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(Product Design and Development)

S. No. Semester Name of Subject Compulsory (C)/ Elective (E) 1 I Semester Product Design and Development Materials and Manufacturing Technology Computer Aided Geometric Design Elective I Elective II 2 II semester Design for manufacturing and Assembly Product Interface Design Computer aided Product Design Project Elective-III 3. III Semester 4. IV Semester State-of-the-art Seminar Thesis Thesis ME 998 ME 999 ME 999 ME 924 ME 929 ME 930 ME 926 Subject Code Credit Dept. offering the subject ME 917 ME 918 ME 928 4 4 4 4 4 4 4 4 4 4 4 12 16 MED MED MED MED MED MED MED MED MED MED MED MED MED 4 4 4 4 4 4 4 4 4 4 0 0 0 0 0 0 0 0 0 0 Weekly load (hours L T P


FIRST SEMESTER ME-917: PRODUCT DESIGN AND DEVELOPMENT Introduction Significance of product design, product design and development process, sequential engineering design method, the challenges of product development, Product Planning and Project Selection: Identifying opportunities, evaluate and prioritize projects, allocation of resources Identifying Customer Needs: Interpret raw data in terms of customers need, organize needs in hierarchy and establish the relative importance of needs., Product Specifications: Establish target specifications, setting final specifications, Concept Generation: Activities of concept generation, clarifying problem, search both internally and externally, explore the output, Industrial Design: Assessing need for industrial design, industrial design process, management, assessing quality of industrial design, Concept Selection: Overview, concept screening and concept scoring, methods of selection. Theory of inventive problem solving (TRIZ): Fundamentals, methods and techniques, General Theory of Innovation and TRIZ, Value engineering Applications in Product development and design, Model-based technology for generating innovative ideas Concept Testing: Elements of testing: qualitative and quantitative methods including survey, measurement of customers response, Intellectual Property: Elements and outline, patenting procedures., claim procedure, Design for Environment: Impact, regulations from government, ISO system.,

Text books and references:

1. Ulrich K. T, and Eppinger S.D, Product Design and Development, Tata McGraw Hill 2. Otto K, and Wood K, Product Design, Pearson 3. Engineering of creativity: introduction to TRIZ methodology of inventive Problem Solving, By Semyon D. Savransky, CRC Press. 4. Inventive thinking through TRIZ: a practical guide, By Michael A. Orloff, Springer. 5. Systematic innovation: an introduction to TRIZ ; (theory of inventive Problem Solving), By John Terninko, Alla Zusman, CRC Press.

ME-918: MATERIALS AND MANUFACTURING TECHNOLOGY Scope and classification of Engineering Materials and Manufacturing Techniques. Types, properties and uses of Metals and Alloys, Manufacturing processes for shaping casting, deforming, sheet metal forming, particulate processing, machining, and finishing and joining. , Advanced methods of manufacturing: Abrasive jet cutting, Ultrasonic machining, Laser beam machining, Electron beam and electrochemical machining., Superalloys: Types, properties, uses and their processing techniques. Nickel-base, Cobalt- base and iron-base superalloys, remelting, Particulate processing, casting, machining, rolling, forging and welding of superalloys, Polymers: Classifications Plastics: Types, properties, uses and manufacturing processing techniques. Thermoplastics, Thermosets, and Elastomers, Composites: Types, properties, uses and manufacturing processing techniques. Metal matrix composites, polymer matrix composites, ceramic matrix composites, FGM., Glass: Types, properties, uses and shaping processes, Ceramics: Types, properties, uses and shaping processes, Property enhancing and surface processing operations: cleaning and surface treatments., Surface coating technology: Scope and classification of coating techniques. Electroplating (metal or composite coatings), Electroless plating (metal or composite coatings), Weld overlays (metal or ceramic coatings), Thermal spraying (metal, plastic, ceramic, or composite coatings), Cladding (thick metal coatings), Chemical vapor deposition (metals, graphite, diamond, diamond like carbon, and ceramics), Physical vapor deposition (metals, ceramics, or solid lubricants), Thermoreactive deposition/diffusion process (carbides, nitrides, or carbonitrides)., Recent development in materials and manufacturing technology., REFERENCES 1.Groover, M.P., Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Wiley Student Edition, John Wiley and Sons, 2005. 2.Budinski, K. G., (1998), Engineering Materials, Properties and Selection, Pub. Prentice-Hall of India, New Delhi, India. 3.Batchelor, A.W., Lam, L.N. and Chandrasekaran, M, Materials Degradation and its Control by Surface Engineering, 2nd Edition, Imperial College Press, 2003. 4.Bunshah, R. F., Handbook of Hard Coatings: Deposition Technologies, Properties and Applications, Noyes Pub. Park Ridge, New Jersey, U. S. A./William Andrew Publishing, LLC, Norwich, New York, U.S.A., 2001. 5.Sims, C. T., Stoloff, N. S., and Hagel, W.C., Superalloys II, John Wiley and Sons, 1987. 6.Callister W. D., Jr., Material Science and Engineering An Introduction, John Wiley & Sons, Inc., 6th Ed., 2003. 7.Patton, W.J., Plastic Technology, Theory, Design and Manufacture; Lenton Publishing Company. 8.Ashby, M.F., Materials Selection in Mechanical Design: Pergamon press, 1992.


