1. FOUNDATION COURSE - nptc.ac.in · Introduction – classification of belt drives – flat belt, V belt and rope drives – open and crossed belt drives – belt materials – merits

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1. FOUNDATION COURSE

Course Code Course Name Credits

0101 English – I 3

0102 Basics of Computer Science – I 4

0103 Mathematics – I 7

0104 Applied Physics – I 3

0105 Applied Chemistry – I 3

0106 Technical Drawing – I 4

0107 Applied Physics Practical – I 1

0108 Applied Chemistry Practical – I 1

0109 Applied Chemistry Practical – I 1.5

0110 English Communication Practical – I 1

0111 English – II 3

0112 Basics of Computer Science – II 4

0113 Mathematics – II 7

0114 Applied Physics – II 3

0115 Applied Chemistry – II 3

0116 Technical Drawing – II 4

0117 Applied Physics Practical – II 1

0118 Applied Chemistry Practical – II 1

0119 Workshop practice – II 1.5

0120 English Communication Practical - II 1

Total Credits 57

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2. CORE COURSES


2201 Mechanics Of Materials 62202 Manufacturing Processes 52203 Fluid Mechanics & Fluid Power 6

2204 Machine Drawing 42205 Mechanics Of Materials & Fluid 3

Mechanics Lab2206 WorkShop -1(Foundary, Welding & Smithy) 3

2207 Applied Thermodynamics 72208 Machine Shop Technology 72209 Electrical & Electronics Engineering 62210 Thermodynamics Lab 32211 Electrical &Electronics Engineering Lab 1.5

2212 Workshoop - II(Lathe & metrology) 3

Total Credit 54.5

3. APPLIED COURSES


2301 Design of Machine Elements 62302 Thermal Engineering 62303 Auto CAD Lab 3

2304 Workshop - II (Special Machines) 32305 Industrial Engineering & Management 72306 CAD / CAM 72307 CAD / CAM LAB 32308 Project Work, Enterpreneurship &

Personal Skills. 1.5

Total Credit 36.5

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4. APPLIED COURSE


CREDIT ABSTRACT

S.No. Course Credits Percentage

2401 Diversified Course - I 5A - Automobile TechnologyB - Metrology & Machine Tool Testing

2402 Diversified Course Lab - I 3A - Automobile TechnologyB - Metrology & Machine Tool Testing

2403 Diversified Course - II 6A - Refrigeration & Air ConditioningB - Mechatronics

2404 Diversified Course Lab - II 3A - Refrigeration & Air ConditioningB - Mechatronics

Total Credit 17

1 FoundationCourses 57.0 34.50

2 Core Course 54.5 33.003 Applied Courses 36.5 22.204 Diversified Courses 17.0 10.30

Total 165.0 100.0

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CURRICULUM AND SCHEME OF EXAMINATIONDIPLOMA IN MECHANICAL ENGINEERING

III TERM

Total 35 27 150 450 600 18

Code No Course Name Hrs /Week Internal External Total

Credit

Scheme of ExaminationAllocation marks

Dura-tionof

exam

IV TERM


Credit


Dura-tionof

exam

Total 35 27.5 150 450 600 18

2201 Mechanics of Materials 6 6 25 75 100 32202 Manufacturing Processes 5 5 25 75 100 32203 Fluid Mechanics & Fluid Power 6 6 25 75 100 32204 Machine Drawing 6 4 25 75 100 3

2205 Mechanics of Materials & FluidMechanics Lab 6 3 25 75 100 3

2206 Workshop - I(Foundry, Welding & Smithy) 6 3 25 75 100 3

2207 Applied Thermodynamics 7 7 25 75 100 32208 Machine Shop Technology 7 7 25 75 100 32209 Electrical &Electronics Engineering 6 6 25 75 100 3

2210 Thermodynamics Lab 6 3 25 75 100 32211 Electrical & Electronics-

Engineering Lab 3 1.5 25 75 100 32212 Workshop - II

(Lathe &Metrology) 6 3 25 75 100 3

5

CURRICULUM AND SCHEME OF EXAMINATIONDIPLOMA IN MECHANICAL ENGINEERING

V TERM

DIVERSIFIED COURSE - I DIVERSIFIED COURSE LABORATORY-I

VI TERM


Credit


Dura-tionof

exam

DIVERSIFIED COURSE - I I DIVERSIFIED COURSE LABORATORY - I I

Total 35 27.5 150 450 600 18

Code No Course Name Hrs /Internal External Total

CreditScheme of Examination Dura-

tionof

Total 35 26 150 450 600 18

2301 Design of Machine Elements 6 6 25 75 100 3

2302 Thermal Engineering 6 6 25 75 100 3

2401 Diversified Course - 1 5 5 25 75 100 3

2303 Auto CAD Lab 6 3 25 75 100 3

2402 Diversified Course Lab -1 6 3 25 75 100 3

2304 Workshop - III(Special Machines) 6 3 25 75 100 3

2401 A - Automobile Technology 2402 A - Automobile Technology Lab2401 B - Metrology & Machine Tool Testing 2402 B -Metrology & Machine Tool

Testing Lab

2403 A - Refrigeration & Air Conditioning 2404 A - Refrigeration & AirConditioning Lab

2403 B - Mechatronics 2404 B - Mechatronics Lab

2305 Industrial Engineering & Management 7 7 25 75 100 32306 CAD / CAM 7 7 25 75 100 3

2403 Diversified Course - II 6 6 25 75 100 3

2307 CAD / CAM Lab 6 3 25 75 100 3

2404 Diversified Course Lab - II 6 3 25 75 100 3

2308 Project Work, Enterpreneurship& Personal Skills 3 1.5 25 75 100 3

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2201 MECHANICS OF MATERIALS

III - TERM (Core Course)

6 Hours / Week Total Hours - 72 Hrs

MAJOR DIVISIONS:

UNIT I a) Mechanical Properties of Materials

b) Simple Stresses and strains

UNIT II a) Geometrical Properties of Sections

b) Thin Cylinders and Spherical Shells

UNIT III a) Shear Force and Bending Moment Diagram

b) Theory of Simple Bending & Deflection of Beams

UNIT IV a) Torsion

b) Springs

UNIT V a) Friction

b) Transmission of Motion

UNIT I

a) MECHANICAL PROPERTIES OF MATERIALS (15 Hrs)

Importance of mechanical properties of materials- definition and briefexplanation of mechanical properties – strength, elasticity, plasticity, ductility,malleability, stiffness, toughness, brittleness, hardness, wear resistance, machinability, castabilityand weldability – fatigue strength, creep – mechanical and temperature creep – cyclic loadingand repeated loading.

b) SIMPLE STRESSES AND STRAINS

Introduction - behaviour of materials when subjected to load - definition – stressand strain – classification of force system – tensile, compressive, shear, bending and torsionalforce system – behaviour of metals in tension upto rupture – stress – strain diagram – limit ofproportionality – elastic limit – yield point – breaking point – ultimate stress – percentageelongation and percentage reduction in area – problems – Hooke’s law – Young’s modulus –working stress – factor of safety – bars of varying section – shear stress and shear strain –modulus of rigidity – problems in tension and compression.

Lateral strain – Poisson’s ratio – volumetric strain – bulk modulus – elastic con-stants and their relationship – problems connecting lateral, linear and volumetric deformation– problems on elastic constants.

Composite bars subjected to tension and compression - temperature stress and strain– problems–no problems in temperature stresses for composite bars - strain energy due toaxial load – proof resilience – modulus of resilience – stresses due to gradual, sudden andimpact loads –problems computing stress and deformation in gradual, sudden, impact andshock loading.

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UNIT II

a) GEOMETRICAL PROPERTIES OF SECTIONS : (15Hrs)

Introduction - centre of gravity – centroid – position of centroids of plane geometri-cal figures such as rectangle, triangle, circle and trapezium – determination of centroid ofangles, channels, I and T sections – problems – moment of inertia – definition – parallel axestheorem – perpendicular axes theorem - M.I of laminae of rectangle, circle, triangle, angle,channel, I and T sections - no derivations required – polar moment of inertia – radius ofgyration – problems.

b) THIN CYLINDERS AND SPHERICAL SHELLS

Introduction to thin and thick cylindrical shells – failure of thin cylindrical shellsubjected to internal pressure – derivation of Hoop stress and longitudinal stress – maximumshear stress- problems – change in dimensions and volume of a thin cylindrical shell due tointernal pressure – problems – change in diameter and volume of a thin spherical shell due tointernal pressure – problems.

UNIT III

a) SHEAR FORCE AND BENDING MOMENT DIAGRAMS: (18Hrs)

Introduction – classification of beams – definition - shear force - bending moment –sign convention – types of loads – relation between load, shear force and bending moment –S.F.D and B.M.D of cantilever and SSB subjected to concentrated load and UDL only –maximum Bending moment - problems on S.F.D and B.M.D for cantilever and S.S.B only.

b) THEORY OF SIMPLE BENDING AND DEFLECTION OF BEAMS

Introduction – theory of simple bending – assumptions – neutral axis - bendingstress distribution – moment of resistance – derivation of flexural formula M/I = f/y = E/R –section modulus – strength and stiffness of beam – problems involving bending equation only.

Deflection – definition of slope and deflection – relation between curvature, slopeand deflection – deflection and slope of cantilever and S.S.B under point loads and udl –double integration method - problems on slope and deflection.

UNIT IV

a) TORSION (10Hrs)

Introduction- theory of torsion and assumptions - derivation of torsion equation T/J= fs/R = Cè / l – torsion of solid and hollow circular shafts – power transmitted – polar modulus– torsional rigidity – strength and stiffness of shafts – comparison of hollow and solid shafts inweight and strength considerations - problems.

b) SPRINGS

Types of springs – laminated and coiled springs - closely coiled helical springssubjected to axial load – problem to determine maximum shear stress, deflection, stiffness andresilience of closely coiled helical springs only.

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UNIT V

a) FRICTION : (14 Hrs)

Friction – force of friction – limiting friction – static friction – dynamic friction –laws of static and dynamic friction – angle of friction – co-efficient of friction – cone of friction- resultant force of friction on sliding body on inclined plane.

b) TRANSMISSION OF MOTION :

i) Belt Drives

Introduction – classification of belt drives – flat belt, V belt and rope drives – openand crossed belt drives – belt materials – merits and demerits of flat, V belts and ropes –velocity ratio of belt drive – effect of belt thickness on velocity ratio – slip of belt – velocityratio of compound belting – length of belt in open and crossed belt drives - no derivations –problems – angle of contact – laws of belting – belt connecting parallel and perpendicularshafts – ratio of tension in flat, V belts and ropes(no derivation) – power transmission by belts– centrifugal tension – condition for maximum power transmission – design of flat belts –problems.

ii) Gear Drives and Chain Drives

Types of gears – Nomenclature of gear – spur, helical and bevel gears – worm andworm wheel – rack and pinion – velocity ratio of a gear drive – merits and demerits of geardrive – simple gear train – compound gear train – problems – epicyclic gear train – applications–chain drive – types - definition - applications

REFERENCE BOOK1. Bansal.R.K, “Text book of Strength of Materials” Laxmi Publications, 2004.2. Khurmi.R.S, “Strength of Materials” S.Chand & Company, 1993.3. Ramamurutham.S, “Strength of Materials” Dhanpat Rai Publications, 1999.4. Prasad.L.B, “Engineering Maechanics and strength of Materials” Khanna

Publishers, Delhi, 1995.5. Khurmi.R.S, “A Text Book of Applied Mechanics” S.Chand & Company, 1983.6. U.L.Jindal, “Applied Mechanics: Statics and Strength Of Materials”, Galgotia Pub,

2000.7. A.S.Sarao and D.S.Khosla, “Fundamentals of Applied Mechanics”, Satya Prakashan,

1997.8. Egor.P.Popov, “Engineering Mechanics and Solids”, Prentice Hall of India, 2000.

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2201 MECHANICS OF MATERIALS

Model Question Paper

Time : 3 Hrs Max.Marks : 75

Note : 1. Answer all Questions

2. Answer any one from Part – A (5 Marks ) and any one from Part – B (10 Marks)

I. A. i) State Hook’s law and define factor of safety.

ii) Define the properties of ductility and malleability

B i) A Steel bar 2m long 20mm wide and 10mm thick is subjected to a pull of 20 KN inthe direction of its length.Find the changes in length, breath and thickness.Take E= 2OO KN / mm2 & Poisson’s ratio = 0.25.

ii) A Spherical ball of 500mm dia,when subjected to a hydrostatic pressure of 5 Mpais found to shrink to a ball of 498.8mm dia.If the Poisson’s ratio of the ball is0.24,find E.

II. A. i) Distinguish between moment of inertia and polar moment of inertia.

ii) Differentiate between the longitudinal stress and circumferential stress in thincylinders subjected to internal pressure.

B. i) Find the moment of inertia about the centroidal axes of an angle section 90 x 75x 20 mm thick with its 90 x 20 mm flange being vertical.

ii) Calculate the increase in volume enclosed by a boiler shell 2.5 long ,1m in diameterwhen it is subjected to an internal pressure of 150 N / mm2. The wall thickness issuch that the maximum tensile stress in the shell is 2150 N / mm2 under this pressure,E = 200 KN / mm2, 1/m = 0.3.

III. A. i) What are the different types of beams.

ii) State any five assumptions made in theory of simple bending.

B. i). A Simply supported beam of length 8m carries a udl of 1KN / m for the entirespan.It also carries a point load of 10 KN at its centre.Find out the max deflectionof the beam.E=200KN/mm2 and I=200 x 106 mm4.

ii) A timber beam is freely supported on supports 6m apart.It carries a udl of 12KN /m for the entire span and a concentrated load of 9 KN at 3.5 m from the rightsupport.If the stress in timber is not to exceed 8N/mm2 , design a suitable rectangularsection with depth equal to twice the breath

IV.A. i) What are the advantages of hollow shaft over the solid shaft?

ii) State the assumptions made in theory of pure torsion.

B. i). A hollow circular shaft of external diameter 75 mm and internal diameter 40 mmis to transmit power at a speed of 40 rpm.If the maximum shear stress is not toexceed 80N/mm2 . Calculate the power in kW transmitted by the shaft.

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ii) Derive expressions for maximum slope and deflection of a simplysupported beam with a central point load.

V. A. i) Define Co-efficient of friction,angle of friction and cone of friction.

ii) State the Law of belting.

B. i) In a flat belt the initial tension is 180N.The angle of lap of the smaller pulley is 170º

.The coefficient of friction between the belt and pulley surface is 0.215.Dia ofpulley is 900 mm and it runs at 540 rpm. Determine the power that can be transmittedat the above speed. Neglect the effect of centrifugal tension.

ii) In a spur gear arrangement,the power transmitted is 3 kN.The driving pinion has 30teeth and 40 mm circular pitch.Calculate the speed in rpm for the pinion.If thepressure between the teeth exerted is not to exceed 600 N.

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2202 MANUFACTURING PROCESSES


5 Hours/Week Total Hours : 60 Hrs

MAJOR DIVISIONS:

UNIT I Foundry

UNIT II Forging and Welding

UNIT III Powder metallurgy and Heat Treatment

UNIT IV Lathe work and Theory of metal cutting

UNIT V Metrology, Press working and Non-Conventional machining processes

UNIT I: FOUNDRY (13 Hrs)

Patterns – definition – pattern materials- factors for selecting pattern materials –single piece solid, split patterns – pattern allowances – core prints – use of core boxes -moulding – definition – moulding boxes, moulding sand – ingredients - silica – clay –moisture and miscellaneous materials – properties of moulding sand – sand additives – mouldingsand preparation – mixing – tempering and conditioning –types of moulding – green sand –dry sand – machine moulding – top and bottom squeezer machines – jolting machines - sandslinger – core – CO2 process core making – types of core – casting using green sand and drysand mould – definition- sand casting - gravity die casting –pressure die casting – hot and cold- chamber casting - centrifugal casting - continuous casting - chilled casting – malleablecasting – melting of cast iron – cupola furnace– melting of non –ferrous metals – crucible andarc furnaces – induction furnaces – instrument for measuring temperature - optical pyrometer- thermo electric pyrometers – cleaning of casting - fetling - tumbling , trimming sand andshot blasting – defects in casting –causes and remedies – safety practices in foundry.

UNIT II : FORGING AND WELDING (12 Hrs)

Cold forging and hot forging – advantages of hot working - hot working operations– rolling – forging , hammer or smith forging, drop forging , upset forging , press forging -roll forging.

