MURUGAPPA POLYTECHNIC COLLEGE Sathyamurthy Nagar, …

L-Scheme Approved in 35th

Academic Board meeting held on 26.2.2013, MPC Page 1 of 184

MURUGAPPA POLYTECHNIC COLLEGE

Sathyamurthy Nagar, Chennai-62

(Academically Autonomous Institution)

REGULATIONS 2012

L - SCHEME

REGARDING ADMISSION, EVALUATION, AWARD OF DIPLOMA UNDER ACADEMIC AUTONOMY APPROVED

IN THE 35TH

ACADEMIC BOARD

DIPLOMA COURSES IN ENGINEERING (SIX-SEMESTER REGULAR, SEVEN-SEMESTER SANDWICH FULL-TIME AND EIGHT SEMESTER PART-TIME)

1. CANDIDATES FOR ADMISSION

1.1 AGE LIMIT

Candidates for admission into the first semester of six-semester Regular, seven-semester Sandwich, eight- semester Part-Time Diploma Courses and to the third semester Regular Diploma courses under Lateral Entry shall satisfy the age limit as prescribed by the Directorate of Technical Education. 1.2 QUALIFICATIONS

1.2.1. Candidates seeking admission into Full-Time and Part-Time Diploma Courses shall be required to have passed X standard examination of the State Board of Education, Tamil Nadu or any other equivalent examination already recognised by the Directorate of School Education Board, Tamilnadu with eligibility for admission to First year of Higher Secondary School in Tamil Nadu. For Part-Time Diploma Course candidates, in addition, weightage is given for industrial experience as prescribed by the Directorate of Technical Education. 1.2.2. Candidates seeking admission to the Second Year (III Semester) of Regular Diploma Courses under Lateral Entry shall be required to have passed the Higher Secondary Certificate (HSC) Examination (Vocational) or 2 year Industrial Training Institute (ITI) Certificate Examination after passing X Std. Examination of State Board of Education as prescribed by the Directorate of Technical Education. 1.3 ELIGIBILITY

Candidates seeking admission shall satisfy the eligibility conditions such as subjects, marks, number of attempts etc, as prescribed by the Directorate of Technical Education, Tamil Nadu.

2. DURATION OF COURSE

The duration for the Full-Time Regular Diploma Course shall be 6 consecutive semesters and for the Sandwich Diploma Course shall be 7 consecutive semesters and spread over 3 and 3 ½ academic years respectively, and for Part-Time Diploma Course shall be 8 consecutive semesters spread over 4 academic years. Each semester shall have a minimum duration of 16 Weeks. One academic year constitutes two semesters. The minimum and maximum period for completion of Diploma Courses are as given below:

Minimum Maximum Regular Diploma Students 3 years 6 years

Lateral Entry Students 2 years 5 years Sandwich Diploma Students 3½ years 6½ years

Part-Time Diploma Students 4 years 7 years



3. BRANCHES OF STUDY

Candidate may be offered at the time of admission, one of the following branches of study or such other branches of study as may be instituted from time to time.

Branch Full-Time Diploma Course Part-Time Diploma Course Civil Engineering Regular and Sandwich Regular

Mechanical Engineering Regular and Sandwich Regular Electrical & Electronics Engineering Regular and Sandwich Regular

Electronics & Communication Engineering

Regular and Sandwich Regular

Computer Engineering Regular --- Mechanical Engineering (Tool & Die) Sandwich Regular

Electronics (Robotics) Sandwich -----

4. SUBJECTS OF STUDY

The subjects of study shall include theory and practical as detailed in the Curriculum. The curriculum also includes project work for Full-Time Regular and Sandwich Diploma Courses as well as for Part-Time Regular Diploma Courses and Industrial training for Sandwich Diploma Courses. 5. EVALUATION OF PERFORMANCE

5.1 THEORY SUBJECTS: The evaluation of students performance in each one of the theory subjects, shall be by continuous assessment comprising two assessment tests, one model exam, one assignment, attendance and an end-semester examination as mentioned below: # 2 Tests of 1 hour duration each for 30 marks shall be conducted and the average mark of the two tests

shall be taken and reduced to 10 marks.

## Model Examination of 3 hour duration for 100 marks shall be conducted during the last week of the semester and marks scored shall be reduced to 5 marks. * For each theory subject, one Assignment is to be given for 30 marks and the marks scored shall be reduced to 5 marks.

** Marks for attendance shall be awarded only to candidates securing above 80% attendance (Minimum required for completion of semesters, (vide clause 8)).

80% - 84% 0-1 mark 84% - 88% 1-2 marks

88% - 92% 2-3 marks 92% - 96% 3-4 marks 96% - 100% 4-5 marks

i.e. 0.25 marks for each percent above 80% *** Answer scripts are valued for 100 marks and reduced to 75 marks as End semester Examination marks.

Components Duration Marks Max. Marks Continuous Assessment (CA) 25

CA Test I and II # 1 Hr. 10 Model Exam## 3 Hrs. 5

Assignment* 5 Attendance** 5

End Semester Examination*** 3 Hrs. 75 Total 100



5.2. PRACTICAL SUBJECTS: (a) For practical subject except “Communication and Life Skills Practical” the Continuous Assessment marks shall be 25 and the End Semester Examination shall be 75. Continuous Assessment and End Semester Examination marks will be assigned as mentioned below: ** Marks for attendance shall be awarded similar to theory subjects. b) For practical subject “Communication & Life Skills Practical” the Continuous Assessment marks shall be 50 and the End Semester Examination shall be 50. Continuous Assessment and End Semester marks shall be assigned as mentioned below:

Components Marks Maximum Marks

Continuous Assessment 50 Professional Communication 20

Life Skills 15 Record 10

Attendance ** 5 End Semester Examination 50

Monodic Communication 30 Dyadic Communication 20

Total 100 ** Marks for attendance shall be awarded similar to theory subjects. 5.3 PROJECT WORK: The evaluation of Project work shall be based on Continuous Assessment consisting of

two periodical Reviews during final semester and End Semester Examination consisting of written test, project report and viva-voce, demonstration and explanation.


Continuous Assessment 25 First Review 10

Second Review 10 Attendance ** 5

End Semester Examination 75

Viva Voce 15

Project Report 10 Demonstration/Explanation 15

Applicability of the Project 05 Written Test 30

Total 100 ** Marks for attendance shall be awarded similar to theory Subjects.

Written Test in 3 topics:

a) Entrepreneurship 5 questions x 2 marks = 10 b) Environment Management 5 questions x 2 marks = 10 c) Disaster Management 5 questions x 2 marks = 10


Continuous Assessment 25 Record 10

Mid Semester Test 10 Attendance ** 5

End Semester Examination 75 Total 100



5.4 INDUSTRIAL TRAINING: Industrial Training for Sandwich Diploma Course students shall be evaluated based on continuous assessment consisting of two periodical Reviews and End Semester Examination of Training Report and viva voce. ** Marks for attendance shall be awarded similar to theory subjects.

6. CLASS ADVISER

The Class Adviser shall be a member of the faculty of the concerned Department to whom a certain member of students of the Department will be assigned. His/her responsibilities are:

• To help the students in planning their subjects of study.

• To give general advise on academic performance.

• To monitor attendance and academic performance of each student.

• To prepare and send the performance evaluation report to the parent / guardian. • To intimate the parent/guardian about the poor performance / attendance.

7. CLASS COMMITTEE

7.1 Branch-wise class committee will be constituted by the Principal every semester with the following members. 1. Teachers of all subjects 2. Two student members from each class nominated by the Head of Department. 3. Class advisers of all classes. 4. Head of Department/Department In-charges – Chairperson 7.2. First and Second Semester Class Committees will be constituted by the Principal with the following members:

1. One senior faculty of each subject. 2. Two student members from each section 3. Department In-charge of General Engineering Department – Chairperson

7.3. The basic responsibilities of the class committee are to review periodically the progress of the classes, and to discuss problems concerning curricula and syllabi, and conduct of classes and to approve the Continuous Assessment marks. 7.4 The class committee shall be required to meet thrice in a semester, first at the beginning of the semester, second in the middle of the semester and third at the end of the semester to approve the continuous assessment marks of the classes.

8. ATTENDANCE REQUIREMENT FOR COMPLETION OF A SEMESTER

A student shall secure not less than 80% attendance during the semester for the completion of a semester.


Continuous Assessment 50 First Review 20

Second Review 20 Attendance** (present in the industry) 10

End Semester Examination 50

Training Report 20

Viva voce 30 Total 100



9. COURSE REPETITION

9.1 A student who secures less than 80% of attendance in a semester, has to repeat all the subjects of that Semester (vide clause 8) in the next academic year 9.2 A student who has not appeared at least in a single examination in theory or practical or project work or industrial training of a particular End-Semester Examination, cannot continue his / her studies in the next semester even if he / she has 80% or more attendance in that semester. 9.3 A student who has fulfilled the attendance requirements and has appeared in any one subject in current semester is not eligible to repeat the same semester.

10. REQUIREMENTS FOR APPEARING IN END SEMESTER EXAMINATION

A candidate shall normally be permitted to appear for the end semester examination of the current semester if he/she has satisfied the semester completion requirements (vide clause 8) and has registered for examination in all subjects of the semester and also has registered for examination in all subjects of earlier semester/s in which he / she has not passed.

11. SANDWICH DIPLOMA COURSE

11.1. The performance and attendance of a student of Sandwich Diploma Course during Industrial Training has to be satisfactory to continue in the Sandwich Diploma Course, otherwise the student has to repeat the Industrial training or discontinue the Diploma Course. The Sandwich Diploma Course Industrial Training is regulated by the Apprenticeship Amendment Act 1983.

11.2. Sandwich Diploma Course students shall complete the industrial training for one year in two spells of six

months each during the course of study, first spell of Industrial Training during the fourth semester and the second spell during the seventh semester.

12. SUBJECTWISE PASSING REQUIREMENTS

12.1. For a pass in the Theory Subject, a student should secure a minimum of 30 marks out of 75 marks in the End Semester Examination and 40 marks out of 100 marks, the Aggregate of Continuous Assessment marks and End Semester Examination marks.

12.2. For a pass in Practical Subject, except the subject “Communication & Life Skills Practical” a student should secure a minimum of 35 marks out of 75 marks in the End Semester Examination and 50 marks out of 100 marks, the Aggregate of Continuous Assessment marks and End Semester Examination marks.

12.3. For a pass in the subject “Communication & Life Skills Practical” and “Industrial training”, a student

should secure a minimum of 25 marks out of 50 marks in the End Semester Examination and 50 marks out of 100 marks, the Aggregate of Continuous Assessment marks and End Semester Examination marks.

12.4. For a pass in Project Work, a student should secure a minimum of 35 marks out of 75 marks in end

semester examination and 50 marks out of 100 marks, the Aggregate of Continuous Assessment marks and end semester examination marks.

12.5. If a student fails in a subject, the Continuous Assessment Marks obtained by him/her in the first

attempt shall be retained and considered valid for all subsequent attempts.



13. DISCIPLINE AND MALPRACTICE IN THE EXAMINATION

13.1. Every student is required to be disciplined and to have decorous behaviour both inside and outside the campus and not to indulge in any activity, which will tend to bring down the prestige of the institution.

13.2. Any act of malpractices by a student during the examinations, such as copying from the answer books

of other students, possession of cell phones, written / printed matters, showing / transferring answer books, discussing with other candidates etc., notified from time to time, will be punishable and will entail debarring from writing the examination up to a maximum of three years and also cancellation of the marks obtained in all the subjects in which the student has appeared during the particular end semester examination by the Awards Committee.

14. CLASSIFICATION OF SUCCESSFUL CANDIDATES

14.1. All successful candidates who secure 75% aggregate marks and above, in all the subjects of 3rd semester to 6th semester and project work for the Regular Diploma Course and in all the subjects of 3rd semester to 7th semester, Project work and industrial training for the Sandwich Diploma Course, and in all subjects of 3rd semester to 8th semester and project work for the Part-Time Diploma Course, passed in FIRST APPEARANCE in the respective semester examinations and also passed in all subjects of First and Second Semester Examinations within the stipulated period of study of 3 years for Full time Regular Diploma Courses, 3½ years for Sandwich Diploma Courses and 4 years for Part-Time Diploma Courses without any break will be declared to have passed in FIRST CLASS WITH

DISTINCTION.

14.2 All candidates who secures aggregate marks 60% and above but below 75% of marks in all the subjects of 3rd to 6th semester and project work for the Regular Diploma Courses, in all the subjects of 3rd semester to 7th semester, project work and industrial training for the Sandwich Diploma Course, and in all subjects of 3rd semester to 8th semester and project work for the Part-Time Diploma Course, and also passed in respective semester examinations including all the subjects of First and Second semester within the stipulated period of 3 years for Regular Diploma Courses and 3½ years for Sandwich Diploma courses and 4 years for Part Time Diploma Courses and without any break will be declared to have passed in FIRST CLASS.

14.3 All other successful candidates shall be declared to have passed in SECOND CLASS.

15. DECLARATION OF RESULTS

The results will be declared after the approval of the marks and classification by the Awards Committee of the institution.

16. REVALUATION

Any candidate can apply for Photocopy of his/her answer script of any Theory subject, he/she had appeared, if he/she is not satisfied with the marks awarded to him/her in the subject. The candidate has to fill-in the prescribed application form and remit Rs.100/- per paper for getting the photocopy of the answer script as per the notification issued by the Chairman, Autonomous Examination. After going through the Answer script if the candidate desires for revaluation, he/she has to pay a re-valuation fee of Rs.400/- per paper, within 3 working days, after receipt of the photocopy of the answer script. The revaluation system is not applicable for Practical subjects, Project work and Industrial Trainings.



17. MARK SHEET

17.1. The Mark sheet issued to each student at the end of each semester, up to pre-final semester will

contain the following: a. The month, and year of the examination. b. The performance in each subject in the form of Marks. c. The result as Pass or Fail.

17.2. The consolidated Mark-sheet issued at the end of the course to each student will contain the following:

a. The Month and year of examination passed in each subject. b. The Performance in each subject in the form of Marks c. The Classification of results

18. ELIGIBILITY FOR AWARD OF DIPLOMA

A student shall be declared eligible for the award of the Diploma if he/she has: 18.1 Registered and successfully completed all the theory and practical subjects and project work (in

the case of Full-Time Regular/Sandwich Diploma Course or Part-Time Diploma Course) and in addition two spells of industrial training in the case of Sandwich Diploma Course (vide clause 11.2).

18.2. No dues to the institution. 18.3. No disciplinary action pending against him / her. 19. AWARD OF DIPLOMA

The State Board of Technical Education and Training, Directorate of Technical Education awards the Diploma to the successful candidates on the recommendations of Awards Committee of the institution.

20. BREAK OF STUDY

Students shall not be permitted to discontinue the course of study for a duration of more than three years during any part of their course of study. However, for students for whom continuous break in study is less than or equal to three years, prior permission of the Chairman, Board of Examination is necessary to continue in the Diploma Course and to appear in the examination. Such students will be awarded only

Second Class.

21. DISCONTINUED STUDENTS OF FIRST SEMESTER

For any student who discontinued his / her studies during the first semester or not appeared in Autonomous Examinations of any First semester subjects, his/her admission gets cancelled. If he/she is willing to study in this institution, he/she has to seek fresh admission to first semester as per the admission norms.

22. POWER TO MODIFY

Notwithstanding all that have been stated above the Academic Board of the institution has the right to modify any of the above regulations from time to time.

****



L - SCHEME CURRICULUM AND SCHEME OF EXAMINATION

DIPLOMA COURSE IN MECHANICAL ENGINEERING (3 YEAR REGULAR)

I Semester

Sl.No Subject Code

Subject Name Hours / Week

ESE Hrs

CAM ESM Total Marks

T P Max. Min for a Pass

Max. Min for a Pass

1 GEL11 Communication Skills in English 4 - 3 25 75 30 100 40

2 GEL12 Engineering Mathematics- I 5 - 3 25 75 30 100 40 3 GEL13 Engineering Mathematics- II 5 - 3 25 75 30 100 40

4 GEL14 Engineering Physics -I 4 - 3 25 75 30 100 40 5 GEL15 Engineering Chemistry- I 4 - 3 25 75 30 100 40

6 GEL16 Engineering Physics -I Practical - 2 3 25 75 35 100 50 7 GEL17 Engineering Chemistry- I

Practical - 2 3 25 75 35 100 50

8 GEL18 Engineering Graphics- I Practical

- 6 3 25 75 35 100 50

9 GEL19 Computer Applications Practical

- 3 3 25 75 35 100 50

Total 22 13 900

II Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 GEL21

Communication Skills in English Practical

- 4 3 25 75 35 100 50

2 GEL22 Engineering Mathematics -III 5 - 3 25 75 30 100 40

3 GEL23 Engineering Mathematics -IV 5 - 3 25 75 30 100 40 4 GEL24 Engineering Physics- II 4 - 3 25 75 30 100 40

5 GEL25 Engineering Chemistry -II 4 - 3 25 75 30 100 40 6 GEL26 Engineering Physics -II Practical - 2 3 25 75 35 100 50

7 GEL27

Engineering Chemistry -II Practical

- 2 3 25 75 35 100 50

8 GEL28

Engineering Graphics- II Practical

- 6 3 25 75 35 100 50

9 GEL29 Workshop Practice - 3 3 25 75 35 100 50

Total 18 17 900



III Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL31 Strength of Materials 6 - 3 25 75 30 100 40

2 MEL32 Manufacturing Technology - I 5 - 3 25 75 30 100 40

3 MEL33 Fluid Mechanics & Fluid Power 6 - 3 25 75 30 100 40 4 MEL34 Computer Aided Machine

Drawing Practical - 6 3 25 75 35 100 50

5 MEL35 Mechanical Testing and Quality Control Practical

- 3 3 25 75 35 100 50

6 MEL36 Fluid Mechanics & Fluid Power Practical

- 3 3 25 75 35 100 50

7 MEL37 Manufacturing Technology - I Practical

- 6 3 25 75 35 100 50

Total 17 18 700

IV Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL41 Thermal Engineering - I 6 - 3 25 75 30 100 40

2 MEL42 Manufacturing Technology - II 5 - 3 25 75 30 100 40 3 MEL43 Renewable Energy Engineering 5 - 3 25 75 30 100 40

4 MEL44 Electrical Drives & Control 5 - 3 25 75 30 100 40

5 MEL45 Thermal Engineering Practical - 4 3 25 75 35 100 50

6 MEL46 Electrical Drives & Control Practical

- 4 3 25 75 35 100 50

7 MEL47 Manufacturing Technology - II Practical

- 6 3 25 75 35 100 50

Total 21 14 700



V Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL51 Design of Machine Elements 6 - 3 25 75 30 100 40 2 MEL52 Elective - I Theory 5 - 3 25 75 30 100 40

3 MEL53 Thermal Engineering - II 5 - 3 25 75 30 100 40 4 MEL54 Automobile Engineering 5 - 3 25 75 30 100 40

5 MEL55 Automobile Engineering Practical

- 4 3 25 75 35 100 50

6 MEL56 Metrology & Measurements and Machine Tool Testing Practical

- 6 3 25 75 35 100 50

7 GEL57 Communication and Life Skills Practical

- 4 3 50 50 25 100 50

Total 21 14 700

MEL52 Elective - I Theory:

MEL 52.1 Modern Machining Processes MEL 52.2 Power Plant Engineering

MEL 52.3 Refrigeration and Air-conditioning

VI Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL61 Industrial Engineering and Management

5 - 3 25 75 30 100 40

2 MEL62 Computer Integrated Manufacturing

5 - 3 25 75 30 100 40

3 MEL63 Elective - II Theory 5 - 3 25 75 30 100 40

4 MEL64 Elective - II Practical - 4 3/16 25 75 35 100 50 5 MEL65 Computer Integrated

Manufacturing Practical - 6 3 25 75 35 100 50

6 MEL66 Process Automation Practical - 4 3 25 75 35 100 50

7 MEL67 Project Work - 6 3 25 75 35 100 50

Total 15 20 700

MEL63 Elective - II Theory:

MEL 63.1 Robotics MEL 63.2 Press Tools

MEL 63.3 Proto-Typing in Product Design

MEL64 Elective - II Practical:

MEL 64.1 Robotics Practical MEL 64.2 Press Tools Practical MEL 64.3 Proto-Typing in Product Design Practical

T – Theory P – Practical ESE – End Semester Examination

CAM – Continuous Assessment Mark ESM – End Semester Examination Mark




DIPLOMA COURSE IN MECHANICAL ENGINEERING (3 ½ YEAR SANDWICH)

I Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 GEL11 Communication Skills in English 4 - 3 25 75 30 100 40 2 GEL12 Engineering Mathematics- I 5 - 3 25 75 30 100 40

3 GEL13 Engineering Mathematics- II 5 - 3 25 75 30 100 40 4 GEL14 Engineering Physics -I 4 - 3 25 75 30 100 40

5 GEL15 Engineering Chemistry- I 4 - 3 25 75 30 100 40 6 GEL16 Engineering Physics -I Practical - 2 3 25 75 35 100 50

7 GEL17 Engineering Chemistry- I Practical

- 2 3 25 75 35 100 50

8 GEL18 Engineering Graphics- I Practical

- 6 3 25 75 35 100 50

9 GEL19 Computer Applications Practical

- 3 3 25 75 35 100 50

Total 22 13 900

II Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 GEL21


- 4 3 25 75 35 100 50


3 GEL23 Engineering Mathematics -IV 5 - 3 25 75 30 100 40 4 GEL24 Engineering Physics- II 4 - 3 25 75 30 100 40

5 GEL25 Engineering Chemistry -II 4 - 3 25 75 30 100 40

6 GEL26 Engineering Physics -II Practical - 2 3 25 75 35 100 50 7

GEL27 Engineering Chemistry -II Practical

- 2 3 25 75 35 100 50

8 GEL28

Engineering Graphics- II Practical

- 6 3 25 75 35 100 50


Total 18 17 900



III Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL31 Strength of Materials 6 - 3 25 75 30 100 40 2 MEL32 Manufacturing Technology - I 5 - 3 25 75 30 100 40

3 MEL33 Fluid Mechanics & Fluid Power 6 - 3 25 75 30 100 40 4 MEL34 Computer Aided Machine

Drawing Practical - 6 3 25 75 35 100 50


- 3 3 25 75 35 100 50


- 3 3 25 75 35 100 50


- 6 3 25 75 35 100 50

Total 17 18 700

IV Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL42 Manufacturing Technology - II 5 - 3 25 75 30 100 40 2 MEL47 Manufacturing Technology - II

Practical - 6 3 25 75 35 100 50

3 MEL48 Industrial Training - I - - 3 50 50 25 100 50

Total 5 6 300

V Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL41 Thermal Engineering - I 5 - 3 25 75 30 100 40 2 MEL43 Renewable Energy Engineering 4 - 3 25 75 30 100 40

3 MEL44 Electrical Drives & Control 4 - 3 25 75 30 100 40 4 MEL51 Design of Machine Elements 5 - 3 25 75 30 100 40

5 MEL52 Elective - I Theory 4 - 3 25 75 30 100 40 6 MEL45 Thermal Engineering Practical - 4 3 25 75 35 100 50

7 MEL46 Electrical Drives & Control Practical

- 3 3 25 75 35 100 50


- 6 3 25 75 35 100 50

Total 22 13 800






VI Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL53 Thermal Engineering - II 5 - 3 25 75 30 100 40 2 MEL54 Automobile Technology 4 - 3 25 75 30 100 40


5 - 3 25 75 30 100 40


5 - 3 25 75 30 100 40

5 MEL 55 Automobile Technology Practical

- 3 3 25 75 35 100 50

6 MEL64 Computer Integrated Manufacturing Practical

- 6 3 25 75 35 100 50

7 MEL66 Process Automation Practical - 3 3 25 75 35 100 50


- 4 3 50 50 25 100 50

Total 19 16 800

VII Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL 63 Elective - II Theory 5 - 3 25 75 30 100 40 2 MEL 64 Elective - II Practical - 4 3/16 25 75 35 100 50

3 MEL 67 Project Work - 6 3 25 75 35 100 50 4 MEL 74 Industrial Training - II - - 3 50 50 25 100 50

Total 5 10 400

MEL63 Elective - II Theory:










DIPLOMA COURSE IN MECHANICAL ENGINEERING (4 YEAR PART TIME)

I Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 GEL11 Communication Skills in English 3 - 3 25 75 30 100 40

2 GEL12 Engineering Mathematics- I 3 - 3 25 75 30 100 40 3 GEL13 Engineering Mathematics -II 3 - 3 25 75 30 100 40

4 GEL14 Engineering Physics -I 3 - 3 25 75 30 100 40 5 GEL15 Engineering Chemistry -I 3 - 3 25 75 30 100 40

6 GEL16 Engineering Physics -I Practical - 1 ½ 3 25 75 35 100 50

7 GEL17

Engineering Chemistry -I Practical

- 1 ½ 3 25 75 35 100 50

8 GEL19

Computer Applications Practical

- 3 3 25 75 35 100 50

Total 15 6 800

II Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 GEL21


- 3 3 25 75 35 100 50


3 GEL23 Engineering Mathematics -IV 3 - 3 25 75 30 100 40

4 GEL24 Engineering Physics -II 3 - 3 25 75 30 100 40 5 GEL25 Engineering Chemistry- II 3 - 3 25 75 30 100 40

6 GEL26 Engineering Physics -II Practical - 1 ½ 3 25 75 35 100 50 7

GEL27 Engineering Chemistry-II Practical

- 1 ½ 3 25 75 35 100 50

8 GEL18

Engineering Graphics - I Practical

- 3 3 25 75 35 100 50

Total 12 9 800



III Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL31 Strength of Materials 4 - 3 25 75 30 100 40 2 MEL32 Manufacturing Technology - I 4 - 3 25 75 30 100 40

3 GEL28 Engineering Graphics - II Practical

- 4 3 25 75 35 100 50



- 3 3 25 75 35 100 50

Total 8 10 500

IV Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL33 Fluid Mechanics & Fluid Power 4 - 3 25 75 30 100 40 2 MEL43 Renewable Energy Engineering 4 - 3 25 75 30 100 40

3 MEL34 Computer Aided Machine Drawing Practical

- 4 3 25 75 35 100 50


- 3 3 25 75 35 100 50


- 3 3 25 75 35 100 50

Total 8 10 500

V Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL41 Thermal Engineering - I 4 - 3 25 75 30 100 40 2 MEL42 Manufacturing Technology - II 4 - 3 25 75 30 100 40

3 MEL45 Thermal Engineering Practical - 3 3 25 75 35 100 50 4 MEL47 Manufacturing Technology - II

Practical - 4 3 25 75 35 100 50


- 3 3 50 50 25 100 50

Total 8 10 500



VI Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL44 Electrical Drives & Control 4 - 3 25 75 30 100 40 2 MEL51 Design of Machine Elements 4 - 3 25 75 30 100 40

3 MEL53 Thermal Engineering - II 4 - 3 25 75 30 100 40 4 MEL46 Electrical Drives & Control

Practical - 3 3 25 75 35 100 50


- 3 3 25 75 35 100 50

Total 12 6 500

VII Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass

1 MEL52 Elective - I Theory 4 - 3 25 75 30 100 40

2 MEL54 Automobile Engineering 4 - 3 25 75 30 100 40


4 - 3 25 75 30 100 40

4 MEL55 Automobile Engineering Practical

- 3 3 25 75 35 100 50

5 MEL65 Computer Integrated Manufacturing Practical

- 3 3 25 75 35 100 50

Total 12 6 500






VIII Semester

Sl.No Subject Code


ESE Hrs

CAM ESM Total Marks


Max. Min for a Pass


4 - 3 25 75 30 100 40

2 MEL63 Elective - II Theory 4 - 3 25 75 30 100 40 3 MEL64 Elective - II Practical - 4 3/16 25 75 35 100 50

4 MEL66 Process Automation Practical - 3 3 25 75 35 100 50 5 MEL67 Project Work - 3 3 25 75 35 100 50

Total 8 10 500 MEL63 Elective - II Theory:









Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : I Subject Code & Name : GEL 11 COMMUNICATION SKILLS IN ENGLISH

Teaching and Scheme of Examinations: No. of Weeks per Semester: 16

Subject Code & Name Instruction Examination

GEL 11 Communication Skills in English

Hours/ Week

Hours/ Semester

Marks Duration in Hours

4 64

Continuous Assessment

End Semester

Examination Total

3

25 75 100

Topics and Allocation of Hours:

Unit No Topics Hours

I Grammar 14

II Grammar 14 III Composition 12

IV Literature – Prose 10 V Literature - Poetry 10

Revision and Test 04

Total 64

OBJECTIVES

• Acquire proficiency in the four major skills of communication viz. (i) Listening (ii) Speaking (iii) Reading and (iv) Writing towards successfully integrating all of the four skills for the effective use of English in Communication.

• Recognize the organization of a text and identify the main points of a text.

• Express ideas in clear and grammatically correct English using appropriate punctuation and Cohesion. • Plan, organize and present ideas coherently by introducing, developing and concluding a topic.

• Use an appropriate style and format to write letters.

• Transcode information from diagrammatic to verbal form.

• Expand notes into a piece of writing



DETAILED SYLLABUS

Unit Name of the Topic Hours

I

GRAMMAR 1. Parts of Speech 2. Functional Analysis 3. Voices 4. Question tags 5. Infinitives and Gerunds 6. Articles 7. Preposition 8. Conjunction

14 Hrs

II

GRAMMAR 1. Number 2. Arrangement of Jumbled words 3. Degrees of Comparison 4. Converting the dialogue into reported speech 5. Synonyms (Matching Textual) 6. Prefixes and Suffixes 7. Idioms and Phrases 8. Writing direction for reaching a place. 9. Tenses

14 Hrs

III

COMPOSITION 1. Comprehension (Question & Answer type) 2. Personal Letter Writing 3. Impersonal Letter Writing 4. Answering the questions based on the dialogue 5. Sequencing the Jumbled Sentences 6. Visual Comprehension 7. Hints Development 8. Advertisement Comprehension

12 Hrs

IV

PROSE 1. Of Trains and Travelers - R.K. Narayan 2. Global Warming - 3. Books- Our Never Failing Friends – B. Selva Durai 4. A Sense of the future – Jacob Bronowsky 5. Macbeth – William Shakespeare 6. The Green House Effect 7. Maori Villages – M.Brown 8. Light Destroys Darkness-

10 Hrs

V

POETRY Ageless Tamil – Arunachalam Chandrasekar 1. Hope – Sri Chinmoy 2. Song of a dream- Sarojini Naidu 3. Poison Tree –William Blake 4. The Storm- Edward Shanks 5. Can Earth be Earth- Garvit.

10 Hrs

Reference Books:

1. A.S.Hornby ,”The Advanced Learners Dictionary of Current English”, Oxford University Press. 2. Wren and Martin,”High School English Grammar and Composition”, S. Chand and Co. 3. Raymond Murphy, “Essential English Grammar”, Cambridge University Press. 4. M.Thomas ,”Common Errors in English”, Lotus Press, New Delhi. 5. CCE Learning to Interact in English, Frank Bros & Co.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : I Subject Code & Name : GEL 12 ENGINEERING MATHEMATICS - I Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


GEL 12 Engineering Mathematics – I

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Determinants and Matrices 15 II Binomial Theorem and Partial Fractions 15

III Straight Lines 15

IV Trigonometry – I 15 V Trigonometry – II 15


Total 80

OBJECTIVES

• Explain the basics of determinants and matrices.

• Solve linear equations in engineering oriented problems.

• Acquire basic knowledge in binomial to find the approximations of infinite expansions both algebraically and numerically.

• Explain the concepts of Straight lines and Pair of straight lines.

• State the trigonometric formulae and apply the same in differential and integral calculus. • Develop logical thinking which is useful in comprehending the principles of all other Subjects.



DETAILED SYLLABUS


I

Determinants

Definition and expansion of Determinants of order 2 and 3. Properties of determinants. Cramer’s rule to solve Simultaneous equations in 2 and 3 unknowns-Simple problems. Problems involving properties of determinants Matrices Definition of matrix. Types of matrices. Algebra of matrices Such as equality, addition, subtraction, scalar Multiplication of matrices. Transpose a matrix, adjoint matrix and Inverse matrix. Simple Problems.

15

II

Binomial Theorem

Definition of factorial notation, Definition of permutation and Combinations with formula. Binomial theorem for positive integral Index (statement only), finding of General and middle terms. Simple problems Problems finding coefficient of Xn, Independent terms. Simple problems. Binomial Theorem for rational index, expansions only up to -3 for negative integers. Simple Expansions. Partial Fractions

Definition of polynomial fraction, proper and improper fractions and definition of partial fractions. To resolve proper fraction into partial fraction with Denominator containing non repeated linear factors, repeated linear factors and irreducible non repeated quadratic factors. Simple problems.

15

III

Straight Lines

Length of perpendicular distance from a point to the line and perpendicular distance between parallel lines. Simple problems. Angle between two straight lines and Condition for parallel and perpendicular lines. Simple problems Pair Of Straight Lines Through Origin

Pair of lines passing through the origin ax2+2hxy+by2=0 expressed in the form

(y-m1x)(y-m2x)=0. Derivation of tan � � ��√��

Condition of parallel and Perpendicular lines. Simple problems Pair of straight lines not through origin.

Condition for General equation of the second degree Ax2+2hxy+by2+2gx+2fy+c=0 to represent pair of lines.

��

Angle between them, condition for parallel and perpendicular lines. Simple problems

15

= 0(statement only)



IV

Trigonometry -I

Trigonometrical ratios of allied angles. Expansion of sin(A±B) and cos (A±B). Problems using this expansion. Expansion of tan(A+B) and problems using this expansion Trigonometrical ratios of multiple angles(2A only) and Sub multiple angles. Simple problems.

15

Hrs

V

Trigonometry-II

Trigonometric ratios of multiple angles(3A only).Simple problems. Sum and Product formulae. Simple problems. Definition of inverse Trigonometric ratios relation between inverse trigonometric ratios. Simple problems.

15

Reference Books:

1. Mathematics for higher secondary – I year and II year, Tamilnadu Text Book Society. 2. Dr.M.K.Venkatraman, Engineering mathematics , National Publishing Co. Chennai, 5th Edition. 3. Dr. P. Kandasamy & Others, Engineering Mathematics, S.Chand & Co Ltd, New Delhi, 4th edition.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : I Subject Code & Name : GEL 13 ENGINEERING MATHEMATICS – II Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


GEL 13 Engineering Mathematics - II

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Circles 15 II Family of Circles. Functions and Limits 15

III Differentiation Methods 15

IV Application of Differentiation - I 15 V Application of Differentiation - II 15


Total 80

OBJECTIVES

� Explain the concepts of Straight lines, Circles and family of circles. � High light the concepts of limits and differentiation. � Acquire knowledge of differentiation, principles and different methods. � Develop the ability to apply these methods to solve technical problems to execute Management plans

with precision.



