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SIT: Department of Mechanical Engineering E-Scheme - w. e. f. 2016-2017

PREFACE

The wave of liberalization and globalization has created an environment for free flow

of information and technology through fast and efficient means the world over. This has lead

to shrinking of world, bringing people from different cultures and environment together,

giving rise to a global village. A shift has been taking place in India from closed economy to

knowledge based and open economy. In order to cope-up with the challenges of handling

new technologies, materials and methods, we have to develop human resources having

appropriate knowledge, professional skills and attitudes. Technical education system is one of

the significant components for human resource development. Polytechnics play an important

role in meeting the requirements of trained technical manpower for industries and field

organizations. The initiatives being taken by the Directorate of Technical Education to revise

the curriculum of existing Diploma programmes as per the needs of the industry are laudable.

In order to meet the requirements of future technical manpower, constant efforts have

to be made to identify new employment opportunities, carry out activity analysis and design

need based curriculum to Diploma programmes. This curriculum document has been

designed by identifying job potential and competency profile of Diploma holders leading to

identification of curriculum areas for the course. It is needless to emphasize that the real

success of the Diploma programme depends upon its effective implementation. This will

require harnessing and effective utilization of resources. In addition to acquisition of

appropriate physical resources, the availability of competent and qualified faculty is essential.

It is time for the managers of technical education system to reorganize the system to accept

the challenges of both quantitative and qualitative expansion of technical education.

There are various online training facilities created by the Government of India

through MHRD for the benefit of both the Teaching and Student community. Facilities like

Spoken-Tutorial, NPTEL, e-Yantra must be exploited to its fullest extent to reap the benefits

of interactive electronic media for teaching-learning process. It is hoped that polytechnics

will carry out job market research on a continuous basis to identify the new skill requirements

and develop innovative methods of course offering and thereby infuse dynamism in the

system.

Principal & Chairman.


ACKNOWLEDGEMENT

We gratefully acknowledge the assistance and guidance received from the following persons;

1. Commissioner and Principal Secretary, Directorate of Technical Education, Govt. of

Tamilnadu.

2. Principal & Chairman, Seshasayee Institute of Technology, Trichy for initiating this

project on designing of curriculum.

3. Madam J. Rama, Regional Officer-IV, Directorate of Technical Education,

Tamilnadu, Dr. D. Brahadeeswaran, Professor(Retd.,) NITTTR,Chennai,

Dr.S.Muruganantham, Principal, GPTC, Srirangam, Trichy , Dr.P.Sakthivel,

Associate Professor, Department of Electronics and Communication Engineering,

College of Engineering, Guindy, Chennai and Thiru P. Srinivasan, Senior

Engineer(IT),Southern railways,Trichy for their assistance and support in evaluation

of this curriculum.

4. Thiru S.K.A.Somaraj, HOD/Mechanical Engineering(T&D),Murugappa Polytechnic

College,Chennai-600062,for his guidance and academic inputs to support the design

of curriculam.

5. Dr.V.Ananthakrishnan, Assistant Professor/Production Engineering, NIT, Trichy –

15 for his guidance and suggestions to improve the standard of the curriculum.

6. Mr. G.M.Rajendran, GM(Retd), B.H.E.L., Trichy –620014 for his practical and

professional inputs and support in the design of this curriculum.

7. All the staff members of the Mechanical Engineering Department for their sustained

effort and support in the design of this curriculum and documentation.


CONTENTS

Sl.NO. PARTICULARS PAGE NO

1.

Department Vision , Mission, PEOs and PO

1

2. Rules and regulations 3

3. Salient Features of the Diploma Programme 10

4. Employment opportunities 11

5. Competency Profile 12

6. Deriving Curriculum Areas from Competency Profile 13

7. Curriculum outline 15

8. Horizontal and Vertical Organization of the Subject 17

9. Content Details 19

10. Model question papers 123

11. Equivalent papers for D-Scheme in E-Scheme 148


1

DEPARTMENT VISION, MISSION, PEOs and PO

Vision and Mission of Department of Mechanical Engineering

VISION

To achieve excellent standard of quality education by keeping with rapidly changing

technologies.

Attaining global recognition in Mechanical Engineering education, and training to

meet the growing needs of the industry and society.

MISSION

To impart quality education in Mechanical Engineering through well designed

curriculum to satisfy all stake holders.

To serve society and the nation by providing professional Mechanical Engineering

leadership to find solution to community, regional and global problems and accept

new challenges in rabidly changing technology.

To create competent professionals who are trained in the design and development of

Mechanical Engineering systems and contribute towards need of industry

requirements.

Program Educational Objectives (PEO)

The educational objectives of the Mechanical Engineering programme are designed to

produce skilled Engineers who are ready to contribute effectively to the Mechanical

Engineering profession and ready to handle challenges in the profession. The

Mechanical Engineering department committed to produced Mechanical Engineers

who:

PEO1: shall apply fundamental technical knowledge and skills to find and create

solutions to technological challenges and problems in various areas of basic

science and Engineering.

PEO2: shall be able to analyze design and use skills in order to formulate and solve

Mechanical Engineering problems.

PEO3: shall be able to practice Mechanical Engineering in a reasonable,

professional and ethical manner and implement eco-friendly sustainable

technologies for the benefit of industry and society

PEO4: To take up higher education and to engage in Mechanical Engineering

research and development and allied area of science and technologies.


2

Program Outcomes (PO)

The programmed targeted and develop the following list of competencies, skills and

abilities among students. They shall be able to

PO1 Apply knowledge of mathematics, basic science and core Mechanical

Engineering to the defined and applied Engineering students.

PO2 Identify, formulate and analyze in reaching substantiated solutions using

analytical tools.

PO3 Conduct investigation of problems, locate, search and select relevant data

from data sheet and literature to provide valid conclusions.

PO4

Design Mechanical Engineering structures, components are process to meet

desired to meet with appropriate consideration for the public health and

safety, cultural, societal, sustainability and environmental considerations.

PO5 Use the current trends and techniques in Mechanical Engineering, skills and

modern Engineering tools. necessary for professional Engineering practice.

PO6

Understand professional and ethical responsibility concerning legal,

contemporary, environmental and cultural issues and consequent

responsibility relevant to the professional Engineering practices and norms

are Mechanical Engineering practice code and IS codes of ethics.

PO7 Function effectively and as a member or leader in diverse teams and in

multidisciplinary environment.

PO8

Communicate effectively with Engineering community with society at large

such as being able to comprehend and write effective report, prepare

documentation, make effective presentations give and receive clear

instructions.

PO9

Function as a member of multidisciplinary teams and to understand

Engineering management’s principles and finance to manage projects under

multicultural environments.

PO10 Recognize the need for and to engage in life-long learning in Mechanical

Engineering allies domains as relevant to rapidly changing technology.


3

DIPLOMA COURSES IN ENGINEERING

(TERM PATTERN)

(Implemented from 2016- 2017)

E – SCHEME

(Common to all Programmes)

R E G U L A T I O N S

1. Description of the Programme:

a. Full Time (3 years)

The Programme for the Full Time Diploma in Engineering shall extend over a period

of three academic years, consisting of 6 terms* and the First Year is common to all

Engineering Programmes.

The Curriculum for all the 6 Terms of Diploma Programmes have been revised and

revised curriculum is applicable for the candidates admitted from 2016 - 2017 academic

year onwards.

b. Sandwich (3½ years)

The Programme for the Diploma in Paper Technology (Sandwich) shall extend over a period

of three and half academic years, consisting of 7 terms* and the First Year is common to all

Engineering Programmes. The courses of diploma Programmes being regrouped for

academic convenience.

During 4th and 7th terms, the students undergo industrial training for six months.

Examination will be conducted after completion of every 6 months of industrial training

2. Condition for Admission:

The candidates shall be required to have passed in the S.S.L.C Examination of the Board of

Secondary Education, Tamilnadu.

(Or)

the Anglo Indian High School Examination with eligibility for Higher Secondary Course in

Tamilnadu

(Or)

the Matriculation Examination of Tamil Nadu.

(Or)

Any other Examinations recognized as equivalent to the above by the Board of Secondary

Education, Tamilnadu.


4

Note: In addition, at the time of admission, the candidate will have to satisfy certain

minimum requirements, which may be prescribed from time to time.

3. Admission to Second year (Lateral Entry):

A pass in HSC (Academic)# or (Vocational) courses mentioned in the Higher Secondary

Schools in Tamilnadu affiliated to the Tamilnadu Higher Secondary Board with

eligibility for University Courses of study or equivalent examination, & should have

studied the following Courses

Sl. No

Programmes # H.Sc

Academic

H.Sc Vocational

Courses Studied Courses Studied

Related

courses

Vocational courses

1 All the Regular and

Sandwich Diploma

Programmes

Maths, Physics &

Chemistry

Maths, Physics

& Chemistry

(any one)

Related Vocational

Courses - Theory &

Practical

. # Subject to the approval of the AICTE

• For the Diploma Programmes related with Engineering/Technology, the related /

equivalent courses prescribed along with Practicals may also be taken for arriving the

eligibility.

• Programmes will be allotted according to merit through counseling by the Principal as

per communal reservation.

• Candidates who have studied Commerce Courses are not eligible for Engineering

Diploma Programmes.

4. Age Limit:

No Age limit.

5. Medium of Instruction:

English

6. Eligibility for the Award of Diploma:

No candidate shall be eligible for the Diploma unless he/she has undergone the

prescribed course of study for a period of not less than 3/3 ½ academic years (Full

Time/Sandwich), affiliated to the State Board of Technical Education and Training,

Tamilnadu, when joined in First Year and 2/2 ½ years (Full Time/Sandwich), if joined

under Lateral Entry scheme in the second year and passed the prescribed examination.

The minimum and maximum period for completion of Diploma Programmes are given

below:


5

Diploma Programmes Minimum Period Maximum Period

Full Time 3 Years 6 Years

Full Time (Lateral Entry) 2 Years 5 Years

Sandwich 3½ Years 6½ Years

Sandwich (Lateral Entry) 2½ Years 5½ Years

7. Programmes of Study and Curriculum outline

The Programmes of study shall be in accordance with the syllabus prescribed from time

to time, both in theory and practical courses.

8. Examinations:

Autonomous Examinations in all Programmes of all the terms under the scheme of

examinations will be conducted at the end of each term for 75 marks.

The internal assessment marks for all the courses will be awarded on the basis of continuous

assessment earned during the term concerned. For each course, 25 marks are allotted for

internal assessment and 75 marks are allotted for Autonomous end Examination.

9. Continuous Internal Assessment:

A. For Theory Courses:

The Internal Assessment marks for a total of 25 marks, which are to be distributed as follows:

i) Course Attendance- 5 Marks

Award of marks for attendance to each Theory/Practical course will

be as per the range given below

% of Attendance Marks

80% - 83% 1 Mark

84% - 87% 2 Marks

88% - 91% 3 Marks

92% - 95% 4 Marks

96% - 100% 5 Marks

ii) Tests # - 10 Marks

2 Tests each of 2 hours duration for a total of 50 marks are to be conducted and the marks so

obtained will be reduced to 5 marks. A Model exam covering all the five units is to be

conducted and the marks will be reduced to 5 marks


6

Question Paper Pattern for the Periodical Test :( Test - I & Test- II)

PART-A: 4 Questions X 2 marks - 8 marks

PART-B: 4 Questions X 3 marks - 12 marks

PART-C: 3 Questions X 10 marks - 30 marks

-------------

Total 50 marks

--------------

iii) Assignment / Online test - 10 Marks

# - From the Academic year 2016-2017 onwards.

For each Course, Three Assignments/ On line tests are to be given/ conducted each for

20 marks and the average marks scored should be reduced for 10 marks.

All Test Papers and Assignment note books after getting the signature with date from

the students must be kept in the safe custody in the Department for verification and

audit. It should be preserved for 2 Terms and produced to the inspection team at the

time of inspection/verification.

Total : 25 marks

B. For Practical Courses:

The Internal Assessment marks for a total of 25 marks are to be distributed as

follows:-

a) Attendance

5 Marks (Procedure for

the Award of marks is the

same as theory courses)

b) Procedure / Observation and

tabulation/ Other Practical related Work

10 Marks

c) Record writing 10 Marks

TOTAL 25 Marks

TEST

UNITS

WHEN TO

CONDUCT MARKS DURATION

Test I

In 2 Units

End of 5th

week 50 2 hours

Test II

In 2 Units

End of 10th

week 50 2 hours

Test III

Model Examination - Compulsory

Covering all the 5 Units.

(Autonomous Examinations-question

paper pattern).

End of the

term

100 3 hours


7

• All the Experiments/Exercises indicated in the syllabus should be completed and the

same to be given for final Autonomous examinations.

• The Record for every completed exercise should be submitted in the subsequent Practical

classes and marks should be awarded for 20 for each exercise as per the above

allocation.

• At the end of the Term, the average marks of all the exercises should be calculated for

20 marks and the marks awarded for attendance is to be added to arrive the internal

assessment marks for Practical.

• The students have to submit the duly signed bonafide record note book/file during

the Practical Autonomous Examinations.

• All the marks awarded for assignments, tests and attendance should be entered in

the Personal Log Book of the staff, who is handling the subject. This is applicable to

both Theory and Practical courses.

10. Life and Employability Skills Practical:

Life and Employability Skills Practical with more emphasis is being introduced in IV

Term for Circuit Branches and in V Term for other branches of Engineering.

Much Stress is given to increase the employability of the student

Internal Assessment Mark : 25 Marks

11. Project Work:

The students of all the Diploma Programmes have to do a Project Work as part of the

Curriculum and in partial fulfilment for the award of Diploma by the State Board of

Technical Education and Training, Tamilnadu. The Project work must be reviewed twice

in the same semester.

a) Internal assessment mark for Project Work:

Project Review I 10 marks

Project Review II 10 marks

Attendance 05 marks (Procedure for the Award of

marks is the same as theory courses)

Total

25 marks


8

Proper records are to be maintained for the two Project Reviews, and they should be

preserved for 2 Semesters and produced to the inspection team at the time of

inspection/verification.

b) Allocation of Mark for Project Work & Viva Voce in Board Examination:

Viva Voce 30 marks

Marks for Report Preparation, Demonstration 35 marks

Written Test Mark $ (from 2 topics for 30

minutes duration) 10 Marks

Total 75 marks

Written Test Mark $:

i) Environment Management: 2 questions X 2 ½ marks = 5 marks

ii) Disaster Management: 2 questions X 2 ½ marks = 5 marks

Total = 10marks

Selection of Questions should be from Question Bank, by the External Examiner.

No choice to be given to the candidates.

12. Scheme of Examinations:

The Scheme of examinations for courses is given in Curriculum outline

13. Criteria for Pass:

1. No candidate shall be eligible for the award of Diploma unless he/she has undergone the

prescribed course of study successfully in an institution approved by AICTE and affiliated to

the State Board of Technical Education & Training, Tamil Nadu and pass all the

courses prescribed in the curriculum.

2. A candidate shall be declared to have passed the examination in a course if

he/she secures not less than 40% in theory courses and 50% in practical courses out of the

total prescribed maximum marks including both the Internal Assessment and the

Autonomous Examinations marks put together, subject to the condition that he/she

secures at least a minimum of 30 marks out of 75 marks in the Autonomous Theory

Examinations and a minimum of 35 marks out of 75 marks in the Autonomous Practical

Examinations.