Welding – arc welding definition – arc welding equipment – arc welding methods -carbon arc, metal arc, metal inert gas ( MIG), tungsten inert gas (TIG) atomic hydrogen ,plasma arc, submerged arc and electro – slag welding - gas welding - definition oxy acetylenewelding – resistance welding – definition -

classification of resistance welding - butt- spot – seam - projection welding – welding relatedprocesses – oxy-acetylene cutting – arc cutting - hard facing -bronze welding - soldering andbrazing special welding processes – cast iron welding – thermit welding – solid slate welding,ultrasonic, diffusion and explosive welding - explosive cladding- modern welding, electronbeam and laser beam welding- types of welded joints – merits and demerits of welded joints –inspection and testing of welded joints– destructive and nondestructive types of tests – magnetic

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particle test -radiographic and ultrasonic test – defects in welding-causes and remedies – safetypractices in welding-three types of flames – gas welding equipment.

UNIT III

POWDER METALLURGY AND HEAT TREATMENT OF METALS (10Hrs)

Methods of manufacturing metal powders - atomization reduction of oxides andelectrolytic deposition – pressing operation – sintering – hot pressing – sizing – infiltration -mechanical properties of parts made by powder metallurgy - design rules for the powdermetallurgy process.

Heat treatment processes – purpose – procedures – applications of various heattreatment processes - iron-carbon equilibrium diagram – full annealing - process annealing -stress relief annealing – spherodising annealing – iso thermal annealing – normalizing –hardening– tempering – quenching medium - different types and their relative merits – case hardening –pack carbursing - cyaniding - nitriding – induction hardening and flame hardening.

UNIT IV: LATHE AND THEORY OF METAL CUTTING (12 Hrs)

Types of lathes – specifications – simple sketches - principal parts – head stock –back geared type – all geared type – tumbler gear mechanism – quick change gear box – apronmechanism – carriage cross slide – automatic, longitudinal – and cross feed mechanism – tailstock and its functions - work holding devices – face plate – three jaw chuck - four jaw chuck-catch plate and carrier – types of centers – machining operations done on lathe – latheattachments – tool post grinders - milling attachments.

Methods of taper turning in lathe – cutting tool materials - high carbon steel – highspeed steel - setellite - carbide – ceramic- single point tool –nomenclature – chip breakers –tool life - cutting speeds and feeds.

UNIT – V : METROLOGY, PRESS WORKING AND NON-CONVENTIONALMACHINING PROCESSES (13 Hrs)

Metrology :

Metrology – micro meter – vernier calipers - vernier height gauge – digital typevernier – micrometers – depth gauges – inside and outside micrometers – applications – feelergauges – plug and ring gauges – snap gauges – thread micrometers – gear tooth vernier – bevelprotractor – slip gauges – sine bar – comparators – mechanical dial gauges – electrical, opticaland pneumatic comparators – profile measurements – optical flat – surface finish measure-ments – profilometers - coordinate measuring machine.

Press working :

Types of presses – mechanical and hydraulic presses – press tools and accessories -press working operations –bending operations – angle bending – curling - seaming – shearingoperations – blanking, punching- curling off – trimming - notching -slitting – lancing – shaving.

Non-Conventional Machining process :

Ultrasonic machining – chemical machining – electro chemical grinding – electricaldischarge machining - wire cut EDM– plasma arc machining – laser machining.

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REFERENCE:1. Kalpakjian, “Manufacturing Engineering & Technology”, Addison Wesley, 1995.2. Hajra Chowdry & Bhattacharya, “Elements of Workshop Technology Vol-I”, Media

Promoters,2005.3. Begeman, “Manufacturing Process” The Book Centre.4. Chapman.W.A.J, “Workshop Technology: Part 1:Introductory Course ” Viva Book (P)

Ltd, New Delhi, 1998.

5. Chapman, “Workshop Technology : Part 2”, Viva Book (P) Ltd, 2000.6. Chapman, “Workshop Technology : Part 3”, Viva Book (P) Ltd, 1998.7. Raghu wanshi, “Workshop Technology”, Dhanpat Raj Publications, 1987.8. Jain.A.K, “Production Technology”, Khanna Puplisher, 15th Edition.9. HMT, “Production Technology”, Tata Mcgraw Hill, 16th Edition.

10. Khurmi, “Workshop Technology”, Niraj Construction & Development Co (P) Ltd ND,1981.

14

2202 MANUFACTURING PROCESSES




2. Answer any one from Part-A (5 Marks ) and any one from Part – B (10 Marks)

I. A. i) What are the factors to be considered for the selection of pattern materials?

ii) State the advantages of die casting.

B. i) Draw a simple sketch of a cupola furnace and explain its working.

ii) Explain the continuous casting process.

II. A. i) State the advantages of Hot working.

ii) Name the equipments required for Gas welding?

B. i) With the aid of simple sketch, Explain the ultrasonic testing of welded joint.

ii) Sketch and explain MIG Welding process

III A. i) What are the different quenching medium and state their uses.

ii) Explain the process of pack carburising.

B. i) What are the methods of manufacturing of metal powders? Explain anyone method.

ii) Write short notes on the following.

a) Cyaniding. b) Nitriding.

IV A i) State the principle parts of a lathe.

ii) What are the different type of operations done on a lathe?

B i) Explain the Apron mechanism in lathe

ii) Explain the nomenclature of a single point cutting tool.

V. A. i) Explain the Angular measurement using sine bar and slip gauges.

ii) Describe angle bending operation.

B. i) Explain Ultrasonic Machining with a simple sketch.

ii) With the aid of line diagram ,describe pneumatic comparator.

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2203 FLUID MECHANICS & FLUID POWER

III – TERM (Core Course)

6Hours / Week Total Hours – 72 Hours

MAJOR DIVISIONS:

UNIT I Properties of fluids and Hydrostatic forces

UNIT II Flow of fluids and Flow through pipes

UNIT III Impact of jets and Hydraulic turbines

UNIT IV Centrifugal and Reciprocating pumps

UNIT V Pneumatic and Hydraulic systems

UNIT I : PROPERTIES OF FLUIDS AND HYDROSTATIC FORCES (13 Hrs)

Introduction – definition of fluid – classification of fluids – ideal and realfluids – properties of a fluid – definition and units.

Pressure – units of pressure – pressure head – atmospheric, gauge and absolutepressure – problems – Pascal’s law and its applications – pressure measurement – piezometertube – simple U-tube manometer – differential U-tube manometer – problems – precautions inusing manometers – mechanical gauges – Bourdon’s tube pressure gauge – diaphragm pressuregauge.

Hydrostatic forces – definition – total pressure – centre of pressure – total pressureand centre of pressure on plane surface immersed – horizontally, vertically and inclined in aliquid – problems - pressure diagrams – problems.

UNIT II : FLOW OF FLUIDS AND FLOW THROUGH PIPES (16 Hrs)

Types of fluid flow – path line and stream line – mean velocity of flow – discharge ofa flowing fluid – equation of continuity of fluid flow – energies of fluid – Bernoulli’s theorem– statement, assumptions and proof – applications and limitations of Bernoulli’s theorem –Venturi meter – derivation for discharge – orifice meter – differences between Venturi meterand orifice meter – problems.

Orifice – types – applications – hydraulic coefficients – determining hydraulicscoefficients – discharge through orifice discharging freely – problems – mouth pieces – classi-fications – discharge through external cylindrical mouth piece – problems.

Flow through pipes – laws of fluid friction – hydraulic gradient line – total energyline – wetted perimeter – hydraulic mean radius – loss of head due to friction – Darcy-Weisbachequation and Chezy’s formula – problems - minor losses (description only) – power transmissionthrough pipes – problems.

UNIT III : IMPACT OF JETS AND HYDRAULIC TURBINES (15 Hrs)

Impact of jet – on a stationary flat plate held normal to the jet and inclined tothe direction of jet – on a flat plate moving in the direction of jet – on a series of moving platesor vanes ( Description only ) – force exerted and work done by the jet– problems.

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Hydraulics turbines – classifications – Pelton wheel – components and working –speed regulation – work done and efficiency of Pelton wheel – working proportions – problems– Francis and Kaplan turbines – components and working – draft tube – functions and types –surge tank – simple surge tank – differences between impulse and reaction turbines.

UNIT IV : CENTRIFUGAL AND RECIPROCATING PUMPS (13 Hrs)

Centrifugal pumps – classifications – working of single stage – components(with types if any) multi stage pumps – advantages – priming – priming chamber – head of apump – manometric, mechanical, overall efficiencies – problems – cavitation – special pumps– deep well and jet pumps – trouble shooting in centrifugal pumps.

Reciprocating pumps – classifications – working of single acting and doubleacting reciprocating pumps – plunger and piston pumps – discharge of a reciprocating pump-theoretical power required – coefficient of discharge – slip – problems – negative slip – indicatordiagram – separation – air vessels (functions and working).

UNIT V : PNEUMATIC AND HYDRAULIC SYSTEMS (15 Hrs)

Pneumatic systems – elements – filter – regulator – lubricator unit – pressure controlvalves – pressure relief valves – pressure regulation valves – directional control valves – 3/2DCV, 4/2 DCV, 4/3 DCV, 5/2 DCV, 5/3 DCV- flow control valves – throttle, shuttle and quickexhaust valves – ISO symbols of pneumatic components – pneumatic circuits – direct controlof single acting cylinder – operation of double acting cylinder – operation of double actingcylinder with metering-in control / metering-out control –use of shuttle valve in pneumaticcircuits – use of quick exhaust valve in pneumatic circuits – automatic operation of doubleacting cylinder – merits and demerits of pneumatic system – applications.

Hydraulic system – elements – merits and demerits – service properties of hydraulicfluids – hydraulic accumulators – weighted or gravity, spring loaded, gas operated, bladdertype accumulators – fluid power pumps – external and internal gear, vane and piston pumps –ISO symbols for hydraulic components – hydraulic circuits using sequence valve – counterbalance valve – hydraulic circuit for – shaping machine, surface grinding or milling machine –hydraulic jack – hydraulic lift – hydraulic intensifiers – hydraulic press – pneumatic system Vshydraulic system.

REFERNCE BOOKS :1. Khurni.R.S, “Hydraulic and Hydraulic Machines” S.Chand & Company, 1997.

2. Bansal.R.K, “Fluid Mechanics and Hydraulic Machines” Laxmi Puplications, 1996.

3. Rajput.R.K, “A Text Book of Hydraulics” S.Chand & Company, 1998.

4. S.Ramamrutham, “Hydraulics, Fluid Mechanics and Fluid Machines” Dhanpat RaiPublications, 2003.

5. Andrew Parr, “Hydraulics and Pneumatics”, Jaico Publishing House, 2004.

6. S.R.Manjumdar, “Oil Hydraulic System”, Tmh, 2006.

7. R.Srinivasan, “Hydraulics and Pneumatic Controls” Vijay Nicole, 2004.

8. K.Shanmuga Sundharam, “Hydraulics and Pneumatic Controls” S.Chand, 2006.

9. V.P.Vasandani, “Hydraulic Machines: Theory and Design”, Khanna Pub, 2004.

17

2203 FLUID MECHANICS & FLUID POWER



Note : 1. Answer all Questions.

2. Answer any one from Part – A (5 Marks ) and any one from Part – B (10 Marks).

I. A. i) Explain the following properties of the fluid and state their units.

(a) Density (b) specific weight (c) specific gravity

ii) Describe the working of a bourdon tube pressure gauge.

B. i) A circular ring of 2.5m external and 1.5 m internal diameters is vertically immersedin water such that the center of the plate is 3.6 m deep from the free surface ofwater. Determine the total pressure and depth of the center of pressure.

ii) A left limb of an U – tube manometer is opened to atmosphere and right limb isconnected to the pipe carrying water pressure. The center of the pipe is at the levelof free surface of mercury. Find the difference in the level of mercury in the limbs,if the absolute pressure of water in the pipe is 15 m of water.

II. A. i) Define hydraulics co efficient.

ii) Define hydraulic gradient line and wetted perimeter.

B. i) State and prove Bernoulli’s theorem.

ii) A venturimeter of size 300 x 100 mm is fitted to the horizontal pipe. Mercury themanometer is connected to the venturimeter reads 100 mm. Find the discharge ofthrough the pipe, if co efficient of venturimeter is 0.98

III A i) Derive an expression for the force exerted by the jet on a moving flat plate

ii) Explain the function of following

(a) surge tank b) draft tube

B i) A jet of water 80 mm dia with a velocity of 15 m/sec and strikes a series of vanesmoving with a velocity of 10 m/sec. Find (a) force exerted by the jet. (b) Work doneby the jet.

ii) Explain with neat sketch the working principle of Kaplan turbine.

IV A i) Explain any four common troubles in centrifugal pumps with their remedies

ii) Draw a neat sketch of piston type reciprocating pump and name its parts.

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B i) Draw a neat sketch and illustrate the parts of a centrifugal pump and explain itsworking principle.

ii) A single reciprocating pump has a plunger diameter of 250 mm and a stroke of350 mm .If the speed of the pump is 60 rpm and delivers 16.5 LPs.

Find (a) theoretical discharge (b) coefficient of discharge (c) slip and(d) percentage of slip.

V. A. i) Write short notes on FRL unit..

ii) Explain with neat sketch the working of bladder type accumulator.

B i) Explain the working of 4/3 DC valve with neat sketch.

ii) Explain the working of an external gear pump with a neat sketch.

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2204 MACHINE DRAWING


6 Hours /Week Total Hours - 72 Hours

MAJOR DIVISIONS :

UNIT I Sectional Views

UNIT II Threaded Fasteners and Machine Elements

UNIT III Limits, Fits, Tolerance and Surface Finish

UNIT IV Assembly Drawings

UNIT I : SECTIONAL VIEWS (4 Hrs)

Review of orthogonal and isometric views - need for sectioning – sectional views-cutting plane- type of sections – full section – half section – removed section – revolvedsection – offset section – local section – thin section – section line ( Hatching line)

UNIT II : THREADED FASTENERS AND MACHINE ELEMENTS (6 Hrs)

Types of fasteners – temporary – permanent – nomenclature of threads – types ofthreads – V threads – square threads, left hand and right hand threads – internal and externalthreads – hexagonal and square bolts and nuts – empirical proportions to draw rivet heads,keys (Taper keys, parallel keys and woodruff keys)

UNIT III : LIMITS, FITS, TOLERANCE AND SURFACE FINISH (8 Hrs)

Limits – fits and tolerance – hole basis system – shaft basis system – types of fits –selection of fits and applications – types of tolerance - tolerance of form and position – geometrictolerance - indication of tolerances and fits on the drawing – roughness, waviness and lay –production methods and surface quality – symbols for lay.

UNIT IV : ASSEMBLY DRAWINGS

(with indication of fit designations wherever necessary) (54 Hrs)

1. Sleeve and cotter joint

2. Gib and cotter joint

3. Knuckle joint

4. Flange coupling

5. Universal coupling

6. Protected type flange coupling

7. Plummer block

8. Swivel bearing

9. Simple eccentric

10. Screw jack

20

11. Petrol engine connecting rod

12. Stuffing box

13. Machine vice

14. Tail stock

REFERENCES:1. Gupta.R.B, “A Text Book of Machine Drawing” Satya Prakasan, 1984.2. Bhatt.N.D,”Machine Drawing” Charotar Book Stall , 1973.3. Gopalakrishnan.K.R, “Machine Drawing” 1998.

4. Gilli.P.S, “Machine Drawing” S.K.Kararia & Sons, 1997.5. PSG, “Design Data Book”PSG Coimbatore, 1982.6. BIS, “BIS Engineering Drawing Practice for Schools and Colleges” BIS, 1989.7. M.L.Mathur, R.S.Vaishwanar, “Engineering Drawing and Graphics”, Jain Bros, 2002.8. R.K.Dhawan, “Machine Drawing”, S.Chand, 1996.

21

2204 MACHINE DRAWING



Note: 1. Answer all questions.

a. Answer part A in Additional sheet and part B in drawing sheet

b. First angle projection shall be followed.

c. Missing Dimensions may be suitably assumed.

Answer ANY FOUR questions: (4 x 5 = 20 )

PART A

i. What is meant by offset section? What are the reasons for local section?

ii. What are the different types of Nuts? State its application.

iii. What are the different types of Rivet heads? State atleast two application of rivetting.

iv. What is meant by Hole Basis and shaft Basis system?

v. Findout the maximum and minimum clearance of a fit with the designation 100 H 11/g7.

vi. Explain the surface roughness symbol with all its features.

PART B

The details of SIMPLE ECCENTRIC are shown.Assemble the parts and draw tofull scale. (55)

i. Top half sectional elevation

ii. Plan

iii. Bill of materials

22

23

2205 MECHANICS OF MATERIALS ANDFLUID MECHANICS LAB


6 Hours/Week Total Hours : 72 Hrs

I . MECHANICS OF MATERIALS LAB

Experiments:

1. Test on Ductile Materials :

Finding Young’s modulus of elasticity, yield points, percentage elongation andpercentage reduction in area, stress-strain diagram plotting, tests on mild steel and cast iron.

