08 Transfer Function Models, Models of Mechanical System

09 Hydraulic servo motors

10 Temperature control system, error detectors

11 Differential equation for mechanical system – transactional & rotational

12 Electrical system – servo, dc motors & ac motors

13 Hydraulic system – liquid level and fluid power system

14 Models of Pneumatic system

15 Thermal system, integrative device

16 Block diagram – definition

17 Components of block diagrams and its benefits

18 Basic properties and gain formula to block diagrams

19 Reduction of block diagram

20 problems on reduction of block diagram

21 Signal flow graphs – reduction of signal flow graphs

22 Mason’s gain Formula for signal flow graph

23 Problems on reduction of signal flow graphs

24 Problems on reduction of signal flow graphs

25 Time response system Introduction

26 Definition, time response for first order system

27 Time response for first order system for unit step – ramp & sinusoidal signals

28 Time response for second order system

29 Time response for second order system for unit step – ramp & sinusoidal

signals

30 Time response specification

31 Problems on time response specification



34 System of stability

35 Routh – hutwtz criteria for system stability

36 Problems on Routh – hutwtz criteria for system stability

37 Polar plots for frequency response & problems

38 Rectangular plots for frequency response

39 Nyquist diagram for system analysis

40 Relative stability concepts of gain margin and phase diagram

41 M & n circles – problems

42 System analysis using logarithmic plots


VII SEMESTER 4

43 Nyquist diagram for system analysis– problems

44 Nyquist diagram for system analysis– problems

45 Bode attenuation diagram

46 Stability analysis – using bode diagram

47 Simplified bode diagram

48 Problems on bode diagram

49 Root locus plots definition construction

50 General Rules for constructing Root Loci

51 Analysis using R-C Plots

52 Problems on graphical relationship

53 Problems on graphical relationship

54 Settling the system gain

55 System compensation series

56 System compensation feed back

57 Physical device foe system compensation – description.

58 State variables – introduction – definition and description

59 Characterization of linear system

60 Introduction to the state concept-state equation

61 Linear continuation data system problems

62 Matrix representation of state equation problems


VII SEMESTER 5

QUESTION BANK

01 Explain briefly the concept of automatic controls.

02 Briefly, explain open loop system with an example.

03 Briefly, explain closed loop system with an example.

04 Briefly, explain concepts of feedback.

05 What are all the requirements of an ideal control system? What are the qualitative

measures of these measurements?

06 Give an example of open loop control system? How can this be modified into a closed

loop one? Compare the performance of both the systems.

07 Distinguish between linear and Non-linear control system

a) Continuous and discrete data system

b) Time invariant and Time variant systems.

08 What is meant by feed back and what are its effects.

09 Briefly, explain about error detectors.

10 Define the following a) Servomechanism b) Regular system c) Follow-up system.

11 With the help of a sketch, explain the following working of a) Speed control system b)

Pressure control system c) Hydraulic control system.

12 Derive the differential equation and obtain the transfer for a field controlled DC

motor.

13 Derive the differential equation and obtain the transfer for a hydraulic system.

14 Derive the differential equation for R – L –C circuit.

15 Obtain the transfer function for the mechanical system as shown in figure.

16 Obtain the transfer for spring mass damper system. (Transactional and rotational) as

in fig a & b


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17 Obtain the transfer function for the electrical circuit as shown in figure. Mention order of

the system.

18 Define the following terms as applied to the response of a second order system

subjected to a unit step input. a) Maximum overshoot, b) Settling time c) Rise time.

19 Obtain an expression for response of first order system for unit step input.

20 In a DC position control servomechanism, a motor supplied by a constant armature

current drives the load. The field current is supplied from dc amplifier, the input to

which is the difference between the voltages obtained from input and output

potentiometers. The load and motor together have a moment of inertia, J = 0.4 kg-

m2 and the viscous friction constant of f = 2 Nm/rad/sec. Each potentiometer

constant of field current. The field time constant is negligible. A) Make a sketch of the

system and show how the hardware is connected. B) Also find the amplifier gain K in

amperes/volt to give an un-damped natural frequency of 10 rad/sec, after obtaining

the transfer function.

21 Obtain the transfer function of the system shown in the figure.

22 The figure shows the Force- current analogues circuit of a transnational mechanical

system. Draw the mechanical system and explain the method employed.


VII SEMESTER 7

23 Derive the transfer function of the circuit shown in fig. If Vi = 5 sin 10t volts, R1=50

& R2=5 Kilo ohms. C = 1microF. Calculate the output voltage in magnitude and in

phase relative to input voltage.

24 Reduce the block diagram shown in the following figure by block diagram reduction

technique to obtain C/R

25 What are the advantages of a Block diagram of a control system? 26 Explain briefly the types of blocks in linear control system.

27 Explain briefly the Rules for block diagram technique.

28 Obtain the overall transfer function of the block diagram by reduction technique


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VII SEMESTER 9

32 Determine C/R for the block diagram shown in fig using Mason’s Gain formula

33 For the signal flow graph shown in figure obtain the transfer function using Mason’s

formula

34 Explain Proportional plus derivative control

35 Explain control action.

36 Briefly explain a) proportional Integral differential controllers

37 Briefly, explain a) Integral b) proportional controllers.

38 List the basic classification of the controllers.

39 Explain briefly the Derivative control action.

40 Explain briefly the Proportional – plus – Integral – plus – derivative Control action.

41 Explain briefly the On – Off controllers.

42 Explain briefly The Velocity feed back.

43 Briefly explain Nyquist stability criteria.

44 For the system with an open loop transfer function as given below plot the Nyquist

diagram and determine the stability of the system

)12()1(

)14()()(

2 +++=

ssS

sSHsG

45 Explain briefly about polar plots. 46 Explain briefly about frequency domain specifications.

47 List out the parameters that are can be measured with the help of Nichols chart.

48 Draw the Nyquist plot of the system of the system whose transfer function is given

by

)3()2(

10)()(

++=

ssSHsG


VII SEMESTER 10

49 The characteristic equation of a feedback control system is given by s3+5Ks2+(2K+3)

s+10=0apply Nyquist criterion to determine the value of K for the system to be in

stable closed loop

50 The open loop transfer function of a system is

)1()1(

2)()(

−++=

ss

sSHsG Draw the

Nyquist plot and ascertain its stability

51 Explain briefly the concept of system stability.

52 Using RH criteria find out the range of K for which the system is stable.

S3+5KS2+(2K+3)S+10=0

53 Explain the importance of routh’s stability criterion.

54 Examine the stability of a second order system whose characteristic equation is given

by q(s)=a2+s2+a1s+a0.

55 Construct the bode plot for a system whose open loop transfer is given by

26258

180)()(

23 +++=

sssSHsG The sketch given shows the Bode magnitude plot

for a system. Obtain the transfer function

56 Sketch the bode magnitude and phase plot for the system having OLTF

)10()2()01.0(

)2.0()()(

++++=

sssS

SkSHsG hence determines the value of k for which the

system is just stable

57 Draw the bode plot of a feedback control system whose loop transfer function is given

by)41()1(

8)()(

sssShsG

++= and hence determine the gain margin and phase

margin of the system. If the gain is to be doubled, what should be the new value of

gain?

58 Sketch the bode plot for a system characterized by the open transfer

function)005.01()001.01(3

)025.01()2.01()(

ssS

ssKsG

++++= show that the system is conditionally

stable. Find the ranges of K for which the system is stable


VII SEMESTER 11

59

Sketch the root locus plots of12)2.5s18)(s2(s

)1()()(

++++

=sK

sHsG for what value of k

the system becomes unstable?

60 Sketch the root locus diagram for the open loop transfer function

10.25)s4)(s4S(s)(

2 +++= K

sG find the value of k and ω at which the system is

marginally stable

61 What are the types of system compensation and explain any one briefly.

62 What are the advantages and disadvantages of Phase Lag compensator?

63 What are the advantages and disadvantages of Phase Lead compensator?

64 What are the advantages and disadvantages of Phase Lag - lead compensator?

65 Explain clearly the need for compensation in a control system.

66 Show the transfer function of lead compensated electrical network as shown in figure.

67 Explain briefly how a tachometer functions as a compensating device

68 Show the transfer function of lead compensated mechanical network as shown in

figure

69 Define the terms 1) State 2) State variables. 70 Define a) State vector b) State space.

71 Write short notes on 1) Controllability 2) observability 3) controllability 4)

observability theorems.

72 Represent MIMO and SISO systems as block diagrams (state variable representation)


VII SEMESTER 12

73 Obtain the state space representation for the system as in given figure.

74 What are the types of state space models?

75 Calculate the final value of the given function F(z)=8. Obtain the state equation of

the system whose difference equation is given by y(K+2) + 4y(K+1)+6y(K) = 3U(K)

76 The characteristic equation of a linear discrete data control system is given by f(z) =

Z3+Z2+Z+K=0, where K is a constant. Find the range of values of K so that the

system is stable.