DETAILED SYLLABUS


I

Circles :

Equation of circle- given centre and radius. General Equation of circle- finding centre and radius. Simple problems. Equation of circle through three non collinear points-Concylic points. Equation of circle on the line joining the points(x1,y1) and (x2,y2) as diameter. Simple problems Length of tangent position of a point with respect to a circle, Equation of tangent. Simple problems.

15

II

Family of Circles :

Concentric circles- Contact of circles(internal and external) Orthogonal Circles - Condition for Orthogonal circles(result only). Simple problems. Limits

Definition of Limits lim� �� xn�an�� =n�� lim� � 0 !"# $$ = 1 lim� � 0 %&# $$ = 1 (θ in radian) results only, problems using above results.

Differentiation:

Definition –Differentiation of xn, sinx Cosx, tanx, cotx, secx, cosecx, logx, u+v, uv, uvw, u/v(results only). Simple problems using the above results.

15

III

Differentiation Methods:

Differentiation of function of functions and implicit functions. Simple problems. Differentiation of Inverse Trigonometric functions and Parametric functions. Simple problems. Successive differentiation up to second order (parametric form not included ). Definition of differential equation,, formation of differential equation. Simple problems

15

IV

Application Of Differentiation-I

Derivative as rate measure. Simple problems Velocity and acceleration. Simple problems. Tangents and Normals. Simple problems

15

V

Application Of Differentiation –II

Definition of Increasing functions, Decreasing function and turning points. Maxima and Minima (for single variable only)- Simple Problems. Partial Differentiation Partial differentiation of two variable upto second orders Only. Simple problems. Definition of Homogeneous functions-Euler’s Theorem. Simple problems.

15



Reference Books:

1 Mathematics for higher secondary – I year and II year, Tamilnadu Text Book Society 2 Dr.M.K.Venkatraman, Engineering mathematics, National Publishing Co. Chennai. 3 Dr. P. Kandasamy & Others, Engineering Mathematics, S.Chand & Co Ltd, New Delhi.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : I Subject Code & Name : GEL 14 ENGINEERING PHYSICS - I Teaching and Scheme of Examination: No. of weeks per semester: 16


GEL 14 Engineering Physics - I

Hours/ Week

Hours/ Semester


4 64


End Semester

Examination Total

3

25 75 100

Topics and Allocation of Hours


I S I units and Statics 12

II Properties of Matter 12

III Dynamics – I 12 IV Dynamics – II 12

V Sound and Magnetism 12 Revision and Test 04

Total 64 OBJECTIVES:

• Understand the importance of SI units and dimensional formulas.

• Acquire broad ideas about resultant, moment of a force and torque of a couple.

• Understand the elastic property and the types of modulii of elasticity.

• Explain the surface tension of liquids and viscosity of fluids.

• Acquire knowledge about projectile motion, circular motion and its application.

• Gain knowledge about rotational kinetic energy and angular momentum. • Acquire broader ideas about variation of acceleration with respect to height and its importance in

launching satellites and concept of weightlessness.

• Understand the propagation of sound, production, properties and uses of ultrasonic. • Explain the importance of hysteresis of magnetic materials and its uses.

• Solve simple problems involving expressions derived in all the above topics.



DETAILED SYLLABUS


I

S I UNITS AND STATICS

Units and Measurement

Unit-Definition-Fundamental Quantities-Definition-Seven fundamental quantities; their SI units and symbol for the units-Dimensional formula for length, mass and time -Supplementary quantities-plane angle and solid angle; their SI units and symbol for the units. Derived physical quantities-Definition-SI units, symbol for the units and derivation of dimensional formula for area, volume, density, velocity, momentum, acceleration, force, impulse, work or energy and power. Conventions followed in SI-Multiples & sub-multiples and prefixes of units. Statics

Scalar and vector quantities – Definitions and examples – Concurrent forces and coplanar forces – Definition - Resolution of a vector into two perpendicular components- Resultant and equilibrant – Definitions- Parallelogram law of forces- statement- Expressions for magnitude and direction of the resultant of two forces acting at a point with an acute angle between them - Lami’s theorem- Statement and explanation- Experimental verification of parallelogram law of forces and Lami’s theorem. Simple problems based on expressions for magnitude and direction of resultant. Moment of a force- Clockwise and anti-clockwise moments - Principle of moments- Couple – Torque acting due to a couple – Experimental determination of mass of the given body using principle of moments

4 Hrs

8 Hrs

II

PROPERTIES OF MATTER

Elasticity Elastic and plastic bodies – Definition - stress, strain - Definitions – Hooke’s law –statement - three types of strain– Elastic and plastic limit – Elastic behaviour of a material, stress- strain curve , elastic range, elastic limit, yield point, plastic limit and breaking point - Young’s modulus, Bulk modulus, Rigidity modulus and Poisson’s ratio – Definitions - Uniform and non uniform bending of beams- Explanation Simple problems based on stress, strain and Young’s modulus. Viscosity Viscosity – Definition - Coefficient of viscosity- Definition, SI unit and dimensional formula - Stream line flow, turbulent flow-Explanation - Critical velocity –Definition- Reynolds number - Experimental determination of coefficient of viscosity of a low viscous liquid by capillary flow method using graduated burette (Variable pressure head method)– Terminal velocity – Definition – Experimental determination of coefficient of viscosity of a high viscous liquid by Stokes’ method – Practical applications of viscosity. Surface Tension

Surface tension & angle of contact- Definitions - Explanation for capillary rise and dip - Expression for surface tension of a liquid by capillary rise method - Experimental determination of surface tension of water by capillary rise method – Practical applications of capillarity. Simple problems based on expression for surface tension.

4 Hrs

5 Hrs

3 Hrs



III

DYNAMICS – I

Projectile Motion Projectile motion, angle of projection, trajectory, maximum height, time of flight, and horizontal range – Definitions - Expressions for maximum height, time of flight and horizontal range – Condition for getting the maximum range of the projectile- Derivation of the equation to show that the trajectory of the projectile is a parabola. Simple problems based on expressions for maximum height, time of flight and horizontal range. Circular Motion Circular motion, angular velocity, period and frequency of revolutions– Definitions – Relation between linear velocity and angular velocity – Relation between angular velocity, period and frequency – Normal acceleration, centripetal force and centrifugal force – Definitions – Expressions for normal acceleration and centripetal force. Simple problems based on expression for centripetal force. Application of Circular Motion Banking of curved paths – Angle of banking – Definition – Expression for the angle of banking of a curved path. { tan θ = v 2 / (r g) } Simple problems based on expression for angle of banking.

5 Hrs

4 Hrs

3 Hrs

IV

DYNAMICS – II

Rotational Motion of Rigid Bodies

Rigid body – Definition - Moment of inertia of a particle about an axis, moment of inertia of a rigid body about an axis – expressions – Radius of gyration – Definition – Expression for the kinetic energy of a rotating rigid body about an axis – Angular momentum – Definition – Expression for the angular momentum of a rotating rigid body about an axis – Law of conservation of angular momentum – Examples. Gravitation

Newton’s laws of gravitation – Acceleration due to gravity on the surface of earth –Difference between mass and weight of a body – Expression for variation of acceleration due to gravity with altitude – Concept of weightlessness. Satellites

Satellites – Natural and artificial – Escape velocity and orbital velocity – Definitions – Expression for escape velocity – Expressions for orbital velocity and period of revolution of a satellite around earth – Geo-stationary and polar satellites – Uses of artificial satellites. Simple problems based on expressions for escape velocity, orbital velocity and period of revolution.

5 Hrs

3 Hrs

4 Hrs

V

SOUND AND MAGNETISM

Sound Wave motion – Introduction and definition – Progressive waves, longitudinal and transverse waves – Examples and comparison –Amplitude, wave length, period and frequency of a wave – Definitions - Relation between wavelength, frequency and velocity of a wave - Stationary or standing waves. Vibrations - Free & forced vibrations and resonance – definitions and examples –Laws of transverse vibrations of a stretched string – Sonometer – Experimental determination of frequency of a tuning fork. Ultrasonic – Introduction – Production of ultrasonic waves by piezo-electric method – Properties and applications. Simple problems based on expression for frequency of vibration. Magnetism

Coulomb’s laws of magnetism – Pole strength and unit pole – Definitions – Magnetic moment, intensity of magnetisation, hysteresis, saturation, retentivity and coercivity – Definitions - Method of drawing hysteresis loop of a specimen using a solenoid – Uses of Hysteresis loop.

8 Hrs

4 Hrs



Text Books:

1. Higher secondary Physics – First year – Volume I & II – Tamil Nadu Text book Corporation, Chennai . 2004

2. Anwar Kamal -- Intermediate physics – Volume I & II– Foundation Books private Ltd. 2008 3. Students’ support material GEL 14 Engineering Physics – I – Department of Physics, M P C.

Reference Books:

1. Resnick and Haliday -- Physics –– Wisley Toppan publishers – England 2. B.L.Theraja -- Engineering Physics –– S. Chand Publishers, New Delhi. 3. R.L. Saighal & H.R. Sarna -- A text book of sound –– S. Chand & C, New Delhi 4. Narayana Kurup --Mechanics –– S. Chand Publishers, New Delhi. 5. Srivatsava – Electricity and Magnetism - S. Chand & Co., New Delhi



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : I Subject Code & Name : GEL 15 ENGINEERING CHEMISTRY - I Teaching and Scheme of Examination: No. of weeks per semester: 16


GEL 15 Engineering Chemistry - I

Hours/ Week

Hours/ Semester


4 64


End Semester

Examination Total

3

25 75 100



I Molecular Mass, Equivalent Mass and Chemical Bonding 12 II Acids & Bases and pH scale, Solutions and Colloids 12

III Electrochemistry and Storage Batteries 12 IV Cell, Corrosion and Prevention of Corrosion 12

V Technology of Water and Photochemistry 12 Revision and Tests 04


• Understand about mole, Gram molar volume, Avogadaro’s Hypothesis and Avogadro’s number.

• Acquire knowledge about Equivalent mass of chemical and the weight ratio with different chemicals combine among themselves.

• Understand the concepts of molecule formation due to ionic, covalent and coordinate bonding.

• Gain knowledge about theories classifying acids and bases and also importance of pH scale. • Gain knowledge about the unit used to measure concentrations of chemical solutions and their usage

in chemical estimations.

• Acquire knowledge about chemistry of colloidal solutions and their applications.

• Understand basic concepts of electrochemistry and also about different types of storage batteries

used.

• Acquire knowledge about formation of Galvanic cell and concentration cell to understand the theories used to explain corrosion of metals.

• Gain knowledge about water sources, impurities present in water, ways to soften water and its industrial applications.

• Study about chemical reactions brought out by sunlight.



DETAILED SYLLABUS


I

MOLECULAR MASS, EQUIVALENT MASS AND CHEMICAL BONDING

Molecular Mass: Molecule - Molecular formula - Molecular Mass – Mole – Definition - Simple calculations - Avogadro’s Hypothesis Application - Relationship between Molecular Mass and Vapour Density - Gram Molecular Volume – Definition - Avogadro’s Number – Definition - Simple Problems. Equivalent Mass: Equivalent Mass & Gram Equivalent Mass – Definition - Determination of Equivalent Mass by Oxide Method (Direct Method) - Simple Problems. Chemical Bonding: Definition – Ionic Bonding – Formation of NaCl – Covalent Bonding – Formation of NH3 – Co-ordinate Bonding – Formation of NH4

+ ion – Metallic Bonding – Electron Sea Model.

12 Hrs

II ACIDS & BASES and pH SCALE, SOLUTIONS AND COLLOIDS

Acids & Bases And Ph Scale:Theories of Acids and Bases – Arrehenius Theory – Lowry Bronsted Theory – Lewis Theory – Advantages of Lewis theory –Definition of pH and pOH – Numerical problems – Indicators – Acid-base concept of indicators (Basic ideas) – Buffer Solution – Definition – Types and examples – Application of pH control in industries – Electronic Concept of Oxidation and Reduction – Definition and example. Solutions:Definition – Methods of Expressing Concentrations of solutions: Percentage by mass and volume, Molarity, Molality, Mole-fraction and Normality – Simple numerical problems. Colloids: Definition – Differences between true and colloidal solutions –Types of Colloidal solutions – Sols – Lyophillic and Lyophobic sols and differences between them – Properties – Tyndall Effect, Brownian Movement, Electrophoresis and Coagulation – Industrial applications – Smoke precipitation (Cottrell’s Method), Purification of drinking water, Cleaning action of soap, Disposal of sewage and Tanning of leather.

12 Hrs

III ELECTROCHEMISTRY AND STORAGE BATTERIES

Electrochemistry: Electrolytes – Differences between metal and electrolyte conduction - Strong and weak electrolytes – Definition – examples – Electrolysis – definition – mechanism – Industrial applications of electrolysis –electroplating –preparation of surface – factors affecting the stability of the coating – Chrome plating – Electro less plating – definition – advantages over electroplating - applications Storage Batteries: Primary, Secondary and fuel batteries – Primary battery – definition and example – Dry cell – construction and working – Secondary battery - definition and example – Lead acid storage cell – construction and working – Nickel/Cadmium battery - construction and working – Fuel cell - definition and example – H2/O2 fuel cell (green cell) – construction and working – Solar cells.

12 Hrs

IV CELL, CORROSION AND METHODS OF PREVENTION CORROSION

Cell: Electrochemical cell –Galvanic cell – Daniel Cell – Nernst Equation – Single Electrode Potential – Oxidation and Reduction Potentials – Electrochemical series – Concentration cells. Corrosion:Definition –types – Theories of corrosion – Galvanic cell formation theory – Differential aeration theory – Factors influencing rate of corrosion. Methods of Prevention of Corrosion:Control of environment – Alloying, Surface coating – Metal coating – Electroplating, Galvanisation and Tinning – Inorganic coating – Anodising and Phosphating – Cathodic protection – Sacrificial anode and Impressed Voltage methods.

12Hrs



V TECHNOLOGY OF WATER AND PHOTOCHEMISTRY

Technology of Water: Sources – depletion of under ground water - reasons – Rainwater harvesting (Basic ideas) – advantages – hard and soft water – carbonate, non-carbonate hardness – methods of expressing hardness – mg/litre, ppm – simple problems – Estimation of total hardness by EDTA method – problems involving total, carbonate, non-carbonate hardness in ppm – softening of hard water – Ion-exchange method, Reverse Osmosis method – Standards of drinking water – Municipal water supply – purification (sedimentation, filtration and sterilization) – Disadvantages of hard water in boilers – Scale formation, Corrosion of boiler metal, Caustic Embrittlement – Priming and Foaming. Photochemistry: Introduction – important terms – Charge transfer, electronic energy migration, emission, excited state, frequency, ground state, Fluorescence, Phosphorescence, Chemiluminescence – Photo electric cell – Photo emission cell – Photosynthesis –general chemical reactions – Chlorophyll and accessory pigments – Mechanism of light reactions – Dark reaction – photosynthesis and acid rain.

12 Hrs

Reference Books:

1. Soni PL - Inorganic chemistry – Sultan Chand & sons. 2. Soni PL - Organic chemistry - Sultan Chand & sons. 3. Jain & Jain - Engineering chemistry - Dhanpat rai & co 4. Uppal - Engineering chemistry - Khanna publishers 5. Dara .S.S - Environmental chemistry & Pollution control - S.Chand & co 6. Tripathy .S.N - Environmental Pollution - Sunakar panda - Vrinda publication 7. Rain water Harvesting-hand book by Chennai Metro Water 8. Higher Chemistry Book Volume I and II, Tamilnadu Text Book Corporation, Chennai.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : I Subject Code & Name : GEL 16 ENGINEERING PHYSICS – I PRACTICAL

Teaching and Scheme of Examination: No. of weeks per semester: 16


GEL 16 Engineering Physics – I Practical

Hours/ Week

Hours/ Semester


2 32


End Semester

Examination Total

3

25 75 100

LIST OF EXPERIMENTS WITH OBJECTIVES:

1. MICROMETER (SCREW GAUGE).

To measure the thickness of the given irregular glass plate using micrometer. To determine the area of the glass plate using a graph sheet and to calculate the volume of the glass plate.

2. VERNIER CALIPERS.

To measure the length and diameter of the given solid cylinder using Vernier calipers and to calculate the volume of the solid cylinder.

3. CONCURRENT FORCES. To verify the parallelogram law of forces and Lami’s theorem.

4. PRINCIPLE OF MOMENTS.

To determine the mass of the given body using principle of moments. 5. POISEUILLE’S METHOD.

To determine the coefficient of viscosity of water by capillary flow method, using graduated burette without stopper (variable pressure head arrangement ).

6. STOKES’ METHOD.

To determine the coefficient of viscosity of a high viscous liquid. 7. SURFACE TENSION.

To determine the surface tension of water by capillary rise method. 8. SONOMETER.

To determine the frequency of the given tuning fork. 9. DEFLECTION MAGNETOMETER

To compare the magnetic moments of the two bar magnets using deflection magnetometer in Tan A position, by equal distance method .

SCHEME OF EVALUATION No. Allocation Marks

1 Formula with Explanation 10 2 Figure/Circuit Diagram with parts & Tabular Column

with proper Units 10

3 Observations 35 4 Calculations 15

5 Result 05 Total 75



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : I Subject Code & Name : GEL17 ENGINEERING CHEMISTRY -I PRACTICAL



GEL17 Engineering Chemistry - I Practical

Hours/ Week

Hours/ Semester


2 32


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• To impart knowledge about volumetric analysis in Acidimetric, Alkalimetry, Permanganametry.

• To give knowledge about estimation of Hardness present in the Water.

• To give knowledge about measurement of pH in various solutions

VOLUMETRIC ANALYSIS (DOUBLE TITRATIONS): -

ACIDIMETRY AND ALKALIMETRY

1. Estimation of Hydrochloric acid 2. Estimation of Sodium Hydroxide 3. Estimation of Sodium Carbonate 4. Comparison of strengths of two acid solutions 5. Comparison of Strengths of two base solutions

PERMANGANAMETRY

6. Estimation of Ferrous Ammonium Sulphate 7. Estimation of Ferrous Sulphate 8. Comparison of Potassium Permanganate.

WATER ANALYSIS

9. Estimation of Total Hardness by EDTA method (Demonstration Experiment) 10. Calculation of pH of four sample solutions and calculation of H+ Ion concentration for a particular sample solution. (Demonstration Experiment)

SCHEME OF EVALUATION

No. Allocation Marks

1 Short Procedure 10 2 I Titration(within 2% error) 25

3 II Titration(within 2% error) 25

4 Calculation(3*5=15) 15

Total 75

Reference:

1. Vogel -Analytical chemistry – Pearson publications 2. Dr. Sudha Rani - Laboratory manual on engineering chemistry Dhanpat rai publication



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : I Subject Code & Name : GEL18 ENGINEERING GRAPHICS-I PRACTICAL Teaching and Scheme of Examination: No. of weeks per semester: 16


GEL18 Engineering Graphics-I Practical

Hours/ Week

Hours/ Semester


6 96


End Semester

Examination Total

3

25 75 100



I 1.1 Drawing office practice (Manual Drafting and Computer Aided Drafting) 1.2 Practice on CAD

12

18

II

2.1 Constructions of conics (Manual Drafting and Computer Aided Drafting)

18

2.2 Constructions of special curves (Manual Drafting and Computer Aided Drafting)

09

III 3.Projection of points and straight lines (Manual Drafting) 15

IV 4.Projection of solids (Manual Drafting and Computer Aided Drafting)

18

Revision and Tests 06

Total 96

OBJECTIVES:

• To understand the importance of drawing.

• To identify the drawing instruments. • To practice the methods of dimensioning both in manual & Acad.

• To construct conics and special curves in manual & CAD.

• To understand the concepts and draw the projection of solid.



DETAILED SYLLABUS


I

Drawing office practice (Manual Drafting and Computer Aided Drafting) Importance of engineering drawing – drawing instruments: drawing board, mini drafter, compass, divider, protractor, drawing sheets etc.,- layout of drawing sheets. Importance of legible lettering and numbering – single stroke letters – upper case and lower case letters-general procedures for lettering and numbering – height of letters – guidelines. Dimensioning – Need for dimensioning – terms and notations as per BIS – Dimension line, Extension line and Leader line – Methods of dimensioning – Importance of dimensioning rules – Exercises. Scales – Study of scales – full size scale, reduced scale and enlarged scale. Practice on CAD Starting Auto CAD-Setting up of a new drawing- Creating a new drawing- Drawing units -Limits - Grid and Snap-Menus and Tool Bars-Save-Open and exiting drawing. Drawing command:Line,Circle,Arc,Polygon,Ellipse,Rectangle,Hatch,Mtext,Pline Modify Commands- Erase – Copy, Mirror, Offset, Array, Move, Rotate, Scale, Stretch, Lengthen, Trim, Extend, Break, Chamfer, Fillet, Explode,Pedit Object Snap methods Dimensions commands Other useful commands- Zoom, Plot, Ltype, Block, Insert, Divide

12 Hrs

18 Hrs

II

Constructions of conics. (Manual Drafting and Computer Aided Drafting) Conics: Different types – Definition of focus, focus and directrix - Applications of ellipse, Parabola and hyperbola. Ellipse: Construction of ellipse by concentric circle method, rectangular method and eccentricity method when focus and directrix are given – Practical applications. Parabola: Construction of parabola by rectangular method, parallelogram method and eccentricity method when focus and directrix are given – Practical applications. Hyperbola: Construction of hyperbola by rectangular method and eccentricity method when focus and directrix are given – Practical applications. Constructions of special curves. (Manual Drafting and Computer Aided Drafting)

Geometric curves: Definition, applications and constructions of cycloid – epicycloids – hypocycloid – exercise. Involute of a circle – Archimedean spiral – helix – exercises.

18Hrs

12Hrs

III

Projection of points.

Projection of points – points in different quadrants. Projection of straight lines.

Projection of straight line – parallel to one plane and perpendicular to other plane – inclined to one plane and parallel to the other plane – parallel to both the planes – inclined to both the planes (simple problems only

15 Hrs

IV

Projection of solids (Manual Drafting and Computer Aided Drafting) Introduction – important terms – classification of solids – triangular and hexagonal prisms and pyramids – solids of revolution – cylinder and cone. Projections of solids in simple positions – parallel to one plane and perpendicular to Other plane – projections of solids with axis inclined to HP – Projections of solids with axis Parallel to both Planes – exercises.

18Hrs



Text Books:

1. GEL 28 Engineering Graphics-CAD, Murugappa Polytechnic, 2007

Reference Books:

1. Gill P.S., “Engineering drawings”, S.K.Kataria & Sons.

2. Bhat N.D. “Engineering drawings”, Charotar Publishing house.

3. Gopalakrishnan.K.R., “Engineering drawing”, (Vol.I and vol.II), Dhanalakshmi publishers, Ed.2, 1970

4. Venugopal.K,Sreekanjana G, “Engineering Graphics” New Age International Publishers.

5. K V Nataraajan “A Text Book of Engineering drawing”.

6. Thomas E.French, Charles J.Vierck, Robert J.Foster, “Engineering drawing and graphic

technology”, McGraw Hill International Editions

7. Barkinson & Sinha, “First Year Engineering drawing”, Pitman Publishers.

8. Shah/ Rana, “Engineering drawing”, Pearson Longman.


Question No.

Allocation Marks

Manual CAD

1 a) Lettering b) Dimensioning

2 4

3 6

2 CAD Practice - 10

3 Conics(Either or Type) 9 6

4 Special Curves(Either or Type) 10 - 5 Projection of Points/Lines 10 -

6 Projection of Solids 9 6

Total 44 31



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : I Subject Code & Name : GEL19 COMPUTER APPLICATIONS PRACTICAL Teaching and Scheme of Examination: No. of weeks per semester: 16


GEL19 Computer Applications Practical

Hours/ Week

Hours/ Semester


3 48


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Do the basic operations on files and folders in Windows • Prepare the documents with pictures in a word processor

• Enter the data in row-wise and column-wise including charts in a Spreadsheet • Present the data in various formats using presentation software

• Enter the data and store the data in a database • Generate the data report from a database

LIST OF EXERCISES

1. Starting and running the Programs in Windows and DOS prompt. 2. Creating, renaming, copying, pasting, searching and removing files and folders in Windows, 3. Creating and formatting a file in Word processor. 4. Inserting table and pictures in a Word processor file. 5. Creating a Mail-merge application in a Word processor. 6. Creating and formatting the data in a Spreadsheet 7. Calculating row-wise and column-wise data using formulae in a Spreadsheet. 8. Inserting and formatting Charts for a series of data in Spreadsheet. 9. Creating a simple presentation in Presentation software 10. Creating a presentation using various transitions and sounds in Presentation software. 11. Creating and entering the data in a database. 12. Generating a data report in a database.


No. Allocation Marks Question -A

1 Procedure 15

2 Execution 15 3 Result/Output 05

Question -B 1 Procedure 15

2 Execution 15 3 Result/Output 05

4 Viva voce 05 Total 75



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : II Subject Code & Name : GEL 21 COMMUNICATION SKILLS IN ENGLISH PRACTICAL Teaching and Scheme of Examination: No. of weeks per semester: 16


GEL 21 Communication Skills in English Practical

Hours/ Week

Hours/ Semester


4 64


End Semester

Examination Total

3

25 75 100

GUIDELINES:

• All the fourteen Exercises given in the list of Exercises should be completed and given for the end semester practical examination.

• In order to develop the Listening, Speaking, Reading and Writing skills each student is provided with a Computer and Soft ware based exercise.

• The external examiners are requested to ensure that the same question paper is not to be given to students while admitting a batch of 30 students during Board Examination.

UNIT I - Fundamental Language Skills (12 hours)

1. Transformation of Sentences

• Interrogative to Assertive • Exclamatory to Assertive

• Changing into negative sentence without changing the meaning. 2. Answering Verbal Questions

• Affirmative and negative 3. Correction of Sentences

• Subject verb agreement

• Articles

• Prepositions

• Wrong usage of words 4. Confusing Words

• Using right word in the correct form in sentence 5. Clauses, Simple, Compound and complex sentences.

UNIT II - Listening (12 hours)

6. Listening Activities-I

• Listening to passage and answering questions like: � Choose the best option, fill in, true or false, sequencing of Sentences.

• Listening to dialogue and answering questions. 7. Listening activities-II

• Listening to passage and answering questions like: Choose the best option, fill in, true or false, sequencing of Sentences.

• Situational conversation • Listening to the conversation and answering the questions

Telephoning Introducing people



UNIT III – Reading (12 hours)

8. Passage – I 9. Passage –II Synonyms, Antonyms, Choose the best option, completing the table, Match the following, arranging the sentences in order, answering Questions fill in choosing the best option.

UNIT IV-Speaking (14 hours)

10. Pronunciation

• Introduction

• Vowels, consonants, diphthongs

• Stress(words and sentences)

• Intonation UNIT V-Writing (14 hours)

11. Summarizing Locating its topic sentence and listing the main points. 12. Newspaper Report Comprehension Reading the Newspaper report and answering the given questions 13. Creative Writing 14. Graphic into Language Conversion of pictorial representation into a passage.

• pie chart

• bar chart • table

References:

1. Communication skills in English Practical Manual 2. Globarena, Educational software. 3. ‘Spoken English For You’ –Level II, G.Radhakrishnan Pillai, Emerald Publishers. 4. ‘Spoken English’, Dr.L. Adinarayana, Neelkamal Publications Pvt.Ltd.

SCHEME OF VALUATION

No. Allocation Marks 1 Listening 15

2 Reading 15 3 Writing 40

4 Viva voce 05 Total 75



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : II Subject Code & Name : GEL 22 ENGINEERING MATHEMATICS – III Teaching and Scheme of Examinations: No. of Weeks per Semester : 16


GEL 22 Engineering Mathematics - III

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Vector Algebra - I 15 II Vector Algebra - II 15

III Integration - I 15

IV Integration - II 15 V Probability Distribution –I 15


Total 80

OBJECTIVES

• Acquire basic knowledge in Vectors to apply in force analysis.

• Explain the concept of integral calculus.

• Acquire basic knowledge in probability distribution.

• Acquires knowledge of mathematical terms, concepts principles of different methods.

• Develop the ability to solve physical problems.



DETAILED SYLLABUS


I

Vector Algebra-I

Introduction:

Definition of vector-types, addition, and subtraction of vectors, properties of addition and subtraction. Properties of addition and subtraction . Position vector. Resolution of vector in two and three dimensions. Directions cosines, direction ratios. Simple problems. Scalar Product Of Vectors :

Definition of Scalar product of two vectors –Properties-Angle between two vectors. Simple Problems. Application Of Scalar Product :

Geometrical meaning of scalar product. Work done by Force. Simple Problems.

15

II

Vector Algebra-II

Vector Product Of Two Vectors :

Definition of vector product of two vectors. Geometrical meaning. Properties –Angle between two vectors- unit vector perpendicular to two vectors. Simple Problems.

Application of Vector Product Of Two Vector And Scalar Triple Product :

Definition of moment of a force. Definition of scalar product of three vectors- Geometrical meaning- Coplanar vectors. Simple Problems.

Product Of More Vectors :

Vector Triple Product. Scalar and vector product of four vectors. Simple Problems

15

III

Integration-I

Introduction:

Definition of integration- Integral values using reverse process of differentiation-Integration using decomposition method. Simple Problems. Integration By Substitution

Integrals of the form '(�)�*+��)�*,� where

)- . �1*, ' 12)3*1)3* ,�, ' 4(�)�*+��)�*,� simple problems

Standard Integrals

Integrals of the form ' 53��6 , ' 533��,

' 53√��3, ' 73�8�3� 3�9, Simple Problems

15

IV

Intrgration-II

Integration By Parts :

Integrals of the form ' �:;- -� ,�, ' ��<:-� ,�, ' �=�3,�, ' ��logx

dx, ' ><��dx Simple Problems.

Bernoulli’s Formula :

Evaluation of the integrals ' �?cosnx dx, ' �? :;-nx dx, ' �?=�3,�,

when m≤2 using Bernoullis formula. Simple Problems Definite Integral

Definition of definite integral. Properties of definite integrals. Simple Problems

15



V

Probability Distribution -I

Random Variable :

Definition of Random variable-Types-Probability mass function-probability Density function. Simple problems. Mathematical Expectation of discrete random variable, mean and variance. Simple Problems. Binomial Distribution :

Definition

@)A � A* � B-�3C3D��3 � � 0,1,2, F F -0 other wise M Statement only. Expression for mean and variance. Simple Problems

15

Reference Books:

1. Mathematics for higher secondary – I year and II year, Tamilnadu Text Book Society. 2. Dr.M.K.Venkatraman , Engineering mathematics , National Publishing Co. Chennai. 3. Dr. P. Kandasamy & Others, Engineering Mathematics, S.Chand & Co Ltd, New Delhi



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : II Subject Code & Name : GEL 23 ENGINEERING MATHEMATICS – IV

Teaching and Scheme of Examinations: No. of Weeks per Semester : 16


GEL 23 Engineering Mathematics - IV

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Complex Numbers – I 15 II Complex Numbers – II 15

III Probability Distribution-II 15

IV Application of Integration and differential equation 15 V Second Order differential equation 15

Revision and test 05

Total 80

OBJECTIVES

• Solve polynomial equations with complex solutions.

• Explain the concept of complex numbers, Demoivre’s theorem and its application to solve Equation.

• Explain the physical and geometrical application of differentiation.

• Explain the applications of integration and to know to solve differential equations.

• Develop the ability to solve the physical problems in fluid dynamics and circuit theory using the concept of differential equations.



DETAILED SYLLABUS


I

Complex Numbers – I

Definition – Conjugates – Algebra of complex numbers( geometrical proof not needed) – Real and imaginary parts. Simple problems. Polar form of complex number – Modulus and amplitude form multiplication and division of complex numbers in polar form. Simple problems. Argand plane – Collinear points, four points forming square, rectangle, rhombus. Simple problems.

15

II

Complex Numbers – II

Demoivre’s Theorem (statement only) – simple problems. Demoivre’s Theorem related problems. Simple problems.

Finding nth roots of unity – solving equation of the form xn ± 1 = 0 where n ≤ 7. Simple problems.

15

III

Probability Distribution –II

Poission Distribution :

Definition N)O � �* � PQRS63! (statement only). Expression for mean

and variance. Simple problems. Normal Distribution :

Definition of normal and standard normal distribution. (Statement only). Constants of normal distribution (results only) – properties of normal distribution – Simple problems using the table for standard normal Distribution. Curve Fitting :

Fitting of straight line using least square method (Result only) Simple problems

15

IV

Application Of Integration And First Order Differential Equation

Area And Volume :

Area – Area of circle, Volume – Volume of cone and sphere. Simple problems.

First Order Differential Equation:

Definition of order and degree of differential equation – Solution of first order variable separable type differential equation. Simple problems. Linear Type Differential Equation

Solution of linear differential equation. Simple problems

15



V

Second Order Differential Equations :

Solution of second order differential equations with constant coefficients in the

form a 5U53 V � 5U53 V �W � 0 . simple problems

Solution of second order differential equations in the form

a 5U53 V � 5U53 V �W � �)�* where a,b and c are constants and f(x) = emx simple

problems.

Solution of second order differential equation in the form a 5U53 V � 5U53 V �W ��)�* where a,b and c are constants and f(x)= sinmx or cosmx. Simple problems

15

Reference Books:

1. Mathematics for higher secondary – I year and II year. Text Book Society. 2. Dr.M.K.Venkatraman, Engineering mathematics , National Publishing Co. Chennai. 3. Dr. P. Kandasamy & Others, Engineering Mathematics , S.Chand & Co Ltd, New Delhi.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : II Subject Code & Name : GEL 24 ENGINEERING PHYSICS - II Teaching and Scheme of Examination: No. of weeks per semester: 16


GEL 24 Engineering Physics - II

Hours/ Week

Hours/ Semester


4 64


End Semester

Examination Total

3

25 75 100



I Heat 12 II Thermodynamics, Liquefaction of gases & Non-Conventional Energy 13

III Light and Remote Sensing 13 IV Electricity 13

V Basics of Electronics 13

Revision and Test 04 Total 64

OBJECTIVES:

• Identify good conductors and insulators of heat. • Analyse the relation between pressure, volume and temperature of gas and to interpret the results.