2. Hardness Test:

Determination of Rock well’s hardness number for various materials like mild steel,high carbon steel, brass, copper and aluminium

3. Torsion Test:

Torsion test on mild steel – relation between torque and angle of twist-determinationof shear modulus-determination of elastic constants for mild steel.

4. Bending and deflection tests:

Determination of Young’s modulus for steel by deflection test.

5. Impact test:

Finding the resistance of materials to impact loads by Izod test or Charpy test.

6.Tests on springs of circular section:

Determination of modulus of rigidity, strain energy, shear stress by load deflectionmethod – Compression and tension test (Closed coil spring only)

7.Shear Test:

Shear test on M.S. bar

II . FLUID MECHANICS LAB

STUDY OF HYDRAULICS & PNEUMATIC SYSTEM (Not for Examination)

1. Pneumatic System:

Study of pneumatic system and its elements – FRL unit pressure Relief valve –Directional control valves – flow control valve.

2.Hydraulic system:

Study of basic hydraulic system and its elements – filter, pressure relief valve, DCVand FCV – Hydraulic system Vs pneumatic system - Hydraulic oil and its properties.

24

Resources required:

Pneumatic trainer kit with air compressor

Hydraulic trainer kit with hydraulic power pack

EXPERIMENTS

1. Bernoulli’s theorem

Verifying the Bernoulli’s theorem

2. Venturi Meter / Orifice meter

Determine the coefficient of meter

3. Pipe friction

Determine the friction factor

4. Reciprocating pump

Performance test on reciprocating pump (Characteristic curves)

5. Centrifugal pump

Performance test on centrifugal pump (Characteristic curves)

6. Impulse turbine

Performance test on impulse turbine.

7. Reaction turbine

Performance test on reaction turbine.

8. Small orifice

Determine the coefficient of discharge through Small orifice piece Byconstant head method and variable head method.

9. External mouth piece

Determine the coefficient of discharge through External mouth piece By variablehead method and constant head method.

SCHEME OF EXAMINATION

S.No Topic Marks

1 Exercise ( Any one fromMechanics of Materials lab/ Fluid Mechanics Lab) 70

2 Viva Voce 5

Total 75

25

2206 WORKSHOP - I

FOUNDRY, WELDING & SMITHY


6 Hours / Week Total Hours: 72 Hrs

I . FOUNDRY EXERCISES

Preparation of sand mould:

1. Single Piece Patterna) Cubeb) Flangec) Pulleyd) Gear Wheel

2. Split Patterna) Straight Pipeb) Bend Pipec) Thumbles

3. Core making (Not for Examination)a) Cylindrical core

4. Melting and casting (Demonstration only)Melting non ferrous metal and making sand casting using any one of the pattern inany one of the following furnace.

a) Oil fired crucible furnaceb) Pit furnace

II . WELDING EXERCISES1. Arc welding

a) Lap jointb) Butt jointc) T- jointd) Corner joint

2. Gas weldinga) Lap jointb) Butt jointc) Gas cutting - Profile cutting ( Not for Examination )

3. Soldering and Brazing (Demonstration only)

26

III . SMITHY EXERCISES

1. Round rod to square rod

2. Round rod to hexagonal rod

3. Round rod to square headed bolt

4. Round rod to hexagonal headed bolt

5. Round rod to flat

IV . LATHE EXERCISES (Not for examination, Only for Class Exercises)

1. Plain Turning

2. Step Turning

3. Step Turning and Chamfering.

∅22

100

27

2207 APPLIED THERMODYNAMICS

IV - TERM (Core Course)

7 Hours / Week Total Hours: 84 Hours

MAJOR DIVISIONS:

UNIT I Thermodynamics and Expansion of gases

UNIT II Steady flow energy equation and Air cycles

UNIT III Internal combustion engines

UNIT IV Fuels and Performance of I.C engine

UNIT V Air compressors and Gas turbines

UNIT I: THERMODYNAMICS AND EXPANSION OF GASES (17 Hrs)

Introduction - definitions and units of mass, weight, volume, density, specific weightand specific gravity - pressure - units - atmospheric, gauge, vacuum and absolute pressure -temperature- Celsius and absolute temperature - S.T.P and N.T.P conditions - heat - specificheat capacity at constant volume and at constant pressure - work - power - energy - types -thermodynamic system - types - properties and state of system - intensive and extensive prop-erties - thermodynamic process - cycle - point and path functions - law of conservation ofenergy - equilibrium - thermodynamic equilibrium - zeroth , first and second laws of thermo-dynamics - problems

Perfect gases - laws of perfect gases - Boyle's, Charles' , Joule's, Regnault's andAvagadro's laws - characteristic gas equation - relation between specific heats and gas constant- universal gas constant - problems - enthalpy - change in enthalpy - entropy - change inentropy - general equations for change in entropy.

Expansion of gases - thermodynamic processes - constant volume, constant pressure, isothermal ( hyperbolic) , isentropic ( reversible adiabatic ) , polytropic, free expansion andthrottling processes - p-V and T-s diagrams, work done , change in internal energy , heattransfer , change in enthalpy , change in entropy for various processes - problems.

UNIT II: STEADY FLOW ENERGY EQUATION AND AIR CYCLES (20 Hrs)

Steady flow system - control volume - steady flow energy equation - applications -steam boiler - condenser - nozzles - steam and gas turbines - reciprocating and rotary compressors- non flow energy equation - problems.

Air cycles - air standard efficiency - reversible and irreversible processes -thermodynamic reversibility - conditions of reversibility - assumptions in deriving air standardefficiency - Carnot cycle - Otto cycle - Joule cycle - Diesel cycle - comparison of Otto cycleand Diesel cycle - ideal and actual p-V diagrams of Otto and Diesel cycles - comparison -problems - dual combustion cycle ( description only).

28

UNIT-III: INTERNAL COMBUSTION ENGINES (17 Hrs)

Introduction - classifications - four stroke cycle petrol and diesel engines - meritsand demerits - two stroke cycle petrol and diesel engines - comparison - constructional detailsof I.C. engine - components of engine - cylinder block, crankcase, cylinder head, liners, oilpan, piston, piston rings, connecting rod, crank shaft, cam shaft, valve and valve train - materialsand manufacturing methods - valve timing diagram for four stroke petrol and diesel engines -port timing diagram for two stroke petrol and diesel engines.

Layout of fuel supply system in petrol engines -A.C. mechanical fuel pump - simplecarburetor - Solex carburetor - layout of fuel supply system in diesel engine- single actingfuel feed pump - CAV fuel injection pump - fuel injectors - types of nozzles - fuel filters.

Ignition systems - compression and spark ignition - coil, magneto and electronicignition systems - governing of I.C. engines - quantity and quality governing - coolingsystems - air cooling - water cooling - merits and demerits.

Lubrication - purpose - properties of lubricants -types of lubrication systems - oilpump and oil filters - scavenging - super charging - effects and applications - turbo charger.

UNIT IV: FUELS & PERFORMANCE OF I.C ENGINES (15 Hrs)

Fuels - classifications - merits and demerits - requirements of a good fuel - combustionof fuels - stoichiometric air required for complete combustion of fuels - excess air - products ofcombustion - problems - calorific value of fuels - higher and lower calorific values - Dulong'sformula - problems - determination of calorific value - Bomb and Junker's calorimeter - problems-Orsat apparatus for flue gas analysis - air pollution - effects and control of pollution

Performance of I.C engines - Testing - thermodynamic and commercial tests - indicatedpower - brake power - friction power - efficiencies of I.C. engines - indicated thermal ,brakethermal, mechanical and relative efficiencies - Morse test - procedure - problems - heat balancesheet - problems.

UNIT V: AIR COMPRESSORS AND GAS TURBINES (15 Hrs)

Air compressors - uses of compressed air - classifications of compressor - workingprinciple of a compressor - single stage reciprocating compressor - compression processes -power required to drive the compressor - problems - clearance volume and its effects - volumetricefficiency - power required to drive the compressor with clearance volume - problems - multistage air compressor -merits and demerits - intercooler - perfect inter cooling - work input onmulti stage compressor - condition for minimum work input in multi stage compressor withperfect inter cooling - ratio of cylinder diameters for minimum work input - problems - rotarycompressors - Roots, vane blowers - centrifugal and axial flow air compressors.

Gas turbines - classifications - advantages and disadvantages of gas turbines - constantpressure gas turbine - gas turbine with regenerator - intercooler - reheater - effects - closedcycle gas turbines - merits and demerits of open and closed cycle gas turbines - turbojetengines - merits and demerits - turbo propeller engines - merits and demerits - ramjet- comparisonof air-craft and industrial gas turbines.

29

REFERENCE BOOKS:

1. Sarkar.B.K, “Thermal Engineering”, Tata Mc Graw Hill, 2002.

2. Khurmi.R.S, “TextBook ofThermal Engineering”, S.Chand & Company Ltd, 2002.

3. Ballaney.P.L, “Thermal Engineering” Khanna Publishers, 2003.

4. Domkundwar, “Course in Thermodynamics and Heat Engines (Thermal Engineering)”,Dhapat rai, 2004.

5. Nag Pk, “Basic and Applied Thermodnamics”, Tata McGraw Hill Pub Co., Ltd., 2004

30

2004.2207 APPLIED THERMODYNAMICSModel Question Paper


NOTE : 1. Answer all questions . Choosing any one from Part - A (5marks) and any onefrom Part - B (10marks)

2. All Questions carry equal marks.

I. A. i) Explain Kelvin -Plank statement of second law of Thermodynamics.

ii) Derive the P-V-T relations of an adiabatic process.

B. i) 0.25kg of air at a pressure of 1bar occupies a volume of 0.3m3. If this air expandsisothermally to a volume of 0.9m3 determine (i) The initial temperature (ii) Finaltemp (iii) external workdone (iv)the heat transfer (v)entropy. Assume R = 0.29 kJ/kg/ °k.

ii) Gas expands according to the law Pv 1.3 = C, from a pressure of 900 KN/m2 andvolume of 0.0025m3 to a pressure of 100KN/m2. How much heat would have beenreceived (or) rejected during this process. Also determine the polytropic specificheat. Take γ = 1.4 and CV = 0.718 kJ/ kg/ °k.

II A. i) Write down & explain the Steady flow energy equation.

ii) Draw the P-V diagram and T-s diagram of carnot cycle and mention various process.

B i) An ideal hot air engine working on carnot cycle between 100°C to 1000°C. Findthe thermal efficiency of the engine. If the engine is supplied with 7200 kJ/min ofheat energy ,find the workdone by the engine and also power developed by theengine.

ii) In an ideal diesel cycle the compression ration is 15: 1 and expansion ratio is 7.5:1The Pressure and the temperature at the beginning of compression are 98 KN/m2

and 44°C respectively and the pressure at the end of expansion is 258.6 KN/m2 .Determine (i) the maximum temp of the cycle (ii) and thermal efficiency of thecycle .take γ = 1.4

III A i) What are the two types of piston rings state its functions.

ii) Compare water cooling engine with air cooled engine.

B i) Explain the typical piston & connecting rod assembly of an I.C. Engine with neatsketch.

ii) Write the construction and working of CAV - Fuel Injection pump with neat sketch.

IV A i) Write the requirements of good fuel material

ii) Define IHP ,BHP & FHP.

B i) Explain the working of Orsat apparatus for flue gas analysis

31

ii) A gas engine working on the constant volume cycle has a swept volume of 0.0008m3 and a clearance volume 0.00015m3. The engine uses 0.85m3 of gas/min ofcalorific value 18 MJ/m3 developing an indicated power of 81.5KW.

Find the efficiency of the engine relative to the air standard efficiency. Take γ = 1.4

V A i) Write the merits and demerits of the Multi stage air compressor

ii) Compare the Air craft gas turbine with Industrial gas turbine.

B i) A single cylinder reciprocating air compressor has a displacement of 0.15m3 .

The suction condition of the Air is 1 bar and 15° C the air after compression to 8bar is Delivered to a receiver at const. Pressure. The compression follows theadiabatic and γ = 1.4. Determine

(a) the temp. at the end of compression

(b) workdone by air during suction,

(c) workdone during compression.

(d) workdone during delivery

(e) Network done on air per cycle,

Take R= 0.287 kJ/ kg/ °k.

ii) Explain with neat sketch the working of Turbojet Engine. What are the advantagesof Turbojet Engine.

32

2208 MACHINE SHOP TECHNOLOGY


7 Hours / Week Total Hours: 84 Hours

MAJOR DIVISIONS

UNIT I Planer, Shaper and Slotter

UNIT II Drilling machines and Milling machines

UNIT III Grinding, Broaching, Boring and Jig boring

UNIT IV Gear manufacturing practice - Forming and Generating processes

UNIT V Semi automatic lathes, Automatic lathes, Jigs & Fixtures

UNIT - I (18 Hrs)

PLANER:

Types of planers - description of double housing planer - specifications - principlesof operation - drives - quick return mechanism - feed mechanism - types, work holding devicesand special fixtures - types of tools - various operations.

SHAPER:

Types of shapers - specifications - standard - plain - universal -principles of opera-tion - drives - quick return mechanism - crank and slotted link - feed mechanism- work holdingdevices - tools and fixtures

SLOTTER:

Types of slotters - specifications - method of operation - Whitworth quick returnmechanism - feed mechanism - work holding devices - types of tools.

UNIT - II (18 Hrs)

DRILLING MACHINES:

Drills - flat drills - twist drills - nomenclature - types of drilling machines - benchtype - floor type - radial type -gang drill - multispindle type - principle of operation in drilling- speeds and feeds for various materials - drilling holes - methods of holding drill bit - drillchucks - socket and sleeve - drilling - reaming - counter sinking - counter boring - spot facing- tapping - deep hole drill - drill jigs.

MILLING MACHINES:

Types - column and knee type - plain - universal milling machine - vertical millingmachine - specification of milling machines - principles of operation - work and tool holdingdevices - arbor - stub arbor - spring collets - adaptors - milling cutters - plain milling cutter -slab milling cutter - slitting saw - side milling cutter - angle milling cutter - T-slot millingcutter - woodruff milling cutter - fly cutter - nomenclature of milling cutter - milling process -conventional milling - climb milling - milling operations - straddle milling - gang milling -vertical milling attachment - types of milling fixtures.

33

UNIT - III (18 Hrs)

GRINDING MACHINES :

Types and classification - specifications - rough grinders - floor mounted hand grinders- portable grinders - belt grinders- precision grinders - cylindrical, surface, centreless grinders- internal grinders - planetary grinders - principles of operations - grinding wheels - abrasives- natural and artificial - dressing and truing of wheels - balancing of grinding wheels - diamondwheels - types of bonds - grit, grade and structure of wheels - wheel shapes and sizes - standardmarking systems of grinding wheels - selection of grinding wheel - mounting of grindingwheels.

BROACHING :

Types of broaching machine - horizontal, vertical and continuous broaching -principles of operation - types of broaches - classification - broach tool nomenclature - broachingoperations - simple examples.

BORING AND JIG BORING :

Boring machines - horizontal and vertical types - fine boring machine - boring tools- jig boring machine - measuring system - hole location procedure - deep hole boring.

UNIT - IV (15 Hrs)

GEAR MANUFACTURING PRACTICE - FORMING AND GENERATING PROCESSES

Gear forming process in milling - dividing head - principles of operation - indexing- linear indexing - rapid, simple - differential and angular indexing - problems - gear milling -cutter selection - nomenclature - module - pressure angle - milling procedure for spur, helicaland bevel gears - problems - other forming processes for manufacture of gears .

Generating process - gear shaper - gear hobbing - principle of operation only - gearfinishing processes - burnishing - shaving - grinding and lapping - gear materials - cast iron,steel, alloy steels, brass, bronze, aluminum, nylon, fibre - no problems.

UNIT - V 15 Hrs)

SEMI AUTOMATIC LATHES:

Types of semi automatic lathes - capstan and turret lathes - difference between turretand capstan - tools and work holding devices - self opening die head - collapsible taps - simpletool layout - process sheet.

AUTOMATIC LATHES:

Automatic lathe - classification of single spindle automatic lathe - principle of auto-matic lathes - automatic screw cutting machines - multi spindle automatic lathes - use of camsin automats.

34

JIGS AND FIXTURES:

Definitions and concept of Jig and fixture - Advantages of jigs and fixtures - elementsof jigs and fixtures - locating devices - 'V' locators - fixed stop locators - adjustable stoplocators - clamping devices - strap clamp, screw clamp- cam action clamp- types of jigs - boxdrill jig - indexing drill jig - types of fixtures - keyway milling fixture - string milling fixture.

REFERENCE BOOKS:1. HMT, “Production Technology” Tata Mcgraw Hill, 2001.2. Jain .A.K, “Production Technology” Khanna Publishers, 1999.

