INDUSTRIAL MATERIALS & METALLURGY
2nd Semester |
S. No. |
Course Code |
Subject |
L |
T |
P |
Credits |
|
1 |
MA 502 |
Advanced Mathematics |
4 |
0 |
0 |
4 |
|
2 |
MT 509 |
Advances in metal forming |
4 |
0 |
0 |
4 |
|
3 |
MA 505 |
Design of Experiments and Research Methodology |
4 |
0 |
0 |
4 |
|
4 |
|
Elective II |
4 |
0 |
0 |
4 |
|
| |
Elective II |
1 |
MT 510 |
Failure Analysis of Materials |
|
|
|
|
|
2 |
MT 511 |
Quality Control and Competence |
|
|
|
|
|
3 |
MT 512 |
Near Net Shape Processing |
|
|
|
|
|
4 |
MT 513 |
Automation and Control of Metallurgical Industry |
|
|
|
Course Name : ADVANCED MATHEMATICS (Special functions and PDE)
Course Code : MA 502
Credits : 4
L T P : 4 0 0
Lecture wise breakup No. of Lectures
SPECIAL FUNCTIONS (24)
Series solution of differential equations, Power series method, Legendre’s polynomial, generating functions, Recurrence relations
Frobenius method, Series solution of Bessel’s differential equation, Modified Bessel’s functions, generating functions, Recurrence relations
Equations reducible to Bessel’s equation
Sturm Liouville problem, orthogonal functions, orthogonality of eigen functions, eigen function expansions
Applications
PARTIAL DIFFERENTIAL EQUATIONS (21)
Solutions of 2nd order partial differential equations using D’Alembert’s method and Fourier series method.
Fourier Bessel series, Fourier Legendre series and Laplace transform methods.
Finite difference approximation to partial derivatives, methods for elliptic equations
Neumann and Mixed Boundary value problem, Methods for parabolic equations and hyperbolic equationsBOOK:1. Advanced Engineering Mathematics, Wylie and Barrett, Mc Graw Hill, 6th edition, 1995.REFERENCES1. Advanced Engineering Mathematics, Kreyszig, John Wiley and Sons, 8th edition, 2001.
2. Advanced Engg. Mathematics, Greenberg, Pearson Education Asia, 2nd edition, 2002
3. Elements of Partial differential equations, Sneddon, Mc Graw Hill, 1998.
Course Name : ADVANCES IN METAL FORMING
Course Code : MT 509
Credits : 4
L T P : 4 0 0Lecture wise breakup No of lectures
Rationale : The course is designed to give an overview of different types of mechanical processes used now a days. This course will make a student competent to undertake a suitable fabrication technique for the forming of the metal.
INTRODUCTION
Fundamentals of Metal Working, elements of the Theory of plasticity, mechanics of metal working, flow stress determination, temperature and strain rate effects in metal working.
Metallurgical structures, workability, experimental techniques for metal working processes, computer aided manufacturing.
MECHANICAL WORKING PROCESSES
Forging, rolling, drawing of rod, wires and tubes, extrusions and sheet metal forming.
MATHEMATICAL ANALYSIS
Mathematical analysis of forging, rolling drawing, extrusions processes.
ADVANCES IN MECHANICAL WORKING TECHNOLOGIES
Newer trends in rolling and forging. technology viz. isothermal forging, liquid forging, powder forging, stamp process etc. Superplastic forming, use of Electromagnetic and water hammer forces etc. Various duplex forming methods like cast weld construction and micro duplexing, slip casting etc
HIGH ENERGY RATE FORMING OPERATIONS
Explosive forming advanced of high-energy rate forming operations & its application in present day technology.
BOOK:
1. DIETER (1988) Mechanical Metallurgy
REFERENCES:
1. EDWARD MIELNIN (1991) Metal working science & Engineering Pub. University of Iowa.
Course Name : DESIGN OF EXPERIMENTS AND RESEARCH METHODOLOGY
Course Code : MA 505
Credits : 4
L T P : 4 0 0
Lecture wise breakup No. of Lectures
Basic principles of design of experiment, Error analysis in experiments.
