SYLLABUS

II Year B.Tech. M.E.

(54013) PRODUCTION TECHSOLOGY

UNIT-I

CASTING: steps involved in making a casting —Advantage of casting and its applications. patterns and patternmaking—Type of patterns - Materials used for patterns, pattern allowances and their construction, Principles of Gating, gating ratio and design of gating systems

UNIT—II

Solidification of casting Concept — Solidification of pure metal and alloys short & long freezing range  alloys. Risers types, function and design, casting design consideration , special casting processes 1) Centrifugal 2) Die, 3) investment

Methods of Melting: crucible  melting and cupola operation, steel making processes, special.

UNIT—III

A) Welding : Classification of welding process types of welds and welded joints and their characteristics design of welded joints, Gas welding, ARC welding, Forge welding,  welding, Termite welding and Plasma (Air and water) welding,

B) Cutting of Metals: Oxy Acetylene Gas cutting, water plasma. Cutting of ferrous, non-ferrous metals.

UNIT-IV

Inert Gas welding, TIG & MIG, Melding, Friction welding. Induction welding, Explosive welding, Laser welding, soldering & Brazing. Heat affected zones in welding; welding defects causes and remedies destructive nondestructive testing of welds.

UNIT - V

Hot working, cold working, strain hardening, ‘recovery, recrystallisation and grain growth. Comparison of properties of Cold and Hot worked parts. Rolling fundamentals — theory of rolling, types of Rolling mills aid products. Forces

in roiling and power requirements.

UNITVI

Stamping, forming and other cold working processes: Blanking and piercing

— bending and forming — Drawing and its types — wire drawing and Tube drawing — coining — Hot and cold spinning- Types of presses and press tools. Forces and power requirement in the above operations.

UNIT- VII

EXTRUSION OFMETALS: Basic extrusion process and its characteristics. Hot extrusion and cold extrusion - Forward extrusion and backward. extrusion

— impact extrusion Hydrostatic extrusion

Forging processes: Principles of forging—Tools and dies — Types Forcing

— Smith forging, Drop Forging — Roll forging—Forging hammers : Rotary forging — forging defects.

UNIT- VIII

Processing of Plastics: Types of Plastics, Properties, applications and their

Processing methods & Equipment (blow &injection modeling)

 (54014) KINEMATICS OF Machinery

UNIT—I

Mechanisms:- Elements or links— Classification— Rigid Link, flexible and fluid link— Types of kinematic pairs — sliding turning, rolling, screw and spherical pairs — lower and higher pails — closed and open pairs — constrained motion — completely. partially or successfully constrained and incompletely constrained

MACHINES:- Mechanism and machines— classification of machines — kinematic chain — inversion of mechanism — inversion of mechanism — inversion of quadric cycle chain— singe and double slider crank chains.

UNIT -II

Straight line motion mechanism: Exact and approximate copiers

and generated types — Peaucellier, Hart and Scott Russul — Grasshopper — Watt T. Chebicheff and Robert Mechanisms and straight line motion.

Pantograph

UNIT-III

KINEMATICS :Velocity and acceleration — Motion of link in machine — Determination of Velocity and acceleration diagrams — Graphical method — Application of  relative velocity method four bar chain.

Analysis of mechanisms: Analysis of slider crank chain for displacement velocity and acceleration of slider — Acceleration diagram for a given mechanism, Kleins construction. Coriolis acceleration, determination of Coriolis component of acceleration.

Plane motion of body :Instantaneous center of rotation, centroids and axodes

— relative motion between two bodies — Three centres in line theorem — Graphical determination of instantaneous centre, diagrams for simple mechanisms and determination of angular velocity of points and inks.

UNIT IV

STEERING Mechanisms: Conditions for correct steering-davis steering gear, Ackermans steering gear — velocity ratio.

HOOKE’S Joints: Single and double Hooke’s joint Universal coupling— application— problems.

UNIT V

CAMS: Definitions of cam and followers — their uses — Types of followers and cams — Terminology — Types of follower motion - Uniform ‘velocity — Simple harmonic motion and uniform acceleration. Maximum velocity and maximum acceleration during outward and return strokes in the above 3 cases

Analysis of motion of followers: rollers follower-circular cam with straight, concave and convex flanks.

UNIT VI

Higher pairs, friction wheels and toothed gears —types — law of gearing.- condition for constant velocity ratio for transmission of motion, Form of teeth; cycloidal and involute profiles. Velocity of sliding — phenomena of interferences - Methods of interference. Condition for minimum number of teeth to avoid interference, expressions for arc of contact and path of contact— Introduction to Helical, bevel and worm gearing.

UNIT VII

Belt Rope and Chain Drives: Introduction. Belt and rope drives, selection of belt drive- types of belt drives, V-belts, materials used for belt and rope drives, velocity ratio of belt drives. slip of belt, creep of belt, tensions for flat belt drive, angle of contact, centrifugal tension, maximum tension of belt, Chains- length, angular speed ratio, classification of chains.