3. TTTI, “Production Processes” TTTI, 1982.4. Hajra Chowdry, “Elements of Workshop Technology Vol I” Media Promoters,

Mumbai, 1982.5. Hajra Chowdry.S.K, “Elements of Workshop Technology: Machine Tools, Volume 2”,

Media Promoters, Mumbai, 2005.6. Chapman.W.A.J, “Workshop Technology: Part 1:Introductory Course ” Viva Book

(P) Ltd, New Delhi, 1998.

7. Chapman, “Workshop Technology : Part 2” Viva Book (P) Ltd, 2000.8. Chapman, “Workshop Technology : Part 3” Viva Book (P) Ltd, 1998.9. Lindberg,”Process and Materials of Manufacture”, Prentice Hall of India, 1999.10. R.J.Santhakumar, “Production Technology”, Anuradha Agencies, 1998.11. P.N.Rao, “Manufacturing Technology”, Tata McGraw Hill, 1998.

12. R.B.Gupta & B.K.Gupta, “Manufacturing Process”, Khanna Publishers, 1998.

13. Mikell.P.Groover, “Fundamentals of Modern Manufacturing”, John Wiley & Sons, 2004.

35

2208 MACHINE SHOP TECHNOLOGY



NOTE : 1. Answer all questions . Choosing any one from Part - A (5marks) And one fromPart - B (10marks)

2. All Questions carry equal marks

I A i) Write the specifications of a planer.

ii) How do you classify different types of shapers?

ii) i) Explain the working principle of a quick return mechanism of a planer by open andcross belt drive with a neat sketch.

ii) Draw a neat sketch of a slotter and explain its working.

II. A. i) Describe the uses of anyone of the tool holding devices used in a drilling machine.

ii) With a simple sketch , describe the operation of Straddle milling process done ona milling machine.

ii) i) Describe the following drilling machine operations

ii) Counter boring b ) Spot facing C) Tapping

ii) Describe the construction and working of a vertical milling machine.

III A i) How the dressing of grinding wheel is done? Explain it.

ii) Write short notes on broaching operation.

ii) i) With a neat sketch describe the nomenclature of a broach.

ii) Draw a block diagram of jig boring machine and explain its salient features.

IV A i) What is gear hobbing? Explain it.

ii) List out the various methods used in gear finishing processes.

ii) i) With the simple sketch explain the working of a simple dividing head.

ii) Describe the gear generation by a gear shaping method with the suitable sketch.

V A i) List out the differences between Capstan and Turret lathe

ii) State the advantages of a jig and Fixture.

ii) i) Assuming the suitable components, prepare a tool layout on a capstan Lathe.

ii) What is a Drill Jig? Describe any one type of drill Jig.

36

2209 ELECTRICAL & ELECTRONICS ENGINEERING


6 Hours/ Week Total Hours: 72 Hrs

MAJOR DIVISIONS

UNIT I DC circuits, Magnetism and Instruments

UNIT II AC fundamentals and transformer

UNIT III DC and AC Machines

UNIT IV Basic Electronics

UNIT V Logic Gates and PLC

UNIT I- DC CIRCUITS, MAGNETISM AND INSTRUMENTS (15 Hrs)

Definitions - Electric current, voltage and resistance- Ohm's Law and Kirchoff'sLaws - Resistance in series, parallel and series parallel - Simple problems -Electromagnetism(Definitions only), Magnetic flux, Flux density, Magnetic field Intensity,MMF, permeability, reluctance, Faraday's laws of electro magnetic Induction - Instruments -Construction and working principle only moving of Iron(Attraction, Repulsion)meter, PMMCmeter, dynamometer wattmeter, induction type single phase energy meter.

UNIT II- AC FUNDAMENTALS AND TRANSFORMER (14 Hrs)

Fundamentals of AC voltage and current- Peak, average, RMS value of sine wave,Frequency, time period, amplitude, power, power factor (Definition only) - Concept of inductiveand capacitive reactance and impedance - Series RLC circuit only - Simple problems - 3 phasesystem - relation between line and phase values in star and delta systems (no derivations) -simple problems- two wattmeter method of measuring power in 3 phase circuits.

TRANSFORMER

Principle of operation and construction of transformer, EMF equation, Losses in atransformer - Efficiency, autotransformer

UNIT III- DC AND AC MACHINES (14 Hrs)

Principle and construction of DC motor, types of DC motors - Applications -Princi-ple of operation of single phase capacitor start induction motor - Three phase Induction motors- Squirrel cage and slip ring IM (construction and 1working principle only) - Servo motors &Stepper motors - types - applications. Selection of motors for Mechanical applications - DOLstarter, Star delta Starter

DC GENERATORS

working principle - construction - EMF equations ( qualitative treatment only ) -types.

37

ALTERNATORS

Basic principle - generation of EMF (1∅ &3∅)- rotating field system - advantages -types of rotors - construction of alternator - frequency, speed and number of poles ( qualitativetreatment only ).

UNIT IV- BASIC ELECTRONICS (14 Hrs)

Semiconductor materials -N type and P type - PN junction , Forward and reversebias, characteristics on PN diode- Half wave rectifier, full wave rectifier, bridge rectifier, zenerand avalanche break down, characteristics of zener diode- application of zener diode.

TRANSISTORS (Qualitative treatment only)

Transistor - construction of NPN and PNP types- Basic bias requirements (CommonEmitter configuration only) photo conductive cells (LDR), light emitting diode (LED), liquidcrystal display (LCD) (Dynamic Scattering Type only)

Thyristors - Principle and working of SCR - characteristics - applications.Introductionto Integrated circuits -Classification and packages only.

UNIT V- LOGIC GATES AND PLC (15 Hrs)

Stepper motor - construction and working principle - applications of stepper motor.Positive and negative logic, definition, symbol, truth table, Boolean expression for OR, AND,NOT, NOR, NAND, EXOR and EXNOR gates.

PROGRAMMABLE LOGIC CONTROLLERS

PLC definition- features and benefits of PLC - Systems and its elements - input andoutput elements - PLC memory system - PLC circuit verses hard wired circuits - sensors -types of sensors - limit switch, reed switch, photo electric sensor, inductive proximity sensor -types of contacts normally open (NO) contact, normally closed (NC) contact -, ladder logicsymbol - AND logic, OR logic, and NOT logic - truth table - steps involved in applicationcircuits using a PLC - PLC scan input , programme scan and output scan.

REFERENCES:

1. Theraja.B.L, “Fundamentals of Electrical Engineering and Electronics”, S.Chand &Company, 2001.

2. Thyagarajan.T, “Fundamentals of Electrical Engineering and Electronics” ScitechPublications Pvt Ltd, 3rd Eition.

3. Mikell.P.Groover, “Automation Production Systems and Computer IntegratedManufacturing”, Prentice Hall of India Pvt Ltd, 1973.

4. Raina .K.B & Battachariya.S.K, “Electrical Design Estimating and Costing”, NewAge International Ltd, 2003.

38

2209 ELECTRICAL AND ELECTRONICS ENGINEERING


Time:3 Hrs Max marks:75

NOTE : 1. Answer all questions . Choosing any one from Part - A (5marks)

and one from Part - B (10marks)


I A i) Define electric current and voltage.

ii) Find the equivalent resistance when two resistors are connected inparallel.

B i) Explain kirchoff"s current and voltage law.

ii) Explain the construction and working of PMMC instrument.

II A i) Define frequency,period and amplitude.

ii) An RLC circuit consists of a resistance value of 100 ohms, a inductor of 0.1 mHand a capacitor of 10 microfarad, calculate

a) impedence b) capacitive reactance and c) Inductive reactance.

B i) Explain the measurement of three phase power using two wattmeter method

ii) Explain the construction and principle of operation of a transformer.

III A i) Write down the applications of DC motor.

ii) State the principle on which the DC generator is working.

B i) Explain the principle of operation of single phase capacitor start induction Motor.

ii) Explain the principle and construction of an alternator.

IV A i) Explain the PN junction diode during forward bias.

ii) Explain the LDR in dynamic scattering mode.

B i) Explain the construction and operation of SCR.

ii) Explain with neat circuit diagram,waveform the working of bridge rectifier withand without filter.

V A i) Explain positive and negative logic.

ii) What are the benefits of PLC.

B i) Explain the construction of stepper motor with neat diagram.

ii) Explain the system layout of PLC.

39

2210 THERMODYNAMICS LAB

IV -TERM (Core Course)

6 Hours / week Total Hours : 72 Hrs

I . LUBRICATION OIL TESTING

1. Determining flash and fire points of the given oil using open and closed cup apparatus.

2. Determining the absolute viscosity of the given lubricating oil using Redwood viscometer.

3 Determining the absolute viscosity of the given lubricating oil using Saybolt viscometer.

II . I.C ENGINES

A . Study Experiments (Not for Examination )

1. Study of petrol engine and its components.

2. Study of diesel engine and its components.

B . Practical Experiments

3. Valve timing diagram of four stroke cycle petrol and Diesel engine.

4. Port timing diagram of two - stroke cycle petrol and Diesel engine.

5. Load test ( performance test ) on petrol engine.

6. Load test ( performance test ) on diesel engine.

7. Morse test on multicylinder petrol engine.

8. Heat balance sheet on I.C.engine.

9. Emission test for petrol and diesel engines.

III . COMPRESSOR

1. Volumetric efficiency of air compressor.

IV . FUELS

A . Study Experiments (Not for Examination )

1. Study of Junker's Gas Calorimeter

B . Practical Experiments

1. Determining the calorific value of the given solid fuel using Bomb calorimeter.

2. Determining the calorific value of the given liquid fuel using Bomb calorimeter.

40

V . REFRIGERATION AND AIR CONDITIONING

1. Performance of refrigeration test rig.

2. Performance of air conditioning test rig.


S.No Topics Marks

1. Experiments 70

2. Viva – Voce 05

Total 75

41

2211 ELECTRICAL & ELECTRONICS ENGINEERING LAB

IV TERM – (Core Course)

3 Hours/ Week Total Hours: 36 Hrs

LIST OF EXPERIMENTS

1. Measurement of unknown resistance using ohm’s law.

2. a) Measurement of power in single-phase circuit by ammeter and watt metermethods.

b) Measurement of voltage current and resistance by using multimeter

(Both analog and digital) in all the ranges.

3. Open and short circuit test on a single phase transformer to find the losses andEfficiency.

4. a) Make a connection for shorting a single-phase induction motor by DOL starterand a 3- phase motor by using star delta starter.

b) Study of starters 3 point DOL and star delta starter.

5. Load test on DC shunt motor to find the efficiency.

6. Load test on 3phase-induction motor at various loads to find the efficiency.

7. a) VI characteristics of PN junction diode.

b) VI characteristics of a SCR

8. a) Construction of a half wave rectifier with out filter

b) Construction of a bridge rectifier with out filter.

9. Verification of truth table for AND ,OR, NOT, NAND, NOR, EXOR,and EXNORGates.

10. Study of PLC systems. ( Not for Examination )


S.No Topics Marks

1. Exercise (Any one from Electricalor Electronics) 70

2. Viva – Voce 05

Total 75

42

2212 WORK SHOP – II

LATHE & METROLOGY

IV -TERM ( Core Course )

6 Hours / Week Total Hours : 72 Hrs

I . LATHE WORK EXERCISES

1. Step Turning

2. Step Grooving with knurling

3. Step with Taper Turning by compound rest Method

4. Knurling and Taper Turning by Taper Turning Attachment

5. Knurling ,Profile &Taper Turning by compound rest Method

6. Double Taper Turning by Taper Turning Attachment

7. Knurling and Forming Practice

8. Ball turning with Knurling

9. Pin & Bush

10.Thread Cutting

11. Taper Turning by compound rest Method and Thread Cutting.

12. Eccentric

II . METROLOGY EXERCISES:

A. Linear Measurements:

1) Determination of the Thickness of ground M.S.Flat, Diameter and length of a turnedCylindrical rod, Inside diameter of a bush using Vernier Caliper.

2) Determination of a Outside Diameter of a Cylindrical Component using outsidemicrometer, Inside Diameter of the bore of a bush using inside micrometer and check theresult with Digital micrometer.

3) Determination of Height of the gauge blocks or parallel bar using vernier height gauge.

B. Angular Measurements:

1. Determination of angle of v- blocks, dovetails in mechanical components using universalbevel protractor.

2. Determination of angle of machined surfaces of components using sine bar with slipgauges.

C. Comparison of Dimension:

Checking the Dimension of a Machined component with standard dimensionedcomponent Using Mechanical Comparators.(both internal and external dimensions)

43

III – SPECIAL MACHINE EXERCISES: (Not for Examinations)

1. Machining a Cube in a planing Machine.

2. Machining a Cube in a Shaping Machine.

3. Drilling holes in a given work piece in a drilling machine.

4. Machining a cube in a Milling machine.

5. Grinding of Rectangular plate in Surface grinding machine.

Enclosures: Sketches of Lathe Exercises & Special Machines.

LATHE EXERCISES:

1. Step Turning

2. Step grooving with Knurling

3. Step with Taper turning

44

4. Knurling and Taper Turning

5. Knurling, Profile and Taper Turning

6. Double Taper Turning

7.Knurling and Forming

45

8. Ball Turning With Knurling

9. Pin & Bush

10.Thread cutting

11. Taper Turning and Thread Cutting

12.Eccentric

46

SPECIAL MACHINES EXERCISES:

1.Planning Machine – Machining a cube

2. Shaping Machine – Machining a cube

3.Drilling Machine – Making a hole in a given workpiece.

47

4. Milling Machine – Machining a cube

5.Grinding Machine – Grinding of Rectangular plate.


S.No. Topic Marks

1. Lathe Work 502. Metrology 203. Viva - voce 5

Total 75

48

2301 DESIGN OF MACHINE ELEMENTS

V - TERM (Applied Course)


MAJOR DIVISIONS

UNIT I a) Selection of engineering materials

b) Design consideration in machine parts

UNIT II Design of shafts, Keys and Couplings

UNIT III Design of Belts & Pulleys

UNIT IV Design of Bearings

UNIT V a) Design of Gears

b) Design of Levers

UNIT I (14 Hrs)

A) SELECTION OF ENGINEERING MATERIALS

Introduction – selection of materials ( ferrous and non- ferrous metals and alloys) –factors affecting the selection of materials – cast iron, wrought iron, steel, alloy steel, alloys ofcopper, tin, aluminium and zinc – non metals – plastics, composite materials – BIS specifica-tions of engineering materials.

B) DESIGN CONSIDERATION IN MACHINE PARTS

Static load – live load – shock load – stress – strain diagram – factor of safety –selection of allowable stresses – procedure for designing machine elements- design of threadedfasteners –problems on tensile, compressive, shear and bearing stresses.

UNIT II DESIGN OF SHAFTS, KEYS AND COUPLINGS (16 Hrs)

Design of shafts – forces on shaft – radial and tangential forces on the shaft due tospur gear drive – forces on the shaft due to belt tensions in the drives – determination ofmaximum bending moment due to these forces – determination of maximum torque transmitted– combined shock and fatigue factors applied to bending and twisting – determination of shaftsize based on combined bending and twisting moments- problems. Keys – form of keys –effect of keyways in sunk keys – taper pins – feather keys and splined shafts - design of sunkkey – problems. Couplings-Design of sleeve and cotter joint - rigid flange couplings –problems.

UNIT III (14 Hrs)

DESIGN OF BELTS AND PULLEYS

Introduction – types of belts - materials for belts – designation of belts – designprocedure for flat belts, V belt drives – design of V belt drives – problems(Design questionbased on approved data book only).

49

Pulleys – material - types – cast iron, steel, wooden, fast and loose pulleys – speedcones or stepped pulleys - belt tensioning devices – manual - – short center drive – gravityidler – pulley method – design of cast iron and steel pulleys - problems.

UNIT IV (12 Hrs)

DESIGN OF BEARINGS

Introduction – types of bearings – applications – ball bearings – radial and thrust ballbearings – single row – double row – self aligning bearings – roller bearing – cylindrical ,spherical, needle and taper – standard dimensions and designation of bearings – materials usedfor balls and rollers – lubrication of bearings – journal bearings – heat generated – heatdissipated – design procedure for journal bearings - problems – (Design questions based onapproved data book only)

UNIT V (16 Hrs)

A ) DESIGN OF GEARS

Introduction – types of gears – spur gear terminology – gear materials –Buckingham– Lewis equation – design procedure for spur gear based on Buckingham – Lewis equationonly – problems (Based on approved data book only).

study of speed reducers – types – components of speed reducers.

B) DESIGN OF LEVERS

Introduction – application – design of hand lever- foot lever – cranked lever problems.

