ED 9121 FINITE ELEMENT METHODS IN MECHANICAL DESIGN (Common for M.

E Degree Programs in Engineering Design, CAD & PDD streams) L T P C 3 1 0 4 OBJECTIVE: At the end of this course the students would have developed a thorough understanding of the basic principles of the finite element analysis techniques with an ability to effectively use the tools of the analysis for solving practical problems arising in engineering design UNIT I GENERAL INTRODUCTION * 10 Introduction- structural element and system- assembly and analysis of a structureboundary conditions- general pattern- standard discrete system- transformation of coordinates- examples direct physical approach to problems in elasticity- direct formulation- displacement approach minimization of total potential- convergence criteria discretization error- nonconforming elements and patch test- solution process- numerical examples UNIT II GENERALIZATION OF FINITE ELEMENT CONCEPTS AND ELEMENT SHAPE FUNCTIONS* 7 Boundary value problems integral or weak statements- weighted residual methodsGalerkin method- virtual work as weak form of equations in solid and fluid mechanics- variational principles establishment of natural variational principles for linear self-adjoint differential equations standard and hierarchical elements- shape functions- rectangular elements- completeness of polynomials- Lagrange familySerendipity family- rectangular prisms- tetrahedral elements- global and local finite element approximation- mapped elements- coordinate transformations- geometrical conformity of elements- evaluation of element matrices- transformation in , and coordinates-order of convergence- numerical integration example problems UNIT III APPLICATIONS TO FIELD PROBLEMS * 9 Solution to problems in linear elasticity- plane problems in elasticity- plates and shells- solution of problems in heat-transfer and fluid mechanics- numerical examples- discussion on error estimates UNIT IV FINITE ELEMENTS IN STRUCTURAL DYNAMICS AND VIBRATIONS ** 10 Dynamic equations- stiffness, mass and damping matrices- consistent and diagonal mass matrices- Extraction of natural frequencies and modes- Reduction of number of degrees of freedom - modal methods - component mode synthesis- harmonic analysis- response history- explicit and implicit direct integration- stability and accuracy- analysis of response spectra- example problems UNIT V NON-LINEAR ANALYSIS *** 9 Non-linear problems in elasticity- some solution methods- plasticity: introduction, general formulation for small strains- formulation for von Mises theory- computational procedure- problems of gaps and contact- geometric non-linearity- modelling considerations Total 45 + 15 = 60 Hours

NOTE At the post-graduate level of instruction the contact hours are to be supplemented by self study by students. As for the examination, modelling considerations, choice of elements, boundary conditions, loading conditions, and basic procedures only need to be emphasized without expecting a complete numerical solution to practical problems.

REFERENCES: 1. *Zienkiewicz.O.C, Taylor.R.L,& Zhu,J.Z The Finite Element Method: Its Basis & Fundamentals, Butterworth-Heinemann (An imprint of Elsevier), First printed in India 2007, India Reprint ISBN:978-81-312-1118-2, published by Elsevier India Pvt. Ltd., New Delhi. 2. **Cook, R.D., Malkus, D. S., Plesha,M.E., and Witt,R.J Concepts and Applications of Finite Element Analysis, Wiley Student Edition, 4th Edition, First Reprint 2007, Authorized reprint by Wiley India(P) Ltd., New Delhi, ISBN-13 978-81-265-1336-9 3. *** Zienkiewicz.O.C, Taylor.R.L The Finite Element Method McGraw Hill International Editions, Fourth Edition, 1991, Volume 2 (Chapters 7&8) 4. Reddy, J.N., Introduction to Non-Linear Finite Element Analysis, Oxford Uniiversity Press, 2008 5. Rao,S.S., The Finite Element Method in Engineering, ButterworthHeinemann(An imprint of Elsevier), reprinted 2006,2007, Published by Elsevier India Pvt. Ltd., New Delhi, Indian Reprint ISBN: 978-81-8147-885-6 6. Huebner,K.H., Dewhirst,D.L.,Smith,D.E & Byron,T.G., The Finite Element Method for Engineers, Wiley Student Edition, Fourth Edition 2004,John Wiley&Sons(Asia)Pve.Ltd., ISBN: 9812-53-154-8 7. Ramamurthi, V., Finite Element Method in Machine Design, Narosa Publishing House, January 2009, ISBN: 978-81-7319-965-3