• Understand the process of Isothermal and Adiabatic changes of gas and basic laws of thermodynamics.

• Acquire knowledge about liquefaction process of gases. • Realise the inevitable need for tapping Alternate energy to address the looming energy crisis.

• Identify the characteristics and properties of LASER, Photo Electric effect and Optical fibre cable and their engineering applications.

• Acquire broader ideas about the process of remote sensing in tapping the earth resources for human benefits.

• Acquire knowledge about heating, chemical and magnetic effects of electric current.

• Understand the effect of self induction and mutual induction. • Gain broader ideas of capacitors, diodes, transistors, integrated circuits and logic gates.

• Identify, analyse and solve Engineering field related problems involving expressions derived in all the above topics.



DETAILED SYLLABUS


I

HEAT

Transfer of Heat Concept of Heat and Temperature – Centigrade, Fahrenheit and Kelvin scales of temperature measurement – Conduction, convection and radiation – Definitions and explanations – Coefficient of thermal conductivity – Definition and SI unit – Selection of good and poor thermal conductors – Properties of thermal radiation. Kinetic Theory of Gases

Postulates – Mean square velocity and Root Mean Square (RMS) velocity of molecules – Definitions and expressions – Expression for the pressure of a gas on the basis of postulates of kinetic theory of gases- Relation between pressure, kinetic energy and absolute temperature of the gas – Mean kinetic energy per molecule of the gas. Simple problems based on the expression for the pressure of a gas. Specific Heat Capacity Specific heat capacity of a substance (solids and liquids) – Definition – Specific heat capacity of a gas at constant volume – Specific heat capacity of a gas at constant pressure – Ratio of specific heat capacities – Explanation for Cp greater than Cv – Derivation of Meyer’s relation – calculation of Universal gas constant R from the gas equation PV = RT.

Simple problems based on Meyer’s relation.

3 Hrs

5 Hrs

4 Hrs

II THERMODYNAMICS, LIQUEFACTION OF GASES & NON-CONVENTIONAL ENERGY

Thermodynamics

Zeroth law and first law of thermodynamics – Explanation - Isothermal and Adiabatic changes - Explanation – Equations for isothermal and adiabatic changes ( No derivation ) Simple problems based on equations P1V1 = P2V2 and P1V1

γ = P2V2γ

Second law of thermodynamics – Clausius statement and Kelvin’s statement – Concept of Carnot’s reversible engine and efficiency. Liquefaction of Gases

Liquefaction, critical temperature, critical pressure and critical volume – Definitions – Principle used in cascade process – Cascade process of liquefaction of oxygen –Disadvantages of cascade process - Joule Thomson effect – Temperature of inversion – Liquefaction of air by Linde’s process. Non – Conventional Energy

Introduction – Non-renewable and Renewable ( Alternate ) energy sources – Examples – Solar energy, wind energy, tidal energy, geothermal energy, Hot Dry Rocks (HDR) and bio-mass – Advantages and disadvantages of renewable energy.

5 Hrs

3 Hrs

5 Hrs

III LIGHT AND REMOTE SENSING

Optical Fibre Cable Refraction – Laws of refraction – Refractive index of a medium / material – Definition – Fibre optics – Introduction – Phenomenon of total internal reflection – Application of total internal reflection in Optical Fibre Cable (OFC) as a wave guide – Advantages of O.F.C. Laser

LASER – Characteristics of LASER – principle of LASER – Spontaneous emission – Stimulated emission – population inversion – Production of LASER using semiconductor (GaAs) diode source – Uses of LASER. Photo Electric Effect

Photo electric effect – Introduction – Hallwachs experimental arrangement –

3 Hrs

3 Hrs

3 Hrs



Einstein’s photoelectric equation – Laws of photoelectric emission – Photo emissive cell –Photo conductive cell - Photo voltaic cell – Applications of photo cells. Remote Sensing

Remote sensing – Introduction – Active and passive remote sensing – Explanation and examples – Components of remote sensing – Data acquisition, data analysis and reference data – Components of electro magnetic spectrum used in remote sensing – Microwave remote sensing – RADAR – principle and working with block diagram .

4 Hrs

IV ELECTRICITY

Electrical Circuits

Ohm’s law – Laws of resistances – Resistivity and Conductivity – Definitions – Kirchoff’s current and voltage laws – Condition for balancing the Wheat stone’s network. Simple problems based on expression for resistivity. Heating and Chemical Effects of Current

Joule’s law of heating – Experimental determination of specific heat capacity of a liquid using Joule’s calorimeter – Faraday’s laws of electrolysis – Electro chemical equivalent (e.c.e) of an element – Definition – Experimental determination of e.c.e. of copper. Simple problems based on expression for e.c.e. Measuring Instruments

Motion of a charged particle inside a uniform magnetic field – Expression for the force acting on a current carrying straight conductor placed in a uniform magnetic field – Fleming’s Left Hand rule – Expression for the torque experienced by a rectangular current carrying coil placed inside a uniform magnetic field – Working of a moving coil galvanometer and its merits – Conversion of galvanometer into an Ammeter and Voltmeter. Simple problems based on conversion of galvanometer into ammeter and voltmeter. Electro Magnetic Induction Faraday’s laws of electro magnetic induction – Lenz’s law – Fleming’s Right Hand Rule – Self induction and mutual induction.

3 Hrs

3 Hrs

5 Hrs

2 Hrs

V BASICS OF ELECTRONICS

Capacitors

Capacitance of a capacitor – Definition – ‘farad’– Definition – Energy stored in a capacitor – Expressions for effective capacitance when capacitors are connected in series and parallel – Applications of capacitors. Simple problems based on expressions for effective capacitance for series and parallel connections of capacitors. Semi Conductors

Semi conductors – Energy bands in solids – Energy band diagram of good conductors, insulators and semi conductors – Fermi Level – Intrinsic semiconductors - Concept of positive holes - Doping – Extrinsic semiconductors – P type and N type semiconductors. Diodes and Transistors

P-N junction diode – Forward bias and reverse bias – Rectification action of diode – Working of full wave rectifier using P N junction diodes in bridge type configuration. PNP and NPN transistors – Three different configurations – Advantages of common emitter configuration – working of NPN / PNP transistor as an amplifier in common emitter configuration. Digital Electronics

3 Hrs

3 Hrs

4 Hrs

3 Hrs



Digital electronics – Introduction – Logic levels – Basic logic gates: OR, AND and NOT gates – Universal logic gates: NAND and NOR gates – Special logic gates: XOR and XNOR gates – Symbolic representation, Boolean expression and Truth table for all above logic gates – Integrated circuits – Levels of integration – SSI, MSI, LSI and VLSI.

Text Books: 1 Higher secondary Physics – First & Second year– Volume I & II – Tamil Nadu text book Corporation

- 2004 & 2005 2 Anwar Kamal -- Intermediate physics – Volume I & II –– Foundation books private Ltd. 3 Students’ support material GEL 24 Engineering Physics – II – Department of Physics, M P C.

Reference Books: 1 Brijlal and Subrahmanyam –Heat and Thermodynamics –. S. Chand & co,New Delhi 2 D.N. Vasudeva --Fundamentals of Electricity –– S. Chand & co., New Delhi 3 G.D. Rai -- Non- Conventional energy sources – Khanna publishers, New Delhi. 4 M. Anji Reddy -- Text book of Remote sensing and Geographical information systems – BS

publications., Hyderabad.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : II Subject Code & Name : GEL 25 ENGINEERING CHEMISTRY -II Teaching and Scheme of Examination: No. of weeks per semester: 16


GEL 25 Engineering Chemistry- II

Hours/ Week

Hours/ Semester


4 64


End Semester

Examination Total

3

25 75 100



I Air Pollution, Water Pollution, Solid Waste Management & Green Chemistry

12

II Fuels, Rocket Propellants & Combustion 12

III Solid State, Extraction of Metals, Powder Metallurgy, Alloys & Abrasives

11

IV Composite Materials, Ceramics, Refractory, Lubricants & Nano -particles

12

V Polymers: Plastics, Rubber & Organic coatings 13 Revision and Test 04


• Understand about pollution, air pollution, water pollution, solid waste management, and Green chemistry.

• Acquire knowledge about Acid rain, Green house effect, Global warming, and Ozone layer depletion. • Understand the terms like sewage, Eutrophication, Disposal of wastes and goals of green chemistry.

• Gain knowledge about fuels, Rocket propellants and combustion. • Understand the structure of solids, Unit cell, bcc, fcc, hcp packing of atoms in metal crystals.

• Understand the extraction of metals, Powder metallurgy, Alloys and Abrasives.

• Acquire knowledge about composite materials, Ceramics, Refractories and Lubricants.

• Gain knowledge about preparation, Properties and uses of Plastics and Rubber

• Study about the Paints, Special Paints and Dyes.

• Identify, analyse and solve Engineering field related problems involving expressions derived in all the above topics.



DETAILED SYLLABUS


I

ENVIRONMENTAL CHEMISTRY

Air Pollution

Definition – Pollutants (SO2, H2S, HF, CO Dust) – harmful effects – Acid rain – formation – Harmful effects – Green House effect – causes – Global Warming – Harmful effects – Ozone layer – importance – causes for depletion of Ozone layer (No equations) – effects of Ozone layer depletion – Control of air pollution. Water Pollution

Causes – (Sewage, effluents, algae microorganisms) – Harmful effects, sewerage – Industrial effluents – harmful effects of heavy metal ions (metals like Lead, Cadmium, Zinc and Copper) – treatment – Eutrophication – Definition and effects – Carcinogenic wastes, pesticides, Insecticides – Health problems. Solid Waste Management

Solid wastes – definition – problems – types of wastes – methods of disposal (land fill – incineration) – recycling – advantages of recycling (Basic ideas). Green Chemistry

Definition – Goals of green chemistry (Basic ideas).

4 Hrs

4 Hrs

3 Hrs

1 Hr

II

FUELS, ROCKET PROPELLANTS AND COMBUSTION

Fuels

Definition – Calorific value – classification, solid fuels – wood-coal – varieties of coal-composition-specific uses-liquid fuels petroleum – fractional distillation – Fractions and uses, Cracking (concept only). Liquid Hydrogen as fuel – gaseous fuels preparation and specific uses of producer gas, water gas, biogas – LPG – composition and uses. Advantages of gaseous fuels. Rocket Propellants

Definition – Essential characteristics – classifications of propellants – brief account of solid & liquid propellants with example. Combustion

Combustion of fuels – Definition – combustion calculation by mass (for solid and liquid fuels) – combustion calculation of gaseous fuels – stoichiometric calculations – volume of air required – excess air – fuel gas – flue gas analysis – Orsat Apparatus – simple numerical problems.

5 Hrs

2 Hrs

5 Hrs

III

SOLID STATE EXTRACTION OF METALS, POWDER METALLURGY, ALLOYS AND

ABRASIVES

Solid State Structure of Solids – Definition and examples for ionic, Molecular, Covalent and Metallic solids – Unit cell – bcc, fcc and hcp packing of metals – examples and properties reflected by the packing of atoms. (No numerical problems). Extraction of Metals

Extraction of Tungsten and Titanium – uses. Powder Metallurgy

Definition – Metal Powder – Preparation of Metal Powder – Atomisation – Reduction of Metal Oxide – Applications of Powder Metallurgy. Alloys

Definition – purpose of Alloying – Non-Ferrous alloys – Definition – Composition and uses of – Nickel alloys – Nichrome, Locanel – Copper alloys – Brass – Dutch metal, Cartridge brass, Germen silver – Bronze – coinage bronze, Gun metal. Aluminium alloys – Duralumin, Magnalumin. Abrasives

Definition – classification – hardness in moh’s scale – Natural abrasives – Diamond, Corundum, Emery, and Garnet – Synthetic abrasives – Carborundum – Boron carbide manufacture – Properties and uses.

3 Hrs

2 Hrs

2 Hrs

2 Hrs

2 Hrs



IV UNIT IV COMPOSITE MATERIALS, CERAMICS, REFRACTORIES, LUBRICANTS AND

NANO-PARTICLES

Composite Materials

Definition – advantages over metals and polymers – general applications – types – fibre reinforced composites – particulate composites – layered composites. (Basic ideas and specific applications) Ceramics

White pottery – Definition – manufacture of White pottery – uses glazing – Definition – purpose – method – salt glazing. Refractory

Definition – requirements – classification with examples and uses of fireclay bricks, Alumina bricks and silica bricks. Lubricants

Definition – characteristics of Lubricants – Types of Lubricants: Solid, Semisolid and liquid lubricants. Nano-Particles

Definition – Area of application – Medicine, Electronics and biomaterials.

3 Hrs

2 Hrs

2 Hrs

3Hrs

2 Hrs

V UNIT V POLYMERS, RUBBER AND ORGANIC COATINGS

POLYMERS: Plastics

Polymerization – types of polymerization – Addition polymerization formation of polythene – condensation polymerization – formation of phenol formaldehyde – types of plastics – thermoplastics & thermo set plastics – Differences-mechanical properties – Advantages over traditional materials, (wood & metal) – specific uses of Bakelite, PVC, Nylon & urea formaldehyde resin – reinforced or filled plastics – definitions – advantages – applications – polymers in surgery biomaterial – definition – Biomedical uses of polyurethane, PVC, polypropylene, polyethylene. Rubber

Natural rubber – preparation from latex – defects of natural rubber compounding – ingredients & their functions – vulcanization purpose – synthetic rubber – Buna-S. Thiokol, Neoprene (Preparation & specific uses only-no equation) reclaimed rubber definition – process – properties – uses. Organic Coatings

Paints – definition – components of paints and their functions – Varnish – Definition – types – preparation of oil varnish – Difference between paint & varnish – special paints – Luminescent, heat resistant, fire retardant, Anti – fouling paints – cement paint, aluminium paint & distemper. Dyes – Acid dyes – basic dyes – Mordant dyes – Definition

4 Hrs

4 Hrs

5 Hrs

Reference Books:

1. Soni PL - Inorganic chemistry – Sultan Chand & sons. 2. Soni PL - Organic chemistry - Sultan Chand & sons. 3. Jain & Jain - Engineering chemistry - Dhanpat rai & co 4. Uppal - Engineering chemistry - Khanna publishers 5. Dara .S.S - Environmental chemistry & Pollution control - S.Chand & co 6. Tripathy .S.N - Environmental Pollution - Sunakar panda - Vrinda publication 7. Rain water Harvesting-hand book by Chennai Metro Water 8. Higher Chemistry Book Volume I and II, Tamilnadu Text Book Corporation, Chennai.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : II Subject Code & Name : GEL 26 ENGINEERING PHYSICS - II PRACTICAL



GEL 26 Engineering Physics - II Practical

Hours/ Week

Hours/ Semester


2 32


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• To impart knowledge about volumetric analysis in Acidimetric, Alkalimetry, Permanganametry. • To give knowledge about estimation of Hardness present in the Water.

• To give knowledge about measurement of pH in various solutions

List of Experiments with objectives:

1. REFRACTIVE INDEX

To determine the refractive index of a transparent liquid (water) using travelling microscope. 2. SPECTROMETER – Angle of the prism.

To measure the angle of the prism using spectrometer

3. SPECTROMETER – Angle of minimum deviation of the prism.

To measure the angle of minimum deviation of the prism using spectrometer and to calculate the refractive index of glass of the prism.

4. LAWS OF RESISTANCES

To verify the laws of resistances by connecting the two given standard resistances (i) in series and (ii) in parallel, using Ohm’s law.

5. METRE BRIDGE

To determine the unknown resistance of the given wire. 6. POTENTIOMETER

To compare the electro motive forces (e.m.fs) of the given two cells.

7. JOULE’S CALORIMETER

To determine the specific heat capacity of water.

8. COPPER VOLTAMETER

To determine the electro chemical equivalent (e.c.e.) of copper.

9. P-N JUNCTION DIODE

To draw the voltage – current characteristics in forward bias and to find the ‘dynamic forward resistance’ & ‘knee voltage’ from the graph

10. P N P TRANSISTOR

To draw the transfer characteristics of a P N P transistor in common emitter configuration and to find the current gain from the graph

11. LOGIC GATES

To find the output conditions for different combinations of the input for NOT gate and 2 inputs AND, OR, NAND , NOR & XOR logic gates, using IC chips. ( IC 7404 –NOT Gate, IC 7408 – AND Gate, IC 7432 – OR gate, IC 7400 – NAND Gate, IC 7402 – NOR Gate & IC 7486 – XOR gate.)

12. Demonstration Experiment:

SOLAR CELL. To draw the V – I characteristics of the solar cell.




1 Formula with Explanation 10 2 Figure/Circuit Diagram with parts 05

3 Tabular Column with proper Units 10 4 Observations (including taking readings) 35

5 Calculations 10 6 Result 05

Total 75



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : II Subject Code & Name : GEL27 ENGINEERING CHEMISTRY -II PRACTICAL



GEL27 Engineering Chemistry –II Practical

Hours/ Week

Hours/ Semester


2 32


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Analyze the given simple salt containing an anion and a cation and to identify its significance and use in day-to-day life.

• The student is introduced to chemical methods of analysis of materials.

List of Experiments:

1. Qualitative Analysis:-

Study of the reactions of the following radicals leading to qualitative analysis of the given CHEMICAL SUBSTANCE soluble in water or in dilute acids. Acid radicals: Chloride, Carbonate, Sulphate, Nitrate Basic radicals: Lead, Cadmium, Copper, Aluminium, Zinc, Calcium, Barium, Magnesium and ammonium salts

Identification of acid and basic radicals in

1. Lime Stone (Calcium Carbonate) 2. Pollutant (Lead nitrate or Cadmium Carbonate) 3. Fertilizer (Ammonium sulphate) 4. Electrolyte (Ammonium Chloride) 5. Fungicide (Copper sulphate) 6. Coagulant (Aluminium Sulphate) 7. Mordant (Zinc Sulphate) 8. Gypsum (Calcium Sulphate) 9. Epsum (Magnesium Sulphate) Students may be asked to analyze the above salts and write the analysis in record book with their significance and use. (If any) 10. Analysis of an Effluent (containing pollutant ions like Lead, Cadmium, Zinc, Copper).

Students may be given any one pollutant in a test tube in solution form and asked to report Metallic pollutant with procedure (Basic Radical Analysis Procedure) and its harmful effects. In the examination one effluent in a test tube containing any one metallic pollutant of the above four may be given.

Reference Books :

1. Vogel -Analytical chemistry – Pearson publications 2. Dr. Sudha Rani - Laboratory manual on engineering chemistry Dhanpat rai publication




1 Acid Radical 23 2 Basic Radical 23

3 Report 04 4 Effluent Procedure 20

5 Harmful effects 05

Total 75



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : II Subject Code & Name : GEL28 ENGINEERING GRAPHICS-II PRACTICAL Teaching and Scheme of Examination: No. of weeks per semester: 16


GEL28 Engineering Graphics-II Practical

Hours/ Week

Hours/ Semester


6 96


End Semester

Examination Total

3

25 75 100

TOPICS AND ALLOCATION OF HOURS:

Sl. No. Topics Hours. 1 Section of Solids (Manual Drafting and Computer Aided Drafting) 15

2 Development of surfaces(Manual Drafting and Computer Aided Drafting) 15

3 Orthographic projections (Manual Drafting and Computer Aided Drafting) 30 4 Isometric projections (Manual Drafting and Computer Aided Drafting) 30

Revision Test 06 Total 96

OBJECTIVES :

• State the importance of drawing. • Understand the concepts and draw the section of solid and true shape

• Draw the development of surfaces.. • Draw orthographic views from isometric drawings.

• Convert orthographic views into isometric drawing.



DETAILED SYLLABUS


I

Sections of Solids (Manual Drafting and Computer Aided Drafting) Introduction – section planes – apparent section – true section – sectional view – need for sectional view – cutting plane – cutting plane line. Section plane perpendicular to VP and parallel to HP – section plane perpendicular to HP and parallel to VP – section plane perpendicular to VP and inclined to HP – section plane perpendicular to HP and inclined to VP – Section of solids in simple positions – parallel to one plane and perpendicular to other plane – axis parallel to both planes showing true shape of section – exercises: Section of simple solids,cube,prism,cylinder,cone,with axis vertical

15 Hrs

II

Development of surfaces (Manual Drafting and Computer Aided Drafting) Need for preparing development drawing with reference to sheet metal work –

Development of cube, cylinder, prism and pyramids, frustum of pyramids and

cones –Exercises in triangular, square, pentagon and hexagon prisms and pyramids,

cylinder And cone.

Development of T-pipe, elbow, ducts, tray, lamp shade and funnel.

15 Hrs

III

Orthographic projection (Manual Drafting and Computer Aided Drafting) Introduction – projection terms – Orthographic projection – Co-ordinate planes of projection – Systems of orthographic projection – First angle Orthographic projection – Third angle Orthographic projection – Comparison of first and third angle projections. Projection of three views (Elevation, Plan, Side view) of simple objects using first

angle projection only – exercises.

30 Hrs

IV

Isometric projections (Manual Drafting and Computer Aided Drafting) Introduction – isometric view – isometric projection – difference between isometric view and isometric projection – isometric scale – methods of drawing an isometric view – box method. Angles in Isometric view – irregular curves in isometric drawing – circles in isometric method – four centre method for drawing an ellipse – arcs of circles in isometric – Draw the isometric view of the object from the given orthographic view – exercises.

30 Hrs

Lab Manual:

1 GEL28 Engineering Graphics-CAD , Murugappa Polytechnic ,2007

Reference Books

1. Gill P.s., “Engineering drawing”, S.K.Kataria & Sons. 2. Bhat N.d., “Engineering drawing”, Charotar Publishing House 3. Gopalakrishnan.K.R., “Engineering Drawing”, (Vol.I and Vol.II), Dhanalakshmi

Publishers, Edition 2, 1970 4. ABook on AutoCAD Release 2009 4. Venugopal.K , Sreekanjana G, “Engineering Graphics” New Age International Publishers. 5. K.V.Nataraajan “A Text Book of Engineering Drawing” 6. Barkinson & Sinha, “First Year Engineering Drawing”, Pitman Publishers. 7. Shah/Rana, ”Engineering Drawing”, Pearson Longman.



SCHEME OF EVALUATION Question


Manual CAD

1 Section of Solids(either or type) 7 8

2 Development of Surfaces 8 7 3 Orthographic Projection 10 10

4 Isometric Projection 15 10 Total 40 35



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : II Subject Code & Name : GEL 29 WORKSHOP PRACTICE Teaching and Scheme of Examination: No. of weeks per semester: 16


GEL 29 Workshop Practice

Hours/ Week

Hours/ Semester


3 48


End Semester

Examination Total

3

25 75 100

FITTING :

• Familiarize safety practices in the workshop.

• Provide awareness on First aid.

• Use of hand tools and measuring instruments. • Practice on Marking and punching.

• Practice on Hacksaw cutting. • Practice on Filing and fitting.

• Practice on Drilling and tapping. Exercises:

1. V-Joint 2. L-Joint 3. Step joint 4. U-Joint 5. Hexagon tail joint 6. Drilling and tapping 1 7. Drilling and tapping 2

Note: 70mm X 50 mm X 3mm thick plate can be used for the above joints. All the exercises should be given for the Autonomous practical examination. Drilling and Tapping operations should be exercised in the Fitting section itself

WIRING :

• Study about the safety in wiring.

• Study of Hand & Power tools and Testing tools.

• Study the purpose of earthing.

• Identify different electrical fitting and accessories.

• Identify standard types of wires with colour codes.

• Identify the symbols used in the circuit diagram. • Practice simple wiring methods.

• Practice in soldering.

Exercises:

1. One lamp controlled by one -way switch. 2. Two lamps controlled by one-way switch in series. 3. Two lamps controlled by one-way switch in parallel. 4. Staircase wiring. 5. Tube light connection. 6. Circuit diagram for a fan.

7. Soldering practice



Note:

Wiring section should be attached with the Fitting section. Experimental boards should be prepared to trace the circuit diagram. The concern faculty / examiner must ensure that the proper precaution has been taken before providing the power to the circuit. All the exercises should be given for the Autonomous practical examination.


No. Allocation Marks 1 Fitting- 2Hrs

Marking and Cutting Dimensions Joint/Finish

10 20 15

45

2 Wiring- 1Hr

Circuit Diagram Assembly and Connection Result

10 10 05

25

3 Viva voce 05

Total 75



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : III Subject Code & Name : MEL31 STRENGTH OF MATERIALS Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL31 Strength of Materials

Hours/ Week

Hours/ Semester


6 96


End Semester

Examination Total

3

25 75 100



I Deformation of metals 18

II Geometrical properties of sections and thin shells 18

III Lateral deformation (SF and BM diagrams, deflection of beams) 18 IV Theory of simple bending and friction 18

V Torsion and springs 18


Total 96

OBJECTIVES:

• Define various mechanical properties of materials. • Calculate the deformation of materials, which are subjected to axial load and shear.

• Determine the moment of Inertia of various sections used in industries.

• Estimate the stresses induced in thin shells.

• Construct SFD and BMD.

• Learn the concepts of deflection of beams subjected to different loads.

• Define types of friction. • Learn the concepts of simple bending

• Calculate the power transmitted by the solid & hollow shafts. • Distinguish different types of spring and their applications.



DETAILED SYLLABUS


I

DEFORMATION OF METALS

Mechanical properties of materials: Engineering materials – Ferrous and non ferrous materials -Definition of mechanical properties such as strength – elasticity, plasticity, ductility, malleability, stiffness, toughness, brittleness, hardness, wear resistance, machinability, castability and weldability--Alloying elements-effect of alloying element - Fatigue, fatigue strength, creep – temperature creep – cyclic loading and repeated loading – endurance limit. Simple stresses and strains: Definition – Load, stress and strain – Classification of force systems – tensile, compressive and shear force systems – Behaviour of mild steel in tension up to rupture – Stress – Strain diagram – limit of proportionality – elastic limit – yield stress – breaking stress – Ultimate stress – percentage of elongation and percentage reduction in area – Hooke’s law – Definition – Young’s modulus - working stress, factor of safety, load factor, shear stress and shear strain - modulus of rigidity. Linear strain – Deformation due to tension and compressive force – Simple problems in tension, compression and shear force. Definition – Lateral strain – Poisson’s ratio – volumetric strain – bulk modulus – volumetric strain of rectangular and circular bars – problems connecting linear, lateral and volumetric deformation – Elastic constants and their relationship - Problems on elastic constants - Definition – Composite bar – Problem in composite bars subjected to tension and compression – Temperature stresses and strains – Simple problems – Definition – strain energy – proof resilience – modulus of resilience – The expression for strain energy stored in a bar due to Axial load – Instantaneous stresses due to gradual, sudden, impact and shock loads – Problems computing instantaneous stress and deformation in gradual, sudden, impact and shock loadings.

18

II

GEOMETRICAL PROPERTIES OF SECTIONS AND THIN SHELLS

Properties of sections: Definition – center of gravity and centroid - position of centroids of plane geometrical figures such as rectangle, triangle, circle and trapezium-problems to determine the centroid of angle, channel, T and I sections only - Definition-centroidal axis-Axis of symmetry. Moment of Inertia – Statement of parallel axis theorem and perpendicular axis theorem. Moment of Inertia of lamina of rectangle, circle, triangle, I and channel sections-Definition-Polar moment of Inertia-radius of gyration – Problems computing moment of inertia and radius of gyration for angle, T, Channel and I sections. Thin Shells: Definition – Thin and thick cylindrical shell – Failure of thin cylindrical shell subjected to internal pressure – Derivation of Hoop and longitudinal stress causes in a thin cylindrical shell subjected to internal pressure – simple problems – change in dimensions of a thin cylindrical shell subjected to internal pressure – problems – Derivation of tensile stress induced in a thin spherical shell subjected to internal pressure – simple problems – change in diameter and volume of a thin spherical shell due to internal pressure – problems.

18

III

LATERAL DEFORMATION-(SF AND BM DIAGRAMS, DEFLECTION OF BEAMS)

Classification of beams – Definition – shear force (SF) and Bending moment(BM) – sign conventions for shear force and bending moment – types of loadings – Relationship between load, force and bending moment at a section – shear force diagram and bending moment diagram of cantilever and simply supported beam subjected to point load and uniformly distributed load (UDL) – Determination of Maximum bending moment in cantilever beam and simply supported beam when they are subjected to point load and uniformly distributed load. Definition – slope, deflection, stiffness and flexural rigidity – Derivations of relationship between slope, Deflection and Radius of curvature – Derivation of slope and deflections of cantilever and simply supported beam by area moment

18



method under point load and UDL load– simple problems.

IV

THEORY OF SIMPLE BENDING AND FRICTION

Theory of simple bending – Assumptions – Neutral axis – bending stress distribution – moment of resistance – bending equation – Definition – section modulus - rectangular and circular sections – strength of beam – simple problems involving flexural formula for cantilever and simple supported beam. Definition – force of friction – limiting friction- static – dynamic friction – angle of friction – co-efficient of friction – cone of friction – laws of static and dynamic friction – ladder problems

18

V

TORSION AND SPRINGS

Theory of torsion – Assumptions – torsion equation – strength of solid and hollow shafts – power transmitted – Definition – Polar modulus – Torsional rigidity – strength and stiffness of shafts – comparison of hollow and solid shafts in weight and strength considerations – Advantages of hollow shafts over solid shafts – Problems. Types of springs – Laminated and coiled springs and applications – Types of coiled springs – Difference between open and closely coiled helical springs – closely coiled helical spring subjected to an axial load – problems to determine shear stress, deflection, stiffness and resilience of closed coiled helical springs.

18

Text Books:

1. Khurmi.R.S, “Strength of Materials”, S.Chand & Co., New Delhi. 2. Ramamrutham.S, “Strength of Materials”, Dhanpat Rai Pub. Co., New Delhi.

Reference Books:

1. Bansal.R.K, “Strength of Materials”, Laxmi Publications Pvt. Ltd., New Delhi. 2. Rattan.S.S, “Strength of materials”, Tata Mcgraw hill, New Delhi. 3. Sarkar.B.K, “Strength of Materials”, Tata Mcgraw hill, New Delhi.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : III Subject Code & Name : MEL32 MANUFACTURING TECHNOLOGY - I Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL32 Manufacturing Technology - I

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Casting processes 15

II Joining processes 15

III Bulk deformation processes and heat treatment 15 IV Manufacturing of plastic components and powder metallurgy 15

V Centre lathe and special purpose lathes 15



• Acquire Knowledge about types of pattern, casting, moulding.

• Explain hot working and cold working processes.

• Describe the various casting processes.

• Appreciate the safety practices used in welding. • Explain powder metallurgy process.

• Distinguish the different heat treatment processes.

• Explain the lathe and its working parts.

• Describe the functioning of semi automatic and automatic lathes.

• Explain bulk deformation processes.

• Explain the manufacturing of plastic components.



DETAILED SYLLABUS


I

CASTING PROCESSES

Patterns – definition – pattern materials – factors for selecting pattern materials – single piece solid, split patterns – pattern allowances – core prints. Moulding – definition – moulding boxes, moulding sand – ingredients – silica – clay – moisture and miscellaneous materials – properties of moulding sand – sand additives – moulding sand preparation – mixing – tempering and conditioning – types of moulding – green sand – dry sand – machine moulding – Top and bottom squeezer machines – Jolting machines – sand slinger- core – CO

2 process core

making – types of core – core boxes. Casting – definition – sand casting using green sand and dry sand – gravity die casting – pressure die casting – hot and cold chamber processes – centrifugal casting – continuous casting – chilled casting – malleable casting – Introduction to Stir casting – melting of cast iron – cupola furnace – melting of non ferrous metals – crucible furnace melting of steel - arc furnaces – induction furnaces – instrument for measuring temperature – optical pyrometer – thermo electric pyrometer – cleaning of casting – tumbling, trimming, sand and shot blasting – defects in casting – causes and remedies – Introduction to Sand reclamation - safety practices in foundry

15

II

JOINING PROCESSES

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 Gas Welding Equipment– Oxy acetylene welding - Three types of flame– resistance welding – classification of resistance welding – butt – spot – seam – projection welding – welding related processes – oxy acetylene cutting – arc cutting – hard facing bronze welding – soldering and brazing special welding processes – cast iron welding – thermit welding – solid slate welding, Introduction to Friction stir welding - ultrasonic, diffusion and explosive welding – explosive cladding – modern welding, electron beam and laser beam welding – types of welded joints – merits and demerits of welded joints – inspection and testing of welded joints – destructive and non destructive types of tests – magnetic particle test – radiographic and ultrasonic test defects in welding – causes and remedies – safety practices in welding – basic acoustic emission techniques – basic welding symbols.

15

III

BULK DEFORMATION PROCESSES AND HEAT TREATMENT

Hot working, cold working – advantages of hot working and cold working– hot working operations – rolling, forging, smith forging, drop forging, upset forging, press forging – roll forging-Extrusion – wire drawing Heat treatment processes – purpose – procedures – applications of various heat treatment processes – Iron – carbon equilibrium diagram – full annealing – process annealing stress relief annealing - spherodising annealing – isothermal annealing – normalizing – hardening – tempering – quenching medium – different types and their relative merits – case hardening – pack carburizing – cyaniding – nitriding – induction hardening and flame hardening- Hardenability (Definition Only)

15

IV

MANUFACTURING OF PLASTIC COMPONENTS AND POWDER METALLURGY

Plastic Components: Types of plastics-Engineering plastics – thermosets – composite - structural foam, elastomers - polymer alloys and liquid crystal polymers Factors Influencing The Selection Of Plastics: Mechanical properties – degradation- wear resistance -frictional properties- special properties-processing – cost

15



Processing of Plastics: Extrusion-general features of single screw extrusion -twin screw extruders and types-Injection moulding types : Plunger type.-Reciprocating screw injection - details of injection mould - structural foam injection mould - sandwich moulding - gas injection moulding - injection moulding of thermosetting materials calendaring and rotational moulding. Design consideration for plastic components. Powder Metallurgy : Methods of manufacturing metal powders – atomization, reduction and electrolysis deposition – compacting – sintering – sizing – infiltration – mechanical properties of parts made by powder metallurgy – design rules for the power metallurgy process.