REFERENCES

1. Pandya, Shah, “Machine Design”, Charator Pub, 11th Edition.2. Gupta, “Machine Design”, Eurasia Pub, 4th Edition.3. Sundararajamoorthy.T.V & Shanmugam, “Machine Design”, Khanna Pub, 7th Edn, 1998.4. PSG “Design Data”, DPV Printers, 2003.5. S.S.Manian, Rajagopal, “Design Data Book”, Balachitra Publishers, 1998.

50

2301 DESIGN OF MACHINE ELEMENTS


Time : 3 Hrs Max.Marks : 75NOTE : 1. Answer all questions . Choose any one from Part - A (5marks) and any one

from Part - B (10marks)2. All Questions carry equal marks.3. Approved Design Data Book is permitted.

I. A i) List out the factors that will affect the selection of a material.

ii) Define the factor of safety for ductile and brittle materials.

B. i) Explain the types of cast-iron with its properties and applications.

ii) A circular punch 20mm in diameter is used to punch a hole through a steel plate10mm thick. If the force necessary to drive the punch through the metal is 250KN,determine the maximum shearing stress developed in the material.

II. A. i) Discuss the radial and tangential forces acting on the shaft due to spur gear drive.

ii) Write down the different types of keys used.

B. i) A shaft made of mild steel is required to transmit 100KW at 300rpm. The supportedlength of the shaft is 3meters. It carries two pulleys each weighing 1500N supportedat a distance of 1m from the ends respectively. Assuming the safe values of stressdetermine the diameter of shaft.

ii) Design a flange coupling to transmit 60kw at 120rpm. The allowable stresses areas follows

Shear stress in shaft and key = 56 N/mm2

Shear stress in bolts = 28 N/mm2

Shear stress in flange = 14 N/mm2

Bending stress in key = 112 N/mm2

III.A. i) What are the materials used for belts?

ii) Write notes on speed cone pulley with simple sketch.

B. i) Discuss the design procedure for flat belt.

ii) A pulley of 1m diameter revolving at 20rpm is to transmit 8KW. Find the width ofa leather belt if the maximum tension is not to exceed 150N in 10mm width.Design the pulley, assuming it to have size arms. Max. shear stress is not to exceed65N/ mm2

IV A i) How the bearings are classified?

ii) State the purposes of lubrication of bearings.

51

B i) Explain with neat sketches, various types of roller bearing.

ii) The load on the journal bearing is 150KN due to turbine shaft of 300mm diameterrunning at 1800rpm. Determine the following.

(a) Length of the bearing if the allowable bearing pressure is 1.6 N/mm2

(b) Amount of heat to be removed by the lubricant per minute if the bearing temperatureis 60°C and viscosity of the oil at 60°C is 0.02kg/ms and the bearing clearance is0.25mm.

V. A. i) Define module and pressure angle.

ii) State the applications of levers.

B i) Design a spur gear drive to transmit 22.39kW at 900rpm. Speed reduction is 2.5.Material for pinion and wheel are C 15 and cast iron grade 30 respectively. Takepressure angle of 20° and working life of the gear as 10,000hrs.

ii) Design a cranked lever for the following dimensions .

Lever of the handle = 320mm

Length of the lever arm = 450mm

Overhung of the journal = 120mm

The lever is operated by a single person exerting a maximum force of 400N at adistance is 1/3rd length of the handle.

52

2302 THERMAL ENGINEERING

V - TERM (Applied Course)


MAJOR DIVISIONS

UNIT I Steam and Expansion of Steam

UNIT II Steam Boilers and Performance of Boilers

UNIT III Thermal Power Plant

UNIT IV Energy Engineering and Management

UNIT V Refrigeration and Air Conditioning

UNIT – I : STEAM AND EXPANSION OF STEAM (16 Hrs)

Introduction – formation of steam – T-h diagram – P-V diagram – T-s diagram -phase diagram – critical conditions – enthalpy of water – enthalpy of evaporation – conditionsof steam – wet, dry and superheated steam – advantages of superheated steam – dryness fraction– enthalpy of wet, dry and superheated steam – specific volume of water and steam – density ofsteam – external work of evaporation – internal latent heat – internal energy of steam – entropyof water and steam – steam tables- Mollier chart – problems.

Expansion processes of steam - constant volume, constant pressure, constanttemperature, hyperbolic, isentropic, polytropic and throttling processes – applications ofisentropic and throttling processes – problems.

Steam calorimeters – bucket, combined separating and throttling calorimeters-problems.

UNIT – II : STEAM BOILERS AND PERFORMANCE OF BOILERS (14 Hrs)

Classification of boilers – high pressure boilers – Lamont and BHEL high pressureboilers – advantages of high pressure boilers, boiler mountings – function, construction andworking – boiler accessories – function, construction and working – comparison of mountingsand accessories – feed water treatment - methods – starting boiler from cold condition – safetyprecautions in boiler operation – Indian boiler act.

Performance of boilers – actual, equivalent and factor of evaporation – boiler efficiency– boiler power - problems – efficiency of economiser and super heater - problems - boiler trial– heat balance sheet – problems.

UNIT - III : THERMAL POWER PLANT (15 Hrs)

Layout of thermal power plant – fuel and ash circuit – water and steam circuit – air andflue gas circuit – cooling water circuit – merits and demerits of thermal power plant – selection ofsite for thermal power plant – air pollution by thermal power plants – pollutant and effects ofpollution – pollution control – cyclone separator – wet scrubber – electrostatic precipitator –control of Nox and SO2.

53

Steam turbine – steam power cycle – Carnot, Rankine and modified Rankine cycles– classification of steam turbine – necessity of compounding – types of compounding – specialturbines.

Steam condensers – elements of condensing plant – classification of condensers – jetcondenser types – surface condensers - types – merits and demerits of jet and surface condensers– sources of air in condenser – condenser vacuum – vacuum efficiency – condenser efficiency– mass of cooling water required – mass of air present – number of tubes – problems.

UNIT - IV : ENERGY ENGINEERING AND MANAGEMENT (12 Hrs)

Nuclear fuels – requirements – fissile and fertile fuels – Nuclear fission and fusion –chain reaction – radio activity – layout of nuclear power plant – merits and demerits – Nuclearreactors – pressurised water reactor – boiling water reactor – Candu type reactor – fast breederreactor – moderators – control rods – coolant – reflectors – biological shield – effect of nuclearradiation – disposal of nuclear wastes- comparison of nuclear power plants with thermalpower plants. Conventional sources of energy – layout of hydal and diesel power plants –merits and demerits – non-conventional sources of energy – solar – wind – tidal – geothermalenergy – gobar gas plant. Introduction to Energy Audit - types.

UNIT V : REFRIGERATION AND AIR CONDITIONING (15 Hrs)

Refrigeration – refrigerators and heat pumps – types and applications of refrigeration –vapour compression refrigeration system – vapour absorption system – comparison – refrigeratingeffect – capacity of refrigerating unit – C.O.P. – actual C.O.P. – power required – mass of iceproduced – problems – C.O.P. of reversed Carnot cycle – Bell-coleman cycle– problems –refrigerants – desirable properties.

Air conditioning – psychrometric properties – dry air – moist air – water vapour –saturated air – dry bulb temperature – wet bulb temperature – wet bulb depression – dew pointtemperature – dew point depression – humidity – specific and relative humidity – psychrometricchart –psychrometric processes – sensible heating and cooling- humidification – dehumidifica-tion – simple problems using psychrometric chart – air conditioning – classification and applicationsof air conditioning system – room air conditioning – central air conditioning – comparison –differences between comfort and industrial air conditioning – factors to be considered in airconditioning – loads encountered in air conditioning systems.

REFERENCE BOOKS:1. Sarkar.B.K, “Thermal Engineering”, Tata McGraw Hill, 2002.2. Khurmi.R.S, “TextBook ofThermal Engineering” S.Chand & Company Ltd, New

Delhi, 2002.3. Ballaney.P.L, “Thermal Engineering”, Khanna Publishers, 2003.4. Nagpal, “Power PlantEngineering”, Khanna Publishers, 15th Edition, 2005.5. Domkundwar, “Power PlantEngineering”, Dhapat rai, 2004.

6. Prasad.M, “Referation and Air Conditioning”, New Age International, 1999.

54

2302 THERMAL ENGINEERING



NOTE : 1. Answer all questions . Choosing any one from Part - A (5marks) and any one fromPart - B (10marks)


I. A i) Distinguish between wet steam & dry steam.

ii) What is mollier diagram ? Explain it with a typical diagram.

B i) Steam is generated at 8bar from water at 32 °C. Find the heat required to produce1Kg of steam (a) When the dryness fraction is 0.8 (b) when the steam is dry andsaturated (c) When the steam is superheated to 300 °C, The specific heat of superheatedsteam may be taken as 2.3 kJ/kg/ °k.

ii) Explain the method of finding out the dryness fraction of the given sample ofsteam by using bucket calorimeter.

II A i) Write the advantages of High pressure boilers

ii) Define the followings

(a) Actual evaporation (b) Equivalent evaporation (c) Factor of evaporation

B i) Write the construction and working of Lamont high pressure boilers with neat sketch.

ii) A Boiler generates 750kg steam / hour at 11 bar absolute and with 40°C superheatand burns 100kg of coal/hour. If the calorific value is 29,300kj/kg, feed watertemperature is 45°C and specific heat of superheated steam is kJ/kg/°k. Calculatethe (a) the factor of evaporation (b) the equivalent evaporation (c) Boiler efficiencyand (d) Boiler power.

III A i) Discuss about the effects of pollution and its control in Thermal power plant.

ii) Write the merits & demerits of Surface condenser.

B i) Write the working of pressure compounding steam Turbine with sketch.

ii) A surface condenser is required to condense 25000kg of steam per hour at a pressureof 0.12bar and 0.88 dryness. Cooling water enters at 30°C and leaves at 40°C. Ifthe velocity of water in the tube should not exceed 2m/s. Determine the number of25mm inner diameter tube that must be used to build the condenser. If the conden-sate temperature is 49°C

IV A i) Discuss about the nuclear waste disposal.

ii) Distinguish between conventional and non conventional energy sources.

55

B i) Describe the working principle of Boiling water reactor plant with neat sketch.

ii) Write the construction and working typical Gobar gas plant with neat sketch

V A i) Compare the vapour compression refrigeration system with vapour absorptionsystem with vapour absorption system

ii) Write the classification and application of air conditioning system.

B i) An ice plant produces 10tonnes of ice in 24hours at 0°C using water at roomtemperature of 20°C. Estimate the power rating of compressor motor if the C.O.Pof the plant is 4 and overall electro – mechanical efficiency is 90%

ii) Write the working of centralized A.C system with sketch. State its advantages.

56

2401A AUTOMOBILE TECHNOLOGY

V – TERM (Diversified Course - I )


MAJOR DIVISIONS

UNIT I Automotive Engines

UNIT II Fuels and fuel feed systems

UNIT III Transmission and Power Trains

UNIT IV Automotive Chassis

UNIT V Automotive Electrical Equipment’s & Pollution Control

UNIT I : AUTOMOTIVE ENGINES (12 Hrs)

Basic Engine Components – Functions , types , materials and construction of –Cylinder block – Cylinder head – Gaskets – Crankcase – oil pan – cylinder liners – Comparisonof liners – Piston – Expansion control in pistons – piston rings – types of compression and oilcontrol rings – piston pin – Connecting rod – methods of connecting piston and Connectingrod – Crankshaft – flywheel – Cam shaft – methods of cam shaft drive arrangements – Valveand Valve arrangements – LIFT

Diesel engine – merits and demerits – Stages of Combustion – Delay period – Variablesaffecting delay period – Combustion chamber – Methods of generating air swirl in dieselengine combustion chamber – Types of combustion chambers – merits and demerits -Introduction to MPFI Engines.

Cooling system – purpose – methods – merits and demerits of air and water cooling– pump assisted cooling systems – components – water pump, fan - thermostat – types –radiator – types – pressure cap – Expansion system – merits – vented and pressurised – expansiontank – troubles in cooling system – loss of coolant , overheating and over cooling – causes.

Lubrication system – purpose – types of lubricants – properties – additives – Servicerating of oil – types of lubricating system – types of filters – methods of cylinder and pistonlubrication – High pressure system – oil pumps –Troubles in lubrication system – oil leakage, low oil pressure and excessive oil consumption – causes.

UNIT II : FUEL & FUEL FEED SYSTEMS (12 Hrs)

Requirements of an ideal petrol – Octane number – detonation – properties of a gooddiesel fuel – Cetane number – Diesel knock – methods of controlling diesel knock – fueladditives – Alternate fuels for petrol and diesel engines – Benzol , Methanol , Ethanol , Naturalgas , LPG , Vegetable oils and Bio – Gas.

Layout of fuel feed system of petrol engine – types of fuel feed systems – A.C.Mechanical fuel pump – S.U. Electrical fuel pump – fuel filter – Air cleaners – types –Carburetion –Classification of Carburetors – Simple carburetor – Carburetor circuits – SolexCarburetor – Construction and operation – petrol injection – necessity – merits and demerits.

57

Layout of diesel fuel feed system – single acting fuel feed pump – injection pumps –Construction and working of distributor type pump – fuel injectors – purpose – types – Single& Multi hole – pintle and pintaux - governors – necessity – types of Governors – Mechanicaland Pneumatic – fuel filters – primary and secondary filters – location & importance

UNIT III : TRANSMISSION AND POWER TRAINS (12 Hrs)

General arrangement of power transmission system – Arrangement of front enginedrive – rear engine rear drive – four wheel drive – applications – clutch – function – Components– Types – Single plate , multiple wet and diaphragm spring clutch – fluid coupling – Clutchtroubles and their causes.

Gear box – purpose – various resistance to motion – types of gear boxes – slidingmesh , constant mesh and synchro mesh – floor shift and steering column gear change – gearbox troubles and their causes.

Drive line – propeller shaft – Universal joint – Cross type only – slip joint – finaldrive – function – types of gear arrangement – straight & spiral Bevel , Hypoid , Worm andWorm Wheel – merits , demerits and application – Hotch kiss drive – Torque tube drive –radius rod.

Differential – purpose – Construction and operation – Self locking and non slipdifferential – Differential troubles and their Causes – forces in the rear axles – Rear axles –Semi floating , three quarter floating and full floating axle – Axle housing – types.

UNIT IV : AUTOMOTIVE CHASSIS (12 Hrs)

Front axle – Types – Stub axle – Types – Steering system – Ackermann Principle ofSteering – Wheel alignment – Factors – Camber , Caster , King pin inclination , Toe in and Toeout on turns - Steering linkages – Steering gears – Cam and double roller , recirculating balltype , Rack and Pinion – Steering troubles and causes – power steering – Necessity – types –Layout of any one type.

Suspension system – Functions – Type of springs – Leaf , coil and Torsion bar –Front suspension systems – independent front suspension – merits anddemerits – types – rear end suspension – Air suspension ( brief description only) – shockabsorber – purpose – telescopic type – construction and working.

Brake system – functions – classification of brakes – drum brakes – leading shoe andtrailing shoe – Self energizing action – hydraulic brake – brake bleeding – Air assisted hydraulicbrakes – Air brake – layout , functions of each component and application only – disc brakes –construction and working – comparison of disc and drum type – brake troubles and theircauses.

Wheels – Disc wheel , wire wheel , spilt wheel and light alloy cast or forged wheels– brief description and applications – tyres – function – construction of tyres – cross and radialply tyres – comparison – properties of tyres – tyre wear and tyre service.

58

UNIT V :

AUTOMOBILE ELECTRICAL EQUIPMENT & POLLUTION CONTROL (12Hrs)

Battery – lead acid battery – Nickel alkaline battery – construction – battery rating –charging – testing – starting system – circuit – construction and operation of starter motor –starting motor drives – over running clutch and Bendix drive – construction and operation –solenoid switch – Charging system – circuit – alternator construction and operation – regulators– Dynamo.

Ignition system – Types – battery coil ignition system – circuit –High tension magneto– Principle of operation of fly wheel magneto – electronic ignition – Ignition system troublesand remedies.

Lighting system – circuit – Head light – Aiming adjustment – sealed beam headlights – directional signal circuits – Horn circuits – Wind screen wiper.

Pollution – Pollutants – source of pollutants – pollution control techniques for petroland diesel engines emission – controlling crank case emission ( PCV ) – controlled evaporativeemission ( VRS , VSS , VRR , ECS and EES ) – Treatment of exhaust gas ( Catalytic converter,EGR ) - Pollution standards in India and European countries.

REFERENCE BOOKS

1. Newton, Steed, “The Motor Vehicle”, The English Language Book Society”, 9thEdition.

2. Williams Crouse, “Automotive Engines”, Tata Mc Graw Hill, 9th Edn, 2003.3. Heitner,J, “Automotive Mechanics”, East West Press, 2nd Edn.4. Kirpal Singh, “Automobile Engineering Vol 1”, Standard Book, 7th Edn.

