mvjce me 6 sem

8/13/2019 Mvjce Me 6 Sem

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DEPT. OF MECHANICAL ENGINEERING MVJCE

VI SEMESTER COURSE DIARY1

06ME61 DESIGN OF MACHINE ELEMENTS II


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VI SEMESTER MVJCE2

SYLLABUS

Sub Code: 06ME61 Exam Hours: 3

Hours / Week: 4 I A Marks: 25

Total Lecture Hrs: 62 Exam Marks: 100

PART - AUNIT 1:

CURVED BEAMS: Stresses in curved beams of standard cross sections used in crane hook,

punching presses & clamps, closed rings andlinks. (5 Hours)

UNIT 2:

CYLINDERS & CYLINDER HEADS: Review of Lames Equations; compound cylinders,

stresses due to different types of fits, cylinder heads,flats. (5 Hours)

UNIT 3:

SPRINGS: Types of springs - stresses in Helical coil springs of circular and non-circular cross

sections. Tension and compression springs, springs under fluctuating loads, Leaf Springs:

Stresses in leaf springs. Equalized stresses, Energy stored in springs, Torsion, BellevilleandRubber springs. (8 Hours)

UNIT 4:

SPUR & HELICAL GEARS: Spur Gears: Definitions, stresses in gear tooth: Lewis equation

and form factor, Design for strength, Dynamic load and wear load. Helical Gears: Definitions,

formative number of teeth, Design based on strength, dynamic and wear loads. (8 Hours)

PART - B

UNIT 5:

BEVEL AND WORM GEARS: Bevel Gears: Definitions, formative number of teeth, Designbased on strength, dynamic and wear loads. Worm Gears: Definitions, Design based on strength,

dynamic, wear loads and efficiency of worm gear drives. (7 Hours)

UNIT 6:CLUTCHES & BRAKES: Design of Clutches: Single plate, multi plate and cone clutches.

Design of Brakes: Block and Band brakes: Self locking of brakes: Heat generation in Brakes.

(7 Hours)

UNIT 7:

LUBRICATION AND BEARINGS: Lubricants and their properties, Mechanisms of

Lubrication bearing modulus, coefficient of friction, minimum oil film thickness, Heat

Generated, Heat dissipated, Bearing Materials, Examples of journal bearing and thrust bearing

design. (7 Hours)

UNIT 8:

BELTS ROPES AND CHAINS: Flat belts: Length & cross section, Selection of V-belts, ropes

and chains for different applications. (5 Hours)


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Design Data Hand Books:

1. Design Data Hand Book K. Lingaiah, McGraw Hill, 2nd Ed.2003.

2. Design Data Hand Book by K. Mahadevan and K.BalaveeraReddy, CBS Publication

3. Machine Design Data Hand Book by H. G. Patil, Shri ShashiPrakashan, Belgaum.

TEXT BOOKS:1. Mechanical Engineering Design: Joseph E Shigley and Charles R.Mischke. McGraw Hill

International edition, 6th Edition 2003.2. Design of Machine Elements: V.B. Bhandari, Tata McGraw Hill

Publishing Company Ltd., New Delhi, 2nd Edition 2007.

REFERENCE BOOKS:1. Machine Design: Robert L. Norton, Pearson Education Asia, 2001.

2. Design of Machine Elements: M. F. Spotts, T. E. Shoup, L. E.

Hornberger, S. R. Jayram and C. V. Venkatesh, Pearson Education,2006.

3. Machine Design: Hall, Holowenko, Laughlin (Schaums Outlines

series) Adapted by S. K. Somani, Tata McGraw Hill Publishing

Company Ltd., New Delhi, Special Indian Edition, 2008.4. Machine Design: A CAD Approach: Andrew D DIMAROGONAS,


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VI SEMESTER MVJCE4

LESSON PLAN

Sub Code: 06ME61 Hours / Week: 04

Sub: Design of Machine Elements-II Total Hours: 62

PeriodNo

Topic To be Covered Remarks

UNIT:1 CURVED BEAMS

1 Introduction to curved beams.

2Stresses in curved beams of standard cross sections used in cranehook.

3 Stresses in punching presses and clamps.

4 Stresses in closed rings and links.

5 Problems

UNIT:2 CYLINDERS & CYLINDER HEADS

6 Introduction to Cylinder and Cylinder Heads7 Lames equation

8 Compound cylinder

9 Stresses due to different types of fits

10 Stresses due to different types of cylinder heads & flats

11 Problems

UNIT:3 SPRINGS

12 Introduction to Springs.

13 Types of springs

14Stresses in Helical coil springs of circular and non-circular crosssections

15 Tension and compression springs

16Springs under fluctuating loads, Energy stored in springs and

problems

17 Torsion, Belleville and Rubber springs and Problems.

18 Leaf Springs: Stresses in leaf springs,Equalized stresses. Problems

19 Problems

UNIT:4 SPUR & HELICAL GEARS

20Introduction to spur and helical gears Definitions, stresses in gear

tooth.

21 Lewis equation and form factor.

22 Design for strength, Dynamic load and wear load.

23 Problems24 Helical Gears: Definitions, formative number of teeth

25 Design based on strength, dynamic and wear loads

26 Problems

UNIT:5 BEVEL AND WORM GEARS

27 Bevel Gears: Definitions, formative number of teeth

28 Design based on strength, dynamic and wear loads

29 Problems on Bevel Gears.


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30 Worm Gears: Definitions

31 Design based on strength, dynamic and Problems

32 wear loads and efficiency of worm gear drives

33 Problems on worm Gears

UNIT:6 CLUTCHES & BRAKES

34 Design of Clutches: Single plate

35 multi plate and cone clutches

36 Problems on clutches

37 Design of Brakes

38 Block and Band brakes

39 Self locking of brakes

40 Problems on brakes

41 Heat generation in Brakes Problems

UNIT:7 LUBRICATION AND BEARINGS

42 Lubricants and their properties

43 Mechanisms of Lubrication

44 Bearing modulus, coefficient of friction

45 Minimum oil film thickness, Heat Generated, Heat dissipated46 Bearing Materials

47 Examples of journal bearing and thrust bearing design

UNIT:8 BELTS, ROPES AND CHAINS

48 Introduction to Belt, Ropes and Chains

49 Flat belts: Length & cross section

50 Selection of V-belts

51 Ropes and chains for different applications

52 Problems & Previous Question Papers


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QUESTION BANK

01 How does the curvature of the beam affect the stress distribution across its crosssection under bending?

Determine the dimension of an I section of a curved beam in witch the and outer fiberstresses are numerically equal in pure bending given that bi + bo = 125mm

02 The horizontal section of crane hook is symmetrical trapezium 100mm deep. The

inner width being 60mm and outer width being 40mm, The hook carries a load of30kn. Inner radius of the hook is 75mm, the load line is nearer to the inner surface ofthe hook by 25mm than the center of curvature at the critical section. Determine

i. Distances from the centroidal and neutral axis.ii. Bending moment at critical section.iii. Extreme intensities of stress at critical section

03 Design a closed coil helical spring for a service load ranging from 2250N to 2757N.

The axial deflection for the load range is 6mm, assume the spring index=5,permissible shear stress is 420Mpa and modulus of rigidity is 840Gpa. Neglect the

effect of stress concentration

04 A helical spring is used in a pressure relief valve. The spring is preloaded to relieve the

pressure at 5Mpa. The diameter of the valve is 20mm. The spring has to undergo adeformation of 3mm to allow for fluid flow, the additional force caused due to this should notexceed 10% of the force required to relieve the pressure. The material for the spring is hot

drawn wire having an elastic strength of 520Mpa.Under torsion. Take a factor of safety of 1.5

and determine all the dimension of the spring if the diameter of the spring is not to exceed10mm

05 Design a valve spring of a petrol engine for the following operating conditions:

Spring load when valve is open = 400NSpring load when valve is closed = 250N

Max. Inside dia. of spring = 25mmLength of spring when valve is open = 40mm

Length of spring when valve is closed = 50mmMax strength = 400Mpa

06 Design a helical spring for a safety valve. The valve must blow off at a pressure of1.2 MPa and should lift by 3mm for 5% increase in pressure. The valve diameter is

