Core Course Structure and Syllabus

Dept. of Mechanical Engineering

M Tech (Manufacturing Science and Engineering)

SEMESTER-I

SEMESTER-II

SEMESTER-III

SEMESTER-IV

ME 510 Subtractive Manufacturing

Metal cutting theory: models for orthogonal and oblique machining. Advancements in conventional machining processes: thin-wall machining, high speed machining, hard turning, ductile regime machining of brittle materials, single point diamond turning (SPDT), vibration assisted machining, and sustainable machining. Computer numerical control (CNC) machining technology: sculptured surface generation using multi-axis CNC machining, machine tool condition monitoring through force, temperature, vibration signals, etc. Modeling of machining processes: electric discharge machining, electro-chemical machining, laser beam machining, lithography based machining processes, etc. Surface integrity of machined products: measurement of surface topography, micro-hardness and residual stresses. Modeling of magneto-rheological finishing (MRF), and chemo-mechanical polishing (CMP).

Texts/ References

1. J. P. Davim, Machining Fundamentals and Recent Advances, Springer, 2008.
2. M. C. Shaw, Metal Cutting, Tata McGraw Hill, New Delhi, 2004.
3. G. K. Lal, Introduction To Machining Science, New Age International Pvt Ltd., 2007.
4. V. K. Jain, Advanced Machining Processes, Allied Publishers, 2009.
5. V. K. Jain, Introduction to Micromachining, 2nd Ed., Narosa, 2010.
6. M. Madou, Fundamentals of microfabrication, CRC Press, 1997.
7. G. Boothroyd and W. A. Knight, Fundamentals of Machining and Machine Tools, CRC-Taylor and Francis, 2006.

ME 512 Welding and Additive Manufacturing

Introduction to welding processes; Classification of joining processes; Type of welds and weld joints; Welding symbols and codes; Arc welding processes; Laser welding; Electron beam welding; Resistance spot welding; Friction welding; friction stir welding; Types of power sources, Current-voltage and arc power – arc length characteristics; Synergic and pulsed welding; Forces on molten droplet, Mode of metal transfer in arc welding; Cold metal transfer.Analysis of heat flow, Cooling rates; Models for welding heat sources, Analytical solution of temperature distribution; Chemical reactions in welding; Solidification in welding and solidification cracking; Phase transformation in welded structure; Weld microstructure; Heat treatment of weld joint; Types of welding defects, their cause and remedies; Distortion and residual stress and their measurement; Weld testing methods: destructive and non-destructive; Analysis of welded structure for fatigue loading; Additive manufacturing: Introduction; Classification; Principle, Welding technology based metal 3D printing; Solid state additive manufacturing, Additive vs. subtractive manufacturing.

Text/References

1. A. O’Brien, Welding Handbook: Welding Processes, Part 1, Vol. 2, 9th Ed., American Welding Society, 2007
2. J. F. Lancaster, The Physics of welding, Pergamon, 1986
3. R. W. Messler, Principles of Welding, John Wiley and Sons, 1999
4. S. Kou, Welding Metallurgy, 2nd Ed., Wiley Interscience, 2003
5. V. M. Radhakrishnan, Welding technology and design, New Age International Private Ltd., 2nd Ed., 2005
6. R. S. Parmar, Welding Processes and Technology, Khanna Publishers, 3rd Ed., 2015
7. J. A. Goldak, Computational Welding Mechanics, Springer, 2005
8. W Steen, Laser Material Processing, Springer-Verlag, 1991.
9. I Gibson, D. W. Rosen, B. Stucker, Additive Manufacturing Technologies, Springer, 2010.

ME 511 Engineering Materials and Characterization

Introduction and classification of materials: metals and alloys, ceramics, polymers and composite. Atomic bonding, crystal structure and grain morphology. Defects in metals. Plastic deformation mechanisms of metals: dislocation slip, deformation twinning, martensitic transformation. Strengthening mechanism of metals. Failure mechanisms: fracture, fatigue and creep. Phase diagrams (Fe-Fe3C phase diagrams), TTT and CCT diagram. Heat treatment. Powder metallurgy. Coating techniques. Composite fabrication: metal matrix, polymer matrix and ceramic matrix composites. Introduction to advanced materials: shape memory alloys, piezoelectric materials, biomaterials, superalloys, high entropy alloys.

