basic of mechanical

7/24/2019 Basic of Mechanical

1/49

TRAINING DETAILS

Day: 1

Date: 25. 03.2014

Topics Covere Stress

Strai!

Types o" Stress A! Strai!

#o$!%&s 'o$($s )actor o" sa"ety

De"or*atio!

Stress:

Stress is Force Acting per Unit area or a resistive Force

offered Against the Force Applied.

Types o" stress:

Tensile Stress (It is Caused By Pull Load)

Copressive Stress(It is Caused By Push Load)

Shear Stress(It is caused At Surface )

Theral Stress(!ue to Teperature)

Strain:


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Strai! is ca$se D$e to Stress. It is T+e Ratio

,et-ee! C+a!%e I! i*e!sio!s A! ri%i!a(

Di*e!sio!. It +as !o $!its

Deformation:

T+e c+a!%e i! Di*e!sio! is ca((e

De"or*atio!

Elastic Limit:

It is /oi!t +ere Stress a! strai! Ratio! Is

co!sta!t .et-ee! t+is Li*it t+e 'ateria(

e+aves E(astica((y

Yield Point:

It is t+e poi!t -+ere t+e 'ateria( starteDe"or*i!% /(astica((y

Ultimate Stress:

It is t+e 'ai*$* Stress +ic+ A *ateria(

ca! -it+ Sta!

Youngs Modulus:

it+i! T+e E(astic Li*it Stress is Direct(y

/roportio!a( to Strai!. It is ooe&s La-.

/roportio!a( Co!sta!t is !o-! as #o!%&s

'o$($s


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Factor of Safety:

It is ratio ,et-ee! (ti*ate Stress a!

ori!% Stress. +i(e Desi%!i!%6 )actor o"

sa"ety is very i*porta!t. T+e Avera%e 5

*$st ,e *ai!tai!e.


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Day: 2

Date: 27.03.2014

Topics Coered

Stress Strai! C$rve

Str$ct$ra( A! its asics

Stress!Strain Cure

Stress strai! c$rve is $se -+i(e esi%!i!%

"or a!y *ateria( .!er Loa test t+is c$rve

is ra-! to 8! t+e e(astic (i*it6 yie( poi!t6

(ti*ate Stress a! ,reai!% /oi!t etc.


5/49

Structural and its "asics:

To ,$i( a str$ct$re -e !ee so*e /ro8(e

(ie

ea*s

C+a!!e(s

A!%(es

SS9a((o- str$ct$ra( sectio!

/(ates

"eams:

ea* Is Str$ct$ra( *e*,er -+ic+ is

s$pporte a! carries (oa -+ic+ is Ri%+ta!%(e to t+e (e!%t+. 'ost(y ;I< ,ea* is $se

,eca$se it +as +i%+ *o*e!t o" i!ertia


6/49

T+ese ,ea*s are speci8e ,y I!ia!

Sta!ar As

IS' 100 9I!ia! Sta!ar 'ei$*

ea*s IS= 125 9I!ia! Sta!ar >$!ior ea*s

ISL 150 9I!ia! Sta!ar Li%+t ea*s

IS 200 9I!ia! Sta!ar ei%+t

ea*s IS 225 9I!ia! Sta!ar eavy

ea*s

100 Speci8es t+e ept+ o" t+e sectio!

C#annel:

Channel is a constructional aterial "ith cross section

as C shape

Channel are specified #y Indian Standard as


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o IS'C 100 9I!ia! Sta!ar *ei$*

c+a!!e(

o IS=C 150 9I!ia! Sta!ar >$!iorC+a!!e(

o ISLC 200 9I!ia! Sta!ar (i%+t

c+a!!e(

$ngle:Angle is also a constructional aterial "ith a Cross

section $L%

%allo& Structured Section:

&allo" Structured Section Is a constructional 'aterial

"hich is a closed section egsteel pipe* tu#e

Parallel flange Beas and coluns are specified #y

British and +uropean Standards such as


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UC ,-./,-./.0 (British Standard)

UB -00/.,1/2.(British Standard)

IP+A 311 (+uropean Standard)

&P+ 411 (+uropean standard)

Types of 'eams "y Supports:

Si*p(y s$pporte

ver+a!%i!%

Ca!ti(ever

)ie

Co!ti!$o$s


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Plates:

Plates are ordinary sheet or plates of various thic5ness

Its thic5ness is selected according to the load applied

Types of Load $cting on "eams:

Concentrated load or Point load

Uniforly distri#uted load

Uniforly varying load

Moment of (nertia


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'oent of inertia of a #ody is defined as the resistance

offered against the rotation or capacity of cross section

against #ending

Day: 3

Date: 2?.03.2014Topics coered

'aterial and its selection

Car#on steel

Alloy Steel


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Car'on Steel:

Car#on steel is an alloy of iron and car#on "hich car#on are

the ain alloying aterials 6ther aterials are added such asanganese* copper* silicon in lo" a7iu percentage

According to The car#on content there are three categories

Sn

o

Types Coposition

, Lo" car#on steel C 11-8 to 1.-8

'n up to 148

. 'ediu Car#on steel C1.98 to 1-48

'n 138 to ,3-8

0 &igh Car#on Steel C1--8 to 19-8

'n108 to 198

4 :ery &igh Car#on

Steel

C1938 to .,8

$lloy steel:

Alloy Steel is steel in "hich t"o or ore alloying

su#stance is added other than car#on to achieve the

desired properties It has t"o types

Low alloy steelAlloying eleents less than ,1-8


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High Alloy steelAlloying eleents ore than ,1-8

)rades and Standard:

*+,-.+-/.,01

Materials Carbon steel Alloy steel

Plate;sheets SA -,- >>

Bolt* @ut*

asher ISI030*34*3=

>>>

Day: 4

Date: [email protected]

Topics coered

, Stain less Steel


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. &astelloy

0 First angle proection and third angle proection

,- Stainless steel:

A Stainless steel is a steel alloy of iniu ,1-8of

chroiu in assIt is rust less and ino7yda#le

Commonly Used Grades

SS 014

SS014L

SS014&

SS.14

SS010

SS0,3

SS0,3L

SS0C?,.

SS401

SS44,

Types of Stainless Steel:

i Ferrritic

ii Austenitic

iii 'artensitic

iv !uple7

v Precipitation &ardening


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i- Ferritic:o 411 Serieso Chroiu is uch (.=8)

o &igh resistance to corrosion

o They are agnetic

o Cannot #e hardened #y heat treatent

o Used in sea "ater

o Used for a5ing car tri and +7haust syste

ii- Martensitic:o Siilar to ferritic*#ut car#on content differ ie* ,8

o &igh strength

o 'oderate corrosion ?esistance

o 'oly#denu and nic5el is addedo &arder and little 'agnetic

o Used in spindle* 5nifes* Shaft* surgical instruent

iii- $ustentic:o 'ost coon steel

o Corrosion resistanceo !uctile and 'allea#le

o Used in 5itchen sin5s and cheical eDuipentEs

i- Duple2:


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Fored #y i7ing the #asic coponents of austenitic

and ferriticsteel

o It contains &igher level of chroiuo Siple to "eld

o +asily fored to specific shapes

o Best Duality

o Used for tools and achinery in arine condition

- Precipitation %ardening:

Basically Austenitic #y adding other eleents to get

desired properties once added it #ecoe e7treely

tough* dura#le and hard "earing

Used in Aircrafts Parts and Pups

/- %astelloy:

&astelloy is the alloy of nic5el* chroiu* and

oly#denuIt has high o7idation resistance* fa#ric

a#ility* and high teperature strength

Composition:


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Ni --8

Mo -,- ,=8

Cr ,4- ,3-8

Fe 4 =8

W 0 4-8

Uses:

Pollution Control

Cheical processing

aste treatent 'arine +ngineering

Pulp and paper production

Sta!ar $se "or aste((oy is

C/34

)rades and Standard :

* +,-.+-/.,01

Materials

Stainless Steel

Plate;sheets SA 240 9GRADE


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Pipe SA 3129GRADE

Tu#eSA 27@

Structural

?od SA 2?79GRADEBolt* @ut* asher AISI 317 9-as+er

A13 ? 9o(t

A14 @ 9!$t

Using )rades: SS 204

SS 304

SS 317

SS 317L

Properties ofmaterials:i. /+ysica( propertiesii. 'ec+a!ica( properties

iii. T+er*a( properties


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i- P#ysical properties: co!$ctivity Te!si(e Stre!%t+

#ie( Stre!%t+

'e(ti!% poi!t

)reeBi!% poi!t

ii- Mec#anical properties: &ardness

To$%+!ess

iii- T#ermal property:

E!tropy E!t+a(py

+- First $ngle and T#ird $nglepro5ection:

First $ngle

,>ect (ies i! t+e 8rst $ara!t

T+e vie-s are iere!t "ro* t+ir a!%(e

ie-erFo,>ectFp(a!e o" pro>ectio!