60mm. The max allowable shear stress is 400MN/m2and the modulus of rigidity is

82.7X103MN/m2take the spring index as 8


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07 a. Explain equalizing the stresses in leaf springs

b. A semi elliptic leaf spring used for automobile suspension consists of three full-length leaves and 15 graduated leaves including the master leaf. The center

distance between the two eyes of the spring is 1m. The maximum force that acts

on the spring is 75kN. The ratio of width to thickness is 9:1 the modulus ofrigidity is 80 Gpa. The leaves are pre-stressed in such a way that the force ismaximum the stress induced in the spring is 450Mpa. Determine 1) the width

and thickness of the leaves 2) The initial gap 3) The load required

08 Design the leaf springs for the rear suspension of a heavy duty truck. The distance

between the axles, front and rear is 6m. The weight of the loaded truck is 2MN andthe center of gravity of the truck lies at 2m from the rear axle and at a height of 2m

from the ground. The number of full length is 2, the material for the spring is steelwith a permissible strength of 250 Mpa. The length of the spring between the eyes is

1600mm and the central band is 100mm wide. Determine the thickness and thenumber of graduated leaves if the width of the leaf is not to exceed 75mm. The

maximum deflection of the spring is limited to 50mm. Determine also the forcerequired to pre stress the spring

09 An internal expanding brake has a inner surface of rim of diameter 500mm. Thedistance between the fulcrums is 100mm. The distance between the fulcrums and the

point of application of efforts is 400mm. The brake linings sustain an angle of 1200at

the center. The material of the lining has the co-efficient of friction of 0.3 and an

allowable bearing pressure of 0.5 Mpa. Determine 1) The effort required to stop therotation of the brake drum. 2) The width of the brake lining. The brake transmits a

power of 30kW at a rated speed of 1500rpm

10 A 75kW at 3000rpm is to be transmitted by a multiple plate clutch. The plates have

friction surfaces of steel and phosphor bronze alternatively run in oil. Design theclutch for 30% overload and sketch the arrangement of plates

11 A simple band brake of drum diameter 650 mm has a band passing over it with anangle of contact of 225

0while one end of the band is connected to the fulcrum, the

other end is connected to the brake lever at a distance of 410 mm from the fulcrum.The brake lever is 1100 mm long. The brake is to absorb a power of 15 kW at 720

rpm. Design the brake lever of rectangular cross section assuming the depth to betwice the width

12 Design a centrifugal clutch with four shoes for transmitting 20kw at 1200 rpm. Thespeed at which engagement begins is 80% of the running speed. The inside radius of

the pulley rim is 150mm. The shoes are lined with Ferodo lining for which =0.25

13 A single block brake with a torque capacity of 15N-m id shown in fig.1. The

coefficient friction is 0.3 and the maximum, pressure on the brake lining is 1MPa.The width of the block is equal to its length. Calculate the actuating force 2) the

dimension of the block 3) the resultant hinge pin reaction

14 An automotive single-plate clutch consists of two pairs of contacting surfaces. The

outer diameter of the friction disc is 270 mm. The co-efficient of friction is 0.3 andthe maximum intensity of pressure is 0.3MPa. The clutch is transmitting a torque of

531 N-m, assuming uniform wear claculate1) the inner diameter of the friction discand 2) spring force required to keep the clutch engaged


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24 A full journal bearing of 50mm dia And 100mm long has a bearing pressure of1.4Mpa. Speed of journal is 900rpm and ratio of journal dia. To the diametrical

clearance is 1000. The bearing is lubricated with oil whose observed viscosity atoperating temperature of 75 degree C may be taken as 0.011Kg/m-s. The temperature

is 35 degree C. find the amount of artificial cooli8ng required and mass of lubricating

oil required, if the difference between the outlet and inlet temperature of oil is10degreeC. Take Sp. Heat of oil as 1850J/Kg/degreeC.

25 A 150mm dia shaft runs at 1500rpm, supporting a load of 10KN. The shaft runs in a

bearing of length 1.5 times the shaft dia. The clearing ratio is 0.015. The absoluteviscosity of the oil is 11cp. At its operating temperature, find the power lost in friction.

26 Determine the dimension of the bearing and journal to support a load of 6KN at750rpm using hardened steel journal and bronze backed babit bearing. An abundance

of oil provided which has a specific gravity of 0.95 at 15.50 C and viscosity of

9.5centistrokes at 820C that may be taken to the limiting temperature of oil. Assume a

clearance of 0.001mm per mm of diameter is allowed.

27 Derive Petroffs equation for the co-efficient of friction in a lightly loaded bearing

28 A shaft running at 600 rpm is supported in a bearing of 60mm dia and 60mm long.The viscosity of oil is 0.014Pa s and the temperature of oil is 1100C. The radial

clearance is 0.03mm. Determine temperature of still air in the bearing if there is noexternal cooling is provided. The temperature of still air in the room is 20

0C

29 A journal bearing is to be design for the main bearing of a four-stroke oil engine tosustain a load of 50KN for shaft diameter of 50mm. The engine runs at speed of

1500rpm determinei. The length and diameter of the bearingii. Viscosity of oil to be used as lubricant, hence suggest a

suitable oil

iii. The co-efficient of friction of the bearing and the heatgenerated.

30 Design the journal bearing for a centrifugal pump from the following data. Load onthe journal=10KN, speed on the journal=900rpm, Ambient temperature=15

0C.

31 A 40BC03 (SKF6308) single- row, deep groove ball bearing, which is to operate at 80 rpm isacted on by an 8KN radial load and 6KN thrust load. The outer ring rotates, and the bearing

is subjected to light shock. Determine the rating and median life of the bearing in hours.

32 Select a single- row, deep groove ball bearing to carry a radial load of 4KN, and a

thrust load 5KN operating speed of 1200rpm, for an average life of 15years at 10hours per day. Assume there are 250 working days per year. The loads are steady and

the outer ring rotates.

33 A belt with cross sectional Power of 60kw at 750rpm is to be an electric motor Give

a complete to compressor transmitted from shaft at 300rpm by v belts. Theapproximate larger pulley diameter is 1500mm. The approximate center distance is

1650mm, and over load area of 350mm2 and weighing .001kg/cm

3 and having an

allowable tensile strength 2 N/mm2 is available for use. The coefficient of friction

between the nearest bearing and is mounted on the shaft having a permissible shearstress of 40N/mm2 with the belt and pulley may be taken as 0.28. The driven pulley is

over hung to the extent of 300mm from help of a key. The shaft, the pulley and thekey are also to be designed.


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DEPT. OF MECHANICAL ENGINEERING VI SEMESTER COURSE DIARY

MVJCE10

VTU QUESTION PAPERS


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06ME62 MECHANICAL VIBRATION


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SYLLABUS




PART - AUNIT 1INTRODUCTION: Types of vibrations, S. H. M, principle of super position applied to Simple

Harmonic Motions. Beats, Fourier theorem and simple problems. (6 Hours)

UNIT 2

UNDAMPED FREE VIBRATIONS: Single degree of freedom systems. Mass Undamped freevibration-natural frequency of free vibration, stiffness of spring elements, effect of mass of

spring, Compound Pendulum. (7 Hours)

UNIT 3

DAMPED FREE VIBRATIONS: Single degree freedom systems, different types of damping,

concept of critical damping and its importance, study of response of viscous damped systems forcases of under damping, critical and over damping, Logarithmic decrement. (7 Hours)

UNIT 4

FORCED VIBRATION: Single degree freedom systems, steady state solution with viscousdamping due to harmonic force. 1) Solution by Complex algebra, Reciprocating and rotating

unbalance, vibration isolationtransmissibility ratio. Due to harmonic exitation and supportmotion. (6 Hours)

PART - B

UNIT 5

VIBRATION MEASURING INSTRUMENTS & WHIRLING OF SHAFTS:

Vibrometer meter and accelerometer. Whirling of shafts with and without air damping.

Discussion of speeds above and below critical speeds. (6 Hours)

UNIT 6

SYSTEMS WITH TWO DEGREES OF FREEDOM: Introduction, principle modes and

Normal modes of vibration, co-ordinate coupling, generalized and principal co-ordinates, Free

vibration in terms of initial conditions. Geared systems. Forced Oscillations-Harmonic

excitation. Applications: a) Vehicle suspension. b) Dynamic vibration absorber. c) Dynamics of

reciprocating Engines. (6 Hours)

UNIT 7

CONTINUOUS SYSTEMS: Introduction, vibration of string, longitudinal vibration of rods,Torsional vibration of rods, Eulers equation for beams. (6 Hours)

UNIT 8NUMERICAL METHODS FOR MULTI DEGREE FREEDOM SYSTEMS:Introduction, Influence coefficients, Maxwell reciprocal theorem, Dunkerleys equation.

Orthogonality of principal modes, Method of matrix iteration-Method of determination of all thenatural frequencies using sweeping matrix and Orthogonality principle. Holzers method,

Stodola method. (8 Hours)


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TEXT BOOKS:

1. Theory of Vibration with Applications: W.T. Thomson and MarieDillon Dahleh, Pearson

Education 5th edition, 2007.