ED 9122

VIBRATION ANALYSIS AND CONTROL**

L T P C 3 0 2 4

OBJECTIVE: (i).To understand the Fundamentals of Vibration and its practical applications. (ii).To understand the working principle and operations of various vibrations Measuring instruments (iii).To understand the various Vibration control strategies UNIT I FUNDAMENTALS OF VIBRATION 10 Introduction -Sources Of Vibration-Mathematical Models- Displacement, velocity and Acceleration- Review Of Single Degree Freedom Systems -Vibration isolation Vibrometers and accelerometers -.Response To Arbitrary and non- harmonic Excitations Transient Vibration Impulse loads-Critical Speed Of Shaft-Rotor systems. UNIT II TWO DEGREE FREEDOM SYSTEM 7 Introduction-Free Vibration Of Undamped And Damped- Forced Vibration With Harmonic Excitation System Coordinate Couplings And Principal Coordinates UNIT III MULTI-DEGREE FREEDOM SYSTEM AND CONTINUOUS SYSTEM 9 Multi Degree Freedom System Influence Coefficients and stiffness coefficientsFlexibility Matrix and Stiffness Matrix Eigen Values and Eigen Vectors-Matrix Iteration Method Approximate Methods: Dunkerley, Rayleighs, and Holzer Method Geared Systems-Eigen Values & Eigen vectors for large system of equations using sub space, Lanczos method - Continuous System: Vibration of String, Shafts and Beams UNIT IV VIBRATION CONTROL 9 Specification of Vibration Limits Vibration severity standards- Vibration as condition Monitoring tool-Vibration Isolation methods- -Dynamic Vibration Absorber, Torsional and Pendulum Type Absorber- Damped Vibration absorbers-Static and Dynamic Balancing-Balancing machines-Field balancing Vibration Control by Design Modification- - Active Vibration Control UNIT V EXPERIMENTAL METHODS IN VIBRATION ANALYSIS 10 Vibration Analysis Overview - Experimental Methods in Vibration Analysis.-Vibration Measuring Instruments - Selection of Sensors- Accelerometer Mountings. -Vibration Exciters-Mechanical, Hydraulic, Electromagnetic And Electrodynamics Frequency Measuring Instruments-. System Identification from Frequency Response -Testing for resonance and mode shapes Total 45 + 30 = 75 Hour ** a Term Project must be given for Assessment 3 (Compulsory) TEXT BOOK: 1. Rao, S.S., Mechanical Vibrations, Addison Wesley Longman, 1995. 2. Thomson, W.T. Theory of Vibration with Applications, CBS Publishers and Distributors, New Delhi, 1990 REFERENCES: 1. Ramamurti. V, Mechanical Vibration Practice with Basic Theory, Narosa, New Delhi, 2000. 2. S. Graham Kelly & Shashidar K. Kudari, Mechanical Vibrations, Tata McGraw Hill Publishing Com. Ltd New Delhi,2007

