ME687A

Modelling of Multiphysics Systems

Credits:

  

 

3L-0T-0L-0D (9 Credits)

 

 

Course Content:


Introduction and dimensional analysis and review of numerical method: Review on vector calculus, scalar/vector fields, linear algebra, notation system, Taylor series, numerical methods for simultaneous linear equations, first/second order ODE and PDE, dimensional analysis; Review and modelling of simple systems: Conservation laws of mass, momentum and energy, thermal transport (Fourier’s Law and Diffusion Equation), mass transport (Fick’s Law, diffusive and convective mass balance), definitions of displacement gradient, strain (Euler/Lagrange), stress (nominal, PK-1/2), momentum conservation, Generalized Hooke’s Law and Navier’s equation, plane stress/strain, continuity and Navier Stokes equations, steady and transient flow models, electrodynamics, Maxwell’s equations, electrochemical transport and kinetics, Butler Volmer and Tafel models, applied numerical problems for each physics; Modelling of coupled multiphysics systems: Thermal-elastic systems, gas-driven and thermal strain-driven actuating devices, Electrostatic-elastic systems, capacitive mass-spring and plate systems, stability analysis and bifurcation diagrams, Fluid-thermal systems, natural convection, Fluid-structural systems, Electrochemical-thermal-mechanical systems; Computational application of multiphysics problems: Numerical modelling of coupled systems in Matlab and COMSOL, one-way and two-ways coupling, dimensional analysis and problem simplification; Multiscale modelling: Introduction to molecular dynamics.

Lecture-wise Breakup (based on 50 min per lecture)

 

I. Introduction and dimensional analysis and review of numerical method (4 Lecture)

  • Introduction to Multiphysics systems; Review of vector calculus; Notation system (conventional/Einstein summation); Scaling and dimensional analysis; Review of numerical methods; Taylor series; 1st and 2nd order ODE; PDE – Euler method, Crank Nicholson; Basic model development in MATLAB. [4 Lecture]

II. Review and modelling of simple systems (15 Lectures)

  • Conservation laws and constitutive equations for thermal, mechanical, fluid, electrochemical and electromagnetic systems. Development of analytical solutions for transient thermal diffusion, deformation of membrane, string and plate; Revision of Navier Stokes, Nernst and Maxwell’s equations; PDE solutions using separation of variable, Green’s theorem, calculus of variations, etc.; Effect of scaling on modelling. [15 Lectures]

III. Modelling of coupled Multiphysics systems (15 Lectures)

  • Thermo-mechanical system – membranes, thermal actuators (bi-metallic), piezo; Fluid-thermal system; Electro/magneto-mechanical system – charged mass/spring, membranes/actuated-combs; Electrochemical-thermal-mechanical system – modelling energy storage devices, ion transport, surface kinetics, deposition dynamics, heat generation modes and thermal diffusion, diffusion-induced stresses. [15 Lectures]

IV. Computational application of Multiphysics problems (3 Lectures)

  • Development of simple Multiphysics models in MATLAB and COMSOL; Fragmentation and analysis of complex problems. [3 Lecture]

V. Multiscale modelling (5 Lectures)

  • Introduction to Multiscale modelling approaches; Project discussion. [5 Lectures]

References:

  1. Modeling MEMS and NEMS, Pelesko and Bernstein, Chapman & Hall/CRC.

  2. Partial Differential Equations: An Introduction, Walter A. Strauss, Wiley.

  3. Computational Partial Differential Equations Using MATLAB, Li and Chen, CRC.

  4. Multiphysics and Multiscale Modeling Techniques and Applications, Young W. Kwon, CRC.

  5. Multiphysics Modeling Numerical Methods and Engineering Applications, Zhang and Cen, Elsevier.

  6. Applied Mechanics of Solids, Allan F. Bower, CRC.

  7. A Compendium of Partial Differential Equation Models Method of Lines Analysis with Matlab, Schiesser and Griffiths, Cambridge.
 