9

14. Classification of successful candidates:

Classification of candidates who will pass out the final examinations from April 2019

onwards (Joined in first year in 2016-2017 / Joined in second year in 2017-2018) will be done

as specified below.

First Class with Superlative Distinction:

A candidate will be declared to have passed in First Class with Superlative Distinction if

he/she secures not less than 75% of the marks in all the courses and passes all the terms in the

first appearance itself and passes all courses within the stipulated period of study 3/ 3½ years

(Full Time/Sandwich) without any break in study.

First Class with Distinction:

A candidate will be declared to have passed in First Class with Distinction if he/she secures

not less than 75% of the aggregate of marks in all the terms put together and passes all the

terms except the I and II terms in the first appearance itself and passes all the courses within

the stipulated period of study 3/3½ years (Full Time/Sandwich) without any break in study.

First Class:

A candidate will be declared to have passed in First Class if he/she secures not less than 60%

of the aggregate marks in all terms put together and passes all the courses within the

stipulated period of study 3/3½ years (Full Time/Sandwich) without any break in study.

Second Class:

All other successful candidates will be declared to have passed in Second Class.

15. Duration of a period in the Class Time Table:

The duration of each period of instruction is 1 hour and the total period of instruction hours

excluding interval and Lunch break in a day should be uniformly maintained as 7 hours

corresponding to 7 periods of instruction (Theory & Practical).

******************************


10

SALIENT FEATURES OF THE DIPLOMA PROGRAMME

IN

MECHANICAL ENGINEERING

1. Name of the Programme : Diploma in Mechanical Engineering

2. Duration of the Programme : Three years

3. Entry Qualification : S.S.L.C or prescribed by Directorate Technical

Education and Lateral Entry in Second Year

Admission for Plus-two Students.

4. Intake : 60+12 for regular course and

60 for Self supporting course

5. Pattern of the Programme : Term Pattern(I to VI)

6. Ratio between Theory &Practical : 50:50(Approx.)


11

EMPLOYMENT OPPORTUNITIES

Employment opportunities for Diploma holder in Mechanical Engineering are

visualized in following industries at various levels / positions.

(1) Manufacturing Industries

o Production,Planning&Control

o Production Engineering and shop floor control

o Process Engineering and Methods control

o Prodcut design&development

o Materials management

o Research and development

(2) Service industries

o Repair and maintenance of machines

o Repair and maintenance of automobiles

o Repair and maintenance of engines

o Reapir and maintenance of other equipments

(3) Consultancy

o Design& Drawing consultants

o CNC machine program consultants

o Maintenance consultants


12

COMPETENCY PROFILE

Keeping in view the employment opportunities of Diploma holders in Mechanical

Engineering, the programme is aimed at developing following knowledge and skills in the

students:

1. Basic understanding of concepts and principles of Mechanical engineering so as to

enable the students to apply the knowledge .

2. Development of communication and interpersonal skills for effective functioning in

the world of work.

3. Ability to read and interpret drawings related to Mechanical Engg.

4. Knowledge of various materials used in Mechanical Engg., their properties and

specifications.

5. Ability to prepare plan, section and elevation of equipments,devices and components

of machines..

6. Ability to understand various manufacturing processes, allied areas and automation in

manufacturing.

7. Understanding of fluid flow, Hydraulics & Pneumatic circuits.

8. Understanding the concepts of Thermodynamics,Thermodynamic processes,working

of Engines,automobiles and energy sources.

9. Ability to Design the machine elements..

10. Ability to calculate the estimate time for producing the components and cost of the

products.

11. Development of generic skills of thinking and problem – solving, communication

attitudes and value system for effective functioning in industrial sectors..

12. Appreciation of the need of clean and green environment and its deterioration by

various emissions from industry and preventive procedures and knowledge of safety

regulations.

13. Understanding of the basic principles of managing men, material and machines /

equipment for the production of components and others.

14. Proficiency in the use of computers.

15. Understanding about automation

16. Basic manual and machining skills for maintaining the quality of materials.

17. Knowledge of properties of materials used for manufacturing..

18. Development of good personality in order to have effective communication and

professional ethics


13

CURRICULUM AREAS AS DERIVED FROM COMPETENCY

PROFILE

The following curriculum areas have been derived based on competency profile.

S.N

O

Competency Curriculum Areas / Subjects

1

Basic understanding of concepts and principles

related to applied sciences like physics,

chemistry and mathematics.

Applied physics

Applied chemistry

Applied mathematics

2

Development of communication and inter

personal skill for effective functioning in the

world of work.

Life and employability skills

3 Understanding of basic concepts and principles

of mechanical, electrical and civil engineering.

Applied Mechanics

General workshop practice

4 Ability to read and interpret drawings related to

Mechanical Engg. Etc,

Engineering Graphics & Machine

drawing

5

Knowledge of various materials used in

Mechanical Engg., their properties and

specifications.

Strength of materials

5

Ability to prepare plan, section and elevation of

equipments, devices and components of

machines..

Computer applications and CAD

practical

6 Proficiency in the use of computers Computer applications and CAD

practical

7

Ability to understand various manufacturing

processes, allied areas and automation in

manufacturing

Manufacturing processes

Special machines

Computer Aided design and

manufacturing

8 Understanding of fluid flow, Hydraulics &

Pneumatic circuits. Fluid mechanics and fluid power

9

Understanding the concepts of

Thermodynamics, Thermodynamic processes,

working of Engines, automobiles and Energy

sources

Heat power engineering

Automobile engineering

Renewable energy sources and

energy components

10 Ability to Design the machine elements. Design of machine elements

11

Ability to calculate the estimate time for

producing the components and cost of the

products.

Industrial Engineering and

management

12

Development of generic skills of thinking and

problem – solving, communication attitudes

and value system for effective functioning in

Industrial Engineering and

management

Total quality management


14

industrial sectors..

12

Understanding of the basic principles of

managing men, material and machines /

equipment for the production of components

and others.

Industrial management

13 Understanding about automation Mechatronics

ABSTRACT OF CURRICULUM AREAS / SUBJECTS / CURRICULUM

OUTLINE a. Core courses

1. Strength of Materials

2. Fluid mechanics and Fluid power

3. Manufacturing processes

4. Strength of materials & Fluid mechanics practical

5. Metrology& Metallography practical

6. Foundry, Smithy & Welding Practical

7. Heat power Engineering

8. Special machines

9. Computer applications and CAD practical

10. Heat power Engineering practical

11. Machining, Machine tool testing and Maintenance practical

Allied courses

12. Machine drawing

13.Electrical Drives & Control Practical

14.Design of Machine elements

15. Automobile Engineering

16. Computer Aided Design and Manufacturing

17. Life and Employability skill practical

18. Industrial Engineering & Management

19. Renewable energy sources and Energy conservation

20. Total Quality management

21. Mechatronics

22. Welding Technology

23.Refrigeration and Air conditioning

24. Industrial welding practical


26.Process Automation Practical

27.Computer aided Design and Manufacturing practical

b. Diversified courses

28. Electrical drives and control practical

29.Special machines practical

30. Project work


15

CURRICULUM OUTLINE

TERM - III

Sl.No Course Code

Course Title

Load

Allocation Mark Distribution Total

Mark T P C Internal External

THEORY

1 3E 3205 Strength of Materials 5 5 25 75 100

2 3E 3206 Fluid Mechanics and Fluid

Power 5 5 25 75 100

3 3E 3207 Manufacturing Processes 5 5 25 75 100

PRACTICAL

4 3E 3301 Machine Drawing 6 3 25 75 100

5 3E 3208 Strength of Materials & Fluid Mechanics Practical

4 3 25 75 100

6 3E 3209 Metrology and

Metallography practical 4 3 25 75 100

7 3E 3210 Foundry ,Smithy and

Welding Practice 6 3 25 75 100

Total 15 20 27 175 525 700

TERM - IV

Sl.No Course Code

Course Title

Load



THEORY

1 3E 4211 Heat Power Engineering 5 5 25 75 100

2 3E 4212 Special Machines 5 5 25 75 100

3 3E 4401 Electrical Drives and Control 5 5 25 75 100

PRACTICAL

4 3E 4213 Computer Applications and CAD Practical

4 3 25 75 100

5 3E 4214 Heat Power Engineering Practical

4 3 25 75 100

6 3E 4302 Electrical Drives and Control Practical

2 4 3 25 75 100

7 3E 4215 Machining, Machine Tool Testing and Maintenance Practice

6 3 25 75 100

Total 17 18 27 175 525 700


16

TERM - V

Sl.No Course Code

Course Title

Load



THEORY

1 3E 5303 Design of Machine Elements 5 5 25 75 100

2 3E 5304 Automobile Engineering 5 5 25 75 100

3 3E 5305 Computer Aided Design and Manufacturing

5 5 25 75 100

4

3E 5306

ELECTIVE Theory 1. Renewable energy sources and energy conservation. 2. Total Quality Management

5 5 25 75 100

PRACTICAL

5 3E 5307 Automobile Engineering Practical

6 3 25 75 100

6 3E 5403 Special Machines Practice 5 3 25 75 100

7 3E 5308 Life and employability skills practical

4 2 25 75 100

Total 20 15 28 175 525 700

TERM - VI

Sl.No Course Code

Course Title

Load



THEORY

1 3E 6309 Industrial Engg. And Management

5 5 25 75 100

2 3E 6310 Mechatronics 5 5 25 75 100

3

3E 6311

ELECTIVE THEORY-II 1.Welding Technology 2.Refrigeration and Air conditioning

5 5 25 75 100

PRACTICAL

4 3E 6312

PRACTICALS ELECTIVE PRACTICAL-II 1.Industrial Welding Practice 2. Refrigeration & Air Conditioning Practical

2 4 4 25 75 100

5 3E 6313 Process Automation Practical 4 3 25 75 100

6 3E 6314 Computer Aided Design and Manufacturing practical

4 3 25 75 100

7 3E 6404 Project work 6 3 25 75 100

Total 1

7

1

8 28 175 525 700


17

HORIZONTAL AND VERTICAL ORGANISATION OF THE SUBJECTS

SL.

NO.

COURS

E CODE SUBJECT

TE

RM

CREDITS

Fou

nd

atio

n

Cor

e

All

ied

Div

ersi

fied

Val

ue

add

ed

Cou

rse

CORE

1 3E 3205 Strength of Materials III 5

2 3E 3206 Fluid Mechanics and Fluid

Power III 5

3 3E 3207 Manufacturing Processes III 5

4 3E 3208 Strength of Materials & Fluid Mechanics Practical

III 3

5 3E 3209 Metrology and

Metallography practical III 3

6 3E 3210 Foundry ,Smithy and

Welding Practice III 3

7 3E 4211 Heat Power Engineering IV 5

8 3E 4212 Special Machines IV 5

9 3E 4213 Computer Applications and CAD Practical

IV 3

10 3E 4214 Heat Power Engineering Practical

IV 3

11 3E 4215 Machining, Machine Tool Testing and Maintenance Practice

IV 3

ALLIED

12 3E 3301 Machine Drawing III 3

13 3E 4302 Electrical Drives and Control Practical

IV 3

14 3E 5303

Design of Machine Elements V 5

15 3E 5304 Automobile Engineering V 5

16 3E 5305 Computer Aided Design and Manufacturing

V 5

17

3E 5306

ELECTIVE Theory 1. Renewable energy sources and energy conservation. 2. Total Quality Management

V 5

18 3E 5307 Automobile Engineering Practical

V 3


18

19 3E 5308 Life and employability skills practical

V 2

20 3E 6309

Industrial Engg. And Management

VI 5

21 3E 6310 Mechatronics VI 5

22 3E 6311

ELECTIVE THEORY-II 1.Welding Technology 2.Refrigeration and Air conditioning

VI 5

23

3E 6312

PRACTICALS ELECTIVE PRACTICAL-II 1.Industrial Welding Practice 2. Refrigeration & Air Conditioning Practical

VI 4

24 3E 6313 Process Automation Practical VI 3

25 3E 6314

Computer Aided Design and Manufacturing practical

VI 3

DIVERSIFIED

26 3E 4401 Electrical Drives and Control IV 5

27 3E 5403 Special Machines Practice V 3

28 3E 6404 Project work VI 3

TOTAL 43 56 11


19

III TERM


20

3E 3205 - STRENGTH OF MATERIALS

RATIONALE

Strength of materials is a core technology course aims at enabling the students to

understand and analyze various types of loads, stresses and strains along with the main causes

of failures of various members. This course is a pre requisite for understanding the principles

of Design of machine elements.

OBJECTIVES

Define various mechanical properties of materials.

Calculate the deformation of materials, which are subjected to axial load and shear.

Determine the moment of Inertias of various section used in the Industry.

Draw the Graphical representation of shear force and bending moment of the beam

subjected to different loads.

Construct SFD and BMD.

Estimate the stresses induced in beams, columns and struts.

Distinguish different types of spring and their applications.

SCHEME OF INSTRUCTIONS AND EXAMINATIONS

TOPICS AND ALLOCATION OF HOURS

Chapter Name of the Topic Hours Marks

Unit I Simple Stresses And Strains 13 15

Unit II Strain Energy & Impact Loading And Geometrical

Properties Of Sections 13 15

Unit III Shear Force, Bending Moment Diagrams And Theory Of

Simple Bending 13 15

Unit IV Bending Stresses In Beams, Columns And Struts 13 15

Unit V Torsion & Springs 13 15

Revision 3

Cycle Tests and Model Examination 7

Total 75 75

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term

Scheme Of Examinations

Theory Practical Duration

(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

3205 5 - 5 80 3 25 75 100


21

DETAILED SYLLABUS

3E 3205 - STRENGTH OF MATERIALS

Unit I : SIMPLE STRESSES AND STRAINS

Definition - Load, stress and strain - Classification of force systems - tensile,

compressive and shear force systems - Behavior of mild steel in tension up to rupture -

Stress - Strain diagram - limit of proportionality -elastic limit - yield stress - breaking

stress - Ultimate stress - percentage of elongation and percentage reduction in area -

Hook’s law - Definition -Young’s modulus - working stress, factor of safety, load

factor, shear stress and shear strain - modulus of rigidity. Linear strain - Deformation

due to tension and compressive force - Simple problems in tension, compression and

shear force. Definition - Lateral strain -Poisson’s ratio - volumetric strain - bulk

modulus - volumetric strain of rectangular and circular bars - problems connecting

linear, lateral and volumetric deformation - Elastic constants and their relationship -

Problems on elastic constants. Definition - Composite bar -Problem in composite bars

subjected to tension ad compression -Temperature stresses and strain - Simple

problems.

Unit II

(i) STRAIN ENERGY AND IMPACT LOADING

Definition Strain energy - proof resilience - modulus of resilience -The

expression for strain energy stored in a bar due to Axial load -Instantaneous stresses

due to gradual, sudden, impact and shock loads -Problems computing instantaneous

stress and deformation in gradual, sudden, impact and shock loadings.

(ii) GEOMETRICAL PROPERTIES OF SECTIONS

Properties of section: Definition - center of gravity and centroid - position of

centroids of plane geometrical figures such as rectangle, triangle, circle and trapezium -

problems to determine the centroid of angle, channel, T and I sections only -Definition

- centroidal axis, Axis of symmetry. Moment of Inertia - Statement of parallel axis

theorem and perpendicular axis theorem. Moment of Inertia of lamina of rectangle,

circle, triangle. I and channel sections. Definition - Polar moment of Inertia - radium of

gyration - Problems computing moment of inertia and radius of gyration - Problems

computing moment of inertia and radius of gyration for angle, T, Channel and I

sections.