V

CENTRE LATHE AND SPECIAL PURPOSE LATHES

Centre Lathe: Theory of lathes – specifications – simple sketches – principal parts – head stock – back geared type – all geared type – tumbler gear mechanism – quick change gear box – apron mechanism – carriage cross slide – automatic, longitudinal and cross feed mechanism – tail stock and its functions – work holding device – face plate – three jaw chuck – four jaw chuck – catch plate and carrier – types of centres – machining operations done on lathe - straight turning – step turning-taper turning-knurling-Thread cutting-Facing-Boring-chamfering–-cutting speed-feed-depth of cut. Semi Automatic Lathes: Types of semi automatic lathes – capstan and turret lathes – difference between turret and capstan – tools and work holding devices – self opening die head – collapsible taps Automatic Lathes: Automatic lathe – classification of single spindle automatic lathe – principle of automatic lathes – automatic screw cutting machines – multi spindle automatic lathes Introduction to copying Lathe

15

Text Books:

1. Hajra Chowdry & Bhattacharaya, “Elements of workshop Technology Volume I & II”, Media Promoters & Publishers Pvt. Ltd., Mumbai 400 007.

2. Khurmi.R.S & Gupta.J.K, “A Text book of workshop Technology”, S.Chand & Co., Ram Nagar, New Delhi. Reference Books:

1. Begeman, “Manufacturing process”, McGraw Hill, New Delhi. 2. Chapman WAJ, “Workshop Technology - Volume I, II, & III”, Vima Books Pvt. Ltd., New Delhi -110 002. 3. Raghuwanshi, “Workshop Technology”, Khanna Publishers 4. Jain & Gupta, “Production Technology”, Khanna Publishers, New Delhi 110 006. 5. Sharma.P.C, “Production Technology”, S.Chand & Co. Ltd., Ram Nagar, New Delhi 110 055. 6. HMT, “Production Technology”, Tata McGraw Hill publishing Co. Ltd., New Delhi- 110 008. 7. Kalpakjian, “Manufacturing Engineering & Technology”.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : III Subject Code & Name : MEL33 FLUID MECHANICS & FLUID POWER Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL33 Fluid Mechanics & Fluid Power

Hours/ Week

Hours/ Semester


6 96


End Semester

Examination Total

3

25 75 100



I Properties of fluids and pressure measurements 18

II Flow of fluids and flow through pipes 18

III Impact of jets, hydraulic turbines, centrifugal and reciprocating pumps

18

IV Pneumatic systems 18 V Hydraulic systems 18



• Define the properties of Fluids.

• Explain the working of pressure measuring devices

• Explain continuity equation and Bernoulli’s Theorem

• Assess the impact of frictional loss of head in flow through pipes • Estimate the discharge through orifices

• Distinguish the working principles of pumps and turbines.

• Explain the working of centrifugal pumps and reciprocating pumps.

• Compare pneumatic system with hydraulic system

• Draw Pneumatic circuits for industrial application.

• State the properties of hydraulic Systems • Develop hydraulic circuit for machine tools applications.



DETAILED SYLLABUS


I

PROPERTIES OF FLUIDS AND PRESSURE MEASUREMENTS

Introduction - Definition of fluid - Classification of Fluids - ideal and real fluids -Properties of a fluid – definition and units - Pressure-units of Pressure - Pressure head-atmospheric, gauge and absolute pressure – problems - Pascal’s law- proof - applications of Pascal’s law - Hydraulic press - Hydraulic jack - Pressure measurement - Piezometer tube - Simple U-tube manometer - Differential U-tube manometer - Inverted Differential manometer - Micro-manometer - Inclined tube micro-manometer - Mechanical Gauges -Bourdon’s Tube Pressure Gauge - Diaphragm pressure gauge - Dead weight pressure gauge.

18

II

FLOW OF FLUIDS AND FLOW THROUGH PIPES

Types of fluid flow - path line and stream line - mean velocity of flow - discharge of a 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 - problems on Bernoulli’s theorem – venturimeter - derivation for discharge - orifice meter - derivation for discharge - difference between venturimeter and orifice meter -problems on venturimeter and orifice meter - Pitot tube – description only – orifice –types – applications - hydraulic co-efficients - determining hydraulic c o-efficients – problems - discharge through a small orifice discharging freely only - problems –experimental method of finding Cv, Cc and Cd - Flow through pipes - laws of fluid friction -

hydraulic gradient line - total energy line - wetted perimeter - hydraulic mean radius - loss of head due to friction - Darcy-Weisbach equation and Chezy’s formula –problems - minor losses (description only) - Power transmission through pipes - problems.

18

III

IMPACT OF JETS, HYDRAULIC TURBINES, CENTRIFUGAL AND RECIPROCATING

PUMPS

Impact of jet - on a stationary flat plate held normal to the jet and inclined to the direction of jet - Impact of jet on a flat plate moving in the direction of jet - Impact of jet on a series of moving plates or vanes - force exerted and work done by the jet - problems. Hydraulic turbines – classifications - Pelton wheel - components and working - speed regulation (theory only) - Francis and Kaplan turbines - components and working - draft tube - functions and types - surge tank - differences between impulse and reaction turbines. Centrifugal Pumps – classifications - construction and working of single stage centrifugal pumps - components with types - theory only - multi stage pumps – advantages - priming – cavitation. Reciprocating Pumps – classifications - construction and working of single acting and double acting reciprocating pumps - plunger and piston pumps - discharge of a reciprocating pump - theoretical power required - coefficient of discharge – slip – problems - negative slip - indicator diagram – separation - air vessel (functions and working) - Special pumps - Jet pump - Turbine pump - Submersible pump.

18

IV

PNEUMATIC SYSTEMS

Pneumatic Systems – elements – filter – regulator - lubricator unit - ISO symbols of pneumatic components – pressure control valves - pressure relief valves - pressure regulation valves - directional control valves - 3/2 DCV - 5/2 DCV – 5/3 DCV flow control valves – throttle valves –shuttle valves – quick exhaust valves –Bleed off valve - pneumatic circuits – direct control of single acting cylinder – operation of double acting cylinder – operation of double acting cylinder with metering-in control - operation of double acting cylinder with metering-out control – use of shuttle valve in pneumatic circuits – use of quick exhaust valve in pneumatic circuits - automatic operation of double acting cylinder single cycle – multiple cycle – merits and demerits of pneumatic system - applications.

18



V

HYDRAULIC SYSTEMS

Hydraulic system – Merits and demerits – Service properties of hydraulic fluids - ISO symbols for hydraulic components - Hydraulic accumulators – Weight of gravity type accumulator – Spring loaded type accumulator - Gas filled accumulator – Pressure intensifier – Fluid power pumps – External and internal gear pump, Vane pump, Radial piston pump – Hydraulic actuators – Cylinders and motors – Valves – Pressure control valves, Flow control valves and direction control valves – types – including 4/2 DCV and 4/3 DCV – their location in the circuit – Counter balance valve.

Hydraulic operation of double acting cylinder with metering-in and metering-out control – application of hydraulic circuits – Hydraulic circuit for - shaping machine - table movement in surface grinding machine and milling machine – comparison of hydraulic and pneumatic systems.

18

Text Books:

1. Khurmi.R.S, “A Text Book of Hydraulics, Fluid Mechanics and Hydraulic Machines”, S.Chand & Co., Ram Nagar, New Delhi – 110 055.

2. Rajput.R.K, “A Text Book of Fluid Mechanics and Hydraulic Machines”, S. Chand & Co,Ram Nagar, New Delhi – 110 055.

Reference Books:

1. Jagadishlal, “Hydraulic Machines”, Metropolitan Book Co. Pvt. Ltd., 1, Faiz Bazaar, New Delhi – 110 006. 2. Andrew Parr, “Hydraulics (A Technician’s and Engineer’s Guide)” 3. FESTO Manual, “Fundamentals of pneumatic control Engineering” 4. Bansal.R.K, “Fluid Mechanics and Hydraulic Machines”, Laxmi Publications Pvt. Ltd, New Delhi – 110 002.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : III Subject Code & Name : MEL34 COMPUTER AIDED MACHINE DRAWING PRACTICAL Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL34 Computer Aided Machine Drawing Practical

Hours/ Week

Hours/ Semester


6 96


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Appreciate the need for sectional view and types of sections.

• Draw sectional views using different types of sections.

• Explain the use of threaded fasteners and the types of threads.

• Compare hole basis system with shaft basis system.

• Select different types of fits and tolerance for various types of mating parts.

• Appreciate the importance of fits and tolerance. • Draw assembled drawings of different types of joints and couplings using CAD.

• Draw assembled drawings of various types of machine elements using CAD.



DETAILED SYLLABUS


I

SECTIONAL VIEWS

Review of sectioning – Conventions showing the section – symbolic representation of cutting plane- types of section – full section, half section, offset section, revolved section, broken section, removed section – section lining.

3

II

LIMITS, FITS AND TOLERANCES

Tolerances – Allowances – Unilateral and Bilateral tolerances. Limits – Methods of tolerances – Indication of tolerances on linear dimension of drawings – Geometrical tolerances – application – Fits – Classifications of fits – Selection of fits – examples

6

III

SURFACE TEXTURE

Surface texture – importance – controlled and uncontrolled surfaces – Roughness – Waviness – lay – Machining symbols

3

IV

KEYS, SCREW THREADS AND THREADED FASTENERS

Types of fasteners – temporary fasteners – keys – classification of keys – Heavy duty keys – light duty keys. Screw thread – Nomenclature – different types of thread profiles – threads in sections – threaded fasteners – bolts – nuts – through bolt – tap bolt, stud bolt – set screw – cap screws – machine screws – foundation bolts

6

V

CAD DRAWING PRACTICE

Detailed drawings of following machine parts are given to students to assemble and draw the sectional or plain elevations / plans / and side views with dimensioning and bill of materials using CAD Software

75

1.Sleeve & Cotter joint 2.Spigot & Cotter joint 3.Knuckle joint 4.Stuffing Box 5.Screw Jack 6.Foot step bearing 7.Universal Coupling 8.Plummer Block 9. Simple Eccentric 10.Machine Vice 11.Connecting Rod 12.Protected type flanged coupling

3D Drawing

1. Geneva Wheel 2. Bearing Block 3. Bushed bearing(Assembly) 4. Gib and Cotter(Assembly) 5. Screw Jack(Assembly)

Note: Take the orthographic view and sectional view from the above assembled 3D drawing.

Reference:

• Lab Manual, “MEL34 COMPUTER AIDED MACHINE DRAWING PRACTICAL”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL34

Reference Books:

1. Gill.P.S, “Machine Drawing”, Katsan Publishing House, Ludiana 2. Gupta.R.B & Satya Prakasan, “A Text book of Engineering Drawing”, Technical India Publications,

NewDelhi 3. Tamta.G.L, “Mechanical Draughtsmanship”, Dhanpat Rai & Sons, Delhi 4. Bhatt .N.D, “Geometrical and Machine Drawing”, Charotar Publishing House, Anand, India. 5. Ghose.D.N, “Engineering Drawing”, Dhanpat Rai & Sons, Delhi.





Part A 1 Written Theory Questions (Unit-I to Unit-IV) – 3 out of 4 Questions

15

Part B 2 2D Drawing (2 or 3 Views) 40

3 3D Model Creation 15 4 Viva-Voce 05

Total 75



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : III Subject Code & Name : MEL35 MECHANICAL TESTING & QUALITY CONTROL PRACTICAL Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL35 Mechanical Testing & Quality Control Practical

Hours/ Week

Hours/ Semester


3 48


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Acquire skills on different types of testing methods of metals.

• Conduct material testing on elasticity, hardness, bending, shear strength

• Acquire knowledge in microstructure of the metals.

• Prepare the metal for microscopic view.

• Conduct non-destructive testing methodology to find fine cracks and flaws etc.

• Determine modules of rigidity of open spring and closed coil springs. Note:

The students should be given training in both sections. All the exercises should be completed. The students should maintain record notebook for the concerned subjects and submit during the END Practical Examinations.


Part – A

MECHANICAL TESTING

Determine stress strain relations for steel. Determine hardness of materials. Perform torsion, bending, impact and shear tests.

Exercises:

1. Test on Ductile Materials:

Finding Young’s Modulus of Elasticity, yield points, percentage elongation and percentage reduction in area, stress strain diagram plotting, tests on mild steel. 2. Hardness Test: Determination of Rockwell’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-determination of shear modulus and shear stress. 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 and Charpy test. 6. Tests on springs of circular section: Determination of modulus of rigidity, strain energy, shear stress and stiffness by load deflection method (Open & Closed coil spring) 7. Shear test: Single or double Shear test on M.S. bar to finding the resistance of material to shear load. 8. Fatigue Testing.

Part – B

QUALITY CONTROL

To study the microscope structure of the metals Determine the microscope structure of the ferrous and nonferrous metals Conduct the liquid penetration test to find crack Conduct magnetic particle test to find cracks

Exercise

1. Using the Metallurgical microscope and identify the grain structure of given specimen. 2. Examine and draw the micro structure of metal samples of Ferrous metals – Low carbon,

Medium & High carbon steel 3. Examine and draw the micro structure of metal samples of Ferrous metals - Grey cast iron and

spheroidal cast iron 4. Examine and draw the micro structure of metal samples of Non- Ferrous metals - Aluminum

alloy 5. Examine and draw the micro structure of metal samples of Non- Ferrous metals - Copper alloy 6. Detection of Cracks in casting using Visual Inspection and ring test 7. Detection of Cracks in casting using Die penetrant test 8. Detection of Cracks in casting using Magnetic particle test

Reference:

• Lab Manual, “MEL35 MECHANICAL TESTING & QUALITY CONTROL PRACTICAL ”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL35



Part A 1 ½ Hrs

1 Observation / Tabulation 05 2 Reading / Calculation 20

3 Result / Graph 10 Part B

1 ½ Hrs 4 Specimen preparation 05

5 View /Exercise 20 6 Result 10

7 Viva-Voce 05 Total 75

Note: All the exercises should be given in the End Examination and students are allowed to select by a lot



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : III Subject Code & Name : MEL36 FLUID MECHANICS & FLUID POWER PRACTICAL Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL36 Fluid Mechanics & Fluid Power Practical

Hours/ Week

Hours/ Semester


3 48


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Determine the co-efficient of discharge of venture meter, orifice meter, mouth piece and orifice.

• Determine the co-efficient of friction in pipes.

• Conduct performance test on centrifugal and reciprocating pumps.

• Conduct performance test on impulse and reaction turbines.

• Design and operate pneumatic circuits.

• Design and operate fluid power circuits. Exercises

Part-A

I. Fluid Mechanics and Machines Lab:-

1. Verifying the Bernoulli’s Theorem 2. Determination of co-efficient of discharge of a mouth piece and orifice by variable head method. 3. Determination of co-efficient of discharge of a venturi meter and orifice meter. 4. Determination of the Friction Factor in a pipe. 5. Performance test on reciprocating pump and to draw the characteristics curves. 6. Performance test on centrifugal pump and to draw the characteristics curves. 7. Performance test on impulse turbine and to find out the Efficiency. 8. Performance test on reaction turbine and to find out the Efficiency.

Part-B

II. Pneumatics Lab:-

1. Direct operation of single and double acting cylinder. 2. Operation of double acting cylinder with quick exhaust valve. 3. Speed control of double acting cylinder using metering-in and metering-out circuits. 4. Automatic operation of double acting cylinder in single cycle-using limit switch and memory

valve. 5. Automatic operation of double acting cylinder in multi cycle-using limit switch and memory valve.

III. Hydraulics Lab:-

1. Direct operation of double acting cylinder. 2. Direct operation of hydraulic motor. 3. Speed control of double acting cylinder metering-in and metering-out control. 4. Speed control of hydraulic motor using metering-in and metering-out control.

Reference:

• Lab Manual, “MEL36 FLUID MECHANICS & FLUID POWER PRACTICAL”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL36




No. Allocation Marks Part A

1 ½ Hrs 1 Observation / Tabulation 15

2 Reading / Calculation 15 3 Result / Graph 05

Part B 1 ½ Hrs

4 Circuit 15 5 Connections 10

6 Execution/Simulation 10 7 Viva-Voce 05

Total 75

Note: Part A: One Exercise from fluid mechanics and machines lab - 35 marks Part B: One Exercise from pneumatics/Hydraulics lab by lot - 35 marks.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : III Subject Code & Name : MEL37 MANUFACTURING TECHNOLOGY – I PRACTICAL Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL37 Manufacturing Technology – I Practical

Hours/ Week

Hours/ Semester


6 96


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Identify the parts of a center lathe

• Identify the work holding devices

• Set the tools for various operations

• Operate the lathe and Machine a component using lathe

• Identify the tools used in foundry.

• Identify the tools and equipments used in welding • Prepare sand moulds for different patterns.

• Perform welding operation to make different types of joints. • Identify the different welding defects.

• Appreciate the safety practices used in welding.



Exercises:

Note: All dimensions in mm Manufacture and estimate the cost of the job for following exercises by assuming the suitable raw material for the final size of the components.

Note to the faculty :-Last job of the raw material(MS Rod Ǿ32x77mm and MS Rod Ǿ25x77mm ) to be retain in student wise or batch wise .This may be verifiable at the time of END Practical Examination by the external examiner All linear dimensions in ± 0.5mm tolerance. All cylindrical dimensions in ± 0.2mm tolerance.

PART-A

1. Lathe

1. Introduction of safety in operating machines.

2. Introduction to lathe and its parts.

3. Introduction to work holding devices and tool holding devices.

4. Types of tools used in lathe work.

5. Types of measuring instruments and their uses.

6. Setting of work and tools.

7. Operation of lathe.

8. Practice on a lathe.

Exercises :

1. Plain turning

2. Step turning

3. Taper turning

4. Knurling

5. Thread cutting

6. Bushing

PART-B

2. Foundry

1. Introduction of tools and equipments

2. Types of patterns

3. Types of sand

4. Preparation of sand moulds

5. Furnaces – crucible furnace and tilting furnace

6. Melting if non ferrous metal

7. Core sands, preparation of cores

Exercises :

Preparation of sand mould : 1. Solid pattern

a. Stepped pulley

b. Bearing top

c. Gear Wheel

d. T-pipe



2. Split pattern

a. Bent Pipe

b. Dumbles

3. Loose Piece Pattern – Dovetail

4. Cylindrical core making

5. Melting and casting – (not for Examination, only for class exercises)

3. Welding

1. Introduction of Safety in welding shop

2. Introduction to hand tools and equipments

3. Arc and gas welding equipments

4. Types of joints

Exercises :

1. Arc welding

• Lap joint (Material : 25 mm x 6mm MS flat)

• Butt joint (Material : 25mm x 6mm MS flat)

• T- joint (Material : 25mm x 6mm MS flat)

• Corner joint (Material : 25mm x 6mm MS flat)

2. Gas Welding

• Lap joint (Material : 25mm x 3mm Ms flat)

• Butt joint (Material : 25mm x 3mm Ms flat)

• T- joint (Material : 25mm x 3mm Ms flat)

• Corner joint (Material : 25mm x 3mm Ms flat)

3. Gas cutting : Profile cutting

4. Spot welding – Lap joint (18/20swg)

5. Demonstration of Soldering and brazing



Lathe Exercises:

Exercise No:1 –Plain turning . Raw Material: MS Rod Ǿ32x77mm

5025

1x45°

Ø3

0

Ø2

5

Exercise No:2-Step turning Raw Material: Exercise No:1

2 5

Ø3

0

2 52 5

Ø25

1 x 4 5 °1 x 4 5 °

Ø2

2



Exercise No:3-Step and taper turning Raw Material: Exercise No:2

251510 25

Ø2

4

1x45°

Ø2

5

Ø29

Ø2

5

1x45°

Ø2

0

Exercise No: 4-Step and taper turning Raw Material: Exercise No: 3

25

Ø20

Ø2

5

Ø24

Ø20

Ø24

Ø29

2051510

1x45°

Ø20

1x45°



Exercise No: 5 Knurling and step turning Raw Material: Exercise No:4

4515 510

Ø2

3 Ø25

Ø18

1x45°

Ø20

1x45°

Exercise No:6 - BSW Thread cutting Raw Material: Exercise No:5

451510 5

3/4"BSW(RH)1x45°

Ø2

3

Ø1

6

1x45°

Ø3

/4"



Exercise No:7 – Metric thread cutting Raw Material: Exercise No:6

40101510

Ø1

2

M12(RH)1x45°1x45°

Exercise No:8- Metric thread cutting Raw Material: Exercise No:7

1x45°

40

M8(RH -2 Start)

Ø1

6

1025



Exercise No: 9-Shaft and bush mating Raw Material: MS Rod Ǿ25x77mm and Ǿ32x30mm

Ø3

0

Ø20

Ø2

4

Ø2

0

55 2020

1x45°1x45°

Exercise No: 10- Thread cutting Raw Material: Exercise No:9

45

Ø15

Ø24

1x45°

255

M20(RH)(OR)3/4"BSW



Exercise No:11- Thread cutting Raw Material: Exercise No:10

M20(LH)(OR)3/4"BSW

1525 5

1x45°

5 25

Ø1

5

Exercise No:12-Eccentric Turning Raw Material: Exercise No:11

15

Ø2

4

30

Ø9

.5

30Ø9

.5

3

eccentricty3mm

Reference:

• Lab Manual, “MEL37 MANUFACTURING TECHNOLOGY – I PRACTICAL”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL37





Part A 2 Hrs

1 Job settings/Calculations/Machine setting

15

2 Machining and Finishing 15 3 Dimensions of the component 15

Part B 1 Hr

4 Preparation of Job/Mould 15 5 Welding/Mould Finishing 10


Note: Part A: One question from Lathe Exercises - 45 marks Part B: One question from Foundry/Welding - 25 marks.

Each Batch/Session the allocation of exercises (Lathe):

75% of the questions in the combination of step, knurling / taper and thread cutting. Remaining 25% of the questions to be in the combination of taper, step, knurling and under cut.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : IV Subject Code & Name : MEL41 THERMAL ENGINEERING -I Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL41 Thermal Engineering -I

Hours/ Week

Hours/ Semester


6 96


End Semester

Examination Total

3

25 75 100



I Basics of thermodynamics and thermodynamic processes of perfect gases

18

II Thermodynamic air cycles and steady flow energy equation & applications

18

III Air compressors and gas turbines 18 IV Fuels & combustion of fuels and Internal Combustion engines 18

V Performance of Internal Combustion engines & heat transfer 18


Total 96

OBJECTIVES:

• Explain the basics of systems and laws of thermodynamics

• Familiarize thermodynamic processes.

• Explain different Air Cycles.

• Apply steady flow energy equation for nozzles and condensers.

• Familiarize the parts, functions and types of Air compressors and determine their efficiency. • Describe the working of the gas turbines.

• Explain different type of fuels and their combustion phenomenon. • Explain the types and functions of IC engines.

• Explain the performance tests on IC engines. • Compare the modes of heat transfer and evaluate the heat transfer by various modes.



DETAILED SYLLABUS


I

BASICS OF THERMODYNAMICS AND THERMODYNAMIC PROCESSES OF PERFECT

GASES

Introduction – definitions and units of mass, weight, volume, density, specific weight, specific gravity and specific volume – pressure – units of pressure – temperature - absolute temperature – S.T.P and N.T.P conditions – heat - specific heat capacity at constant volume and at constant pressure – work – power – energy – types - law of conservation of energy – thermodynamic system – types – thermodynamic equilibrium - properties of systems – intensive and extensive properties –State of System- process – cycle – point and path functions - zeroth , first and second laws of thermodynamics - problems Perfect gases – laws of perfect gases – Boyle’s, Charles’ , Joule’s, Regnault’s and Avogadro’s laws –General Gas Equation- characteristic gas equation – relation between specific heats and gas constant – universal gas constant - problems –Thermodynamic Processes-Change in Internal Energy- enthalpy – change in enthalpy – entropy – change in entropy – general equations for change in entropy. Constant volume, constant pressure , isothermal(hyperbolic) , isentropic ( reversible adiabatic ) , polytropic, – p-V and T-s diagrams, work done , change in internal energy , heat transfer , change in enthalpy , change in entropy for various processes – problems - Free expansion and throttling processes .

18

II

THERMODYNAMIC AIR CYCLES AND STEADY FLOW ENERGY EQUATION &

APPLICATIONS

Air cycles – air standard efficiency – reversible and irreversible processes – assumptions in deriving air standard efficiency – Carnot cycle – Otto cycle – Joule cycle – Diesel cycle – comparison of Otto cycle and Diesel cycle -Comparison of ideal and actual p-V diagrams of Otto and Diesel cycles – problems - dual combustion cycle ( description only). Steady flow system – control volume – steady flow energy equation – assumptions –Engineering applications – steam boiler – condenser – nozzles – steam and gas turbines – reciprocating and rotary compressors –Centrifugal pump – non flow energy equation – problems.

18

III

AIR COMPRESSORS AND GAS TURBINES Air Compressors-uses of compressed air – classifications of Air compressor – reciprocating compressor - single stage reciprocating compressor – compression processes – power required to drive the compressor ( Neglecting clearance Volume)– problems – clearance volume and its effects – volumetric efficiency – power required to drive the compressor with clearance volume – problems – multi stage compression –merits and demerits –Two stage compressor with imperfect cooling- with perfect inter cooling - work input – condition for minimum work input in multi stage compressor with perfect inter cooling – ratio of cylinder diameters for minimum work input - problems – rotary compressors – Roots blower - vane blowers – centrifugal and axial flow air compressors. Gas turbines –uses - classifications – merits and demerits of gas turbines - constant pressure combustion gas turbine – gas turbine with – intercooler – reheater - regenerator -effects – closed cycle gas turbines - merits and demerits of open and closed cycle gas turbines – jet propulsion -turbojet engines – merits and demerits – turbo propeller engines – merits and demerits - ramjet– merits and demerits –Rocket engines – applications of rockets.

18



IV

FUELS & COMBUSTION OF FUELS AND INTERNAL COMBUSTION ENGINES Classifications of fuels - merits and demerits – requirements of a good fuel – combustion equations – stoichiometric air required for complete combustion of fuels – excess air – products of combustion – problems – analysis of exhaust gases- Orsat apparatus - calorific value of fuels – higher and lower calorific values – Dulong’s formula – problems – determination of calorific value – Bomb and Junker’s calorimeter – problems -Internal combustion engines. Classifications of I.C Engines – components of I.C Engines and functions- material and method of manufacturing - four stroke cycle petrol and diesel engines – two stroke cycle petrol and diesel engines - comparison of four stroke and two stroke engines – Comparison of petrol and diesel engines - valve timing diagram for four stroke petrol and diesel engines – port timing diagram for two stroke petrol and diesel engines.

18

V

PERFORMANCE OF I.C ENGINES AND HEAT TRANSFER

Testing - thermodynamic and commercial tests – indicated power – brake power – friction power – efficiencies of I.C. engines – indicated thermal ,brake thermal, mechanical and relative efficiencies – Specific fuel consumption – problems - Morse test – procedure – problems – heat balance sheet – problems.

Modes of heat transfer – heat transfer by conduction – Fourier’s Law- Thermal conductivity – heat conduction through plane and composite walls – heat conduction through a cylinder – simple problems – heat transfer by convection – heat exchanger – Parallel flow and Counter flow – LMTD – forced convection – natural convection – heat transfer by radiation – Radioactive properties- definitions of black and white and opaque , transparent & grey bodies.

18

Text Books: 1. Rajput .R.K, “Thermal Engineering”, Laxmi publications Pvt Ltd, New Delhi. 2. Nag.P.K, “Applied Thermodynamics”, TATA Mcgraw - Hill Publishing Company, New Delhi. 3. Khurmi.R.S & Gupta.J.K,” Thermal Engineering”, S.Chand & Co, New Delhi

Reference Books:

1. Ballaney.P.L , “ Thermal Engineering”, Khanna Publishers, New Delhi. 2. Sarkar.B.K , “Thermal Engineering”, Dhanpat Rai & Sons, New Delhi . 3. Domkundwar & Kothandaraman.C.P, “Applied Thermodynamics”, Khanna publishers, New Delhi.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : IV Subject Code & Name : MEL42 MANUFACTURING TECHNOLOGY - II Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL42 Manufacturing Technology - II

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Theory of Metal cutting, Drilling machines and Boring Machines 15

II Reciprocating Machines 15

III Milling machines and gear generating processes 15 IV Abrasive Process, Broaching & Non-Conventional Machining 15

V Jigs & Fixtures, Press work 15



• Explain the working of machine tools planer, shaper and slotter. • Compare various work holding devices

• Explain the working of machine tools drilling machine and milling machine.

• Distinguish various types of milling cutter.

• Classify the different types of grinders and grinding wheels.

• Explain the broaching operation and boring operation and their applications.

• Explain the milling procedure for spur, helical and bevel gears. • Explain the various types of gear generating processes

• Compare the various types of jigs and fixtures.

• Explain the different types of press working operations.

• Appreciate the use of non-conventional machining processes.



DETAILED SYLLABUS


I

THEORY OF METAL CUTTING, DRILLING MACHINES AND BORING MACHINES

Theory of Metal Cutting: Cutting tool material-High carbon Steel-High Speed Steel-Stellites-Cemented carbides-ceramics-Properties, Composition and applications for the above-Single point cutting tool-nomenclature-tool life-Types of Chips - Chip Breakers. Drilling Machines: Drills-flat drills-twist drills-nomenclature-types of drilling machines-bench type-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-drill chucks-socket and sleeve-drilling-operation-reaming-counter sinking-counter boring-spot facing-tapping-deep hole drilling. Boring Machines: Boring machines-horizontal and vertical types-fine boring machines-boring tools

15

II

RECIPROCATING MACHINES

Planer: Types of planers-description of double housing planer-specifications-principles of operation-drives-quick return mechanism-feed mechanism- work holding devices and special fixtures-types of tools-various operation. Shaper: Types of shapers-specifications-standard-plain-universal-principles of operations-drives-quick return mechanism-crank and slotted link-feed mechanism-work holding devices-Special fixture-various operations. Slotter: Types of slotters-specifications-method of operation-Whitworth quick return mechanism-feed mechanism-work holding devices-types of tools.

15

III

MILLING MACHINES AND GEAR GENERATING PROCESSES

Milling Machines: Types-column and knee type-plain-universal milling machine-vertical milling machine-specification of milling machines-principles of operation-work and tool holding devices-arbor-stub arbor-spring collet-adapter-milling cutters-cylindrical milling cutter-slitting cutter-side milling cutter-angle milling cutter-T-slot milling cutter-woodruff milling cutter-fly cutter-nomenclature of cylindrical milling cutter-milling process-conventional milling-climb milling-milling operations-straddle milling-gang milling-End milling - vertical milling attachment. Generating Process: gear shaper-gear hobbing-principle of operation only-gear finishing processes-burnishing-shaving-grinding and lapping-gear materials-cast iron, steel, alloy steels, brass, bronze, aluminum and nylon.

15

IV

ABRASIVE PROCESS, BROACHING AND NON-CONVENTIONAL MACHINING

Abrasive Process: Types and classification-specifications-rough grinding – pedestal grinders- portable grinders- belt grinders-precision grinding-cylindrical grinder- centerless grinders – surface grinder- tool and cutter grinder - planetory grinders-principles of operations-grinding wheels-abrasives-natural and artificial diamond wheels-types of bonds-grit, grade and structure of wheels-wheel shapes and sizes-standard marking systems of grinding wheels-selection of grinding wheel-mounting of grinding wheels-Dressing and Truing of wheels-Balancing of grinding wheels. Broaching: Types of broaching machine-horizontal, vertical and continuous broaching-principles of operation-types of broaches-classification-broach tool nomenclature-broaching operations-simple examples. Non-Conventional Machining Processes: Construction, working, Process parameters and applications of Ultrasonic machining-chemical machining-electro chemical grinding-electrical discharge machining-plasma arc machining-LASER machining-Advantages – Disadvantages.

15



V

JIGS & FIXTURES, PRESS WORK

Jigs And Fixtures: Definitions and concept of Jig and fixture-Advantages of jigs and fixtures-elements of jigs and fixtures-locating devices-'V' locators-fixed stop locators-adjustable stop locators-clamping devices-strap clamp, screw clamp-cam action clamp-types of jigs-box drill jig-indexing drill jig-types of fixtures-keyway milling fixture-string milling fixture. Press Working: Types of presses-mechanical and hydraulic presses-press tools and accessories-press working operations-bending operations-angle bending-channel bending -curling-Drawing-shearing operations - blanking, piercing, trimming-notching-lancing-shaving-parting off-Embossing - Coining.

15

Text Books:

1. Hajra Chowdry & Bhattacharaya, “Elements of workshop Technology Volume I & II”, Media Promoters & Publishers Pvt. Ltd., Mumbai- 400 007.

2. Jain & Gupta, “Production Technology”, Khanna Publishers, New Delhi -110 006. Reference Books:

1. HMT, “Production Technology”, Tata McGraw Hill publishing Co. Ltd., New Delhi- 110 008. 2. Myro N Begman, “Manufacturing process”, Tata McGraw Hill Publishing Co. Ltd.,New Delhi. 3. Chapman WAJ, “Workshop Technology - Volume I, II, & III”, Vima Books Pvt. Ltd., New Delhi -110 002. 4. NITTTR, “Production processes”, Tata McGraw Hill Publishing Co. Ltd., New Delhi- 110 008.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : IV Subject Code & Name : MEL43 RENEWABLE ENERGY ENGINEERING Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL43 Renewable Energy Engineering

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Fundamentals of energy 15

II Solar energy 15

III Wind energy 15 IV Bio-energy 15

V Ocean and geo-thermal energy 15



• Aware current energy technologies and climate change • Aware current energy scenario

• Understand the principle of solar radiation

• Learn principles of solar energy conversion

• Learn the principles of wind energy conversion

• Explain the working of wind mills

• Learn principles of Bio energy generation • Explain the working of different Bio-gas plants

• Learn the principles of OTEC

• Learn the principles of Geo-Thermal energy conversion



DETAILED SYLLABUS


I

FUNDAMENTALS OF ENERGY

Introduction to Energy-Energy consumption and standard of living-classification of energy resources-consumption trend of primary energy resources-importance of renewable energy sources-energy chain-common forms of energy-advantages and disadvantages of conventional energy sources-salient features of non-conventional energy sources-environmental aspects of energy-energy for sustainable development-energy density of various fuels-availability of resources and future trends. Energy scenario in India – Overall production and consumption-Availability of primary energy resources: Conventional, Non-Conventional-Estimated potential and achievement-Growth of energy sector and its planning in India – Energy conservation: Meaning and importance-Introduction to Energy Auditing.