Mechanical characterization: tensile test, hardness test, impact test, fracture/fatigue/creep test; X-ray diffraction (XRD) technique: characterization and analysis; Microscopy techniques and analysis of results: optical microscopy (OM), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS/EDX/EDAX), electron backscatter diffraction (EBSD), transmission electron microscopy (TEM), atomic force microscopy (AFM), scanning tunneling microscopy (STM); Principles and applications of thermal analysis: differential thermal analysis (DTA), differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), thermomechanical analysis (TMA), dynamic mechanical analysis (DMA/DMTA).

Texts/ References

1. W. D. Callister, Material Science and Engineering: an Introduction, Wiley, 2002.
2. G. Dieter, Mechanical Metallurgy, Mc-Graw Hill, 1996.
3. R. F. Speyer, Thermal Analysis of Materials, Marcel Decker, 1994
4. B. Fultz and J. M. Howe, Transmission Electron Microscopy and Diffractometry of Materials, Springer 2008.
5. ASTM handbook, vol. 3, 1997
6. ASM hand book Materials characterization, Vol 10, 1998
7. C. R. Brundle, C. A. Evans Jr., S. Wilson, Encyclopedia of Materials Characterization, Butterworth-Heinemann, 1992.
8. R. W. Cahn, and E. Lifshin, Concise Encyclopedia of Materials Characterization, Pergamon, 1993.
9. E. N. Kaufmann, Materials characterization, Wiley Interscience, 2003.
10. B. D. Cullitey, Elements of X-ray diffraction, Addison-Wesely, 1968.
11. E. Lifshin, X Ray Characterization of Materials, Wiley-Vch 1999.

ME 513 Physics of Deformation Processes

Introduction of deformation processes from the point of view of underlying physics. Stresses and Strain: stress and strain behavior of materials, plastic and tangent modulus, work hardening, plastic instability in tensile test, empirical stress-strain equations, effect of pressure, strain-rate and temperature, analysis of stress tensor, eigenvalues, decomposition into deviatoric and hydrostatic components, octahedral stresses, analysis of strain and strain rates, stress equilibrium and virtual work, objective stress rates. Plasticity: the criteria of yielding, isotropic and anisotropic hardening, rules of plastic flow, Levy-Mises and PrandtlReuss equations, anisotropic flow rule, Hill’s 1948 and 1979 yield criteria for anisotropic yielding. Upper bound theorem and its application in deformation processes like rolling, wire drawing, extrusion, forging. Lower bound theorem with a few applications. Slab method and its application in deformation process like symmetric/asymmetric rolling, forging, wire drawing and extrusion. Elastoplastic sheet bending. Analysis of autofrettage. Theory of slip line field and its application in metal forming. Heat transfer analysis in deformation processes with examples from rolling and friction stir welding/processing. Workability and dynamic materials model.

Texts/ References

1. U. S. Dixit and R. Ganesh Narayanan, Metal Forming: Technology and Process Modelling, McGraw Hill Education, New Delhi, 2013.
2. P. M. Dixit and U. S. Dixit, Modelling of Metal Forming and Machining Processes: By Finite Element and Soft Computing Methods, Springer, London, 2008.
3. W. F. Hosford and R. M. Caddell, Metal forming: mechanics and metallurgy, Cambridge University Press, London, 2011.
4. J. Chakrabarty, Theory of plasticity, Elsevier Butterworth-Heinemann Company, Singapore, 2006.
5. Y. V. R. K. Prasad and S. Sasidhara, Hot working guide: a compendium of processing maps, ASM International, Materials Park, OH, 1997.
6. B. L. Juneja, Fundamentals of metal forming processes, New Age International, New Delhi, 2007.

ME 515 Manufacturing Laboratory

Measurement of cutting forces, surface roughness, tool wear, temperature in machining. Experiments in rolling. Measurement of microhardness. Ring compression test for the estimation of friction in metal forming. Open-die forging and load evaluation. Hydraulic and pneumatic systems. Sensors and transducers. Study of robots. Design of simple electronic circuits. Microprocessors and PLCs for manufacturing applications. Electrochemical machining, laser and plasma cutting. Vacuum coating.

Computer Aided Design (CAD), Computer Aided Process Planning (CAPP) and manufacturing of products using Subtractive and Additive Manufacturing processes. Inspection of the products manufactured by Subtractive and Additive Manufacturing. Comparative analysis of the products realized through two routes of manufacturing.

References

1. I. Zeid, CAD/CAM theory and practice, McGraw-Hill Higher Education, 1991
2. C. K. Chua and K. F. Leong, 3D printing and additive manufacturing, World Scientific Publishing Company, 2014.

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