ME659A

TRIBOLOGY OF MACHINING PROCESSES

Credits:

  

 

3L-0T-0L-0D (9 Credits)
 

Course contents:


Fundamentals of machining, Mechanics of metal cutting, Thermomechanical analysis, Chip formation, Basic tribo-interaction in machining, Governing factors at machining interfaces, Methods for predicting friction, Frictional regimes, Friction models, Special tribometry, Cutting tool wear, Wear modes and characterization, Wear models, Wear monitoring and control, Modern lubri-coolant methods, Sustainability aspects in machining, Influence of lubri-coolant method of machined surface integrity, Surface engineering, Development of modern cutting tools, Laser processing and coatings, Coating degradation mechanisms, Experimental techniques in machining, Wear map generation, Split tool, Quick stop method, Ballistic machining, Chip geometry control, Surface and sub-surface characterization, Formation and detection of adiabatic shear banding

Lecturewise Breakup (Based on 75 min per lecture)


I. Machining Science: A tribological perspective (6 Lectures)

  • Mechanics of metal cutting, Stresses and strains in machining, Thermal complexities, Thermomechanical modeling, Chip formation and its signature, Basic tribological interaction, Formation of machining tribo-pairs (macro and micro scale)

II. Friction in machining (6 Lectures)

  • Governing factors at various interfaces, Experimental methods and analytical techniques for predicting friction, Zorev’s friction model, Influence of machining parameters, Frictional regimes over tool rake/flank face/edge, Cutting edge and stagnation zone, Open and close tribometry tests

III. Cutting tool wear: Mechanism, characterization, and control (6 Lectures)

  • Types and mechanisms of tool wear, Edge dulling and wear, Plastic lowering of cutting edges, Machining parameters and Arrhenius wear equations, Basic and advanced methods for characterizing wear modes, Diffusion couple configurations, Material dependence on wear genesis and growth, Wear monitoring and control, Single and multi-sensor fusion-based wear monitoring

IV. Modern cooling and lubrication methods (5 Lectures)

  • Capillary zone and fluid penetration, Sustainability of machining processes, Cryogenic machining, MQL/nMQL/Cryo-MQL, Hybrid cooling and lubrication, High-pressure jet cooling, Vortex tube and air cooling, Machined surface and sub-surface damages

V. Surface engineering for effective machining (6 Lecture)

  • Surface finish, Edge finish, PCE and SCE finish, fracture roughness, Cutting tool manufacturing and related secondary operations, Hard and soft coatings, Coated tools (architecture and selection), Coating degradation mechanisms, Methods of surface structuring, Laser surface processing, Micro blasting, Mechanisms for improved machining tribology, Combinatorial approaches for improved cutting

VI. Experimental techniques in machining (6 Lectures)

  • Split tool method, Wear map criteria for cutting, Quick stop method, Inverse identification, High heat-high strain rate tests, Chip geometry/shape analysis and control, Ballistic machining and chip formation, White layer and microcrack formation (in chip and work), RS depth profiling, finished surface damage analysis, Detection of ASB in ferrous and non-ferrous alloys

VII. Demonstrations (5 Lectures)

  • R/R test on flank wear and its discussion, Surface structuring, Wettability and structured surfaces

References:

  1. Manufacturing Science, A. Ghosh, A.K. Mallik, Second Edition, EastWest Press, 2010, ISBN-978-8176710633

  2. Introduction to Tribology, H. Tennekes and J. L. Lumley, MIT Press

  3. Tribology: Friction and Wear of Engineering Materials, I. Hutchings, P. Shipway, Second Edition, Butterworth-Heinemann, 2017, ISBN: 978-0081009109

  4. Introduction to Machining Science, G.K. Lal, Third Edition, New Age International publishers, 2007, ISBN: 978-8122421040

  5. Fundamentals of Modern Manufacturing, M.P. Groover, Seventh Edition, Wiley, 2019, ISBN: 978-1119635697

Prepared by :


Sarvesh Mishra

 

 

ME645A

Solar Energy Technology

Credits:

  

 

 3L-0T-0L-0D (9 Credits)
 

Course Content:


Basic concepts, radiation spectrum, extraterrestrial radiation, sun earth relationship, Concept of time, terrestrial radiation, Diffuse and direct radiation, relationship between important angles, Angle of incidence on a tilted plane, shading, measurement of radiation, Radiation estimation on tilted plane, radiation augmentation, Flat plate collector, thermal analysis, Air heater, testing procedure, Single and double axes tracking, Parabolic trough collector, Compound parabolic concentrators, Basics of photovoltaic effect, Band bending, PN junction diode, bias, Light generated current, effect of temperature and intensity

Lecturewise Breakup (based on 50min per lecture):


I. Solar radiation and finding intensity on a tilted surface (12 Lectures)

Solar time and clock time, earth sun angles, observer specific angles, incidence angle on a general plane, sun path diagram, determination of shadow profile, wave spectrum of solar radiation, thermal and optical contribution, radiation exchange between surfaces, extraterrestrial radiation, atmospheric attenuation, Tracking of the sun, single axis tracking scenarios, Radiation on tilted surface