10

ED 9123

MECHANISMS DESIGN AND SIMULATION**

L T P C 3 0 2 4

UNIT I INTRODUCTION 9 Review of fundamentals of kinematics-classifications of mechanisms-components of mechanisms mobility analysis formation of one D.O.F. multi loop kinematic chains, Network formula Gross motion concepts-Basic kinematic structures of serial and parallel robot manipulators-Compliant mechanisms-Equivalent mechanisms. UNIT II KINEMATIC ANALYSIS 9 Position Analysis Vector loop equations for four bar, slider crank, inverted slider crank, geared five bar and six bar linkages. Analytical methods for velocity and acceleration Analysis four bar linkage jerk analysis. Plane complex mechanismsauxiliary point method. Spatial RSSR mechanism-Denavit-Hartenberg Parameters Forward and inverse kinematics of robot manipulators. UNIT III PATH CURVATURE THEORY, COUPLER CURVE 9 Fixed and moving centrodes, inflection points and inflection circle. Euler Savary equation, graphical constructions cubic of stationary curvature. Four bar coupler curve-cusp-crunode-coupler driven six-bar mechanisms-straight line mechanisms UNIT IV SYNTHESIS OF FOUR BAR MECHANISMS 9 Type synthesis Number synthesis Associated Linkage Concept. Dimensional synthesis function generation, path generation, motion generation. Graphical methods-Pole technique-inversion technique-point position reduction-two, three and four position synthesis of four- bar mechanisms. Analytical methods- Freudensteins Equation-Blochs Synthesis. UNIT V SYNTHESIS OF COUPLER CURVE BASED MECHANISMS & CAM MECHANISMS 9 Cognate Lingages-parallel motion Linkages. Design of six bar mechanisms-single dwell-double dwell-double stroke. Geared five bar mechanism-multi-dwell. Cam Mechanisms- determination of optimum size of cams. Mechanism defects. Study and use of Mechanism using Simulation Soft-ware packages. Students should design and fabricate a mechanism model as term project. Note: Tutorial/Practice: 30 Hrs
**

Total 45 + 30 = 75 Hrs

a Term Project must be given for Assessment 3 (Compulsory)

REFERENCES: 1. Robert L.Norton., Design of Machinery,Tata McGraw Hill, 2005. 2. Sandor G.N., and Erdman A.G., Advanced Mechanism Design Analysis and Synthesis, Prentice Hall, 1984. 3. Uicker, J.J., Pennock, G. R. and Shigley, J.E., Theory of Machines and Mechanisms, Oxford University Press, 2005. 4. Amitabha Ghosh and Asok Kumar Mallik, Theory of Mechanism and Machines, EWLP, Delhi, 1999. 5. Kenneth J, Waldron, Gary L. Kinzel, Kinematics, Dynamics and Design of Machinery, John Wiley-sons, 1999. 6. Ramamurti, V., Mechanics of Machines, Narosa, 2005.

11

MA 9106

APPLIED MATHEMATICS FOR ENGINEERING DESIGN Common to M.E. (Engg. Design)/M.E. (CAD)/M.E. (PDD) L T P C 3 1 0 4

UNIT I 2 D RANDOM VARIABLES 9 Joint distributions Marginal and Conditional distributions functions of two dimensional random variables Regression curve - Correlation. UNIT II COMPUTATIONAL METHODS IN ENGINEERING 9 Boundary value problems for ODE Finite difference methods Numerical solution of PDE Solution of Laplace's and Poisson equation Liebmann's iteration process Solution of heat conduction equation by Schmidt explicit formula and CrankNicolson implicit scheme Solution of wave equation UNIT III TENSOR ANALYSIS 9 Summation convention Contravariant and covariant vectors contraction of tensors inner product quotient law metric tensor Christoffel symbols covariant differentiation gradient, divergence and curl UNIT IV CALCULUS OF VARIATION 9 Variation and its properties Euler's equation functionals dependent on first and higher order derivatives functionals dependent on functions of several independent variables problems with moving boundaries direct methods Ritz and Kantorovich methods UNIT V FAST FOURIER TRANSFORM 9 Discrete Fourier transform linearity and periodicity inverse N-point DFT DFT approximation of Fourier coefficients sampled Fourier series Approximation of Fourier transform by an N-point DFT FFT Computational efficiency of FFT Total: L: 45 + T: 15 = 60 REFERENCES: 1. James, G., Advanced Modern Engineering Mathematics, 3rd edition, Pearson Education, 2004. 2. Grewal, B.S., Numerical methods in Engineering and Science, 7th edition, Khanna Publishers, 2005. 3. Grewal, B.S., Higher Engineering Mathematics, 40th edition, Khanna Publishers, 2007. 4. Gupta, A.S., Calculus of variations with applications, Prentice-Hall of India, New Delhi, 1997. 5. O'Neil, P.V., Advanced Engineering Mathematics, Thomson Asia Pvt. Ltd., Singapore, 2003. 6. Andrews, L.C. and Philips, R. L. Mathematical Techniques for Engineers and Scientists, Prentice Hall of India, 2006.

