ANNA UNIVERSITY : : 600 025 CURRICULUM 2005 - FULL TIME MODE (4 Semesters) M.E.

PRODUCT DESIGN AND DEVELOPMENT SEMESTER I Code No. Course Title THEORY MA1606 Probability and Statistical methods PD1601 Integrated Product and Process Development-I PD1602 Concepts and Computer Applications in Design PD1603 Product Engineering Tools PD1604 Metals and Manufacturing Processes E1*** Elective-I PRACTICAL PD1605 Digital Product Development Lab SEMESTER II Code No. Course Title THEORY PD1651 Integrated Product and Process Development-II PD1652 Quality in Design PD1653 Non-metals and Manufacturing processes PD1655 Finite Element Analysis E2*** Elective-II E3*** Elective-III PRACTICAL PD1654 Design Studio Lab SEMESTER III Code No. THEORY PD1701 E4*** E5*** PRACTICAL PD1751 Course Title Design Paradigm Elective IV Elective V Project Work Phase I SEMESTER IV Code No. Course Title PD1751 Project Wok - Phase II * As per the Regulations 2005. L 0 T 0 P 24 M * L 3 3 3 0 T 0 0 0 0 P 0 0 0 12 M 100 100 100 * L 3 3 3 3 3 3 0 T P 1 0 0 0 0 0 0 0 0 0 0 0 0 3 M 100 100 100 100 100 100 100 L 3 3 3 3 3 3 0 T P 1 1 0 0 0 0 0 0 0 0 0 0 0 3 M 100 100 100 100 100 100 100

ELECTIVES FOR PRODUCT DESIGN AND DEVELOPMENT

Course Code CD1622 CD1623 CD1651 CM1651 ED1651 IC1672 IE1721 PD1621 PD1671 PD1721

Course Title Rapid Prototyping and Tooling Tribology in Design Mechanical Vibration Robotics and Sensors Optimization Techniques in Design Computational Fluid Dynamics Enterprise Resource Planning Reverse Engineering Advanced Mechatronics Supply Chain Management

L 3 3 3 3 3 3 3 3 3 3

T 0 0 0 0 0 0 0 0 0 0

P 0 0 0 0 0 0 0 0 0 0

M 100 100 100 100 100 100 100 100 100 100

MA1606

PROBABILITY AND STATISTICAL METHODS

3 1 0 100

1.

PROBABILITY AND RANDOM VARIABLE

Probability Random variables Binomial, Poisson, Geometric, Uniform, Normal, Exponential distributions Moments Moment generating functions and their properties Functions of random variables. 2. ESTIMATION THEORY 9

Multiple and Partial correlations Partial and Multiple regression Estimation of Parameters using Maximum likelihood estimator and Method of moments. 3. TESTING OF HYPOTHESIS 9

Basic definitions of statistical hypothesis Tests based on Normal, t, chi-square, and F distributions for mean, variance and proportion. 4. DESIGN OF EXPERIMENTS 9

Analysis of variance One way and Two way classifications Completely Randomized Design Randomized Block Design Latin Square Design 22 Factorial Design. 5. MULTIVARIATE ANALYSIS 9

An overview of multivariate methods, multivariate normal distribution, Eigen values and Eigen vectors. L-45 T-T-15 REFERENCES 1. 2. 3. 4. Gupta, S.C. and Kapoor, V.K., Fundamentals of Mathematical Statistics, Sultan Chand and Sons, New Delhi, 2001. Johnson, R.J., Miller & Freunds Probability and Statistical for Engineers, 6th Edition, PHI, 2002. Jay, L.Devore, Probability and Statistics for Engineering and Sciences, Thomson and Duxbury, Singapore, 2002. Dallas E Johnson, Applied Multivariate methods for data analysis, Thomson and Duxbury Press, 1998. Total = 60

PD1601

INTEGRATED PRODUCT AND PROCESS DEVELOPMENT I 3 1 0 100

OBJECTIVE To study about the successful product development strategies, product planning activities, specifications, various methods for concept selection and architecture planning. 1. INTRODUCTION 9

Characteristics of Successful Product Development-Who Designs and Develops Products-Duration and Costs of Product Development- Challenges of Product Development -Development Processes and Organizations-A Generic Development Process-Concept Development: The Front-End Process Adapting the Genetic Product Development Process- Product Development Process Flows-The AMF Development Process-Product Development Organizations-The AMF Organization 2. PRODUCT PLANNING 9