77 Solve the following difference equation by using Z transform method x(k+2) +

3x(k+1) + 2x(k) = 0 when x(0) =0, x(1)=5.

78 List out the properties of Z transform.

79 List out the properties of Starred function.

80 List out the applications of sampled data technique.

81 List out the advantages of Digital computer control.

82 Determine the state controllability and observability of the system described by

83 Obtain the state model of the system whose closed loop transfer function is


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VII SEMESTER 20

QUESTION PAPERS


VII SEMESTER 21


VII SEMESTER 22

06ME72 - COMPUTER INTEGRATED

MANUFACTURING


VII SEMESTER 23

SYLLABUS

Sub Code: 06ME72 IA Marks: 25

Hrs/Week: 04 Exam Hours: 3 Total Hrs: 52 Exam Marks: 100

UNIT – 1 COMPUTER INTEGRATED MANUFACTURING SYSTEMS: Introduction, Automation definition, Types of automation, CIM, processing in

manufacturing, Production concepts, Mathematical Models-Manufacturing lead time, production rate, components of operation time, capacity, Utilization and availability, Work-

in-process, WIP ratio, TIP ratio, Problems using mathematical model equations. 8 Hrs

UNIT - 2

HIGH VOLUME PRODUCTION SYSTEM: Introduction Automated flow line-symbols, objectives, Work part transport-continuous,

Intermittent, synchronous, Pallet fixtures, Transfer Mechanism-Linear-Walking beam, roller chain drive, Rotary-rack and pinion, Ratchet & Pawl, Geneva wheel, Buffer storage, control

functions-sequence, safety, Quality, Automation for machining operation. 6 Hrs

UNIT - 3 ANALYSIS OF AUTOMATED FLOW LINE & LINE BALANCING: General terminology and analysis, Analysis of Transfer Line without storage-upper bound

approach, lower bound approach and problems, Analysis of Transfer lines with storage buffer, Effect of storage, buffer capacity with simple problem, Partial automation-with numerical

problems, flow lines with more than two stages, Manual Assembly lines, line balancing problem 6 Hrs

UNIT - 4 MINIMUM RATIONAL WORK ELEMENT

Work station process time, Cycle time, precedence constraints. Precedence diagram, Balance delay methods of line balancing-largest Candidate rule, Kilbridge and Westers method,

Ranked positional weight method, Numerical problems covering above methods and computerized line balancing 6 Hrs

UNIT - 5 AUTOMATED ASSEMBLY SYSTEMS: Design for automated assembly systems, types of automated assembly system, Parts feeding devices-elements of parts delivery system- hopper, part feeder, Selectors, feed back, escapement and placement analysis of Multistation Assembly Machine analysis of single station assembly. Automated Guided Vehicle System: Introduction, Vehicle guidance and routing, System management, Quantitative analysis of AGV’s with numerical problems and application. 8 Hrs

UNIT - 6 COMPUTERIZED MANUFACTURING PLANNING SYSTEM: Introduction, Computer Aided Process Planning, Retrieval types of process planning,

Generative type of process planning, Material requirement planning, Fundamental concepts of MRP inputs to MRP, Capacity planning


VII SEMESTER 24

UNIT - 7

CNC MACHINING CENTERS: Introduction to CNC, elements of CNC, CNC machining centers, part programming,

fundamental steps involved in development of part programming for milling and turning.

UNIT - 8 ROBOTICS: Introduction to Robot configuration, Robot motion, programming of Robots end effectors,

Robot sensors and Robot applications. [This is required for CIM automation lab 06MEL77]

TEXT BOOKS: 1. Automation, Production system & Computer Integrated manufacturing, M. P. Groover”

Person India, 2007 2nd edition. 2. Principles of Computer Integrated Manufacturing, S. Kant Vajpayee, Prentice Hall India.

REFERENCE BOOKS:

1. Computer Integrated Manufacturing, J. A. Rehg & Henry. W. Kraebber. 2. CAD/CAM by Zeid, Tata McGraw Hill.


VII SEMESTER 25

LESSON PLAN

Subject code :06ME72 Hours/Week : 05 Subject Name : COMPUTER INTEGRATED MANUFACTURING Total Hours : 52

Hour

No Topics to be covered Unit-1: COMPUTER INTEGRATED MANUFACTURING SYSTEMS

01 Introduction to computer integrated manufacturing systems, Automation Definition.

02 Types of Automation, computer integrated manufacturing systems.

03 Processing in manufacturing.

04 Production concepts.

05 Mathematical models-Manufacturing lead-time., Production rate,

06 Components of operation time,. Capacity, Utilization and availability.

07 Problems related to MLT,

08 Production rate, components of operation time,. Capacity, , Utilization and availability

09 Work-in-process.-Work-in-process [WIP] Ratio, Tip Ratio

10 Problems using mathematical model equations.

Unit-2: HIGH VOLUME PRODUCTION SYSTEM 11 Introduction automated flow line-symbols.

12 Objectives, Work part transport-continuous, Intermittent, synchronous, pallet fixtures.

13 Transfer mechanism-linear-walking beam.

14 Roller chain drive, Rotary-rack and pinion. 15 Ratchet and Pawl, Geneva wheel, Buffer storage.

16 Control functions-sequence, safety, and quality

17 Automation for machining operation.

Unit-3: ANALYSIS OF AUTOMATED FLOW LINE & LINE BALANCING

18 General Terminology and analysis, Analysis of Transfer line without storage upper

bound approach.

19 Lower bound approach and problems.

20 Analysis of Transfer lines with storage buffer.

21 Effect of storage buffer, buffer capacity with simple problems.

22 Partial automation-with numerical problems.

23 Flow lines with more than two stages

24 Manual Assembly lines.

25 Line balancing problems.

Unit-4: MINIMUM RATIONAL WORK ELEMENT

26 Work station process time, Cycle time.

27 Precedence constraints, precedence diagrams.

28 Balance delay methods of line balancing-largest candidate rule. 29 Kilbridge and westers method., problems.

30 Ranked positional weight method., problems.

31 Computerized line balancing.


VII SEMESTER 26

Unit-5: AUTOMATED ASSEMBLY SYSTEMS

32 Design for automated assembly systems.

33 Types of automated assembly systems. 34 Parts feeding devices-elements of parts delivery system-hopper., Part feeder, selectors

& feed back.

35 Escapement and placement analysis of multi-station assembly machine.

36 Analysis of single station assembly.

37 Introduction to Automated Guided Vehicle System [AGV].

38 Vehicle guidance and routing system management.

39 Quantitative analysis of AGV’s,

40 Problems and applications of AGV’s.

Unit-6: COMPUTERISED MANUFACTURING PLANNING SYSTEM

41 Introduction to computerized manufacturing planning system.

42 Computer aided process planning.

43 Retrieval types of process planning.

44 Generative types of process planning.

45 Material process planning,

46 Fundamental concepts of MRP inputs to MRP

47 Capacity planning.

Unit-7: CNC MACHINING CENTERS

48 Introduction to CNC machines.

49 Elements of CNC.

50 CNC machining centers. 51 CNC part programming.

52 Fundamental steps involved in the development of CNC part programming.

53 CNC part programming for Turning. 54 Part programming for Turning models. 55 CNC part programming for Milling 56 Part programming for Milling models

Unit-8: ROBOTICS

57 Introduction to Robotics., Robot configuration.

58 Robot motion.

59 Programming of Robot’s end effectors.

60 Robot sensors.

61 Robot applications.

62 Introduction to CIM automation lab problems.


VII SEMESTER 27

QUESTION BANK

CHAPTER 1: Computer Integrated Manufacturing

1. Define the term CAD, CAM & CIM.

2. Define the term Automation and Briefly explain the different types of automation with their salient features

3. List the various reasons for Automation.

4. Comparison between Automation and CIM?

5. Briefly explain the different types of production system with an example.

6. Enlist the functions in the Manufacturing system.

7. What are the Arguments for and against in favor of the Automation?

8. With neat sketch explain the information processing cycle in a typical manufacturing organization.

9. Enlist the automation strategy with their effect? Briefly explain each of them.

10. Define the following term with respect to Production concepts

� Production rate � Plant capacity

� Utilization � Availability

� Manufacturing lead time � Work in process.

11. Write a note on MLT? Give the expression of MLT for different types of

production. 12. Explain the following with respect to WIP.,

� WIP ratio � TIP ratio

13. A certain part is routed through 6 machines. The parts are made in very large

quantities on a flow production line in which an automated work handling system is used to transfer parts between the machines. The transfer time between stations is 15

seconds. The total time required to setup the entire line is 150 hrs. Operation time for individual machines are given in the following table.,

Machine Operation time (min)

1 5

2 3.5

3 10

4 1.9

5 4.1

6 2.5

Determine: -

1) The MLT for an average production part coming of the line 2) Production rate for operation 3 3) Theoretical production rate for the entire production line.