ED 9164

DESIGN OF HYDRAULIC AND PNEUMATIC SYSTEMS

LT P C 3 0 0 3 5

UNIT I

OIL HYDRAULIC SYSTEMS AND HYDRAULIC ACTUATORS

Hydraulic Power Generators Selection and specification of pumps, pump characteristics. Linear and Rotary Actuators selection, specification and characteristics. UNIT II CONTROL AND REGULATION ELEMENTS 12

Pressure - direction and flow control valves - relief valves, non-return and safety valves - actuation systems. UNIT III HYDRAULIC CIRCUITS 5

Reciprocation, quick return, sequencing, synchronizing circuits - accumulator circuits - industrial circuits - press circuits - hydraulic milling machine - grinding, planning, copying, - forklift, earth mover circuits- design and selection of components - safety and emergency mandrels. UNIT IV PNEUMATIC SYSTEMS AND CIRCUITS 16

Pneumatic fundamentals - control elements, position and pressure sensing - logic circuits - switching circuits - fringe conditions modules and these integration sequential circuits - cascade methods - mapping methods - step counter method compound circuit design - combination circuit design. UNIT V INSTALLATION, MAINTENANCE AND SPECIAL CIRCUITS 7

Pneumatic equipments- selection of components - design calculations application fault finding - hydro pneumatic circuits - use of microprocessors for sequencing PLC, Low cost automation - Robotic circuits. Total 45 REFERENCES: 1. Antony Espossito, Fluid Power with Applications, Prentice Hall, 1980. 2. Dudleyt, A. Pease and John J. Pippenger, Basic fluid power, Prentice Hall, 1987. 3. Andrew Parr, Hydraulic and Pneumatics (HB), Jaico Publishing House, 1999. 4. Bolton. W., Pneumatic and Hydraulic Systems , Butterworth Heinemann, 1997. 5. K.Shanmuga Sundaram, Hydraulic and Pneumatic Controls: Understanding made Easy" S.Chand & Co Book publishers, New Delhi, 2006 (Reprint 2009)

30

ED 9166

MAINTENANCE ENGINEERING

LTPC 3 0 03 8

UNIT I

INTRODUCTION TO MAINTENANCE SYSTEMS

Introduction to repair and Maintenance -Maintenance as business - Maintenance systems such as reactive, preventive, predictive or proactive systems - Human resources management in Maintenance management -maintainability- Inherent and overall availability. - Mean time between failures, mean time to repairs and mean down time - Testability and supportability - Design for Maintenance - Poor maintainability aspects - Design for reliability. UNIT II CONDITION BASED MAINTENANCE 7

Condition based monitoring of equipment and systems -condition monitoring techniques such as a) Vibration analysis, b) Ultrasonic detection techniques, c) Thermography, d) Oil and lubricant analysis, e) Motor condition monitoring (MCM) Shaft alignments through laser - Vibration instruments -Outline on Thermography UNIT III MAINTENANCE TECHNIQUES SUCH AS RELIABILITY CENTRED MAINTENANCE(RCM),TOTAL PRODUCTIVE AINTENANCE(TPM)& CMMS 10

Reliability centred Maintenance-Failure Mode and Effect Analysis-Root cause Analysis- logic tree analysis-Criticality matrix - Total Productive Maintenance, Overall Equipment Effectiveness-Lean manufacturing- TPM and TPO- Relationship between OEE and world-class Maintenance- Ladder of Maintenance improvementComputerized Maintenance management system in a business scenario- data acquisition for effective management of CMMS. UNIT IV ASSET PLANNING AND SCHEDULING OF ACTIVITIES IN MAINTENANCE