Unit III (i) SHEAR FORCE AND BENDING MOMENT DIAGRAMS

Classification of beams - Definition - shear force and Bending moment - sign

conventions for shear force and bending moment - types of loadings - Relationship

between load, force and bending moment at a section - shear force diagram and

bending moment diagram of cantilever and simply supported beam subjected to point

load and uniformly distributed load - Determination of Maximum bending moment in

cantilever beam and simply supported beam when they are subjected to point load and

uniformly distributed load.

(ii) THEORY OF SIMPLE BENDING

Definition - slope, deflection, stiffness and flexural rigidity - Derivations of

relationship between slope, Deflection and Radius of curvature -Derivation of slope


22

and deflections of cantilever and simply supported beam by area moment method

under point load and UDL load - simple problems.

Unit IV (i) BENDING STRESSES IN BEAMS

Theory of simple bending - Assumptions-Neutral axis - bending stress

distribution - moment of resistance- bending equation - Definition - section modulus -

rectangular and circular sections -strength of beam - simple problems involving

flexural formula for cantilever and simply supported beam.

(ii) COLUMNS & STRUTS

Definition of column and strut—classification—critical load—End

conditions—Euler’s theory of long columns—Assumptions—sign conventions—

Euler’s critical load of columns with varied conditions - Equivalent length of

columns—Slenderness Ratio—Limitations of Euler’s formula—Safe load or working

load—Rankine’s empirical Formula for critical load of any column-problems

Unit V (i) TORSION

Theory of torsion -Assumptions - torsion equation - strength of solid and

hollow shafts - power transmitted - Definition -Polar modulus -Torsional rigidity -

Strength and stiffness of shafts -Comparison of hollow and solid shafts in weight and

strength consideration - Advantages of hollow shafts over solid shafts - Problems.

(ii) SPRINGS

Types of springs - Laminated and coiled springs and applications -Types of

coiled springs - Difference between open and closely coiled helical springs - closely

coiled helical spring subjected to an axial load - problems to determine shear stress,

deflection, stiffness and resilience of closed coiled helical springs.

Reference Books:

Sl.No. Name of the Book Author Publisher

1 A text book of strength of

materials Dr.R.K.Bansal

Laxmi publications, New

Delhi.

2 Mechanics of Structures-Vol. I &

II. S.B.Junarkar,

Charoitar Book stall-

Anand.

3 Strength of Materials R.S.Khurmi S.Chand, New Delhi.

4 Applied Mechanics R.S.Khurmi S.Chand, New Delhi.

5 Strength of Materials A.S.Ramamrutham Dhanpatrai &co,

New Delhi

Online Resources :

1. http://physics.fe.uni-lj.si/students/literatura/20131029085254762_1.pdf

2. www.slideshare.net

3. www.nptel.ac.in


23

4. www.studentsfocus.com

Course Outcome:

Understand and distinguish the behavior of simple load carrying members subjected

to an axial, shear and thermal Loading.

Interpret the Variation of moment of inertia for different Mechanical Engineering

Sections such as fly wheel.

Draw and Compare the shear force and bending moment diagram on beams under

varying load conditions.

Assess Bending and shear stresses in beams subjected to different loadings for

different machine parts.

Differentiate in strain energy stored in a body when the load is suddenly applied and

gradually applied.

Design simple solid and hallow shaft for power transmission keeping view of

Environmental and sustainability aspects.


24

3E 3206 FLUID MECHANICS AND FLUID POWER

RATIONALE

Mechanical engineering diploma holders are required to deal with problem of fluid

flow and use of hydraulic and pneumatic circuits. Hence knowledge and skills about fluid

flow and hydraulic and pneumatic circuits are required to be imparted for enabling them to

perform above function. This course aims at development of knowledge and skills about

various properties of fluids, fluid power machines and hydraulic and pneumatic systems.

OBJECTIVES:

Making the students to resolve hydraulic related problems at the current scenario.

Define the properties of Fluids.

Explain the working of pressure measuring devices.

Explain continuity equation and Bernoulli’s Theorem.

Assess the impact of frictional loss of head in flow through pipes.

Estimate the discharge through orifices.

Distinguish the working principles of pumps and turbines.

Explain the working of centrifugal pumps and reciprocating pumps.

Draw Pneumatic circuits for industrial application.

State the properties of hydraulic Systems.

Develop hydraulic circuit for machine tools applications.



Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

3206 5 - 5 80 3 25 75 100


Unit I Basic principles of fluid mechanics & flow of fluids 13 15

Unit II Pipe flow, impact of jets and hydraulic turbines 13 15

Unit III Reciprocating pumps & centrifugal pumps 13 15

Unit IV Pneumatic systems 13 15


25

DETAILED SYLLABUS

3E 3206 FLUID MECHANICS AND FLUID POWER

Unit I (i) BASIC PRINCIPLES OF FLIUD MECHANICS

Fluids – Definition – Properties – Density – Specific weight – specific volume –

Relative density – Viscosity – Vapour pressure – compressibility – Surface tension –

Capillarity - Ideal and Real fluids – Newtonian and Non-Newtonian fluids – pressure –

Atmospheric pressure – Absolute pressure – Gauge pressure and vacuum pressure–

Pressure measurement –Bourdon pressure gauge.

(ii) Flow of fluids

Types of flow – Laminar flow – Turbulent flow – Steady flow – Unsteady flow –

Uniform flow – Non Uniform flow – mean velocity – Continuity equation – Bernoulli’s

equation – Proof – Applications – Venturimeter - Orifice meter – Pitot tube –Problems.

Unit II PIPE FLOW, IMPACT OF JETS AND HYDRAULIC TURBINES

(i)Pipe Flow

Froude’s experiment – Wetted perimeter – Wetted area – Hydraulic radius –

Head loss due to friction – Darcy-Weishbach equation – Minor losses (No derivation) –

problems.

(ii)Impact of Jets

Impact of jet on fixed and series of moving flat vanes – Work done and

efficiency – Simple problems on the above.

(iii)Hydraulic turbines

Layout of a Hydro-electric power plant – Classification of turbines – Working

of Pelton wheel, Francis turbine and Kaplan turbine – Differences between impulse and

reaction turbines –-Surge tanks –Draft tubes-Types.

Unit III PUMPS

(i)Reciprocating pump

Reciprocating pump – Classification – Single acting – Double acting

Reciprocating pumps – Plunger and piston pump – differences – Discharge of

reciprocating pump – Theoretical power required – Coefficient of discharge – Slip –

Percentage slip – Negative slip –Cavitation – Air vessels – Trouble shooting, causes and

remedies-Problems on discharge, slip, percentage slip, theoretical power required.

(ii)Centrifugal Pump

Components and working of a single stage centrifugal pump – Types of casing –

types of impellers – Multi stage pumps – Priming – Self priming pump – Constant speed

Characteristic curves – Jet pump – Trouble shooting, causes and remedies – Comparison

Unit V Hydraulic systems 13 15

Revision 3


Total 75 75


26

of centrifugal pump and reciprocating pumps – No problems.

Unit IV PNEUMATIC SYSTEMS

Pneumatic Systems – elements – filter – regulator - lubricator unit -

pressure control valves - pressure relief valves - pressure regulation valves -

directional control valves - 3/2 DCV - 5/2 DCV – 5/3 DCV flow control valves –

throttle valves –shuttle valves – quick exhaust valves – ISO symbols of pneumatic

components – pneumatic circuits – direct

control of single acting cylinder – operation of double acting cylinder – operation

of double acting cylinder with metering-in control - operation of double acting cylinder

with metering-out control – use of shuttle valve in pneumatic circuits – use of quick

exhaust valve in pneumatic circuits - automatic operation of double acting cylinder

single cycle – multiple cycle – merits and demerits of pneumatic system - applications.

Unit V HYDRAULIC SYSTEMS

Hydraulic system – Merits and demerits – Service properties of

hydraulic fluids Hydraulic accumulators – Weight of gravity type accumulator –

Spring loaded type accumulator - Gas filled accumulator – Pressure intensifier – Fluid

power pumps – External and internal gear pump, Vane pump, Radial piston pump –

ISO symbols for hydraulic components – Hydraulic actuators – Cylinders and

motors – Valves – Pressure control valves, Flow control valves and direction

control valves – types – including 4/2 DCV and 4/3 DCV – their location in the circuit.

Hydraulic operation of double acting cylinder with metering-in and

metering-out control – application of hydraulic circuits – Hydraulic circuit for -

shaping machine - table movement in surface grinding machine and milling machine

– comparison of hydraulic and pneumatic systems.

Reference Books :


1 Fluid Mechanics and

Machines Dr.R.K.Bansal Laxmi publications, New Delhi.

2 Hydraulic & Fluid

Mechanics

P.N.Modi and

S.N.Seth

Standard Book House,New

Delhi.

3 Hydraulic Systems Hand

Book --

Utility Publications Limited,

Secunderabad

4 Industrial Hydraulics John Pippenger

&Tyler Hicks

Mc Graw Hill International

Book Company

5 Audel’s Practical Guide

to Fluid power --

D.B.Taraparevale Sons & Co.,

Pvt Ltd., Bombay.


27

Online Resources:

1. www.faadooengineers.com

2. www.bookboon.com

3. www.smartzworld.com

Course Outcome:

Understand the properties of fluids pressure measuring devices, Types of fluids and

flows, and Bernoullie’s theorem & their applications.

Understand the major loss and minimum loss of head in flow through pipes working

principles of turbines.

Understand the working principles and performance of centrifugal pumps and

reciprocating pumps.

Understand pneumatic and hydraulic systems.Identify different hydraulic circuits and

their applications


28

3E 3207 MANUFACTURING PROCESSES

RATIONALE

Manufacturing, the major and the most important aspect in industries needs utmost

care and attention. Knowledge about various processes and allied areas will be of great use to

the personnel involved in production. This will provide the students an opportunity to skill

themselves for the industrial scenario.

OBJECTIVES:

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

Describe the various casting processes.

Knowledge about various welding process and its working principle.

Appreciate the safety practices used in welding.

Acquire knowledge about various forming technologies.

Knowledge about plastic components, types and moulding processes.

Knowledge on composites manufacturing methodology

Study about the drilling process.

Study about metrology and measuring instruments.


TOPICS AND ALLOCATION OF HOURS:

Unit Name of the Topic Hours Marks

I Foundry technology 13 15

II Welding technology 13 15

III Forming technology 13 15

IV Manufacturing of Plastic Components and Composite

manufacturing 13 15

V Drilling & metrology 13 15

Revision 3 --

Cycle tests & model examination 7 --

Total 75 75

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

3207 5 - 5 80 3 25 75 100


29

DETAILED SYLLABUS

3E 3207 MANUFACTURING PROCESSES

Unit I FOUNDRY TECHNOLOGY

Patterns: Definition - types of pattern - solid piece - split piece - loose piece - match plate -

sweep - skeleton - segmental – shell pattern materials - pattern allowances.

Moulding: Moulding sand - constituents - types - properties of moulding sand - moulding

sand preparation - moulding tools - moulding boxes - types of moulds - green sand mould -

dry sand mould - loam mould - methods of moulding - moulding machines jolting -

squeezing - sand slinger construction and working principle.

Cores: Essential qualities of core - materials - core sand preparation - core binders - core

boxes - CO2 process core making - types of core.

Metallurgy: - Introduction - Iron-carbon diagram.

Melting furnaces: Blast furnace - Cupola furnace - crucible furnace - types - pit furnace -

coke fired - oil fired - electric furnace - types - direct arc - indirect arc - induction furnace -

working principles.

Casting: Shell mould casting - investment casting - pressure die casting - hot chamber die

casting - cold chamber die casting - gravity die casting - centrifugal casting - continuous

casting - defects in casting - causes and remedies.

Unit II WELDING TECHNOLOGY

(i)Arc Welding: Definition - arc welding equipment - electrode types - filler and flux

materials - arc welding methods - metal arc - Metal Inert gas (MIG) - Tungsten inert gas

(TIG) - Submerged arc Electro slag welding - resistance welding - spot welding - butt

welding - seam welding - Plasma arc welding - Thermit welding - Electron beam welding -

Laser beam welding - friction welding - ultrasonic welding - Induction welding - working

principle - applications - advantages and disadvantages.

(ii)Gas welding: Oxy-acetylene welding - advantages - limitations - gas welding equipment

- Three types of flames - welding techniques - filler rods. - Flame cutting - soldering -

brazing - difference between soldering and brazing. Types of welded joints - merits and

demerits of welded joints - inspection and testing of welded joints - destructive and non-

destructive types of tests - magnetic particle test - radiographic and ultrasonic test - defects

in welding - causes and remedies.

Unit III FORMING TECHNOLOGY

(i)Forging: Hot working, cold working - advantages of hot working and cold working- hot

working operations - rolling, forging, smith forging, drop forging, upset forging, press

forging - roll forging.

(ii)Press Working: Types of presses - mechanical and hydraulic presses - press tools and

accessories - press working operations - bending operations - angle bending - channel

bending - curling - drawing - shearing operations - blanking, piercing, trimming - notching -

lancing.

(iii)Powder Metallurgy: Methods of manufacturing metal powders - atomization,


30

reduction and electrolysis deposition - compacting - sintering - sizing - infiltration -

mechanical properties of parts made by powder metallurgy - design rules for the power

metallurgy process.

Unit IV MANUFACTURING OF PLASTIC COMPONENTS & COMPOSITE

MANUFACTURING

(i)Plastic Components: Types of plastics - Engineering plastics –thermosets –

composite - structural foam, elastomers - polymer alloys and liquid crystal polymers.

Factors Influencing the Selection Of Plastics - Mechanical properties – degradation -

wear resistance - frictional properties - special properties –processing – cost Processing of

Plastics: Extrusion-general features of single screw extrusion - twin screw extruders.

Injection moulding types: Plunger type - Reciprocating screw injection - details of

injection mould - structural foam injection mould - sandwich moulding - gas injection

moulding -injection moulding of thermosetting materials - calendaring and rotational

moulding. Design consideration for plastic components.

(ii)Composite manufacturing: Introduction – characteristics of composite

manufacturing - constituents – Glass fibers manufacturing process – hand laminating

process – autoclave processing – filament winding – pultrusion process – liquid

composite process – working principles by schematic diagram only – advantages –

disadvantages.

Unit V DRILLING AND METROLOGY

(i)Drilling Machines: Drills - flat drills - twist drills - nomenclature of twist drill - types of

drilling machines - bench type - floor type - radial type - gang drill - multi spindle type -

principle of operation in drilling - methods of holding drill bit - drill chucks - socket and

sleeve -drilling operation - reaming - counter sinking - counter boring - spot facing - tapping

- deep hole drilling.

(ii)Metrology: Definition - need of inspection - precision - accuracy - sensitivity -

magnification - repeatability - calibration - comparator - Advantages - requirements –

mechanical comparator - optical comparator - electrical comparator - pneumatic

comparator - Principles - advantages and disadvantages.

(iii)Measuring instruments: Construction and principles only - Steel rule - Calipers:

outside caliper - inside caliper - jenny caliper - Combination set - Feeler gauge - Pitch screw

gauge - Vernier caliper - Digital calliper - Vernier height gauge - Micrometer - Inside

micrometer - Thread micrometer - Slip gauges - requirement - Indian standard - care and

use - Sine bar - types - uses - limitations - Working principle of clinometers, autocollimator,

angle decker.