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T#ird $ngle pro5ection

T+e o,>ect (ies i! t+ir $ara!t

T+e vie-s are iere!t "ro* 8rst a!%(e

ie-erFp(a!e o" pro>ectio!Fo,>ect

Sym'ol for Pro5ection:

Day: 5 7Date: 2.03.2014 31.03.2014

Topics Coered:

!it co!versio!s


20/49

Sta!ars a! Graes

!it co!versio!

,Pressure

.Flo" rates

0Teperature

,- Pressure

1pasca(H0.00014503 /si

1arH14.503 /si

1/siH0.07@7 ,ar

1 ,arH100000 N *J

/- Flo& rates

1 (iter+o$rH0.2741? %a((o!+o$r

1 %a((o!+o$rH3.?@5 (itre+o$r

1*i((i(itre+o$rH0.001(itre+o$r


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1*i((i(itre+o$rH0.0002741? %a((o!+o$r

1(itre+o$rH1000 *i((i(itre+o$r

1 c$,ic *etresecH3700000 %+o$r

1 c$,ic *etersecH1000 %sec

+- Temperature

1 e%ree Ce(si$sH33.@ )

1 )a+re!+eitHF1?.22 e%ree Ce(si$s


22/49

Day: 3

Date: .,-.0-/.,0

Topics Coered:

1. 6elding2. Types of &eld 5oints3. 7omenclature of &eld4. Edge preparation5. 6elding sym'ol

7. 6elding mac#ines?. 6elding Process

6elding:

e(i!% is t+e process o" >oi!i!% t-o si*i(ar *ateria(s ,y

+eati!% process.

Types of &eld 8oints:

e( >oi!ts ca! ,e c(assi8e accori!% to

Type o" -e(

/ositio! o" -or piece

Le!%t+ o" -e(

y Type o" -e( it ca! ,e c(assi8e i!to

"utt &eld Fillet 6eld

Plug &eld

Slot &eld

Seam &eld

Spot &eld


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y t+e positio! o" -e(

"utt 5oint Lap 5oint

T 5oint

Corner 5oint

Edge 5oint

y t+e (e!%t+ o" t+e -e(:

Continuous 6eld

(ntermittent 6eldo C#ain "ot# Sides

o Staggered

6eld 7omenclature:


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6elding Sym'ols:

Edge preparation:

It is the preparation #efore "elding to increase the strength of the "eld


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6elding Process:

$rc 6elding Process:

Ato*ic yro%e! e(i!%

Car,o! Arc e(i!% Gas *eta( Arc -e(i!%

/(as*a Arc -e(i!%

92y Fuel )as 6elding:

y acety(e!e e(i!%

y yro%e! e(i!%

esistance 6elding:

Resista!ce Spot e(i!%

Resista!ce Sea* e(i!%

9t#er 6elding Process:

E(ectro! ea* e(i!%

Laser ea* e(i!%


27/49

Types of &elding Mac#ines:

TIG -e(i!% 'ac+i!es'IG -e(i!% 'ac+i!esS'A e(i!% 'ac+i!esyF"$e( e(i!% 'ac+i!es


28/49

Day: ;

Date: ./-.0-/.,0

Topics Coered:

Drilling

Milling

)rinding

S#aping

Drilling:

!rilling is the process of creating a hole in a "or5 piece using drill

#it

Types o" Dri((i!%:

Spot Drilling

Centre Drilling

Deep hole drilling

Gn Drilling

!repanning

Mi"ro drilling

#ibration Drilling

Spot Dri((i!%:

Spot drilling is the process of drilling a hole "hich guide

the final hole


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Ce!tre Dri((i!%:

The purpose of center drilling* it acts as the center for variousoperations

Deep o(e Dri((i!%:

!eep hole drilling is used "here the length of the hole is ,1 ties

greater than the dia of the hole

G$! Dri((i!%:


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Milling:

'i((i!% is t+e process o" re*ovi!% *ateria( $si!% *$(ti poi!tc$tti!% too(

Types of Milling Mac#ines:

%ori


31/49

$'rasies in )rinding 6#eels:

Sand Stones Emery

Diamonds

Corundum $luminum o2ide

Silicon Car'ide


32/49

S#aping Mac#ines:

S+api!% is t+e i! o" reciprocati!% *ac+i!e -+ic+

$ses a si!%(e poi!t c$tti!% too( to re*ove *eta(s.

Types of S#aper Mac#ines:

%ori

Date: .+-.0-/.,0


33/49

Topics Coered:

Basic Concepts of Therodynaics

La"s of therodynaics

"asic Concept of

T#ermodynamics:

!hermodynami"sis study of heat and its relation to

"or5 and energy Thero&eat* !ynaicsPo"er

System$ Srronding$ %ondary&

Therodynaic syste* or system$is defined as aDuantity of atter or a region in space chosen for

study

The region outside the syste is called the

Srrondings'

The real or iaginary surface that separates the syste fro its surroundings is called the

%ondary'


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Types of System:

T+e syste* i! -+ic+ t+e e!er%y tra!s"er a!

