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Reliability-Engg.Pdf Category L T P Credit 14MERC0 RELIABILITY ENGINEERING PE 3 0 0 3 Preamble Reliability engineering is engineering that emphasizes dependability in the lifecycle management of a product. Dependability, or reliability, describes the ability of a system or component to function under stated conditions for a specified period of time. The students can able to identify and manage asset reliability risks that could adversely affect plant or business operations. Prerequisite 14ME310 - Statistical techniques Course Outcomes At the end of the course, the students will be able to: CO 1. Explain the basic concepts of Reliability Engineering and its Understand measures. CO 2. Predict the Reliability at system level using various models. Apply CO 3. Design the test plan to meet the reliability Requirements. Apply CO 4. Predict and estimate the reliability from failure data. Apply CO 5. Develop and implement a successful Reliability programme. Apply Mapping with Programme Outcomes COs PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 CO1. S S - S M - - - - - - - CO2. S S - S S - - - - - - M CO3. S S S S S - - - - - - M CO4. S S - S M - - - - - - M CO5. S S S S M - - - - - - M S- Strong; M-Medium; L-Low Assessment Pattern Continuous Assessment Tests Bloom‟s Category Terminal Examination 1 2 3 Remember 20 20 20 20 Understand 40 40 40 40 Apply 40 40 40 40 Analyse - - - - Evaluate - - - - Create - - - - Course Level Assessment Questions Course Outcome 1 (CO1): Write the concept of Reliability Define the term “Reliability management Explain the term “Bath Tub Curve Course Outcome 2 (CO2): State and explain the possible causes of low reliability of modern engineering systems Compare the availability of the following two unit systems with repair facilities: a)Series system with one repair facility, b)Series system with two repair facilities Passed in Board of Studies Meeting held on 26.11.2016 Approved in 53rd Academic Council Meeting held on 22.12.2016 B.E. Degree (Mechanical Engineering) - 2014-15 Course Outcome 3 (CO3): Calculate a) the expectation b)the second moment about the origin and c)the variance for the following probability distributions. X = 8 12 16 20 24 p(X) = 1/8 1/6 3/8 1/4 1/12 2. Draw Fault –tree diagrams for the systems shown in the following figures: a) b) A A B C B C Course Outcome 4 (CO4): What is failure data analysis What are the different techniques of risk analysis? How do you assess the design process in safety Course Outcome 5 (CO5): Explain the various risk measurement systems in modern industrial scenario Explain about various risk reduction resources in a chemical industry How the risk assessment will support the industrial safety. Concept Map Syllabus Introduction :Basic definitions: Reliability, Availability, Serviceability, Failure rate, ReliabilityMathematics, Failure distribution - constant failure rate model, Time dependent failure rate models and its types, Bath tub curve. case study or Videos on Human Reliability, Software Reliability. System Reliability: Reliability Block Diagram - Series, Parallel & combined series- parallelconfigurations; redundant-active and passive types, Failure Mode, Effects and Criticality Passed in Board of Studies Meeting held on 26.11.2016 Approved in 53rd Academic Council Meeting held on 22.12.2016 B.E. Degree (Mechanical Engineering) - 2014-15 Analysis (FMECA), Failure Reporting, Analysis and Corrective Action System (FRACAS), Fault Tree Analysis (FTA), System state analysis-Markov Model, Availability, Downtime. Reliability testing: Failures and types of failures; Intrinsic & extrinsic failures; Failurecascade; Failure mode; Failure rate, MTTF, MTBF, Accelerated life testing (ALT) - Qualitative ALT, Quantitative ALT & its types, AF, Samples Reliability estimation and life Prediction: Types of Failure data - Data censoring,Parametric and Non Parametric distribution, Probability density function, Exponential, Normal, lognormal &weibull distributions, weibull Goodness of fit distributions, Electronics reliability prediction-parts count, parts stress method, MIL standard, Naval Surface Warfare Center (NSWC). Reliability Management: Design for Reliability, Relationship between Reliability and safetyfactor, Stress-Strength interference theory, Reliability growth testing, Reliability centered maintenance (RCM), Spares planning. Text Book 1. Kailash C. Kapur, Michael Pecht, ReliabilityEngineering, John Wiley & Sons, 2014. Reference Books Srinath L.S, “Reliability Engineering”, Affiliated East-West Press Pvt Ltd, New Delhi, 1998. Modarres, “Reliability and Risk analysis”, Marshal Dekker Inc.1993. John Davidson, “The Reliability of Mechanical system” published by the Institution of Mechanical Engineers, London, 1988. Smith C.O. “Introduction to Reliability in