15

II

SOLAR ENERGY

Introduction – Solar radiation at the earth's surface-Solar Radiation measurements-Estimation of average solar Radiation. Solar energy collectors- Classifications-Flat plate collectors-Concentrating collectors-Comparison. Solar water heaters-Solar industrial heating system – Solar Refrigeration and Air-Conditioning Systems-Solar cookers-Solar furnaces-Solar greenhouse-Solar Distillation-Solar pond Electric power plant-Distributed Collector- Solar thermal Electric power plant. Principles of photovoltaic conversion of solar energy – types of solar cells – Specifications of Solar cells - solar Photo Voltaic applications.

15

III

WIND ENERGY

Introduction-Basic principles of wind energy conversion: Nature of the wind, power in the wind, forces on the blades and wind energy conversion-wind data and energy estimation-site selection-classification of wind energy conversion systems-Advantages and Disadvantages-Types of wind machines-Horizontal axis machine-Vertical axis machine-Generating system-Energy Storage–Application of wind energy-Safety and environmental aspects.

15

IV

BIO – ENERGY

Introduction – photo synthesis – usable forms of bio mass, their composition and fuel properties-Biomass resources – Biomass conversion technologies – Urban waste to energy conversion – Biomass gasification – biomass liquification – biomass to ethanol production – Biogas production from waste Biomass – types of bio gas plants - applications – Bio diesel production – Biomass energy programme in India.

15

V

OCEAN AND GEOTHERMAL ENERGY

Ocean energy resources – principle's of ocean thermal energy conversion (OTEC) – Methods of Ocean thermal electric power generation – Energy utilisation – basic principle of tidal power – components and operations of tidal power plant – Energy and Power forms of waves – Wave energy conversion devices. Geothermal Energy – Geothermal Sources – Prime movers for Geothermal energy conversion – Advantages and Disadvantages – Applications – Material selection for geothermal power plants – Geo thermal exploration – Operational and Environmental problems – Prospects of geothermal energy in India.

15

Text Books:

1. Rai.G.D, “Non Conventional Energy Sources”, Khanna Publishers, New Delhi.

2. Rajput.R.K, “Non Conventional Energy Sources and Utilisation”, S.Chand & Company Ltd.,2012.

3. Twidell, J.W. & Weir, A, “Renewable Energy Sources”, EFN Spon Ltd.,.

4. Khan.B.H, "Non-Conventional Energy Resources”, Tata Mc Graw Hill.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : IV Subject Code & Name : MEL44 ELECTRICAL DRIVES & CONTROL Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL44 Electrical Drives & Control

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I DC circuits and DC machines 15

II AC circuits and AC machines 15

III Stepper and servo motors & drives 15 IV Power supplies and logic gates 15

V Control elements and PLC 15



• Explore fundamental electric circuit laws. • Explain the working principle of DC and AC Electrical machines.

• Identify the effective uses of drives of Electrical machines.

• Analyse the various power supply circuits.

• Select the field controlled elements.

• Explain the construction and working of Transformer.

• Compare the different types of Logic gates. • Appreciate the safety practices followed in Electrical system.

• Compare the use of servo motors and stepper motors in electrical driving system

• Identify PLC Input outputs.

• Identify the use of Control elements.



DETAILED SYLLABUS


I

DC CIRCUITS AND DC MACHINES

Definition- Electric current, voltage and resistance -Ohm’s law and Kirchoff’s law- Resistance in series and parallel and series, parallel – simple problems- electromagnetism (definitions only ) – magnetic flux, flux density magnetic field intensity, MMF, permeability, reluctance, Faraday’s law of electromagnetic induction, electrical and mechanical units DC generators – construction, principle of operation, types and application. DC motors: - construction, principle of operation, types and application. Necessity of starters: Three point, four point starters.

15

II

AC CIRCUITS AND AC MACHINES

Fundamentals of AC voltage, and current – peak, average, RMS value of sine wave, frequency, time period, amplitude, power and power factor (definition only) - star and delta connection relationship between phase, line voltage and current in star and delta connections. Transformer: Principle of operation and construction – EMF equation (no definition)- losses in Transformer – efficiency – application. Alternator construction – principle of operation – types and applications. AC machine: AC motors- Principle of operation of single phase capacitor start induction motor- applications- Three phase induction motors – Squirrel cage and slip ring Induction motors (construction and working principle only) - application – speed control of 3Ф Induction motor -Necessity of starters – DOL and star/delta transformer

15

III

STEPPER AND SERVO MOTORS & DRIVES:

PMDC, Stepper motor- construction and working principle and applications - Servo motor – types: brushless servo motor, permanent magnet servo motor construction and applications. Industrial drives- types, group drive, individual drive, multi motor drive, block diagram of Variable frequency drive , stepper motor drive: single stepping and half stepping. Servo drives Electrical safety: - importance of earthing - electric shock: first aid, precautions - causes of accident and their preventive measures. Energy conservation

15

IV

POWER SUPPLIES AND LOGIC GATES

Diode – terminals: anode and cathode, forward biasing and reverse biasing – use of diode in rectifiers – half wave and full wave – necessity of filters- Regulated power supplies: IC voltage regulators – SMPS, UPS and Inverters – General description and their applications Display devices – LED, 7 segment LED, LCD Logic gates: Positive and negative logic, definition, symbol truth table, Boolean expression for OR, AND, NOT, NOR, NAND, EXOR AND EXNOR gates – Universal logic Gates: NAND, and NOR.

15

V

CONTROL ELEMENTS AND PLC

Fuses – selection of fuse – necessity of fuse- fuse switch units. Sensors: Photo electric sensor, Inductive proximity sensors, Temperature sensors. Switches: Push button switch, selector switch, limit switch, pressure switch, temperature switch, float switch and reed switch. Relays – NO, NC – usage- bimetallic thermal overload relays. Contactors- usage – necessity of contactor- Solenoid type contactor Circuit breakers – Miniature case Circuit breaker (MCCB) and Miniature Circuit breaker (MCB), Oil Circuit breakers (OCB), Earth leakage circuit breaker (ELCB) Features of PLC-PLC Block diagram- PLC scan - Fixed and modular PLC-Ladder logic-NO, NC contacts-Coils-AND, OR.

15



Text Books:

1. Theraja.B.L, “A course in electrical engineering “, S Chand & Co,. 2. Bhattacharya.S.K & Brijinder Singh, “Control of Machines”, New Age Publishers, 2010 3. Bapat.Y.N, “Electronic Circuits & System- Analog and Digital”, Tata Mc Graw Hill .

Reference Books:

1. Hughes, “Electrical Technology”, Pearson Education. 2. Allen Mottershed, “Electronic Device and Circuits- An introduction”, Prentice Hall of India.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : IV Subject Code & Name : MEL45 THERMAL ENGINEERING PRACTICAL



MEL45 Thermal Engineering Practical

Hours/ Week

Hours/ Semester


4 64


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Determine the flash and fire point and viscosity of oil.

• Draw the valve timing diagram of petrol and diesel engines.

• Draw the port timing diagram of petrol and diesel engines.

• Conduct performance test on petrol and diesel engines.

• Prepare heat balance sheet for an IC engine.

• Identify the parts of a high pressure boiler and their applications. • Identify the boiler mountings and accessories and their functions

• Conduct of C.O.P of Refrigerators.




Study Exercise: (Not for examinations)

1. Study of high pressure boiler. (With model)

2. Study of boiler mountings and Accessories.(With model)

PART-A

1. Determine flash and fire point of the given oil using open cup apparatus.

2. Determine flash and fire point of the given oil using closed cup apparatus.

3. Determine the absolute viscosity of the given lubricating oil using Redwood viscometer.

4. Determine the absolute viscosity of the given lubricating oil using Say bolt viscometer.

5. Port timing diagram of two stroke petrol Engine

6. Valve time diagram for four stroke petrol Engine.

7. Valve time diagram for four stroke diesel engines.

PART-B

8. Load test (Performance test) on Four Stroke Petrol Engine.

9. Load test (Performance test) on Four Stroke diesel Engine.

10. Morse test on Multi-cylinder petrol engine.

11. Heat balance test on Four Stroke Petrol engine.

12. Heat balance test on Four Stroke Diesel engine.

13. Volumetric efficiency of Air Compressor.

14. Thermal Conductivity measurement using guarded plate apparatus

15. Determination of COP of Refrigeration System

Reference:

• Lab Manual, “MEL45 THERMAL ENGINEERING PRACTICAL”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL45


Part A 1 Hr

1 Observation / Tabulation 10 2 Reading / Calculation 10

3 Result / Graph 05 Part B 2 Hrs

4 Observation / Tabulation 15

5 Reading / Calculation 20 6 Result / Graph 10




Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : IV Subject Code & Name : MEL46 ELECTRICAL DRIVES & CONTROL PRACTICAL



MEL46 Electrical Drives & Control Practical

Hours/ Week

Hours/ Semester


4 64


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Identify starters for different motors.

• Test the characteristics of DC and AC machines.

• Identify and select controlling elements.

• Explore the performance of ELCB, MCB.

• Design regulated power supplies.

• Identify display devices - LED, 7 segments LED, LCD. • Identify the drive circuit for special motors.

• Test the speed control circuit of the special motors. LIST OF EXPERIMENTS:

Part- A

1. Verification of Ohm’s Law 2. Testing of DC starters – 3 point and 4 point starter

3. Load test on DC shunt motor

4. Load test on transformer

5. Testing of AC starters- DOL , star - Delta starter

6. Load test on single phase induction motor

7. Load test on three phase squirrel cage motor

8. Testing of relays, contactors ,push buttons and limit switch

9. Prepare earthing and trace out MCB, ELCB connections

Part- B

10. Construction and testing of Half wave and Full wave rectifier.

11. Construction and testing of IC voltage regulator using IC 7805.

12. Trace out circuits and connections of SMPS, UPS, and inverters.

13. Verification of truth tables for logic gates.

14. Verification of universal gates.

15. Identification and testing of display devices- LED, 7 segment LED, Laser diode.

16. Construction and testing of Stepper motor drive.

17. Construction and testing of Servo motor drive.



Reference:

• Lab Manual, “MEL46 ELECTRICAL DRIVES & CONTROL PRACTICAL”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL46



Part A 1 ½ Hrs

1 Circuit diagram 05 2 Connections & Readings 15

3 Calculations & Graph 15 Part B

1 ½ Hrs 4 Circuit diagram 15

5 Connections & Readings 15 6 Execution 05




Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : IV Subject Code & Name : MEL47 MANUFACTURING TECHNOLOGY –II PRACTICAL Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL47 Manufacturing Technology –II Practical

Hours/ Week

Hours/ Semester


6 96


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Identify a milling machine and its parts

• Identify a cylindrical grinder, surface grinder and tool and cutter grinder

• Identify the tools and instruments used in milling.

• Handle the different types of work holding devices

• Machine a component using different machine tools.

• Calculate the indexing for a work • Machine a gear using milling machine.

• Machine a cutting tool using Tool and Cutter grinder. • Machine a plug gauge using Cylindrical grinding machine.

SYLLABUS

1. Introduction to milling machine and its parts. 2. Introduction to grinding machine and its parts 3. Introduction to work holding devices. 4. Types of cutter used in milling machine 5. Types of grinding wheels used in grinding machines 6. Setting of work, tools and cutters in milling and grinding machines 7. Operation performed in milling and grinding machines 8. Operation of milling and grinding machines.

EXERCISES:

1. Prepare a square block from round rod using Milling machine 2. Prepare a ‘V’ Block using Milling machine 3. Prepare a Groove cut using Milling machine 4. Prepare a Spur Gear using milling machine by Simple Indexing 5. Prepare a Spur Gear using milling machine by Differential Indexing 6. Prepare a Hexagon by straddle milling process using milling machine 7. Prepare a Helical Gear using milling machine 8. Prepare a Plug Gauge using Cylindrical Grinding machine 9. Prepare Progressive type Plug gauge Progressive type Plug gauge using 10. Cylindrical Grinding machine 11. Prepare a Facing Tool using Tool and Cutter Grinder 12. Prepare a plain surface using surface Grinder 13. Prepare a Parting Tool using Tool and Cutter Grinder 14. EDM Spark erosion – Elliptical Hole 15. EDM Spark Erosion – Hexagon Hole 16. EDM Wire cut - Square Hole



Note: Sketches enclosed

Note: All dimensions in mm

Note to the faculty :-Last job of the raw material (MS Rod Ǿ32x33mm, MS Rod Ǿ25x98mm and 13x13x75 mm MS square rod) to be retained in student wise or batch wise .This may be verifiable at the time of END Practical Examination by the external examiner All Linear dimensions are in ± 0.5 mm tolerance and all cylindrical dimensions ± 0.2 mm tolerance except grinding operation.

PART-A

I MILLING Exercise No:1 Raw Material: Ǿ 32x33mm MS rod Milling a maximum size of square block from a 32 mm diameter round rod

30

Ø32



Exercise No:2-‘V’ Block Milling Raw Material: Exercise No:1

14

22

22

90°

8

3

Exercise No:3- Groove Milling Raw Material: Exercise No.2

6

3

14

87

106

3

3

7

90°8

3

8



Exercise No: 4- Spur Gear milling (Simple Indexing) Raw Material: Ǿ 32x105 mm MS rod

Ø15

Ø28

Ø30

100

Spur Gear, Z=15,m=1.5

15

Ø30

Ø17

15Ø15

5 22,5

Ø30

Ø20

1522,5 5

Ø15

Exercise No:5- Spur Gear milling (Differential Indexing) Raw Material: Exercise No: 4

Spur Gear (Differential Indexing)

m=1.5,Z=17

Ø15

Ø30

Ø28

Spur Gear, Z=15,m=1.5

15

100

155 22,5

Ø15 Ø17

1522,5 5

Ø20

Ø30

Ø15



Exercise No:6- Hexagon by straddle milling process Raw Material: Exercise No: 5

Hexagonal milling using straddle milling process

25(or)26

Ø15

100

15155

Ø15 Ø17

22,5 15

Ø17

22,5 5

Ø15

Exercise No:7- Helical Gear Milling

Raw Material: Exercise No: 6

100

Helical Gear (RH or LH), Helix Angle =6°

Z=15,m=1.5

22,5 15

Ø17

Ø15

Ø15

Ø17

5 15Ø15

Ø17

22,5 515



PART-B

GRINDING

CYLINDRICAL GRINDING

Exercise No:8- Plug Gauge (Cylindrical Grinding) Raw Material: Exercise No:7

90

22,5

Cylindrical Grinding( Tolerance ±0.02)

Ø17

15

Ø18.2

22,515

Ø18.25

15

Exercise No: 9- Progressive type Plug gauge (Cylindrical Grinding) Raw Material: Exercise No: 8

15

2,5

15 5 1515 22,5

90

Cylindrical Grinding(Tolerance ±0.02)

Ø15.75

Ø15.5



Surface Grinding

Exercise No:10- Surface Grinding Raw Material: 13x13x75 mm MS square rod

11 ± 0.05

Surfa ce G r in d ing T o le ran ce Fo r1 1m m s id e is ± 0 .05

75 11 ± 0 .0 5

TOOL AND CUTTER GRINDING Exercise No:11- Facing Tool (Tool and Cutter Grinder) Raw Material: Exercise No: 10

8°

8°

6°

16° 8°

6°



Exercise No: 12- Parting Tool (Tool and Cutter Grinder) Raw Material: Exercise No: 11

16°

6°

5

6°

8°

6°

6°

Reference:

• Lab Manual, “MEL47 MANUFACTURING TECHNOLOGY –II PRACTICAL”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL47


Milling or Grinding or EDM Exercise

1 Job settings/Calculations/Machine setting

25

2 Machining and Finishing 30 3 Dimensions of the component 15


END EXAMINATION

Exercise should be given either in Milling or Grinding or EDM in the End Examination for 75Marks.

A. Milling Exercise

• Milling a V- block from the given round rod

• Milling a V- block & groove as in the Ex no3

• Milling a spur gear by simple indexing at the centre of the rod

• Milling a spur gear by differential indexing at the centre of the rod

• Milling a helical gear at the centre of the rod

B. Grinding Exercise

• Grinding a plug gauge

• Grinding a rectangular/ square using surface grinding machine and Grinding a facing tool

using tool and cutter grinder

• Grinding a rectangular/ square using surface grinding machine and Grinding a parting tool

using tool and cutter grinder

C. EDM Exercise • EDM Spark erosion – Elliptical Hole

• EDM Spark Erosion – Hexagon Hole

• EDM Wire cut - Square Hole



MEL48 INDUSTRIAL TRAINING – I

The students are expected to gain a working experience in various departments of an industry / organisation and hence learning the industrial management in a practical way. The students have to undergo a six months industrial training (PHASE I) during the IV semester in a related industry / organisation. During the training period the students are maintaining an Industrial diary to record their observation and learning. On completion of training, a training report should be submitted to the Head of the Department. Industrial training of Sandwich students will be evaluated based on Continuous Assessment of two periodical reviews and an End semester Examination on Assessment of Training Report and viva-voce.

SANDWICH DIPLOMA COURSE - INDUSTRIAL TRAINING

1. Introduction

The main objective of the Sandwich Diploma Course is to mould a well rounded technician acclimated with industrial environment while being a student in the institution. The Sandwich Diploma Course study is pursued by students, in 7 semesters of 3½ years duration, the subjects of 3 years - Full Time Diploma Course being regrouped for academic convenience. While in the 4th semester students undergo Industrial Training-I for 6 months (December through May). They also do course work in the institution for one day in a week, while in the 7th semester they undergo another spell of 6 months (June through November) Industrial training-II. The Apprenticeship (Amendment) Act 1973 is followed in regulating the Industrial training procedure for Sandwich Course.

I SEM II SEM III SEM IV SEM V SEM VI SEM VII SEM

First Spell - IV Semester (December - May) Second Spell - VII Semester (June - November) 2. Attendance Certification

Every month students have to get their attendance certified by industrial supervisor in the prescribed form. Students have also to put their signature on the form and submit it to the institutional staff in-charge. Attendance and submission of Review reports will be duly considered while awarding the Continuous Assessment mark. 3. Training Reports

The students have to prepare two types of reports:

• Weekly report in the form of diary to be submitted to the concerned staff in-charge of the institution. This will be reviewed while awarding Continuous Assessment mark.

• Comprehensive report at the end of each phase of Industrial Training will be reviewed while awarding End semester Examination marks.

3.1 Industrial Training Diary

Students are required to maintain the record of day - today work done. Such record is called Industrial training Diary. Students have to write this report regularly. All days of the week should be accounted for clearly giving attendance particulars (Presence, Absence, Leave, Holiday etc). The concerned Industrial supervisor is to check periodically these progress reports.

Institutional study

Industrial Training



3.2 Comprehensive Training Report

In addition to the diary, students are required to submit a comprehensive report on training with details of the organisation where the training was undergone after attestation by the supervisors. The comprehensive report should be incorporating study of plant/ product /process/ construction along with intensive in-depth study on any one of the topics such as processes , methods, tooling, construction and equipment, highlighting aspects of quality, productivity and system. The comprehensive report should be completed in the last week of Industrial training. Any data, drawings etc should be incorporated with the consent of the Organisation. 4. Scheme of Evaluation

Components SCHEME OF EVALUATION


Continuous Assessment Mark

1 First review 20 2 Second review 20

3 Attendance 10 End Examination 4 Comprehensive Training Report 20




Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : V Subject Code & Name : MEL51 DESIGN OF MACHINE ELEMENTS Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL51 Design Of Machine Elements

Hours/ Week

Hours/ Semester


6 96


End Semester

Examination Total

3

25 75 100



I Design of Joints And Fasteners 18

II Design of shafts, couplings and keys 18

III Design of friction drives (flat belt and v-belt) 18 IV Design of bearings 18

V Design of levers and spur gears 18



• Design riveted joints, welded joints, sleeve and cotter joint and knuckle joint. • Design eye bolts, cylinder cover studs.

• Design shafts, keys and couplings required for power transmission.

• Compare the different types of couplings.

• Design flat and V-belt for power transmission.

• Aware different chain drive types

• Study the various types of bearings and their applications. • Design journal bearings.

• Design spur gear used for power transmission.

• Design hand lever, foot lever and cranked lever.



DETAILED SYLLABUS


I

DESIGN OF JOINTS AND FASTENERS

Names of engineering materials - Factors affecting selection of material – BIS designation of Ferrous materials – Preferred number-Factor of safety and allowable stress - Procedure for designing machine elements – Types of failures – Problems on tension, compression, shear and bearing. Joints: Design of- sleeve and cotter joint - knuckle joint-welded joint. Fasteners: Design of bolted joints - eye bolts - cylinder cover with bolts, studs - pins.

18

II

DESIGN OF SHAFTS, COUPLINGS AND KEYS

Shafts: Design of shafts subjected to – twisting moment – bending moment – combined twisting and bending moments – fluctuating loads – design of shafts based on rigidity. Keys: Types of keys - design of sunk keys only - Effect of keyways on shaft-problems. Couplings: Requirements of good couplings – types - design of - rigid protected type flange couplings - marine couplings – pin type flexible coupling (Description only).

18

III

DESIGN OF FRICTION DRIVES (Flat belts and V-belts)

Flat Belts: Types of belts - materials for belt -– types of belt drives – Speed ratio – effect of slip - length of flat belts –Tension Ratio - centrifugal tension - power transmitted – condition for maximum power - transmission – Initial Tension - problems - design procedure of flat belts - design of flat belt based on manufacturer’s data only – problems. V-Belts: V-belt drive - comparison with flat belt drive - designation of V-belts – length of belt - power transmitted – Design of V-belt using manufacturer’s data only – Problem. Chain Drives - Types

18

IV

DESIGN OF BEARINGS

Bearings: Classifications of bearings – sliding contact and rolling contact bearings - radial and thrust bearings - roller bearing – types - Designation of ball bearings - materials used for bearings - journal bearings - heat generated - heat dissipated - cooling oil requirement – problems - design of journal bearings –Problems. Design based on approved data books only.

18

V

DESIGN OF LEVERS AND SPUR GEARS

Levers: Types of levers – applications - mechanical advantage – leverage - displacement ratio - design of-hand lever-foot lever-cranked lever - problems. Spur gears: Gear drives - merits and demerits over belt drive – Classification of gears - gear materials - spur gear terminology - design of spur gears based on Lewis & Buckingham equation - Problems – speed reducer – types –(Approved data books only).

18

Text Books: 1. Pandya & Shah, “Machine Design”, Charotar Publishing House. 2. Sundararajamoorthy.T.V & Shanmugam.N, “Machine Design”, Anuradha Publications, Kumbakonam. 3. PSG College of Technology, “Design Data Book”, DPV Printers, Coimbatore. 4. Design Data Book – Approved by DOTE.

Reference Books:

1. Khurmi.R.S & Gupta.J.K, “A text book of Machine Design”, Eurosia Publishing House Pvt. Limited, New Delhi-110 055.

2. Bandari, ”Machine Design” 3. Holowenko & Laughlin, “Theory and Problems of Machine Design”, Schaum’s outline Series.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : V Subject Code & Name : MEL52.1 MODERN MACHINING PROCESSES



MEL52.1 Modern Machining Processes

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Automatic Lathes and Gear Manufacturing 15

II Mechanical Energy Based Processes 15

III Electrical Energy Based Processes 15 IV Chemicals and Electro Chemical Energy Based Processes 15

V Thermal Energy Based Processes 15



• Explain the working of automatic lathe. • Compare different types of gear manufacturing methods.

• Explain the construction and working of ultrasonic machines.

• Explain the construction and working of Abrasive Jet Machines

• Explain the working of Electrical energy based machining processes.

• Compare wire EDM and Spark EDM Machines

• Compare different Chemical machining processes. • Compare different Electrochemical machining processes.

• Explain the working of LBM and Plasma arc machinery.

• Explain the applications and limitations of modern machining process.



DETAILED SYLLABUS


I

AUTOMATIC LATHES AND GEAR MANUFACTURING

Automatic Lathes: Automatic lathe – classification of single spindle automatic lathe – principle of automatic lathes – automatic screw cutting machines – multi spindle automatic lathes Transfer Machines – In-line & Rotary types, advantages & disadvantages. Gear Manufacturing Processes: Gear Broaching - Gear shaper-gear hobbing-principle of operation only-gear finishing processes-burnishing-shaving-grinding and lapping-gear materials-cast iron, steel, alloy steels, brass, bronze, aluminum, nylon.

15

II

MECHANICAL ENERGY BASED PROCESSES

Ultrasonic Machining: Principle- Transducer types – Concentrators - Abrasive Slurry - Advantages and Limitations – Applications. Abrasive Jet Machining: Process- Principle - Advantages and Limitations – Applications. Abrasive Water Jet Machining: Principle –Advantages and Limitations – Practical Applications

15

III

ELECTRICAL ENERGY BASED PROCESSES

Electrical Discharge Machining (EDM), Mechanism of metal removal – Dielectric Fluid – Electrode Materials - Spark Erosion Generators – Electrode Feed System – Tool Electrode Design – Characteristics of Spark Eroded Surfaces - Advantages and Limitations – Practical Applications EDM Wire Cut and Grinding: Principle – Wire Feed System - Advantages and Limitations – Practical Applications

15

IV

CHEMICALS AND ELECTRO CHEMICAL ENERGY BASED PROCESSES

Chemical Machining: fundamentals, Principle –classification and selection of Etchant -chemical milling, Engraving, Blanking, Drilling and Trepanning-Advantages and limitations –Applications. Electro Chemical Machining: Electro-chemistry of the process-Electrolytes-Electrolyte and their Properties – Advantages and Limitations – Applications -Electro Chemical Grinding: Honing, cutting off, Deburring and turning.

15

V

THERMAL ENERGY BASED PROCESSES

Electron Beam Machining: Principle –Generation and control of electron beam-Advantages and Limitations – Applications. Laser Beam Machining: Principle –Solid and Gas Laser Application – Thermal Features of LBM - Advantages and Limitations – Applications. Ion Beam Machining: Equipment – Advantages and Limitations – Applications. Plasma Arc Machining: Principle –Gas mixture– Types of Torches –Advantages and Limitations – Applications.

15

Text Books: 1. Pandey.P.C & Shan.H.S, “Modern Machining Process”, Tata Mc Graw – Hill Publishing Company

Limited, New Delhi. 2. Jain.V.K, “ Advanced Machining Process”, Allied Publishers PVT Limited.

Reference Books:

1. Amitadha Bhattacharyya, “New Technology”, The Institution Of Engineers, (India). 2. HMT Banglore, "Production Technology”, Tata Mc Graw–Hill Publishing Company Limited, New Delhi. 3. Sharma.P.C, ”Text Book of Production Engineering”, S. Chand & Company Ltd., Ramnagar, New Delhi. 4. Hajra Choudhury.S.K, Bose.S.K, Hajra Choudhury.A.K, Nirjhar roy, “Elements of workshop

Technology”,



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : V Subject Code & Name : MEL52.2 POWER PLANT ENGINEERING



MEL52.2 Power Plant Engineering

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Sources of energy and economics of power plant 15

II Steam power plant 15

III Hydro Electric power plant 15 IV Diesel engine and gas turbine power plants 15

V Nuclear and other power plants 15



• Identify various sources of natural energy. • Aware the economics of Power plant

• Convert natural energy into electrical energy.

• Compare various types of power plants like thermal, Hydel, Diesel and Gas turbine power plants.

• Explain the working of Hydro electric power plant and its merits.

• Explain the Power production in a Nuclear Power Plant.

• Identify the various parts of a Power plant and its utility. • Aware the environmental aspects of power plants

• Explain the working of power plants operating on renewable energy sources.

• Aware present energy scenario and need for energy conservation



DETAILED SYLLABUS


I

SOURCES OF ENERGY AND ECONOMICS OF POWER PLANT

Power – Sources of energy – Fuels – Types of fuels – Solid fuels, Liquid fuels, Gaseous fuels – Calorific value of fuels – Types of coal – Coal selection – Requirements of fuel – Hydel Potential energy – Nuclear energy – Comparison of Sources of power – Non conventional sources of energy – Solar energy, Wind energy, Tidal power and Bio gas. Types of loads – Economic load sharing – Economics in plant selection – Economic of power generation – Choice of power station – Energy rates – Types of tariff.

15

II

STEAM POWER PLANT

Layout of steam power plant – Fuel and Ash handling – Combustion for burning coal, Mechanical stackers, Pulverizes, Electrostatic Precipitators, Draughts-Different types, Surface condensers - Types of cooling towers – Steam turbines – Steam engines – Advantages of steam turbines over steam engines – Boilers – Types of boilers – Principles of steam power plant design – Factors affecting steam plant design – Thermal power plants environmental control.

15

III

HYDRO ELECTRIC POWER PLANT

Water power – Application of hydro power plant – Lay out of Hydro electric power plant – Elements of Hydro electric power plant – Classification of Hydro electric power plant – Advantages of Hydro electric power plant – Mini and Micro hydro power plants – Types of Dams – Pen stock – Draft tube – Surge tank – Hydraulic turbines – Classifications – Turbine governing – Cavitations – Safety measures in Hydro power stations – Control room functions – Switch gear – Site selection – Comparison of Hydro electric power plant and steam power plant.

15

IV

DIESEL ENGINE AND GAS TURBINE POWER PLANTS

Types of diesel engine power plants – Layout and components – Diesel engine power plant auxiliaries – Engine starting methods – Advantages of Diesel engine power plant – Application of Diesel engine power plant - Site selection. Gas turbine power plant – Classification – Elements of simple gas turbine power plant – Layout – Open and Closed cycles – Reheating, Regeneration and Inter cooling – Combined cycles - Applications and advantages of Gas turbine plant.

15

V

NUCLEAR AND OTHER POWER PLANTS

Nuclear energy – Fission, Fusion reaction – Nuclear power plant layout – Elements of Nuclear power plant – Types of reactors – Pressurized water reactor – Boiling water reactor – Waste disposal and safety – Advantages of Nuclear power plant – Comparison of Nuclear power plant and steam power plant – Site selection and Commissioning procedures. Solar thermal power generation plants – Geo thermal power generation-Tidal power generation-Tidal power generation – Wind mills – Bio gas plants.

15

Text Books: 1. Arora.S.C & Domkundwar ,“A Course in Power plant Engineering”, S. Dhanpat Rai. 2. Nag. P.K, “Power Plant Engineering”, Tata McGraw – Hill.

Reference Books:

1. El-Wakil M.M, “Power Plant Technology”, Tata McGraw-Hill. 2. Ramalingam.K.K, “Power Plant Engineering”, Scitech Publications. 3. Nagpal.G.R, “Power Plant Engineering”, Khanna Publishers. 4. Rai.G.D, “Introduction to Power Plant Technology”, Khanna Publishers.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : V Subject Code & Name : MEL52.3 REFRIGERATION AND AIR-CONDITIONING



MEL52.3 Refrigeration And Air-Conditioning

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Refrigeration system and refrigeration equipments 15

II Vapour compression refrigeration system ,vapour absorption refrigeration system and cryogenic refrigeration systems

15

III Refrigeration flow controls, refrigerants and lubricants and applications of refrigeration

15

IV Psychometrics and comfort air conditioning systems 15

V Cooling load calculations and duct design , energy conservation

techniques 15


Total 80

OBJECTIVES:

• Explain the working of open and closed air system of refrigeration.

• Describe the working and construction of compressors used for air conditioning. • Explain vapour compression refrigeration system.

• Explain vapour absorption refrigeration system. • Compare the properties and applications of various refrigerants.

• Define the parameters used in psychrometry.

• Use Psychrometry chart

• Describe the equipment used for air conditioning.

• Estimate the cooling load for the given requirement.

• Explain the industrial application of refrigeration.



DETAILED SYLLABUS


I

REFRIGERATION SYSTEM AND REFRIGERATION EQUIPMENTS

Thermodynamic state of a pure substance, modes of heat transfer –laws of heat transfer - 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 of working of open and closed air system of refrigeration – advantages and disadvantages – and its application of air cycle-problems Compressor – principle of working and constructional details of reciprocating and rotary 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 cooling towers. Evaporators- natural circulation and forced circulation type – principle of working constructional details.

15

II

VAPOUR COMPRESSION REFRIGERATION SYSTEM ,VAPOUR ABSORPTION

REFRIGERATION SYSTEM AND CRYOGENIC REFRIGERATION SYSTEMS

Principle of working of vapour compression system – analysis of vapour compression cycle using T-s diagram and p-H diagram- refrigerating effect- compression work - C.O.P - effect of superheating and under cooling – effect of evaporative pressure and condenser pressure-problems – liquid vapour refrigeration heat exchangers - advantages and disadvantages of superheating and under cooling –use of flash chamber and accumulator. Simple absorption system – Electrolux system - solar absorption refrigeration system- absorption system comparison with mechanical refrigeration system. Refrigerators for above 2 K- Philips Refrigerator--Giffered McMohan refrigerator- refrigerators for below 2 K - Magnetic refrigeration systems.-Cryogenic Treatment of Metal.

15

III

REFRIGERATION FLOW CONTROLS, REFRIGERANTS AND LUBRICANTS AND

APPLICATIONS OF REFRIGERATION Capillary tube-automatic expansion valve-thermostatic expansion valve-electronic expansion valve-solenoid valve-evaporator pressure regulator –suction pressure regulator-classification of refrigerants-selection of a refrigerant-properties and applications of following refrigerants SO

2 , CH

4 ,F

22, and NH

3 –CFCs refrigerants-

equivalent of CFCs refrigerants (R-123a,R-143a,R-69S)- blends of refrigerants(R400 and R500 Series) – Effects of CFC on ozone layer - lubricants used in refrigeration and their applications. Slow freezing –quick freezing- cold storage-frozen storage-freeze drying –dairy refrigeration –ice cream cabinets-ice making – water cooler, milk cooler, bottle cooler-frost free refrigeration. Introduction to Unconventional refrigeration.

15

IV

PSYCHOMETRICS AND COMFORT AIR CONDITIONING SYSTEMS

Psychrometry properties - adiabatic saturation of air by evaporation of water- psychometric chart and its uses – psychometric processes – sensible heating and cooling - humidifying and heating - dehumidifying and cooling - adiabatic cooling with humidification - total heating or cooling processes -sensible heat factor - by pass factor – adiabatic mixing – evaporative cooling - problems – governing optimum effective temperature – comfort chart-design consideration. Equipment for air conditioning and insulation factors – air purification – temperature control – humidity control – dry and wet filters- centrifugal dust collector – air washer humidifier – dehumidifier - fans and blowers – grills and registers – summer and winter air conditioning, window and split air conditioners –

15



– properties of ideal insulator, types of insulating materials .