(10)
Classification of experimental designs, Design and analysis of one factor experiments -Completely randomized and randomized complete block designs, Analysis of variance.
(8)
Estimation of parameters, Residual analysis and model checking, Sample size problem.
(5)
Design with two blocking variables, Latin squares, Analysis of data from a Latin square.
(2)
Experiment with two factors- Introduction, Main effects and interactions, Two-factor analysis of variance, Graphic analysis, Choice of sample size.
(6)
Design of Experiments with the help of orthogonal arrays, Taguchi’s Robust parameter design, Analysis, Noise factors, Tolerance on control factors.
(5)
Research Methodology – Nature and objective of research, Research topic, Literature review, Formulation of problem, Research design, Sampling techniques, Data collection, Statistical and sensitive analysis of data, Interpretation of result and report writing.
(10)BOOKProbability and Statistics for Engineers and scientists, Walpole, Myers, Myers and Ye, 7th ed, 2002, Pearson Education.REFERENCESStatistics in Research, Bernand Ostle and Richard N.Mensing 3rd ed, 1975, Oxford & IBH Pub Co.
Probability and Statistics in Engineering, Hines, Montgomery, Goldsman and Borror, 4th ed, 2003, John Wiley & Sons.
Experimental design, Theory & application, Federer, 1955, Oxford & IBH pub Co.
Course Name : FAILURE ANALYSIS OF MATERIALS
Course Code : MT 510
Credits : 4
L T P : 4 0 0Lecture wise breakup No of lectures
METAL FAILURE
basic reasons, various types.
BASIC PRINCIPLES OF METAL DEFORMATIONIntroduction to crystal geometry, Deformation, Basic models of deformation, Resolved shear stress, relations of slip to crystal structure, critical resolved shear stress.
FRACTURE IN METALSTypes of fracture, Theoretical cohesive shear strength, Griffith theory, objections to Griffith theory, Nucleation of crack – different models, Propagation of crack, effect of grain size on brittle fracture, intergranular brittle fracture, effect of inclusions, temp. on brittle fracture, fracture toughness.
TECHNIQUES OF FAILURE ANALYSISDestructive and Non-destructive Testing, Macro- examination, Microscopic examination, TEM, SEM,X-Ray diffraction techniques
FAILURE MODESFailure by fatigue, creep, fretting creep, oxidation impact, wear, corrosion, case studies.
TOTAL QUALITY MANAGEMENT
A strong link to failure analysis, Quality control concept, quality assurance.
BOOKS:
1. Metal Fracture - P.F. Temson, Paragon Press
2. Plastic Deformation & fracture of materials - H. Mugaraei, VCM Pub. Weinheim
3. Non destructive evaluation and quality assurance – Baldev Raj & sreenivasan, Interline Pub. Co. Bangalore.
4. Metals Hand Book - Testing of metals.
Course Name : QUALITY CONTROL AND COMPETENCE
Course Code : MT 511\
Credits : 4
L T P : 4 0 0Lecture wise breakup No of lectures
Rationale: The students should integrate their role of metallurgical production w.r.t. industrial quality requirements & the productivity + quality dependent state of industrial sustainability.
Basic Concepts in Quality Assurance & industrial Competence. Quality Assurance Terminologies & Technology, Definitions, Approaches and Important issues, Product & Process Quality Control Sampling, Statistical Quality Control, Acceptance Sampling Methods-Single, Multiple and Sequential Sampling Plans; Recent developments in inspection methods. Product Quality Control.
Quality Improvement. Improvement by process control, product and process design,.
Process Evaluation and Control by Control Charts, Designs of Experiment etc. Various control charts including CUSUM charts and Multivariate charts, Process Capability Studies. Various basic designs; Special Methods like EVOP, RSM and ROBUST Designs. Various indices, SPAN PLAN METHOD and use of Nomographs
Case studies in Offline and Online quality control.