VII SEMESTER 28

14.The avg parts produced is a certain batch has to be processed through an avg of 6 machines. There are 20 new batches of parts launch each week. Other pertinent

information are, Avg operation time = 6 min = 0.1 hrs , Avg setup time = 5 hrs

Avg batch size = 25 parts , Avg non-operation time = 10 hrs. There are 18 work centers in the plant and the plant operates for an avg of 70 production

hrs / week. Scrap rate is negligible. Determine 1) MLT for avg part Ans. 105 hrs

2) Plant capacity Ans. 700 pc/week 3) Plant utilization Ans. 71.43 %

15. In certain factory an avg of 20 new orders are processed every month 50 parts are to be processed on an avg for every order. The processing of the order is carried out through

10 machines in the factory the following data is made available for further computations, Operation time / machines for each part = 15 min

Non operation time per order at each machines = 8 hrs Setup time per order = 4 hrs

No of machines in factory = 25 No of hrs of plant operation / month = 160 hrs

% of machines operational at any time = 80 % % of machines under repair and maintenance at any time =20%

You are required to computer the following,

1) MLT per product. Ans 245 hrs 2) Plant capacity per month. Ans 969.7 pc/months

3) Plant utilization. Ans 103.125% 4) WIP Ratio. Ans 98%

16. A certain part is routed to the 6 machines in a batch production plant. The setup and

operation time for each machine is given in following table. The batch size is 100 units and the avg non-operation time per machine is 12 hrs.

Machine Set up

time (min)

Operating cycle

time(min)

M/C 1 4 5

M/C 2 2 3.5

M/C 3 8 10

M/C 4 3 1.9

M/C 5 3 4.1

M/C 6 4 2.5

Determine

1) MLT Ans 141 hrs 2) Production rate for operation 3 and 5. Ans Production rate for 3 & 5 is 4.055

pieces/hr and 10.1698 pieces/hr respectively

17. The average part produced in a certain Batch manufacturing plant must be processed

through an average of 6 machines. 20 new batches of parts are launched each week. Average operation time= 6min, Average setup time = 5hrs. Average batch size = 25 parts,

Average Non operation time per batch = 10 hrs. There are 18 machines in the plant and the plant operates an average of 70 production hrs per week. Neglecting scrap rates determine

the following.


VII SEMESTER 29

i. The MLT for an average Plant

ii. The plant Capacity iii. The plant utilization &

iv. Explain how the non operation time to be affected by the plant utilization

CHAPTER 2: High Volume Production System

1. Briefly explain the Automated flow lines with their objectives. 2. Enlist the symbols used in the production system diagrams.

3. Differentiate between In-Line type and Rotary Type. 4. Briefly explain the various methods of work part transport in automated flow line.

5. Write a note on Buffer storage.

6. Briefly explain the mechanism used in the Buffer storage. 7. State the design and fabrication considerations for an automated flow line.

8. With a neat sketch explain the following transfer mechanisms � Walking beam transfer system

� Chain Driven Conveyor � Rack and Pinion

� Geneva Mechanism.

CHAPTER 3: Analysis of Automated flow lines and line balancing

CHAPTER 4: MINIMUM RATIONAL WORK ELEMENT

1. An indexing machine performs 10 assembly operations at 10 specific stations. The total cycle time including transfer time/station is 18 sec. The station breakdown with a

probability P=0.061, which can be considered equal for all the stations. When this work stoppage occur, it takes an average of 2.5 min to correct the fault parts. Compute the

following by using both the approaches.

� Frequency of the line stop. � Average production time.

� Average production rate. � Proportion of down time.

� Line efficiency. Comment on which it has the less down time.

2. The following data apply at a 12 station in-line transfer machine. P= 0.01 ( All stations

have an equal probability of failure) Ct = 0.3 min & ADt = 3 min. Using upper bound and lower bound approach compute the following.

� Frequency of line stops � Average production rate � Line efficiency

3. A 10 station transfer machine used for producing pump component has an ideal cycle time Ct= 1 min, with an estimated breakdowns of all types occurring with a frequency of F-

0.10 Breakdown/cycle and an average down time per line stop is 6 min. The scrap rate for the current conventional method is 5% and is considered a good estimate for the transfer

line. The starting casting for the component casts Rs 75 each and it will cost Rs 3000/hr to operate the transfer line. Cutting tools are estimated to cost Rs 7.5.work part. Using these

data compute the following measures of line performance. � Production rate � Number of hrs required to meet the demand of 1500 units/week � Line efficiency � Cost per unit produced.


VII SEMESTER 30

4. A 20 station transfer line has an ideal cycle time Ct = 1.2 minutes. The probability of

station breakdowns per cycle is equal for all stations and P=0.005 breakdowns per cycle. The average down time per cycle is 8 minutes. For each of the upper bound and lower bound

approaches, determine � Frequency of the line stops � Average actual production rate � Line efficiency

5. The following list defines the precedence relation ships and elemental times for a new

model toy.

Element Te (min) Immediate Predecessors

1 0.5 -

2 0.3 1

3 0.8 1

4 0.2 2

5 0.1 2

6 0.6 3

7 0.4 4,5

8 0.5 3,5

9 0.3 7,8

10 0.6 6,9

1. Construct the precedence diagram for this job 2. Assign work elements to stations using different methods of line balancing.

Determine the number of stations required and the corresponding balance delay.

6. Briefly explain the basic measures of automated flow lines

7. Briefly explain the starving and blocking of the stations

8. Explain the upper bound approach and lower bound approach in analyzing transfer lines without storage buffer.

9. Explain the upper bound approach and lower bound approach in analyzing transfer lines with storage buffer.

10. With an example, explain “precedence Diagram”.

11. Define the following

� Total work content � Cycle time

� Zoning constraint � Position constraint

� Balance delay

12. Briefly explain the different types of Line balancing methods in detail

13. Write a note on computerized Line balancing

14. Briefly explain about the Partial Automation.

15. Briefly explain the assembly process

16. What is meant by the term precedence constraints?

17. What are the steps involved in the computerized line balancing?

18. what is the difference between the largest candidate rule and the Kilbridge and

Wester method.


VII SEMESTER 31

CHAPTER 5: AUTOMATED ASSEMBLY SYSTEM

1. Briefly explain the different types of Automated assembly line.

2. With neat sketch briefly explain the elements of parts feeding device. 3. Write a note on Automated guided vehicles.

4. Explain the different types of guidance system used in AGV. 5. Define ASRS & briefly explain the basic components involved in it.

6. List the benefits of ASRS & Application of ASRS. 7. Briefly explain the analysis of single station assembly machine 8. Briefly explain the analysis of Multi station assembly machine.

CHAPTER 6: COMPUTERIZED MANUFACTURING PLANNING SYSTEM

1. Define GT? Explain the part Families in GT.

2. What is process planning? With neat flow chart explain the retrieval type CAPP. 3. List and explain the benefits of CAPP systems

4. Explain the following automated process planning system � CAM-I CAPP

� MULTI CAPP

� MIP LAN � AUTAP

5. Briefly explain generative CAPP systems 6. Explain the typical activities in a production planning and control system.

7. Briefly explain the objectives of MRP. 8. Define MRP? Explain fundamental concepts of MRP

9. Differentiate between MRP Versus Order point systems 10. Briefly explain the structure of an MRP system with neat block diagram

11. List the benefits & limitations of MRP 12. Briefly explain various elements involved in MRP implementation

13. Briefly explain the Misconception about MRP. 14. Briefly explain the capacity planning. 15. Write short notes on

� Capacity planning

� Bill of Materials

� MPS � Inventory record files.

CHAPTER 7: CNC MACHINING CENTERS

1. Define CNC and explain the basic components in CNC system. 2. what are the advantages of CNC systems over NC system.

3. write a short notes on CNC machining centers. 4. what are the steps involved computer assisted part programming.

5. what are the steps involved in development of part programming for milling? 6. what are the steps involved in development of part programming for turning.?

CHAPTER 8: ROBOTICS 1. Explain about different Robot configurations. 2. write a brief note on End effectors. 3. write a brief note on Robot sensors 4. Write short notes on Industrial applications of robot?

