P- 601 QUALITY ENGINEERING & MANAGEMENT

 

Teaching Scheme Theory Hrs.             Practical Hrs.		Examination Scheme
		Marks	Theory Hrs.	Practical/Oral Marks	Term work Marks	Total Marks
04	02	100	03	25	25	150

1. THEORY

1. Quality & Quality Control

Definition and concept of quality, factors influencing quality, Quality characteristics and parameters, of fitness for use, Reliability concepts-calculations, need for inspection, Methods and stages of inspection, stores inspection, quality of design, manufacture and use, spiral of quality progress. Common patterns of variations- the normal, binominal and position distribution and their properties, quality control-it’s introduction and benefits, manufacture process control- concepts and techniques, control charts for variables and attributes, quality planning in industries, total quality control-it’s scope and application, esq. principles and their applications, quality cost concepts, economics of quality control effort, seven tools of quality control, cost reduction programmed.

 

2. Designing for Quality

         Cost effectiveness concept, elements of reliability in design, factors such as availability, maintainability, human aspects, and cost and product performance.

 

3. Acceptance Sampling

Concept, sampling by attributes, single and double sampling plans, inspections by samples, acceptable quality level, lot tolerance percent defective, consumers and producer’s risk, construction and use of operating characteristic curves, use of standard sampling tables and related ISI, design of experiments, sampling by variables, continues sampling plan, vendor ratings.

 

4. Quality Audit and Motivation

Purpose and need of quality audit, prerequisites and scope of QA, management related factors and worker related problems, management and operator controllable defects, quality rating, pride in product, industrial employee relations, education and training, incentive schemes, worker motivation, zero defect programme, quality circle concept- it’s expectation and launching, organizing quality improving methods.

 

5. Quality Information System

Definition and scope, relation of QIS to MIS, planning computer based information system, output of information summary reports in an inspection information system, controlling quality- computer software- quality control manual.

 

6. ISO-9000 Implementation and Registration

ISO system of International standards, its Recent amendments, importance, benefits, procedure for implementation, certifying agencies, Introduction to QS-9000.

 

B.   TERM-WORK

       It shall consist of experiments industrial case studies and exercise problem solved by computer. Assessment of term work will be on continuous bases.

   C.   PRACTICAL / ORAL

It shall be based on term work prepared and on syllabus topics as above.

   D.  REFERANCE BOOKS

                1. Quality planning and analysis by J.M. Juran & Frank M Gryna.

                2. Quality and Reliability and integrated approach by Smith

                3. Quality Management by I.S.T.E

                4. Quality Circles by I.S.T.E

              5. Statistical Methods and Inspection Techniques in Quality control.  By I.S.T.E

P- 602     TOOL DESIGN

 

Teaching Scheme Theory Hrs.          Practical Hrs.		Examination Scheme
		Marks	Theory Hrs.	Practical/Oral Marks	Term work Marks	Total Marks
04	02	100	03	25	25	150

 

1. A. THEORY

 

1. 1.  INTRODUCTION Tool design practice, procedure of tool design, process planning  and tool  design.
2. 2  MECHANICS OF MACHINING   Place of machine in production , classification  of material removal  processes,  or orthogonal  and  oblique cutting, types  of cutting tool mechanics, their  characteristics and selection criteria, mechanics of metal cutting- effect of tool-geometry and other cutting parameters, types of cutting fluids,  their characteristics and  selection; types of chips formed, concept of  specific  cutting pressure , types of tool wear, factors  causing  wear, economical cutting  speed, mach inability of metals.
3. 3.  DESIGN OF SINGLE POINT CUTTING TOOLS  Tool geometry for single point cutting tool, tool  signature , Design of single point cutting tools such as solid tools , tipped tools, coated tipped tools, throw away type tools and diamond  tools.
4. 4.  DESIGN  OF MULTIPOINT TOOLS  Design of milling cutters, gear milling cutters,  hobs gear  shaping tools , broaches, drills, reamers, taps &  dies for thread cutting, boring tools, flat from tools, circular form tools. Standard tool holders & standard tooling and  their design for turrets and automates.
5. 5. DESIGN OF PRESS TOOLS Design  of press tools , effect of clearances, theory of  deformation, stages of cutting operation center of pressure, strip  layout , die and punch  design, design of  simple, compound and progressive  dies, methods of mounting punches  and dies, design of  drawing  dies, bend allowances  bending  and  forming dies, Dies for die-casting and  forging operations.

6. JIGS AND  FIXTURE Essential requirements of jigs & fixtures  economics of jigs and fixtures , principles of location and  clamping, location and clamping  devices, types of drill bushes, types of jigs and types of fixtures like fixtures for milling , welding , heat treatment  , grinding , assembly and inspection  processes, standardization in jigs and fixtures , principle  of work holders, common work holders for production like vises, chucks, arbors, mandrels & collets.