2. Mechanical Vibrations: V.P. Singh, Dhanpat Rai & Company Pvt.Ltd., 3rd edition, 2006.

REFERENCE BOOKS:

1. Mechanical Vibrations: S.S. Rao, Pearson Education Inc, 4thEdition, 2003.2. Mechanical Vibrations: S. Graham Kelly, Schaums OutlineSeries, Tata McGraw Hill,

Special Indian edition, 2007.3. Theory & Practice of Mechanical vibrations: J.S. Rao & K.Gupta, New Age International

Publications, New Delhi, 2001.4. Elements of Vibrations Analysis: Leonanrd Meirovitch, Tata

McGraw Hill, Special Indian edition, 2007


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LESSON PLAN


Sub: Mechanical Vibration Total Hours: 62

Period

No Topic To be Covered Remarks1. Introduction, types of vibration-

free,forced,random,torsional,longitudinal, rotational etc.,

2. Simple harmonic motion concept, phase difference3. principle of superposition and its derivation4. Beats phenomena5. Fourier theorem derivation for solving problem6. Problem solving7. Introduction to undamped free vibration ,examples. SDOF system8. Mass undamped system, natural frequency of free vibration9. Stiffness of spring element-series,parallel,etc,problem10. Effect of mass of spring ,derivation, problem11. Compound pendulum derivation, problem12. Different problem approach13. Different problem approach14. Different problem approach15. Introduction to damped free vibration ,examples.SDOF system16. Different types of damping viscous damping,17. Concepts of critical damping and its important18. Overdamping,underdamping -derivation19. Logarithmic decrement problem solving20. Problem solving21.

Problem solving22. Introduction to forced vibration ,examples.SDOF system

23. Steady state solution with viscous damping due to harmonic force24. Solution by complex algebra25. Reciprocating and rotating unbalance system with example

,derivation

26. Vibration isolation, transmissibility ratio.27. Harmonic excitation, and support motion28. Problem approach29. Introduction to vibration measuring instruments30. Vibrometer working principle31. Problems on Vibrometer32. Accelerometer working principle33. Problems on Accelerometer34. Whirling of shafts explanation with air and without air damping35. Critical speed of shaft derivation ,36. Problems on Critical speed of shaft derivation37. Introduction to two degrees of freedom38. Principle mode and normal modes of vibration39. Problems on Principle mode and normal modes of vibration


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Period

NoTopic To be Covered Remarks

40. Co-ordinate coupling derivation41. Generalized and principle co-ordinate system, initial condition42. Vehicle suspension, dynamic vibration absorber43. Problems on dynamic vibration absorber44. Dynamics of reciprocating engines, problem approach45. Problems on Dynamics of reciprocating engines46. Problem solving47. Introduction to continuous system, vibration of string derivation48. Longitudinal vibration of rods derivation49. Torsion vibration of rods, derivation, problem50. Eulers equation for beams derivation51. Introduction to multi degree of freedom52. Influence coefficients, Maxwell reciprocal theorem53. Dunker leys equation, orthogonality of principal modes54. Problems on Dunker leys equation, orthogonality of principal

modes55. Methods of matrix iteration56. Problems on matrix iteration57. Holzer method, problem approach58. Problems on Holzer method59. Stodola method, problem approach60. Problems on Stodola method61. Problem approach62. Problem approach


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.

06ME63 MODELLING & FINITE ELEMENT

ANALYSIS


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SYLLABUS




PART - AUnit 1INTRODUCTION: Equilibrium equations in elasticity subjected to body force, traction forces,

stress strain relations for plane stress and plane strain, Boundary conditions, Initial conditions,

Eulers Lagranges equations of bar, beams, Principal of a minimum potential energy, principle

of virtual work, Rayleigh-Ritz method, Galerkins method., Guass elimination Numerical

integration. 07Hrs

Unit 2BASIC PROCEDURE :General description of Finite Element Method, Engineering

applications of finite element method, Discretization process; types of elements 1D, 2D and 3D

elements, size of the elements, location of nodes, node numbering scheme, half Bandwidth,

Stiffness matrix of bar element by direct method, Properties of stiffness matrix, Preprocessing,post processing. 06Hrs

Unit 3INTERPOLATION MODELS : Introduction, Polynomial form of interpolation functions-

linear, quadratic and cubic, Simplex, Complex, Multiplex elements, Selection of the order of the

interpolation polynomial, Convergence requirements, 2D Pascal triangle, Linear interpolation

polynomials in terms of global coordinates of bar, triangular (2D simplex) elements, Linear

interpolation polynomials in terms of local coordinates of bar, triangular (2D simplex) elements,

CST element. 06 Hrs

Unit 4

HIGHER ORDER AND ISOPARAMETRIC ELEMENTS : Lagrangian interpolation,

Higher order one dimensional elements- quadratic, Cubic element and their shape functions,

properties of shape functions, Truss element, Shape functions of 2D quadratic triangular elementin natural coordinates , 2D quadrilateral element shape functions linear, quadratic, Biquadric

rectangular element( Nodded quad lateral element), Shape function of beam element, Hermiteshape function of beam element. 07 Hrs.

PART B

Unit 5DERIVATION OF ELEMENT STIFFNESS MATRICES AND LOAD VECTORS: Direct

method for bar element under axial loading, trusses, beam element with concentrated and

distributed loads, B matrices, Jacobian, Jacobian of 2D triangular element, quadlateral ,Consistent load vector, Numerical integration. 07 Hrs.

Unit 6HEAT TRANSFER PROBLEMS : Steady state heat transfer, 1d heat conduction governing

equation, boundary conditions, One dimensional element, Functional approach for heat

conduction, Galerkin approach for heat conduction, hat flux boundary condition, 1D heattransfer in thin fins. 06 Hrs.


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Unit 7APPLICATIONS I : Solution of bars, stepped bars, plane trusses by direct stiffness method.

Solution for displacements, reactions and stresses by using elimination approach, penalty

approach. 06Hrs.

Unit 8

APPLICATIONS II: Solution of beam problems, heat transfer 1D problems with conductionand convection. 07Hrs.

TEXT BOOKS:

1. Finite Elements in engineering, Chandrupatla T. R., 2nd Edition, PHI,2000

2. The Finite Element Method in Engineering , S. S. Rao, 4th Edition,Elsevier,2006.

REFERENCE BOOKS:

1. Textbook of Finite Element Analysis, P.Seshu,PHI, 2004.

2. Finite Element Method, J.N.Reddy, McGraw Hill International Edition.

3. Finite Element Analysis, C.S.Krishnamurthy,Tata McGraw Hill Publishing

Co.Ltd, New Delhi, 1995.


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LESSON PLAN


Sub: Modeling and Finite Element Analysis Total Hours: 62

Period

No Topic To be Covered Remarks

1Equilibrium equations in elasticity subjected to body force,traction forces

2 Stress strain relations for plane stress and plane strain,

3 Boundary conditions, Initial conditions,

4 Eulers Lagranges equations of bar

5 Beams, Principal of a minimum potential energy

6 Principle of virtual work

7 Rayleigh-Ritz method, Galerkins method

8 Guass elimination Numerical integration.

9 General description of Finite Element Method

10 Engineering applications of finite element method,

11Discretization process; types of elements 1D, 2D and 3D

elements

12size of the elements, location of nodes, node numbering scheme,

half Bandwidth

13 Stiffness matrix of bar element by direct method

14 Properties of stiffness matrix, Preprocessing, post processing.

15 Polynomial form of interpolation functions- linear

16 Polynomial form of interpolation functions- quadratic and cubic

17 Simplex, Complex, Multiplex elements

18Selection of the order of the interpolation polynomial,

Convergence requirements

192D Pascal triangle, Linear interpolation polynomials in terms of

global coordinates of bar, triangular (2D simplex) elements

20Linear interpolation polynomials in terms of local coordinates of

bar,

21Linear interpolation polynomials in terms of local coordinates

triangular (2D simplex) elements

22Linear interpolation polynomials in terms of local coordinates

CST element

23 Lagrangian interpolation

24 Higher order one dimensional elements- quadratic

25 shape functions

26 Cubic element and its shape functions27 Truss element, properties of shape functions,

28Shape functions of 2D quadratic triangular element in natural

coordinates

29 2D quadrilateral element shape functions linear, quadratic

30 2D quadrilateral element shape functions quadratic

31 Biquadric rectangular element (Noded quadrilateral element

32 Shape function of beam element..


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Period

NoTopic To be Covered Remarks

33 Hermite shape function of beam element

34 Direct method for bar element under axial loading

35 Direct method for trusses element under axial loading,

36 beam element with concentrated

37 beam element with distributed loads,

38 Jacobian matrices, Jacobian of 2D triangular element

39 Quadrilateral, Consistent load vector,.

40 Numerical integration

41Steady state heat transfer, 1D heat conduction governing

equation,

42 boundary conditions, One dimensional element,

43 Functional approach for heat conduction

44Galerkin approach for heat conduction, heat flux boundary

condition,

45 1D heat transfer in thin fins.