Total Quality Management. Perspective, methodologies and procedures
Road map to TQM: Quality Function Deployment, ISO 9000, Quality Cost System, KAIZEN, Quality Circles, Quality Policy Deployment and Models for organizational excellence.
Reliability Engineering. Statistical analysis of life time data and determination of Reliability, Availability and Maintainability ; Development and Applications of Fault Tree Diagrams, Cause and Effect Diagrams, FMECA and FRACAS.
JIT, Total Productivity Maintenance, Robust processes and lean manufacturing
BOOK:
1. Mitra Amitava: Pearson Educational Publishers
REFERENCES:
- A.J. Duncan (1965), Quality Control and Industrial Statistics, Richard D.Irwin INC. USA.
- A.V. Feigenbaum (1987), Total Quality Control, McGraw Hill International Editions, USA.
- S.Halpern (1979), The Assurance Sciences, Prentice Hall India Ltd., New Delhi.
- A. Zaidi (1995), SPC: Concepts, Methodologies and Tools, Prentice Hall India Ltd., N. Delhi.
- D.C. Montogomery (1984), Design and Analysis of Experiments, John Wiley and Sons, USA.
- J. M. Juran (1988), Quality Control Handbook, McGraw Hill Book Company USA.
- W.E. Deming (1992), Out of Crisis
- Masaaki Imai (1991), KAIZEN: The key to Japan's Competitive Success, McGraw Hill International Editions , USA
Course Name : NEAR NET SHAPE PROCESSING
Course Code : MT 512
Credits : 4
L T P : 4 0 0Lecture wise breakup No of lectures
Near net shape processing : Injection molding, Lanxide process, Cold and Hot Isostatic pressing, Hot Pressing, Extrusion and Super plastic forming.
Near Net Shape Forging
Bulk and Sheet metal forming
Powdered Metal technique
Molten metal techniques
Manufacturing small section products such as strip, fibre, flake, wire directly from molten metal.
Spray rolling, the Taylor wire process, melt spinning, melt overflow, melt drag, melt extraction, double roll quenching, thin slab casting (belt drive) and laser glaze process. Mass and heat flow analysisCourse Name : AUTOMATION AND CONTROL OF METALLURGICAL INDUSTRY
Course Code : MT 513
Credits : 4
L T P : 4 0 0Lecture wise breakup No of lectures
Rationale: The current trend of automation in Metallurgical Industry imposes lot of responsibility on the new metallurgical engineers, to fit into industrial processes, and understand automation systems useful to them
Basics of Industrial automation. Benefits and competencies in metallurgical Industry. objectives of automation and control processes. Use of computers, numerical control methods, microprocessor controls, electrical controls, etc.
Measuring and control equipments and their automation. Thickness control, pressure control, stress control, heat and temperature control, atmosphere control etc. Instruments for measurement and indication, and automatic controls.
Regulation and control of temperatures in furnaces, PID controllers, Control of Feed rate in particulate systems and solid materials, reheating furnaces (rolling mills; walking beam, rocking hearth etc) Regulation and control of energy supply in furnaces. Control of thickness in rolling mills. Control of length, dia, dimensions of billets, pipes etc.
Sampling and automation of composition Control of liquid metal in metallurgical refining and alloy making. Drawing of samples; use of robotics. Control of silicon, carbon equivalent in cast iron production. End of pipe solutions in environment control in metallurgical industry.
Automation of metal pouring in foundries, press pour system etc. Simulation softwares for metal castings . Riser Designing & Solidification softwares.Control and development of net shaping methods. Softwares in welding operations.
CASE STUDIES: Automation and control in steel plants, Mini steel plants, Rolling Mills, Foundries, and Metal powder Production industries. Automation in welding Industries.
BOOKS:
1. NML Computer Applications in Metallurgy : National Metallurgical laboratory, jamshedpur.
2. Krishan kant ; Computer Based Industrial Control
3. Parmar: Welding Technology, Khanna Publishers
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