II. Flat Plate collectors (12 Lectures)

Useful heat gain, collector heat removal factor, temperature distribution along the fluid and the fin analysis in the cross direction, top and bottom loss coefficient, collector efficiency factor, collector flow factor, critical radiation level, different designs of the flat plate collectors, air heaters, evacuated tube collectors, stagnation temperature, single axis tracking modes


III. Photovoltaic systems (8 Lectures)

Semiconductors, intrinsic and extrinsic carrier concentrations, Fermi function, carrier motion, band bending, constancy of Fermi level across a P-N junction, continuity equation of carriers, space charge region, built-in potential, carrier concentration profile, forward and reverse bias, carrier injection, contribution of carriers in total current, dark I-V curve, solar generation, light generated current, maximum power point, cell efficiency, effect of radiation intensity and temperature


References:

  1. Solar Engineering of Thermal Processes, Duffie and Beckman, Fourth edition, 2013, Wiley Publication

  2. Solar Energy – principles of thermal collection and storage, SP Sukhatme, JK Nayak, third edition, 2008, McGraw Hill

  3. Solar photovoltaics – Fundamentals, technologies and applications, CS Solanki, third edition, 2015, Prentice Hall India Learning Pvt. Ltd

  4. Solar energy engineering – processes and systems, SA kalogirou, first edition, 2009, Academic Press

Prepared by :


Jishnu Bhattacharya
 

ME261

Primary Manufacturing Processes

Credits:

  

 

2L-0T-1P-0A (7 Credits)
 

Objectives


The main objective of this course is to acquaint students with various manufacturing processes such as casting, joining, bulk deformation and additive manufacturing. The course includes design aspects, mechanistic analysis and defects associated with these processes.

Course content


Introduction to primary manufacturing processes and properties of materials; Casting and solidification of alloys: Mechanism; Analysis of cooling curve; Runner and gating system design; Riser design; Joining processes: Fusion welding mechanism; Heat flow and material transfer 12 mechanism; Microstructure formation; Welding defects and inspection; Bulk deformation processes: Brief review of plastic deformation and yield criteria; Mechanistic analysis of Forging, Rolling, Drawing and Forming processes including defects; Additive manufacturing processes: Mechanistic analysis of polymers, metals and ceramics based additive manufacturing processes.

Total number of lectures: 28

Lecturewise breakup


1. Introduction and Manufacturing Properties of Materials : 1-2 Lectures

2. Casting : 6-8 Lectures

  • Overview of casting and solidification of alloys and its mechanism; Estimation of solidification time, analysis of cooling curve; Runner and gating system design; Riser design; Defects and their causes; Industrial casting processes; Crystal growth

3. Joining: 4-5 Lectures

  • Overview of joining process; Fusion welding mechanism; Heat flow and material transfer mechanism; Analysis of cooling curve; Microstructure formation; Welding defects and inspection; Industrial joining processes

4. Bulk Deformation: 7-8 Lectures

  • Overview of bulk deformation process; Brief review of plastic deformation and yield criteria; Mechanistic analysis of Forging, Rolling, Drawing and Forming processes including defects

5. Additive Manufacturing: 4-5 Lectures

  • Overview of additive manufacturing process; Mechanistic analysis of polymers, metals and ceramics based additive manufacturing processes

Recommended books

    1. Ghosh, A. Mallik, A.K. Manufacturing Science (2nd edition), EastWest Press

    2. Groover, M.P. Fundamentals of Modern Manufacturing (2nd edition), John Wiley

    3. Kalpakjian, S. Schmid, S.C. Manufacturing Engineering and Technology, Pearson Education

    4. Loper, C.R. Rosenthal, P.C. Heine, R.W., Principles of Metal Casting, McGraw Hill

    5. Little, R. Welding and Welding Technology, McGraw Hill

    6. Dieter, G.E. Mechanical Metallurgy, McGraw Hill

    7. Gibson, I. Rosen, D.W. Stucker, B. Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing, Springer

Proposing instructors: Dr. V. Kumar, Dr. S. Mishra, Dr. K. Ramani, Dr. U. Roy, Dr. S. Mukhopadhyay, Dr. M. Law, Dr. A. Kumar, Dr. N. Sinha, Dr. S. Bhattacharya