46 Solution of bars,47 Solution of bars

48 Solution of bars

49 Stepped bars by direct stiffness method.

50 Plane trusses by direct stiffness method.

51Solution for displacements, reactions and stresses by usingelimination approach of bars

52Solution for displacements, reactions and stresses by usingelimination approach of bars

53Solution for displacements, reactions and stresses by usingelimination approach truss

54 Reactions and stresses by using Penalty approach.55 Problems by using Penalty approach.

56 Problems by using Penalty approach.

57 Solution of beam problems

58 Solution of beam problems

59 Heat transfers 1D problem with conduction.

60 Problem on 1D problem with conduction

61 Heat transfers 1D problem with convection.

62 Problem on 1D problem with convection.


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QUESTION BANK

1. Define a shape function.2. What are the properties that the shape function should satisfy?3. Explain linear interpolation4. What are interpolation functions?5. What is symmetric banded matrix?6. Derive the Hermite shape functions for a beam elements.7. Derive the shape functions fro a CST element and also the displacement matrix.8. Explain the convergence criteria with suitable examples and compatibility requirements

in FEM.

9. Derive the expression for stiffness matrix for a 2-D truss elements.10.For a four nodded quadrilateral element, derive an expression for Jacobian matrix.11.Derive the shape function for a 3 noded triangular element.12.Explain Simplex, complex and multiplex elements.13.Explain 2D Pascal triangle14.With an example, explain node numbering and element connectivity for a ID bar.15.Using Potential energy approach, obtain the element stiffness matrix for a ID bar

element.

16.Derive [BT ] fro a two nodded one dimensional heat element (conduction)17.Determine the nodal displacements18.Determine the stress in each material19.Determine the reaction forces.20.Solve the following system of simultaneous equations by Gaussian elimination method.

x1- 2x2+ 6x3= 0

2x1+ 2x2+ 3x3= 3

-x1+ 3x2= 2


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06ME64 MECHATRONICS & MICROPROCESSOR


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SYLLABUS




PART A

Unit 1

INTRODUCTION OF MECHATRONICS: Introduction of Mechatronics systems,

Measurement system, control systems, microprocessor based controllers, Mechatronics approach

and their associated problems. Examples and discussion on typical systems. 07 Hrs

Unit 2REVIEW OF TRANSDUCERS: Introduction of Transducers, Classifications, light sensors,

selection of selectors, and inputting data by switches, their merits and demerits. 06 Hrs

Unit 3

ELECTRICAL ACTUATION SYSTEMS: Electrical systems, Mechanical switches, solidstate switches, solenoids, DC & AC motors, Stepper motors and their merits and demerits.

06 Hrs

Unit 4

SIGNAL CONDITIONING: Introduction to signal conditioning. The operational amplifier,

Protection, Filtering, Wheatstone bridge, Digital signals Multiplexers, Data acquisition,

Introduction to Digital system processing Pulse-modulation. 07 Hrs

PART B

Unit 5INTRODUCTION TO MICROPROCESSORS: Evaluation of Microprocessor, Organization

of Microprocessors (Preliminary concepts), basic concepts of programming of microprocessors.

Review of concepts Boolean algebra, Logic Gates and Gate Networks, Binary & Decimalnumber systems, memory representation of positive and negative integers, maximum andminimum integers. Conversion of real numbers, floating point notation, representation of

floating point numbers, accuracy and range in floating point representation, overflow andunderflow, addition of floating point numbers, character representation.

07 Hrs

Unit 6

Logic function, Data word representation. Basic elements of control systems 8085A processor

architecture terminology such as CPU, memory and address, ALU, assembler data registers,

Fetch cycle, write cycle, state, bus, interrupts. Micro Controllers. Difference between

microprocessor and micro controllers. Requirements for control and their implementation in

microcontrollers. Classification of micro controllers. 07 Hrs

Unit 7

ORGANIZATION & PROGRAMMING OF MICROPROCESSORS: Introduction to

organization of INTEL 8085-Data and Address buses, Instruction set of 8085, programming the

8085, assembly language programming. 06 Hrs


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Unit 8

CENTRAL PROCESSING UNIT OF MICROPROCESSORS: Introduction, timing and

control unit basic concepts, Instruction and data flow, system timing, examples of INTEL 8085

and INTEL 4004 register organization. 06 Hrs

Text Books:

1. Microprocessor Architecture, Programming And Applications With8085/8085A R.S. Ganokar, Wiley Eastern.

2. Mechatronics W.Bolton, Longman, 2Ed, Pearson Publications, 2007.

Reference Books:1. Mechatronics Principles & applications by Godfrey C.Canwerbolu,

Butterworth Heinemann 2006.

2. Mechactrionics Dan Necsulescu, Pearson Publication, 2007.

3. Introduction Mechatronics & Measurement systems, David.G. Aliciatore &

Michael.B.Bihistaned, Tata McGraw Hill, 2000.

4. Mechatronics: Sabri Centinkunt, John Wiley & Sons Inc. 2007.5. Mechatronics: Nitaigour Premchand Mahalik. Tata McGraw Hill, 2003


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LESSON PLAN


Sub: Mechatronics and Microprocessor Total Hours: 62

Period Topic to be covered Remarks

1. (PART-A)Introduction to mechatronic systems

2. Measurement systems and basic functions and applications.3. Open control system with example.4. Close control system with example.5. control systems applications.6. Microprocessor based controllers.7. Mechatronics application i.e Automatic camera & washing machine8. Mechatronics application i.e Automatic Engine system9. Definition and classification of transducers.10. Characteristics of transducer and sensors.11. Definition and classification of sensors.12. Principle and working of Eddy current sensors.13. Principle of working and applications proximity sensors.14. Principle of working and applications Hall effect sensors.15. Principle of working and applications of light sensors16. Electrical actuation systems introduction.17. Mechanical switches Relay working principle.18. Solid-state switches, types.19. Diode and its characteristics.20. Transistor and its characteristics.21. Traic and characteristics.22. Types of field effect sensors.23. MOSFET constructions.24. SCR and its characteristics.25. D.C Motor, principle and constriction details.26. Types of D.C Motors27. Brush less type D.C Motor.


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28. A.C.Motors and its Types29. Definition of Stepper Motors.30. Types of stepper motors31. PM stepper motor32. Variable Reluctance stepper motor.33. Hybrid stepper motor.34. (PART-B)

Introduction to microprocessors

35. Evolution of Microprocessor.36. Organization of Microprocessors.37. Basic concepts of programming of microprocessors.38. Review of concepts Boolean algebra39. . Logic Gates and Gate Networks.40. Binary & Decimal number systems.41. Conversion of real numbers.42. Representation of floating point numbers43. Introduction to organization of INTEL 8085 Microprocessor.44. 8085A processor architecture terminology .45. Requirements for control and their implementation in

microcontrollers46. Data and Address buses.47. Instruction set of 8085.48. Programming the 8085.49. Introduction, timing and control unit basic concepts.50. Instruction and data flow, system timing51. Examples of INTEL 8085 and INTEL 4004 register organization.52. (PART-A)

Introduction to signal conditioning

53. The operational amplifier.54. Protection, Filtering.55. Wheatstone bridge and its working56. Digital signals Multiplexers.


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57. Data acquisition system.58. Introduction to Digital system processing Pulse-modulation.59. ADC & DAC60. Difference between ADC & DAC61. Revision62. Revision


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QUESTION BANK

1. Define measurement and measurement system.2. Explain the function of signal conditioner.

3. Define the term MECHATRONICS with the help of block diagram.

4. Give an example of measurement system and compare with elements of generalizedmeasurements.

5. Define open loop control system, explain the neat diagram with an example of open loop

system

6. Define closed loop control system, explain the neat diagram with an example of closed loop

system.

7. Enumerate the difference between closed loop and open loop system.

8. What sequential control illustrate with an example.

9. Explain with block diagram the working of microprocessor-controlled washing machine.

10. Explain how microprocessors are use full in automatic camera.

11. Define sensor and transducer.

12. What is meant by detect transducer? Give an example.

13. What is meant by performance transducers?

14. What are the terminologies associated with the performance of transducers.15. Explain the static characteristics of transducers.