10

Asset and spare part management, - Conventional spare Parts management techniques such as Economic Order Quantity, two bin systems - Latest trends in monitoring through bar codes, mobile computer and wireless data transmissions -. Different aspects of planning and scheduling of Maintenance, such as shutdownsCritical aspects of both routine and shut down Maintenance -. bar charts - PERT network during shut down -Man power Training and utilization of skilled manpower Sequencing of activities. UNIT V SAFETY AND OTHER ASPECTS OF MAINTENANCE FUNCTIONS 10 Safety Engineering. - Hazard analysis -General rules and guidelines in safety and hazard prevention - Analytical tools - Hazard analysis- Fault Tree Analysis - Sneak Circuit analysis - Integrated approach to Maintenance- Statistical distributions such as normal, gamma and Weibull in Maintenance- Maintenance effectiveness. TOTAL: 45

32

TEXT BOOK: 1. Maintenance Engineering and Management: K.Venkataraman-PHI Learning2007 REFERENCES: 1. Kelly. A and Harris, M. J, Management of Industrial maintenance, Butter worth & Co., 1978 2. David J. Smith, Reliability and Maintainability in Perspective, McMillan,2nd Edition, 1985. 3. Gwidon W Stachowiak and Andrew W. Batchelor, Engineering Tribology, Butterwork-Heinmann, 2001 4. John V.Grimaldi & Rollin H.Simonds, Safety Management, AITBS Publishers & Distributors, 2001

33

ED9171 UNIT I

RAPID PROTOTYPING AND TOOLING INTRODUCTION

LTPC 3 0 0 3 7

Need - Development of RP systems RP process chain - Impact of Rapid Prototyping and Tooling on Product Development Benefits- Applications Digital prototyping - Virtual prototyping. UNIT II LIQUID BASED AND SOLID BASED RAPID PROTOTYPING SYSTEMS 10

Stereolithography Apparatus, Fused deposition Modeling, Laminated object manufacturing, Three dimensional printing: Working Principles, details of processes, products, materials, advantages, limitations and applications - Case studies. UNIT III POWDER BASED RAPID PROTOTYPING SYSTEMS: 10

Selective Laser Sintering, Direct Metal Laser Sintering, Three Dimensional Printing, Laser Engineered Net Shaping, Selective Laser Melting, Electron Beam Melting: Processes, materials, products, advantages, applications and limitations Case Studies. UNIT IV REVERSE ENGINEERING AND CAD MODELING 10

Basic concept- Digitization techniques Model Reconstruction Data Processing for Rapid Prototyping: CAD model preparation, Data Requirements geometric modeling techniques: Wire frame, surface and solid modeling data formats - Data interfacing, Part orientation and support generation, Support structure design, Model Slicing and contour data organization, direct and adaptive slicing, Tool path generation. UNIT V RAPID TOOLING 8

Classification: Soft tooling, Production tooling, Bridge tooling; direct and indirect Fabrication processes, Applications. Case studies - automotive, aerospace and electronic industries. Total Periods: 45 TEXT BOOK: 1. Rapid prototyping: Principles and applications, second edition, Chua C.K., Leong K.F., and Lim C.S., World Scientific Publishers, 2003. 2. Rapid Tooling: Technologies and Industrial Applications, Peter D.Hilton, Hilton/Jacobs, Paul F.Jacobs, CRC press, 2000. REFERENCES: 1. Rapid prototyping, Andreas Gebhardt, Hanser Gardener Publications, 2003. 2. Rapid Prototyping and Engineering applications : A tool box for prototype development, Liou W.Liou, Frank W.Liou, CRC Press, 2007. 3. Rapid Prototyping: Theory and practice, Ali K. Kamrani, Emad Abouel Nasr, Springer, 2006