REFERENCE BOOKS :


1 Workshop technology,

Vol.I ,II & III Chapman

English language book

society.

2 Elements of workshop Hajra choudry& Media promoters &


31

technology,

Vol.I &II

bhattacharya publishers ltd.,

Bombay

3 Work shop technology Raghuvanshi Dhanpat rai &

sons,newdelhi

4 Production processes ------ T.t.t.i. chennai

5 Production technology Jain & gupta Khanna publishers,

Newdelhi.

6 Production technology Hmt Tata mcgrawhill

Online Resources:


2. www.nptel.ac.in

3. www.studentskey.in

Course Outcome:

Understand the different types of patterns, castings, moulding and different types of

melting furnaces.

Knowledge about various welding process and its working principle and different

types of welding joints.

Understand the concepts of Non-distructive testing procedures and Appreciate the

safety practices used in welding.

Understand the Hot working, cold working processes and

Understand the press tools and accessories, Types of presses and its different types of

press working.

Understand the concepts of powder metallurgy and its various types of processes.

Knowledge of design rules for the power metallurgy.

Understand the concepts of different Types of Engineering plastics and their

properties, manufacturing of different types of plastics

Knowledge of concepts of composite and their manufacturing.

Understand the nomenclature of twist drill, types of drill and drilling machines and

principle of operation in drilling.

Knowledge of measuring instruments .


32

3E 3301 MACHINE DRAWING

RATIONALE

Diploma holders are required to read and interpret drawings. Hence it is essential that

they should have competency in preparing drawings, sketches and assembly of various

machine parts.

OBJECTIVES:

Appreciate the need of sectional view and types of sections.

Draw sectional views using different types of sections.

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

Compare hole basis system with shaft basis system.

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

Draw assembled drawings of different types of joints and couplings.

Draw assembles drawings of various types of machine elements AutoCAD.


DETAILED SYLLABUS

3E 3301 MACHINE DRAWING

Unit I SECTIONAL VIEWS

Review of Orthogonal and Isometric views – need for sectioning –

Sectional views – cutting plane – Types of sections – full section – half section –

removed section – revolved section – offset section – local section – thin section –

section line or hatching line.

Unit II THREADED FASTENERS & MACHINE ELEMENTS

Types of fasteners – temporary – permanent – nomenclature of threads –

types of threads – V threads – square threads, left hand and right hand threads –

internal and external threads – hexagonal and square bolts and nuts – empirical

proportion to draw rivet heads, keys--Taper keys, parallel keys and woodruff

keys.

Unit III LIMITS, FITS, TOLERANCES AND SURFACE FINISH

Limits – fits and tolerance – hole basis system – shaft basis system -

Types of fits - selection of fits and applications - Types of tolerance of form and

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

3301 - 6 3 90 3 25 75 100


33

position - indication of tolerances and fits on the drawing - Roughness, waviness

and lay – production methods and surface quality symbols for lay.

Unit IV ASSEMBLY DRAWINGS

(with indication of fit designations wherever necessary)

1. Sleeve and Cotter joint

2. Gib and Cotter joint

3. Knuckle joint

4. Universal coupling

5. Protected type flange coupling

6. Plummer block

7. Swivel Bearing

8. Simple eccentric

9. Screw jack

10. Machine Vice

Reference Books :


1 Machine Drawing N.D.Bhatt Charotar Book stall

2 Intermediate Engineering

Drawing. A.C. Parkinson

Wheeler Publishing,

Allahabad

3 Machine Drawing N.Siddhewar Charotar Book Stall,Anand

4 A Text book of Machine

Drawing R.B.Gupta

Satya Publications,

New Delhi

5 Machine Drawing K.S.Gopalakrishnan Subha’s stores, Bangalore

6 Machine Drawing P.S.Gill. S.K.Kataria & Sons,

New Delhi

Online Resources

1. www.way2engineer.com

2. www.smartzworld.com

3. www.geethanjaliinstitutions.com

Course Outcome:

Knowledge of section view and types of sections and understanding the use of

threaded fasteners and the types of threads.

Knowledge of sectional views using different types of sections.

Identify different types of fits and tolerance for various types of mating part.


34

Knowledge of different types of joints and couplings.

Drawing Knowledge of various types of machine elements AutoCAD.


35

3E 3208 STRENGTH OF MATERIALS AND FLUID MECHANICS PRACTICAL

RATIONALE:

Diploma holders in this course are required to experience the mechanical properties of

materials, fluid flow, fluid machines and hydraulic and pneumatic systems. The knowledge

thus acquired helps them in understanding the behavior of materials when stressed, and the

functioning of fluid power machines, hydraulic and pneumatic systems.

OBJECTIVES:

Determine stress strain relations for steel and cast iron.

Determine hardness of materials.

Perform torsion, bending, impact and shear tests

Determine coefficient of discharge of venture meter and orifice meter.

Determine the friction in pipes.

Verify Bernoulli’s theorem.

Conduct performance test on centrifugal and reciprocating pump.

Conduct performance test on impulse and reaction turbine.

Design and make fluid power circuits


EXAMINATION SCHEME

TOPIC Marks Duration

Mechanics of Materials Laboratory 35 11/2 Hours

Fluid Mechanics Laboratory 35 11/2 Hours

Viva Voce 5 3 Hours

List of Experiments

1. STRENGTH OF MATERIALS LABORATORY

1. Test on ductile materials:

Finding Young’s modulus of elasticity, yield points, percentage elongation and

percentage reduction in area, stress-strain diagram plotting. Tests on mild steel and

cast iron.

2. Hardness test :

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3D3209 - 4 3 60 3 25 75 100


36

Determination of Rock well’s and Brinell’s Hardness number for various materials

like mild steel, high carbon steel, brass, copper and aluminum.

3. Torsion test:

Torsion test on mild steel – relation between torque and angle of twist –

Determination of shear modulus -- determination of elastic constants for mild steel.

4. Bending and deflection tests:

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

5. Impact test:

Finding the resistance of materials to impact loads by (a) Izod test (b) Charpy test.

6. Tests on springs of circular section:

Determination of modulus of rigidity, strain energy, shear stress by load deflection

method – compression and tension test (closed coil spring only).

7. Shear test:

Determination of shear strength of a given metal (M.S).

2 . FLUID MECHANICS LABORATORY

1. Verification of Bernoulli’s Theorem.

2. Determination of Co-efficient of discharge of the Venturimeter.

3. Determination of Co-efficient of discharge of the Orifice meter.

4. Determination of Co-efficient of friction of the pipes.

5. Determination of slip and co-efficient of discharge of the reciprocating

pump.

6. Test on Centrifugal pump--constant speed and Characteristic curves.

i) Head vs Discharge ii) Efficiency vs Discharge

iii) Shaft power vs Discharge

7. Performance test on Pelton wheel.

8. Performance test on Francis Turbine.

9. Performance test on Kaplan Turbine.

10. Study of Pneumatic and Hydraulic circuits.

Course Outcome:

Gaining Practical knowledge on stress strain relations for steel and cast iron

measurement of hardness of materials

Understanding the behavior of the materials by performing torsion, bending, impact

and shear tests

Determining coefficient of discharge of venture meter and orifice meter, the friction

in pipes.

Verification of Bernoulli’s theorem.

Knowledge of performance of centrifugal and reciprocating pump impulse and

reaction turbine.

Identifying different hydraulic Circuits.


37

3E 3209 - METROLOGY & METALLOGRAPHY PRACTICAL

OBJECTIVES:

Familiarize about measuring techniques of Metrology instruments.

Select the range of measuring tools.

Obtain accurate measurements.

Determine the least count of measuring instruments.

Study the working principle of Microscope.

Specimen preparation of ferrous and non-ferrous metals.

Grinding, polishing and mounting of specimen.

Non-destructive testing of metals for cracks.

Crack detection – Visual inspection, Die penetration method

Prepare the record of work for the exercises.


EXAMINATION SCHEME

TOPIC Marks Duration

Metrology Excersise 35 1 1/2 Hours

Metallography Excersise 35 1 1/2 Hours

Viva Voce 5 3 Hours

List of Experiments

1. METROLOGY SECTION:

1. Measure the dimensions of ground MS flat / cylindrical bush using Vernier Caliper

compare with Digital / Dial Vernier Caliper.

2. Measure the diameter of a wire using micrometer and compare the result with digital

micrometer

3. Measure the thickness of ground MS plates using slip gauges

4. Measure the angle of a V-block / Taper Shank of Drill / Dovetail using universal

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

3210 - 4 3 60 3 25 75 100


38

bevel protractor.

5. Measure the angle of the machined surface using sine bar with slip gauges.

6. Measure the geometrical dimensions of V-Thread using thread Vernier gauge.

7. Measure the geometrical dimensions of spur gear.

2) METALLOGRAPHY SECTION:

1. Find the grain structure of the given specimen using the Metallurgical Microscope.

2. Prepare a specimen to examine the micro structure of the Ferrous and Non- ferrous

metal.

3. Detect the cracks in the specimen using Visual Inspection and ring test.

4. Detect of cracks in specimen using Die penetration test.

5. Detect the cracks in specimen using Magnetic particle test.

Course Outcome:

Understanding the different measuring techniques of Metrology instruments.

Understanding the working principle of microscope

Concepts of Specimen preparation of ferrous and non-ferrous metals.

Knowledge of Non-destructive testing of metals for cracks.


39

3E 3210 FOUNDRY, SMITHY & WELDING PRACTICE

RATIONALE:

A Diploma holder technician should get more opportunity to know about machines,

equipment and its operations which will help to be more confident and practical oriented.

Workshop SKILL is also a kind of ESSENTAL PRACTICAL KNOWEDGE required

for the Engineering students in general and Diploma Students in particular. A Diploma

holder must know how to behave and work on shop floor. This helps to develop psychomotor

skill and attitude. Workshop practice is the backbones of the real industrial work situation,

which helps in development and enhancement of relevant skill required by the technical

working in engineering industries and workshops.

In order to have a balanced overall development of diploma engineers, it is necessary

to integrate theory with practice. Workshop practices are included in the curriculum in order

to provide hands on experience about use of different tools and basic manufacturing

practices. Knowledge about casting processes and allied areas will be of great use to the

personnel involved in production.

Diploma holders are responsible for supervising production processes to achieve

production targets and for optimal utilization of resources. For this purpose, knowledge about

various machining processes is required to be imparted.

Handling Mechanical Engineering Materials is a core technology subject in

Mechanical Engineering Discipline. A Mechanical Engineering diploma holder deals with

various materials required for cutting tools, Dies, Gears, Bearings and many other

applications. Knowledge of selection of proper tool materials, heat treatments for specific

materials, ferrous and non- ferrous materials and their alloys for various engineering

application, as well as insulating, refractory and plastic materials as per the requirements is

essential.

This subject will help the student to be familiarized with working principles and

operations like forging, rolling, extrusion, press working, lathe, drilling, milling, casting,

welding, brazing and soldering etc., which are the basic production processes.

The basic knowledge of these material processing will be helpful to select the most

appropriate process for getting the desired results in terms of getting the raw material

converted to finished product as per the requirements.

They will be using different types of tools/equipment in different shops for fabrication

purposes. Besides above, the development of dignity of labour, precision, safety at work

places, team working and development of right attitude, are other objectives.

The workshop experiences would also help them to understand the complexity of

industrial working in relative shorter duration of time. The students are advised to undergo

each skill experience with an understanding of know-how with special emphasis on know-

why for the various instructions/practices imparted to them in each shop.

Mechanical diploma technician is expected to know basic workshop practice like, Gas

Welding, gas Cutting, casting and hot working processes. The students are required to

identify, operate and control various machines. The students are required to select and use

various tools and equipment for welding, casting and forging operations.


40

Student shall calculate the cost of material and labour cost for their job from the

drawing.

OBJECTIVES:

After the completion of this training, the students should be able to

Comprehend the need of various sections in a workshop.

Demonstrate observance of the safety consciousness and good housekeeping in a

workshop.

Follow the standard procedure for workshop practice.

Select and use appropriate materials for various sections of a workshop.

Use of various tools, instruments and machines for different operations in Black

smithy, Foundry and Welding sections.

Prepare the required jobs for correctly according to given specification in various

sections of a workshop.

Know the properties of Engineering Materials like Metals, non-metals, ferrous metals

and non-ferrous metals.

Identify the various operations in smithy.

Understand various heat – treatment processes & its applications.

Know the behaviour of materials under various load conditions.

SCHEME OF INSTRUCTION AND EXAMINATION

SCHEME OF EXAMINATION.

Each student will be examined (A). Welding and (B). II. Material Processing Practice &

Smithy Practice

Students will be examined (A) and (B) or (C) by lot.

NOTE:-

The students should be given training in all the sections. All the exercises should be

completed. The students should maintain record notebook for the concerned trades

and submit during the Board Practical Examinations.

All the exercises should be given in the question paper and students are allowed to

select by a lot. Students should have liberty to do the examination for 3 Hrs. No fixed time

for each trade. The number of instrument /equipment facility should be available for each

batch strength during examination.

Course

Code

Instruction

Credits

Examination

Hours/

Week

Hours/

Semester Internal Examination Total Duration

3E

3210 6 90 3 25 75 100 3 Hrs.


41

ALLOCATION OF MARKS.

Max. Marks:- 75.

WELDING - 35 marks

Job Preparation - 10

Weld bead - 10

Penetration / Reinforcement - 10

Joint / Finish - 5

And

SMITHY PRACTICE - 35 marks

Job Preparation - 10

Forming - 10

Dimension - 10

Finishing - 5

(or)

FOUNDRY - 35 marks

Sand Preparation - 10

Mould - 10

Gate formation - 10

Result - 5

Viva-voce - 5 marks

TOTAL - 75 marks

MAJOR DIVISIONS:

Material Processing practice and Smithy practice.

Welding practice.

Foundry practice.

TOPICS:

Review about General Safety precaution in Workshop.

Review about First Aid.

Review about Fits, Tolerance, Allowance.

Need of Black Smithy section, Foundry section and Welding section.

Study about layout of Black Smithy section, Foundry section and Welding section.

Industrial application of Black Smithy section, Foundry section and Welding section.

Identify, select and use various measuring, marking, holding, striking and cutting

tools & equipment in the above sections.

Safety precautions to be taken in Black Smithy, Welding and Foundry sections.


42

Care & maintenance of tools and equipment used in Black Smithy, Welding and

Foundry sections.

Read and interpret job drawings.

Defects in forged components.

Identification of different types of materials such as Steel, Brass, Copper, Aluminium

etc.,

Know the materials which can be welded and materials which cannot be welded.

Preparation of edges by filing.

Igniting the flame and setting the various types of flames.

Understand types of moulding sand types of pattern and identify casting defects.

Understand the need of pattern allowances.

Understand various sand casting processes.

List of Experiments

I. FOUNDRY

PREPARATION OF FOLLOWING GREEN SAND MOULD:

1. Flange coupling (solid)

2. Flange coupling (self-core)

3. Bush bearing

4. Gear wheel

5. T – pipe

6. Yoke

7. Preparation of Core

8. Bent Pipe

9. Bearing top

DEMO EXERCISES:

Green sand mould of Grooved pulley, Loose Piece Pattern (Dovetail).

Melting and Casing of Dumbbell and Spigot pipe etc.,

II. MATERIAL PROCESSING PRACTICE & SMITHY PRACTICE.

a). Material processing operation by evaluating and comparing the responses before

and after the treatment.

