22563: Advanced Manufacturing Processes Syllabus for Mechanical Engineering 5th Sem I – Scheme MSBTE

Advanced Manufacturing Processes detailed Syllabus for Mechanical Engineering (ME), I – scheme has been taken from the MSBTE official website and presented for the diploma students. For Subject Code, Subject Name, Lectures, Tutorial, Practical/Drawing, Credits, Theory (Max & Min) Marks, Practical (Max & Min) Marks, Total Marks, and other information, do visit full semester subjects post given below.

For all other Diploma in Mechanical Engineering (ME) Syllabus for 5th Sem I – Scheme MSBTE, do visit Diploma in Mechanical Engineering (ME) Syllabus for 5th Sem I – Scheme MSBTE Subjects. The detailed Syllabus for advanced manufacturing processes is as follows.

Rationale:

For the complete Syllabus, results, class timetable, and many other features kindly download the iStudy App
It is a lightweight, easy to use, no images, and no pdfs platform to make students’s lives easier.
.

Competency:

The aim of this course is to help the student to attain the following industry identified competency through various teaching learning experiences:

• Maintain the functioning of advanced manufacturing processes and equipment.

Course Outcomes:

The theory, practical experiences and relevant soft skills associated with this course are to be taught and implemented, so that the student demonstrates the following industry oriented COs associated with the above mentioned competency:

1. Maintain the non conventional machining process to produce complex and hard to machine components.
2. Produce components using milling machine.
3. Choose relevant machining process to produce gears.
4. Maintain CNC machine to produce components effectively.
5. Prepare CNC part programs for simple components.
6. Maintain the functioning of automated equipment.

Suggested Exercises:

For the complete Syllabus, results, class timetable, and many other features kindly download the iStudy App
It is a lightweight, easy to use, no images, and no pdfs platform to make students’s lives easier.
.

Instruments Required:

The major equipment with broad specification mentioned here will usher in uniformity in conduct of experiments, as well as aid to procure equipment by authorities concerned.

Equipment Name with Broad Specifications

1. Abrasive Jet machining
2. Electro Discharge Machine
3. Electro Chemical Machine: Tool area 10mmx30mm or 15mmx20mm; Cross Head Stroke 40 mm; Supply Single phase 230 V. A.C.; Electrical Output Rating 0-100 Amps and voltage from 0 – 25 V DC; Tool Feed Rate In the range of 0 2 to 1 mm / min.; Machining Time 0 to 1999 seconds, variable through touch screen.; Display For voltage, output current; feed rate electrolyte temp; Protection For Current overload, short circuit; USB Port For data storage; pulsating facility On time 100 microseconds to 1 second variable, off time 100 microseconds to 1 second variable, plus amplitude lv-lOv variable; LCD display For forward and reverse, feed rate settings, feed rate; Tool Area 300 square mm;
4. Lathe machine, turning tool, boring tool, Standard dial bore gauge. Minimum 500 mm between centre, with required set of work holding devices, cutting tools, accessories and tool holders
5. Milling machine, face milling cutter, side and face milling cutter, end mill cutter. Minimum 500 mm longitudinal traverse, with required indexing head, set of work holding devices, cutting tools, accessories and tool holders.
6. Drilling Machine (Bench type, or Column type, or if possible Radial): Minimum 25 mm capacity, with required set of work holding devices, cutting tools, accessories and tool holders.
7. CNC Turning 250 with standard accessories and multi controller changing facility with simulated control panel and related software. Training or Productive type minimum diameter 25 mm, Length 120 mm with ATC. (Suggested.
8. CNC Milling 250 with standard accessories and multi controller changing facility with simulated control panel and related software. Training or Productive type-X axis travel – 225 mm, Y axis travel – 150 mm, Z axis travel – 115 mm, with ATC.(Suggested.
9. CNC Simulation software and control pads (CAMLAB CNC Software, MasterCAM/NXCAM/, DONC CNC machine simulator, PRO, SWANSOFT, CAPSMILL and CAPSTURN IN cam software, DONCMILL AND DONCTURN software.
10. PRO_,FICNC programming manuals and watch PROF1CNC on https://youtu.be/3ghwlpmhwpm to integrated CNC machine with multipleindustry standard CNC controllers like FANUC, SIEMENS. FAGOR AND MITSUBISHI.
11. Any Latest educational version of CAD/CAM integration software .
12. Robotic Arm

Unit 1

Non-Conventional Machining Processes

Total Teaching Hours – 10

Distribution of Theory Marks

R Level – 02

U Level – 04

A Level – 06

Total Marks – 12

Unit Outcomes (UOs) (in cognitive domain)

1. Describe with sketches the working principle of the given non – conventional machining method and draw set up of the same.
2. Describe advantages, limitations and applications of the given non -conventional machining method.
3. Recommend the non conventional machining method for the given job with justification.
4. Recommend the process parameters for the given job and non-conventional machining process with justification.