45

ED 9154

COMPOSITE MATERIALS AND MECHANICS

LTPC 3 003

OBJECTIVE i) To understand the fundamentals of composite material strength and its mechanical behavior ii) Understanding the analysis of fiber reinforced Laminate design for different Combinations of plies with different orientations of the fiber. Thermo-mechanical behavior and study of residual stresses in Laminates during processing. Implementation of Classical Laminate Theory (CLT) to study and analysis for residual stresses in an isotropic layered structure such as electronic chips. LAMINA CONSTITUTIVE RELATIONS 12

iii) iv)

UNIT I

Definition Need General Characteristics, Applications. Fibers Glass, Carbon, Ceramic and Aramid fibers. Matrices Polymer, Graphite, Ceramic and Metal Matrices Characteristics of fibers and matrices. Lamina Constitutive Equations: Lamina Assumptions Macroscopic Viewpoint. Generalized Hookes Law. Reduction to Homogeneous Orthotropic Lamina Isotropic limit case, Orthotropic Stiffness matrix (Qij), Typical Commercial material properties, Rule of Mixtures. Generally Orthotropic Lamina Transformation Matrix, Transformed Stiffness. Manufacturing: Bag Moulding Compression Moulding Pultrusion Filament Winding Other Manufacturing Processes. UNIT II FLAT PLATE LAMINATE CONSTITUTIVE RELATIONS 10

Definition of stress and Moment Resultants. Strain Displacement relations. Basic Assumptions of Laminated anisotropic plates. Laminate Constitutive Equations Coupling Interactions, Balanced Laminates, Symmetric Laminates, Angle Ply Laminates, Cross Ply Laminates. Laminate Structural Moduli. Evaluation of Lamina Properties from Laminate Tests. Quasi-Isotropic Laminates. Determination of Lamina stresses within Laminates. UNIT III LAMINA STRENGTH ANALYSIS 5

Introduction - Maximum Stress and Strain Criteria. Von-Misses Yield criterion for Isotropic Materials. Generalized Hills Criterion for Anisotropic materials. Tsai-Hills Failure Criterion for Composites. Tensor Polynomial (Tsai-Wu) Failure criterion. Prediction of laminate Failure UNIT IV ANALYSIS OF LAMINATED FLAT PLATES Equilibrium Equations of Motion. Energy Formulations. Static Bending Buckling Analysis. Free Vibrations Natural Frequencies 10 Analysis.

18

UNIT V

EFFECT OF THERMAL PROPERTIES

Modification of Hookes Law due to thermal properties - Modification of Laminate Constitutive Equations. Orthotropic Lamina - special Laminate Configurations Unidirectional, Off-axis, Symmetric Balanced Laminates - Zero C.T.E laminates, Thermally Quasi-Isotropic Laminates Total TEXT BOOK: 1. Gibson, R.F., Principles of Composite Material Mechanics, McGraw-Hill, 1994, Second Edition - CRC press in progress. 2. Hyer, M.W., Stress Analysis of Fiber Reinforced Composite Materials, McGraw-Hill, 1998 REFERENCES: 1. Issac M. Daniel and Ori Ishai, Engineering Mechanics of Composite Materials, Oxford University Press-2006, First Indian Edition - 2007 2. Mallick, P.K., Fiber Reinforced Composites: Materials, Manufacturing and Design, Maneel Dekker Inc, 1993. 3. Halpin, J.C., Primer on Composite Materials, Analysis, Techomic Publishing Co., 1984. 4. Agarwal, B.D., and Broutman L.J., Analysis and Performance of Fiber Composites, John Wiley and Sons, New York, 1990. 5. Mallick, P.K. and Newman, S., (edition), Composite Materials Technology: Processes and Properties, Hansen Publisher, Munish, 1990. 6. Madhujit Mukhopadhyay, Mechanics of Composite Materials and Structures, University Press (India) Pvt. Ltd., Hyderabad, 2004 (Reprinted 2008) 45

19