Product Planning Process- Identify Opportunities- Evaluating and Prioritizing ProjectsAllocating Resources and Timing- Pre-Project Planning-Reflect on the Results and the Process-Identifying Customer Needs- Raw Data from Customers- Interpreting Raw Data in Terms of Customer Needs-Organizing the Needs into a Hierarchy-Establishing the Relative Importance of the Needs-Reflecting on the Results and the Process 3. PRODUCT SPECIFICATIONS 9

What Are Specifications -When Are Specifications Established-Establishing Target Specifications-Setting the Final Specifications-Concept Generation-The Activity of Concept Generation-Clarify the Problem- Search Externally-Search Internally-Explore Systematically- Reflect on the Results and the Process 4. CONCEPT SELECTION 9

Concept Selection- Overview of Methodology-Concept Screening-Concept TestingDefine the Purpose of the Concept Test- Choose a Survey Population- Choose a Survey Format- Communicate the Concept- Measure Customer Response-Interpret the ResultsReflect on the Results and the Process 5. PRODUCT ARCHITECTURE 9

Product Architecture-Implications of the Architecture-Establishing the ArchitectureDelayed Differentiation-Platform Planning-Related System-Level Design Issues L : 45 T : 15 Total : 45

TEXT BOOK 1. Product Design and Development, Karl T.Ulrich and Steven D.Eppinger, McGraw Hill International Edns.1999 REFERENCE: 1. Concurrent Engg./Integrated Product Development. Kemnneth Crow, DRM Associates, 26/3,Via Olivera, Palos Verdes, CA 90274(310) 377-569,Workshop Book 2. Effective Product Design and Development, Stephen Rosenthal, Business One Orwin, Homewood, 1992,ISBN, 1-55623-603-4 3. Tool Design Integrated Methods for successful Product Engineering, Stuart Pugh, Addison Wesley Publishing,Neyourk,NY,1991, ISBN 0-202-41639-5 4. www.me.mit/2.7444

PD1602 CONCEPTS AND COMPUTER APPLICATIONS IN DESIGN 3 0 0 100 OBJECTIVE: To study the fundamentals of strength of materials, design of mechanical components, various geometric transformations, modeling techniques, visual realism methods and CAD software capabilities 1. INTRODUCTION 7

Tensile, Compressive and Shear stresses - Theory of bending, torsion and stresses Biaxial state of stress- Principal stresses and Principal planes 2. COMPUTER AIDED DESIGN OF MACHINE COMPONENTS 8

Design of mechanical components - Theories of failure Factor of Safety Fatigue strength - Solving design problems for Shafts, Gears, Springs and Belts using Auto-LISP /C 3. INTRODUCTION TO COMPUTER GRAPHICS 10

Output primitives (line, circle etc.) Algorithms 2D and 3D transformations Translation, Scaling, Rotation and Reflection etc.- Windowing Clipping. 4. MODELING AND VISUAL REALISM 10

Representation of the curves Continuity Requirements - Wire frame Surface Solid modeling Hidden line Surface Solid algorithms 5. ASSEMBLY AND CAPABILITIES OF CAD SOFTWARE 10

Mechanical assembly of parts Animation of mechanisms

- Data Exchange Mass property calculations

TOTAL : 45 TEXT BOOK 1. William .M. Newman and Robert .F. Sproull " Principle of Computer Graphics ", McGraw Hill Book Co. Singapore ,1989. 2. Donald Hearn and .M. Pauline Baker " Computer Graphics " Prentice Hall , Inc., 1992 REFERENCES: 1 Mikell .P. Groover and Emory .W. Zimmers Jr. " CAD/CAM Computer -- Aided Design and Manafacturing" Prentice Hall ,Inc., 1995. 2. Ibrahim Zeid " CAD/CAM -- Theory and Practice " - McGraw Hill , International Edititon , 1998.

PD1603 AIM

PRODUCT ENGINEERING TOOLS

3 0 0 100

To study about the tools required for various design activities, improvement methodologies and quality control charts and other standards. 1. TOOLS FOR CONCEPT DEVELOPMENT 9

Products division, Quality function Deployment, concept engineering Tools for Design Development: design failure mode and design analysis, Reliability prediction- Tools for Design Optimization: The Taguchi Loss Function, Optimizing Reliability- Tools for Design Verification: Reliability Testing, Measurement system Evaluation, Process Capability Evaluation. 2. TOOLS FOR PROCESS IMPROVEMENT 9

Process improvement methodologies, The Deming Cycle-FADE-Basic tools for process improvement: flow charts, run charts and control charts, check sheets, histograms, Pareto diagrams, Cause and Effect Diagrams-Scatter Diagrams-Other tools for process improvement: Kaizen Blitz, Poka-yoke (mistake proofing), process simulation-Engaging the work force in process improvement. 3. STATISTICAL PROCESS CONTROL 9

Quality control measurements-SPC Methodology- Control charts for variables dataSpecial Control charts for variables data- Control Charts for Attributes- Summary of control charts construction chart, np-charts,c & u charts Designing control charts:sampling,size,frequency-SPC,ISO 9000:2000, AND SIX SIGMA-Pre control.