Topics and Sub-topics

1. Fundamentals of Non – conventional methods – Needs and types of non -conventional methods. Importance of methods.
2. Working principle, set up, process parameters of – EDM,, WEDM ECM, PAM, AJM, USM, EBM and LBM.
3. Advantages, limitations and applications of – EDM,, WEDM ECM, PAM, AJM, USM, EBM and LBM.

Unit 2

For the complete Syllabus, results, class timetable, and many other features kindly download the iStudy App
It is a lightweight, easy to use, no images, and no pdfs platform to make students’s lives easier.
.

Unit 3

Gear Manufacturing

Total Teaching Hours – 10

Distribution of Theory Marks

R Level – 02

U Level – 02

A Level – 06

Total Marks – 10

Unit Outcomes (UOs) (in cognitive domain)

1. Explain with sketches procedure of the given gear manufacturing process.
2. Draw sketches of the given gear hob, hobbing process or gear shaping process.
3. Explain with sketches the given gear finishing process.
4. Recommend the process parameters for the given gear manufacturing and finishing process with justifications.

Topics and Sub-topics

1. Gear manufacturing methods: Function and types of gears, gear manufacturing methods.
2. Gear hobbing – Working principle, types of gear hobbing, advantages, limitations and applications of gear hobbing
3. Gear shaping – Gear shaping by pinion cutter, gear shaping by rack cutter, advantages, limitations and applications of both the methods and Comparison of gear hobbing and gear shaping
4. Gear finishing methods-Need of gear finishing, gear finishing methods,
   1. Gear shaving
   2. Gear grinding
   3. Gear burnishing
   4. Gear lapping
   5. Gear honing

Unit 4

Fundamentals of Computer Aided Manufacturing (CAM)

Total Teaching Hours – 10

Distribution of Theory Marks

R Level – 02

U Level – 04

A Level – 06

Total Marks – 12

Unit Outcomes (UOs) (in cognitive domain)

1. State the functions of the given elements of the CNC Machine
2. Select tools and tool holders used on a CNC machine for the given job with justification
3. Explain the given work and tool holding and changing devices used on a CNC turning centre
4. Explain the given work and tool holding and changing devices used on a CNC Machining centre

Topics and Sub-topics

1. CAM concept, NC (Numerical Control), CNC (Computerized Numerical Control) and DNC (Direct Numerical Control) -concept, features and differences.
2. CNC machines: Types, classification, working and constructional features Advantages, limitations and selection criteria.
3. Elements of CNC machines – Types, sketch, working and importance of: Slide ways; Re-circulating ball screw; Feedback devices (transducers, encoders); Automatic tool changer (ATC); Automatic pallet changer (APC);
4. CNC tooling : Tool presetting-concept and importance; Qualified tools- definition need and advantages; Tool holders- types and applications.
5. CNC turning centres: Types; Features; Axes nomenclature; Specification; Work holding devices -types, working and applications.
6. CNC machining centres: Types; Features; Axes nomenclature; Specification; Work holding devices-types, working and applications.

Unit 5

For the complete Syllabus, results, class timetable, and many other features kindly download the iStudy App
It is a lightweight, easy to use, no images, and no pdfs platform to make students’s lives easier.
.

Unit 6

Automation and Robotics

Total Teaching Hours – 10

Distribution of Theory Marks

R Level – 02

U Level – 02

A Level – 04

Total Marks – 08

Unit Outcomes (UOs) (in cognitive domain)

1. Compare Fixed and flexible Automation on given parameters with justification.
2. Justify the use of Group Technology for the given situation.
3. Justify the use of FMS in a given situation.
4. Explain a Robotic system used for a given manufacturing environment.
5. Select different components of Robotics with justification.

