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AMIE Mechanical Engineering Syllabus ( Section B ) 2021
Design of Mechanical Systems
- The essential inputs to a design engineer. Stages in design. Creative and evolutionary design. Problem formulation. Preliminary design and analysis.
- Conceptual design : Alternative designs, feasibility analysis and design space, best design constraints, system integration, rational design.
- Design process and design cycle. Design morphology.
- Design data bases and design standards.
- Selection of materials and processes. Accuracy, surface finish, tolerances, statistical nature of loads, part dimensions. Probabilistic design, factor of safety.
- Detailed design of simple systems involving pressure vessels, fasteners, pins and welds.
- Optimal design of machine elements and systems. Minimum weight and minimum cost design rigidity and strength.
- Reliability of systems, failure rate and component life, MTBF, reliability considerations in design.
- Static and dynamic analysis of engineering systems involving shafts, linkages, couplers, transmission devices, toothed elements, etc.
Optimization – Theory and Applications
- Introduction to optimisation : Historical development. Engineering applications. Statement of an optimisation problem, classification and formulation of optimisation problems, optimisation techniques.
- Classical optimisation methods : Single variable optimisation, multivariable optimisation with and without constraints.
- Linear programming : Standard form of a linear programming problem ( LPP ), geometry of LPPs, related theorems, linear simultaneous equations, pivotal reduction, simplex method, revised simplex method, duality, decomposition, transportation and assignment problems.
- Nonlinear programming ( unconstrained ) : Uni – modal function, exhaustive search, bi – section and golden section methods, interpolation methods, random search methods, univariate method, gradient of a function, conjugate gradient, quasi – Newton and variable metric methods.
- Nonlinear programming ( constrained ) : Complex method* cutting plane method, method of feasible directions, transformation techniques, penalty function methods, convergence checks.
- Geometric programming : Introduction to geometric programming, polynomial, unconstrained and constrained problems..
- Dynamic programming : Introduction to dynamic programming, multistage decision processes, computational procedures, calculus and tabular methods.
Analysis and Synthesis of Mechanisms and Machines
- Mechanisms and machines, kinematic pair, elements, chains and inversions, degree of freedom, movability, Grubler’s criterion, four – link mechanisms, Grashof’s criteria.
- Kinematic analysis, instantaneous centres, Kennedy theorem, velocity analysis using velocity difference and instantaneous centres, acceleration analysis, velocity and acceleration images.
- Kinematic synthesis, graphical method using inversion and overlay, three – point synthesis problems, motion, path and function generation. Freudenstein’s method of three point synthesis of four link mechanisms.
- Dynamic force analysis of four – bar and slider crank mechanisms, turning moment and flywheel analysis.
- Types of governors, characteristics of centrifugal governors, stability control of speed hunting of governors.
- Balancing of rotating masses : Two balancing masses in two planes for complete dynamic balance. Determination of balancing masses, balancing of rotors, balancing of internal combustion engines, balancing of multicylinder inline engines, V – twin cylinder, multi – row W – engine and radial engine. Lanchester technique for balancing internal combustion engines with rotating eccentric weights.
Types of cam followers, selection of motion, displacement diagrams, cam profile determination.
- Gears and gear trains, fundamental law of gearing, involute tooth profile, undercutting and interference. Minimum number of teeth, types of gears, simple, compound and epicyclic gear trains.
- Gyroscopic action in machines, simle precession of a symmetrical rotating body.
Design of Machine Tools
- Conceptualisation of mechanical systems for prescribed scheme; Layout of machine tool elements; Introduction to machine tool drives and mechanisms; General principles of machine tool design.
- Design of drive systems; Regulation of speed and feed; Kinematic structure of machine tool gear box; Hydraulic, mechanical and electrical speed regulation.
- Design of machine tool structures : Material selection; Welded vs. cast structure; Static and dynamic stiffness; Choice of element sections and their design.
- Analysis of spindles, bearings, slides and guides.
- Control systems for machine tools.