V

COOLING LOAD CALCULATIONS AND DUCT DESIGN , ENERGY CONSERVATION

TECHNIQUES

Different heat sources – conduction heat load – radiation load of sun – occupants load – equipment load - infiltration air load – miscellaneous heat sources –fresh air load - problems. Classification of duct systems - Duct design – equal friction method – velocity reduction method – problems. Chilled water Systems -Air handling Units. Energy conservation and design decisions - heat reclaim – thermal storage – ice builder – ice harvester – variable refrigerant flow (VRF) – variable primary flow (VPF).

15

Text Books:

1. Ballaney.P.L, “Refrigeration and air conditioning”, Khanna Publishers, New Delhi -110 006. 2. Jain.V.K, “Refrigeration and air conditioning”. 3. Wilbert F. Steocker , “Industrial Refrigeration Hand Book”.

Reference Books:

1. Domkundwar, “A course in refrigeration and air conditioning”. 2. Dossat , “Principles of refrigeration” 3. Audels, “Home refrigeration and air conditioning”, Theo. Audel & Co. publisher, New York. 4. Arora.C.P, “Refrigeration and air conditioning”. 5. Randell Fd Barron, “cryogenic systems”.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : V Subject Code & Name : MEL53 THERMAL ENGINEERING - II Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL53 Thermal Engineering - II

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Formation and properties of steam & Thermodynamic processes of vapour.

15

II Steam Boilers and Performance of Boilers 15 III Thermal Power Plants and Steam Turbines and Condensers 15

IV Refrigeration and Air-Conditioning 15 V Conventional Sources of Energy and Nuclear power plant. 15



• Define various types of steam.

• Explain the working of Boiler. • Compare various types of Boilers.

• Familiarize boiler mounting and accessories. • Describe various circuits used in the thermal power plant.

• Explain working of steam turbine and condensers.

• Compare conventional energy sources with Non-Conventional Sources of energy.

• Explain working of nuclear power plant.

• Appreciate the application of refrigeration and air-conditioning.

• Define various parameters used in the psychrometry.



DETAILED SYLLABUS


I

FORMATION AND PROPERTIES OF STEAM & THERMODYNAMIC PROCESSES OF

VAPOUR

Steam - Properties – formation of steam– saturation temperature – enthalpy of water – enthalpy of evaporation – conditions of steam – wet, dry and superheated steam -dryness fraction – enthalpy of wet, dry and superheated steam -advantages of superheated steam –Property diagrams – p-v diagram - T-H diagram – T-V diagram – T-S diagram - phase diagram-H-S diagram –P-H diagram – critical conditions of water-– specific volume of water and steam – density of steam – external work done during evaporation – internal latent heat – internal energy of steam – entropy of water and steam – steam tables- Mollier chart – problems. Determination of dryness fraction of steam – bucket calorimeter - combined separating and throttling calorimeters-problems. Expansion processes of steam - constant volume, constant pressure, constant temperature, hyperbolic, polytrophic, isentropic and throttling processes – problems.

15

II

STEAM BOILERS AND PERFORMANCE OF BOILERS

Introduction -Classification of boilers – comparison of fire tube and water tube boilers– high pressure boilers – advantages of high pressure boilers - Lamont and BHEL high pressure boilers – boiler mountings and function-construction and working – boiler accessories and function-construction and working – comparison of mountings and accessories – feed water treatment – internal and external treatments - starting boiler from cold condition – safety precautions in boiler operation – clauses of Indian boiler act. Evaporation rate- actual, equivalent and factor of evaporation – boiler efficiency – factors influencing boiler efficiency - boiler power - problems – boiler plant - efficiency of economizer and super heater - problems - boiler trial – heat losses in a boiler- heat balance sheet – problems

15

III

THERMAL POWER PLANT AND STEAM TURBINES AND CONDENSERS

Selection of site for thermal power plant -Layout of thermal power plant – fuel and ash circuit – water and steam circuit – air and flue gas circuit – cooling water circuit – merits and demerits of thermal power plant –– air pollution by thermal power plants – pollutants, effects and control – cyclone separator – wet scrubber – electrostatic precipitator – control of No2 and SO2.fiudised bed combustion- thermal and noise pollution. Basic steam power cycles – Carnot, Rankine and modified Rankine cycles – classification of steam turbine-Impulse and reaction turbines-Difference – necessity of compounding – Methods of compounding – special turbines. Steam condensers – elements of condensing plant – classification of condensers – jet condenser -types – surface condensers - types – Comparison of jet and surface condensers – sources of air in condenser – condenser vacuum – vacuum efficiency – condenser efficiency-Dalton’s Law – mass of cooling water required – mass of air present – number of tubes – problems-Cooling Towers.

15

IV

REFRIGERATION AND AIR CONDITIONING

Refrigeration – Refrigerant-Properties - refrigerators and heat pumps – types and applications of refrigeration Systems –refrigerating effect –unit of Refrigeration – C.O.P. – actual C.O.P.- Air Refrigeration System – reversed Carnot cycle – C.O.P of refrigerator , heat pump &Heat Engines –Power Required –Mass of Ice Produced –Problems Bell-coleman cycle– problems – Vapour’compression refrigeration system -vapour absorption system –Comparision-refrigerants – desirable properties-Introduction to food refrigeration. Psychrometry-psychometric properties – dry air – moist air – water vapour – saturated air – dry bulb temperature – wet bulb temperature – wet bulb

15



depression – dew point temperature – dew point depression – humidity – specific and relative humidity – psychrometric chart –psychrometric processes – sensible heating and cooling- By-Pass Factor-humidification – dehumidification –Mixing of Air Stream -simple problems using psychrometric chart – air conditioning – classification and applications of air conditioning system – room air conditioning – central air conditioning – comparison –comfort and industrial air conditioning – factors to be considered in air conditioning – loads encountered in air conditioning systems.

V

CONVENTIONAL SOURCES OF ENERGY AND NUCLEAR POWER PLANT

Conventional sources of energy – layout of hydel and diesel power plants – merits and demerits Nuclear fuels –fissile and fertile fuels – Nuclear fission and fusion – chain reaction – radio activity – layout of nuclear power plant – merits and demerits – Nuclear reactors -Components–Reactor Core -moderators – control rods – coolant – reflectors – biological shield-Reactor Vessels-Classification of Reactor- pressurized water reactor – boiling water reactor – Candu type reactor – fast breeder reactor –– effect of nuclear radiation – Fuel Cycle –Site selection-Safety-Floating Nuclear Power Plants-Uranium Enrichment-Methods-disposal of nuclear wastes- comparison of nuclear power plants with thermal power plants-Nuclear Power Plant in India.

15

Text Books: 1. Rajput .R.K, “Thermal Engineering”, Laxmi publications Pvt Ltd, New Delhi. 2. Khurmi.R.S & Gupta.J.K,” Thermal Engineering”, S.Chand & Co, New Delhi 3. Nagpal.G.R, “Power plant Engineering”, Khanna Publishers, New Delhi. 4. Ballaney.P.L, “Refrigeration and Air conditioning”, Khanna Publishers, New Delhi.

Reference Books:

1. Ballaney.P.L , “ Thermal Engineering”, Khanna Publishers, New Delhi. 2. Sarkar.B.K , “Thermal Engineering”, Dhanpat Rai & Sons, New Delhi . 3. Domkundwar & Kothandaraman.C.P, “Power Plant Engineering Thrmodynamics”, Khanna publishers,

New Delhi. 4. Manohar Prasad, “Refrigeration and Air conditioning”. 5. Sharma.P.C, “Power Plant Engineering”, S.K. Kataria & sons, New Delhi.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : V Subject Code & Name : MEL54 AUTOMOBILE ENGINEERING Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL54 Automobile Engineering

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Automobile engines 15

II Fuel and fuel feed systems 15

III Transmission and power train 15 IV Automobile chassis 15

V Automobile electrical equipments & pollution control 15



• Explain about the constructional details of an Automobile engines • Explain different cooling systems and lubricating systems

• Learn properties of various fuels and additives

• Describe fuel feed systems for petrol and diesel engines with all devices involved in it.

• Explain the construction and functional features of the power transmission systems.

• Explain the construction and functional features of the power trains.

• Explain the functions of different types of steering, suspension and brake systems. • Describe the different types of chassis and their functions.

• Familiarize electrical and electronic equipments used in automobile.

• Appreciate the modern techniques for automobile pollution control.



DETAILED SYLLABUS


I

AUTOMOBILE ENGINES Basic Engine Components – Functions , types , materials and construction of – Cylinder block – Crankcase – oil pan - Cylinder head – Gaskets – cylinder liners – Comparison of liners – Piston – Expansion control in pistons – piston rings – types of compression rings and oil control rings – piston pin – Connecting rod - methods of connecting piston and Connecting rod – Crankshaft – flywheel – Cam shaft – methods of cam shaft drive arrangements – Valve and Valve mechanism – L-I-F-T.

Cooling systems – purpose – types – air and water cooling systems – merits and demerits – thermo siphon system - pump assisted water cooling systems – components – water pump, fan - thermostat – types - radiator – types – pressure cap – vapour recovery cooling system – merits - vented and pressurized expansion tank – temperature sensors - troubles in cooling system – loss of coolant , overheating and over cooling – causes.

Lubrication systems – purpose – properties of lubricants - types of lubricants – additives – Service rating of oil – types of lubricating systems – Petroil and high pressure lubrication system - Full pressure system – techniques of cylinder and piston lubrication – oil pumps - oil filters – full flow and bypass filter systems - Troubles in lubrication system – oil leakage , low oil pressure, high oil pressure and excessive oil consumption – causes.

15

II

FUEL AND FUEL FEED SYSTEMS

Requirements of an ideal petrol – Octane number – detonation - Pre-ignition – properties of a good diesel fuel – Diesel engine – Stages of Combustion – Delay period – Variables affecting delay period – Methods of generating air swirl in diesel engine combustion chambers – Types of combustion chambers – merits and demerits.-Cetane number – Diesel knock – methods of controlling diesel knock – comparison of detonation and diesel knock - fuel additives – Alternate fuels for petrol and diesel engines

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 – defects - Carburetor circuits – Solex Carburetor - Construction and operation – petrol injection – merits and demerits – DTSI – VTI – CCVTI – PGMFI – MPFI system.

Layout of diesel fuel feed system – single acting fuel feed pump – fuel injection pumps – Construction and working of distributor type pump – CRDI system - fuel injectors – types – Single & Multi hole – pintle and pintaux - governors – Mechanical and Pneumatic governors - fuel filters – primary and secondary filters

15

III

TRANSMISSION AND POWER TRAINS

General arrangement of power transmission system – Arrangement of front engine rear drive – rear engine rear drive – front engine front drive - four wheel drive – applications – clutch – function – Components – Types - Single plate , multi plate and diaphragm spring clutch – fluid coupling – Clutch troubles and their causes – Automatic Transmission.

Gear box – purpose – various resistance to motion – types of gear boxes – sliding mesh, constant mesh and synchromesh – floor shift gear changer – gear box troubles and their causes.

Drive line – propeller shaft – Universal joint – Cross type only – slip joint – final drive – function – types of gear arrangement – straight & spiral Bevel , Hypoid ,

15



Worm and Worm Wheel – merits , demerits and application – Hotch kiss drive – Torque tube drive – radius rod.

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

IV

AUTOMOBILE CHASSIS

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

Suspension system – Functions – Type of springs – Leaf , coil and Torsion bar – Front suspension systems – independent front suspension – merits and demerits – types – rear end suspension – Air suspension - shock absorber – purpose – telescopic type – construction and working.

Brake system – functions – classification of brakes – drum brakes – leading shoe and trailing shoe – Self energizing action – hydraulic brake – brake bleeding - Air assisted hydraulic brakes – Air brake – layout , functions of each component and application only – disc brakes – construction and working – comparison of disc and drum type – brake troubles and their causes – anti lock brake system.

Wheels – types of wheels – brief description and applications – tyres – function – construction of tyres – cross and radial ply tyres – comparison – properties of tyres – tubeless tyre - tyre wear and tyre service.

15

V

AUTOMOBILE ELECTRICAL EQUIPMENT & POLLUTION CONTROL

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

Ignition system – Types – battery coil ignition system –High tension magneto – electronic ignition –Ignition system troubles and remedies.

Lighting system – circuit – Head light – Aiming and adjustment – sealed beam head lights – directional signal circuits – fluorescent lamp - Horn circuits – Wind screen wiper.

Governing of I.C engines – Quantity and Quality governing -

Pollution – Pollutants – source of pollutants – pollution control techniques for petrol and diesel engines emissions – controlling crank case emission ( PCV ) – controlling evaporative emission ( VRS , VSS , VVR , ECS and EEC ) – Treatment of exhaust gas ( Catalytic converter , EGR ) – introduction to Vehicle Mechatronics – radio interference – suppressors – audio, video systems.

15



Text Books : 1. Kirpal singh, “Automobile engineering vol- 1 & 2”, Standard publishers distributors, New Delhi. 2. Narang.G.B.S, “Automobile Engineering”, Khanna Publishers, New Delhi. 3. William H.crouse and Donald .L. Anglin, “Automotive Mechanics”, Tata Mc Graw – Hill Publishing

Company Ltd, New Delhi. 4. Harbans Singh Reyat, “The Automobile”, S.Chand & Co Ltd, New Delhi

Reference Books:

1. Heinz Heisler, “Vehicle and Engine technology. Vol. I”, ELBS 2. Joseph Heitner, “Automotive Mechanics”, East –west Press (P) Ltd, New Delhi 3. Mathur.M.L & Sharma.R.P, “Internal Combustion engines”, Dhanpat Rai & Sons, New Delhi 4. Gupta.R.B & Satya Prakashan, “Automobile Engineering”



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : V Subject Code & Name : MEL55 AUTOMOBILE ENGINEERING PRACTICAL Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL55 Automobile Engineering Practical

Hours/ Week

Hours/ Semester


4 64


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Identify the various tools and their applications used in Automobile.

• Dismantle and assemble parts of petrol engine.

• Dismantle and assemble parts of diesel engine.

• Service AC fuel pump, oil pump and water pump.

• Service carburettors.

• Dismantle and assemble fuel injection pump & fuel injectors. • Dismantle and assemble of power transmission and differential unit.

• Dismantle and assemble steering gear box. • Testing and charging of batteries.

• Overhauling of starter motor, alternator & dynamo. • Troubleshoot the electrical circuits in automobile.


PART – A

1. Identification and application of mechanic’s tools. 2. Dismantling and assembling of four stroke petrol engine and diesel engine and identification of parts. 3. Cleaning, inspecting and measuring cylinder bore using cylinder bore dial gauge and suggesting the

next over size. 4. Removing decarburizing, inspecting and replacing connecting rods and adjusting the bearings. 5. Removing camshaft, replacing timing gears, removing valves, lapping and adjusting valve clearance. 6. Removing, servicing and replacing of fuel pump, oil pump & water pump. 7. Removing, servicing & replacing SOLEX carburetor/MPFI system. 8. Dismantling and assembling of inline fuel injection pump / CRDI system. 9. Dismantling, assembling & testing of injectors.

PART – B

1. Removing and replacing of pressure plate and clutch plate, fingers adjustment. 2. Dismantling, inspecting and assembling of gear box and find out the gear ratios. 3. Dismantling, inspecting and assembling of final drive and differential units. Adjusting of backlash and

correct tooth contact of crown and pinion of differential unit. 4. Dismantling, assembling and adjusting of steering gear box and find gear ratio. 5. Test a battery with specific gravity test and charge the battery with constant amperage / voltage

method. 6. Dismantling, overhauling and assembling of starter motor. 7. Dismantling, overhauling and assembling of alternator / dynamo. 8. Trace the automobile electrical system with respect to battery coil ignition system.



9. Trace the automobile electrical system with respect to (i) horn relay circuit, (ii) Wiper circuit & explain with neat circuit diagram.

Reference:

• Lab Manual, “MEL55 AUTOMOBILE ENGINEERING PRACTICAL”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL55



1 ½ Hrs 1 One question from PART - A 35 1 ½ Hrs 2 One question from PART – B 35




Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : V Subject Code & Name : MEL56 METROLOGY & MEASUREMENT AND MACHINE TOOL TESTING

PRACTICAL Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL56 Metrology & Measurement and Machine Tool Testing Practical

Hours/ Week

Hours/ Semester


6 96


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Familiarize about measuring techniques of Metrology instruments. • Select the range of measuring tools.

• Obtain accurate measurements. • Set up instrument for machine tool testing.

• Observe the machine tool alignment and results.

• Observe the manufacturing accuracy of machine tools.


Note:

• The students should be given training in both sections (Part-A & Part-B). All the exercises should be completed and the students should maintain record notebook for the concerned exercise and submit during the END Practical Examinations.

PART – A METROLOGY & MEASUREMENT

Syllabus:

1. Introduction to linear measurement

2. Introduction to angular measurement

3. Introduction to geometric measurements

4. Linear Measuring Instruments

Vernier Caliper, Micrometer, Inside Micrometer, Vernier Height gauge, Depth Gauge and

Slip Gauge.

5. Angular Measuring Instruments – Universal Bevel Protractor, Sine Bar.

6. Geometric measurement - Gear tooth Vernier caliper, Thread micrometer



EXERCISES:

I. LINEAR MEASUREMENTS:

1. Determine the thickness of ground MS flat to an accuracy of 0.02mm using Vernier caliper. 2. Determine the diameter and length of cylindrical objects to an accuracy of 0.02mm using vernier

caliper. 3. Determine the inside diameter of a bush component to an accuracy of 0.02 using Vernier caliper. 4. Determine the diameter of a cylindrical component to an accuracy of 0.01mm using micrometer

and check the result with digital micrometer 5. Determine the height of gauge block or parallel bars to an accuracy of 0.02mm using Vernier

height gauge. 6. Determine the depth of a blind bore component to an accuracy of 0.02mm using vernier depth

gauge. 7. Determine the thickness of ground MS plates using slip gauges

II. ANGULAR MEASUREMENTS:

1. Determine the angle of V-block, Taper Shank of Drill and Dovetails in mechanical components using universal bevel protractor.

2. Determine the angle of machined surfaces of components using sine bar with slip gauges.

III. GEOMETRIC MEASUREMENT

1. Measure the geometrical dimensions of V-Thread using 3 wire method 2. Measure the geometrical dimensions of spur gear.

IV. MEASUREMENTS USING CMM

1. Study of CMM & its Supporting Software and Measurement of Simple Components using CMM (Circle ,Plane ,Cone, Cylinder)

PART – B

MACHINE TOOL TESTING

Geometrical Test: Position of machine tool components and displacement of machine tool components relative to one another is checked. The instruments required for Geometrical tests are Dial Gauge, test mandrel, Straight edge, Squareness, sprit level.

• Test for level of installation of machine tool in Horizontal and Vertical Planes.

• Test for Flatness of machine bed and for straightness and parallelism of bed ways on bearing surface. • Test for perpendicular of guide ways to other guide ways or bearing surface.

• Test for true running of the main spindle and its axial movements. • Test for parallelism of spindle axis to guide ways or bearing surfaces.

• Test for line of movements of various members like spindle and table cross slides.

• Practical test in which some test pieces are done and their accuracy and finish is checked.

EXERCISES:

1. Testing of Lathe machine alignments and prepare a test chart. a) Level of lathe. b) True running of spindle. c) Alignment of both centres. d) Parallelism of main spindle to saddle movements.

2. Testing of Shaping machine alignments and prepare a test chart. a) Level of machine. b) Table top parallel to its transverse movement. c) Ram movement parallel to table top.



3. Testing of Tool and Cutter grinder alignments and prepare a test chart. a) Level of Tool and Cutter. b) True running of spindle. c) Parallelism of Table top to its movement.

4. Testing of Pillar type drilling machine alignments and prepare a test chart. a) Level of the Drilling machine. b) True running of Spindle Taper. c) Squareness of Spindle axis with Table.

5. Testing of Surface Grinding machine alignments and prepare a test chart. a) Level of the Surface Grinding Machine. b) Parallelism of Table Top to its movement. c) Parallelism of Spindle axis to the Table Top. d) Squareness of Table with Vertical movement of Spindle.

6. Testing of Milling machine alignments and prepare a test chart. a) Level of the Machine b) Cutter Spindle Axial slip c) True running of internal Taper. d) Table surface parallel with Arbor. e) Test on Column.

7. Testing of Slotting machine alignments and prepare a test chart. a) Level of the Slotting machine. b) Ram movement perpendicular to the Table Top. c) Table Top parallel to its transverse movement.

Reference:

• Lab Manual, “MEL56 METROLOGY & MEASUREMENT AND MACHINE TOOL TESTING PRACTICAL”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL56



Part A 1 Hr

1 Least Count calculation/ Tabulation 10 2 Reading/ Calculation 10

3 Result 05 Part B 2 Hrs

4 Drawing/Procedure 10

5 Alignment test /Calculation 25 6 Result & Test Chart 10

7 Viva-Voce 05

Total 75

Note: All the exercises should be given in the question paper and students are allowed to select by a lot



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : V Subject Code &Name : GEL57 COMMUNICATION AND LIFE SKILLS PRACTICAL

Teaching and Scheme of Examination: No. of Weeks per Semester: 16

Subject Code &Name

Instruction Examination

Marks

Duration in Hours

Hours/ Week

Hours/ Semester

Continuous

Assessment

End Semester Examination Total

GEL57

Communication and Life Skills Practical

4 64 50 50 100

3


Sl. No. Section

No. of Hours

1 Part-A:Monodic Communication 16

2 Part-B:Dyadic Communication 16

3 Part-C:Professional Communication 16

4 Part-D:Life Skills 16

Total 64

SPECIFIC INSTRUCTIONAL OBJECTIVES

Communication is crucial as it influences every aspect of one’s personal development. Having a sound grounding in reading and writing techniques allows a student to progress on to higher level literacy skills. Many students struggle because their basic decoding is so inaccurate that advanced comprehension is difficult for them. Because of their poor exposure and poor use of English language in various spheres of life they suffer proper communication. They also tend to be ‘afraid’ of words and in turn they are not able to develop their personal vocabulary. In other words, without solid literacy skills, the student’s prospects and life chances are limited. It is a fact that Communication skills and Life Skills shapes one’s personality.

MONODIC COMMUNICATION

The student is able to: 1. Practice using departmental words and terminology in sentences. 2. Prepare and perform oral presentations. 3. Introduce oneself and others. 4. Deliver welcome address and vote of thanks. 5. Compere a program. 6. Describe the visuals. 7. Take notes and answer very short questions. 8. Comprehend an auditory/oral passage.



DYADIC COMMUNICATION

The student is able to: 1. Adopt various communicative functions. 2. Prepare and perform a dialogue. 3. Adopt the basics of telephone etiquette.

PROFESSIONAL COMMUNICATION

The student is able to: 1. Prepare a resume. 2. Take part in a group discussion. 3. Communicate through body language. 4. Adopt the interview skills with professional presence. 5. Perform mock interview. 6. Present a Technical paper

LIFE SKILLS

The student is able to: 1. Prepare for and deal with change. 2. Adopt motivation, goal-setting and self-esteem. 3. Adopt Teamwork skills. 4. Adopt Time management. 5. Adopt Emotional intelligence skills. 6. Assert Positively. 7. Adopt Interview etiquette. 8. Plan career. 9. Assess his/her Strength, weakness.

COMMUNICATION AND LIFE SKILLS PRACTICAL

SYLLABUS

PART A: MONODIC COMMUNICATION (16 hours)

a) Vocabulary enrichment: recording important words and terminology alphabetically connected to the concerned department – playing antakshari.

b) Introducing oneself: using greeting phrases – opening and closing with courteous notes – supplying personal information.

c) Introducing others: using greeting phrases – opening and closing with courteous notes – with information.

d) Welcome address, vote of thanks and compering a program: keeping notes – and personal information of the dignitaries – concerned.

e) Making an Oral Presentation: Preparing the presentation - Talking about people, animals and places – Keywords technique and the rehearsal – Presentation outline – Performing the presentation – answering the questions.

f) Oral description: a picture from an English magazine – a visual advertisement – a natural scene. g) Auditory/Oral comprehension – small passage – small dialogue -very short story – note - taking skill. h) News Caption: giving caption for a news item from an English daily.

PART B: DYADIC COMMUNICATION: COMMUNICATIVE FUNCTIONS (16 hours )

a) Dialogue: preparing and performing - Meeting people, exchanging greetings and taking leave – Giving instructions and seeking clarifications – Thanking someone and responding to thanks - minimum seven exchanges including the courteous openings and closings – ten common contexts.

b) Telephonic dialogue: telephonic etiquette - Answering the telephone and asking for someone – Dealing with a wrong number – Taking and leaving messages – Making enquiries on the phone-ordering for supply-bookings and arrangements-handling the complaints – calling for appointment.

PART C: PROFESSIONAL COMMUNICATION (16 hours)

a) Group Discussion - Taking part in a Group Discussion – focus on team spirit. b) Interview - Frequently asked questions in an interview – Mock interview - Body language. c) Resume Writing – components. d) Technical paper presentation



PART D: LIFE SKILLS (16 hours)

a) Preparing for and dealing with change. b) Motivation, goal-setting and self-esteem. c) Team working skills. d) Time management e) Emotional intelligence skills f) Career planning. g) Assertive Skills. h) Interview skills.

References:-

1. Lab manual," Communication and Life Skills Practical ", MPC.D.7.09.GEL57 2. Malcolm Goodale, “Professional Presentations with VCD”, Cambridge University Press 3. B.Jean Naterop and Rod Revell, “Telephoning in English with 2 Audio CDs”, Cambridge University Press 4. Priyadarshi Patnaik, “Group Discussion and Interview Skills with VCD”, Cambridge University Press 5. Kamalesh Sadanand and Susheela Punitha, “Spoken English: A Foundation Course for Speakers of Tamil”,

Orient BlackSwan. 6. S. P. Dhanavel, “English and Soft Skills”, Orient BlackSwan 7. Robert Sherfield and et al, “Developing Soft Skills”, Pearson Education. 8. “Poly Skills: A course in communication skills and Life skills”, Cambridge University Press. 9. S.P.Dhanavel , “English and Communication Skills for Students of science and Engineering”, Orient

BlackSwan. 10. Kandula Nirupa Rani, Jayashree and Indira, “Speak Well”, OrientBlackSwan. 11. Ken Taylor, “Fifty ways to improve your telephoning and teleconferencing Skills”. 12. English Weeklies/monthlies/journals like ELTOI 13. Mr.Rangarajan, “Frozen thoughts”, monthly journal for Life skills / www.frozenthoughts.com

NOTES OF GUIDANCE

Role of the media:

To equip a learner with vocabulary, particularly active vocabulary and standard everyday expressions ,using English dailies and watching selective English T.V. channels both in the classroom and outside the classroom is focused. Such a provision is recommended for the students to establish familiarity with the English dailies and selective English T.V. channels. Minimum two copies of two English dailies in the laboratory room (students can bring their own copies also).Minimum two systems with net connection for information collection in the laboratory itself. Synopsis of the news item:

During every lab work day, students must choose a news item from the English daily or weekly or monthly, and write a synopsis of the chosen news item, in not more than five lines. The news item should be pasted on the left page and synopsis on the right page (the chosen news item should not be politically, socially or communally controversial). Students should exercise care in choosing the news items. Teachers have to advise them on this aspect. This can be done outside the class hours also but every record exercise should begin with the synopsis of news item of the date of the lab session.

For example, first lab exercise namely departmental vocabulary and antakshari is performed on 15/12/2013. The student should choose a news item from any English daily of 15/10/2013 and record the synopsis on the right page (in not more than 5 lines) under the caption Synopsis of the news item of the

day/date 15/10/2013.There is no harm in repeating or copying the lines from the passage. The essence of the passage should be there. The cutout news item for presenting the synopsis should be pasted on the left page of the record notebook.

This is to be done with interest for developing one’s personality. This work does not carry any marks but without which the record exercise should not be valued. This is the precondition for valuing the record exercise. Each record exercise follows the synopsis of the chosen news item.

At the bottom of the synopsis, the student should record the dictionary meaning of atleast one

strange word found in the chosen news item. At the end of every month, a minimum of 10 Headlines of 10 different days i.e. one Headline a day from anyone English daily should be pasted on the right or left page of the Record Note Book. (This work does not carry marks but this is the precondition for marking the record exercises)



External examiner, before signing the record notebook, should verify whether the Newspaper works were recorded/pasted in the record notebook.

Verbal communication in any language begins with sounds in isolation, union and word formation. Learning everyday words and expressions is the primary factor. Grammar comes next. One can enrich one’s every day vocabulary by reading English magazines and listening to or watching an English channel on television. So an English laboratory should be equipped with a minimum of two copies of two English dailies and English weeklies or monthlies.

Watching English channels helps the students improve their vocabulary and expressions. If there is a provision, students may be permitted to watch selective, mind corruption free English channels (sports, education, news, animal channels and so on) for at least 15 min. during the English lab sessions. This will serve as motivation for the students and help them shed their inhibition. What is antakshari? (Polar word game) This game can be played on the stage by two or three students using the departmental words. Suppose Mr. A belongs to Dept.of Electrical and Electronics and he says his departmental word ‘ ampere ‘Mr. B has to supply a word beginning with the ending letter of Mr. A’s word. The word ampere ends with the letter ‘ e’ so

Mr. B says ‘ electrical ‘.Mr. A has to continue with the letter ‘ l ’. Like that five pairs of words are to be spoken.(Letter ending only, not sound ending. ) Suppose departmental words are not available in some English letters like ‘ x ‘ ‘ y ‘ ‘ z ‘ the students may be permitted to use common words.

ANTAKASHARI ( Five Exchanges ) (Dept. of Mechanical Engineering.)

EXAMPLE: Mr. A Mr. B 1. Governor Reservoir 2. Rack Kelvin 3. Nut Tool 4. Lathe Emission 5. Naphtha Anvil

Introducing oneself:

One is not expected to introduce one’s family. One or two sentences on his family will do. Care must be taken to include general proficiency, titles and merits, awards possessing or secured in academic activities like paper presentation, participation in inter polytechnic or intra polytechnic competitions, sports activity, forums like NCC,NSS, hobby, ambition, strengths and weaknesses.

Introducing others – merits – credentials—one or two points on his family. Vote of thanks / Welcome address.No doubt it should be all-covering but Focus should be on the important persons/invitees/chief guest and the message of the speaker. Description (pictures from English weekly/daily) Pictures may be displayed through projector or Magazine cuttings may be used. Just five lines on the picture will do. Auditory/oral comprehension: A Passage from any English daily of the week of the examination is to be read out for two to three minutes in the end examination. Display of recorded passages can be used as an addition in the class room. The use of pre-recorded passage discouraged in the end examination. Oral presentation: Students must be encouraged to use English magazines and internet for collecting information on the topic, noting keywords and use them in their presentation in his own language. One must be able to talk extempore for 2 min on any topic, given a time of two minutes for organizing his/her thoughts. The topics can be kept simple and general (current events of interest like sporting event for headline of the day). It must be totally an oral activity without the aid of any other media. News Caption: A news item ,without heading,of not more than ten lines from an English daily of the week of the conduct of Examination is to be given. The caption may be a passive construction or a catchy phrase on the given news item.



Face to face dialogue: Selective nine situations / topics are to be performed in the class room. (Minimum seven exchanges with courteous openings and closings). Telephonic dialogue: Selective seven situations to be given. (Minimum seven exchanges). Resume writing: cover letter—the components of a resume like sender’s address, recipient’s address, career objective to be explained. Group Discussion: Topics of common interest, avoiding controversial ones, are to be given for discussion. A group may consist of six members. Students should be exposed to 44 phonemes (sounds) in English language and their symbols. There shall be no question on this end examination.

LIST OF EXERCISES:-

MONODIC COMMUNICATION AND DYADIC COMMUNICATION

1. Departmental Vocabulary alphabetically (using it in sentence, antakshari).Using the words orally in sentences

2. Introducing oneself and others 3. Vote of thanks / Welcome address 4. Description (pictures from English weekly/daily) 5. Auditory/oral comprehension 6. Oral presentation 7. Face to face dialogue 8. Telephonic dialogue

PROFESSIONAL SKILLS

9. Resume writing 10. Technical paper presentation 11. Group Discussion

Life Skills:

12. Preparing for and dealing with change. 13. Motivation, goal-setting and self-esteem. 14. Teamwork skills. 15. Time management 16. Emotional intelligence skills 17. Career planning. 18. Assertive Skills. 19. Interview skills.

Life skills are to be intensely inculcated through lectures, quotes, anecdotes and case studies. An excellent awareness of the eight essential life skills is to be created through continuous internal assessment. Five assignments in these topics are to be recorded in the record note book.

� A minimum of five assignments on five different topics. � Each assignment to be assessed for fifteen marks. � The total marks to be reduced to an average of fifteen marks. � All the topics to be covered in the lab.

Scheme of Evaluation

Components Marks Maximum marks

Continuous Assessment 50 Professional Communication 20

Life Skills 15 Record 10

Attendance 5 End semester Exam 50

Monodic Communication 30 Dyadic Communication 20

Total 100



COMMUNICATION AND LIFE SKILLS PRACTICAL

Allocation & Statement of Marks End Examinations :

Duration:3Hrs. A. Monodic communication : 30 Marks

Use in sentence

(5 marks)

Vote of thanks / welcome address

(5 marks)

Auditory/Oral comprehension

(10 marks)

Description/ Oral

presentation (5 marks)

News caption

(5 marks)

Total

(30 marks)

B. Dyadic communication: 20 Marks

Antakshari (10 marks)

Dialogue (10 marks)

Total (20 marks)

Continuous Assessment:

C. Professional communication: 20 Marks

Group Discussion (10 marks)

Resume (10 marks)

Total (20 marks)

D. Life Skills: 15 Marks (Average mark of Five Exercises) E. Record : 10 Marks

F. Attendance: 5 Marks

FACE TO FACE DIALOGUE TOPICS

1. Between Friends (On any acceptable topic). 2. Between a conductor and a passenger. 3. Between a doctor and a patient. 4. Between a Shopkeeper and a Buyer. 5. Between a Teacher and a Student. 6. Between a tourist and a guide. 7. In a Bank. 8 At a railway enquiry counter. 9. Lodging a complaint. Note: A resourceful teacher may add a few more topics of common interest. TELEPHONIC DIALOGUE TOPICS

1. Placing an order. 2. Making Enquiries. 3. Fixing appointments 4. Making a hotel reservation. 5. Dealing with a wrong number. 6. Travel arrangements. 7. Handling complaints.