1. Hardening process (Air, Water, Oil, Salt solution etc.,)

2. Annealing process

3. Flame hardening

b). JOB PRACTICE (Cold bending operation)

1. Round to square rod

2. S-hook

3. Ring

4. Spike

5. Link


43

c). DEMO EXERCISES (Hot forging operation)

1. Round to square rod and vice-versa.

2. Chisel.

3. Forming of Square head and Round head.

III. WELDING

EXERCISES DETAILS – JOB PRACTICE:

a). ARC Welding

1. Butt joint

2. Lab joint

3. ‘T’ joint

4. Corner joint

b). GAS WELDING

1. Lap joint

2. ‘T’ joint

3. Corner joint

C). BRAZING, SOLDERING

1. Lap joint – Brazing

2. Soldering

b). DEMO EXERCISES

Repairing of worn out shaft by ARC welding. Profile cutting by Gas cutting &

Plasma cutting, Spot welding, Gouging etc.,

Course Outcome:

Understanding the Use of various tools, instruments and machines for different

operations in Black smithy, Foundry and Welding sections.

Identify the various operations in smithy.

Understand various heat – treatment processes and its applications.


44

IV TERM


45

3E 4211 HEAT POWER ENGINEERING

RATIONALE

The knowledge on the concept of Thermodynamics, Thermodynamic Processes,

Steady flow energy equation and steam properties and performance of Boilers are vital.

OBJECTIVES

Explain a basics of systems, laws of thermodynamics and thermodynamic

processes.

Explain different types of Air Cycles.

Apply steady flow energy equation for nozzles and condensers etc

Explain a air compressors and gas turbines

Explain a formation and properties of steam and steam calorimeters.

Explain a steam boilers and performance of boilers.



CHAPTER NAME OF THE TOPIC HOURS MARKS

I Thermodynamics and expansion of gases 13 15

II Steady flow energy equation and air cycles 13 15

III Air compressors and gas turbines 13 15

IV Formation & properties of steam and steam

calorimeters 13 15

V Steam boilers and performance of boilers 13 15

Revision 3


Total 75 75

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

4211 5 - 5 75 3 25 75 100


46

DETAILED SYLLABUS

3E 4211 HEAT POWER ENGINEERING

UNIT I THERMODYNAMICS AND EXPANSION OF GASES

Introduction - definitions and units of mass, weight, volume, density,

specific weight gravity - pressure - units - atmospheric, gauge, vacuum and absolute

pressure -temperature - Celsius and absolute temperature - S.T.P and N.T.P conditions

- heat -specific heat capacity at constant volume and at constant pressure - work -

power -energy - types - thermodynamic system - types -properties and state of system

-intensive and extensive properties - thermodynamic process - cycle - point and path

function - law of conservation of energy - equilibrium - thermodynamic - zeroth , first

and second law of thermodynamics- problems

Perfect gases - law of perfect gases - Boyle's, Charles', Joule's, Renault’s

and Avogadro’s law -characteristic gas equation - relation between specific heats and

gas constant - universal gas constant - problems -enthalpy -change in enthalpy -

entropy - change in entropy - general equation for change in entropy.

Expansion of gases - thermodynamic processes - constant volume, constant

pressure, isothermal (hyperbolic), isentropic (reversible adiabatic), polytrophic, free

expansion and throttling processes - p-V and T-s diagrams, work done, change in

internal energy, heat transfer, change in enthalpy, change in entropy for various

processes - problems.

UNIT II STEADY FLOW ENERGY EQUATION AND AIR CYCLES

Steady flow system - control volume - steady flow energy equation -

applications- steam boiler - condenser -nozzles - steam and gas turbines -reciprocating

and rotary compressors - non flow energy equation - problems.

Air cycles - air standard efficiency- reversible and irreversible processes -

thermodynamic reversibility - conditions of reversibility assumptions in deriving air

standard efficiency -Carnot cycle- Otto cycle - Joule cycle -Diesel cycle -comparison

of Otto cycle and Diesel cycle- ideal and actual p-V diagram of Diesel cycles –

comparison - problems - dual combustion cycle (description only).

UNIT III AIR COMPRESSORS AND GAS TURBINES

Air compressor - uses of compressed air - classifications of compressor –

working principle of a compressor - single stage reciprocating compressor –

compression processes - power required to drive the compressor - problems -

clearance volume and its effects - volumetric efficiency - power required to drive the

compressor with clearance volume -problems- multi stage air compressor - merits and

demerits -intercooler - perfect inter cooling - work input on multi stage compressor -

condition for minimum work input in multi stage compressor with perfect inter

cooling - ratio of cylinder diameter for minimum work input - problem - rotary

compressors - Roots, vane blowers - centrifugal and axial flow air compressors.

Gas turbines- classifications - advantages and disadvantages of gas turbines –

constant pressure gas turbine - gas turbine with regenerator - inter cooler – reheater -


47

effects -closed cycle gas turbines - merits and demerits of open and closed cycle gas

turbine -turbojet engines- merits and demerits - turbo propeller engines- merits and

demerits -ramjet- Rocket Engines Types- Applications of Rockets.

UNIT IV FORMATION & PROPERTIES OF STEAM AND STEAM

CALORIMETERS

Steam - Properties – formation of steam – saturation temperature – enthalpy of

water – enthalpy of evaporation – conditions of steam – wet, dry and superheated

steam -dryness fraction – enthalpy of wet, dry and superheated steam -

advantages of superheated steam – Property diagrams – p-v diagram - T-H diagram

– T-V diagram – T-S diagram - phase diagram - H-S diagram –P-H diagram –

critical conditions of water – specific volume of water and steam – density of steam

– external work done during evaporation – internal latent heat – internal energy

of steam – entropy of water and steam –steam tables - Mollier chart – Simple

problems.

Expansion process of Steam: Constant Volume process –Constant Pressure

Process – Constant Temperature process –Hyperbolic Process – Isentropic

process – Polytrophic process –Throttling process. – Simple problems. Steam

Calorimeter: Determination of dryness fraction of steam –bucket calorimeter -

combined separating and throttling calorimeters-Simple problems.

UNIT V STEAM BOILERS AND PERFORMANCE OF BOILERS

(i)Steam Boilers: introduction - Classification of boilers – comparison of fire tube

and water tube boilers– high pressure boilers – advantages of high pressure boilers -

Lamont and BHEL high pressure boilers – Super critical boilers – Ultra super critical

boilers (Description only) – boiler mountings and function - construction and

working – boiler accessories and function - construction and working – comparison

of mountings and accessories – feed water treatment – internal and external

treatments - starting boiler from cold condition – safety precautions in boiler

operation – causes of Indian boiler act.

(ii)Performance of boilers:- Evaporation rate- actual, equivalent and factor of

evaporation – boiler efficiency – factors influencing boiler efficiency - boiler

power – Simple problems – boiler plant - efficiency of economizer and super heater –

Simple problems - boiler trial – heat losses in a boiler- heat balance sheet – Simple

problems.

Reference Books :


1. Thermal Engineering, Edn.

18 R.S.Khurmi and J.K..Gupta S.Chand & Co.

2. Applied Thermodynamics, P.K.Nag Tata McGraw Hil

Publishing Co.


48

3. Thermal engineering P.L Bal aney Khanna Publishers

4. Thermal engineering B.K Sarkar Dhanpat Rai &Sons

5. Applied Thermodynamics Domkundwar and

C.P kothandaraman Khanna Publishers

Online Resources:

1. www.technicalsymposium.com


3. http://www.pdfquestion.in/6205.html

Course Outcomes

Understanding the concepts of basics systems, laws of thermodynamics and

thermodynamic processes.

Identify different types of Air Cycles

Application of steady flow energy equation for nozzles and condensers etc

Understanding the concepts of different types of air compressors and gas turbines

Understand the formation and properties of steam and steam calorimeters.

Understanding the concepts of different types of steam expansion processes

Knowledge of different types of steam boilers, boiler mountings and their

accessories, Indian Boiler Act.

Evaluating the performance of boilers.


49

3E 4212 SPECIAL MACHINES

RATIONALE

In the process of manufacturing we should possess adequate and through

knowledge about the working of conventional as well as non conventional machines. The

topics included aim to inculcate in the students the skills of metal cutting, milling, grinding,

CNC machines and other machining processes which are very much essential for a

technician to at promptly and with precision.

OBJECTIVES

Understand the plastic components and its process.

Study the manufacturing of Composite materials.

Study the working of various machine tools: Planer, Shaper and Slotter.

Study the various work holding devices

Study various types of milling cutter.

Study the different types of grinders and grinding wheels.

Study the broaching operation and their applications.

Study the milling procedure for spur, helical and bevel gears.

Study the various types of gear generating processes

Study the use of non-conventional machining processes.

Study the CNC machines working principle and its components.




Unit I Theory of metal cutting & Lathe 13 15

Unit II Reciprocating Machines and Broaching Machine 13 15

Unit III Milling Machines and Gear Generating Processes 13 15

Unit IV Abrasive Process and Non- Conventional Machining

Processes 13 15

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

4212 5 - 5 75 3 25 75 100


50

Unit V CNC Machine and Its Components 13 15

Revision 3


Total 75 75

DETAILED SYLLABUS

3E 4212 SPECIAL MACHINES

UNIT I THEORY OF METAL CUTTING & LATHE MACHINE

(i)Theory of metal cutting: Introduction - orthogonal cutting - oblique cutting - single point

cutting tool - nomenclature - types of chips - chip breakers - cutting tool materials - properties

- tool wears - factors affecting tool life - cutting fluids - functions - properties of cutting fluid.

(ii)Centre Lathe: Introduction - specifications - simple sketch - principal parts - head stock -

back geared type - all geared type - feed mechanism - tumbler gear mechanism - quick

change gear box - apron mechanism - work holding device - three jaw chuck - four jaw chuck

- centres - faceplate - mandrel - steady rest - follower rest - machining operations done on

lathe - straight turning - step turning - taper turning methods: form tool - tailstock set over

method - compound rest method - taper turning attachment - knurling - Thread cutting -

Facing - Boring - chamfering -grooving - parting-off - eccentric turning - cutting speed - feed

- depth of cut - metal removal rate.

(iii)Semi-Automatic Lathes: Types of semi-automatic lathes - capstan and turret lathes -

Geneva indexing mechanism - bar feeding mechanism - difference between turret and capstan

- work holding devices - tool holders.

UNIT II RECIPROCATING MACHINES

(i)Planer: Introduction - description of double housing planer –specifications -

principles of operation – drives - quick return mechanism - feed mechanism - work

holding devices and special fixtures - types of tools - operations.

(ii)Shaper: Introduction – specifications – principles of operations standard shaper –

quick return mechanism - crank and slotted link –hydraulic shaper - feed mechanism -

work holding devices – fixture -operations.

(iii)Slotter: Introduction – specifications - method of operation - Whitworth quick return

mechanism - feed mechanism - work holding devices -types of tools.

(iv)Broaching: Types of broaching machine - horizontal, vertical and continuous

broaching - principles of operation - types of broaches – classification - broach tool

nomenclature - broaching operations.

UNIT III MILLING MACHINES AND GEAR GENERATING PROCESSES

(i)Milling Machines: Types - column and knee type – plain - universal milling machine -

vertical milling machine - principles of operation -specification of milling machines -

work holding devices - tool holding devices - arbor - stub arbor - spring collet – adapter.

(ii)Milling cutters: cylindrical milling cutter - slitting cutter -side milling cutter - angle

milling cutter - T-slot milling cutter - woodruff milling cutter - fly cutter -nomenclature of


51

cylindrical milling cutter. Milling operations: straddle milling - gang milling - vertical

milling attachment. Indexing plate – differential indexing - simple indexing – compound

indexing – simple problems.

(iii)Generating Process: gear shaper - gear hobbing - principle of operation only. Gear

finishing processes: burnishing – shaving -grinding and lapping - gear materials.

UNIT IV ABRASIVE PROCESS AND NON- CONVENTIONAL MACHINING PROCESSES

(i)Abrasive Process: Types and classification – specifications - rough grinding –

pedestal grinders - portable grinders - belt grinders -precision grinding - cylindrical

grinder - centerless grinders – surface grinder - tool and cutter grinder - planetary

grinders - principles of operations - grinding wheels – abrasives - natural and artificial

diamond wheels - types of bonds - grit, grade and structure of wheels -wheel shapes and

sizes - standard marking systems of grinding wheels - selection of grinding wheel -

mounting of grinding wheels -Dressing and Truing of wheels - Balancing of grinding

wheels.

(ii)Non-Conventional Machining Processes: Construction, working and applications of

Ultrasonic machining - chemical machining - electro chemical grinding - electrical

discharge machining - plasma arc machining - LASER machining - Advantages –

Disadvantages. Micro Machining – Cryogenic Machining-High Speed Machining-

NanoMachining.

UNIT V CNC MACHINE AND ITS COMPONENTS

(i)CNC Machines: Numerical control – definition – working principle of a CNC system –

Features of CNC machines - advantage of CNC machines – difference between NC

and CNC – Construction and working principle of turning centre – Construction and

working principle of machining centre – machine axes conventions turning centre and

machining centre – Coordinate measuring machine – construction and working principle.

(ii)Components of CNC machine: Slide ways – requirement – types –friction slide ways

and antifriction slide ways - linear motion bearings –recirculation ball screw – ATC – tool

magazine – feedback devices –linear and rotary transducers – Encoders - in process

probing - tool material – tool inserts.

Reference Books :


1. Production Technology -------- HMT

2. Workshop Technology Vol. I, II & III – Chapman Edward Arnold Publications

Ltd, London.

3. Production Process – TTTI, MADRAS.

4. Elements of Work Shop Technology

Vol.II

Hajra Choudry

and Battacharya.

Media promoters & Publishers

private Ltd, Mumbai.

5. Manufacturing Processes Myro L.Bezema. ---------


52

6. Production Technology Jain and Gupta. Smt.Smitra Handa – NewDelhi

Khanna Publishers - NewDelhi

7. Manufacturing process Myro N Begman Tata McGraw Hill,

NewDelhi

8. Principles of the manufacturing of

Composite materials Suong V Hoa

DES tech Publication,

Pennsylvania – 17602 U.S.A.

Online Resources:

1. www.scribd.com/doc/132759046/Manufacturing-Technology-II-Notes-pdf

2. www.vidyarthiplus.com

3. www.rejinpaul.com

Course Outcomes

Understanding the plastic components and its process and manufacturing of

Composite materials.

Knowledge of working principle of various machine tools: Planer, Shaper and Slotter

and various work holding devices

Understanding the various types of milling cutter and the different types of grinders

and grinding wheels.

Knowledge of broaching operation and their applications.

Knowledge of milling procedure for spur, helical and bevel gears.

Understanding the concepts of non-conventional machining processes.


53

3E 4401 ELECTRICAL DRIVES AND CONTROL

RATIONALE

Automation is being the order of the day to improve the production with high quality

consciousness. It involves electrically operated switches, sensors controlled through

electrically driven motors actuators. The subject aims in introducing the basic electrical DC

and AC circuits and motors and also focuses on the various special control devices like

stepper, servo drives and its controlling elements.

OBJECTIVES

Explore fundamental electric circuit laws.

Explain the working principle of DC and AC electrical machines.

Identify the effective uses of the drives of electrical machines.

Analyze the various power supply circuits.