Topics and Sub-topics

1. Automation-Define, need of automation, high and low cost automation, examples of automations.
2. Types of Automation – Fixed (Hard) automation, programmable automations and Flexible automations (Soft) Comparison of types of automations.
3. Group Technology- concept, basis for developing part families, part classification and coding with example, concept of cellular manufacturing. Advantages and limitations.
4. Flexible Machining System- Introduction, concept, definition and need, sub systems of FMS, comparing with other manufacturing approaches.
5. Introduction to Robotics- definition of robot and robotics, advantages disadvantages and applications.
6. Components of Robotics manipulator, end effectors, actuators, sensors, controller, processor and software.

Note: To attain the COs and competency, above listed UOs need to be undertaken to achieve the Application Level and above of Blooms Cognitive Domain Taxonomy

Note:

Legends: R=Remember, U=Understand, A=Apply and above (Blooms Revised taxonomy)

Note: This specification table provides general guidelines to assist student for their learning and to teachers to teach and assess students with respect to attainment of UOs. The actual distribution of marks at different taxonomy levels (of R, U and A) in the question paper may vary from above table.

Suggested Student Activities:

Other than the classroom and laboratory learning, following are the suggested student-related co-curricular activities which can be undertaken to accelerate the attainment of the various outcomes in this course. Students should conduct following activities in group and prepare reports of about 5 pages for each activity, also collect/record physical evidences for their (students) portfolio which will be useful for their placement interviews.

1. Prepare journal based on practical performed in measurement laboratory. Journal consist of drawing, observations, required measuring tools, equipments, date of performance with teacher signature.
2. Tabulate various cutting tools materials with main elements, properties and applications.
3. List process parameters for various machines (Each student will be given different machine).
4. Calculate RPM for lathe, milling cutter and drill spindle; based on given data. (Each student should be given different data for diameters and cutting speeds)
5. Prepare a report on at least one industrial component with its complete technical details covering the points like design criterion, features included with Dimensional/Geometric constraints, manufacturing resource requirements, challenges in controlling its quality and cost, etc.
6. Collect the technical details about all production facilities available at nearby industry/industries.
7. Visit or participate in the technical events, exhibition, conference, seminar etc.
8. Collect/download at least four different machine tool catalogues including at least one special purpose, non-conventional or advanced machine.
9. Collect/download at least one catalogue each of cutting tool, work holding device and tool holder.

Suggested Special Instructional Strategies:

For the complete Syllabus, results, class timetable, and many other features kindly download the iStudy App
It is a lightweight, easy to use, no images, and no pdfs platform to make students’s lives easier.
.

Suggested Micro-Projects

Only one micro-project is planned to be undertaken by a student that needs to be assigned to him/her in the beginning of the semester. In the first four semesters, the micro-project are group-based. However, in the fifth and sixth semesters, it should be preferably be individually undertaken to build up the skill and confidence in every student to become problem solver so that s/he contributes to the projects of the industry. In special situations where groups have to be formed for micro-projects, the number of students in the group should not exceed three.

The micro-project could be industry application based, internet-based, workshopbased, laboratory-based or field-based. Each micro-project should encompass two or more COs which are in fact, an integration of PrOs, UOs and ADOs. Each student will have to maintain dated work diary consisting of individual contribution in the project work and give a seminar presentation of it before submission. The total duration of the micro-project should not be less than 16 (sixteen) student engagement hours during the course. The student ought to submit micro-project by the end of the semester to develop the industry oriented COs.

A suggestive list of micro-projects are given here. Similar micro-projects could be added by the concerned faculty:

1. Prepare a list of industrial components which are produced through non conventional machining processes and describe the manufacturing procedure of the same in brief
2. Prepare a list of domestic and industrial components on which Lapping, honing, buffing, Electroplating, Galvanizing, metal spraying and powder coating are performed. For each process collect information about the material, machines and other resources required. Also prepare list of industries in your state doing these
3. Manufacture any product like a small assembly of components which has been designed in the course Design of Machine Elements. Student will prepare the report on following.
   1. Prepare production drawings of the assembly and details.b Manufacture the parts.
   2. Note down work holding devices, cutting tools and cutting parameters used for each part and each operations. Summarize this in tabular form.
   3. On completion, present and share the experience of this mini project with photos/videos of mini project execution and with work distribution executed. Use power point presentation.
4. Produce job with various machining methods:
   1. Part should include plain/taper turning, knurling, threading, cylindrical/surface grinding, etc.
   2. Sketch the production drawing of the part.
   3. Outline the processes.
   4. Calculate/select, set, observe and record the cutting parameters for each process.
   5. List the cutting tools and measuring instrument like vernier caliper, micrometer or gauge if any you have used. Also state specifications of each.
   6. List the work holding devices you have used. Also state specifications of each.
   7. Produce the part
5. Produce a complex job:
   1. Part should include shaping, milling, drilling, tapping, boring, slotting, surface grinding, cylindrical grinding, super finishing like lapping, polishing etc.
   2. Select and sketch the production drawing of the part.
   3. Outline the processes. Prepare process plan for the same.
   4. Prepare workshop layout and route sheet.
   5. Produce the part, Calculate/select, set, observe and record the cutting parameters for each process.
   6. List the cutting tools you have used. Also state specifications of each.
   7. List the work holding devices you have used. Also state specifications of each.
6. Prepare a technical report on specifications, operating procedure, selection of operational parameters, details about tool/work holders used, machine setting, product details being manufactured for each method/machine like gear forming/generating, honing/lapping/buffing machine, Non-conventional machine, Jig boring machine, Broaching machine etc.
7. Visit a work shop which contains latest industrial Turret lathe, Capstan lathe, Single spindle automats, Automatic machines. Write a detail report on working of such machine or machines, parts produced, and other relevant information. Identify the jobs produced on such machines and draw the sketches of jobs.
8. Prepare a report on how to select parameters for machining Aluminum, Mild steel, Stainless steel and Inconel materials on CNC machine.
9. Comparative study of any two CNC turning centers or any two Vertical Machining centers and report the differences.
10. Comparative study of two different CNC systems for turning centers: Fanuc and Fagor using suitable virtual CNC machine simulator software.
11. Study and report 10 commonly used work piece materials and best grades of cutting tools that used to cut them efficiently.
12. Study machining process and reduce machining cycle time of parts from local CNC job shops.
13. Study of two different CNC systems for VMC: Siemens and MITSUBISHI M 70 with the help of CNC machine simulator software and furnish the report
14. Explore PROMI CNC programming manuals and watch PROFICNC on https://youtu.be/3ghwlpmhwpm to integrated CNC machine with multiple industry standard CNC controllers like FANUC, SIEMENS, FAGOR AND MITSUBISHI.

Suggested Learning Resources:

1. Manufacturing Science and Technology Rao, K Vara Prasada New Edge Publication, New Delhi, 2009, ISBN: 978-81-224-2759-2
2. Unconventional manufacturing processes Singh M.K. New Edge Publication, New Delhi, 2009, ISBN: 978-81-224-2244-3
3. A text book of Production Engineering Sharma P.C. S.Chand Publication, New Delhi 8th Edition 2012, ISBN 978812190116
4. Machine Tools Technology Kandasami G. S. Khanna Publishers, New Delhi, 2/e, 1989
5. Manufacturing ProcessesVol II Bawa H.S. McGraw Hill, New Delhi, ISBN – 0070583722
6. Fundamentals of Metal Machining and Machine Tools Knight W. A., Boothroyd Geoffrey McGraw-Hill Education, New Delhi, 2006, ISBN 1-57444-659-2
7. Production Technology HMT, Banglore McGraw-Hill Education, New Delhi, 2001, ISBN 13:978-0-07-96443-3
8. Advanced Machining Processes Jain V. K. Allied Publishers, Mumbai, 2009 ISBN 81-7764-294-4
9. CNC Machines. Pabla B.S., Adithan M. New Age International, New Delhi, 2014, ISBN: 9788122406696
10. Computer Numerical Control-Turning and Machining centres Quesada Robert Prentice Hall India, New Delhi, 2014 ISBN: 978-0130488671
11. CAD/CAM Sareen Kuldeep S. Chand, New Delhi, 2012 ISBN: 9788121928748
12. Introduction to NC/CNC Machines Vishal S. S.K. Kataria and Sons, New Delhi, 2010, ISBN: 978-8188458110
13. Computer Aided Manufacturing Rao P N, Tiwari N K, Kundra T Tata McGraw Hill, New Delhi, 2017 ISBN: 978-0074631034
14. CAD/CAM: computer aided design and manufacturing Groover Mikell P, Zimmered W Emory Prentice Hall, New Delhi, 2011 ISBN: 9780131101302

Software/Learning Websites:

For the complete Syllabus, results, class timetable, and many other features kindly download the iStudy App
It is a lightweight, easy to use, no images, and no pdfs platform to make students’s lives easier.
.

For detail Syllabus of all other subjects of Mechanical Engineering, I – scheme do visit Mechanical Engineering 5th Sem Syllabus for I – scheme.

For all Mechanical Engineering results, visit MSBTE Mechanical Engineering all semester results direct links.