TELEPHONE LANGUAGE AND PHRASES IN ENGLISH

Answering the phone

" Good morning/afternoon/evening, Madras Enterprises, Premila speaking.” " Who's calling, please?” Introducing yourself

" This is Raghavan speaking.” " Hello, this is Raghavan from Speak International.”



Asking for someone

" Could I speak to Mr. Raman, please?” " I'd like to speak to Mr Raman, please.” " Could you put me through to Mr Raman, please?” " Could I speak to someone who …” Explaining

" I'm afraid Mr. Raman isn't in at the moment”. " I'm sorry, he's in a meeting at the moment.” " I'm afraid he's on another line at the moment.” Putting someone on hold

" Just a moment, please.” " Could you hold the line, please?” " Hold the line, please.” Problems

" I'm sorry, I don't understand. Could you repeat that, please?” " I'm sorry, I can't hear you very well. Could you speak up a little, please?” " I'm afraid you've got the wrong number.” " I've tried to get through several times but it's always engaged.” " Could you spell that, please?” Putting someone through

" One moment, please. I'll see if Mr Raman is available.” " I'll put you through.” " I'll connect you.” " I'm connecting you now”. Taking a message

" Can I take a message?” " Would you like to leave a message?” " Can I give him/her a message?” " I'll tell Mr. Raman that you called” " I'll ask him/her to call you as soon as possible.” " Could you please leave your number? I shall ask him to get back to you.” Pl.note: The above ones are samples only. A resourceful teacher may add more.

DAY-TO-DAY EXPRESSIONS ( For dialogues )

COMMON PARLANCE

How are you? Fine. Thank you. How are you? Me too. How do you do? How do you do? It’s good to see you again. Glad to meet you. Thank you. Thanks very much. Welcome. Hello! How is everything? Just fine. Thanks. What’s new? Nothing much. I’m pleased to meet you. The pleasure is mine. I’ve heard Paul speak about you often. Only good things! I hope. Look who’s here! Are you surprised to see me?



Sure. I thought you were in Chennai. I was, but I got back yesterday. Sorry, May I help you? So kind of you. That’s so nice of you. Nice talking to you. Nice meeting you. It’s getting late, and I’ve to go now. Certainly. Come back soon. In that case, I’ll be seeing you. Fine. Thank you. Welcome So long. See you later. Take care. Bye. Good-bye. Could you tell me the time, please? Certainly. It is 5.35 p.m. My watch says 5.40 p.m. Then your watch is five minutes fast. Excuse me. Can you tell me the way to …? May I come in? How is the weather today? It is pleasant. / sunny / rainy / warm /windy. I am sorry, Can you repeat what you have said. I am sorry, I can’t hear you properly. It is not audible. Can you please repeat it? Beg your pardon; I don’t get your words clearly. How do you feel now? Are you ok? I am fine. And how about you? I am fine. Thank you. GROUP DISCUSSION Let me begin with introducing this concept, Well, this is to convey that At the outset, I am here to convey At this juncture, I would like to May I intervene? May I add? Kindly permit me to say If you could allow me to say Let me add a few words Let me first answer your question Can you please allow me to convey Excuse me; I would like to add further On behalf of my colleagues, On their behalf Firstly/ secondly/ thirdly. Finally/ conclusively/ at the end / Summing up Eventually/ in the event of In spite of / otherwise/ although/ though

Please Note:

� The above ones are samples only. � A resourceful teacher may add more. � A potential student may exhibit variety.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : VI Subject Code & Name : MEL61 INDUSTRIAL ENGINEERING AND MANAGEMENT Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL61 Industrial Engineering and Management

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Plant Engineering and Plant safety 15

II Work study, Method study and Work measurement 15

III Production Planning and Control & Total Quality Management 15 IV Principles of Management and Personnel Management 15

V Financial Management and Material Management 15



• Explain the different types of layout and compare them. • Appreciate the safety aspects and its impacts on an organization.

• Compare different productivity improvement technique.

• Explain different work measurement techniques.

• Estimate standard time for a job.

• Explain production planning and control and its functions.

• Study the role of PPC as a tool for cost control. • Prepare process control charts.

• Explain the principles of management and function of management.

• Compare different organizational structure.

• Explain the selection and training of staff.

• Analyse inventory control system and the tools used in stock control.

• Explain the procurement and consumption cycle.



DETAILED SYLLABUS


I

PLANT ENGINEERING AND PLANT SAFETY

Plant Engineering: Plant – Selection of site of industry – Plant layout – Principles of good layout – types – process, product and fixed position – Cellular manufacturing- techniques to improve layout – Principles of material handling equipment – Plant maintenance – importance – Break down maintenance, preventive maintenance and scheduled maintenance.

Plant Safety: Importance – Incident / accident – cost and causes of accident – accident proneness – Planning for accident prevention – Safety laws and regulations – Hazardous work environment - Indian factories act 1948 and provision – Industrial disputes – settlement of industrial disputes.

15

II

WORK STUDY, METHOD STUDY AND WORK MEASUREMENT

Work Study: Productivity – Standard of living – method of improving productivity – Objectives – Importance of good working conditions. Method Study: Definition – Objectives – Selection of a job for method study – Basic procedure for conduct of method study – Tools used – Operation process chart, Flow process chart, two handed process chart, Man machine chart, String diagram and flow diagram- Introduction to Ergonomics. 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 – Techniques of work measurement

15

III

PRODUCTION PLANNING AND CONTROL & TOTAL QUALITY MANAGEMENT Production Planning and Control: Introduction – Major functions of production planning and control – Pre planning – Methods of fore casting – Routing and scheduling – Dispatching and controlling – Critical path method (CPM)/ PERT (Description Only). Production – types – Characteristics – Economic Batch Quantity (EBQ) – Principles of product and process planning – make or buy decision – problems- Lean Manufacturing. Total Quality Management: Quality – Definitions of quality – Dimensions of quality - Performance, features, reliability, conformance, durability, serviceability, aesthetics and perceived quality – Concepts of TQM, Deming wheel of continuous improvement – PDCA Cycle – Quality Circle (QC) – Definition – Objectives – Organisation and functioning of QC. QC Tools – Check sheet – histogram – Pareto diagram – Stratification – Cause and effect (ISHIKAWA diagram) – Scatter diagram – Control charts (X, R, p, c) – (Description only) – Six sigma – Inspection – Types of inspection – Inspection Vs Quality control – Operating Charecteristic curve (O.C curve) – Sampling inspection – Single and double sampling plan. Introduction to ISO 9000: 2000 Quality Management system and its objectives. 5S Concepts – SEIRI, SEITON, SEISO, SHIKETSU and SHITSUKE – needs and objectives. Total Productive Maintenance (TPM) – Definition and Objectives.

15

IV

PRINCIPLES OF MANAGEMENT AND PERSONNEL MANAGEMENT

Principles of Management: Definition of management – Administration – Organization – F. W. Taylor’s and Henry Fayol’s Principles of Management – Functions of Manager – Types of organization – Line, Staff, Taylor’s Pure functional types – Line and staff and committee type – Directing – Leadership – Styles of Leadership – Qualities of a good leader – Motivation – Positive and negative motivation. Personnel Management: Responsibility of human resource management – Selection procedure – Training of workers – Apprentice training – On the job

15



training and vestibule school training – Job evaluation and merit rating – objectives and importance – wages and salary administration – Components of wages – Wage fixation – Type of wage payment – Halsey’s 50% plan, Rowan’s plan and Emerson’s efficiency plan – Problems.

V

FINANCIAL MANAGEMENT AND MATERIAL MANAGEMENT

Financial Management: Fixed and working capital – Resources of capital – Shares preference and equity shares – debentures – Type of debentures – Public deposits, Factory costing – Direct cost – Indirect cost – Factory overhead – Selling price of a product – Profit – Problems. Depreciation – Causes – Methods – Straight line, Sinking fund and percentage on diminishing value method – Problems. Material Management: Objectives of good stock control system – ABC analysis of inventory – Procurement and consumption cycle – Economic order quality problems – Supply chain management – Introduction – Purchasing procedure – Store keeping – Bin card.

15

Text Books :

1. Khanna.O.P, “Industrial Engineering and Management”, Dhanpat Rai Publications (P) Ltd., New Delhi. 2. Banga.T.R & Sharma.S.C, “Engineering Economics and Management”, McGraw Hill, New Delhi.

Reference Books:

1. Heinz Weihrich,Harold Koontz, “Management, A global perspective”, McGraw Hill international edition.

2. Joseph L. Massie, “Essentials of Management”, Prentice-Hall of India, New Delhi.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : VI Subject Code & Name : MEL62 COMPUTER INTEGRATED MANUFACTURING Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL62 Computer Integrated Manufacturing

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Introduction CIM and computer aided design & analysis 15

II Computer aided manufacturing and rapid prototyping 15

III CNC machines and components 15 IV Part programming 15

V FMS, integrated material handling and robot 15


Total 80

OBJECTIVES:

• Understand the concept and requirement of the integration of the design and manufacturing.

• Acquire knowledge about the computer assistance in the design process and analysis. • Understand the concepts of manufacturing with computer assistance in the shop floor.

• Learn the concept of rapid proto typing • Learn the principle and working of the CNC machines.

• Understand the principle of latest manufacturing machines like EDM and RPT. • Learn the method of CNC programming with international codes.

• Learn the concept of group technology, FMS and CIM

• Acquire the knowledge in the material handling equipment.

• Learn the principles of AGV and robots.



DETAILED SYLLABUS


I

INTRODUCTION CIM AND COMPUTER AIDED DESIGN & ANALYSIS

CIM: Introduction of CIM – concept of CIM - evolution of CIM – CIM wheel – Benefits – integrated CAD/CAM. CAD: Computer Aided Design – Introduction – CAD definition – Shigley’s design process – CAD activities – benefits of CAD. Types of CAD system –Host and terminal based CAD system - PC based CAD system – workstation based CAD system – graphics workstation – CAD software packages. 2D&3D transformations – translation, scaling, rotation and concatenation. Geometric modeling: Techniques: Wire frame modeling – surface modeling – solid modeling: Boundary representation – Constructive Solid Geometry – Comparison. Graphics standard – Definition –Need - GKS – IGES – PHIGS – DXF. Cost involved in design changes – Concept of Design for Excellence (DFX) – Guide lines of Design for Manufacture and assembly (DFMA)-Design of Disassembly (Reverse Assembly) Finite Element Analysis: Introduction – Development - Basic steps – Advantage.

15

II

COMPUTER AIDED MANUFACTURING AND RAPID PROTOTYPING

CAM: Definition – functions of CAM – benefits of CAM – Group technology – Part families - Parts classification and coding - coding structure – Optiz system, MICLASS system and CODE System - process planning – CAPP – Types of CAPP : Variant type, Generative type – advantages of CAPP - production planning and control – computer integrated production management system – Master Production Schedule (MPS) – Capacity planning – Materials Requirement Planning –Manufacturing Resources Planning – Shop floor control system - Just in time manufacturing philosophy- Introduction to enterprises resources planning. Product Development Cycle – Sequential engineering – Concurrent engineering. Rapid proto typing: concept and applications – materials – types - Stereo lithography – laser sintering – Deposition Modeling - 3D printing.

15

III

CNC MACHINES AND COMPONENTS

CNC Machines: Numerical control – definition – components of NC systems – development of NC – DNC – Adaptive control systems – working principle of a CNC system – Features of CNC machines - advantage of CNC machines – difference between NC and CNC – Construction and working principle of turning centre – Construction and working principle of machining centers – machine axes conventions turning centre and machining centre – design considerations of NC machine tools. CNC EDM machine – Working principle of die sinking and wire EDM machines - Coordinate Measuring Machines: construction and working principles. Components of CNC machine.

Drives: spindle drive – dc motor – Feed drives – dc servo motor and stepper motor – hydraulic systems – Slide ways – requirement – types – friction slide ways and anti friction slide ways - linear motion bearings – recirculation ball screw – ATC – tool magazine – feedback devices – linear and rotary transducers – Encoders - in process probing.

15

IV

PART PROGRAMMING

PART PROGRAMMING: NC part programming – methods - manual programming – conversational programming – APT programming - Format: sequential and word address formats - sequence number – coordinate system – types of motion control: point-to-point, paraxial and contouring – Datum points: machine zero, work zero, tool zero NC dimensioning – reference points – tool material – tool inserts - tool offsets and compensation - NC dimensioning – preparatory functions and G codes, miscellaneous functions and M codes –interpolation: linear interpolation and circular interpolation - CNC program procedure.

15



Part Program – macro – sub-program – canned cycles: stock – mirror images – thread cutting – Sample programs for lathe : Linear and circular interpolation - Stock removal turning – Peck drilling – Thread cutting and Sample programs for milling: Linear and circular interpolation – mirroring – sub program – drilling cycle – pocketing – Generating CNC codes from CAD models – post processing. (Description only)

V

FLEXIBLE MANUFACTURING SYSTEMS (FMS), INTEGRATED MATERIAL HANDLING

AND ROBOT

Types of manufacturing - introduction to FMS – FMS components – FMS layouts – Types of FMS: flexible manufacturing cell – flexible turning cell – flexible transfer line – flexible machining systems – benefits of FMS - introduction to intelligent manufacturing system – virtual machining. Computer Integrated material handling – Automated Guided Vehicle (AGV): working principle – types - benefits – Automatic Storage and Retrieval Systems (ASRS). ROBOT – definition – robot configurations – basic robot motion – robot programming method – robotic sensors –Tactile and range sensors - industrial applications: characteristics, material transfer, machine loading, welding, spray coating, assembly and inspection.

15

Text Books :

1. Radhakrishnan.R, Subramanian.S & Raju.V, “CAD/CAM/CIM”, New Age International Pvt. Ltd., New Delhi.

2. Mikell P.Groover, Emory Zimmers Jr, “CAD/CAM”, Prantice Hall of India Pvt., Ltd., New Delhi. 3. Sinha.S.K, “NC Programming”, Galgotia Publications Pvt. Ltd.

Reference Books:

1. Dr.Rao.P.N, “CAD/CAM Principles and Applications”, Tata Mc Graw Hill Publishing Company Ltd. 2. Ibrahim Zeid, “Mastering CAD/CAM”, Tata McGraw-Hill Publishing Company Ltd., New Delhi. 3. Mikell P. Groover, “Automation, Production Systems, and Computer-Integrated Manufacturing”,

Prentice Hall India. 4. Yoram Koren, “Computer control of manufacturing systems”, McGraw Hill Book Co., New Delhi.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : VI Subject Code & Name : MEL63.1 ROBOTICS Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL63.1 Robotics

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Fundamentals of robot technology 15

II Robot controller, drive systems and end effecters 15

III Sensors and machine vision 15 IV Robot kinematics and robot programming 15

V Robot applications in manufacturing 15


Total 80

OBJECTIVES:

• Understand the anatomy and configuration of robots • Explain various components of robots

• Gain knowledge on different controllers used in robots

• Learn various drive systems and end effecters for robots

• Develop knowledge on principle and application of various sensors for robots

• Learn machine vision system for robots

• Explain the kinematics of robots • Acquire skill to program and control robot

• Understand to adopt robot to various industrial applications

• Aware economic and safety aspects of robots



DETAILED SYLLABUS


I

FUNDAMENTALS OF ROBOT TECHNOLOGY

Introduction – Definitions-Robot Anatomy – Basic configuration of Robotics – Robot Components – Manipulator, End effecter, Driving system, Controller and Sensors. Mechanical arm – Degrees of freedom – Links and joints – Types of joints – Joint notation scheme – Pitch, Yaw, Roll – Classification of robots – Work envelope, Work Volume – Structural Characteristics of Robotics – Effect of structure on Control, Work envelop and Work volume.

15

II

ROBOT CONTROLLER, DRIVE SYSTEMS AND END EFFECTERS

Robot controller – Four types of controls – Open loop and closed loop controls – Speed of response and stability – Precision of movements: Spatial resolutions, accuracy and repeatability. Pneumatic drives – Hydraulic drives – Mechanical drives – Electrical drives – Stepper motors, DC Servo motors and AC Servo motors – Salient features – Applications and Comparisons of Drives.

End effecters – Grippers – Mechanical Grippers, Magnetic Grippers, Vacuum Grippers, Two fingered and Three fingered Grippers, Internal and External Grippers – End Of Arm Tooling (EOAT)- Selection and Design considerations.

15

III

SENSORS AND MACHINE VISION

Requirements of Sensors – Principles and applications of the following types of sensors – Position sensors: Piezo-electric sensors, LVDT, Resolvers, Optical encoders and Pneumatic position sensors – Range sensors – Proximity sensors: Inductive, Capacitive, Ultrasonic and Optical proximity sensors – Touch sensors: Binary sensors, Analog sensors – Wrist sensors – Slip sensors. Machine vision system – Camera – Frame grabber – Sensing and digitizing image data – Signal conversion – Image storage – Lighting techniques – Image processing and analysis – Data reduction: Edge detection, Feature extraction and object recognition – Applications – Inspection, Identification, Visual serving and navigation.

15

IV

ROBOT KINEMATICS AND ROBOT PROGRAMMING

Forward kinematics, Inverse kinematics and differences – Forward kinematics and Reverse kinematics of manipulators with Two, Three and Four degrees of freedom – Deviations. Robot programming – Teach pendant programming – Lead through programming – Robot programming languages – VAL Programming – Motion commands, Sensor commands, End effecter commands and Simple programs.

15

V

ROBOT APPLICATIONS IN MANUFACTURING

Robot applications – Material handling – Press loading and unloading – Die casting – Machine tool loading and unloading – Spot welding – Arc welding – Spray painting – Assembling – Finishing – Automatic Guided Vehicle – Adopting robots to workstations – Requisite robot characteristics and Non requisite robot characteristics – Stages in selecting robots for industrial applications – Safety considerations for robot operations – Robotics in the future – Economical analysis of robots – Social implications.

15



Text Books:

1. Groover.M.P, “Industrial Robotics – Technology, Programming and Applications”, MC Graw Hill. 2. Yoram Koren, “Robotics for Engineers”, McGraw-Hill Book Co.,

Reference Books:

1. Fu.K.S.Gonzalz.R.C., and Lee C.S.G, “Robotics Control, Sensing, Vision and Intelligence”, McGraw-Hill Book Co.,

2. Janakiraman.P.A, “Robotics and Image Processing”, Tata McGraw-Hill. 3. Doughales – R. Halconnjr, “An Introduction to Robotics”



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : VI Subject Code & Name : MEL63.2 PRESS TOOLS Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL63.2 Press Tools

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Press working fundamentals, operations, and machinery 15

II Press & press tool accessories and types of die construction 15

III Bending and forming dies 15 IV Drawing dies and dies for secondary operations 15

V Fine blanking tool and specialized press tool applications 15


Total 80

OBJECTIVES:

• Explain the fundamentals of press working, to be familiar with the various press working operations and machines.

• Appreciate the safety practices in press working operations. • Explain with the various press and press tool accessories

• Compare the different types of Die construction. • Explain the various bending, forming and other miscellaneous press working operations.

• Demonstrate about the construction and operation of the different bending dies.

• Define the various drawing and other related processes

• Explain the construction and operating principle of drawing and combination dies.

• Explain the basic concepts and the advantages of fine blanking process

• Demonstrate the construction and working principle of various fine blanking dies. • Appreciate the concepts of SMED and quick die changes and its advantages in bringing down the

press set up time.

• Troubleshoot in various press tools.



DETAILED SYLLABUS


I

PRESS WORKING FUNDAMENTALS, OPERATIONS, AND MACHINERY :

Theory of cutting sheet metal:- Analysis of cutting, clearance, cutting terminology, stages of cutting, penetration, burr. Effects of clearance variation – Secondary shear, large clearance, clearance selection, typical force curves. Other cutting

characteristic – Dish distortion, spacing distortion, typical wear. Forces for cutting

sheet metal – Cutting with square faces, cutting with shear, shear on punch, slug bending force, shear on die steel, stripping force. Press working operations:- Operation for producing blanks – Shearing, cutting off, parting, blanking. Operation for cutting holes – Punching, piercing, slotting, perforating. Operations for progressive working – Notching, semi notching, lancing, parting, cutting off. Operations for size control – Trimming , slitting, shaving. Safety in press working. Press working mechanism:- Presses according to their functions – energy producing press, force producing presses, stroke controlled presses. Press

according to their energy supply – Mechanical, hydraulic, Pneumatic, electromagnetic presses. Presses according to their construction – Solid or gap frame, open back inclinable, knee frame, horning, open end or end wheel. Press

according to their operation – Single action, double action, triple action, multi slide press. Parts of press, Press operating parameters – Tonnage, shut height, stroke, shut height adjustment, strokes per minute, die space. Special purpose presses – Dieing press, spotting press, press brake, gang punching press, automatic press, transfer press, multi slide machine

15

II

PRESS & PRESS TOOL ACCESSORIES AND TYPES OF DIE CONSTRUCTION

Press & Press tool Accessories : Mechanical handling devices:- Feeding and reeling mechanisms for coiled sheet metal – Reels and cradles ( decoiler) , roll feeds and its types, hitch feeds. Feeding mechanism for individual parts – Hopper feeds, dial feeds, chutes, slides, magazine feeds, step feeds, special feeds. Ejection mechanism – Gravity, air, kicker, lifter, shovel, mechanical hand, ejection by next part. Transfer mechanisms – Conveyors, shuttle, turnover, turnaround, stacker, rails. Types of die construction

Types of die construction:- Cut off, drop through, return type, compound, combination, continental, sub press, follow die, progressive die, transfer die, shuttle die. Function and nomenclature of die components:- Die, die set, die plate, punch, stripper plate, Die spring, rubber keeper, stripper bolt, solid stripper, knockout plate, hold down plate, pad plate, blank holder, pressure pin, die cushion. Attachment components – Dowel, screw, key. Miscellaneous components – Heal, stop block, bolster plate, backing plate, pilot, gauges, insert, cams, hinges and rockers. Commercially available die components – Die sets, die set attachment devices, punches, die buttons, retainers, springs, fluid springs, die cushion and its types.

15

III

BENDING AND FORMING DIES:-

Bending of sheet metal – Bending theory, neutral axis, metal movement, spring back, methods of overcoming spring back. Bending Operations – Bending, flanging, hemming, curling, seaming, corrugating. Types of Bending dies ( construction and

working principle) – V bending and its types, edge bending, u bending. Bending operations done using press brake. Forming operations – Embossing, bulging, crimping, tube forming. Forming dies – Construction and working principle of solid form dies, pad form dies, curling dies, embossing dies, coining dies, swaging dies, bulging dies.

15



Assembly dies - Riveting, tab stake, upset stake, crimping. Miscellaneous press working operations – slugging, restrike or spank, extrude (holes), coining, hot trimming, cold trimming of die castings and plastic mouldings, riveting, burnishing or sizing, Ironing.

IV

DRAWING DIES AND DIES FOR SECONDARY OPERATIONS

Drawing operations – Shallow drawing, deep drawing. Analysis of cup drawing:-

Stages of drawing - Bending, straightening, friction, compression , tension, stretch forming. Variables of drawing - Bending and straightening variables, friction variables, compression variables, stretch forming variables, analysis of draw speed. Draw dies &its construction and working principle – Conventional draw die, redrawing die, reverse re drawing die, drawing of square or rectangular shapes. Drawing with flexible tooling – Marform process, Hydro form process, Hydro dynamic process, Verson- wheelon process. Draw die details – Blank holders blank holding pressure and its importance, air vents, drawing inserts, draw beads. Drawing defects, causes and remedies.

Dies for secondary operations: - Construction and working principle of – Semi piercing dies, shear form dies, dies for formed contours, notching die, shaving die, side piercing die.

15

V

FINE BLANKING TOOL AND SPECIALISED PRESS TOOL APPLICATIONS

Fine blanking:- Definition and Applications of fine blanking, Working principle of fine blanking tool, V Ring – function of V ring, Dimensions of V ring. Comparison of fine blanking with blanking. Strip width and margin calculations, Calculation of press, Fixing minimum distance from die aperture. Factors affecting Tool life. Importance of punch and die radius. Materials suitable for fine blanking, work hardening during fine blanking, steel, copper and copper alloys, aluminum and aluminum alloys. Fine Blanking Machines:- Working principle – Ram movement, Drive systems-Mechanical drives, hydraulic drives, Machine force, Ring indenter force, counter force. Fine blanking tools:- Different types of tools – Compound die tooling system with sliding punch, compound die tooling with fixed punch. Clearance calculation – Importance of clearance. Specialized Press Tool Applications:- Construction, advantage and applications of advanced multistage tooling, unit tooling, angular piercing tools, CNC turret press. Principle or Quick Die Change (QDC) – need and advantages. Single Minute Exchange of Dies (SMED) – concept need and advantages. Factors Affecting Tool Service Life:- Introduction, Elements of Tool performance, Procedure for investigation of tool failure, Trouble shooting in press tools, effect of heat treatment on service life of tools.

15

Text Books:

1. Donald F. Eary. & Edward A. Reed, “Techniques of Press working sheet metal”, Prentice-Hall,Inc., 2. Donaldson, “Tool Design”, Tata McGraw-hill Book Company. 3. Eugene ostergaard.D, “Advanced die making”, McGraw-Hill Book Company.

Reference Books:

1. Dr.John G.Nee, “Fundamentals of Tool Design”, Society of Manufacturing Engineers. 2. ASTME, "Tool Engineers Hand Book", McGraw-hill Book Company. . 3. Paquin.J.R, “Die design fundamentals”, Industrial Press Inc,. 4. Eugene ostergaard.D, “Basic die making”, McGraw-hill Book company,. 5. Ivana Suchy, “Hand book of Die Design”, McGraw-Hill Book company. 6. American Society of Metals – Hand book – Volume 4 ( Forming)



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : VI Subject Code & Name : MEL63.3 PROTO-TYPING IN PRODUCT DESIGN Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL63.3 Proto-Typing In Product Design

Hours/ Week

Hours/ Semester


5 80


End Semester

Examination Total

3

25 75 100



I Digital proto typing for product design 15

II Assembly structure and design documentation 15

III Principle of rapid prototyping and liquid based RP systems 15 IV Solid based RP system and powder based RP system 15

V Rapid tooling and reverse engineering 15


Total 80

OBJECTIVES:

• Understand the difference between a DP tools used in the industry.

• Understanding the user interface of the DP tool & three basic scenarios for sharing data among multiple teams.

• Advantages of 3D Modeling compared to 2D Modeling.

• Designing a part & assembly using the DP tool.

• Use the design Accelerator & dynamic simulation in the DP tool.

• Understanding the advantages of having the complete documentation and visualization.

• Explain the principles of rapid prototyping • Compare Solid based RP system, liquid based RP system and powder based RP System

• Explain Rapid tooling • Learn Reverse engineering process.



DETAILED SYLLABUS


I DIGITAL PROTO TYPING FOR PRODUCT DESIGN

Introduction To digital prototyping and PL.M identify the main stages in the design process cycle. The principles and importance of concurrent engineering. Three basics scenario for sharing data among multiple teams. How digital design software supports concurrent engineering. Ideation and conceptual design base introduction, benefits and use cases of ideation and conceptual design.

15

II

ASSEMBLEY SRUCTURE AND DESIGN DOCUMENTATION

Top Down and Bottom up design methods, manufacturing and engineering bill of materials (BOMs), Team and Collaborative based design, Assembly environment, constraints, standard components design for change in context, design documentation requirements, importance and benefits of design documentation. Design visualization throughout product development, benefits of design visualization.

15

III

PRINCIPLE OF RAPID PROTOTYPING AND LIQUID BASED RP SYSTEMS

PRINCIPLE OF RAPID PROTOTYPING History-solid freeform fabrication-commercial development-RP development-3D system’s stereo lithography process-3D system’s selective laser sintering-3D helisys laminated object manufacturing-stratasys fused deposition modeling-principles of rapid prototyping-creation of solid models-conversion to STL file-slicing-making or growing the prototyping-post processing.

LIQUID BASED RP SYSTEMS

Materials-photopolymer development-photopolymer chemistry classification-3D systems stereo lithography process-SLA system-advantages-merits-demerits-application. Solid creation system-d-MEC modeling- CMET solid object UV laser plotter-SOUP process-SOUP machines advantages-disadvantages.

15

IV

SOLID BASED RP SYSTEM AND POWDER BASED RP SYSTEM

SOLID BASED RP SYSTEM

Materials-polymer metal-composites stratasys fused deposition modeling systems helisys - Laminated object manufacturing systems-solidscapes 3D systems - Multijet modeling systems-principle-process-product-advantages- disadvantages for all the above 4 systems POWDER BASED RP SYSTEM

Materials-polymer-metal-ceramic-3D systems principle –process-protect-advantages-disadvantages for all the above 4 systems

15

V

RAPID TOOLING AND REVERSE ENGINEERING

RAPID TOOLING

Room temperature vulcanising silicone rubber mould-CAST aluminum and zinc Kirk site tooling-vacuum casting-plastic mould-investment cast tooling DIRECT METHOD :

Copper polyamide tooling-direct metal laser sintering-selective laser sintering rapid steel-laminated tooling-laser engineering net shaping-controlled metal buildup.

REVERSE ENGINEERING

Measuring device-contact type non contact type-CAD model constriction from point cloud-preprocessing, point clouds to surface model creation, medical data processing data handling and reduction method-uniform and non uniform grid method, three dimensional grid method-application

15



Reference Books:

1. Otto.K and Wood.K, “Product Design”, Pearson Education. 2. Ullman.D.G, “The Mechanical Design Process”, McGraw-Hill. 3. Pahl.G and Beitz.W, “Engineering Design”, Springer. 4. Shigley.E & Larry D. Mitchell, “Mechanical Engineering Design”, Joseph McGraw-Hill. 5. Bhandari.V.B, “Design of machine elements”, Tata Mcgraw Hill Pub. 6. Sybex, “Mastering Autodesk Inventor” 7. Autodesk Inventor 2012 for Designers by CADCIM Technologies.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : VI Subject Code & Name : MEL64.1 ROBOTICS PRACTICAL Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL64.1 Robotics Practical

Hours/ Week

Hours/ Semester


4 64


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Outline on fundamentals of robotics

• Acquire knowledge structure and elements of robot

• Write a Program for Pick and Place

• Write a Program for Pick and Stack

• Use SCORBASE and ARISTO Software

• Operate and control robot through Programming • Operate and control robot through teach Pendant

• Interpolate of Robot in various industries List of Experiments:

Part -A

1. Robot system connection and component recognition 2. Robot operation, moving the various axis continuous and intermittent motions. 3. Writing programs off-line

a. Homing operation b. Recording positions c. Writing programs for pick and place at least five programs

Write programs off-line with score base and Aristo Software

1. Use of loops and subroutines with program

2. Programs using XYZ Coordinates.

3. Teaching positions via XYZ co-ordinates

4. Measurement of Robot characteristics

5. Measurement of Robot work envelope

6. Measurement of Robot of motion

7. Measurement of Repeatability

8. Study of Vision system in Robot



Part -B

Write programs On-line with Nachi VS05G-01 Six Axis

1. Writing Program for Record Position

2. Writing Program for Pick and Stack

3. Writing Program for Pick and Place

4. Writing Program for moving the various Axis continuous and intermittent motion

5. Writing Program using XYZ Co-Ordinates

6. Writing Program for Measurement of Repeatability

7. Writing Program for Measurement of Robot motion

8. Writing Program using loops and Subroutines

Reference:

• Lab Manual, “MEL64.1 ROBOTICS PRACTICAL”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL64.1


No. Allocation Marks Part A 1 Writing the Part Program 20

2 Execution/Simulation in the software 20 Part B 3 Enter and editing the program in the Online 10

4 Execution 20 5 Viva-Voce 05

Total 75



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : VI Subject Code & Name : MEL64.2 PRESS TOOLS PRACTICAL Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL64.2 Press Tools Practical

Hours/ Week

Hours/ Semester


4 64


End Semester

Examination Total

16

25 75 100

OBJECTIVES:

• Design and fabricate blanking tool

• Design and fabricate compound tool

• Design and fabricate progressive tool

• Design and fabricate bending tool

• Design and fabricate drawing die

• Use different machine tool in fabricating press tools

DETAILED SYLLABUS

Ex.no Name of the exercise TIME (Hrs)

1 Design and Fabrication of Blanking Tool / Piercing Tool 12

2 Design and Fabrication of Compound Tool / Combination Tool 14 3 Design and Fabrication of Progressive Tool 14

4 Design and Fabrication of U Bending Tool / Edge Bending Tool 12

5 Design and Fabrication of Drawing die 12

Total 64

Note:-

1. Batch size should not be more than 5 students. 2. The examination duration is 16 Hours. 3. Students should be trained in Press Setting, Tool setting, shut height adjustment, trial production

using the tool fabricated by them and rectification of tool defects if any. 4. For end semester examination any one of the above tool is to be fabricated, fitted in the press and

trial production should be taken. The evaluation of the performance should be based on the component dimensions and finish obtained from the tool fabricated by the student during the 16 hours examination.

5. Allocation of marks for end semester examination. Design of Tool - 15 marks Tool making - 30 marks Tool finish - 10 marks Tool setting & trial production - 10 Marks Viva Voce - 10 Marks

Total - 75 Marks

Reference:

• Lab Manual, “MEL64.2 PRESS TOOLS PRACTICAL”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL64.2



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : VI Subject Code & Name : MEL64.3 PROTOTYPING IN PRODUCT DESIGN PRACTICAL



MEL64.3 Prototyping In Product Design Practical

Hours/ Week

Hours/ Semester


4 64


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Understand the difference between a DP tools used in the industry.

• Understanding the user interface of the DP tool & three basic scenarios for sharing data among multiple teams.

• Advantages of 3D Modeling compared to 2D Modeling. • Designing a part & assembly using the DP tool.

• Use the design Accelerator & dynamic simulation in the DP tool. • Understanding the advantages of having the complete documentation and visualization.

Exercise:

Introduction to DP Tool (15 hrs.)Getting to know the User Interface – Home Screen – Navigating the main Screen – Options Bar – Application Menu & Quick Access Toolbar – Describe the function of a sketch. Describe the various types of sketches. Create sketches of 3D models. Basic Modeling Considerations – Describe part creation within the design process. Add placed features to existing parts. Create complex shapes by sweeping or lofting profiles. Use IGES surfaces in the design process.