Select the field controlled elements.

Explain the construction and working of transformer.

Compare the different types of logic gates.

Appreciate the safety practices followed in electrical systems.

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


TOPICS AND ALLOCATION OF MARKS

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

4401 5 - 5 75 3 25 75 100


Unit I DC circuits and DC machines 13 15

Unit II AC circuits and AC machines 13 15

Unit III Stepper and servo motors & drives 13 15

Unit IV Power supplies and logic gates 13 15

Unit V Control elements 13 15

Revision 3


54

DETAILED SYLLABUS

3E 4401 ELECTRICAL DRIVES AND CONTROL

UNIT I DC CIRCUITS AND DC MACHINES

Definitions - Electric current, voltage and resistance - Ohm’s Law and Kirchhoff’s

Laws - Resistance in series and parallel and series, parallel - Simple problems -

Electromagnetism (Definitions only), Magnetic flux, Flux density, Magnetic field Intensity,

MMF, permeability, reluctance, Faraday’s laws of electromagnetic Induction, electrical and

mechanical units.

DC generators – Construction, principle of operation, types and applications.

DC motors – Construction, principle of operation, types and applications. Necessity of

starter- Three point, four point starters.

Necessity of starter: three point, four point starters.

UNIT II AC CIRCUITS AND AC MACHINES

Fundamentals of AC voltage and current - Peak, average, RMS value of sine wave,

Frequency, time period, amplitude, power & power factor (Definition only) - 3Ф circuits:

Star and Delta Connections - relationship between phase and line voltage in Star and phase

and line current in Delta connections.

Transformers: Principle of operation and construction – Types - EMF equation(no

definition) – losses in transformer – efficiency – applications- Auto Transformer(Principle

Only).

Alternator : Construction – principle of operation – types and applications.

AC machines: AC motors – principle of operation of single phase capacitor start

induction motor only – applications – Three phase induction motors – Squirrel cage and Slip

ring induction motors (Construction and working principle only) – applications – speed control

of 3Ф induction motor –Necessity of starters – DOL and star delta starter.

UNIT III STEPPER AND SERVO MOTORS & DRIVES:

PMDC, Stepper motor – construction, working principle and applications – servo

motor – types: brushless servo motor, permanent magnet servo motor - construction and

applications.

Industrial drives – Types: group drive, individual drive, multi motor drive - block

diagram of variable frequency drive, stepper motor drive; single stepping and half stepping.

Servo drives.

Electrical Safety: Importance of earthing - electric shock: first aid, precautions –

causes of accident and their preventive measures. Energy conservation: Energy conservation

measures in Homes & Industries.

Cycle tests and model Examination 7

Total 75 75


55

UNIT IV POWER SUPPLIES AND LOGIC GATES

Diode –forward biasing and reverse biasing – use of diode in rectifiers – half wave,

full wave & Bridge rectifiers – necessity of filters – Regulated power supplies: IC voltage

regulators – SMPS, UPS and inverters – General description and their applications.

Display devices – LED, 7 segment LED, LCD.

Logic gates: Positive and negative logic, definition, symbol, truth table, Boolean

expression for OR, AND, NOT,NOR,NAND,EXOR and EXNOR gates – Universal logic

gates: NAND and NOR

UNIT V CONTROL ELEMENTS

Fuses – selection of fuse – necessity of fuse – fuse switch units.

Sensors: Photo electric sensor, Inductive proximity sensors, Temperature sensors.

Switches: Push button switch, selector switch, limit switch, pressure switch, Temperature

switch, Float switch and reed switch. Relays – NO,NC – usage – bimetallic thermal overload

relays Contactors – Usage – Necessity of contactor – Solenoid type contactor Circuit Breakers

– Miniature case circuit breaker (MCCB) and Miniature circuit breaker(MCB), Oil Circuit

breakers(OCB), Earth leakage circuit breakers(ELCB). Features of PLC –PLC block diagram

– PLC scan – fixed and modular PLC ladder logic – NO,NC contacts – coils – AND, OR.

Reference Books :


1. A Course in Electrical Engineering B.L.Theraja S Chand & Co,

2. Control of Machines S.K.Bhattacharya,

Brijinder singh

New Age

publishers

3. Electronic circuits & systems –

Analog and Digital. Y.N.Bapat

Tata Mc Graw

Hill.

4. Electrical Technology Hughes Pearson

Education.

5. Electrical Device and Circuits–An

Introduction Allen Mottershed

Prentice Hall of

India.

Online resources:



3. www.sasurieengg.com

Course Outcomes


56

Indentifying fundamental electric circuit laws.

Understanding the working principle of DC and AC electrical machines.

Identify the effective uses of the drives of electrical machines.

Understand and Select the field controlled elements.

Understand the construction and working of transformer.

Compare the different types of logic gates.

Appreciate the safety practices followed in electrical systems.

Compare the use of servo motors in electrical driving system


57

3E 4213 COMPUTER APPLICATIONS AND CAD PRACTICAL

RATIONALE

The contemporary progressing world is fast with the latest production systems. The

advanced manufacturing of products is developed instantly using CAD software. Even a

small scale industry is now using a CAD software as it has become the heart of the design

department. So CAD has now become inevitable in industries.

Accuracy and precision are the two important things that decide the quality of a

product to survive its competitors in the market. Using CAD software design, the uniform

accuracy, multiples of copies and storing in a small space for long time are assumed.

The CAD software considerable improves the creativity and flexibility of a designer.

The syllabus here enables a candidates to draw an industrial drawing within the optimum

reach of a diploma cadre.

OBJECTIVES:

On completion of the exercises, the students must be able to

Use the different facilities available in the word processor

Analyze the data sheet

Create and manipulate the database

Prepare PowerPoint presentation

Practice on CADD commands in making 2D Drawings.

Draw assembled drawings using CADD.

Draw sectional views using different types of sections.

SCHEME OF INSTRUCTIONS AND EXAMINATIONS:

List of Experiments :

PART - A: COMPUTER APPLICATIONS

WORD PROCESSING

Introduction - Menus - Tool bar - Create - Edit - Save - Alignment - Font Size -

Formatting - Tables - Fill Colors - Page Setup - Preview - Water marking - Header - Footer

- Clip art.

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

4213 - 4 2 60 3 25 75 100


58

Exercises

1. Create a news letter of three pages with two columns text. The first page contains some

formatting bullets and numbers. Set the document background colour and add

'confidential' as the watermark. Give the document a title which should be displayed in

the header. The header/ footer of the first page should be different from other two pages.

Also, add author name and date/ time in the header. The footer should have the page

number.

2. Create the following table using align, border, merging and other attributes.

Seshasayee Institute of Technology E- Governance

Register

Number June July August September

Cumulative

%

16304501

16304502

16304503

16304504

16304505

SPREADSHEET

Introduction - Menus - Tool bar - Create - Edit - Save - Formatting cells - Chart

wizard - Fill Colors - Creating and using formulas - Sorting - Filtering.

Exercises

3. Create a table of records with columns as Name and Donation Amount. Donation amount

should be formatted with two decimal places. There should be at least twenty records in

the table. Create a conditional format to highlight the highest donation with blue colour

and lowest donation with red colour. The table should have a heading.

4. Prepare line, bar and pie chart to illustrate the subject wise performance of the class for

any one semester.

DATABASE

Introduction - Menus - Tool bar - Create - Edit - Save - Data types - Insert - Delete -

Update - View - Sorting and filtering - Queries - Report - Page setup - Print.

Exercises

5. Prepare a payroll for employee database of an organization with the following details:

Employee Id, Employee name, Date of Birth, Department and Designation, Date of

appointment, Basic pay, Dearness Allowance, House Rent Allowance and other

deductions if any. Perform simple queries for different categories.

6. Design a pay slip for a particular employee from the above database. PRESENTATION

PRESENTATION

Introduction - Menus - Tool bar - Create - Edit - Save - Slide transition - Insert image

- Hyper link - Slide numbers - View slide show with sound - Photo album - Clip art.


59

Exercises

7. Make a presentation with atleast 10 slides. Use different customized animation effects on

pictures and clip art on any four of the ten slides.

PART - B: CAD

INTRODUCTION

Introduction - History of CAD - Applications - Advantages over manual drafting -

Hardware requirements - Software requirements - Windows desktop - CAD screen interface -

menus - Tool bars - How to start CAD - How to execute command - types of co-ordinate

systems - Absolute - Relative - Polar.

DRAWING AIDS AND EDITING COMMANDS

Creating objects (2D) - Using draw commands - Creating text - Drawing with

precision - Osnap options - drafting settings - drawing aids - Fill, Snap, Grid, Ortho lines -

Function keys - Editing and modify commands - Object selection methods - Erasing object -

Oops - Cancelling and undoing a command - Copy - Move – Array Offset - Scale - Rotate -

Mirror - Break - Trim - Extend - Explode. Divide - Measure - stretch - Lengthen - Changing

properties - Color - line types -LT scale - Matching properties - Editing with grips - Pedit -

Ddedit - Mledit.

BASIC DIMENSIONING, HATCHING, BLOCKS AND VIEWS

Basic dimensioning - Editing dimensions - Dimension styles - Dimension system

variables. Machine drawing with CAD. Creation of blocks - Wblock - inserting a block -

Block attributes - Hatching -Pattern types - Boundary hatch - working with layers -

Controlling the drawing display - Blipmode - View group commands - Zoom, redraw, regen,

regenauto, pan, viewres - Real time zoom. Inquiry groups - calculating area - Distance -

Time - Status of drawing - Using calculator.

CAD EXERCISES

Detailed drawings of following machine parts are to be given to students. Draw the

assembled views (two views only) and bill of materials.

The elevation / sectional elevation / plan / sectional plan / side view with dimensioning.

1. Sleeve & Cotter joint

2. Screw jack

3. Plummer Block

4. Simple Eccentric

5. Machine Vice

6. Protected type flanged Coupling


60

3E 4214 HEAT POWER ENGINEERING PRACTICAL

RATIONALE

Diploma holders in this course are required to experience the performance of air

compressors, internal combustion engines and vapor compression refrigerator. The

knowledge thus acquired helps them in understanding the concepts of basic thermodynamics.

OBJECTIVES

Determine the flash point, power point and viscosity of oil.

Identify the parts of petrol engine and their functions.

Identify the parts of diesel engine and their functions.

Draw the Valve timing diagram of petrol Engine.

Draw the port timing diagram of two stroke petrol engine.

Conduct performance test on petrol engines.

Conduct performance test on diesel engines.

Identify the parts of a high pressure boiler and their applications.

Prepare heat balance sheet for an I.C. Engine.


List of Experiments:

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

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

3. Determining the absolute viscosity of the given lubricating oil using Redwood

viscometer.

4. Determining the absolute viscosity of the given lubricating oil using Saybolt

viscometer.

5. Valve timing diagram of four stroke petrol & diesel engines.

6. Port timing diagram of two-stroke petrol & diesel engines.

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

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

9. Morse test on multicylinder petrol engine.

10. Heat balance test on I.C. engine.

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

4214 - 4 2 60 3 25 75 100


61

11. Volumetric efficiency of air compressor.

12. COP of refrigerators.

COURSE OUTCOMES

Evaluating different properties of oil.

Identification of the parts of petrol and diesel engine and their functions.

Evaluating the performance of petrol/diesel engines

Knowledge of parts of a high pressure boiler and their applications

3E 4302 ELECTRICAL DRIVES AND CONTROL PRACTICAL

RATIONALE

In this course the students will verify the principles behind the construction of various

electrical & electronics equipments and circuits and also learn the performances of

transformer, DC and AC motors, Stepper and Servo motor drivers, rectifiers and verify the

truth table for various types of gates.

OBJECTIVES

Identify starters for different motors.

Test the characteristics of DC and AC machines

Identify and select controlling elements

Explore the performance of ELCB, MCB.

Design regulated power supplies.

Identify display devices – LED, 7 segment LED, LCD.

Identify the drive circuit for special motors.

Test the speed control circuit of the special motors.


LIST OF EXPERIMENTS:

PART A

1. Verification of Ohm’s law.

2. Load test on DC shunt motor.

3. Load test on single phase transformer.

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term


Theor

y

Practic

al

Duration

(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E 4302 - 4 2 60 3 25 75 100


62

4. OC & SC tests on single phase transformer.

5. Measurement of Earth Resistance using Megger.

6. Study of DC motor Starters – 3 Point & 4 Point Starters.

7. Study of AC motor starters – DOL & star – Delta starters.

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

9. Speed Control of DC shunt motor by Armature control & Field control.

10. Study of single phase induction motor.

PART B

11. V-I characteristics of semiconductor diode.

12. Construction and testing of Half wave rectifier.

13. Construction and testing of full wave rectifier.

14. Construction and testing of bridge rectifier.

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

16. Verification of truth tables for logic gates.

17. Verification of universal gates.

18. Study of stepper motor.

19. Study LED & 7 segment LED

20. Study of Servo motor.

Course Outcomes

Evaluating the performance of DC and AC machines

Identify and select controlling elements

Explore the performance of ELCB, MCB.

Knowledge of regulated power supplies.

Identify display devices – LED, 7 segment LED, LCD.

Identify the drive circuit for special motors.

Understand the speed control circuit of the special motors.


63

3E 4215 MACHINING, MACHINE TOOL TESTING AND MAINTENANCE

PRACTICE

OBJECTIVES:

Part –A Machining practice


Demonstrate observance of the safety consciousness and good housekeeping in the

workshop.

Comprehend the need of various Measuring Instruments and Machine Tools in the

workshop.


Select and use appropriate Tool materials for various types of materials.

Uses of various types of tools, instruments for different operations.

Know and identify machine tools for manufacturing different components.

Operate & control different machines tools and equipment.

Produce jobs as per specified dimensions.

Part –B : Machine Tool Testing and Maintenance Practice

Study of Indian Standard Test charts.

Set up instrument for machine tool testing.

Observe the machine tool alignment and results.

Observe the manufacturing accuracy of machine tools.

Study the maintenance of the machine components.

Study the trouble shooting procedures and methods.

Prepare the record of work for all the exercises.


Autonomous Examination Note: Examinations will be conducted in both Part A and Part B. Students should be given exercises by selecting one exercise from each part by lot. All the exercises should be given in the question paper and students are allowed to select by a lot. All the exercises should be given in the question paper and students are allowed to select by a lot

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

4214 - 6 3 60 3 25 75 100


64

PART- A. Machining 40 (2 Hrs.)

Preparation 10 Dimensions 20

Finishing 10 PART-B MACHINE TOOL TESTING AND 30 (1 Hr.) MAINTENANCE PRACTICE

Readings / Dismantling 20 Test Chart / Assembly 10

Viva-voce 5 TOTAL 75

MAJOR DIVISIONS

Part-A: Machining Tools practice

Lathe.

Drilling.

Tool& Cutter grinding.

Cylindrical grinding.

Surface grinding.

TOPICS



Need of Machine Tools practice.

Study about layout of the Machine shop

Industrial application of the above sections.

Identify, select and use various measuring, marking, striking, cutting tools and

equipment holding in the above sections.

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

Understand types of Cutting Tools.

Know the machinability of the materials.

Selection of tools, preparing it in ready condition (tool sharpening).

Speed, Cutting speed, Feed, Depth of cut etc.,

Understand various types of work holding devices in lathe operations.

Care & maintenance of tools and equipment used in the above sections.


Safety precautions to be taken in the above sections.

