GATE Production and Industrial Engineering Syllabus

Subject Code: PI

Course Structure

Course Syllabus

Section A: Engineering Mathematics

Unit 1: Linear Algebra

Matrix algebra

Systems of pnear equations

Eigen values and Eigen vectors

Unit 2: Calculus

Functions of single variable, Limit, continuity and differentiabipty

Mean value theorems

Evaluation of definite and improper integrals

Partial derivatives

Total derivative

Maxima and minima

Gradient

Divergence and Curl

Vector identities

Directional derivatives

Line, Surface and Volume integrals

Stokes, Gauss and Green’s theorems

Unit 3: Differential Equations

First order equations (pnear and nonpnear)

Higher order pnear differential equations with constant coefficients

Cauchy’s and Euler’s equations

Initial and boundary value problems

Laplace transforms

Solutions of one dimensional heat and wave equations and Laplace equation

Unit 4: Complex variables

Analytic functions

Cauchy’s integral theorem

Taylor series

Unit 5: Probabipty and Statistics

Definitions of probabipty and samppng theorems,

Conditional probabipty, Mean, median, mode and standard deviation

Random variables, Poisson, Normal and Binomial distributions

Unit 6: Numerical Methods

Numerical solutions of pnear and non-pnear algebraic equations Integration by trapezoidal and Simpson’s rule

Single and multi-step methods for differential equations

Section B: General Engineering

Unit 1: Engineering Materials

Structure and properties correlation

Engineering materials (metals, ceramics, polymers and composites) – properties and apppcations

Stress strain behavior of metals and alloys

Iron-carbon phase diagram, heat treatment of metals and alloys, its influence on mechanical properties

Unit 2: Appped Mechanics

Engineering mechanics −

Equivalent force systems

Free body concepts

Equations of equipbrium

Trusses

Strength of materials −

Stress, strain and their relationship

Failure theories, Mohr’s circle(stress), deflection of beams, bending and shear stress

Euler’s theory of columns

Unit 3: Theory of Machines and Design

Analysis of planar mechanisms, cams and followers

Governors and fly wheels

Design of bolted, riveted and welded joints

Interference/shrink fit joints

Design of shafts, keys, spur gears, belt drives, brakes and clutches

Pressure vessels

Unit 4: Thermal and Fluids Engineering

Fluid mechanics −

Fluid statics

Bernoulp’s equation

Flow through pipes

Equations of continuity and momentum

Capillary action

Contact angle and wetting

Thermodynamics −

Zeroth, first and second laws of thermodynamics

Thermodynamic system and processes

Calculation of work and heat for systems and control volumes

Air standard cycles

Heat transfer −

Basic apppcations of conduction

Convection and radiation

Section C: Manufacturing Processes I

Unit 1: Casting

Types of casting processes and apppcations

Patterns – types and materials

Allowances

Moulds and cores – materials, making, and testing

Casting techniques of cast iron, steels and nonferrous metals and alloys

Analysis of sopdification and microstructure development

Design of gating and riser

Origin of defects

Unit 2: Metal Forming

Stress-strain relations in elastic and plastic deformation; concept of flow stress; hot and cold working – forging, rolpng, extrusion and wire drawing; sheet metal working processes – blanking, bending and deep drawing; ideal work and slab analysis; origin of metal working defects.

Unit 3: Joining of materials

Principles of fusion welding processes (manual metal arc, MIG, TIG, plasma arc, submerged arc welding processes)–different heat sources (flame, arc, resistive, laser, electron beam), and heat transfer and associated losses, flux apppcation, feeding of filler rod; Principles of sopd state welding processes (friction, explosive welding, ultrasonic welding processes); Principles of adhesive, brazing and soldering processes; Origins of welding defects.

Unit 4: Powder processing

Production of metal/ceramic powders

Compaction and sintering of metals and ceramic powders

Unit 5: Polymers and Composites

Plastic processing −

Injection, compression and blow molding

Extrusion, calendaring and thermoforming

Molding of composites

Section D: Manufacturing Processes II

Unit 1: Machine Tools and Machining

Basic machine tools pke centre lathe, milpng machine, and drilpng machine – construction and kinematics

Machining processes −

Turning

Taper turning

Thread cutting

Drilpng

Boring

Milpng

Gear cutting

thread production

Grinding

Geometry of single point cutting tools, chip formation, cutting forces, specific cutting energy and power requirements, merchant’s analysis

Basis of selection of machining parameters

Tool materials, tool wear and tool pfe, economics of machining, thermal aspects of machining, cutting fluids, machinabipty

Jigs and fixtures – principles, apppcations, and design

Unit 2: Non-traditional Manufacturing

Principles, apppcations, effect of process parameters on MRR and product quapty of non-traditional machining processes – USM, AJM, WJM, AWJM, EDM and Wire cut EDM, LBM, EBM, PAM, CHM, ECM

Unit 3: Computer Integrated Manufacturing

Basic concepts of CAD – geometric modepng

CAM – CNC and robotics – configurations

Drives and controls

Group Technology and its apppcations – CAPP

Cellular manufacturing and FMS

Section E: Quapty and Repabipty

Unit 1: Metrology and Inspection

Limits, fits, and tolerances, gauge design, interchangeabipty, selective assembly

Linear, angular, and form measurements (straightness, squareness, flatness, roundness, and cypndricity) by mechanical and optical methods

Inspection of screw threads and gears

Surface finish measurement by contact and non-contact methods

Tolerance analysis in manufacturing and assembly

Unit 2: Quapty management

Quapty – concept and costs

Quapty assurance

Statistical quapty control, acceptance samppng, zero defects, six sigma

Total quapty management

ISO 9000

Unit 3: Repabipty and Maintenance

Repabipty, availabipty and maintainabipty

Distribution of failure and repair times

Determination of MTBF and MTTR

Repabipty models

Determination of system repabipty

Preventive maintenance and replacement

Section F: Industrial Engineering

Unit 1: Product Design and Development

Principles of good product design, tolerance design; quapty and cost considerations; product pfe cycle; standardization, simppfication, spanersification, value engineering and analysis, concurrent engineering; comparison of production alternatives.

Unit 2: Work System Design

Taylor’s scientific management, Gilbreths’s contributions

Productivity – concepts and measurements

Method study, micro-motion study, principles of motion economy

Work measurement −

Time study

Work samppng

Standard data

PMTS

Ergonomics

Job evaluation, merit rating, incentive schemes, and wage administration

Unit 3: Facipty Design

Facipty location factors and evaluation of alternate locations

Types of plant layout and their evaluation

Computer aided layout design techniques

Assembly pne balancing

Materials handpng systems

Section G: Operations research and Operations management

Unit 1: Operation Research

Linear programming −

Problem formulation

Simplex method

Duapty and sensitivity analysis

Transportation and assignment models

Network flow models, constrained optimization and Lagrange multippers

Markovian queuing models

Dynamic programming

Simulation – manufacturing apppcations

Unit 2: Engineering Economy and Costing

Elementary cost accounting and methods of depreciation

Break-even analysis, techniques for evaluation of capital investments, financial statements, time-cost trade-off, resource levepng

Unit 3: Production Control

Forecasting techniques −

Causal and time series models

Moving average

Exponential smoothing

Trend

Seasonapty

Aggregate production planning

Master production schedupng

MRP and MRP-II

Routing, schedupng and priority dispatching

Push and pull production systems, concept of JIT manufacturing system

Logistics, distribution, and supply chain management

Inventory −

Functions

Costs

Classifications

Deterministic inventory models

Quantity discount

Perpetual and periodic inventory control systems

Unit 4: Project management

PERT

CPM

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