UNIT VIII

GEAR TRAINS: Introduction— Train value — types — Simple and reverted wheel train—Epicyclic gear Train. Methods of finding train value or velocity

— Epicyclic gear trains. Selection of gear box-Differential gear for an automobile

(54015)APPLIED THERMODYNAMICS-I

UNIT-I

Actual cycles and their analysis: Introduction, comparison of air standard and actual cycles, Time loss factor, Heat loss factor, exhaust blow down-loss due to gas exchange process ,volumetric efficiency, loss due to rubbing friction actual and fuel-air cycles of CI engines

UNIT-II

IC. ENGINES: Classification - Working principles, Valve and portTiming

Diagrams Air — Standard, air-fuel and actual cycles - Engine systems — Fuel, .

Carburetor, Fuel Injection System, Ignition, Cooling and Lubrication. -

UNIT-III

Combustion in SI Engines; Normal Combustion and abnormal combustion

— Importance of flame speed and effect of engine variables —Type of Abnormal combustion, pre-ignition and knocking (explanation of) — Fuel requirements and fuel rating, anti knock additives — combustion chamber — requirements,.

types. _—

UNIT-IV

Combustion in CI. Engines: Four stages of combustion— Delay period and its importance — Effect of engine variables — Diesel Knock— Need for air movement, suction, compression and combustion induced turbulence — open and divided combustion chambers and nozzles used — fuel requirements and fuel rating.

UNIT -V

Testing and Performance: Parameters of performance - measurement of cylinder pressure, fuel consumption, air intake, exhaust gas composition, Brake power — Determination of frictional losses and indicated power — Performance test —-Heat balance sheet and chart.

UNIT-IV

COMPRESSORS — Classification —positive displacement and roto dynamic

machinery — Power producing and power absorbing machines, fan. blower and compressor — positive displacement and dynamic types — reciprocating and rotary types.

Reciprocating: Principle of operation, work required, Isothermal efficiency volumetric efficiency and effect of clearance, stage compression, undercooling, saving of work, minimum work condition for stage compression.

UNIT-VII

Rotary (Positive displacement type) : Roots Blower, vane sealed compressor, Lysholm compressor — mechanical details and principle of working —efficiency considerations,

Dynamic Compressors : Centrifugal compressors: Mechanical details and principle of operation — velocity and pressure variation. Energy transferimpeller blade shape-losses, slip factor, power input factor, pressure coefficient and adiabatic coefficient — velocity diagrams — power.

UNIT- VIII

Axial Flow Compressors: Mechanical details and principle of operation velocity triangles and energy transfer per stage degree of reaction, work done factor - isentropic efficiency- pressure rise calculations — Polytrophic efficiency

(54016) MECHANICS OF FLUIDS AND HYDRAULIC

MACHINES

UNIT-I

Fluid static Dimensions and units: physical properties of fluids- specific gravity, viscosity, surface tension- vapour pressure and their influence on fluid motion- atmospheric, gauge and vacuum pressures — measurement of pressure- Piezometer, U-tube a differential manometers.

UNIT II

Fluid kinematics :Stream line, path line and streak lines and stream tube, classification of flows-steady & unsteady, uniform & non uniform, laminar & turbulent, rotational & irrotational flows-equation of continuity for one dimensional flow and three dimensional flows.

Fluid dynamics: Surface and body forces—Euler’s and Bernoulli’s equations for flow along a streamline, momentum equation and its application on force on pipe bend.

UNIT III

Closed conduit flow: Reynolds experiment- Darcy Weisbach equation- Minor losses in pipes- pipes in series and pipes in parallel- total energy line hydrau1ic gradient line.

Measurement of flow: pitot tube, venturimeter. and orifice meter, Flow nozzle

UNIT-IV

BOUNDARY LAYERCONCEPTS: Definition, thicknesses, characteristics along thin plate, laminar and turbulent boundary layers ( No derivation) boundary layer in transition, separation of boundary layer, submerged objects

--drag and lift.

UNIT V

Basics of turbo machinery : Hydrodynamic force of jets on stationary and moving flat, inclined, and curved vanes, jet striking centrally and at tip, velocity diagrams, work done and efficiency. flow over radial vanes.

UNIT-VI

Hydraulic turbines:Classification of turbines,heads qnd efficiencies, impulse and reaction turbines, pelton wheel,francis turbines and Kaplan turbine working proportions ,work done, efficiencies, hydraulic design-draft tube theory-fuctions and efficiency

UNIT-VII

Performance Of hydrauljc turbines: Geometric similarty. Unit and specific quantities, characteristic curves governing of turbines ,selection of type of turbine, cavitation surge tank, water hammer.

UNIT -VIII

CentrIfulgal pumps: Classification working ,work done — barometric head- losses and efficiencies specific speed- performance characteristic curves, NPSH.