5. Explain the different methods of programming a robot.


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QUESTION BANK


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06ME73 – MANUFACTURING PROCESS - III


VII SEMESTER 39

SYLLABUS

Subject Code: 06ME73 IA Marks: 25 No. of Lecture Hrs./ Week: 04 Exam Hours: 03

Total No. of Lecture Hrs.: 62 Exam Marks: 100

PART – A

UNIT - 1

INTRODUCTION AND CONCEPTS: Classification of metal working processes, characteristics of wrought products, advantages and limitations of metal working

processes.Concepts of true stress, true strain, triaxial & biaxial stresses. Determination of flow stress. Principal stresses, Tresca & Von-Mises yield criteria, concepts of plane stress &

plane strain. 7 Hrs

UNIT - 2 EFFECTS OF PARAMETERS: Temperature, strain rate, friction and lubrication, hydrostatic

pressure in metalworking, Deformation zone geometry, workability of materials, Residual stresses in wrought products. 6 Hrs

UNIT - 3 FORGING: Classification of forging processes. Forging machines & equipment. Expressions

for forging pressures & load in open die forging and closed die forging by slab analysis, concepts of friction hill and factors affecting it. Die-design parameters. Material flow lines in

forging. Forging defects, Residual stresses in forging. Simple problems. 7 Hrs

UNIT - 4 ROLLING: Classification of Rolling processes. Types of rolling mills, expression for RoIling

load. Roll separating force. Frictional losses in bearing etc, power required in rolling, Effects of front & back tensions, friction, friction hill. Maximum possible reduction. Defects in rolled

products. Rolling variables, simple problems. 6 Hrs

PART - B UNIT - 5

DRAWING: Drawing equipment & dies, expression for drawing load by slab analysis, power

requirement. Redundant work and its estimation, optimal cone angle & dead zone formation, drawing variables, Tube drawing, classification of tube drawing, simple problems. 7 Hrs

UNIT - 6

EXTRUSION: Types of extrusion processes, extrusion equipment & dies, deformation, lubrication & defects in extrusion. Extrusion dies, Extrusion of seamless tubes. Extrusion

variables, simple problem 6 Hrs

UNIT - 7 SHEET & METAL FORMING: Forming methods, dies & punches, progressive die, compound

die, combination die. Rubber forming. Open back inclinable press (OBI press), piercing, blanking, bending, deep drawing, LDR in drawing, Forming limit criterion, defects of drawn

products, stretch forming. Roll bending & contouring, Simple problems 6 Hrs


VII SEMESTER 40

UNIT - 8

HIGH ENERGY RATE FORMING METHODS: Principles, advantages and applications, explosive forming, electro hydraulic forming, Electromagnetic forming.

POWDER METALLURGY: Basic steps in Powder metallurgy brief description of methods of production of metal powders, conditioning and blending powders, compaction and sintering

application of powder metallurgy components, advantages and limitations. 7 Hrs

TEXT BOOKS: Mechanical metallurgy (SI units), by G.E. Dieter, Mc Graw Hill pub.2001

Manufacturing Engineering and Technology by Serope Kalpakjian and Stevan R.

REFERENCE BOOKS:

1. Materials and Processes in Manufacturing by E.paul, Degramo, J.T. Black, Ronald, A.K. Prentice -hall of India 2002

2. Principles of Industrial metal working process - G.W. Rowe, CBSpub. 2002 3. Manufacturing Science, hy Amitabha Ghosh & A.K. Malik - East -Westpress 2001

4. Theory of plasticity by Dr. Sadhu Sing


VII SEMESTER 41

LESSON PLAN

Sub Code: 06ME73 Hours/week: 5

Sub: Manufacturing Process-III Total Hours: 62

Hours Topics Proposed to be Covered

1 Unit1: Introduction and Concepts: Classification of metal working

processes. 2 Wrought Products, Characteristics of wrought products. 3 Advantages and Limitations of metal working processes. 4 Concepts of true stress, true strain, triaxial and biaxial stresses. 5 Methods for the determination of flow stress. 6 Principal stresses. 7 Tresca and Von-mises yield criteria. 8 Concepts of plane stress and plane strain. 9 Brief description of methods of metal deformation analysis. 10 Simple Problems. 11 Unit 2 Effect of Parameters: Effects of temperature, strain rate. 12 Friction and lubrication, Hydrostatic pressure in metalworking. 13 Deformation zone geometry, workability of materials. 14 Residual stresses in wrought products.

15 Unit 8 High Energy Rate Forming Methods: Introduction, Classification

of Energy Rate Forming processes. 16 Principles of Energy Rate Forming processes, advantages and applications. 17 Explosive forming. Electro hydraulic forming. 18 Electromagnetic forming. 19 Powder metallurgy: Introduction, Basic steps in powder metallurgy, 20 Advantages and Limitations of Powder metallurgy 21 Brief description of methods of production of metal powders, 22 Brief description of methods of production of metal powders, Continued.. 23 Conditioning and Blending of powders. 24 Compaction and Sintering. 25 Applications of powder metallurgy components.

26 Unit 7 Sheet Metal Forming: Introduction, Advantages and Limitations of

Sheet Metal Forming. 27 Forming methods dies and punches. 28 Progressive die, compound die, combination die. 29 Rubber forming, open back inclinable press (OBI press). 30 Piercing, blanking, bending and stretch forming. 31 Roll bending and contouring. 32 Applications of Sheet Metal Forming.

33 Unit 4 Rolling: Introduction, Advantages and Limitations of rolling

processes. 34 Classification of rolling processes. 35 Types of rolling mills. 36 Expressions for rolling load. 37 Roll separating force. 38 Frictional losses in bearing etc, power required in rolling, 39 Effects of front and back tensions, frictions, & friction hill. 40 Maximum possible reduction. Defects in rolled products. 41 Simple Problems. 42 Unit 6 Extrusion: types of extrusion processes. 43 Extrusion equipment and dies. 44 Deformation and lubrication. 45 Defects in extruded products. 46 Extrusion of seamless pipes and tubes. 47 Extrusion of seamless pipes and tubes. Continued.. 48 Unit 3 Forging: classification of forging processes. 49 Forging machines and equipment.


VII SEMESTER 42

50 Expressions for forging pressure and load in open die forging by slab

analysis.

51 Expressions for forging pressure and load in and closed die forging by slab

analysis. 52 Concepts of friction hill and factors affecting it. 53 Die- design parameters. Material flow lines in forging. 54 Forging of a connecting Rod.

55 Forging defects, residual stresses in forging. 56 Simple Problems. 57 Unit 5 Drawing: Drawing equipment and dies, 58 Expression for drawing loads by slab analysis, power requirement. 59 Redundant work and its estimation. 60 Optimal cone angle and dead zone formation. 61 Drawing Variables & Tube Drawing.

62 Classification of tube Drawing & Simple problems.

Text books:

1. Materials and processes in manufacturing by E.paul, Degramo, J.T Black, Ronald, A.K. Prentice – hall of India 2002.

2. Manufacturing Engineering and Technology by Serope Kalpakjian and Stevan.R.Schmid, Pearson

Educational Aisia, 4th Edition, 2002.

Reference book:

1. Mechanical Metallurgy by G.E.Dieter, Mc Graw Hill pub.2001. 2. Manufacturing Science by Amitabha Ghosh and A K Malik – East – west press 2001. 3. deformation processing by W A Backofen, Addissen Weslay, 1973.


VII SEMESTER 43

QUESTION BANK

UNIT 1:

INTRODUCTION & CONCEPTS OF METAL FORMING PROCESS

1. What are the main characteristics of hot working as compared to cold working?

2. Write the difference between Hot, Cold and Worm Metal Working Process.

3. How are metal forming processes classified. Explain with neat sketches.

4. Explain the characteristics of wrought products? 5. Write the advantages and disadvantages of metal forming processes.

6. What is the concept of True stress and True Strain? Write the advantages of using the True stress and True

Strain.

7. Establish the relationship between the True stress and True Strain with nominal Stress and Strain.

8. Explain Triaxial and Biaxial Stresses. 9. Explain the concept of Plane Stress and Plane Strain. 10. Define Principal stress and derive an equation for the determination of principal stresses on an oblique

plane.

11. What is Yield Criteria? Describe the Von-mises and Tresca’s Yield Criteria for a Three Dimensional Stress

Field.

12. Define Flow stress? List and explain different Experiment Conducted to Determine the Flow Stress.

13. Flow stress of a material is given by σ0=Kεn MPa, Where K= Strength Co-efficient = 140, n = strain

hardening effect = 1.2, ε = true Strain. If a plate having a thickness 20mm is reduced to a thickness 15mm

by a suitable metal working process, find the value of mean Flow Stress.

14. A tensile specimen with a 12mm initial diameter and 50mm gauge length reaches a maximum load at 90KN

and fractures at 70KN. The maximum load (i.e. ultimate tensile system) and the fracture stress. What is

the engineering strain at fracture?

15. An aluminum alloy having σ0 (uniaxial flow stress) as 500 MPa is subjected to three principal stresses: σx as 200 MPa (tensile), σy = 100 MPa (tensile), σz = 50 MPa (compressive) and shear stress = 50 MPa (τxy). Will the material exhibit yielding? If not, what is the safety factor?