4.

BENCHMARKING AND ESTABLISHING ENGINEERING SPECIFICATIONS

Benchmarking Approach Support tools for the benchmarking process: indented assembly cost analysis, form diagram, trend analysis- Setting product specifications: Basic, Advanced method. 5. PROJECT MANAGEMENT 9

Understanding and representing tasks: Tasks, charts- Baseline project planning Accelerating projects-project execution- Postmortem execution. TOTAL -45

TEXT BOOK: 1. Product Design & Development, KARL T. ULRICH, STEVEN D. EPPINGER, TATA McGRAW-HILL- 3rd Edition, 2003

REFERENCES: 1. Product Design Techniques in Reverse Engineering and New Product Development, KEVIN OTTO & KRISTIN WOOD, Pearson Education (LPE), 2001. The Management and control of Quality-6th edition-James R. Evens, William M Lindsay Pub:son south-western(www.swlearning.com)

2.

PD1604

METALS AND MANUFACTURING PROCESS

3 0 0 100

AIM

To study about various types of materials, manufacturing methods, tolerances in an industry and various case studies for optimization
1.

INTRODUCTION

Factors for mechanical, electrical and thermal properties Dimensional geometrical tolerances selection of materials 2. TYPES OF MATERIALS 10

Ferrous Ferrous Alloys, steel, stainless steel, etc. Non-ferrous, Aluminum, Copper, etc. Non ferrous alloys, Brass, Gun Metal, etc. Material Cost Cost usage ratio 3. MANUFACTURING METHODS 12

Metal extrusion, metal stamping, fine blanking, four slide metal parts, cold headed parts, extruded parts, tube and section bends, rolled formed parts, power metal parts forging electro forming parts specialized forming methods, turned parts, machined round holes, drilled parts, milled parts, planned shaped and slotted parts, screw threaded contoured and internal ground parts, centerless ground, electrical discharged, roller furnished parts, electro chemical and advanced machined parts. Sand cast, die cast, investment cast and other cast products. HERF Process Machined components conventional, nonconventional 4. ASSEMBLY OF COMPONENTS 10

Press fitting riveting screwing flanged connections - welded parts electric arc gas welding brazing soldering advanced techniques PCB 5. CASE STUDIES 6

Design for minimum cost, material, and process Total : 45 REFERENCES: 1. Mechanical Metallurgy, G.E. Dieter, McGraw Hill, 1987 2. Heat Treatment of Metals, B. Zakharove, Peace Publications., 1962

PD1605

DIGITAL PRODUCT DEVELOPMENT LAB-I

0 0 3 100

CAD Introduction. Sketcher Solid modeling Extrude, Revolve, Sweep, etc and Variational sweep, Loft ,etc Surface modeling Extrude, Sweep, Trim ..etc and Mesh of curves, Free form etc Feature manipulation Copy, Edit, Pattern, Suppress, History operations etc. Assembly-Constraints, Exploded Views, Interference check Drafting-Layouts, Standard & Sectional Views, Detailing & Plotting. Total-45 hr Equipments required CAD work stations 10 Nos CAD 3D Modelling software with assembly, Mechanism simulation and drafting modules : 10 Nos

DIGITAL PRODUCT DEVELOPMENT LAB-II

0 0 3 100

CNC Machines Features, Tooling CNC program simulation in FANUC/SINUMERIC systems. CAD/CAM connection & DNC link. Cutter path generation for Planar machining, Surface Machining, Cavity machining, Fixed & variable contour machining, Drilling,Turning, tool&die and mould machining Practical in Production CNC Machining & Turning Centres and Rapid Prototyping Machine Post processing & CNC code Generation for advanced machining.

Equipments required CAM Software for tool path generation for planer machining, contour machining, drilling, turning etc. & post processing modulus for different CNC controllers Medium production type CNC turning center with popular industrial type controller Medium production type CNC machining center with popular industrial type controller

10 Nos