- Dynamics of machine tools : Machine tools as a closed loop system. Dynamic stability.
- Forced vibration and chatter in machine tools.
- Concept of modular design; Concepts of aesthetic and ergonomics applied to machine tools.
- Acceptance tests and standardisation of machine tools.
Computer and Engineering Design
- Computer aided design of engineering systems. Applications in modelling, analysis, design and manufacturing.
- Computer graphics, raster graphics and interactiveness, pixels and graphic display in computers, windows and view – ports, lines and circles, graphic data storage and manipulation, hardware display, input and output devices.
- Geometric transformations – two, three – dimensional and homogeneous transformations, rotation, translation, mirror, perspective, projections, etc.
- Computer aided drafting. Introduction to Auto CAD – use of menus and icons, twodimensional drawings using auto CAD lines, circles, tangents, simple machine drawings, dimensioning, blocks and layers, editing and adding text to a drawing.
- Advanced auto CAD – three – dimensional drawings. Curves, surfaces and solid models, customizing. Auto CAD, auto LISP.
- Design of curves – PC, Beizer and B – spline curves, normal, tangent, curvature and torsion of curves. Blending of two curves.
- Design of surfaces, tangent and normal planes. Curvature and twist, surface patches – PC, Baizer and B – spline, ruled and developable surfaces, swept and revolved surfaces.
- Solid modeling – wire frame, constructive solid geometry ( CSG ) and boundary representation ( B – rep ); parametric instancing. Cell decomposition, spatial occupancy enumeration, generalized sweep.
- Mass property calculations – curve length, surface area, volume, centroid, mass, moment, etc.
- Finite element analysis : Fundamentals of finite element analysis; discretization, mesh generation, pre and post processing and simple applications.
- Deformation of metals, stress – strain curves, temperature and strain rate effects, ductility and toughness, plane – strain deformation, mechanism of plastic deformation, control of material properties – alloying and heat treatment.
- Sand casting : Pattern materials and allowances, moulding materials, properties ol moulding sand, effects of moulding ingredients on mould properties, estimation of pouring time, mechanism of solidification, rate of solidification in an insulating mould, riser design and placement, residual stresses.
- Elements of plasticity – yield criteria and flow rule, plastic instability. Analysis of forming processes – forging, rolling, extrusion, wire and strip drawing, using slab method, deep drawing, blanking and piercing. Lubrication and friction in metal forming.
- Metal cutting : Mechanics of orthogonal cutting, chip formation in turning, shaping, planning, milling and drilling, evaluation of surface roughness in machining, heat generation, estimation of average tool temperature, tool wear mechanism and tool life testing, variables affecting tool life machining economics – estimation of cost and optimum cutting conditions.
- Metal grinding : Basic mechanics of grinding process, forces and specific energy, grinding temperature – heat sources and estimation of average temperature, wheel wear mechanism, estimation of surface roughness.
- Non – conventional machining : Classification of processes, mechanism of material removal and effects of process parameters in AJM, USM, ECM, EDM, LBM, EBM and PAM.
- Welding and allied processes : Bonding process in welding, principles of solid – state welding, fusion welding, soldering and brazing, effects of process parameters, metallurgy of welding stress distribution and heat affected zone.
Computer Aided Manufacturing
- Basic definitions of manufacturing systems : Definitions, design, planning and control.
- Part design and CAD : Engineering design, design drafting and its interpretation, inspection and measurement. A brief history of CAD, CAD hardware and software. Fundamentals of geometric modeling. CAD data exchange.
- Process engineering : Experience – based planning, process capability analysis, basic machining and other manufacturing process calculations, process optimisation.
- Hard automation : Introduction to automated manufacturing, fixed automated manufacturing systems, workpiece handling hardware for automation and economics of automation.
- Programmable logic controllers : Function of controllers, control devices, programmable logic controllers.
- Data communication and local area networks in manufacturing : Fundamentals of data communication and local area networks.