16. List the different methods of Metal Deformation Analysis and Explain the Slab Method.

17. Explain the FEM used in analyzing the deformation process.

UNIT 2: EFFECTS OF PARAMETERS

1. What are the effects of Residual Stresses in metalworking? How do you relieve the Residual stresses?

2. Explain the different methods of lubrication in metalworking?

3. Discuss the importance of the following in designing successful forming process (a) Deformation Zone

geometry (b) Friction & Lubrication.

4. Explain the effect of Strain Rate in metalworking?

5. Explain what do you mean by workability of materials.

6. Explain the Residual Stress in the wrought Products. 7. Explain the effect of Strain Rate in metalworking?

8. Explain the different mechanisms of friction during metalworking?

UNIT 3:

FORGING

1. What do you mean by forging? Give detailed classification of different forging processes.

2. With a help of a neat diagram explain different forging equipments.

3. List the difference between open and closed forging. 4. Give the difference between mechanical and hydraulic presses.

5. List the difference between open and closed forging. 6. Give the difference between mechanical and hydraulic presses.

7. Explain with the help of a neat sketch Steam hammer used in forging.

8. What do you mean by forging? Give detailed classification of different forging processes.

9. Explain with the help of a neat sketch Heavy Hydraulic press in detail. 10. Explain with the help of a neat sketch Board Drop hammer used in forging.

11. Sketch and explain step-by-step procedure of drop forging of connecting rod.


VII SEMESTER 44

UNIT 4:

ROLLING 1. Explain the classification of rolling processes. 2. With the help of neat sketch explain different Types of rolling mills.

3. Explain the Advantages and Limitations of rolling processes.

4. Derive an Expression for rolling load. 5. Define & Explain Roll separating force. 6. List & Explain Defects in rolled products. 7. Explain the Following

• Frictional losses in bearing

• Effects of front and back tensions

• Friction in rolling & Friction Hill

• Maximum possible reduction

UNIT 5

DRAWING 1. Derive Expressions for drawing loads by slab analysis & power required for drawing. 2. List & Explain different Drawing Dies. 3. List & Explain the Drawing Variables. 4. Define Tube Drawing & give the Classification of tube Drawing. 5. Explain redundant work and its estimation.

6. Optimal cone angle and dead zone formation in drawing

UNIT 6: EXTRUSION

1. Explain with the help of a neat sketch Different equipments used in Extrusion.

2. Explain with the help of a neat sketch Extrusion Forging and Impact Extrusion.

3. List and Explain the Defects in the Extruded Products. 4. Explain with the help of a neat sketch Direct Extrusion and Indirect Extrusion. 5. Explain with the help of a neat sketch Hydrostatic Extrusion. 6. List and explain the different methods of Extrusion of Seamless Tubes.

UNIT 7: SHEET & METAL FORMING

9. With the help of neat sketch classify and explain sheet metal presses in detail.

10. With the help of neat sketch, explain different dies used in sheet metal work.

11. List and explain the different press driving mechanisms.

12. Write the classification of dies and explain with the help of neat sketches.

13. With the help of neat sketch explain fly ball and power press.

14. With the help of neat sketch Explain shearing, blanking and related operations in detail.

15. With the help of neat sketch Explain in detail bending operations.

16. What do you mean by spring back effect? How to overcome it?

17. Give the difference between mechanical and hydraulic presses.

UNIT 8:

HIGH ENERGY RATE FORMING & POWDER METALLURGY

1. Write the detailed Classification of Energy Rate Forming processes.

2. Explain the Principles of Energy Rate Forming processes?

3. With the help of neat sketch explain Explosive forming?

4. With the help of neat sketch explain Electro hydraulic forming?

5. With the help of neat sketch explain Electromagnetic forming?

6. What are the advantages of powder metallurgy forming over conventional forging?

7. Explain briefly basic steps of powder metallurgy process?

8. Mention the applications of powder metallurgy?

9. What are the different factors that influence powder metallurgy process? Explain briefly.

10. What are the various finishing operations carried out on powder metallurgy products after sintering?

Explain any two of them.

11. Briefly explain cold iso static pressing in powder metallurgy with a suitable diagram.

12. What do you mean by pre sintering and sintering? Explain

13. Explain various methods of powder metallurgy production.

14. Draw the outline of processes and operations involved in making powder metallurgy parts.


VII SEMESTER 45

06ME74 - OPERATIONS RESEARCH


VII SEMESTER 46

SYLLABUS

Subject Code: 06ME74 IA Marks : 25 Hours./ Week : 05 Exam Hours : 03

Total Hours. : 62 Exam Marks : 100

PART - A

UNIT - 1

INTRODUCTION: Linear programming, Definition, scope of Operations Research (O.R) approach and

limitations of OR Models, Characteristics and phases of OR Mathematical formulation of L.P. Problems.

Graphical solution methods. 7Hrs

UNIT - 2

LINEAR PROGRAMMING PROBLEMS: The simplex method - slack, surplus and artificial variables. Concept

of duality, two phase method, dual simplex method, degeneracy, and procedure for resolving degenerate cases.

8Hrs

UNIT - 3

TRANSPORTATION PROBLEM: Formulation of transportation model, Basic feasible solution using different

methods, Optimality Methods, Unbalanced transportation problem, Degeneracy in transportation problems,

Applications of Transportation problems. Assignment Problem: Formulation, unbalanced assignment problem,

Traveling salesman problem. 9 Hrs

UNIT - 4

SEQUENCING: Johnsons algorithm, n - jobs to 2 machines, n jobs 3machines, n jobs m machines without

passing sequence. 2 jobs n machines with passing. Graphical solutions priority rules. 7Hrs

PART - B

UNIT - 5

QUEUING THEORY: Queuing system and their characteristics. The M/M/1 Queuing system, Steady state

performance analysing of M/M/ 1 and M/M/C queuing model. 7Hrs

UNIT - 6

PERT-CPM TECHNIQUES: Network construction, determining critical path, floats, scheduling by network,

project duration, variance under probabilistic models, prediction of date of completion, crashing of simple

networks. 9Hrs

UNIT - 7

GAME THEORY: Formulation of games, Two person-Zero sum game, games with and without saddle point,

Graphical solution (2x n, m x 2 game), dominance property. 8Hrs

UNIT - 8

INTEGER PROGRAMMING: Gommory’s technique, branch and bound lgorithm for integer programming

problems, zero one algorithm 7 Hrs

TEXT BOOKS:

1. Operations Research and Introduction, Taha H. A. – Pearson

Education edition

2. Operations Research, S. D. Sharma –Kedarnath Ramnath & Co

2002.

REFERENCE BOOKS:

1. “Operation Research” AM Natarajan, P. Balasubramani, A

Tamilaravari Pearson 2005

2. Introduction to operation research, Hiller and liberman, Mc Graw

Hill. 5th edition 2001.

3. Operations Research: Principles and practice: Ravindran, Phillips

& Solberg, Wiley India lts, 2nd Edition 2007

4. Operations Research, Prem Kumar Gupta, D S Hira, S Chand Pub,

New Delhi, 2007


VII SEMESTER 47

LESSON PLAN

Sub code: 06ME74 Hrs/Week : 05

Sub: OPERATION RESEARCH Total Hours : 62

Hours Topics to be covered

PART-A

Unit-1: INTRODUCTION

01 Introduction to operation research.

02 Definition to Linear programming,

03 Scope of Operations Research

04 Approach and limitations of OR Models

05 Characteristics and Phases of OR

06 Mathematical formulation of L.P. Problems

07 Graphical solution methods

Unit-2: LINEAR PROGRAMMING PROBLEMS 08 Introduction to linear programming problems

09 The simplex method

10 Slack, Surplus and artificial variables.

11 Concept of duality

12 Two phase method

13 Dual simplex method

14 Degeneracy problems

15 Procedure for resolving degenerate cases

Unit-3: TRANSPORTATION PROBLEM

16 Formulation of transportation model,

17 Basic feasible solution using different methods

18 Optimality Methods

19 Unbalanced transportation problem

20 Degeneracy in transportation problems.

21 Applications of Transportation problems.

22 Assignment Problem.

23 Formulation of unbalanced assignment problem.

24 Traveling salesman problem.

Unit-4: SEQUENCING 25 Introduction to Job sequencing.

26 Johnson’s algorithm.

27 n - jobs to 2 machines.

28 n jobs 3machines.

29 n jobs m machines without passing sequence.

30 2 jobs n machines with passing.


VII SEMESTER 48

31 Graphical solutions priority rules.

PART-B

Unit-5: QUEUING THEORY 32 Introduction to queuing theory.

33 Queuing system and their characteristics

34 The M/M/1 Queuing system

35 Steady state performance

36 Analyzing of M/M/ 1

37 M/M/C queuing model.

38 Problems on queuing models

Unit-6: PERT-CPM TECHNIQUES 39 Introduction PERT-CPM techniques.