16. Explain the dynamic characteristics of transducers.17. How the transducers are classified.

18. Explain the Hall effect transducers.19. Explain the light sensor with their classified.

20. Explain with sketch inputting data by switches.21. Explain microprocessor based digital control system.

22. Explain digital numbering system.

23. Explain Binary and hexadecimal numbering system.

24. Explain the Logic functions & Data word representation25. What are the basic elements of control system?

26. Explain with neat sketch 8085A Processor architecture Terminology.

27. Explain the Microprocessor with a neat diagram.

28. Enumerate the difference between Microprocessor and micro controllers.

29. What is meant by Electrical actuating system?30. What are the Devices used in electrical actuator system.

31. Name solid-state switches and explain?

32. What are diodes? What is meant by forward and reverse bias diode?

33. Explain the working of thyristors with a block diagram.

34. What is Polar transistor? What is the difference configuration of Transistor?

35. What is D.C motor? Explain the principle of working of a D.C Motor.

36. Explain with a circuit diagram and characteristics curves, shunt wound D.C Motors.37. Explain with neat sketch the feed back control system using PMW?

38. Explain a block diagram the basic principle of variable speed A.C motors.

39. What is meant Stepper motor and what are its performance characteristics.

40. What is meant by hybrid stepper motor?

41. Explain the specification terms of stepper motor.

42. What is meant by hydraulic actuation system?

43. Explain with a neat sketch principle of variable reluctance stepper motor44. Explain with neat sketch working of hydraulic system.


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45. Enumerate the difference between pneumatic and hydraulic system.

46. What are the Different types of OP-Amps? Explain each of them with neat Sketch.

47. What are the Characteristics of ideal operational Amplifier?

48. What is an Amplifier and Operational Amplifier?

49. What is the difference between passive and active filters?

50. Explain with neat Circuit diagram and instrumentation amplifier.

51. Explain with neat Circuit diagram the application of Comparators.52. Explain with neat Circuit diagram the use of Amplifier in Audio CD Player?


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VTUQUESTION PAPERS


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06ME65 HEAT & MASS TRANSFER


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SYLLABUS




PART-AUNIT-1

INTRODUCTORY CONCEPTS AND DEFINITIONS:Modes of heat transfer: Basic laws

governing conduction, convection and radiation heat transfer; thermal conductivity; heat transfer

coefficient; radiation heat transfer; combined heat transfer mechanism. Boundary conditions of

1st, 2

ndand 3

rdkind.

CONDUCTION: Derivation of general three dimensional conduction equation in Cartesian

coordinate, special cases, discussion on 3-D conduction in cylindrical and spherical coordinatesystem (No derivation). One dimensional conductional equations in rectangular, cylindrical and

spherical coordinates for plane and composite walls. Overall heat transfer coefficient. Thermalcontact resistance. 7 hours

UNIT-2

VARIABLE THERMAL CONDUCTIVITY: Derivation of heat flow and temperature

distribution in plane wall. Critical thickness of Insulation without heat generation, Thermal

resistance concept & its importance. Heat transfer in extended surfaces of uniform cross-section

without heat generation, Long fin, short fin with insulated tip and fin connected between two

heat sources. Fin efficiency and effectiveness. Numerical problems. 6 hours

UNIT-3

ONE-DIMENSIONAL TRANSIENT CONDUCTION: Conduction in solids with negligible

internal temperature gradient (lumped systenm analysis), Use of Transient temperature charts

(Heislers charts) for transient conduction in slab, long cylinder and sphere; use of Transient

temperature charts for transient conduction in semi-infinite solids. Numerical problems.6 hours

UNIT-4CONCEPTS AND BASIC RELATIONS IN BOUNDARY LAYERS:Flow over a body

velocity boundary layer; critical Reynolds number; general expressions for drag coefficient anddrag force; thermal boundary layer; general expressions for local heat transfer coefficient;

Average heat transfer coefficient; Nusselt number. Flow inside a duct-velocity boundary layer,hydrodynamic entrance length and hydro dynamically developed flow; flow through tubes

(internal flow)(discussion only). Numerical based on empirical relation given in data handbook.

FREE OR NATURAL CONVECTION: Application of dimensional analysis for free

convection- physical significance of Grashoff number; use of correlations of free convection in

vertical, horizontal; and inclined flat plates, vertical and horizontal cylinders and spheres,

Numerical problems. 7 hours


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PART-B

UNIT-5

FORCED CONVECTIONS: Application of dimensional analysis for forced convection.

Physical significance of Reynolds, Prandtl, Nusselt and Stanton numbers. Use of various

correlations for hydro dynamically and thermally developed flows inside a duct, use of

correlations for flow over a flat plate, over a cylinder and sphere. Numerical problems. 6 hours

UNIT-6HEAT EXCHANGERS: Classification of heat exchangers; overall heat transfer coefficient,

fouling and fouling factor; LMTD, Effectiveness-NTU methods of analysis of heat exchangers.Numerical problems. 6 hours

UNIT-7

CONDENSATION AND BOILING:Types of condensation (discussion only) Nusselts theory

for laminar condensation on a vertical flat surface; use of correlations for condensation on

vertical flat surfaces, horizontal tube and horizontal tube banks; Reynolds number for

condensate flow; regimes of pool boiling correlations. Numerical problems. Mass transfer

definition and terms used in mass transfer analysis, Ficks First law of discussion (nonumericals). 7 hours

UNIT-8

RADIATION HEAT TRANSFER: Therma radiation; definitions of various terms used in

radiation heat transfer; Stefan-Boltzman law,Kirchoffs law, Plancks law and Weins

displacement law. Radiation heat exchange between two parallel infinite black surfaces, between

two parallel infinite gray surfaces; effect of radiation shield; intensity of radiation and solid

angle; lamberts law; radiation heat exchange between two finite surfaces- configuration factor.Numerical problems. 7 hours

Text Books:1. Heat & Mass transfer, by Tirumaleshwar, Pearson-2006

2. Heat transfer, by P.K. Nag, Tata Mc Graw Hill 2002

Reference Books:

1. Heat transfer, a practical approach, Yunus A- Cengel Tata Mc Graw Hill

2. Principles of heat transfer by Kreith Thomas Learning 2001

3. Fundamentals of heat and mass transfer by Frenk P. Incropera and David P.

Dewitt, John Wiley and sons.

4. Heat and Mass Transfer,by B K Venkanna, Ellite Publisher, Mangalore.


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[

LESSON PLAN


Sub: Heat and Mass Transfer Total Hours: 52

Hour

No

Topics to be coveredRemarks

1. INTRODUCTORY CONCEPTS AND DEFINITIONS: Modes ofheat transfer: Basic laws governing conduction,;

2. convection and radiation heat transfer, thermal conductivity3. Heat transfer coefficient; radiation heat transfer4. Combined heat transfer mechanism. Boundary conditions of 1 st, 2nd

and 3rdkind

5. CONDUCTION: Derivation of general three dimensionalconduction equation in Cartesian coordinate

6. Special cases, discussion on 3-D conduction in cylindrical andspherical coordinate system (No derivation).

7. One dimensional conductional equations in rectangular, cylindricaland spherical coordinates for plane and composite walls.

8. Overall heat transfer coefficient. Thermal contact resistance.9. VARIABLE THERMAL CONDUCTIVITY: Derivation of heat

flow and temperature distribution in plane wall.

10. Critical thickness of Insulation without heat generation, Thermal

resistance concept & its importance.

11. Heat transfer in extended surfaces of uniform cross-section without

heat generation,

12. Long fin, short fin with insulated tip and fin connected between twoheat sources.

13. Fin efficiency and effectiveness,Numerical problems.

14. ONE-DIMENSIONAL TRANSIENT CONDUCTION: Conductionin solids with negligible internal temperature gradient (lumped

system analysis)

15. Use of Transient temperature charts (Heislers charts) for transientconduction in slab,

16. Use of Transient temperature charts for transient conduction insemi-infinite solids.

17. Long cylinder and sphere;Numerical problems.

18. CONCEPTS AND BASIC RELATIONS IN BOUNDARY

LAYERS: Flow over a body velocity boundary layer;

19. Critical Reynolds number; general expressions for drag coefficient

and drag force; thermal boundary layer;

20. General expressions for local heat transfer coefficient; Average heat

transfer coefficient; Nusselt number.


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21. Flow inside a duct-velocity boundary layer, hydrodynamic

entrance length and hydro dynamically developed flow;

22. Flow through tubes (internal flow)(discussion only). Numerical

based on empirical relation given in data handbook.

23. FREE OR NATURAL CONVECTION: Application of

dimensional analysis for free convection- physical significance ofGrashoff number;

24. Use of correlations of free convection in vertical vertical and

horizontal cylinders and spheres, Numerical problems

25. FORCED CONVECTIONS: Application of dimensional analysis

for forced convection. , horizontal; and inclined flat plates,.