Design”, McGraw Hill, London, 1976. Charles E. Ebeling, “An introduction to Reliability and Maintainability engineering”, TMH, 2004 Roy Billington and Ronald N. Allan, “Reliability Evaluation of Engineering Systems”, Springer, 2007. Handbook of Reliability Prediction Procedures for Mechanical Equipment Logistics Technology Support CARDEROCKDIV, NSWC-11 May 2011, West Bethesda, Maryland 20817-5700. Course Contents and Lecture Schedule Module Topic No. of Lectures No. 1 INTRODUCTION 1.1 Basic definitions: Reliability, Availability, 1 Serviceability, Failure rate 1.2 Reliability Mathematics, Failure distribution- 2 constant failure rate model 1.3 Time dependent failure rate models and its types, 1 Bath tub curve 1.4 Case study or videos on Human Reliability, 1 Software Reliability 2. SYSTEM RELIABILITY 2.1 RBD-Series, Parallel & combined series-parallel 2 configurations 2.2 Redundant-active and passive types 2 2.3 FMECA, FRACAS, Fault tree analysis (FTA), 1 System state analysis 2.4 Markov Model, Availability, Downtime 2 Passed in Board of Studies Meeting held on 26.11.2016 Approved in 53rd Academic Council Meeting held on 22.12.2016 B.E. Degree (Mechanical Engineering) - 2014-15 3 RELIABILITY TESTING 3.1 Failures and types of failures; Intrinsic & extrinsic 2 failures 3.2 Failure cascade; Failure mode; Failure rate, MTTF, 2 MTBF 3.3 Accelerated life testing (ALT) - Qualitative ALT 1 3.4 Quantitative ALT & its types, AF, Samples 2 4 RELIABILITY ESTIMATION AND LIFE PREDICTION 4.1 Types of Failure data - Data censoring 1 4.2 Parametric and Non Parametric distribution 2 4.3 Probability density function, Exponential, Normal, 2 lognormal &weibull distributions 4.4 Weibull Goodness of fit distributions 2 4.5 Electronics reliability prediction-parts count, parts 2 stress method 4.6 MIL standard, NSWC 1 5 RELIABILITY MANAGEMENT 5.1 Design for Reliability 2 5.2 Relationship between Reliability and safety factor 1 5.3 Stress-Strength interference theory 2 5.4 Reliability growth testing 1 5.5 RCM, Spares planning 1 TOTAL 36 Course Designers: 1. S. Karthikeyan [email protected] Accelerated Life Testing? Traditional life data analysis involves analyzing times-to-failure data obtained under normal operating conditions in order to quantify the life characteristics of a product, system or component. For many reasons, obtaining such life data (or times-to-failure data) may be very difficult or impossible. The reasons for this difficulty can include the long life times of today's products, the small time period between design and release, and the challenge of testing products that are used continuously under normal conditions. Given these difficulties and the need to observe failures of products to better understand their failure modes and life characteristics, reliability practitioners have attempted to devise methods to force these products to fail more quickly than they would under normal use conditions. In other words, they have attempted to accelerate their failures. Over the years, the phrase accelerated life testing has been used to describe all such practices. As we use the phrase in this reference, accelerated life testing involves the acceleration of failures with the single purpose of quantifying the life characteristics of the product at normal use conditions. More specifically, accelerated life testing can be divided into two areas: qualitative accelerated testing and quantitative accelerated life testing. In qualitative accelerated testing, the engineer is mostly interested in identifying failures and failure modes without attempting to make any predictions as to the product's life under normal use conditions. In quantitative accelerated life testing, the engineer is interested in predicting the life of the product (or more specifically, life characteristics such as MTTF, B(10) life, etc.) at normal use conditions, from data obtained in an accelerated life test. Qualitative vs. Quantitative Accelerated Tests Each type of test that has been called an accelerated test provides different information about the product and its failure mechanisms. These tests can be divided into two types: qualitative tests (HALT, HAST, torture tests, shake and bake tests, etc.) and quantitative accelerated life tests. This reference addresses and quantifies the models and procedures associated with quantitative accelerated life tests (QALT). Qualitative Accelerated Testing Qualitative tests are tests which yield failure information (or failure modes) only. They have been referred to by many names including: . Elephant tests . Torture tests . HALT (Highly accelerated life testing) . HAST (Highly accelerated stress test) . Shake & bake tests Qualitative tests are performed on small samples with the specimens subjected to a single severe level of stress,
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