Introduction: Design Methodology, Historical Development. Application of computers in Product Development and Design. Curve Modeling: Explicit and Implicit Equations, Intrinsic Equations, Parametric Equations, Coordinate Systems, Hermite curve, four point form, Straight lines. Splines , Bezier curves, B-spline curves, Bezier and B-Spline curve fit. Rational Polynomials, Introduction to NURBS. Surface Modeling: Sixteen point form, Algebraic and Geometric form, Tangent and Twist Vectors, Normal, Parametric space of a surface, Blending Functions, Four Curve Form, Plane surface, Cylindrical Surface, Ruled surface, Surfaces of Revolution. Introduction to Bezier Surface, B-Spline Surface and NURBS surface. Solid Modeling: Introduction to solid Modeling: CSG and B-Rrep schemes. Transformations: Translation, Rotation, Scaling Symmetry and Reflection, Homogeneous Transformations. Reverse Engineering: Place of Reverse Engineering in Product Development. Data Acquisition Methods, Practical Problems in data acquisition, Preprocessing: Registration, Segmentation, Triangulation, Definition, Surface Fitting Methods- Bezier, B-spline & NURBS, CAD model creation. Reference Books: 1. Mathematical Elements of Computer Graphics, Rogers and Adams, McGraw Hill. 1994 2. CAD CAM Theory and Practice: I. Zeid, Tata-McGraw Hill, 2006 3. Computer-Aided Design, R K Srivastava, Umesh Publications, Delhi, 2007, 3rd edition 4. Geometric Modeling: Michael E. Mortenson, John Wiley, 1992. 5. Computer-Aided Engineering Design, B Sahay and A Saxena, 2004. 6. Kathryn A. Ingle, Reverse Engineering, McGraw-Hill, 2004. 7. Vinesh Raja, Kiran J. Fernades, Reverse Engineering: An Industrial Perspective, Springer Verlag, 2006. ME 924: DESIGN FOR MANUFACTURING AND ASSEMBLY Introduction: Design philosophy steps in Design process General Design rules for manufacturability basic principles of design Ling for economical production creativity in design. Materials: Selection of Materials for design Developments in Material technology -- criteria for material selection Material selection interrelationship with process selection process selection charts. MACHINING PROCESS: Overview of various machining processes -- general design rules for machining - Dimensional tolerance and surface roughness Design for machining Ease Redesigning of components for machining ease with suitable examples. General design recommendations for machined parts.