5. Kirpal Singh, “Automobile Engineering Vol II”, Automobile Engines, StandardBook, 8th Edn.

6. Harban, “Automobile Engineering”, S.Chand.7. M.L.Mathur, R.P.Sharma, “A Course in Internal Combustion Engines”, Dhanpat

Rai, 2004.8. Narang.G.B.S, “Automobile Engineering”, Khanna Pub, 5th Edition.9. Gupta, “Automobile Engineering”, Sathya Prakasan, 5th Edition.

59

2401A AUTOMOBILE TECHNOLOGY




2. Answer any one from Part – A (5 Marks ) and any one from Part –B (10 Marks)

I. A. i) Explain the necessity of lubricating system and good properties of lubricants.

ii) Compare dry liner and wet liner.

B. i) Explain any 5 types of engine components and functions with their neat sketch.

ii) Write the construction and working of water cooling system with neat sketch.

II A i) Explain the octane and cetane number.

ii) Write the necessity and types of Governor.

B i) Explain the construction, working and defects of solex carburetor with neat sketch.

ii) Explain the construction and working of AC Mechanical pump with neat sketch.

III A i) Write the functions of clutch and compare the wet and dry clutch.

ii) Give 5 comparison between Hotch kiss drive and torque tube drive.

B i) Explain the Construction and function of differential unit with neat sketch

ii) Explain the working of constant mesh gear box with neat sketch.

IV A i) Explain the following

a) caster b) camber c) kingpin inclination

ii) Write the comparison between cross and radial ply tyres.

B i) Explain the construction and working of Telescopic shock absorber with neat sketch.

ii) Write the construction and working of air assisted hydraulic brakesystem with sketch.

V A i) Write ignition troubles and their remedies.

ii) Write pollution Control techniques for petrol and diesel engines.

B i) Explain the Construction and Working of Battery coil ignition system with propersketch.

ii) Write the construction and working of over running clutch driving mechanism withneat sketch.

60

2401B METROLOGY AND MACHINE TOOL TESTING

V – TERM ( Diversified Course - I )

5 Hours / Week Total Hours: 60 Hrs

MAJOR DIVISIONS

UNIT I Standard Measurement and Linear Measurement

UNIT II Comparators & Measurement by Light wave Interference

UNIT III Auto Collimator and Material Testing

UNIT IV Angular Measurement and Circular Division

UNIT V Recent Trend in Engineering Metrology and Machine Tool Testing

UNIT I – STANDARD MEASUREMENT AND LINEAR MEASUREMENT(12 Hrs)

Introduction – objectives of engineering metrology-accuracy and precision ,reliability – interchangeability – Classification of measurement - linear and angularmeasurements, Instruments for precision measurement of external and internal features – slipgauges – classification – Indian standard on slip gauges – their manufacture, calibration ofequipment’s and accessories –standard of measurements – line standard and standard wavelength standard.

Limits, fits and tolerance of gauges – IS: 919-1963 – Definitions of MMC, LLCallowance and terminology –Guide for selection of fits, Importance of Hole basis system andshaft basis system, the Newall system – Taylor’s principle – ISO system of limits and fits –plain gauges - Gauges for taper etc.

UNIT II

COMPARATORS & MEASUREMENT BY LIGHTWAVE INTERFERENCE (10 Hrs)

Comparators-Mechanical, Electrical, Electronic and Pneumatic comparators – SolexAir Gauge , Differential comparators , optical projectors - Testing and calibration of gauges –measurement by light wave interference – principles of interference – interferometers – NPLflatness interferometer – Laser interferometer – its construction and uses.

UNIT III - AUTO COLLIMATOR AND MATERIAL TESTING (12 Hrs)

Auto collimator and its application - Optical flats and their uses – Measurement ofstraightness, flatness, squareness, parallelism – profile measurements – test for checking rotation– Destructive and Non-Destructive testing – Hardness testing – Tensile and shear testing –Bend test, creep test –Magnetic particle test – Liquid penetrant test - Xray test –UltrosonicTest - Eddy current test.

UNIT IV - ANGULAR MEASUREMENT AND CIRCULAR DIVISION (12 Hrs)

Bevel protractors – Sine bars – Angle gauges - optical instruments -Division headsand circular tables, Measurement of surface finish – various methods of measuring surfaceroughness – 10 point average method – Root Mean Square method - surface meter –Talysurf- Dial indicators and indicating gauges.

61

UNIT V – RECENT TREND IN ENGINEERING METROLOGY ANDMACHINE TOOL TESTING (14 Hrs)

Metrology of screw thread – Metrology of Gears – Measuring Machines – Co –ordinate Measuring Machines (CMM)- Electro optical inspection - Recent development inoptical measurements – laser telemetric system – Feeler microscope – profile checks usinglaser computers in Metrology – Automatic Gear measuring Machines - ON line and IN processmeasurements.

Machines tool testing purpose – types of geometrical checks on machine tools –alignment tests on lathe, milling, drilling, shaper and surface grinder – leveling, True running,parallelism. Axial slip of lead screw – practical test.

REFERENCES1. Jain, “Engineering Metrology (WB)”, Khanna Publisher, 18th Edn, 2004.2. A.K.Sawhney, “Mechanical Measurement and Instrumentation”, Dhanpat Rai, 2006.3. C.Elanchezhian, “Engineering Metrology”, Eswar Press, 2004.4. S.Sirohi & Radhakrishnan, “Mechanical Measurement”, New Age International, 1999.

62

2401B METROLOGY AND MACHINE TOOL TESTING




2. Answer any one from Part – A (5 Marks ) and any one from Part –B (10 Marks)

I. A. i) State the objectives of Metrology.

ii) Define MMC and LLC

B. i) Explain the Manufacturing and Calibration of Slip Gauges

ii) Describe the 2 different methods of measuring the diameter of a plain ring gaugeand also state the degree of accuracy you would expect in each case . State theadvantages of each method.

II. A. i) What is a Comparator? Classify different types of comparators.

ii) What is the fundamental difference between Length and Flatness Interferometers?

B. i) Explain Optical Projector with a neat sketch

ii) Explain NPL Flatness Interferometer with its construction and uses

III.A. i) Define Straightness and Parallelism

ii) Explain the Shore Scleroscope Hardness Testing method

B. i) Explain the method of detection of cracks in a casting by using Magnetic particleMethod.

ii) Explain how the flaws in a material can be detected using Ultrasonic Non-DestructiveTesting Method. List out its advantages.

IV. A. i) State the essential requirements for accuracy in the construction of a Sine bar.

ii) Describe the method of checking the accuracy of a circular table using Autocollimator

B. i) Describe the various components of a Bevel Protractor with a neat sketch

ii) Sketch a Dial Indicator and explain its working mechanism

V. A i) Give a list of measuring instruments for measuring Screw Thread elements

ii) Explain the term “Alignment Test” of a Machine Tool

B. i) Describe with a neat sketch, working principle and applications of CMM

ii) Explain the method of checking profile of a Turbine Blade using Laser Viewerwith a neat sketch

63

2303 AUTOCAD LAB

V- TERM (Applied Course)

6Hours/Week Total Hours- 72 Hrs

INTRODUCTION

Introduction – History of AutoCAD – Applications – Advantages over manual drafting– Hardware requirements – Software requirements – windows desktop – AutoCAD screeninterface – menus – toolbars – How to start AutoCAD – command groups - How to executecommand- types of coordinate system -absolute-relative-polar.

DRAWING TOOLS

Creating objects(2D) – using draw commands – Line, Arc, Circle, Ellipse, Donut,Polygon, Point, Pline, sketch, Trace- creating 2D solid.

TEXT TOOL AND DRAFTING SETTING

Creating Text – dtext, mtext, text style- Mline, Spline – Drawing with precision –Osnap options – drafting setting- Limits – Units-drawing aids- Fill, Snap, Grid, Ortho lines-Function keys.

EDITING TOOLS

Editing and Modify commands – object selection methods – erasing object –oops-canceling and undoing a command – copy – move – array –offset – scale – rotate – mirror –break- trim – extend –explode - Divide – measure – stretch – lengthen

OBJECT PROPERTIES

Changing properties – color –Line types –Ltscale-Matching properties – editing withgrips – Pedit –ddedit –mledit.

GRAPHICAL USER CONTROL

Controlling the drawing display – blipmode –view group commands- zoom redraw,regen, regen auto, pan, viewers-real time zoom.

STATUS & BLOCKS

Inquiry groups – calculating area – distance – time – status of drawing – usingcalculator- Creation of blocks – Wblock- inserting a block – block attributes- hatching –patterntypes-boundary hatch- working with layers.

DIMENSIONING ( TOOL /STYLES)

Basic dimensioning – editing dimensions – dimension styles – dimensioning systemvariables.

TECHNICAL DRAWING WITH AUTOCAD

Detailed drawing, Assembly drawing, sectional views, auxillary views, Bill of materials-creating prototype drawing.

64

ISOMETRIC DRAWING

Isometric Drawing – Isometric projection – Drawing Iso Circles – DimensioningIsometric objects.

FILE HANDLING

File commands –file import and export-plotting drawing – external references – 3Dfundamentals – 2D to 3D conversion.

DRAWING EXERCISE PRACTICE ( Assembly Drawing )

2D Drawings:

1. Socket and Spigot Joint 2. Flange Coupling

3. Universal Coupling 4. Machine Vice

5. Swivel Bearing 6. Screw Jack

7. Tail Stock

3D Drawings:

8. Sleeve and Cotter Joint 9. GIB and Cotter Joint


S.No Topic Marks

1 20 Objective types question 20

2 Isometric drawing creation (Drawing 10, Dimensions 5)

15

3 M/c Drawing construction (Drawing 20, Assembly 5 Sectioning & Dimensions 10)

35

4 Viva Voce 5

Total 75

65

2402A AUTOMOBILE TECHNOLOGY LAB

V – TERM ( Diversified Course Lab - I )


I. EXPERIMENTS IN ENGINES

1. Study of Auto Mechanic’s Tools and Engine Components.

2. Dismantling, Overhauling and Assembling of piston, connecting rod and crankshaftassembly.

3. Dismantling , Inspecting, Overhauling and assembling of Valve actuating mechanismand Adjusting Valve clearance on I head and L type engines.

4. Cylinder bore inspection, measurement, reboring and honing of cylinder block.

5. Removing, Overhauling and Replacing of water pump and Lubricating oil pumps (Gear& Rotor type )

6. Dismantling, Overhauling Assembling and Testing of mechanical fuel pump.

7. Dismantling, Inspecting, Overhauling and assembling of Solex Carburetor.

8. Dismantling, Inspecting and assembling of Inline Diesel pump and fuel injectors.

II . EXPERIMENTS IN TRANSMISSION

1. Dismantling, Overhauling assembling and adjusting of clutches ( use of clutch adjustingfixture )

2. Dismantling, Overhauling and assembling of sliding mesh, Constant mesh and synchromesh gear boxes.

3. Dismantling , Overhauling , Assembling and Adjusting back lash, Correct teeth contactof crown and pinion of differential unit.

4. Dismantling, Overhauling, assembling and adjusting steering gear box and checkingsteering column end play, cross shaft end play and back lash of steering gear.

III. EXPERIMENTS IN BRAKE & WHEEL

1. Dismantling , Overhauling , Assembling , bleeding and adjusting of hydraulic brakingsystem.

2. Front wheel alignment.

3. Removing , Inspecting , Overhauling and replacing tyre & tube (Vulcanizing)

IV. EXPERIMENTS IN ELECTRICAL EQUIPMENTS

1. Removing , Inspecting , Testing & charging the battery ( Specific gravity test – high rate- discharge test )

2. Dismantling , Inspecting , Overhauling and assembling of Starter motor.( Armature testing - short , open & ground )

66

3. Dismantling, Inspecting Overhauling and Assembling of Alternator.

4. Removing, Inspecting, Overhauling, Replacing and Adjusting of Ignition distributorand spark plugs setting - ignition timing.

5. Engine tune up, aiming and adjusting of Head Light Assembly, checking of Rear Lamp,Parking Lamp and Direction Indicator etc.,


S.No Topic Marks

1 Dismantling of Components 35

2 Overhauling / Assembling / Tune up

35

3 Viva Voce 5

Total 75

67

2402B METROLOGY & MACHINE TOOL TESTING LAB

V – TERM (Diversified Course Lab - I)


I. LINEAR MEASUREMENTS

1. Study of Vernier caliper and measure the required dimensions of standard workpiecesgiven.

2. Study of Micrometer and find the diameter ,thickness of various test workpieces given.

3. Study of Screw thread micrometer and find the core diameter, pitch diameter, rootdiameter of the various thread pieces given.

4. Study of Dial micrometer and dial caliper and measure the required dimensions ofstandard workpieces.

5. Study of Depth gauge micrometer and find accurately the depth of various holes providedin the test pieces.

6. Study of slip gauges and build up the required given dimensions and test with vernierheight gauge.

7. Study of gear tooth vernier caliper and measure the various parameters of the gears.

II. ANGULAR MEASUREMENTS

1. Measure the tapers and surfaces using Sine bar with dial indicator and slip gauges.

2. Measure the angle of the given workpieces using sine bar.

3. Measure the taper and eccentricity of workpieces with the help of dial indicator.

4. Measure the angles of the given workpieces using Bevel protractor.

5. Study of angle plate and check the angles in conjunction with surface plates – markingout the dimensions on the various types of workpieces.

III. INSPECTION USING GAUGES (Not For Examination)

1. Study and check the dimension of the work pieces using cylindrical plug gauge, tapergauge and snap gauge

IV. SURFACE ROUGHNESS MEASUREMENT

1. Measure the surface roughness using surface roughness tester.

V. PROFILE CHECKING (Not For Examination)

1. Plot and check the profile of the given components using profile projector.

VI. NON-DESTRUCTIVE TESTING (Not For Examination)

1. Study of Ultrasonic and X-ray test for inspecting defects in a metal.

2. Inspect the metal for surface defects using Liquid Penetrant Test.

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VII. MACHINE TOOL TESTING

1. Using dial indicator find the squareness ,parallelism and alignment of both centres oflathe and find the squareness, parallelism of Milling Machine.

2. Using the dial indicator find the squareness, parallelism and true running of taper inspindle of drilling machine and find the squareness, parallelism of Shaper.

3. Machine the shaft having diameter of 50 mm , length of 300 mm in the lathe and checkthe parallelism of spindle axis with bed, allignment of both centres and accuracy of thecarriage travel along the bed.


S. No Topic Marks

1 Measurement of Components 30

2 Machine Tool Testing 40

3 Viva Voce 5

Total 75

69

2304 WORKSHOP – III (SPECIAL MACHINES)

V – TERM (Applied Course)


EXERCISES:

I. Introduction and Study of Different Machine Tools

1. a. Introduction to shaping ,planing , slotting machine and its parts.

b. Introduction to Millling, Grinding, Turret and capstan lathe, Tool and cutter grinderand its parts.

2. Introduction to work holding devices, tool holding devices, types of tools used inshaping, planing, slotting and grinding machines.

3. a. Study of cutting tools used in different Machine Tools like Milling machine , Grindingmachines, Turret and capstan lathe.

b. Machine setting and Work setting for different components in the above machine tools.

II. Machining Exercises

1. Machining of Hexagonal shape from circular block in slotting machine

2. Machining of Pin & bush in capstan lathe.

70

3. Cylindrical grinding of shaft in cylindrical grinding machine.

4. Machining of ‘V’ block in shaping machine.

5. Machining of Dove-tail in shaping machine.

71

6. Step Milling in Milling Machine

7. Form milling in milling machine.

72

8. Machining of spur gear in milling machine

9. Surface grinding of rectangular plate in surface grinding machine.

(Not for Examination)

10 Drilling and Tapping in rectangular plate.

(Not for Examination)

73

11. Machining of slot in planing machine.

12. Grinding of single point tool in Tool and Cutter Grinder.

A - Top rake angle 1 & 6 - FaceB - Lip angle 2 - Shank

C - Front clearance angle 3 - Side flankD - Side rake angle 4 - End flank

E - End clearance angle 5 - BaseF - Side cutting edge angle 6 - End cutting edgeG - End cutting edge angle 7 - Nose

H - Nose angle 8 - Side cutting edge

9 - Nose radius

74

13. Grinding of Cylindrical shaft in centreless grinding machine ( Not for Examination)

14. External thread cutting operation

15. Machining of spur gear in Gear hobbing machine.

16. Machining of slots and splines in Slotting machine.

17. Setting of tools in turret and capstan lathe for the given component. Draw the tool layoutfor the given component and setting of tools in capstan and turret lathe. (Not for Examination)


S. No Topic Marks

1 Special Machines – 1 Exercise

70

2 Viva voce 5

Total 75

75

2305 INDUSTRIAL ENGINEERING AND MANAGEMENT

VI - TERM (Applied Course)


MAJOR DIVISIONS

UNIT I Plant Engineering And Plant Safety

UNIT II Work Study, Method Study and Work Measurement

UNIT III Production Planning and Control & Quality Control

UNIT IV Principles of Management and Personnel Management

UNIT V Financial Management and Material Management

UNIT – I PLANT ENGINEERING AND PLANT SAFETY (16 Hrs)

PLANT ENGINEERING :

Plant location – selection of site for industry – plant layout – objectives of scientificlayout – types - process, product and fixed position layout – techniques used to improve layout– principles of material handling equipments – plant maintenance - importance– break downmaintenance, preventive maintenance and scheduled maintenance.