- Fundamentals of numerical control : Historical developments and principles of NC, classification of NC, NC part programming, manual and computer – assisted part programming.
- Introduction to industrial robots : Power sources, actuators and transducers. Robot applications. Economic considerations of robotic systems.
- Group technology : Introduction, coding and classification, benefits of group technology.
- Process planning : Introduction, manual process planning, computer aided process planning, variant and generative approaches, simple examples.
Tool and Die Design
- Influence of tools and dies on quality, productivity and environment, tool design methods and procedures, tool making practices, tooling materials and treatment.
- Jigs and fixtures. Basic principles of locating and clamping, development of fixture using locating, clamping, indexing tool setting elements, force analysis, standardisation of elements, illustrative examples of machining, welding, assembly and inspection fixtures.
- Design of cutting tools and special tools ( form cutters and broachers ), tooling for CNC, introduction to modular fixtures and tools.
- Die design : Design of sheet metal blanking, piercing, bending and deep drawing dies. Progressive die design.
- Mould design : Introduction to die casting and injection mould design. General mould construction. Design of ejection, feed and cooling systems. Parting surface design. Side cores and side cavities. Product design for die casting and injection molding.
- Cost estimation and cost benefit analysis.
- Definition of automation, reasons for automating, pros and cons of automation.
- Fundamentals of manufacturing and automation : Manufacturing operations and automation strategies, production economics.
- High volume production systems : Detroit type automation, analysis of automated flow lines, assembly and line balancing, automated assembly systems.
- Numerical control production systems : CNC, DNC and adaptive control.
- Industrial robots : Robotics technology, robot applications.
- Material handling and storage : Automated materials handling, automated storage and retrieval systems.
- Flexible manufacturing systems ( FMS ) : FMS workstations, material handling and storage systems, computer control systems, planning the FMS, analysis methods for FMS, applications and benefits.
- Automated inspection and testing : Inspection and testing, statistical quality control, automated inspection principles and methods, sensor technologies for automated inspection, coordinate measuring machines, other contact inspection methods, machine vision and other optical inspection methods, and non – contact inspection methods.
- Introduction : Concept of management, concept of a system, production system, production functions.
- Organisation fundamentals : Guidelines for good practice, organisation structures, organisation charts, span of control, number of levels, number of executives, management functions.
- Production economics : Kinds of costs, evaluation of capital investments. Capital budgeting, break – even analysis, make or buy decisions, evaluation of alternatives, discounted cash flow, equivalent comparison methods, depreciation.
- Aggregate planning : Planning time horizons, inputs to aggregate planning systems, single and multistage aggregate planning systems, decision processes for aggregate planning – graphical method, linear decision rule, and linear programming method – Demand management. Time span for forecasts, forecasting system, forecasting methods – time series, casual and predictive forecasting methods, selection of a forecasting method.
- Scheduling : Scheduling process scheduling for a multistage production system, sequencing production operations, Johnson’s rule.
- Facilities management : Plant location – factors influencing plant location, cost factors, plant location decision process, selection of a location for new facilities, evaluation of alternative regions and sub – regions. Plant layout – objectives, decision process, types of layouts, comparison of layouts. Line balancing and sequence analysis concepts. Materials handlingdevices
for materials handling, basic considerations in the selection of materials handling system.
- Human factor engineering : Methods analysis and works measurement, methods study, process analysis, operation process chart, operator process chart, motion study, principles of motion economy, motion analysis. Time study – types of studies, procedure for job time study, physical environment.
- Quality management : Three aspects of quality, functional responsibility for quality in a manufacturing system, economics of quality assurance, quality control, QC decision variables, process control, control charts, acceptance sampling, single, double and sequential sampling plans, concept of total quality control ( TQC ).
- Maintenance management : Maintenance functions, concept of reliability engineering, reliability improvement, preventive maintenance, preventive maintenance policy, repair policy, replacement decisions, queuing theory and its applications in maintenance.
- Introduction to PERT / CPM.
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