METAL CASTING: Appraisal of various casting processes, selection of casting process, - general design considerations for casting casting tolerances use of solidification simulation in casting design product design rules for sand casting. METAL JOINING: Appraisal of various welding processes, Factors in design of weidments general design guidelines pre and post treatment of welds effects of thermal stresses in weld joints design of brazed joints. Forging Design factors for Forging Closed die forging design parting lines of die5 drop forging die design general design recommendations. Extrusion & Sheet Metal Work: Design guidelines for extruded sections - design principles for Punching, Blanking, Bending, Deep Drawing Keeler Goodman Forming Line Diagram Component Design for Blanking. ASSEMBLE ADVANTAGES: Development of the assemble process, choice of assemble method assemble advantages social effects of automation. AUTOMATIC ASSEMBLY TRANSFER SYSTEMS : Continuous transfer, intermittent transfer, indexing mechanisms, and operator - paced free transfer machine. DESIGN OF MANUAL ASSEMBLY: Design for assembly fits in the design process, general design guidelines for manual assembly, development of the systematic DFA methodology, assembly efficiency, classification system for manual handling, classification system for manual insertion and fastening, effect of part symmetry on handling time, effect of part thickness and size on handling time, effect of weight on handling time, parts requiring two hands for manipulation, effects of combinations of factors, effect of symmetry effect of chamfer design on insertion operations, estimation of insertion time. REFERENCE BOOKS: 1. Geoffrey Boothroyd, "Assembly Automation and Product Design", Marcel Dekker Inc., NY, 1992. 2. Engineering Design Material & Processing Approach George E. Deiter, McGraw Hill Intl. 2nd Ed. 2000. 3. Geoffrey Boothroyd, "Hand Book of Product Design" Marcel and Dekken, N.Y. 1990. 4. A Delbainbre "Computer Aided Assembly London, 1992.


Anthropometry Anthropometric measures, reporting and use of anthropometric data, design procedure. Workspace Design Postural triangle, design for standing operator, design for sitting operator, design for hand use, design for foot operation. Auditory Interface Process of hearing, auditory perception: pitch, loudness and timbre, digitization of sound. Tactile Interface and Haptic Interface

Physiology of touch, haptic interface, force-feedback technologies, interaction of touch and vision. Visual Interface Human eye, preattentive processing, detection, estimating magnitude, multiple attributes, design principles. Displays and Controls: Visual displays: display technologies, information coding, physical characteristics. Controls: control selection, identification. Combining displays and controls. Human Information Processing Human information processing model, information coding, improving performance. Graphic-user Interface Screen design and layout, user action and control, appropriate appearance. Hand Tool Design Ergonomically oriented hand tool design, safe design for hand tool. References : 1. Bailey, R. W., Human Performance Engineering: A guide for system designers, Prentie Hall. 2. Sanders, S. M. and McCormick, E. J., Human Factors in Engineering and Design, McGraw Hill. 3. Bridger, R. S., Introduction to Ergonomics, McGraw Hill. 4. Kroemer, K., Kroemer, H., and Kroemer-Elbert, K. E., Ergonomics - How to design for ease and efficiency, Prentice Hall. 5. Dix, A., Finlay, J., Abowd, G. D. and Beale, R., Human Computer Interaction, Pearson Education. ME 930: COMPUTER AIDED PRODUCT DESIGN Introduction: World Class manufacturing, Product definition, Engineering Design Process, Prototype Design and Innovation, Impact of Cost, Quality and time, Key Process Requirements for Rapid Prototyping. Product Prototyping, Prototype planning and management, Prototype cost estimation, Prototype Design Methods and tools. Materials Selection and Product Prototyping. Phases of Prototyping. Fundamentals of R.P. Classification of R.P. Processes. Rapid Prototyping Process: - Automated Processes, Difference between Additive and Subtractive Processes, Process Chain, steps in involved in R.P. Types of R.P. systems: - Liquid Based, Solid Based, & Powder Based. Application of R.P. in Manufacturing and Rapid Tooling. Rapid Prototyping and Manufacturing Benchmarking Modeling practice on softwares such as IDEAS, UNIGRAPHICS, ProE, etc.