26.Physical significance of Reynolds, Prandtl, Nusselt and Stanton

numbers.

27. Use of various correlations for hydro dynamically and thermally

developed flows inside a duct,

28. Use of correlations for flow over a flat plate, over a cylinder and

sphere. Numerical problems.

29. HEAT EXCHANGERS: Classification of heat exchangers overall

heat transfer coefficient,;

30. fouling and fouling factor; LMTD, Effectiveness-

31. NTU methods of analysis of heat exchangers. Numerical problems.

32. CONDENSATION AND BOILING: Types of condensation

(discussion only)

33. Nusselts theory for laminar condensation on a vertical flat surface;

34. use of correlations for condensation on vertical flat surfaces,

35. horizontal tube and horizontal tube banks;

36. Reynolds number for condensate flow

37. ; regimes of pool boiling correlations.

38. Numerical problems.

39. Mass transfer definition and terms used in mass transfer analysis,

40.Ficks First law of discussion (no numericals).

41. RADIATION HEAT TRANSFER: Thermal radiation;

42. Definitions of various terms used in radiation heat transfer;

43. Stefan-Boltzman law,Kirchoffs law,.

44. Plancks law and Weins displacement law


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QUESTION BANK


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VTU QUESTION PAPERS


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06ME665 NON TRADITIONAL MACHINING


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SYLLABUS




PART - AUnit 1

INTRODUCTION: History, Classification, comparison between conventional and Non-

conventional machining process selection. Water Jet Machinery: Principal, Equipment,

Operation, Application, Advantages and limitations of water Jet machinery

06 Hrs

Unit 2MECHANICAL PROCESS: Ultrasonic machining (SUM): Introduction, equipment, tool

materials & tool size, abrasive slurry, cutting tool system design:- Magnetostriction assembly,

Tool cone (Concentrator), Exponential concentrator of circular cross section & rectangular cross

section, Hallow cylindrical concentrator. Mechanics of cutting-Theory of Miller & Shaw., Effect

of parameter: Effect of amplitude and frequency and vibration, Effect of grain diameter, effect of

applied static load, effect of slurry, tool & work material, USM process characteristics: Materialremoval rate, tool wear, Accuracy, surface finish, applications, advantages & Disadvantages of

USM. 08 Hrs

Unit 3

ABRASIVE JET MACHINING (AJM): Introduction, Equipment, Variables in AJM: Carrier

Gas, Type of abrasive, size of abrasive grain, velocity of the abrasive jet, mean No. abrasive

particles per unit volume of the carrier gas, work material, stand off distance (SOD), nozzle

design, shape of cut. Process characteristics-Material removal rate, Nozzle wear, Accuracy &

surface finish. Applications, advantages & Disadvantages of AJM. 06 Hrs

Unit 4

ELECTROCHEMICAL AND CHEMICAL METAL REMOVAL PROCESS:Electrochemical machining (ECM): Introduction , study of ECM machine, elements of ECM

process : Cathode tool, Anode work piece, source of DC power, Electrolyte, chemistry of theprocess, ECM Process characteristics Material removal rate, Accuracy, surface finish, ECM

Tooling: ECM tooling technique & example, Tool & insulation materials, Tool size Electrolyteflow arrangement, Handling of slug, Economics of ECM, Applications such as Electrochemical

turning, Electrochemical Grinding, Electrochemical Honing, deburring, Advantages,

Limitations. 06 Hrs

PART B

Unit 5

CHEMICAL MACHINING (CHM) : Introduction, elements of process, chemical blankingprocess : Preparation of work piece, preparation of masters, masking with photo resists, etching

for blanking, accuracy of chemical blanking, applications of chemical blanking, chemical

milling (contour machining): process steps masking, Etching, process characteristics of CHM:

;material removal rate accuracy, surface finish, Hydrogen embrittlement, advantages &

application of CHM . 06 Hrs


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Unit 6

THERMAL METAL REMOVAL PROCESSES: Electrical discharge machining (EDM)

introduction, machine, mechanism of metal removal, dielectric fluid, spark generator, EDM

tools (electrodes) Electrode feed control, Electrode manufacture, Electrode wear, EDM tool

design choice of machining operation electrode material selection, under sizing and length of

electrode, machining time. Flushing pressure flushing suction flushing, side flushing, and pulsedflushing synchronized with electrode movement, EDM process characteristics: metal removal

rate, accuracy surface finish, Heat affected Zone. Machine tool selection, Application EDMaccessories / applications, electrical discharge grinding, Traveling wire EDM. 08 Hrs

Unit 7

PLASMA ARC MACHINING (PAM): Introduction, equipment non-thermal generation ofplasma, selection of gas, Mechanism of metal removal, PAM parameters, process characteristics.

Safety precautions, Applications, Advantages and limitations. 05 Hrs

Unit 8

LASER BEAM MACHINING (LBM): Introduction, equipment of LBM mechanism at metal

removal, LBM parameters, Process characteristics, Applications, Advantages limitations

ELECTRON BEAM MACHINERY (EBM): Principles, equipment, operations, applications,

advantages and limitation of EBM. 07 Hrs

TEXT BOOKS:

1. Modern machining process, by PANDEY AND SHAH, TATA McGraw Hill

20002. New technology by BHATTACHARAYA 2000

REFERENCE BOOKS:

1. Production Technology, by HMT TATA McGraw Hill. 20012. Modern Machining Process by ADITYA. 2002

3. Non-Conventional Machining by P.K.Mishra, The Institution of Engineers(India) Test book series, Narosa Publishing House 2005.


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LESSON PLAN


Sub: Non Traditional Machining Total Hours: 62

Period Topics to be covered Remarks1. Introduction :History2. Classification of NTM3. Comparison btw conventional & Non conventional machining

process

4. Abrasive Jet Machining :Introduction5. AJM Equipment6. Variables in AJM7. Continuation8. Process characteristics of AJM9. Applications ,Adv& Disadv10.

Electro chemical Machining : Introduction11. Study of ECM

12. Elements of ECM Process13. Chemistry of process14. ECM Process characteristics15. ECM Tooling technique and example ,Tool and insulation materials16. Electrolyte Flow arrangement ,handling of slug17. Economics of ECM ,Applications of ECM18. EC turning ,EC grinding ,EC honing deburring19. Advantages and limitations20. Chemical Machining: Introduction21. Elements of process, Chemical blanking process22. Preparation of work piece, preparation of masters, masking with

photo resists

23. Etching for blanking ,Accuracy of chemical blanking24. Applications of chemical blanking25. Chemical milling: Process steps-masking ,etching26. Process characteristics of CHM27. Hydrogen Embritlement ,Adv and application of CHM28. Ultra sonic machining : Introduction29. Equipment30. Tool materials& tool size31. Abrasive slurry32. Cutting tool system design33. Mechanics of cutting ,Theory of miller and shaw34. Effect of parameter35. USM process characteristics36. Adv and Disadv, Applications of USM37. Electrical discharge machining: introduction, equipment38. Mechanism of metal removal39. Dielectric fluid, Spark generator


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40. EDM tools41. Electrode feed control42. Electrode manufacture ,Electrode wear43. EDM tool design44. Choice of machining operation, electrode material selection ,under

sizing and length of electrode

45. Flushing technique :pressure flushing ,suction flushing46. EDM process characteristics47. Applications of EDM48. Electrical discharge grinding49. Traveling wire EDM50. Plasma arc machining : Introduction ,equipment51. Non thermal selection of gas52. Mechanism of metal removal53. Pam parameters ,process characteristics54. Safety precautions ,Applications Adv and disadv55. Laser Beam Machining :introduction56. Equipment of LBM ,mechanism of metal removal57. LBM parameters ,process characteristics58. Applications ,Advantages and limitations59. Electron Beam Machining priciples,equipment,operations60. Applications ,adv and disadv of EBM61. Revision62. Revision


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QUESTION BANK

ULTRA SONIC MACHINING

1. What is ultrasonic machining?

USM is a mechanical material removal process in which the material is removedby repetitive impact of abrasive particles carried in liquid medium on to the work surface, by

a shaped tool, Vibrating at ultrasonic frequency.

2. What are the advantages of USM?Advantages

High accuracy and good surface finishNo heat generation during machining

Capability of drilling circular and non-circular holes in very hard materials.

No thermal effects on mechanical work piece.

Non-conductive materials can be machined.

3. What are the Disadvantages of USM?Tool wear

Frequent turning is required

Low material removal rate.

Not economical for soft materials.

Not suitable for heavy stock removal.