LIST OF EXPERIMENTS:

PART – A : Machining Practice


65

1. LATHE

EXERCISES

a) JOB PRACTICE

1. Plain turning & Drilling

2. Step Turning

3. Taper turning (Tailstock off-set method, Compound rest method, by Taper turning

- attachment)

4. Knurling

5. Thread cutting (R.H. & L.H.)

6. Simple eccentric

DEMO EXERCISES

Internal thread cutting, Square thread cutting, Boring, Step boring, etc.,

2. DRILLING

Introduction to drilling machine tool and its parts.

Four side machining by filling and drilling & reaming 5 holes of various sizes with

both Straight shank drill and Taper shank drill.

Taping operations

a) Hand tap [both Metric and B.S.W.].

b) Machine tap.

DEMO EXERCISES:

1. Making of sample blind hole.

2. Making hole in a tapered job/V block.

3. CYLINDRICAL GRINDING

Introduction to Cylindrical grinding machine tool and its parts.

Grind the cylindrical trained model in the lathe to an accuracy of +0.01mm.

DEMO EXERCISES:

1. Prepare a Plug Gauge using Cylindrical Grinding machine to an accuracy of

+0.01mm.

2. Prepare Progressive type Plug gauge Progressive type Plug gauge using Grinding

Machine to an accuracy of +0.01mm.

4. SURFACE GRINDING

Introduction to Surface grinding machine tool and its parts.

1. Grind the surface of the specimen to be practiced for the tool and cutter

grinder to an accuracy of +0.01mm.


66

DEMO EXERCISES:

1. Grinding of a wedge shape job on a Surface grinder to an accuracy of +0.01mm.

5. TOOL & CUTTER GRINDING

Introduction to Tool and Cutter grinding machine tool and its parts.

1. Prepare “Facing Tool” using Tool and cutter Grinder.

2. Prepare “Parting Tool” using Tool and cutter Grinder.

PART – B : MACHINE TOOL TESTING AND MAINTENANCE PRACTICE

MACHINE TOOL TESTING

Conduct geometrical test on machines with permissible deviations.

Study the testing instruments and calibration to the standards.

Prepare a test chart for the various tests and mention the errors.

I. Machine Tool Alignment

EXERCISES

1. Conduct the following test for the lathe machine and prepare a test chart.

Check the level of slide ways.

Check the straightness of carriage movement.

Check the parallelism of tailstock movement to carriage movements.

Check the run-out of the spindle.

Check the parallelism of the axis of the outside of tailstock sleeve to carriage

movement.

2. Conduct the following test for the shaping machine and prepare a test chart.

Check the flatness of table top face.

Check the parallelism of table top face to its transverse movement.

Check the parallelism of table top face to the ram movement.

Check the parallelism of T-slot of top face to the ram movement.

Check the squareness of table side face to its transverse movement.

3. Conduct the following test for the drilling machine and prepare a test chart.

Check the level of the machine.

Check the flatness of the table surface.

Check the run-out of the internal taper of the spindle.

Check the straightness of the pillar and squareness of the spindle axis.

Check the squareness of the table surface to the vertical movement of the

spindle housing

4. Conduct the following test for the milling machine and prepare a test chart.

Check the straightness of the vertical movement of the knee.

Check the squareness of the table surface to the column ways for knee.


67

Check the flatness of the table surface.

Check the parallelism of the table surface to its movement.

Check the run-out of the internal taper of the spindle.

II. Maintenance

Dismantle, inspect and assemble the following machine components.

1. Tailstock

2. Three jaw chuck

3. Four jaw chuck

Course Outcomes:


workshop.

Understand the uses of various types of tools, instruments for different operations.

Identify machine tools for manufacturing different components.

Understand the manufacturing accuracy of machine tools.

Understand the maintenance of the machine components.


68

V TERM


69

3E 5303 DESIGN OF MACHINE ELEMENTS

RATIONALE

The main objective of Machine Design is to create new and better machine

components to improve the existing one. A mechanical engineer should have thorough

knowledge of design of machine elements to avoid the failure of machines or components.

OBJECTIVES

Design riveted joints, welded joints, sleeve and cotter joint and knuckle joint.

Design eye bolts, cylinder cover studs.

Design shafts, keys and couplings required for power transmission.

Compare the different types of couplings.

Design flat and V-belt for power transmission.

Study the various types of bearings and their applications.

Design journal bearings.

Design spur gear used for power transmission.

Design hand lever, foot lever and cranked lever



Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

5303 5 - 5 75 3 25 75 100


Unit I Engineering materials, joints and fasteners 13 15

Unit II Design of shafts, couplings and keys 13 15

Unit III Design of flat belts and v-belts 13 15

Unit IV Design of bearings 13 15

Unit V Design of levers and spur gears 13 15

Revision 3


Total 75 100


70

DETAILED SYLLABUS

3E 5303 DESIGN OF MACHINE ELEMENTS

UNIT I ENGINEERING MATERIALS, JOINTS AND FASTENERS

General Considerations in Machine Design. Engineering materials - Factors affecting

selection of material – BIS designation of Ferrous materials – Preferred number - Factor

of safety and allowable stress –

Stresses: Tension, Compression, Shear, Bearing pressure Intensity, Crushing, bending

and torsion - problem.

Creep strain and Creep Curve- Fatigue, S-N curve, Endurance Limit -Stress

Concentration – Causes & Remedies. Theories of Elastic Failures – Principal normal

stress theory, Maximum shear stress theory & maximum distortion energy theory.

Joints: Design of sleeve and cotter joint, knuckle joint and welded joint.

Fasteners: Design of bolted joints - eye bolts - cylinder cover with

bolts, studs - pins.

UNIT II DESIGN OF SHAFTS, COUPLINGS AND KEYS

(i)Shafts: Design of shafts subjected to – twisting moment – bending moment –

combined twisting and bending moments – fluctuating loads – design of shafts based on

rigidity.

(ii)Keys: Types of keys - design of sunk keys only - Effect of keyways on shaft-problems.

(iii)Couplings: Requirements of good couplings – types - design of - rigid protected type

flange couplings - marine couplings – pin type flexible coupling (Description only).

UNIT III DESIGN OF FLAT BELTS AND V-BELTS

(i)Flat Belts: Types of belts - materials for belt -– types of belt drives – Speed ratio – effect

of slip - length of flat belts –Tension Ratio T1/T2=eµθ- centrifugal tension - power

transmitted – condition for maximum power - transmission – Initial Tension - problems -

design procedure of flat belts - design of flat belt based on manufacturer’s data only –

problems.

(ii)V-Belts: V-belt drive - comparison with flat belt drive - designation of V-belts – length

of belt - power transmitted – Design of V-belt using manufacturer’s data only – Problem.

UNIT IV DESIGN OF BEARINGS

Bearings: Classifications of bearings – sliding contact and rolling contact bearings - radial

and thrust bearings - roller bearing – types -Designation of ball bearings - materials used

for bearings - journal bearings - heat generated - heat dissipated - cooling oil requirement –

problems - design of journal bearings –Problems.

Design based on approved data books only.

UNIT V DESIGN OF LEVERS AND SPUR GEARS

(i)Levers: Types of levers – applications - mechanical advantage –leverage -

displacement ratio - design of-hand lever-foot lever cranked lever - problems.

(ii)Spur gears: Gear drives - merits and demerits over belt drive –Classification of


71

gears - gear materials - spur gear terminology -design of spur gears based on Lewis

& Buckingham equation -Problems – speed reducer – types –(Approved data books only)

REFERENCE BOOKS:

Online Resources:


2. studentskey.in/

3. www.iannauniversity.com

Course outcome:

Design riveted joints, welded joints, sleeve and cotter joint and knuckle joint.

Design eye bolts, cylinder cover studs.

Design shafts, keys and couplings required for power transmission.

Compare the different types of couplings.

Design flat and V-belt for power transmission.

Design journal bearings.

Design spur gear used for power transmission.

Design hand lever, foot lever and cranked lever


1 Machine Design Pandya & Shah Charotar Publishing

2 Machine Design T. V. Sundararaja Moorthy & Khanna Publishers – New

3 Design Data Book PSG Tech DPV printers, Coimbatore.

4 Design Data Book ------------ Bala Chitra Publishers

5 A text book of

machine design R. S. Khurmi & J. K. Gupta S.Chand, New Delhi


72

3E 5304 AUTOMOBILE ENGINEERING

RATIONALE

These days, automobiles have become a necessity instead of luxury. At present, there

is exponential development in automobile industry with regard to pollution control. The

diploma holders in Mechanical Engineering are required to supervise the manufacture, repair

and maintenance of vehicles. Hence, knowledge and skills are to be imparted to them

regarding automobile industry as a whole.

OBJECTIVES:

Explain about the constructional details of an IC engine including cooling and

lubrication system.

Describe fuel feed systems with all devices involved in it (Both for petrol and diesel

engines).

Explain the construction and functional features of the power transmission systems

and various parts involved in it.

Explain the functions of different types of steering and brake systems.

Familiarize electrical and electronic equipment used in automobile.

Describe the different types of chassis and their functions.

Appreciate the techniques for automobile pollution control.




Unit I Automotive engines, Engine lubrication and cooling system 13 15

Unit II Fuels, Fuel feed system and pollution control 13 15

Unit III Transmission and power trains 13 15

Unit IV Front axle, steering system, suspension system, braking system,

wheels and tires

13 15

Unit V V Auto Electricals and Autotronics 13 15

Revision 3

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per Term


Theory Duration

(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E 5304 5 5 75 3 25 75 100


73


Total 75 75

DETAILED SYLLABUS

3E 5304 AUTOMOBILE ENGINEERING

UNIT I AUTOMOTIVE ENGINES PARTS, ENGINE LUBRICATION AND COOLING

SYSTEM

(i)Automotive engine parts

Principal mechanism and parts of an engine—cylinder head, block, crank case,

sump, liner, piston, piston rings, connecting rod, crank shaft, cam shaft, timing gears,

valves and valve operating mechanism (L-head, I head and OHC only) Air cleaner-Intake

and Exhaust manifold.

(ii)Engine lubrication

Friction in engines—purpose of lubrication—methods of lubrications—splash—

pressure—semi pressure--wet sump and dry sump lubrication—oil filters—crank case

ventilation—Troubles, causes and remedies.

(iii)Engine cooling

Necessity for cooling—effects of inadequate cooling and overheating of engine

parts—types of cooling—air cooling—liquid cooling—merits and demerits of air and

liquid cooling-forced circulation system—pressure sealed cooling—radiator—water

pump—thermostat—antifreeze solutions—troubles, causes and remedies.

(iv)Fuels

S.I. engine fuels—Important characteristics—volatility characteristic—vapor

lock tendency—crank case oil dilution—gum formation—knocking—pre-ignition—

detonation—octane requirement factors—gasoline additives.

C.I. engine fuels—Diesel oil—Characteristics of diesel fuel—smoke formation—

diesel knock—detonation.

UNIT II FUEL FEED SYSTEM, COMBUSTION CHAMBERS ALTERNATE FUEL &

VEHICLES AND POLLUTION CONTROL

S.I. engine combustion chamber—Air fuel ratio C.I. Engine diesel combustion

chamber—open, swirl, and pre-combustion chambers—components of fuel injection

system—fuel feed pump—Types of injection system—Jerk type fuel injection pump—

Distributor type fuel injection pump—Common Rail Direct Injection (CRDI)--

Governors—mechanical and pneumatic governors—Description of super charging and

Turbo charging—Troubles, causes and remedies of petrol and diesel fuel system.

Alternate fuels—Brief description of alternate fuels—alcohol—natural gas—

LPG—hydrogen—vegetable oil and biogas-Operation with Hydrogen- Fuel Cells- Fuels

Cell Vehicle- Electric Vehicle-Drive System.

Pollution control—Air pollution—Emission from automobiles—Nitrogen


74

oxides—Soot—carbon monoxide—Hydrocarbons—aldehydes—other exhaust

components—Emission regulation for cars—pollution control techniques—noise

pollution—vehicle noise—noise specifications—Effects of noise on human beings—

Noise reduction.

UNIT III TRANSMISSION AND POWER TRAINS

General arrangement of power transmission system—Four wheel drive—Forces

acting on a motor vehicle—Air, Rolling and gradient resistance—tractive effort—

clutch—Necessity for a clutch—Types-single plate, Diaphragm, multi plate wet clutch,

fluid coupling—clutch linkages—fault diagnosis and remedies.

Gear box—Necessity for a gear box—Types of gear box—sliding mesh gear

box—Constant mesh gear box—synchromesh device – Epi-cyclic gear trains—Gear box

troubles, causes and remedies.

Propeller shaft and universal joints—Function of the propeller shaft—Universal

joint—constant velocity joint (Cross type only)—Telescopic propeller shaft—Hotch kiss

drive—Torque tube drive.

Final drive—Functions and applications—Differential—purpose—construction

and operation—purpose and brief description of double reduction, Non-slip, self-locking

differential—Fault diagnosis and remedies.

Axles—Types of axles and applications—Floating axles—Semi-floating—Three

quarter floating and full floating—rear hub construction—bearing arrangements.

UNIT IV FRONT AXLE, STEERING SYSTEM, SUSPENSION SYSTEM, BRAKING

SYSTEM, WHEELS AND TIRE

Front axle—stub axle and wheel mountings—Elliot, Reverse Elliot and lemoine

types—steering system requirements and functions—Ackerman principle—steering

system components—steering gears—Rack and pinion, cam and roller, screw and lever,

recirculating ball type—power steering—wheel alignment—king pin inclination—

camber—castor—Toe in and Toe out—steering troubles—possible causes and remedies.-

Power Steering.

Suspension system—Function—Front independent suspension—Rear

independent suspension—stabilizer rod—torsion bar—shock absorber—purpose—

Telescopic type—construction and working—Anti roll bar—leaf spring suspension—Air

suspension (Brief description only)—suspension system fault diagnosis and remedies.

Brake system—Need—Classification of brakes—drum brake—Disc brake—

mode of operations—mechanical, hydraulic, pneumatic—Air assisted hydraulic brake—

servo action and self energisation—brake adjustment—brake fault diagnosis and

remedies.

Wheels—types—Spoke, disc and cast wheels—tires—Tubeless tire –purpose

and construction of tire—bias ply and radial ply tire—tire maintenance—Effect of over

and under inflation.


75

UNIT V AUTO ELECTRICALS AND AUTOTRONICS

Ignition system—Battery coil ignition system—Magneto ignition system—

Electronic ignition system—Distributor—Spark plug—cold and hot plugs.

Starter motor and the cranking circuit—Types of starter motor—Series, shunt

and compound motors—Starter drives—Bendix drive—Over running clutch—solenoid

operated starters.

Generator and the charging circuit—D.C. generator—A.C Generator

[Alternator]—current regulators—Voltage regulator and cutout relay -cable colors.

Lighting and signaling circuit: Lighting—sealed-beam head lights—composite

head lights—Halogen sealed Beam Head lights—Dimmer switches—Brake lights—

Directional [Turn] signals—courtesy lights.

Windshield wipers—Horns—Cruise control—Power windows—Power seats—

Electric power door locks—Electronic stability Program.

Developments in Automobile Vehicles-Variable valve Timing-Electronics in

Automobiles-Engine Management System-Control System Components-Sensors- Sensor

Types-Electronic Control Unit-Actuators-Control System-Electronically Controlled

Carburetor-Gasoline Injection System.