PLANT SAFETY :

Importance – accident – cost and causes of accident – accident proneness – planningfor accident prevention – safety laws and regulations – Indian Factories act 1948 governingsafety, health and welfare of workers – industrial disputes – collective bargaining – jointconsultation- arbitration.

UNIT – II WORK STUDY, METHOD STUDY & WORK MEASUREMENT (16 Hrs)

WORK STUDY :

Productivity- Standard of living – method of improving productivity – objectives –importance of good working conditions.

METHOD STUDY :

Definition – objectives – selection of job for method study – basic procedure forconduct of method study – tools used in method study – operation process chart, flow processchart, two handed process chart, man machine chart, string diagram and flow diagram.

WORK MEASUREMENT :

Definition – basic procedure in making a time study – employees rating factor –application of time allowances – rest, personal, process, special and policy allowances –calculation of standard time – problems – basic concept of production study, ratio delay study– analytical estimating – synthesis from standard data and predetermined motion time standards(PMTS).

76

UNIT III PRODUCTION PLANNING AND CONTROL AND QUALITY CONTROL (16 Hrs)

PRODUCTION PLANNING AND CONTROL:

Introduction – major functions of production planning and control – importance ofPPC as nerve centre – preplanning – methods of forecasting – past experience estimate, salesforce estimate, market research, trend line and correlative methods - routing and scheduling -dispatching and controlling – types of production - characteristics – principles of productplanning and process planning – make or buy decision – problems.

QUALITY CONTROL :

Definition – objectives – types of inspection – first piece inspection, floor inspectionand centralized inspection – advantages and disadvantages of each type – difference betweeninspection and quality control. Introduction to statistical quality control – type of measurements– method of variables – method of attributes – uses of X, R, “p” and “c” charts – O.C. curve– sampling inspection – single and double sampling plan – Introduction to ISO 9000.

UNIT IV PRINCIPLES OF MANAGEMENT AND PERSONNEL MANAGEMENT 17 Hrs)

PRINCIPLES OF MANAGEMENT:

Definition of management – administration – organization – theories of manage-ment – F.W. Taylor’s and Henry Fayol‘s principles – functions of manager – planning –organizing – types of organization – line, staff, Taylor’s pure functional types – line and staffand committee type – directing – leadership – types of leadership – qualities of a good leader- communication – formal and informal communication – motivation – positive and negativemotivation - controlling - Just In Time - Total Quality Management - Quality Circle and ZeroDefect concept - Management Information Systems.

PERSONNEL MANAGEMENT :

Responsibility of human resource management – policies and functions – selectionprocedure – training of workers – apprentice training, on the job training and vestibule schooltraining - job evaluation and merit rating – objectives and importance - wages and salaryadministration – components of wages – wage fixation – types of wage payment – time ratesystems – Halsey’s 50% plan, Rowan’s system and Emerson’s efficiency plan – problems.

UNIT – V FINANCIAL MANAGEMNT AND MATERIAL MANAGEMENT (19 Hrs)

FINANCIAL MANAGEMENT :

Fixed and working capital – resources of capital – shares – types – preference andequity shares – debentures – types of debentures – public deposits, factory costing – direct cost– indirect cost – factory over head – fixation of selling price and profit of a product –problems,depreciation – causes – methods – straight line, sinking fund and percentage on diminishingvalue method - problems

77

MATERIAL MANAGEMNT:

Objectives of a good stock control system – ABC analysis of inventory – procurementand consumption cycle – safety stock - re-order level – lead time – Economic ordering quantity– problems – purchasing procedure – store keeping – Bin card.

REFERNECES :

1. Khanna. O.P, “Industrial Engineering and Management”, Dhanpat Rai Publications,2003.

2 Kumar.B, “Industrial Engineering ”, Khanna Pub, 2001.

3 Ahuja.K.K, “Industrial Management and Organizational Behaviour”, Khanna Pub, 2001.4. Jain.K.C, “Production Planning and Industrial Management”, Khanna Publisher, 5th

Edn,1997.5. Banga.T.R & Sharma.S.C, “Engineering Economics and Manufacturing”, Khanna Pub,

1996

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2305 INDUSTRIAL ENGINEERING AND MANAGEMENT




2. Answer an one from Part – A (5 Marks ) and any one from Part – B (10 Marks)

I. A. i) Explain the important factors to be considered in selection of a Material HandlingEquipment.

ii) State the differences between Breakdown Maintenance and PreventiveMaintenance

B. i) Explain Preventive Maintenance with its functions and advantages.

ii) What is meant by Industrial Dispute? What are the methods adopted for solvingthe disputes? Explain Collective Bargaining and Joint Consultation types of settlingthe disputes.

II. A. i) Explain String Diagram with a neat sketch

ii) What is PMTS? What are its advantages?

B. i) What are the techniques used to improve the Productivity? Briefly explain eachmethod.

ii) What is Flow Process Chart? List out its types. Explain any one type in detail.

III.A. i) What is Market Research? Explain briefly , the methods adopted in Market Research.

ii) State the differences between Variable Inspection and Attribute Inspection.

B. i) A car manufacturer buys a component for his car at Rs.10 per unit. If he decides tomake it himself, fixed cost and variable costs will be Rs. 1000 and Rs.5 percomponent respectively. Decide whether to Make or Buy the component.

ii) What are the types of inspection? Explain each type in detail with its advantagesand disadvantages.

IV A i) What is Morale ? State its advantages.

ii) Distinguish between Wage and Salary. What are the components of wages?.

B. i) Explain Taylor’s pure Functional Organisation with a chart. State its merits anddemerits.

ii) What are the different types of Training to workers? Discuss the merits and demeritsof each. Also mention the field of application.

79

V. A. i) What are the difference between Share holder and Debenture holder?

ii) Determine the Economic Ordering Quantity from the following data.

Average Annual Demand = 30,000 units

Inventory Carrying Cost = Rs.2.50 per unit

Cost of placing an order = Rs.70

B. i) A machine was purchased for Rs.12000. The estimated useful life of the machine is5 years. The scrap value is Rs.2000. Find out the depreciation rates determinedfrom the following methods.a) Straight Line method

b) Sinking Fund Method with an interest rate of 5% on depreciation fund.

ii) Discuss about ABC Analysis with a graph. List out its advantages.

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2306 CAD / CAM

VI – TERM (Applied Course )


MAJOR DIVISIONS

UNIT I Computer Aided Design and Geometric Modelling

UNIT II Computer Aided Manufacturing and CIM

UNIT III CNC Machines

UNIT IV CNC Components & Part Programming

UNIT V GT-FMS-AGV-Robotics

UNIT-I: COMPUTER AIDED DESIGN AND GEOMETRIC MODELLING(16 Hrs)

Introduction – CAD definition – activities – benefits of CAD – Stages of CAD –CAD hardware – Input and Output devices – display devices – types of CAD system – CADsoftware – AutoCAD – Auto CAM – computer communications – principle of net working -network techniques – graphic work station.

Interactive graphics – 2D and 3D transformation – geometric modelling techniques–types of geometric models – wire frame – surface model – solid modeling – geometric entities– curves and surfaces – combined solids primitives – advantages of wire frame, surface, solidmodels – graphic standards – GKS – IGES–DXF.

UNIT II : COMPUTER AIDED MANUFACTURING AND CIM (16 Hrs)

CAM definition – Function of CAM – benefits of CAM – Integrated CAD/CAMorganization – process planning – structure of process plan – operations of a typical CAPP- Computerintegrated production system – Master production schedule – capacity planning – shop floorcontrol – Material requirement planning (MRP) – Manufacture resource planning (MRP II) – Justin time manufacturing philosophy (JIT)

Concept of CIM – Evaluation of CIM – CIM hardware – software- Introduction tointelligent manufacturing system.

UNIT III : CNC MACHINES (16 Hrs)

Numerical control – Definition – Components of NC systems- Development of NC-DNC- CNC and adaptive control systems- Working principle of a CNC System- Advantages ofCNC machines – difference between NC and CNC – Types of Turning centre- horizontal,vertical machines- CNC machining centres - horizontal spindle, vertical spindle, universalmachines .

CNC drilling, grinding, EDM machines -Coordinate measuring machines-construction, working principles and specifications-maintenance of CNC machines- Integrationof CNC machines in CIM environment – hierarchical planning and control concepts.

81

UNIT IV : CNC COMPONENTS & PART PROGRAMMING (20 Hrs)

Spindle drives- DC drive – AC drive spindles – slide ways- linear motion bearings –Recirculation ball screw – ATC – tool magazine – feedback drives – rotary encoder disc –linear transducer.

NC part program – manual part program – CNC program procedure – co-ordinatesystem – reference points – zero points – preparatory and miscellaneous functions (G-Codes &M - Codes) – part program – conversational programming – APT programming – toolinformation – speed – feed data – interpolation – macro – subroutines – canned cycles – mirrorimage – thread cutting – sample program for lathe, milling, drilling - EDM – milling centre /turning centre.

UNIT V : GT-FMS-AGV-ROBOTICS (16 Hrs)

Group technology – part family – classification and coding – coding structure –Opitz, MICLASS, code system, DCASS system –facility –design using group technology –economic modeling in a group technology environment – benefits of GT.

FMS introduction – components of an FMS system – workstations – material handling& storage –planning of FMS – computer controlled system – application and benefits of FMS.

AGV – components – functions – benefits.

Robot – definition – basic elements of a Robot – types – applications – geometricalrequirement of CAD/Robot linkage – integration of Industrial Robot in a CIMsystem.Ergonomics – aesthetics – elements of product design – ergonomic factor.

REFERENCE BOOKS:1. Groover.M.P & Zimmers.E.W, “CAD/CAM Computer Aided Design and

Manufacturing”, Prentice Hall of India, 1999.2. Radhakrishnan.P, Subramaniyan.S & Raja.V, “CAD / CAM / CIM”, New Age

International Ltd, 2001.3. Ibrahim Zeid, “CAD / CAM Theory and Practice”, Tata McGraw Hill, 2001.4. Sadhu Singh, “Computer Aided Design and Manufacturing”, Khanna Publisher, 2004.5. P.N.Rao, “CAD / CAM”, Tata McGraw Hill, 2002.

82

2306 CAD/CAM




2. Answer any one from Part – A (5 Marks ) and any one from Part – B(10 Marks)

I. A. i) Define CAD.State the activities of CAD.

ii) What are the advantages of wireframe modelling?

B. i) Briefly explain the hardware of a CAD system.

ii) Briefly explain the ‘CSG’ and ‘B-rep’ techniques used in solid modelling.

II. A. i) State the benefits of CAM.

ii) Write notes on Manufacture resource planning.

B. i) Explain the operations of a typical CAPP software.

ii) Briefly explain the hardware of a CIM System.

III.A. i) Compare NC and CNC System.

ii) Write down the important weekly maintenance activities of CNC Machine.

B. i) Explain the construction and working of a vertical milling centre.

ii) Explain the construction and working principle of a coordinate measuring machine.

IV. A. i) Write notes on “Recirculation ball screw”.

ii) What is meant by preparatory and miscellaneous function?

B. i) Explain reference points and zero points in CNC with simple diagram.

ii) Write a CNC part program to machine the following component.

V. A. i) Describe opitz coding system in GT.

ii) State the elements of product design.

B. i) Explain the components of a FMS System.

ii) Define Robot.Describe the mechanical configuration of Robot with sketches.

83

2403A REFRIGERATION AND AIR CONDITIONING

VI – TERM (Diversified Course - II)


UNIT I (a) Refrigeration system

(b) Refrigeration equipments

UNIT II (a) Vapour compression refrigeration system

(b) Vapour absorption refrigeration system

UNIT III (a) Refrigeration flow controls, refrigerants and lubricants

(b) Applications of refrigeration

UNIT IV Psychrometry and comfort air conditioning

UNIT V (a) Air conditioning systems

(b) Cooling load calculations

UNIT I (18 Hrs)

(a) REFRIGERATION SYSTEM

Thermodynamic state of a pure substances, modes of heat transfer –laws of heattransfer - mechanisms of production of cold - unit of refrigeration –types of refrigeration –reversed Carnot cycle - C.O.P of heat engine-heat pump- refrigerating machine – principle ofworking of open and closed air system of refrigeration – advantages and disadvantages –problems.

(b) REFRIGERATION EQUIPMENTS

Compressor – principle of working and constructional details of reciprocating androtary compressors, hermetically and semi hermetically sealed compressors- condensers-principle of working and constructional details of air cooled and water cooled condensers,evaporative condensers- advantages and disadvantages - natural and forced draught coolingtowers.

Evaporators- natural circulation and forced circulation type – principle of working -constructional details.

UNIT II (15 Hrs)

(a) VAPOUR COMPRESSION REFRIGERATION SYSTEM

Principle of working of vapour compression system – analysis of vapour compressioncycle using T-s diagram and p-H diagram- refrigeration effect- compression work - C.O.P -effect of superheating and under cooling - problems – effect of evaporative pressure andcondenser pressure - liquid –vapour refrigeration heat exchangers - advantages and disadvantagesof superheating and under cooling –use of flash chamber and accumulator.

84

(b) VAPOUR ABSORPTION REFRIGERATION SYSTEM

Simple absorption system – Electrolux system -NH3 and Lithium Bromide system –comparison with mechanical refrigeration system.

UNIT III (11 Hrs)

(a) REFRIGERANT FLOW CONTROLS, REFRIGERANTS AND LUBRICANTS

Capillary tube-automatic expansion valve-thermostatic expansion valve- solenoidvalve-evaporator pressure regulator –suction pressure regulator-selection of a refrigerant-properties and applications of following refrigerants - SO2 , CH4 , F11, F12 , F22, and NH3 –lubricants used in refrigeration and their applications.

(b) APPLICATIONS OF REFRIGERATION

Slow freezing –quick freezing- cold storage-frozen storage-freeze drying –dairyrefrigeration –ice cream cabinets-ice making – water cooler, milk cooler, bottle cooler-frostfree refrigeration.

UNIT IV (13 Hrs)

PSYCHROMETRY AND COMFORT AIR CONDITIONING

Definitions of dry air, moist air, water vapour, Avagadro’s law, Dalton’s law of partialpressure - dry and wet bulb temperature - dew point - humidity - specific and absolute -relative humidity - degree of saturation - enthalpy of moist air- adiabatic saturation of air byevaporation of water- psychrometric chart and its uses – psychrometric processes – sensibleheating and cooling - humidifying and heating - dehumidifying and cooling - adiabatic coolingwith humidification - total heating or cooling processes -sensible heat factor - Bypass factorwith simple problems – factors governing optimum effective temperature – comfort chart-design consideration.

UNIT V (15 Hrs)

(a) AIR CONDITIONING SYSTEMS

Equipment for air conditioning and insulation factors – air purification – tempera-ture control – humidity control – dry and wet filters- centrifugal dust collector – air washerhumidifier – dehumidifier - fans and blowers – grills and registers – summer and winter airconditioning, window type air conditioner – central plant system – properties of ideal insulator,types of insulating materials –air distribution and duct systems – tools and installation, servicingand maintenance of R & AC systems.

(b) COOLING LOAD CALCULATIONS

Different heat sources – conduction heat load – radiation load of sun – occupantsload – equipment load - infiltration air load – miscellaneous heat sources –fresh air load -simple problems.

85

REFERENCES BOOKS1. S.C.Arora & S.Domkundwar, “A Course in Refrigeration & Air Conditioning”

Dhanpat Rai & Sons, 1989.

2. Domkundwar, “A Course in Refrigeration and Air Conditioning ”, Dhapat rai, 1998.3. Dossat, “Principles of Refrigeration”, Pearson Education, 2003.4. C.P.Arora, “Refrigeration & Air Conditioning”, Addison Wesley, 2000.5. Prasad.M, “Referation and Air Conditioning”, New Age International, 1999.

86

2403 A REFRIGERATION AND AIRCONDITIONING




2. Answer any one from Part – A (5 Marks ) and any one from Part – B(10 Marks)

I. A. i) What is Unit of Refrigeration?

ii) What are the advantages of Forced Draft Cooling Towers?