40 Network construction

41 Determining critical path

42 Determining floats

43 Scheduling by network

44 Project duration

45 Variance under probabilistic models

46 Prediction of date of completion

47 Crashing of simple networks

Unit-7: GAME THEORY 48 Introduction to Game Theory

49 Formulation of games

50 Two person-Zero sum game

51 Games with saddle point 52 Games without saddle point

53 Graphical solution (2 x n) game

54 Graphical solution (m x 2) game 55 Dominance property

Unit-8: INTEGER PROGRAMMING 56 Introduction to Integer Programming.

57 Gommory’s technique. 58 Branch logarithm for integer programming problems.

59 Bound logarithm for integer programming problems.

60 Zero one logarithm.

61 Applications of integer programming.

62 Problems.


VII SEMESTER 49

QUESTION BANK


VII SEMESTER 50


VII SEMESTER 51

06ME753 - PRODUCT DESIGN AND

MANUFACTURING


VII SEMESTER 52

SYLLABUS

Subject Code:06ME753 IA Marks: 25 Hours./ Week:05 Exam Hours: 03 Total Hours.:52 Exam Marks: 100

PART - A

UNIT - 1 INTRODUCTION TO PRODUCT DESIGN: Asimow’s model: Definition of product design, Design by Evolution, Design by Innovation, Essential Factors of Product design, Production-Consumption Cycle, Flow and

Value Addition in the Production-Consumption Cycle, The Morphology of Design ( The seven phases), Primary

Design Phases and Flowcharting, Role of Allowance, Process Capability and Tolerance in Detailed Design &

Assembly. 9 Hrs

UNIT - 2 PRODUCT DESIGN PRACTICE AND INDUSTRY: Introduction, Product Strategies, Time to Market, Analysis

of the Product, The S’s Standardization, Renard Series, Simplification, Role of Aesthetics in Product Design,

Functional Design Practice. 8 Hrs

UNIT - 3 REVIEW OF STRENGTH, STIFFNESS AND RIGIDITY CONSIDERATIONS IN PRODUCT DESIGN:

Principal Stress Trajectories (Force-Flow Lines), Balanced Design, Criteria and Objectives of Design, Material

Toughness: Resilience Designing for Uniform Strength, Tension vis-a-vis Compression. Review of Production

Process: Introduction, Primary Processes, Machining Process, Non-traditional Machining Processes. 8 Hrs

UNIT - 4 DESIGN FOR PRODUCTION – METAL PARTS: Producibility requirements in the Design of machine

Components, Forging Design, Pressed components Design, Casting Design, and Design for Machining Ease,

The Role of Process Engineer, Ease of Location Casting and Special Casting. Designing with Plastic, rubber, ceramics and wood: Approach to design with plastics, plastic bush bearings, gears in plastics, rubber parts,

design recommendations for rubber parts, ceramic and glass parts. 8 Hrs

PART - B

UNIT - 5 OPTIMIZATION IN DESIGN: Introduction, Siddal’s Classification of Design Approaches, Optimization by

Differential Calculus, Lagrange Multipliers, Linear Programming (Simplex Method), Geometric Programming,

Johnson’s Method of Optimum Design. 7 Hrs

UNIT - 6 ECONOMIC FACTOR INFLUENCING DESIGN: Product Value, Design for Safety, Reliability and Environmental

Considerations, Manufacturing Operations in relation to Design, Economic Analysis, Profit and Competitiveness,

Break – even Analysis, Economic of a New Product Design. 7 Hrs

UNIT - 7 HUMAN ENGINEERING CONSIDERATIONS IN PRODUCT DESIGN: Introduction, Human being as Applicator

of Forces, Anthropometry; Man as occupant of Space, The Design of Controls, of controls, the Design of

Displays, Man/Machine Information Exchange. 7 Hrs

UNIT - 8 VALUE ENGINEERING AND PRODUCT DESIGN: Introduction, Historical Perspective, What is Value? Nature

and Measurement of Value, Normal Degree of Value, Importance of Value, The Value analysis Job Plan,

Creativity, Steps to Problems-solving and Value Analysis, Value Analysis Test, Value Engineering Idea

Generation Check-list Cost Reduction through value engineering case study on Tap Switch Control Assembly, Material and Process Selection in Value Engineering Modern Approaches to Product Design: Concurrent Design and Quality Function Deployment (QFD). 9Hrs

TEXT BOOKS: 1. Product Design and Manufacturing, A.C. Chitale and R.C. Gupta, PHI 4

th edition 2007.

2. Product Design & Development, Karl T. Ulrich & Steven D, Epinger, Tata Mc. Graw Hill, 3rd Edition,

2003 REFERENCE BOOKS:

1. New Product Development, Tim Jones, Butterworh Heinmann, Oxford, mc 1997.

2. New Product Development: Design & Analysis by Roland Engene Kinetovicz, John Wiley and Sosn

Inc., N.Y. 1990


VII SEMESTER 53

LESSON PLAN Semester: VII No.of Periods:62 Subject: Product Design & Manufacturing Hrs/Week:04

Sub. Code: 06ME753 Total Hours: 52

Hour. No

TOPICS TO BE COVERED

1. INTRODUCTION TO PRODUCT DESIGN: Asimow’s model: Definition of product design, Design by Evolution,

2. Design by Innovation, Essential Factors of Product design 3. Production-Consumption Cycle 4. Flow and Value Addition in the Production-Consumption Cycle, 5. The Morphology of Design ( The seven phases) 6. Primary Design Phases 7. Flow charts 8. Role of allowance, process capability, tolerance in detailed design & assembly 9. PRODUCT DESIGN PRACTICE AND INDUSTRY: Introduction, Product

Strategies 10. Time to Market, Analysis of the Product 11. The S’s Standardization, 12. Renard Series, Simplification, 13. Role of Aesthetics in Product Design 14. Functional Design Practice. 15. Role of Functional Design Practice 16. REVIEW OF STRENGTH, STIFFNESS AND RIGIDITY CONSIDERATIONS IN

PRODUCT DESIGN: Principal Stress Trajectories (Force-Flow Lines

17. Balanced Design, Criteria and Objectives of Design 18. Material Toughness: Resilience Designing for Uniform Strength

19. Tension vis-a-vis Compression.

20. Review of Production Process: Introduction 21. Primary Processes

22. Machining Process 23. Non-traditional Machining Processes 24. DESIGN FOR PRODUCTION – METAL PARTS: Producibility requirements in the

Design of machine Components

25. Forging Design, Pressed components Design

26. Casting Design, and Design for Machining Ease 27. The Role of Process Engineer, Ease of Location Casting and Special Casting 28. Designing with Plastic, rubber, ceramics and wood.

29. Approach to design with plastics, plastic bush bearings, gears in plastics, rubber parts

30. Design recommendations for rubber parts

31. ceramic and glass parts

32. OPTIMIZATION IN DESIGN: Introduction, Siddal’s Classification of Design

Approaches

33. Optimization by Differential Calculus

34. Lagrange Multipliers 35. Linear Programming (Simplex Method)

36. Geometric Programming.

37. Johnson’s Method of Optimum Design

38. ECONOMIC FACTOR INFLUENCING DESIGN: Product Value, Design for Safety

39. Reliability and Environmental Considerations

40. Manufacturing Operations in relation to Design 41. Economic Analysis

42. Profit and Competitiveness

43. Break – even Analysis 44. Economic of a New Product Design


VII SEMESTER 54

45. HUMAN ENGINEERING CONSIDERATIONS IN PRODUCT DESIGN:

Introduction

46. Human being as Applicator of Forces

47. Anthropometry; Man as occupant of Space

48. The Design of Controls, of Displays 49. The Design of Displays 50. Man Information Exchange

51. Machine Information Exchange

52. VALUE ENGINEERING AND PRODUCT DESIGN: Introduction

53. Historical Perspective, What is Value? Nature and Measurement of Value.

54. Normal Degree of Value, Importance of Value, The Value analysis Job Plan

55. Creativity, Steps to Problems-solving and Value Analysis

56. Value Analysis Test 57. Value Engineering Idea Generation Check-list 58. Cost Reduction through value engineering case study on Tap Switch Control

Assembly

59. case study on Tap Switch Control Assembly

60. Material and Process Selection in Value Engineering 61. Modern Approaches to Product Design 62. Concurrent Design and Quality Function Deployment (QFD).


VII SEMESTER 55

QUESTION BANK

01 Define Product Design. Explain Design by evolution and design by innovation.

02 Explain the Essential factors to be considered for product design.

03 Explain Asimov’s model

04 Explain with a neat sketch the production – consumption cycle for a product.

05 Explain the morphology of a design process

06 Define allowance and explain its role in PDM

07 Define process capability, tolerance and their relationship with PDM

08 What is the product strategy of an organization and how does it affect the design of

the product?