 B. TERM WORK

       Term work to be prepared by the candidate will be based on the topics of above syllabus. It will consist of following:

1. (a)      Practical work on area of metal cutting
2. (b)      Design & drawing in area of   press tool and jigs and fixtures.

 

        C. PRACTICAL/ ORAL

            It shall be based on term work prepared and on syllabus topics as above.

        D. REFERENCE BOOKS

1. 1. Fundamentals of Tool Design  By A.S.T.M.E\
2. 1. Metal cutting principles    By Milton C. Shaw.
3. 1. Fundamental of Metal Machining and Machine Tools By Geoffrey Boothroyd.
4. 1.  Tool Design    By Donaldson, Lecain, Goold.
5. 1. Typical Examples and Problems in Metal cutting and  Tool By N. Nefedov, K. Osipov.
6. 1.  Tool Design  By charles Bradford Cole.
7. 1. An Introduction  to Jig & Tool Design By M.H.A. Kempster.

1.  

P- 603 MANUFACTURING PROCESSES-III

 

Teaching Scheme Theory Hrs.             Practical      Hrs.		Examination Scheme
		Marks	Theory Hrs.	Practical/Oral Marks	Term work Marks	Total Marks
04	02	100	03	25	25	150

 

A         THEORY

 

1.         SEMIAUTOMATES & AUTOMATES Semi Automatic Capstan and Turret Lathes, Their Working and Tooling, Tool Layouts on Semi Automates, Single Spindle and Multi-spindle Automates, Bar Type and Chucking Type Machines, Their Principle of working, Construction Details and Tool Setting, Evaluation of process time and Cam Design.

 

2.         THREAD MANUFACTURING

Thread Forming and Thread Cutting Methods such as Thread Chasing, Dye Threading, Thread Tapping, Thread Cutting on Lathe, Thread Rolling, Thread Milling and Thread Grinding, Their Constructional Details, Working Principles, Tooling and Effect of Different process parameters.

 

3.         GEAR MANUFACTURING

Selection of suitable gear materials, forming and generating methods of gear cutting, forming on Milling machine, shapers and broaching machines etc. & generation processes such as Rack Planning, Hobbing, Shaping, Bevel finishing processes such as grinding, lapping etc.

 

4.         UNCONVENTIONAL MACHINING PROCESSES

Necessity of Unconventional Machining processes, Working process variables, relative merits and field of applications of unconventional processes such as EDM, ECM, ECG, USM, EBM, LBM, PAM and WJM etc.

 

5.       ADVANACE CHIPLESS FORMING PROCESSES

Principle of working, advantages and limitations of High Velocity rate forming and High-energy rate forming techniques and their field of applications.

 

6.         METAL FINISHING & COATING PROCESSES:

            Principles, working, advantages, limitations and applications of Metal finishing       processes          such as Honing, Lapping, Super-finishing etc., and coating processes        such as Zinc      plating,

             Chrome-plating, dull plating, cladding, blackening, powder            coating etc.

 

B.        PRACTICAL /ORAL

            It will be based on term work prepared and on topics of subject as above

C.        TERM WORK

It will consist of journal writing on topics of the syllabus as above, and practical applications.

D.        REFERENCE BOOKS

1.  Capstan & Turret Lathes     By Durmey.

2.   Technology  of  Gear Cutting     By A. Bhattarchaya

3.   Workshop Technology               By Hajra Choudhary

4.   Production Technology              By O.P. Khanna & M.Lal

5.   Manufacturing  Technology        By P.N. Rao TMH  Edision

6.   Metal working Technology         By Richard L. Little

P- 606 SEMINAR 

 

Teaching Scheme Theory Hrs.             Practical Hrs.		Examination Scheme
		Theory Marks	Theory Hrs.	Practical/Oral Marks	Term work Marks	Total Marks
**	02	**	**	25	25	50

 

A.       GENERAL GUIDELINES

 

The student will select a topic in the area of Production Engineering or in any other relevant area in consultation with the faculty members of the Department and will work extensively to study and explore the topic, using available literature through all kind of media. The student will have to prepare a report after such study. The report should preferably address principles, practices, applications, benefits, recent innovations and advancements in the field of topic selected. Relevant case studies, live examples, analysis, original research are to be included to strengthen the work and report.

 

B.  TERM WORK

 

Term work will consist of Report prepared on the work carried out as above on the selected topic. Report to be prepared to the satisfaction of the concerned faculty member.

 

C. PRACTICAL/ ORAL

 

The work done as above and report prepared thereof will have to be defended before the panel of examiners.