B. i) Explain the construction and working details of Vane type Rotary Compressor.

ii) Explain the Construction and working details of Mechanical Draft CoolingTowers

II. A. i) Explain the use of Temperature-Entropy diagram

ii) Explain the use of Flash Chamber in Refrigeration.

B. i) Explain the Construction and working details of Electrolux Refrigeration System.

ii) An Ammonia Refrigeration Plant produces 30 Tons of ice at 0 °C in 24 Hrs.Temperature range in the compressor is from 25 °C to - 15 °C. The vapour is drysaturated at the end of compression. Assume a COP of 60% of the theoretical,calculate the Power required in KW to drive the compressor. Latent Heat of ice is335 KJ/Kg

III.A i) What are the properties of an ideal refrigerant.

ii) Explain Airblast type of freezing

B i) Explain the Working of Automatic Expansion Valve with a neat sketch.

ii) Explain the Freeze Drying method of preservation of products in detail.

IV. A. i) What are the factors governing Optimum Effective Temperature.

ii) Define : (a) Water Vapour (b)Dew Point Temperature(c)Degree of saturation

B. i) Explain the Humidifying and Heating process with Psychrometric Chart

ii) In a cooling application , moist air enters at the rate of 100 Kg per minute at 35 °Cand 50% RH. The Apparatus DewPoint of the coils is 5°C and Bypass Factor is0.15. Determine

E n t h a l p y ( K J / K g ) E n t r o p y ( K J / K g . ° K ) T e m p ( ° C )

h f h g s f s g

- 1 5 - 5 4 . 5 6 1 3 0 4 . 9 9 - 2 . 1 3 3 8 5 . 0 5 8 5

2 5 1 0 0 . 0 4 1 3 1 9 . 9 2 0 . 3 4 7 3 4 . 4 8 5 2

87

a) Outlet condition of moist air

b) Capacity of the cooling coil

V A. i) Briefly explain about the Centrifugal Dust Collector

ii) What are the advantages of Central Air Conditioning System

B. i) Describe various types of Duct Systems employed to supply conditioned air tooutlets

ii) A spray cooling coil is chosen to operate under the following conditions.

Air inlet condition = 28 °C DBT and 21°C WBT

Air outlet condition = 28 °C DBT and 21°C WBT

Total Amount of Airflow = 2000 m3/min

Chilled water inlet and outlet conditions are 7°C and 12°C respectively. Find the following

a) Cooling Load on the coil

b) Water flow rate through the coil.

88

2403B MECHATRONICS

VI - TERM (Diversified Course - II)


MAJOR DIVISIONS

UNIT – I Theory of Mechatronics

UNIT – II Sensors and Transducers

UNIT – III Actuators

UNIT – IV Programmable Logic Controller

UNIT – V Industrial Design and Fault finding

UNIT – I : THEORY OF MECHATRONICS (17 Hrs)

Automation – definition – need, advantages and disadvantages of automation -Mechatronics -What is mechatronics – Definition of mechatronics – benefits of mechatronics -Mechatronicsin manufacturing – Mechatronics in products – Mechatronics &Engg. Design – A modularapproach to mechatronics & Engg. Design – The engineer & mechatronics – mechatronicstechnology – Mechanical systems & design – Tradition Vs Mechatronics – The mechatronicsapproach – Replacement mechanism – simplification mechanism – Enhancement mechanism– Synthesis of mechanism – control – The design process.

UNIT – II : SENSORS AND TRANSDUCERS (15 Hrs)

Sensors and Transducers – Performance terminology- Displacement, position andproximity – Velocity and motion – Force – Fluid pressure, Liquid flow, liquid level – temperature- light sensors – selection of sensors.

UNIT – III : ACTUATORS (12 Hrs)

Pneumatic and Hydraulic System

Actuation systems, pneumatic and hydraulic systems, Directional control valves,Pressure control valve, Cylinders, Process control valves, Rotary actuators.

Electrical actuation systems

Electrical systems, mechanical switches, solid state switches, solenoids principle ofworking, types, specification and control of DC motor – AC motors , Stepper motors.

UNIT – IV : PROGRAMMABLE LOGIC CONTROLLER (14 Hrs)

Basic structure – Input / Output processing – Programming – mnemonics – Timers,internal relays and Counters – shift register – Master and jump controls – Data handling –Analogue input/output – selection of PLC – Introduction to signal processing (QualitativeTreatment only)

89

UNIT – V : INDUSTRIAL DESIGN AND FAULT FINDING (14 Hrs)

Man-M/C interface

Industrial design & Ergonomics – Introduction – elements of product design – ergo-nomic factors for advanced manufacturing systems.

Information transfer – from M/c to Man- Human response to stimuli - Informationfrom man to m/c

Fault finding

Fault detection techniques – common hardware faults.

Possible design solutions – Timed switch , bathroom scales.

REFERENCES

1. Mechatronics – Second Edition - W.Bolton –Pearson Education Asia.

2. Mechatronics – Hmt. Tata Mcgraw-Hill Publishing Company Limited, New Delhi 1998.

3. Mechatronics: (Electronics In Products And Processes) By .A. Bradley and others -Chapman And Hall

4. Fundamental of Mechatronics By C.R. Venkataraman - Sapna Book House, Bangalore –560019.

5. Mechatronics system design - Devadas Shetty & Richard A. Kolk

90

2403 B MECHATRONICS



NOTE : 1. Answer all questions . Choosing any one from Part –A (5marks)

And one from Part – B (10marks)


I. A. i) Write any three advantages and disadvantages of Automation.

ii) Give the benefits of Mechatronics.

B. i) Explain briefly about the major elements in a Mechatronics system.

ii) Explain the Mechatronics design process.

II. A. i) Write the application of any two types of proximity sensors in Mechatronics.

ii) How the sensors are selected.

B i) Explain any one displacement sensor with sketch.

ii) Explain the principle of operation of a strain gauge. When it is employed?

III A. i) What is the pressure control valve?

ii) Describe the principle of working of a solenoid.

B. i) Briefly explain elements used in hydraulic system.

ii) Explain the principle of operation and controlling of a stepper motor

IV A. i) Give the Basic structure of PLC.

ii) Write short notes on selection of PLC.

B i) What are methods available for programming PLC. Explain any one type .

ii) Explain How the data handling done in PLC.

V A i) Give the elements of product design.

ii) What are the common hardware faults.

B i) Briefly explain how information transfer from machine to man & man to machine.

ii) Explain the design solutions to bathroom scales.

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2307 CAD/CAM LAB

VI TERM (Applied Course)

6 Hours/ Week Total Hours – 72 hrs

CAD LAB

I. 3D CAD DRAWING – STUDY IN SOLID MODELLING ( Not for Examination)

1. a) Predefined 3D objects - converting 2D plan into a 3D model - 3D mesh - 3D face -3D poly- Creating surfaces-Rulsurf - Revsurf - Tabsurf -Edgesurf -isolines - 3DView - viewports - VPoint - hide-dview- model space - paper space.

b) 3D solid primitives -creating region-pedit- extrude - revolve - combining object -union - subtract - intersect - Align - Fillet - Chamfer-Advanced 3D editing techniques-align- 3D array - Mirror3D - Rotate3D.

2. a) Working with UCS - 3D Coordinate system - DDUCS - Plan - UCS icon

b) Solids Rendering - materials attaching and detaching- Shade with colour -Slice andsectioning - script - 3D Orbit-calculating mass properties.

II. COMPONENT DRAWING PRACTICE IN 3D

1. Gear wheel – Geneva

2. Square headed bolt and hexagonal nut

3. V - Block

4. Bushed Bearing

5. Wall Bracket

6. Piston with rings / Flange coupling

7. Screw Jack

8. Nozzle / Machine vice

CAM LAB

I. STUDY EXERCISES ( Not for Examination)

1. Introduction to CNC, CNC Turning and Milling Center.

2. G codes and M codes, Structure of program, Simulation Software practice

II. EXERCISES IN CNC MACHINES & CNC SIMULATION PACKAGE

( Using CNC HMT Econo Junior Lathe, Denford CNC Trainer Lathe, Denford CNCMilling Machine)

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1. Step Turning operation using canned cycle in CNC lathe

2. Turning operation for circular interpolation using simulation package

3. Taper turning & Peck drilling operation using simulation package

4. Thread Cutting & Grooving operation using canned cycle in CNC lathe

5. Milling operation for linear & circular interpolation in CNC Milling Machine

6. Milling operation for circular interpolation & Drilling using simulationpackage

7. Drilling & Counter boring operation using simulation package

8. Milling operation for Mirror image using simulation package

9. Simple exercise of machining a component using Master CAM software.

CAM LAB EXERCISES

1. Step Turning

2. Turning - Circular Interpolation

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3. Taper Turning & Peck Drilling

4. Thread Cutting and Grooving

5. Milling for Linear & Circulation Interpolation

6. Milling for Circular Interpolation & Drilling

94

7. Counter Boring & Drilling

8. Milling for Mirror Image


or

S.No Topic Marks

1A 3D solid Drafting & Calculate Mass properties 55

1B CNC Program writing 15

Viva Voce 5

Total 75

S.No. Topics Marks

1A CNC Program writing , Simulation and Machining 55

1B 3D Solid Modelling Commands Sequence 15

Viva Voce 5

Total 75

95

2404 A REFRIGERATION AND AIR CONDITIONING LAB

VI –TERM ( Diversified Course Lab - II )

6 Hrs /Week Total Hours : 72 Hrs

1. a) Study of various sizes of copper tubing

b) Study of Refrigeration Tools

2. Various operations on copper tubing

a) Cutting

b) Bending

c) Flaring.

d) Swaging

3. Soldering operation on copper tubing

4. Study of constructional features of the following

a) Domestic Refrigerator

b) Water Cooler

c) Window Air Conditioner

4. Set and adjust the following equipments

a) Thermostat.

b) Low pressure and High pressure cut out.

c) Thermostatic expansion valve.

6. Determination of Refrigerating Effect, C.O.P and Compressor Capacity of an open typesystem with Capillary tube

7. Determination of Refrigerating Effect, C.O.P and Compressor Capacity of an open typesystem with Thermostatic expansion valve

8. Determination of the C.O.P of a sealed system

9. Determination of the Capacity of a Window Air Conditioner.

10. Determination of the Efficiency of a Cooling Tower

11. Determination of the Capacity of a Car Air Conditioner.

12. Determination of the Capacity of a Cooling Coil

13. Dismantling and Assembling of Window Air Conditioner.

14. Wiring of Refrigerator

15. Wiring of Window Air Conditioner

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16. a) Transferring the refrigerant from storage cylinder into service cylinder.

b) Evacuate the entire system

17. a) Pumping down the refrigerant from the system

b) Charging the refrigerant in the system

18. Purging air from the system

19 a) Locating leaks in a system.

b) Checking oil level in the compressor.

20. Tracing common faults in R & A/ C units and their remedies.


S . N o T o p i c M a r k s

1 E x e r c i s e ( C O P / C a p a c i t y / E f f i c i e n c y ) 5 0

2 V a r i o u s o p e r a t i o n s o n c o p p e r t u b e / S e r v i c i n g / S t u d y E x e r c i s e 2 0

3 V i v a V o c e 5

T o t a l 7 5

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2404B MECHATRONICS LAB

VI - TERM ( Diversified Course - II )


I . PNEUMATICS

1. a) Study of pneumatic system - elements - pressure control valves - directional controlvalves (DCV)

b) Direct operation of a single acting cylinder.

2. a) Direct operation of a double acting cylinder.

b) Operations of single acting cylinder controlled from two different positions usingshuttle valve.

3. a) Operation of a double acting cylinder with quick exhaust valve.

b) Speed control of double acting cylinder using metering in and metering out circuit.

II . SENSORS

1. Strain measurement using strain gauge.

III . MICROPROCESSOR AND MICRO CONTROLLER BASED KIT

(Control system flow chart)

1. a) Microprocessor based D.C. motor control.

b) Microprocessor based stepper motor control.

2. Microprocessor based controlling of different outputs(Stepper motor, DC motor

& 230V AC bulbs etc.,) by using inputs.

3. Controlling of DC motor using 8051 micro controller kit.

4. Controlling of Stepper motor using 8051 micro controller kit.

IV. PROGRAMMABLE LOGIC CONTROLLER (PLC)

Relay ladder logic (RLL) programming

(using siemens s7 200, allen bradley micrologix 1500 & Keyence plc)

1. a) Study of PLC system and its elements.

b) Operation of a motor using AND logic control.

2. a) Operation of a motor using OR logic control.

b) Direct operation of a motor using latch circuit .

3. a) On-delay timer control of a motor.

b) Off-delay timer control of a motor.

4. a) PLC based temperature control.

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b) Programming for Automatic Battery tester.

5. Programming for Elevator.

6. Programming for traffic control.

7. Speed control of DC motor using PLC.

V . CNC CONTROL SYSTEM

1. a) Study of CNC controller Sinumeric 802S (Specifications & Elements of the system)

b) Programming on Sinumeric 802S CNC system and Diagnostics.

2. a) Write a CNC part program for turning operation, execution and verification onSinumeric 802S.

b) Write a CNC part program for drilling operation, execution and verification onSinumeric 802S.

VI . LSM CONTROLLER

HIGH LEVEL PROGRAMMING (Visual basic)

1.a) Control of DC servo motor in open loop with and without time delay using LSM controller.

b) Control of DC servo motor in closed loop with and without time delay using LSMcontroller.

2. a) Loop operation of LSB between two positions without and with time delay andnumber of times by using LSM controller.

b) Integrated control of AC non servo motor, Pneumatic cylinder and axes drives byPLC using LSM controller.

3. a) Control of pneumatic cylinder Number of strokes with and without time delay.

b) Control of AC non servo motor in clock wise and anti clock wise direction with andwithout time delay.

4. a) Control of pneumatic cylinder and AC non servo motor by using digital inputs.

b) Making Slider crank Mechanism using Creative Kit


S.No Topic Marks

1 Pneumatics / Sensors / Microprocessor / Micro controller based kit

30

2 PLC / CNC Control System / LSM Controller 40

3 Viva Voce 5

Total 75

99

2308 PROJECT WORK, ENTREPRENEURSHIP AND PERSONAL SKILLS

VI- TERM (Applied Course )

3Hours /Week Total Hours : 36 Hrs

I. PROJECT WORK - INCLUDING REPORT

1. PROJECT WORK

A Project is a task in a selected area engaged by an individual or group of Studentswith guidance of one or two faculty and / or from an Industry.

2. REPORT

The students should submit project report for evaluation. The project report shouldcontain synopsis, description, detailed work and drawings, cost particulars, performance studyreport, any improvements needed, conclusion and bibliography.

II. PERSONAL SKILLS

The student is evaluated in the following areas are related to his project.

1. COMMUNICATION SKILL (PROJECT PRESENTATION)

Each student is to give a seminar in the project work.Presentation by OHP / Powerpoint is preferred.

2. GROUP DISCUSSION

The students will be evaluated by 1.participation 2. Respecting others view 3.Accepting ones own mistakes 4. Reaction 5. Team sprit.

3. INTERVIEW / VIVA VOCE

The students will be asked to answer the questions for the interview may be theproject or any other relevant subject. regarding the project in English only.

III. ENTREPRENEURSHIP

Objective type questions may be asked in the Examination for a period of 1Hour.

MAJOR DIVISIONS

UNIT 1 Entrepreneurship

UNIT 2 Business Counseling

UNIT 3 Finance

UNIT 4 Marketing

UNIT 5 Industry

UNIT 1 : ENTREPRENEURSHIP

Definitions of Entrepreneurship – Characteristics of Entrepreneurship – Traits of aentrepreneur – Types of entrepreneur – Functions of an entrepreneur – Behavioral patterns ofentrepreneurs.

100

UNIT 2 : BUSINESS COUNSELLING

Business opportunity guidance – Project identification – Techno-economic survey –Market research – Project formulation – Project selection – Project report format – Contents ofproject report.

UNIT 3 : FINANCE

Sources of finance – Types of loans available – Financial Institutions – Institutionsassisting entrepreneurs.

UNIT 4 : MARKETING

Marketing channels – Channel design – choice of channel – Alternative channels ofdistribution – Mercantile agents – Merchant middlemen – Wholesalers – Retailers.

UNIT 5 : INDUSTRY

Types of industries – Steps for starting a small industry – preparation of projectreport – Guidelines, procedures, and formalities for registration – Selection of type oforganisation – Sole proprietorship – partnership – Joint stock company – Factors influencingthe choice of an organisation.

REFERENCE BOOK

Entrepreneurial Development - O.P.Gupta, N.P. Srinivasan


S.No. Topic Marks

1 Project work / Personal skills / Viva voce 50

2 Entrepreneurship (25 Questions X 1 Mark) 25

Total 75

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