09 How do you analyse the market and when do you think will be the right time to

market?

10 Explain with example “Renard series”

11 Explain the role of a designer

12 Define industrial design organization

13 Explain the basic design considerations

14 List and explain the problems faced by industrial designers

15 Explain the various models developed by industrial designers

16 Explain the role of aesthetics in PDM

17 With a neat sketch explain principal stress and strain

18 Define a balanced design

19 Explain the importance of toughness, resilience in PDM

20 List the objectives of design

21 Explain the Producibility requirements in PDM

22 Explain the design of a forged component

23 Explain the design of a welded component

24 Explain the design of a pressed component

25 Explain the location of clamps when designing a product

26 Explain the design of a casting

27 Explain the design of a expanded or wire component

28 Explain the design consideration for a plastic component

29 Explain the design consideration for a ceramic component

30 Explain the design consideration for a rubber component

31 Explain the design consideration for a wooden component

32 Explain the dimensional factors in PDM

33 How are optimization techniques applied to design of a product? Give suitable

examples

34 Define product value

35 Explain “Design for safety”

36 Explain “Design for reliability”

37 Explain “Design for environment”

38 Explain the manufacturing operations with respect to PDM

39 Explain economic analysis of a PDM with example

40 Define Anthropometrics in PDM

41 Explain the design of various controls devices in PDM

42 Define Value Engineering

43 How is value engineering applied to PDM

44 How do you measure the value of a product?

45 What is normal degree of value of a product?

46 Explain value analysis

47 Explain the steps of value analysis

48 Explain the reduction process through value engineering

49 Explain the case study on value engineering on Tap Switch Assembly

50 How do you select material and through value engineering

51 Define concurrent Engineering?

52 What are the advantages of Con current engineering

53 Explain Rapid Prototyping with example

54 Explain Quality Function Deployment (QFD)


VII SEMESTER 56

QUESTION PAPERS


VII SEMESTER 57


VII SEMESTER 58

06ME766 – ROBOTICS


VII SEMESTER 59

SYLLABUS

Subject Code : 06ME766 IA Marks : 25

No. of Lecture Hrs./ Week : 05 Exam Hours : 03

Total No. of Lecture Hrs. : 62 Exam Marks : 100

PART - A UNIT - 1

INTRODUCTION AND MATHEMATICAL REPRESENTATION OFROBOTS:

History of Robots, Types of Robots, Notation, Position and Orientation of a Rigid Body, Some Properties of

Rotation Matrices, Successive Rotations, Euler Angles For fixed frames X-Y-Z and moving frame ZYZ.

Transformation between coordinate system, Homogeneous coordinates, Properties of T A B , Types of Joints:

Rotary, Prismatic joint, Cylindrical joint, Spherical joint, Representation of Links using Denvit- Hartenberg

Parameters: Link parameters for intermediate, first and last links, Link transformation matrices, Transformation

matrices of 3R manipulator, PUMA560 manipulator, SCARA manipulator 7 Hrs

UNIT - 2

KINEMATICS OF SERIAL MANIPULATORS:

Direct kinematics of 2R, 3R, RRP, RPR manipulator, puma560 manipulator, SCARA manipulator, Stanford arm,

Inverse kinematics of 2R, 3R manipulator, puma560 manipulator. 6 Hrs

UNIT - 3

VELOCITY AND STATICS OF MANIPULATORS:

Differential relationships, Jacobian, Differential motions of a frame (translation and rotation), Linear and angular

velocity of a rigid body, Linear and angular velocities of links in serial manipulators, 2R, 3R manipulators,

Jacobian of serial manipulator, Velocity ellipse of 2R manipulator, Singularities of 2R maipulators, Statics of

serial manipulators, Static force and torque analysis of 3R manipulator, Singularity in force domain. 7 Hrs

UNIT - 4

DYNAMICS OF MANIPULATORS:

Kinetic energy, Potential energy, Equation of motion using Lagrangian, Equation of motions of one and two

degree freedom spring mass damper systems using Lagrangian formulation, Inertia of a link, Recursive

formulation of Dynamics using Newton Euler equation, Equation of motion of 2R manipulator using Lagrangian,

Newton- Euler formulation. 6 Hrs

PART - B UNIT - 5

TRAJECTORY PLANNING: Joint space schemes, cubic trajectory, Joint space schemes with via points, Cubic

trajectory with a via point, Third order polynomial trajectory planning, Linear segments with parabolic blends,

Cartesian space schemes, Cartesian straight line and circular motion planning 7 Hrs

UNIT - 6

CONTROL: Feedback control of a single link manipulator- first order, second order system, PID control, PID

control of multi link manipulator, Force control of manipulator, force control of single mass,Partitioning a task

for force and position control- lever, peg in hole Hybrid force and position controller 8 Hrs

UNIT - 7

ACTUATORS: Types, Characteristics of actuating system: weight, powerto- weight ratio, operating pressure,

stiffness vs. compliance, Use of reduction gears, comparision of hydraulic, electric, pneumatic actuators,

Hydraulic actuators, proportional feedback control, Electric motors: DC motors, Reversible AC motors, Brushles

DC motors, Stepper motors- structure and principle of operation, stepper motor speed-torque characteristics

6 Hrs

UNIT - 8

SENSORS: Sensor characteristics, Position sensors- potentiometers, Encoders, LVDT, Resolvers, Displacement

sensor, Velocity sensorencoders, tachometers, Acceleration sensors, Force and Pressure sensors – piezoelectric,

force sensing resistor, Torque sensors, Touch and tactile sensor, Proximity sensors-magnetic, optical,

ultrasonic, inductive, capacitive, eddy-current proximity sensors. 5 Hrs


VII SEMESTER 60

TEXT BOOKS:

1. Fundamental Concepts and Analysis, Ghosal A., Robotics,

Oxford,2006

2. Introduction to Robotics Analysis, Systems, Applications, Niku,

S. B., Pearso Education, 2008

REFERENCE BOOKS:

1. Introduction to Robotics: Mechanica and Control, Craig, J. J.,

2nd Edition, Addison-Welsey, 1989.

2. Fundamentals of Robotics, Analysis and Control, Schilling R. J.,

PHI, 2006


VII SEMESTER 61

LESSON PLAN

Semester: VII No.of Periods:62 Subject: Robotics Hrs/Week:04

Sub. Code: 06ME766 Total Hours: 52 Hour

No Topics to be covered

1 Introduction and mathematical representation of robots: History of robots,

Types of Robots

2 Notation, position and orientation of a rigid Body

3 Some properties of rotation Matrices, Successive Rotations

4 Euler Angles for fixed frames X-Y-Z and moving frame ZYZ

5 Transformation between coordinate system

6 Homogeneous coordinates, Types of joints: Rotary, Prismatic joint,

7 Cylindrical joint, Spherical joint

8 Representation of links using Denvit-Hartenberg Parameters: Link parameters for

intermediate, first and last links

9 Link transformation matrices

10 Transformation matrices of 3R manipulator, PUMA560 manipulator, SCARA

manipulator

11 Kinematics of Serial manipulators: Direct Kinematics of 2R, 3R

12 RRP, RPR manipulator

13 PUMA560 manipulator

14 SCARA manipulator

15 Standard arm

16 Inverse kinematics of 2R, 3R manipulator

17 Inverse kinematics of PUMA560 manipulator

18 Velocity and Statics of Manipulators: Differential relationships

19 Jacobean, Differential motions of a frame (translation & rotation)

20 Linear and Angular velocity of a rigid body

21 Linear and Angular velocities of links in Serial manipulators, 2R, 3R manipulators

22 Jacobian of serial manipulator

23 Velocity ellipse of 2R manipulator

24 Singularities of 2R manipulators

25 Statics of Serial manipulators, Static force and torque analysis of 3R manipulator,

Singularities in force domain

26 Dynamics of Manipulators: Kinetic energy, potential energy,

27 Equation of motion using Lagrangian

28 Equation of motions of one & two degree freedom spring mass damper systems using

Lagrangian formulation

29 Inertia of a link


VII SEMESTER 62

30 Recursive formulation of dynamics using Newton Euler equation

31 Equation of motion of 2R manipulator using Lagrangian

32 Newton-Euler formulation

33 Trajectory planning: Joint Space Schemes, cubic trajectory

34 Joint Space Schemes with via points

35 Cubic trajectory with a via point

36 Third order polynomial trajectory planning

37 Linear segments with parabolic bends

38 Cartesian space schemes

39 Cartesian straight line and circular motion planning.

40 Control: Feedback control of a single link manipulator- first order system

41 Feedback control of a single link manipulator- Second order system

42 PID control

43 PID control of multi link manipulator

44 Force control of manipulator

45 Force control of single mass

46 Partitioning a task for force and position control- lever

47 Peg in hole Hybrid force and position controller.

48 Actuators: Types, Characteristics of Actuating System: weight, power-to-weight

ratio, Operating pressure, stiffness vs. compliance

49 Use of reduction gears, comparison of hydraulic

50 electric, pneumatic actuators

51 Hydraulic actuators, proportional feedback control,

52 Electric motors: DC motors, Reversible AC motors

53 Brushles DC motors, Stepper motors- structure and principle of operation, Stepper

motor speed-torque characteristics.