Reciprocating pumps: Working Discharge slip, indicator diagrams

(54017)MACHINE DRAWING

Machine drawing convention

Need for drawing conventions-introduction to IS conventions

a)Conventional representation of materials, common machine elements and parts such as screws, nuts, bolts, keys, gears, webs, ribs.

b)Types of sections — selection of section planes and drawing of sections and auxiliary sectional views. Parts not usually sectioned.

c)Methods of dimensioning, general rules for sizes and placement of dimensions for holes, centers., curved and tapered features.

d)Title boxes, their size, location and details-common abbreviation & their liberal usage

e)Types of Drawings —working drawing for machine parts

I. Drawing of Machine Elements and simple parts

Selection of Views, additional views for the following machine elements and parts with every drawing proportions.

a) Popular forms of Screw threads, bolts, nuts, stud bolts, tap bolts, set screws.

b) Keys. cottered joints and knuckle joint.

c) Riveted joints for plates

d) Shaft coupling, spigot and socket pipe joint.

e) Journal, pivot and collar and foot step bearings.

II. Assembly Drawings:

Drawings of assembled views for the part drawings of the following using

conventions and easy drawing proportions.

a) Engine parts — stuffing boxes, cross heads, Eccentrics, Petrol Engine connecting rod, piston assembly.

b)Other machine parts - Screws jacks Machine, Vices Plummer block. Tailstock

c)Valves: Steam stop valve, spring loaded safety valve, feed check valve and air cock.

NOTE First angle projection to be adopted. The student should be able to provide working drawings of actual parts.

(54018)NUMERICAL METHODS

UNIT-I

:roots of non linear equation

Solution of Algebraic and Transcendental Equations: Introduction — Bisection Method — The Method of False Position— The Iteration Method-newton-raphson method.

UNIT-II

:Solution of linear equation:

Existence of solution — Gauss Elimination method — gauss elimination Pivoting. Gauss Jordon Method- Ill conditioned systems — Jacobi iterative method — Gauss Seidel Method — Convergence of Iterative methods.

UNIT_III

I           NTERPOLATION

Intoduction- Errors in Polynomial lnterpolation —Finite differences- Forward Differences- blackward differences -- Symbolic relations and separation of symbols- Difference Equations - Differences of a polynomial-Newton’s formulae for interpolation —Interpolation with unevenly spaced points- Lagrange’s Interpolation formula - Cubic spline.

UNIT IV:

 Least squares method:

Linear,non linear and curvilinear curve fitting-multiple linear regression

UNIT V:

Numerical differential and integration

Numerical differentiation and integration trapezoidal rule,simpson’s 1/3 rule and 3/8^th rule.

UNIT-VI:

Numerical solutions of initional value problems in ordinary differential equation:

Numerical solution of Ordinary Differential equations: Solution by Taylor’s series-Picard’s Method of successive Approximations-Eulers Method Runge-Kutta Methods —Predictor-Corrector Methods- Adams- Bashforth Method.

UNIT-VII:

Boundary values &eigen value problems:

Shooting method,finite difference method and solving eigen values problems,power method.

UNIT-VIII:

Solution of partial differential equations:

Classification of partial differential equation-finite difference method for:

Elliptic equations —Laplace equations — Leibmano’s iterative method

Parabola equations — Solution of heat equation (One dimensional).

(54604) PRODUCTION TECHNOLOGY LAB

Minimum of 12 exercises need to be performed

I.METAL CASTING LAB

1. Pattern Design and making - for one casting drawing.

2. Sand properties testing - Exercise -for strengths, and permeability —

3. Moulding Melting and Casting - I Exercise

II WELDING LAB:

I. ARC Welding Lap & Butt Joint- 2 Exercises

2. Spot Welding - I Exercise

3. TIG Welding - I Exercise

4. plasma welding and Brazing -2 Exercises (Water Plasma Device)

III. MECHANICAL PRESS WORKING:

1. Blanking & Piercing operation and study of simple, compound and

progressive press tool.

2. Hydraulic Press Deep drawing and extrusion operation.

3. Bending and other operations

IV PROCESSING OF PLASTICS

1. Injection Moulding

2. Blow Moulding

 (54605) MECHANICS OF FLUIDS AND HYDRAULIC MACHINES LAB

1.Impact of jets On Vanes,

2.Performance Test on Pelton Wheel.

3.Performance Test on Francis Turbine.

4.Performance Test on Kaplan Turbine.

5.performance Test on Single Stage Centrifugal Pump.

6.Performance Test on Multi Stage Centrifugal Pump.

7performance Test on Reciprocating Pump.

8.Calibration of Venturimeter

9.Calibration of Orifice meter.

10.Determination of friction factor for a given pipe I inc.

11.Determination of loss of head due to sudden contraction in a pipeline.

12.Verification of Bernoulli’s Theorems

Note: Any 10 of the above 12 experiments are to be conducted.