4. What are the applications of USM?

Almost all the material can be machined except some soft materials.Diamond, Tungsten, Tungsten carbide, and synthetic ruby can be

successfully machined.USM can be used for drilling, grinding, profiling, coining, threading and

even for welding.For preparing wire drawing dies and tool room items.

Used in jewellery for shaping jewelsDrilling of screw threads and curved holes in brittle materials.

5. What are the components of USM?

Ultrasonic transducer

Concentrator

Tool

Abrasive slurry

Abrasive feed mechanism

Tool feed mechanism6. What is ultrasonic transducer?

The device used for converting any type of energy into ultrasonic wavers or vibration is

called ultrasonic transducer.

7. Write short noted on piezoelectric crystals?

Piezoelectric crystals are used foe inducing ultrasonic vibrations since they posses thecapability of changing their dimensions to the given electrical energy or in other sense

they have the capability converting electrical energy into mechanical vibrations.


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8. What is magnetostrictive effect?

It is the one in which the material changes its dimension is in response to a

magnetic field.

9. What are the magnetostrivtive materials employed in USM?

Nickel, Iron cobalt called as permendum , iron aluminum called as

alter.

10.What is the purpose of concentrator used in USM?The main purpose of the concentrator is to increase the amplitude of the vibration

obtained from the transducer.

11. What is abrasive Slurry?The abrasive slurry is nothing but a mixture of abrasive grains and the carrier fluid,

generally water.

12. What are the different types of concentrators?

Conical Type

Exponential typeStepped type.

13. What are the characteristics of carrier fluid?

Good wetting characteristic

High thermal conductivity

Non-toxic and non-corrosive.

Should have low viscosity.

14. What are the elements of Carrier Fluid?

Act as a coolant.Act as an acoustic bond between the work piece and the tool.

Helps efficient transfer of energy.Act as medium to carry the abrasive machined materials and worm abrasives

15. What are the types of feed mechanisms used in USM?

Spring type

Counter weight type

Motor type

Pneumatic and hydraulic type

ABRASIVE JET MACHINING

1.Define AJM?It is the material removal process where the material is removed or machined by the

impact erosion of the high velocity stream of air or gas and abrasive mixtrue, which is focused

on to the work piece.

2. How does AJM differ from conventional sand blasting process?AJM differ from the conventional sand blasting process in the way that the abrasive is

much finer and effective control over the process parameters and cutting. Used mainly to cuthard and brittle materials, which are thin and sensitive to heat.


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3. What are the advantages of AJM process?

Low capital cost

Less vibration.

Good for difficult to reach area.

No heat is genera6ted in work piece.

Ability to cut intricate holes of any hardness and brittleness in the material.Ability to cut fragile, brittle hard and heat sensitive material without damage.

4. What are the applications of AJM?

For abrading and frosting glass, it is more economical than acid etching and grinding.For doing hard suffuses, safe removal of smears and ceramics oxides on metals.

Resistive coating etc from ports to delicate to withstand normal scrappingDelicate cleaning such as removal of smudges from antique documents.

Machining semiconductors such as germanium etc.

5.Write the Disadvantages of AJM process?

Low metal removal rate.

Due to stay cutting accuracy is affected.Parivles is imbedding in work piece.

Abrasive powder cannot be reused.

6. Give the formula for find the material remove rate for brittle metal?

MRR = 1.04 ( MV3/2

/ 1/4

H3/4

)

7.Give a summary of the abrasive of their application for different operation?

ABRASIVE APPLICATION

(1) Aluminium Cleaning, Cutting and Deburrig

(2) Silicon Carbide. Faster cleaning, Cutting.

(3) Glass Heads Matt polishing, cleaning

(4) Crushed glass Peening and cleaning.

8.Write the formula for find the MRR for ductile materials?

MRR = 0.5 ( MV2/ H)

9. What are the Process parameters affecting the MRR in AJM?

Gas Pressure.Velocity of Particles.

Abrasive mass flow rate.Mixing ratio.

Nozzle Tip Distance.

10. What are the disadvantages of using abrasives again and again?

Cutting ability of the abrasives decreases after the large

Contamination of wears materials clogging the nozzle and the cutting unit orifices.


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11. What are the different types of nozzles heads used in AJM?

Right angle head.

Straight head.

12. Why oxygen should not be used in AJM? Oxygen should not be used because of fire

hazard problem.

13. What are the different types abrasives used in AJM?

Aluminium oxides, silicon carbides, Crushed glass, Sodium bicarbonate, Dolomite.

14. Reuse of abrasives is not recommended in AJM. why?Reuse of abrasives is not recommented since the cutting ability of abrasive decrease after

the usage and also the contamination of wear materials clogging the nozzle and thecutting unit orifice.

LASER BEAM MACHINING

1.What is Laser?It is acronym of light amplification by stimulated emission of radiation.

2.What is Maser?

Laser can be melt diamond when focused by lens system. The energy density being of

two order 100,000 KW/cm2.

This energy is due to atoms that have light energy level. When such

an atom impinge with electromagnetic waves having resonant frequency.

3.What are the characteristics of Laser beam?1.Material removal

2.Material shaping3.Welding

4.Thermo kinetic change.4.What are the gases commonly used in LASER?

The gases commonly used are:He, Ne, Argon, Co2 etc.

5.What are the advantages of Laser drilling?

No physical contact between work root pair hence there is no possibility if breakage

or wear of root. Precision location is ensured by focusing of the beam Large aspect ratio can be

achieved.

6.What are the characteristics of Laser used in Laser machining?

1. Can be focused to maximum intensity or to lower intensity as needed.2. Can be moved rapidly on the work.

3. Remote cutting over long standoff distances.

7.What are the fundamentals of photons used in Laser?In the Laser the photons are in ground state at 0 oC they are brought to the excited state

by means of absorption of energy by temperature change, collision etc.


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8.What are the emission lines?

The atoms when this they are bringing down goes to the excited state by stimulated

emission and emit photons within 10 nano secs. They have the same wavelength as the excited

photons.

9.What is the Maser principle?

The energy density of laser with 100,000Kw/cm2

. The atoms at this state will impingewith electrons waves having resonate frequency. This is known as maser.

10.What is population inversion?

If the atoms in the excited state are greater than that of the ground state then it isknown as population inversion.

11.How does Laser melting works?

It melts and vaporizes the unwanted material by means of narrow pulsed laser operating

at 2 to 100pilses/sec Because of this high accuracy is not possible to micro sized holes.

12.What is solid state Laser?

Solid state Laser is the Lasers, which consist of a hot nat, which may be crystalline solid/glass, doped with an active material whose atoms provide the lasing action.

ELECTRON BEAM MACHINING

1) Define EBM?

It is the thermo-electrical material removal process on which the material is

removed by the high velocity electron beam emitted from the tungsten filament made to

impinge on the work surface, where kinetic energy of the beam is transferred to the workpiece material, producing intense heat, which makes the material to melt or vaporize it

locally.

What is the characteristic of the electron beam?High concentrated energy.

Deep penetration into the metals.Low distortion.

Any material either conductive or non-conductive can be processed.

3) Write the application of electron beam?

- Thin film machining.

- Surface treatment.

- Engraving metals and non-metals.

- Cutting of materials.

4) What are the main elements of the EBM equipment?

Electron Gun.

Beam focusing and deflecting units.

Work Table.

Vacuum chamber

5) What is the function of magnetic lens used in EBM?It converges the beam into a narrow spot into the work piece.


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ELECTRO CHEMICAL MACHINING

1) Define ECM?

It is the controlled removal of metals by the anodic dissolution in an electrolytic

medium, where the work piece (anode) and the tool (cathode) are connected to the electrolytic

circuit, which is kept, immersed in the electrolytic medium.

2) Write the Faradays first law of electrolysis?The amount of any material dissolved or deposited is proportional to the quantity of

electrolyte passed.

3) Write the Faradays second law of electrolysis?The amount of different substances dissolved or deposited by the same quantity of

electricity are proportional to their chemical equivalent weight.

4) Write Ohms law?

Current, I = V/R

V = VoltageR = resistance

5) What are the factors that influence oxidation in ECM?

(i) Nature of work piece. (ii) Type of electrolyte. (iii) Current density.

(iv) Temperature of the electrolyte.

6) What are the materials used to make the tool electrode?

Copper and copper alloys, titanium, aluminum, brass, bronze, carbon,Monel and reinforced plastic.

7) What are the main functions of electrolysis in the ECM?

i) For completing the electric circuit between the tool and the work piece and toallow the reaction to proceed efficiently.

ii) To remove the products of machining from the cutting region.iii) To carry away the heat generated during the chemical reaction.

iv) To avoid ion concentration at the work piece- tool gap.