54 Sensors: Sensor characteristics, position sensors- potentiometers

55 Encoders, LVDT, Resolvers

56 Displacement sensor, Velocity sensorencoders

57 Tachometers, Acceleration sensors

58 Force and pressure sensors-piezo electric, force sensing resistor

59 Torque sensors, touch and tactile sensor

60 Proximity sensors-magnetic, Optical, ultra-sonic

61 inductive, capacitive

62 eddy-current proximity sensors


VII SEMESTER 63

QUESTION BANK 1. Define a Robot 2. Explain the history of Robotics 3. Explain automation and Robotics

4. How Robot is different from mechanical manipulator

5. State and explain various aspects that justify the needs of Robots in industry 6. A cylindrical coordinated robot has a vertical reach of 500mm and a stroke of 320mm what is the

minimum height of the work table to able the robot to reach the object kept on the table?

7. Enumerate the complete robot classification.

8. Define a robot with ad with a diagram explain the anatomy of robot.

9. With a neat sketch differentiate and highlight the four common types of robot configurations

10. Explain robot specifications. 11. Define repeatability resolution and accuracy 12. Explain the properties of rotation matrices

13. Explain the types of joints Rotary,prismatic,cylindrical and spherical.

14. Write a short note on DH convention

15. List the steps involved in DH convention 16. Explain the coordinate frame assignment of DH representation

17. Define and illustrate link and joint parameters .Explain their uses

18. Give the Euler angle representation for the RPY system and derive the rotation matrix

19. Explain the homogeneous transformation matrix and interpret the partitioning with application

20. Get Euler angles for system I representation by applying inverse kinematic solution

21. Derive kinematic equation for the SCARA robot giving coordinate frame diagram and kinematic

parameters.

22. Derive the kinetic equation for the elbow manipulator with coordinate frame

Diagram and kinematic parameters.

23. Explain the geometric solution of inverse kinematic with an example of two degree system

manipulator.

24. Explain the kinematics of PUMA 560 manipulator

25. Derive the equation of motion for a single link manipulator given the mass and length of the link.

26. Explain the Linear and angular velocities of links in serial manipulators

27. Explain the statics of serial manipulator

28. Explain the static force and torque analysis of 3R manipulator

29. Explain the singularity in force domain

30. Discuss Lagrange-Euler formulations for a robotic manipulator

31. Explain Lagrange-Euler formulations for a robot arm

32. Explain the following briefly as applied to robot arm dynamic analysis

1.Kinetic Energy

2.Potential energy

3.Joint velocities

33. Derive the equation of motion for a single link manipulator given the mass and length of the link

34. What is Lagrangian .Give the Lagrange-Euler formulations for the joint force /torque

35. Derive the dynamic equation of motion for a Revolute-Prismatic (RP) robot arm manipulator.

36. Explain the following as applied to a robot arm and also discuss their importance

1.Inertia Terms

2.Coupling inertia

3 Centrifugal force

4.Coriolis component

5.Gravity term

37. It is given that a two link manipulator has to exert a force of f=10i+5j at its tool tip. The jacobian for

the manipulator is given by J=[-(l1 S1 +l2S12) -l2S12,(l1C1+l2C12),

l2C12 ]

Given that l1=12 l2=10 θ1=30 and θ2=45 Determine the joint torques

38. Describe any 4 controllers used in robotic systems mentioning their respective transfer functions

39. Draw block diagram and obtain the transfer function that corresponds to spring –mass-damper system

suspended from a fixed wall.

40. Explain the responses of second order systems

41. Explain the transient response of second order system

42. Explain the control concept of robotic manipulator system


VII SEMESTER 64

43. With the block diagram and transfer function explain the following

1. Proportional control 2. Derivative control 3. Integral control

44.Explain the advantages of the following controllers

1. PD controller 2. PID controller

45.Explain the use of damping factor and the natural frequency in deciding the response of a robotic joint

described by a differential equation

46. Develop a model ofr transfer function of a dc motor diving a robot joint.

47. For a pring –mass damper system with stiffness k=4.mass m=2 and the damping coefficient

c=4.The system is known to possess unmodeled response at w resonant =8.0 rad/sec. Determine the

velocity gain kv and the positional gain kp of the critically damped system with reasonably high stiffness.

48. Explain trajectory planning and show how t trajectory planning is done in case of PTP robot having

constant maximum velocity and finite acceleration and deceleration

49. Discuss trajectory planning for PTP robot considering modified constant velocity motion of joint.

50. What are the various forms of input required to be provided as constraints to the robot path planning.

51. Describe various path control modes in robotics

52. Discuss advantages and disadvantages between joint space scheme and Cartesian space schemes

53. Enumerate trajectory generation polynomial types

54. Explain the parameters involved in path planning with 3rd degree polynomial.

55. Write a short notes on object recognition technique

56. Enlist desirable sensor and transducer features

57. Give the classification of sensors with examples.

58. With neat sketch explain the tactile sensors and the range sensors.

59.Sketch and explain a 6 component wrist sensor based on strain gauge element for force/ torque

sensing.

60. Describe desirable engineering features of sensors and transducers.

61. Explain various velocity sensors with sketch

62.Explain various touch and tactile sensors, proximity sensors.

63.What are the advantages of Hall effect transducer?

64.Explain with diagram components of digital image processing.

65. Explain the principle and working of Inductive type, ultrasonic and optical proximity sensors.

66.Give the performance specifications for the force sensors.

67. Explain the piezo electric force and pressure sensors.

68.Explain various types and their characteristics of actuating systems

69.Explain the use of reduction gears.

70.Compare hydraulic,pneumatic,electric actuators.

71.Describe a stepper motor used in actuating systems

72.Explain the speed-torque characteristics of a stepper motor


VII SEMESTER 65

06MEL77 - CIM & AUTOMATION LAB


VII SEMESTER 66

SYLLABUS Subject Code : 06MEL77 IA Marks : 25

No. of Practical Hrs./ Week : 03 Exam Hours : 03

Total No. of Practical Hrs. : 42 Exam Marks : 50

PART - A

CNC part programming using CAM packages. Simulation of Turning, Drilling, Milling operations. 3 typical

simulations to be carried out using simulation packages like Master- CAM, or any equivalent software.

PART - B

(Only for Demo/Viva voce)

1. FMS (Flexible Manufacturing System): Programming of Automatic storage and Retrieval system (ASRS) and

linear shuttle conveyor Interfacing CNC lathe, milling with loading unloading arm and ASRS to be carried out

on simple components.

2. Robot programming: Using Teach Pendent & Offline programming to perform pick and place, stacking of

objects, 2 programs.

PART - C

(Only for Demo/Viva voce)

Pneumatics and Hydraulics, Electro-Pneumatics: 3 typical experiments on

Basics of these topics to be conducted.

Scheme of Examinations

Two questions from Part A – 40 Marks (10 Write up +30)

Viva Voce – 10 Marks

Total – 50 Marks


VII SEMESTER 67

06MEL78 - DESIGN LABORATORY


VII SEMESTER 68

SYLLABUS Subject Code : 06MEL78 IA Marks : 25

No. of Practical Hrs./ Week : 03 Exam Hours : 03

Total No. of Practical Hrs. : 42 Exam Marks : 50

PART - A

1. Determination of natural frequency, logarithmic decrement, damping

ratio and damping coefficient in a single degree of freedom vibrating

systems (longitudinal and torsional)

2. Balancing of rotating masses.

3. Determination of critical speed of a rotating shaft.

4. Determination of Fringe constant of Photoelastic material using.

a) Circular disc subjected to diametral compression.

b) Pure bending specimen (four point bending )

5. Determination of stress concentration using Photoelasticity for simple

components like plate with a hole under tension or bending, circular disk

with circular hole under compression, 2D Crane hook.

PART - B

6. Determination of equilibrium speed, sensitiveness, power and effort of

Porter/Prowel /Hartnel Governor. (only one or more)

7. Determination of Pressure distribution in Journal bearing.

8. Determination of Principal Stresses and strains in a member subjected to

combined loading using Strain rosettes.

9. Determination of stresses in Curved beam using strain gauge.

10. Experiments on Gyroscope (Demonstration only)

Scheme of Examination:

One question from Part A - 20 Marks (05 Write up +15)

One question from Part B - 20 Marks (05 Write up +15)

Viva - Voce - 10 Marks

------------

Total: 50 Marks

06me71 – control engineering · modern control engineering – k. ogatta 2. automatic control...

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