Introduction to DP tool (Designing the part)

1. Getting to know the User Interface

2. Work in sketching to define the form of the product

3. Work with constraint affecting design intend

4. Creating Complex forms for the product.

5. Work concurrently on an assembly project. Managing the Assemblies (15 hrs.)Managing the assemblies Assemble a mechanical piece of equipment using constraints. Use Alt-drag to apply assembly constraints. Create an adaptive part. Use the Content Library. Use Design Accelerator. Create and use iMates to constrain parts. Use motion and transitional constraints. Use the contact Solver. Use design view representations. Work with weldments. Managing the Assemblies

6. Working with different assembly constraints.

7. Working with different assembly design workflows

8. Design Accelerator & Design Validation tools.



9. Simulate direct and indirect motion on components in an assembly.

10. Working with welding assemblies ( weldmet )

Analyzing a Design, Design Accelerator & Dynamic Simulation (15 hrs.)Analyze an assembly using drive constraints. Check assemblies for collision between parts. Analyze an assembly for interference. Calculate the physical properties of a part. Analyze faces and then apply a suitable draft angle. Use the Bolted Connection Generator. Design a chain drive. Design a shaft. Dynamic Simulation to Improve product Design Add a joint. Convert an existing constraint. Insert a spring. Insert a revolution joint. Drive a camshaft. View simulation results. Analyzing a Design, Design Accelerator & Dynamic Simulation

11. Analyzing the assemblies for collision & interference. 12. Check the physical properties of product.

13. Create a set of fasteners for assemblies & perform the strength check.

14. Design the motor shaft & v-Belt chain drive.

15. Review the cam valve simulation.

Documents & Visualization (15 hrs.)Identify the basic stages of drawing creation. Describe the key characteristics of document management systems. Create a fully annotated orthographic sketch of a part. Describe the main parts of the Autodesk Inventor drawing environment. Describe drawing standards and why they are important. Create annotated views of a part. Creating a fully annotated set of drawing; create a presentation file. Create an assembly drawing. Add balloons to the assembly. Create a parts list. Create and review a DWF file. Render an assembly. Use existing lighting and scene styles. Create an animation file. Animate a camera.

Visualization , Documentation & other CAD Formats

16. Describe drawing Standards & Creating views (Base view, Projected view, Auxiliary, Section view, Detailed view )

17. Create presentation file

18. Detailing and Annotation ( Retrieving dimensions from the model )

19. Creating part list & Adding balloons to the assembly.

20. Create and review a DWF file for better visualization

Designing Cable and Harness Assemblies Cable, & Tube & Pipe Assemblies (10 hrs.) Create a harness assembly. Manually add wires. Import wires using a wire list. Create harness segments. Route wires through the segment. Create a new tube and pipe style. Insert a fitting from the Content Center. Insert a published fitting. Create a route. Create a run. Designing Cable and Harness Assemblies, & Tube & pipe Assemblies

21. Manually add the wires in the assembly & import wires using wire list. 22. Create harness segments & Routing wires through the segment.



23. Create a new tube and pipe style, Insert a fitting from the content Center.

24. Insert a published fitting. Create a route. Create a run.

Reference:

• Lab Manual, “MEL64.3 PROTOTYPING IN PRODUCT DESIGN PRACTICAL”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL64.3



1 2D Creation 10 2 3D Parts creation 20

3 3D Assembly 25 4 Simulation 15




Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : VI Subject Code & Name : MEL65 COMPUTER INTEGRATED MANUFACTURING PRACTICAL Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL65 Computer Integrated Manufacturing Practical

Hours/ Week

Hours/ Semester


6 96


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Study the working principle of CNC machines

• Study the datum points and offsets.

• Differentiate incremental System with absolute system

• Study the simulation software package.

• Write program and simulate in the Lathe software and Milling software.

• Prepare a part program, edit and execute in CNC Turning centre. • Prepare a part program, edit and execute in CNC Machining centre.

• Produce components in the CNC Turning centre and CNC Machining centre.

LIST OF EXERCISES:

Introductions (12Hours)

1. Study of CNC lathe, milling 2. Study of international standard G-Codes and M-Codes 3. Program writing – Turning simulator – Milling simulator, IS practice – commands – menus 4. Editing the program in the CNC machines. 5. Execute the program in the CNC machines.



PART A (Simulation) – 36 Hrs.

CNC Turning Simulation 1. Create a part program for step turning and simulate in the software - Using Linear interpolation.

1817

Ø30

Ø23

Ø15

6

2. Create a part program for taper turning and simulate in the software - Using Box turning cycle.

Ø23

Ø15

8126

Ø30

5 10



3. Create a part program for circular interpolation and simulate in the software - Using Circular interpolation.

86

Ø30

5

Ø23

Ø15

R8

22

R4

4. Create a part program for multiple turning operations and simulate in the software - Using Stock removal cycle.

R4

R8

Ø31

Ø24

14

R 3.5

10



5. Create a part program for thread cutting, grooving and simulate in the software - Using canned cycle.

5

5

6

Ø30

25

M15 X 1.5

6. Create a part program for internal drills, boring and simulate in the software.

Ø23

Ø33

Ø15

561210



CNC Milling Simulation

1. Create a part program for grooving and simulate in the software - Using Linear interpolation and Circular interpolation.

100

13

70

70

15

R15

R15

2. Create a part program for drilling and counter sinking and simulate in the software - Using canned cycle.

20

100

25

25

100

60

50

25



3. Create a part program for mirroring and simulate in the software - Using subprogram.

1418

100

100

14

18

4. Create a part program for rectangular and circular pocketing and simulate in the software - Using canned cycle.

100

30

10

10

100

30

Ø30



PART B (Machining) – 36 Hrs.

CNC Turning Machine Material: Aluminum or acrylic fibre rod or Plastic

1. Using Box turning cycle – Create a part program for step and taper turning and produce component in the Machine.

Ø23

Ø15

8126

Ø30

5 10

2. Using Circular interpolation - Create a part program for circular interpolation and produce component in the Machine.

86

Ø30

5

Ø23

Ø15

R8

22

R4



3. Using Stock removal cycle – Create a part program for multiple turning operations and produce component in the Machine.

R4

R8

Ø31

Ø24

14

R 3.5

10

4. Using canned cycle - Create a part program for thread cutting, grooving and produce component in the Machine.

5

5

6

Ø30

25

M15 X 1.5



CNC Milling Machine Material: Aluminum or acrylic fibre or plastic

1. Using Linear interpolation and Circular interpolation – Create a part program for grooving and produce component in the Machine.

100

13

70

70

15

R15

R15

2. Using canned cycle - Create a part program for drilling, counter sinking and produce component in the Machine

20

100

25

25

100

60

50

25



3. Using subprogram - Create a part program for mirroring and produce component in the Machine.

1418

100

100

14

18

Revision and Test 12 Hrs

Note:

• Examination should be conducted to produce the components in the Machine. The exercises should be given accordingly by the external examiner.

• Students should be allowed to the machine after simulation and with print out. Reference:

• Lab Manual, “MEL65 COMPUTER INTEGRATED MANUFACTURING PRACTICAL”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL65



PART –A 1 Writing the part program 20 2 Execution/ Simulation in the software 20

PART –B 3 Enter and editing the program in the machine

20

4 Component machining 10




Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : VI Subject Code & Name : MEL66 PROCESS AUTOMATION PRACTICAL Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL66 Process Automation Practical

Hours/ Week

Hours/ Semester


4 64


End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Use PLC system and its elements for process control

• Write ladder logic for logic controls such as AND,OR

• Familiarize the working of function blocks in PLC

• Use ON-Delay timer to control a motor

• Use OFF-Delay timer to control a motor

• Use counter function block (Up counter and Down counter) • Control the automatic operation of pneumatic cylinder using PLC

• Control sequential operation of pneumatic cylinders using PLC

LIST OF EXERCISES:

1. Study of PLC system and its elements

Control a Process Using PLC

1. Direct operation of a motor using latching circuit. 2. Operation of a motor using ‘AND’ logic control. 3. Operation of a motor using ‘OR’ ‘control. 4. On-Delay control of a motor. 5. Off –Delay control of a motor. 6. Automatic operation of a Double acting cylinder-single cycle. 7. Automatic operation of a Double acting cylinder-single cycle - forward, time delay, return. 8. Automatic operation of Double acting cylinder-Multi cycle. 9. Automatic operation of Double acting cylinder-N cycles (using counter function block) 10. Sequential operation of a Double Acting Cylinder and a motor. 11. Sequential operation of two Double Acting Cylinders for the sequence A+, B+, B-, A-.

Reference:

• Lab Manual, “MEL66 PROCESS AUTOMATION PRACTICAL”, Murugappa Polytechnic College, M.P.C.D.07.09.MEL66





1 Logic Circuit Diagram 30

2 Entry and Edit of Logic circuit 30 3 Execution of circuit 10


NOTE: All the exercises should be given (except the study exercise) and students are allowed to select an exercise by a lot.



Course Name : DIPLOMA IN MECHANICAL ENGINEERING Semester : VI Subject Code & Name : MEL67 PROJECT WORK Teaching and Scheme of Examinations: No. of Weeks per Semester: 16


MEL67 Project Work

Hours/ Week

Hours/ Semester


6 96 Continuous Assessment

End Semester

Examination Total

3

25 75 100

OBJECTIVES:

• Implement the theoretical and practical knowledge gained through the curriculum into an application suitable for a real practical working environment preferably in an industrial environment

• Get exposure on industrial environment and its work ethics.

• Understand what entrepreneurship is and how to become an entrepreneur. • Learn and understand the gap between the technological knowledge acquired through curriculum

and the actual industrial need and to compensate it by acquiring additional knowledge as required.

• Carry out cooperative learning through synchronous guided discussions within the class in key dates, asynchronous document sharing and discussions, as well as to prepare collaborative edition of the final project report.

• Understand the facts and importance of environmental management.

• Understand and gain knowledge about disaster management

CONTINUOUS ASSESSMENT:

The Continuous assessment should be calculated based on the review of the progress of the work done by the student periodically as follows.

Detail of assessment Period of assessment Max. Marks

First Review 6th week 10

Second Review 14th week 10

Attendance Entire semester 5

Total 25



EVALUATION FOR END EXAMINATION:

DETAILED SYLLABUS

ENTREPRENEURSHIP, ENVIRONMENTAL & DISASTER MANAGEMENT

1. ENTREPRENEURSHIP

1.1 Introduction – Entrepreneur - characteristics of Entrepreneur - contributions of an Entrepreneur -

functions of entrepreneur - Barriers to entrepreneurship - Roll of government in Entrepreneurial

development.

1.2 Small scale industries (SSI) - SSI role in country’s economic growth – importance of SSI -starting of

an SSI - Government organization and Non-governmental organizations supporting SSI -

DIC,NSIC,SIDO,KVIC, Development banks and their objectives - role of commercial banks in

assisting SSI - Women entrepreneurs and opportunities – Subsidy and concessions to Small Scale

Industries.

2. ENVIRONMENTAL MANAGEMENT

2.1 Introduction – Environmental Ethics – Assessment of Socio Economic Impact – Environmental

Audit – Mitigation of adverse impact on Environment – Importance of Pollution Control – Types

of Industries and Industrial Pollution.

2.2 Solid waste management – Characteristics of Industrial wastes – Methods of Collection, transfer

and disposal of solid wastes – Converting waste to energy – Hazardous waste management

Treatment technologies.

2.3 Waste water management – Characteristics of Industrial effluents – Treatment and disposal

methods – Pollution of water sources and effects on human health.

2.4 Air pollution management – Sources and effects – Dispersion of air pollutants – Air pollution

control methods – Air quality management.

2.5 Noise pollution management – Effects of noise on people – Noise control methods.

3. DISASTER MANAGEMENT

3.1 Introduction – Disasters due to natural calamities such as Earthquake, Rain, Flood, Hurricane,

Cyclones etc – Man made Disasters – Crisis due to fires, accidents, strikes etc – Loss of property

and life.

3.2 Disaster Mitigation measures – Causes for major disasters – Risk Identification – Hazard Zones –

Selection of sites for Industries and residential buildings – Minimum distances from Sea –

Details of Mark allocation Max Marks

Viva Voce … 15 marks Project Report … 10 marks Demonstration … 15 marks Applicability of the Project … 05 marks

45

Written Test in 3 topics for 1 hour:

a) Entrepreneurship 5 questions X 2 marks = 10 marks

b) Environment Management 5 questions X 2 marks = 10 marks

c) Disaster Management 5 questions X 2 marks = 10 marks Selection of Questions from Question Bank by the Examiner, no choice need be given to the candidates.

30

Total 75



Orientation of Buildings – Stability of Structures – Fire escapes in buildings - Cyclone shelters –

Warning systems.

3.3 Disaster Management – Preparedness, Response, Recovery – Arrangements to be made in the

industries / factories and buildings – Mobilization of Emergency Services - Search and Rescue

operations – First Aids – Transportation of affected people – Hospital facilities – Fire fighting

arrangements – Communication systems – Restoration of Power supply – Getting assistance of

neighbors / Other organizations in Recovery and Rebuilding works – Financial commitments –

Compensations to be paid – Insurances – Rehabilitation.

LIST OF QUESTIONS

1. ENTREPRENEURSHIP

1. What is entrepreneurship? Explain.

2. Who is a successful entrepreneur? Why?

3. List the various stages of decisions an entrepreneur has to make before reaching the goal of his

project.

4. List the types of industries.

5. Define small scale industry.

6. What are the qualities of an Entrepreneur?

7. What are the expectations of Entrepreneurship?

8. What are the various SSI that can flourish in your district?

9. Identify the infrastructural needs for an industry.

10. Identify the natural resources available in your area for starting a SSI.

11. What are the various agencies involved in the establishment and development of various SSI?

12. What are the roles of District Industries Centre?

13. Name some of the agencies funding SSI.

14. What are the various concessions and incentives available for a SSI?

15. List the points to be considered with relations to building, water and electricity before a SSI is started.

16. List the points to be considered with relation to human resource before a SSI is started.

17. Name some consumer products with wide demand that can be manufactured by a SSI.

18. Identify the non-qualified industries that may not be given financial assistance and concessions.

19. What is feasibility study?

20. What is the importance of SSI?

21. List some industries identified as pollution free industries.

22. List some industries identified as industries with pollution problem.

23. What is an industrial zone?

24. What is an industrial estate?

25. What are the facilities available in an industrial estate?

26. Identify the various training agencies associated with SSI.

27. What is applied technology?

28. From whom you shall get applied technology for starting a SSI?

29. From where you shall get repairing and testing facilities?

30. What are the various training agencies available for acquiring SSI training?



31. List the governmental agencies from whom you shall get financial assistance for a SSI.

32. What are the steps involved in preparing a feasibility report?

33. What are the factors to be considered regarding raw materials for a SSI?

34. Name some SSI that may not need raw materials.

35. Differentiate various classifications of industries.

36. What is a LSI?

37. What are the features of a SSI?

38. Name some products that may not need electricity for production.

39. What are the factors to be considered for starting a SSI?

40. What are the advantages of becoming an entrepreneur?

41. If you opt to be an entrepreneur what are the steps you would take to become a successful

entrepreneur?

42. What are the facilities available for a new SSI in an industrial estate?

43. List the various government departments that would be associated with a SSI.

44. Why do entrepreneurs fail?

45. What are the types of entrepreneurs?

2. ENVIRONMENTRAL MANAGEMENT

1. What is the responsibility of an Engineer-in-charge of an Industry with respect to Public Health?

2. Define Environmental Ethic.

3. How Industries play their role in polluting the environment?

4. What is the necessity of pollution control? What are all the different organizations you know, which

deal with pollution control?

5. List out the different types of pollutions caused by a Chemical / Textile / Leather / Automobile /

Cement factory.

6. What is meant by Hazardous waste?

7. Define Industrial waste management.

8. Differentiate between garbage, rubbish, refuse and trash based on their composition and source.

9. Explain briefly how the quantity of solid waste generated in an industry could be reduced.

10. What are the objectives of treatments of solid wastes before disposal?

11. What are the different methods of disposal of solid wastes?

12. Explain how the principle of recycling could be applied in the process of waste minimization.

13. Define the term ‘Environmental Waste Audit’.

14. List and discuss the factors pertinent to the selection of landfill site.

15. Explain the purpose of daily cover in a sanitary landfill and state the minimum desirable depth of daily

cover.

16. Describe any two methods of converting waste into energy.

17. What actions, a local body such as a municipality could take when the agency appointed for collecting

and disposing the solid wastes fails to do the work continuously for number of days?

18. Write a note on Characteristics of hazardous waste.

19. What is the difference between municipal and industrial effluent?



20. List few of the undesirable parameters / pollutants anticipated in the effluents from oil refinery

industry / thermal power plants / textile industries / woolen mills / dye industries / electroplating

industries / cement plants / leather industries (any two may be asked)

21. Explain briefly the process of Equalization and Neutralization of waste water of varying characteristics

discharged from an Industry.

22. Explain briefly the Physical treatments “Sedimentation” and “Floatation” processes in the waste

water treatment.

23. Explain briefly when and how chemical / biological treatments are given to the waste water.

24. List the four common advanced waste water treatment processes and the pollutants they remove.

25. Describe refractory organics and the method used to remove them from the effluent.

26. Explain biological nitrification and de-nitrification.

27. Describe the basic approaches to land treatment of Industrial Effluent.

28. Describe the locations for the ultimate disposal of sludge and the treatment steps needed prior to

ultimate disposal.

29. List any five Industries, which act as the major sources for Hazardous Air Pollutants.

30. List out the names of any three hazardous air pollutants and their effects on human health.

31. Explain the influence of moisture, temperature and sunlight on the severity of air pollution effects on

materials.

32. Differentiate between acute and chronic health effects from Air pollution.

33. Define the term Acid rain and explain how it occurs.

34. Discuss briefly the causes for global warming and its consequences

35. Suggest suitable Air pollution control devices for a few pollutants and sources.

36. Explain how evaporative emissions and exhaust emissions are commonly controlled.

37. What are the harmful elements present in the automobile smokes? How their presence could be

controlled?

38. What is the Advantage of Ozone layer in the atmosphere? State few reasons for its destruction.

39. Explain the mechanism by which hearing damage occurs.

40. List any five effects of noise other than hearing damage.

41. Explain why impulsive noise is more dangerous than steady state noise.

42. Explain briefly the Source – Path – Receiver concept of Noise control.

43. Where silencers or mufflers are used? Explain how they reduce the noise.

44. Describe two techniques to protect the receiver from hearing loss when design / redress for noise

control fail.

45. What are the problems faced by the people residing along the side of a railway track and near to an

Airport? What provisions could be made in their houses to reduce the problem?

3. DISASTER MANAGEMENT

1. What is meant by Disaster Management? What are the different stages of Disaster management?

2. Differentiate Natural Disasters and Man made Disasters with examples.

3. Describe the necessity of Risk identification and Assessment Surveys while planning a project.

4. What is Disasters recovery and what does it mean to an Industry?



5. What are the factors to be considered while planning the rebuilding works after a major disaster due

to flood / cyclone / earthquake? (Any one may be asked)

6. List out the public emergency services available in the state, which could be approached for help

during a natural disaster.

7. Specify the role played by an Engineer in the process of Disaster management.

8. What is the cause for Earthquakes? How they are measured? Which parts of India are more

vulnerable for frequent earthquakes?

9. What was the cause for the Tsunami 2004 which inflicted heavy loss to life and property along the

coast of Tamilnadu? Specify its epicenter and magnitude.

10. Specify the Earthquake Hazard Zones in which the following towns of Tamilnadu lie: (a) Chennai

(b) Nagapattinam (c) Coimbatore (d) Madurai (e) Salem.

11. Which parts of India are experiencing frequent natural calamities such as (a) heavy rain fall (b) huge

losses due to floods (c) severe cyclones

12. Define basic wind speed. What will be the peak wind speed in (a) Very high damage risk zone – A, (b)

High damage risk zone, (c) Low damage risk zone?

13. Specify the minimum distance from the Sea shore and minimum height above the mean sea level,

desirable for the location of buildings.

14. Explain how the topography of the site plays a role in the disasters caused by floods and cyclones.

15. Explain how the shape and orientation of buildings could reduce the damages due to cyclones.

16. What is a cyclone shelter? When and where it is provided? What are its requirements?

17. What Precautionary measures have to be taken by the authorities before opening a dam for

discharging the excess water into a canal/river?

18. What are the causes for fire accidents? Specify the remedial measures to be taken in buildings to

avoid fire accidents.

19. What is a fire escape in multistoried buildings? What are its requirements?

20. How the imamates of a multistory building are to be evacuated in the event of a fire/Chemical

spill/Toxic Air Situation/ Terrorist attack, (any one may be asked).

21. Describe different fire fighting arrangements to be provided in an Industry.

22. Explain the necessity of disaster warning systems in Industries.

23. Explain how rescue operations have to be carried out in the case of collapse of buildings due to

earthquake / blast / Cyclone / flood.

24. What are the necessary steps to be taken to avoid dangerous epidemics after a flood disaster?

25. What relief works that have to be carried out to save the lives of workers when the factory area is

suddenly affected by a dangerous gas leak / sudden flooding?

26. What are the difficulties faced by an Industry when there is a sudden power failure? How such a

situation could be managed?

27. What are the difficulties faced by the Management when there is a group clash between the

workers? How such a situation could be managed?

28. What will be the problems faced by the management of an Industry when a worker dies because of

the failure of a mechanical device due to poor maintenance? How to manage such a situation?

29. What precautionary measures have to be taken to avoid accidents to labourers in the Industry in a

workshop / during handling of dangerous Chemicals / during construction of buildings / during the

building maintenance works.

30. Explain the necessity of medical care facilities in an Industry / Project site.



31. Explain the necessity of proper training to the employees of Industries dealing with hazardous

products, to act during disasters.

32. What type of disaster is expected in coal mines, cotton mills, Oil refineries, ship yards and gas plants?

33. What is meant by Emergency Plan Rehearsal? What are the advantages of such Rehearsals?

34. What action you will take when your employees could not reach the factory site because of

continuous strike by Public Transport workers?

35. What immediate actions you will initiate when the quarters of your factory workers are suddenly

flooded due to the breach in a nearly lake / dam, during heavy rain?

36. What steps you will take to avoid a break down when the workers union of your Industry have given a

strike notice?

37. List out few possible crisis in an organization caused by its workers? What could be the part of the

middle level officials in managing such crisis?

38. What types of warning systems are available to alert the people in the case of predicted disasters,

such as floods, cyclone etc.

39. Explain the necessity of Team work in the crisis management in an Industry / Local body.

40. What factors are to be considered while fixing compensation to the workers in the case of severe

accidents causing disability / death to them?

41. Explain the legal / financial problems the management has to face if safely measures taken by them

are found to be in adequate.

42. Describe the importance of insurance to men and machinery of an Industry dealing with dangerous

jobs.

43. What precautions have to be taken while storing explosives in a match/ fire crackers factory?

44. What are the arrangements required for emergency rescue works in the case of Atomic Power

Plants?

45. Why residential quarters are not constructed nearer to Atomic Power Plants?



MEL74 INDUSTRIAL TRAINING – II

The students are expected to gain a working experience in various departments of an industry / organisation and hence learning the industrial management in a practical way. The students have to undergo a six months industrial training (PHASE II) during the VII semester in a related industry / organisation. During the training period the students are maintaining an Industrial diary to record their observation and learning. On completion of training, a training report should be submitted to the Head of the Department. Industrial training of Sandwich students will be evaluated based on Continuous Assessment of two periodical reviews and an End semester Examination on Assessment of Training Report and viva-voce.

SANDWICH DIPLOMA COURSE - INDUSTRIAL TRAINING

1. Introduction

The main objective of the Sandwich Diploma Course is to mould a well rounded technician acclimated with industrial environment while being a student in the institution. The Sandwich Diploma Course study is pursued by students, in 7 semesters of 3½ years duration, the subjects of 3 years - Full Time Diploma Course being regrouped for academic convenience. While in the 4th semester students undergo Industrial Training-I for 6 months (December through May). They also do course work in the institution for one day in a week, while in the 7th semester they undergo another spell of 6 months (June through November) Industrial training-II. The Apprenticeship (Amendment) Act 1973 is followed in regulating the Industrial training procedure for Sandwich Course.

I SEM II SEM III SEM IV SEM V SEM VI SEM VII SEM

First Spell - IV Semester (December - May) Second Spell - VII Semester (June - November) 2. Attendance Certification

Every month students have to get their attendance certified by industrial supervisor in the prescribed form. Students have also to put their signature on the form and submit it to the institutional staff in-charge. Attendance and submission of Review reports will be duly considered while awarding the Continuous Assessment mark. 3. Training Reports

The students have to prepare two types of reports:

• Weekly report in the form of diary to be submitted to the concerned staff in-charge of the institution. This will be reviewed while awarding Continuous Assessment mark.

• Comprehensive report at the end of each phase of Industrial Training will be reviewed while awarding End semester Examination marks.

3.1 Industrial Training Diary

Students are required to maintain the record of day - today work done. Such record is called Industrial training Diary. Students have to write this report regularly. All days of the week should be accounted for clearly giving attendance particulars (Presence, Absence, Leave, Holiday etc). The concerned Industrial supervisor is to check periodically these progress reports.

Institutional study

Industrial Training



3.2 Comprehensive Training Report

In addition to the diary, students are required to submit a comprehensive report on training with details of the organisation where the training was undergone after attestation by the supervisors. The comprehensive report should be incorporating study of plant/ product /process/ construction along with intensive in-depth study on any one of the topics such as processes , methods, tooling, construction and equipment, highlighting aspects of quality, productivity and system. The comprehensive report should be completed in the last week of Industrial training. Any data, drawings etc should be incorporated with the consent of the Organisation. 4. Scheme of Evaluation

Components SCHEME OF EVALUATION


Continuous Assessment Mark

1 First review 20 2 Second review 20

3 Attendance 10 End Examination 4 Comprehensive Training Report 20


* * *


QUESTION PAPER PATTERN : END EXAMINATION

• Each subject syllabus contains FIVE units

• DURATION 3 HOURS

• MAXIMUM MARKS: 100

PART – A (1 x 10 = 10 Marks)

• Answer all the questions (10 QUESTIONS : TWO Questions from each unit)

PART – B (2 x 4 x 5 = 40 Marks)

• Answer any TWO Questions out of three questions from each Unit. Each Question carries 4

Marks.

PART – C (10 x 5 = 50 Marks)

• Answer any ONE Question out of Two questions from each unit. Each Question carries 10 Marks

• Each 10 Marks Question options are

(i) One full question of 10 marks

(ii) Two sub divisions a) 6 / 5 / 4

b) 4 / 5 /6


Sathyamurthy Nagar, Chennai – 600 062

MEL43 RENEWABLE ENERGY SOURCES

MODEL QUESTION PAPER

Time: 3 Hrs Max. Marks: 100

Note: 1. Answer ALL the questions in PART-A (1 Mark each)

2. Answer any TWO questions from each Unit in PART-B (4 Marks each)

3. Answer any ONE question from each unit in PART-C (10 Marks each)

4. The question paper contains TWO pages.

PART – A

(1 X 10 = 10)

1. Write any two nuclear energy fuels.

2. Define the term “Green Power”.

3. Write any two commonly used absorbent-refrigerant combinations used in solar refrigeration.

4. What are the types of solar cells?

5. List the wind data’s commonly recorded.

6. What is the use of “Dump Load” in wind energy generating system?

7. Define “Photosynthesis”.

8. Write the reaction taking place during “Transesterification” process during Bio-Diesel production.

9. What are the types of tides?

10. What are the types of hydrothermal convective systems for geothermal energy?

PART-B

((4 x 2) x 5 = 40)

UNIT-I

11. Explain Green house effect.

12. What do you mean by Energy conservation and what is the importance of conserving energy?

13. List out Energy density of various fuels.

UNIT – II

14. How will you estimate average solar radiation?

15. With a simple line diagram explain natural circulation solar water heater.

16. What are the applications of solar photovoltaic?

UNIT – III

17. Describe Wind data and wind energy estimation.

18. Explain Site selection consideration for wind power generation.

19. Explain the basic components of wind energy generation system.

UNIT – IV

20. Explain the process of gasification of solid Bio-fuels.

21. Explain production of Ethanol from Biomass.

22. Explain about Biomass energy programme in India.

UNIT – V

23. What are the advantages & Disadvantages of wave energy?

24. What are the advantages and applications of geothermal energy?

25. Explain about geothermal potential in India.

PART-C

(10 x 5 = 50)

UNIT – I

26. Discuss about the availability and future trends of Primary energy resources in India. (10)

27. List out the common pollutants from power plants and their harmful effects. (10)

UNIT –II

28. Explain measurement of intensity of solar radiation by Pyrheliometer. (10)

29. i) Explain the working of solar pond Electric power plant. (5)

ii) Explain the principle of photovoltaic conversion of solar energy (5)

UNIT –III

30. i) How to estimate power in the wind? (4)

ii) With simple sketch explain working of Darrieus rotor type vertical wind mills. (6)

31. i) Explain about wind energy storage. (5)

ii) What are the precautionary steps to be taken at wind energy projects with respect

environmental aspects? (5)

UNIT –IV

32. With a simple sketch explain Municipal Solid waste to energy plant. (10)

33. i) With a simple diagram Explain floating dome type Biogas Plant. (6)

ii) Explain the process of gasification of solid Bio-fuels. (4)

UNIT –IV

34. i) Explain any one wave-energy conversion device. (6)

ii) What are the advantages & Disadvantages of wave energy? (4)

35. i) Explain Dry steam type geothermal power plant. (6)

ii) What are the advantages of geothermal energy? (4)

***********


Sathyamurthy Nagar, Chennai – 600 062

MEL51 DESIGN OF MACHINE ELEMENTS

MODEL QUESTION PAPER

Time: 3 Hrs Max Marks : 100

Note: 1. Answer ALL the questions by either or choice

2. Each question carries 20 marks.

3. Design data book approved by DOTE and Chairman, Autonomous

Examinations are permitted

4. The question paper contains TWO pages.

UNIT - I

I a. Name the type of steel with its composition designated as given below:

XT72WI8Cr4V1

(5)

b. Write the procedure for design of machine elements.

(5)

c. Design a sleeve and cotter joint to connect two rods for transmitting a maximum tensile

load of 100KN. The rods sleeve and cotters are made of same material and the

permissible stresses in the material are 65N/mm2 in tension, 130N/mm

2 in compression

and 50N/mm2 in shear.

(Or)

(10)

II a. An eye bolt is used for lifting a load of 50KN. Find the nominal diameter of the bolt, if the

tensile stress is not to exceed 100 N/mm2. Assume coarse threads, if the bolt extends

50mm into the component. What will be the shear stress in the threaded portion of the

bolt?

(10)

b. A stream engine cylinder has an effective diameter of 350mm and the maximum stream

pressure acting on the cylinder cover is 1.2N/mm2. Calculate the number and the size of

studs required to the secure cylinder cover. Assume permissible stress in the studs as

335N/mm2.

(10)

UNIT-II

III A shaft is supported on bearings A& B 800mmbetween centers A 20˚ straight both spur

gear with 600mm pitch diameter is located 200 mm to the right of left hand bearing A

and a 700mm diameter pulley is mounted 250mm towards the left of bearing B. The

gear is driven by a pinion with a downward tangential force while the pulley drives the

horizontal belt having 180 angle of wrap. The pulley also serves a flywheel and weighs

2000N. The maximum belt tension is 3:1. Determine the maximum bending moment &

the necessary shaft diameter, if the allowable shear stress of the material is 40N/mm2.

(Or)

(20)

IV Design a protected type cast iron flange coupling for a steel shaft transmitting 15KN at

200 rpm and having an allowable shear stress of 40 MPa. The working stress in the bolt

should not exceed 30MPa. Assume that the same material is used for shaft and key and

the crushing stress is twice the value of its shear stress. The maximum torque is 20%

greater than the full load torque. The shear stress for cast iron is 14MPa.

(20)

UNIT - III

V a. List the types of belts and material used for it. (5)

b. Write short notes on belt materials (5)

c. A leather belt drive transmits 15KNW power. The center distance between the pulleys

is twice the diameter of the big pulleys. The speeds of the big and small pulleys are

480rpm and 1440rpm respectively. The belt should operate at velocity of 20m/s

approximately and stresses in the belt should not exceed 2.25 N/mm2. The density of

the leather is 0.95gm/cc and the coefficient of the fiction is 0.35. The thickness of the

belt is 5mm. Calculate (a) the diameter of the pulleys (b) the length and width of the

belt and (c) the belt tensions.

(Or)

(10)

VI Design a V-belt drive and calculate the actual belt tension and average stress from the

following data:

Diameter of the driven pulley = 500mm, diameter of the driving pulley = 150mm, center

distance between pulley= 925mm, speed of driven pulley= 300rpm, speed of driving

pulley= 1000rpm, power transmitted = 7.5KW.

(20)

UNIT-IV

VII a. How bearings are classified. (5)

b. What are the advantages of Ball and Roller bearings over journal bearings? (5)

c. A 75 mm journal bearing 100mm long is subjected to 2.5KN at 600rpm. If the room

temperature is 24˚C, determine the viscosity of oil to be used to limit the bearing

surface temperature at 50˚C. Take D/C=100 and K=0.484˚C/m2/W.

(Or)

(10)

VIII a. Design a suitable journal bearing for a centrifugal pump from the following data:

Load on bearing 14KN

Diameter of a journal 80mm

Speed 1440rpm

Bearing characteristic number 30 X 10-6

Permissible bearing pressure 0.7 X 1.4N

Average atmospheric pressure 30˚C

Calculate the cooling requirement using hasche’s equation. Use Mckee’s equation for

calculating the friction coefficient. Assume L/D=2.

(20)

UNIT-V

IX a. Explain the applications of levers. (5)

b. Design a hand lever of rectangular section subjected to a maximum load of 250 N at

the end of moment arms of 1.2m. The thickness of the lever is constant and is equal

to 0.375 times the width of the lever near to the boss. Permissible shear stress for

the shaft material is 40N/mm2 and the permissible bending stress for the lever

material is 1N/mm2.

(Or)

(15)

X Design a spur gear drive to connect an electric motor to a reciprocating pump,

both string mounted on the same bed. Speed of the motor is 1440 rpm; speed

reduction desired is 10:1. Motor power is 36.8KW. The gears are to have 20˚

pressure angle. The maximum number of teeth on pinion is 24.

(20)

****