8) What are the properties are expected from the electrolysis used in the ECM?

i) High thermal conductivity.

ii) Low viscosity and high specific heat.

iii) Should chemically stable even at high temperature.

iv) Should be non-toxic and non-corrosive.

9) What are the electrolysis commonly used in ECM?

15 -20 % Nacl in water, sodium nitrate, potassium nitrate, sodium sulphate,

sodium chromate and potassium chloride.

10) What are the results, which is in improper selection of electrolyte in ECM?

(i) Low machining rate. (ii) Over cut and stray cutting.


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11) What are the methods generally used to filter the electrolyte?

(i) Running the system until it is contaminated completely and replace it.

(ii) Centrifugal separation.

(iii) Sedimentation.

(iv) Use of clarifiers.

12) What are the characteristics of a good ECM tool?

(i) It should be a good conductor of electricity and heat.(ii) Easily machinable.

(iii) Resistant to chemical reaction.(iv) It offers resistance to the high electrolyte pressure.

13) What are the problems that occur while improperly selecting the electrolyte flow?

Cavitations, stagnation and vortex formation.

14) What are the parameters that affect the MRR?

(i) Feed rate. (ii) Voltage. (iii) Concentration of the electrolyte.

(iv) Temperature of the electrolyte. (v) Current density. (vi) Velocity of the electrolyte.

15) How the current density affect the MRR?Current density is controlled not only by the amount of current but also

by the size of the gap between the tool and the work piece. A small gap results in high current

density, which in turn produce more material removal.

16) What are the advantages of ECM?

ECM is simple, fast and versatile method.

Surface finish can be extremely good.

Fairly good tolerance can be obtained.

17) What are the limitations of ECM?Large power consumption and the related problems.

Sharp internal corners cannot be answered.Maintenances of higher tolerances require complicated contours.

18) What are the applications of ECM?ECM is used for sinking, profiling and contouring, multi hole drilling, trepanning,

broaching, honing, steel mill applications, surfacing, sawing, contour machining of hand to hand

machine materials.

ELECTO CHEMICAL GRINDING

1.Define ECG.

ECG is the material removal process in which the material is removed by the

combination of Electro- Chemical decomposition as in ECM process and abrasive due to

grinding.

2. Which material is used to make the grinding wheel?

Metal bonded diamond (or) Aluminum oxide.

3.What are the important functions of abrasive particles used in ECG?It acts as insulator to maintain a small gap between the wheel and work piece. They are

electrolysis products from the working area. To cut chips if the wheel should contact the workpiece particularly in the event of power failure.


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4.What are the advantages of ECG?

i) No thermal damage to work piece.

ii) Wheel wear is negligible.

iii) No distortion of the work piece.

5.What are the disadvantages of ECG?High capital costs, because of the special wheel tool. Power consumption is quite

high. Electrolyte is corrosive.

6.What are the limitations of ECG?1.The work material must be conductive.

2.Nit suitable for machining soft material.3.Require dressing tools for preparing the wheels.

7.What is the application of ECG?

1.Precision grinding of hand metals economically.

2.Grinding Carbide cutting tools inserts.

3.To grind end mill cutters more precisely.

PLASMA ARC WELDING

1. Define plasma

Plasma is defined as the gas, which has been heated to a sufficiently high

temperature to become ionized.

2. What are the advantages of plasma arc welding?

a. Exothermic oxidation takes place.

b. DC power supply

3. What are the metals that can't be machined by plasma arc machining?

a. Stainless steel

b. Monelc. Super alloys

4. What is the basic heating phenomenon that takes place in plasma arc welding?

The basic heating phenomenon that takes place at the work piece is a combinationof anode heating due to direct electron bombardment recombination of molecules on the work

piece.

5. How does the basic plasma is generated.

The basic plasma is generated by subjecting a stream of gas to the electronbombardment of the electric arc.

6. How the initial ionization is accomplished in plasma arc machining.

A high voltage arc established between electrode and nozzle accomplishes initial ionization.

7. Why does gas formed in plasma do in P.A.M?

This gas stabilizes the arc and prevents it from diverging.


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8. How another source of heating achieved in P.A.M

It is desirable to achieve a third source of heating by injecting oxygen into work area

to take advantage of exothermic oxidation.

9. Write the principle of P.A.M

Once the material has been raised to molten point the high velocity gas stream

blows the material away.

10.Write the circuitry details in PAM.+ ve terminal connected to work piece and -- ve terminal connected to electrode.

12. Which type of power supply is used in P.A.MDC power supply is used.

13. Which part is constricted by plasma?

Nozzle duct is constricted by plasma.

WATER JET MACHINING

1. What are the properties of water jet machining about effect cutting action?

High pressure, high velocity jet of water.

2. What are the types of units and its purpose used in water jet cutting system?

a. Pump -- to generate high pressure

b. Machining unit-- to actually cut the material with the jet nozzle.c. Filtration unit -- to clear the water after use.

3. Why we are using the diamond nozzle.

a. High hardness metalb. Working life is more compared to other jewel nozzle such as ruby or sapphire.

4. Why do you select proper cutting fluid in WJM?

Cutting fluids mainly depends on the operation requirement, quality of finish,

cutting speed and overall cost

5. Does there is any environmental effects while using the water jet machining.

There is no environmental pollution such as dust suspended in the air

because the water jet drains any dust simultaneously

When cutting.

6. What are the advantages of WJC over conventional cutting methods?

a. Because of point cutting WJC is able to cut materials almost any pattern.

b. Material loss due to machining is minimum.

c. WJC will not burn surfaces or produces a heat an affected zone.

d. No environmental pollution.


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7. What are the applications of WJM?

*Aero space

*Automobile

*Paper pulp industries

8. What are the commonly used additives in WJM?

1.Crly cerine2.Polyethylene oxide

3.Long chain polymers

9. What is optical tracing system?It employs an optical scanner that traces a line drawing and produces electronic

signals that control the X-rays.

ELECTRICAL DISCHARGE MACHINING

1. Define electrical discharge machining?

EDM is the controlled erosion of electrically conductive materials by the initiation ofrapid and repetitive spark discharge between the electrode tool to the cathode and work to anode

separated by a small gap kept in the path of dielectric medium. This process also called spark

erosion.

2. What are functions of dielectric fluid used in EDM?

1.It acts as an insulating medium

2.It cools the spark region and helps in keeping the tool and work piece

cool.3.It maintains a constant resistance across the gap.

4.It carries away the eroded metal particles.

3. Basic requirement of dielectric fluid used in EDM?1.Stable Dielectric strength.

2.It should have optimum viscosity.3.It should have high flash point.

4.It should be chemically stable at high temperature and neutral.

5.It should not emit toxic vapours.

4 What the dielectric fluids commonly used in EDM?

1.Petrolium based hydrocarbon fluids.

2.Parafin, white sprite, transformer oil.

3.Kerosine, mineral oil.4.Ethylene glycol and water miscible compounds.

5. What are the prime requirements of tool material in EDM?

1.It should be electrically conductive.

2.It should have good mach inability.3. It should have low erosion rate.

4. It should have low electrical resistance.


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6. Name some of the tool material used in EDM?

1.Copper, brass, alloys of Zinc &tin.

2.Hardend plain carbon steel

3.copper tungsten, silver tungsten, tungsten

4.Copper graphite and graphite.

7. What is the process parameter efficiency the MRR?1.Energy discharge

2.Capacitance.3.Size of work piece.

4.M/c tool design

8. Write the formula for finding the energy discharge in EDM?

W=(1/2) X EIT

W-discharge energy

I-Current

T-timeE-voltage

9. What is the effect of capacitance in EDM?

Increasing the capacitance causes the discharge to increase and increase both the peak

current and discharge time.

10. How do you increase the inductance of the circuit?

A piece of iron or steel be allowed to lodge between the leads it would increase theinductance of the circuit and reduce the M/C rate.

11. Define W/T ratio?

It is the ratio of volume of work removed to the volume of tool removed.

12. What is cycle time?It is the sum of discharge time and waiting time.

13. Define over cut?

It is the discharge by which the machined hole in the work piece exceeds the electrode

size and is determined by both the initiating voltage and the discharge energy.

14. Define Rehardening?

While metal heated to a temperature above the critical and then rapidly cooled by the

flowing dielectric fluid the metal is rehardened.

15. What is recast metal?

Metal heated to a temperature above the melting point and which is not displaced by the

action of the spark discharge, resoldifies as recast metal.

16. Explain electrode wear?

A crater is produced in the electrode, which is likewise dependent on the electrodematerial and the energy of the discharge.


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