*ass tra!s"er taes p(ace is ca((e 9pen

systeme.%. Co*pressor

T+e syste* i! -+ic+ o!(y e!er%y tra!s"er

taes p(ace is ca((eClosed System. ere

*ass tra!s"er oes!&t taes p(ace.

T+e Syste* -+ic+ oes!&t ec+a!%e a!ye!er%y a! *atter is ca((e (solated

system

Types of Energies:

Potential energyis t+e e!er%y store -it+i!t+e o,>ect e.%. E!er%y store i! t+e spri!%6 a* etc.

()* mass + g + height

?inetic energyis t+e e!er%y o" *otio!. Every

o,>ect i! *otio! +as i!etic e!er%y


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(nternal energyis t+e e!er%y associate -it+ t+e

i!ter!a( *o(ec$(es o" t+e s$,sta!ce.

La&s of T#ermodynamics:

First la&o" t+er*oy!a*ics states t+at

!et -or tra!s"er is e$a( !et +eat tra!s"er

i.e. e!er%y ca! !eit+er ca! create !orestroye

Second la& 'y @elin plan@says t+at

it is i*possi,(e to co!str$ct a +eat po-er

e!%i!e -+ic+ -ors o! a cyc(ic process

-+ic+ co!verts t+e a,sor,e +eat "ro* a

reservoir i!to e$iva(e!t a*o$!t o" -or.

Second la& 'y clausiussays t+at it is

i*possi,(e to tra!s"er +eat "ro* co( ,oy to

+ot ,oy -it+o$t t+e $se o" eter!a( -or.

T#ird la&says t+at t+e e!tropy o" t+e

per"ect crysta( at a,so($te Bero te*perat$reis Bero


36/49

Day: ,.

Date: .0-.0-/.,0

Topics Coered:

)ntropy

)nthalpy

Spe"i,i" heat

nternal )nergy

Latent Heat

Sensible Heat

Dimensioning .les

Ent#alpy:

+nthalpy is the su of internal energy and flo" "or5

H

*

U/


37/49

(

#

& +nthalpy

UInternal +nergy

Ppressure

: :olue

Entropy: +ntropy is the therodynaic property and it depends upon the

change in teperature #y heat transfer

S

*

0

1!

S +ntropy

&eat Transfer

T Teperature

(nternal Energy:


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It is the total energy Possessed #y a #ody Thus internal energy

is the su of potential energy and 5inetic energy of the

olecules of the #ody

SpeciAc %eat:

Specific heat is the heat reDuired to raise the

teperature of the unit ass of the su#stance to one degree

Celsius

Latent %eatB

It is the aount of heat released or a#sor#ed during the change

of state of su#stance at constant teperature

Sensi'le %eat:

Sensi#le heat is the energy reDuired to change the teperature

of a su#stance "ith no phase change

Dimension ules:

, Avoid placing any diensions inside the part unless there is

no other option

. Avoid diensioning to hidden features

0 Avoid contact of values

4 Al"ays place diension to the ost descriptive vie"


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- !iension rounded corners G arc features as radial

3 If sae value is repeated any ties* then use a general

note

= Al"ays diension holes in their circular vie"

2 !iension cylindrical o#ect as diaeter in their rectangular

vie"

9 For etric diensions less than , does place a Hero at

decial Point

,1 For inches diensions less than ,% dont place a Hero

introduction at decial Point

,, 6verall diensions should #e outside of saller

diensions

,. !o not duplicate diensions to avoid using on necessary

,0 !iension line should never intersect other diension line

,4 Center Line should not e7tend fro vie" to vie"

,- Arro" heads 0 J ,

Day: ,,

Date: .-.0-/.,0


40/49

Topics Coered:

Conduction

Convection

?adiation

Cooling

Lu#ricants

Cond"tion&

The transfer of heat fro one su#stance to

another #y direct contact

+7aples

Touching the &ot Pan

Touching the &ot su#stance

Con2e"tion&

Convection is the oveent of olecules

"ithin fluids

+7aples Boiling of ater and Convection happened #et"een the

olecules

.adiation&


41/49

+nergy that is radiated or transitted in the

for of raysIt is the heat transfer #y electroagnetic

"aves

+7aples

'icro"ave oven

Light Bul#

&eat fro a Fire

Cooling: Cooling is for reoval of heat produced #y the

oving parts and Burning of fuel #y the circulation of the

coolant

(roperties o, the "oolants&

&igh heat transfer rate high #oiling point

Lo" elting point

Lo" po"er reDuireents for puping

@onto7ic

@onreactive

!ypes o, "ooling system&

LiDuid Cooling, Thero syphon Cooling Syste

. Forced Circulation cooling Syste

Air Cooling


42/49

Lu'rication: Lu#rication is the process to reduce "ear #et"een

oving parts using lu#ricants

(roperties o, the Lbri"ants&

It should have &igh :iscosity

Its 6iliness Should #e &igh

It should have &igh Flash Point

It should #e :olatile

It Should Posses !elergency Property

It should Posses !eulsi#ility

!ypes o, Lbri"ating System&

Pet roil syste

Pressure lu#rication Syste

Splash type Lu#rication Syste

Sei pressure Lu#rication Syste


43/49

Day: ,/,+

Date: .3-.0-/.,0

!opi"s Co2ered&

Properties of fluids

Types of flo"

Flo" through pipes and its losses

Pups and its types Pipe standard as per A@SI B,3,1

(roperties o, ,lid&

3' Density or Mass Density

!ensity of the su#stance is the ass per unit volue

4' Weight Density

eight density is the "eight per unit volue

5' Spe"i,i" 2olme

Specific volue is the ratio of the volue to its assIt is the

reciprocal of !ensity

6' Spe"i,i" gra2ity

It is the ratio of the density of the su#stance to the density of the

standard su#stance

7' Compressibility

It is the A#ility to copress a su#stance #y Pressure

8' #apor pressre


44/49

:apour pressure is the pressure e7erted #y the vapour in

therodynaic eDuili#riu to its phase in a closed syste

9' Cohesion

Cohesion is the property attraction of the li5e olecules of the

su#stance

:' Adhesion

Adhesion is the property of the su#stance for the attraction

#et"een disli5e olecules

;' Sr,a"e tension

The cohesive force #et"een the liDuid olecules is responsi#le

for the phenoenon surface tension It is the property of the surface of

the liDuid allo"s resisting the e7ternal force

3


45/49

Uni,orm ,low&

Unifor flo" is the flo" "here the velocity of the fluid is constant

Non-Uni,orm Flow&

It is the flo" "here the velocity of the fluid is varia#le

!rblent Flow&

Flo" of fluid is KigHag* flo" layers intersect each other

Laminar Flow&

Flo" layers are parallel to each other throughout the flo"

Flow throgh (ipes&

Flo" through pipes is flo" of fluids through closed conduit* !ue to

pressure it occupies the "hole space* if it occupies the "hole space it is

called pipe flo" and "hen its flo" "ith the space it is called channel

flo"

Losses in ,low throgh pipes&

Loss in head due to pipe friction Loss in head due to sudden enlargeent

Loss in head due to sudden contraction

Loss of head due to entry into pipe

Loss of head due to e7it fro pipe

Loss of head due to o#struction

Loss of head due to change in direction

Loss of head due to


46/49

/$*ps

/ositiveDisp(ace*e!t

Rotary

)(e2i,(eI*pe((er

/ro%ressi!%Cavity

/erista(tic

Ea!e

Ro((er

Gear

Lo,e

Scre-

Reciprocati!%

/isto!

Diap+ra%*

/($!%er

Ki!etic

T$r,i!e

Ce!tri"$%a(

Loss of head due to various pipe fitting

(mp and its types&

(ositi2e displa"ement pmps&


47/49

This type of pups a5es a trapping of fi7ed aount of

fluid and forcing the trapped aount into the !ischarge

Chara"teristi" o, positi2e Displa"ementpmps&

Positive !isplaceent pup can theoretically produce

the sae flo" at given rpSo it is the constant flo"

device 6n increase in pressure lea5age happens

It cannot #e operated "hen discharge valve closes Itay daage the pup

?elief valve and safety valve is reDuired at discharge side

to avoid daage of pups

Chara"teristi" "r2e ,or (ositi2e Displa"ement

(mps&


48/49

The dashed line sho"s actual positive displaceent pup perforance This

line says that the discharge pressure of the pup increases* soe aount of liDuid

"ill lea5 fro the discharge* reducing the flo" rate of the pup The rate at "hich

liDuid lea5s fro the discharge to its suction is called Slippage'

(ositi2e Displa"ement (mps are sed when=

,) :iscosity of the fluid is lo".) &igh efficiency is needed

0) e used varia#le viscosity application4) Suction lift application is needed


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basic of mechanical

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