Electronic Diesel Control-Pilot Injection-Unit Injector-Common Rail Fuel

Injection System. Automatic Transmission-Electronic Transmission Control-Electronic

Automatic Gear Box-Air Bags--Drive By Wire-ABS-Sensotronic Braking Control-Wind

Screen-Lighting System-Alloy Wheels- Tubeless Tires. Awareness on Computerized

Engine test Rig-Awareness on Noise Vibration, Emission and Harshness in Automobile.

Reference Books :

S.No Name of the Book Author Publisher

1. Motor Manuals—Volume

I to IV A.W.Judge,

Chapman & Hall Ltd., 37,

ESSEX st., W.C.2.

2. Automotive Mechanics William H.Crouse,

Tata McGraw Hill

Publishing company ltd.

New Delhi.

3. Motor Vehicles Newton and Steeds. --------

4. Practical Automobile

Engineering Staton Abbey,

Odhams press ltd.,

Longacre, London, U.K.

5. Automobile Engineering

Theory and Practice K.K.Ramalingam

SCITECH Publications,

Chennai.

6. Automobile Electrical and

Electronic systemS James.D.Halderman

Prentice Hall, Engelwood

cliffs, New jersey


76

Online Resources:

1. www.vssut.ac.in


3. www.readorrefer.in

Course outcome:

Understand the constructional details of an IC engine including cooling and

lubrication system.

Describe fuel feed systems with all devices involved in it (Both for petrol and diesel

engines).

Understand the construction and functional features of the power transmission

systems and various parts involved in it.

Understand the functions of different types of steering and brake systems.

Describe the different types of chassis and their functions.

Appreciate the techniques for automobile pollution control.


77

3E 5305 COMPUTER AIDED DESIGN AND MANUFACTURING

RATIONALE

Today is the world of competition. To meet the market strategies, an industry has to

use the latest manufacturing technologies. The computers have the impact on the

development of latest manufacturing automation technologies. Today all the design and

manufacturing systems make use of computers. This course is meant to impart knowledge

about CAD systems, Geometric modeling techniques, CNC machines, CNC Part

Programming, Flexible Manufacturing systems and the various activities of Computer

Integrated Production Management system.

OBJECTIVES

Understand the concept and requirement of the integration of the design and

manufacturing.

Acquire knowledge about the computer assistance in the design process and analysis.

Understand the concept of manufacturing with computer assistance in the shop floor.

Understand the principle of latest manufacturing techniques like RPT & RT.

Learn the method of CNC programming with international codes.

Acquire the knowledge in the material handling equipment and robot.

Study of Concurrent Engineering and its tools and Augmented Reality.


TOPICS AND ALLOCATION OF MARKS

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

5305 5 - 5 75 3 25 75 100


Unit I Computer Aided Design 13 15

Unit II Computer Aided Manufacturing

13 15

Unit III CNC programming, rapid prototyping

13 15

Unit IV Computer Integrated Manufacturing, flexible manufacturing

systems, automatic guided vehicle, robot 13 15


78

DETAILED SYLLABUS

3E 5305 COMPUTER AIDED DESIGN AND MANUFACTURING

UNIT I COMPUTER AIDED DESIGN

Computer Aided Design: Introduction – definition – Shigley’s design

process – Ohsuga Model - CAD activities – benefits of CAD - CAD software

packages.

Transformations: 2D & 3D transformations – translation, scaling, rotation and

concatenation. Geometric modelling: Techniques - Wire frame modelling –

applications – advantages and disadvantages. Surface modelling – types of

surfaces – applications – advantages and disadvantages – Solid modelling –

entities – advantages and disadvantages – Boolean operations - Boundary

representation – Constructive Solid Geometry

– Comparison. Graphics standard: Definition – Need - GKS – OpenGL - IGES

– DXF.

Finite Element Analysis: Introduction – Development - Basic steps – Advantage.

UNIT II COMPUTER AIDED MANUFACTURING

Computer Aided Manufacturing: Introduction - Definition –

functions of CAM – benefits of CAM.

Group technology: Part families - Parts classification and coding -coding

structure – Optiz system, MICLASS system and CODE

System.

Process Planning: Introduction – Computer Assisted Process

Planning (CAPP) – Types of CAPP - Variant type, Generative type –advantages of

CAPP.

Production Planning and Control (PPC): Definition – objectives -Computer

Integrated Production management system – Master Production Schedule (MPS)

– Capacity Planning – Materials Requirement Planning (MRP) – Manufacturing

Resources Planning (MRP-II) – Shop Floor Control system (SFC) - Just In

Time manufacturing philosophy (JIT) - Introduction to Enterprise Resources

Planning (ERP) – Supply chain management

Unit V Concurrent engineering, quality function deployment,

product development cycle, augmented reality. 13 15

Revision 3


Total 75 75


79

UNIT III CNC PROGRAMMING, RAPID PROTOTYPING

CNC PART PROGRAMMING: Manual part programming -coordinate system –

Datum points: machine zero, work zero, tool zero - reference points - NC

dimensioning – G codes and M codes –linear interpolation and circular interpolation

- CNC program procedure - sub-program – canned cycles - stock removal –

thread cutting – mirroring – drilling cycle – pocketing.

Rapid prototyping: Classification – subtractive – additive –advantages and

applications - materials. Types - Stereo lithography (STL) – Fused deposition

model (FDM) – Selective laser sintering (SLS) - three dimensional printing (3D) –

Rapid tooling

UNIT IV COMPUTER INTEGRATED MANUFACTURING, FLEXIBLE

MANUFACTURING SYSTEMS, AUTOMATIC GUIDED VEHICLE,

ROBOT

CIM: Introduction of CIM – concept of CIM - evolution of CIM – CIM wheel –

Benefits – integrated CAD/CAM.

FMS: Introduction – FMS components – FMS layouts – Types of FMS: Flexible

Manufacturing Cell (FMC) – Flexible Turning Cell (FTC) – Flexible Transfer

Line (FTL) – Flexible Machining System (FMS) – benefits of FMS -

introduction to intelligent manufacturing system – Lean Manufacturing & Agile

Manufacturing (Brief Description only)

AGV: Introduction – AGV - working principle – types – benefits.

ROBOT: Definition – robot configurations – basic robot motion –

robot programming method – robotic sensors – end effectors –

mechanical grippers – vacuum grippers - Industrial applications of

Robot: Characteristics - material transfer and loading – welding -spray coating -

assembly and inspection.

UNIT V CONCURRENT ENGINEERING, QUALITY FUNCTION

DEPLOYMENT, PRODUCT DEVELOPMENT CYCLE,

AUGMENTED REALITY.

Concurrent Engineering: Definition – Sequential Vs Concurrent

engineering – need of CE – benefits of CE.

Quality Function Deployment (QFD): Definition – House of Quality (HOQ) –

advantages – disadvantages. Steps in Failure Modes and Effects Analysis

(FMEA) – Value Engineering (VE) – types of values – identification of poor

value areas – techniques – benefits. Guide lines of Design for Manufacture and

Assembly (DFMA).

Product Development Cycle: Product Life Cycle - New product

development processes. Augmented Reality (AR) – Introduction - concept –

Applications.


80

REFERENCE BOOKS

Online Resources:

1. www.faadooengineers.com


3. www.srividyaengg.ac.in

Course outcome:

Understand the concept and requirement of the integration of the design and

manufacturing.

Understand the concept of manufacturing with computer assistance in the shop floor.

Understand the principle of latest manufacturing techniques like RPT & RT.

Learn the method of CNC programming with international codes.

Understand the concept of Concurrent Engineering and its tools and Augmented

Reality.


1 CAD / CAM / CIM R.RadhaKrishnan,

S.Subramanian

New Age International

Pvt,Ltd

2 CAD / CAM Mikell P.Groover,

Emory Zimmers

Jr.Premtice Hall of India

Pvt., Ltd

3 NC programming S.K.Sinha Galgotia Publications

Pvt. Ltd

4 CAD/CAM principles and

applications, Dr.P.N.Rao

Tata Mc Graw Hill

publishing company ltd

5 CAD / CAM Ibrahim Zeid

Mastering Tata McGraw-

Hill Publishing company

Ltd,

New Delhi

6

Automation, Production

systems, and computer –

integrated manufacturing

Mikell P.Groover Pearson Education Asia

7 Computer control of

manufacturing systems yoram koren McGraw Hill Book


81

3E 5306.1 RENEWABLE ENERGY SOURCES AND ENERGY CONSERVATION.

RATIONALE:

Electrical Energy requirement is the major crisis and hence any saving in Electrical

energy is equivalent to production of Electrical Energy. Saving can be achieved by the

utilization of Renewable Energy Sources.

OBJECTIVES:

Study about the fundamentals of Energy.

Study of construction and principle of Wind energy, Solar energy, Tidal energy and Bio

energy.

Understand the PV design and its components.

Understand the energy management and auditing techniques.

Study the energy conservation process.




Unit I Fundamentals of energy, wind energy 11 15

Unit II Solar energy, application, storage 10 15

Unit III Solar photovoltaic system and Design, ocean, tidal, wave

energy.

10 15

Unit IV Bio-energy 10 15

Unit V Energy conservation techniques and energy audit 10 15

Revision 3


Total 60 75

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

5306.1 4 - 4 60 3 25 75 100


82

DETAILED SYLLABUS

3E 5306.1 RENEWABLE ENERGY SOURCES AND ENERGY CONSERVATION

UNIT I (i)FUNDAMENTALS OF ENERGY

Introduction to Energy-Energy consumption and standard of living

classification of energy resources-consumption trend of primary energy resources-

importance of renewable energy sources- energy for sustainable development.

(ii)WIND ENERGY

Introduction-Basic principles of wind energy conversion: Nature of the

wind, power in the wind, forces on the blades and wind energy conversion-wind data

and energy estimation-site selection classification of wind energy conversion

systems- components of

conversion systems-Advantages and Disadvantages-Types of wind

machines-Horizontal axis machine-Vertical axis machine-Generating

system-Energy Storage–Application of wind energy-Safety and environmental

aspects.

UNIT II SOLAR ENERGY

Introduction – Solar radiation at the earth's surface - Solar Radiation

measurements - Estimation of average solar Radiation. Solar energy collectors –

Classifications - Flat plate collectors -Concentrating collectors - performance

parameter - tracking system compound parabolic concentrator-parabolic trough

concentrators concentrator with point focus-heliostats-comparisons of various

collectors-efficiency of collector-selection of collector for various applications. Solar

Thermal Application: Solar water heaters-Solar industrial heating system – Solar

Refrigeration and Air-Conditioning Systems Solar cookers-Solar furnaces-Solar

greenhouse-Solar Distillation Solar pond Electric power plant-Distributed Collector-

Solar thermal Electric power plant. Solar thermal energy storage: sensible storage-latent

heat storage - thermo chemical storage.

UNIT III (i)Solar photovoltaic System and Design:

Solar photovoltaic a brief history of PV,PV in silicon: basic principle,

crystalline PV; reducing cost and raising efficiency, thin film PV, other innovative

technologies, electrical characteristics of silicon PV cells and modules, grid connected

PV system, cost of energy from PV ,Environmental impact and safety. System design

of solar photovoltaic system: Load analysis-solar array Design-Battery Design-

Simple formulas. System design procedure. Case Studies: Designing solar home

lighting system - Designing stand alone solar PV Power plant - Designing solar

PV water pumping system - Only arriving load capacity - solar array sizing -

Battery sizing - Inverter capacity and mountings.

(ii)Ocean energy, Tidal & Wave energy:

Ocean energy resources – principle's of ocean thermal energy conversion

(OTEC) – Methods of Ocean thermal electric power generation – Energy


83

utilization – basic principle of tidal power – components and operations of tidal

power plant – Energy and Power forms of waves – Wave energy conversion devices.

UNIT IV BIO – ENERGY

Introduction – photo synthesis – usable forms of bio mass, their

composition and fuel properties-Biomass resources – Biomass conversion

technologies – Urban waste to energy conversion – Biomass gasification – biomass

liquification – biomass to ethanol production – Biogas production from waste

Biomass – types of bio gas plants applications – Bio diesel production – Biomass

energy programme in India.

UNIT V Energy Management and Audit, Conservation:

Definition, Energy audit - need, Types of energy audit, Energy

management (audit) approach-understanding energy costs, Bench marking, Energy

performance, Matching energy use to requirement, Maximizing system efficiencies,

Optimizing the input energy requirements, Fuel and energy substitution, Energy audit

instruments Energy Conservation Techniques- Need and importance of energy

conservation -Principles of energy conservation- Methods of energy conservation-

Cogeneration and its application-Combined cycle system - Concept of energy

management - Study of different energy management techniques like-Analysis of

input-Reuse and recycling of waste.

Economic approach of Energy Conservation - Costing of utilities like

steam, compressed air, electricity and water-Ways of improving boiler efficiency-

Thermal insulation, Critical thickness of insulation Waste heat recovery systems, their

applications, criteria for installing unit-An introductory approach of energy conservation

in compressed air, refrigeration, air conditioning, pumps and fans.

Online Resources:

1. www.vssut.ac.in/lecture_notes/lecture1428910296.pdf

2. www.faculty.itu.edu

3. www.che.utexas.edu/course/che359&384/lecture_notes.html

4. www.nptel.ac.in

Course outcome:

Understand t the fundamentals of Energy.

Understand the construction and principle of Wind energy, Solar energy, Tidal energy and

Bio energy.

Understand the PV design and its components.

Understand the energy management and auditing techniques.


84

3E 5306.2 TOTAL QUALITY MANAGEMENT

RATIONALE:

Quality and customer satisfaction in every product and every activity is the

order of the day. As there is a shift from quality control to quality management in all

activities, the concept Total Quality Management and the pillars of TQM are to be given to

Engineers, who are designing products and production systems.

OBJECTIVES:

Define quality and appreciate its signature.

Explain the concept of TQM.

Appreciate the use of principles of TQM to meet customer satisfaction.

Solve problem using the Quality control tools.

Apply Brainstorming and quality circle to solve problems.

Use PDCA cycle for continuous improvement.

Appreciate the benefits of implementing 5S concepts.

Collect, classify and present the data.

Determine the process capability of a manufacturing process.

Practice on management planning tools.

Use Bench Mark and JIT concepts.




Unit I Basic concepts of total quality management 11 15

Unit II Continuous process improvement – q7 tools 10 15

Unit III Statistical Fundamentals 10 15

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

5306.2 4 - 4 60 3 25 75 100


85

Unit IV Control charts 10 15

Unit V Management planning tools & bench marking 10 15

Revision 3


Total 60 75

DETAILED SYLLABUS

3E 5306.2 TOTAL QUALITY MANAGEMENT

UNIT I BASIC CONCEPTS OF TOTAL QUALITY MANAGEMENT

Quality-Definitions - Dimensions of quality - Brainstorming and its

objectives - Introduction to TQM – Characteristics – Basic concepts – Elements –

Pillars – Principles - Obstacles to TQM implementation – Potential benefits of

TQM – Quality council –Duties – Responsibilities – Quality statements – Vision

– Mission –Quality policy statements – Strategic planning – Seven steps to

strategic planning – Deming philosophy- Customer delight - ISO 9001:2008

Quality Management System requirements and implementation.

UNIT II CONTINUOUS PROCESS IMPROVEMENT – Q7 TOOLS

Input / Output process model – Juran Trilogy – PDCA (Deming

Wheel) cycle – 5S Concepts – SEIRI, SEITON, SEISO, SEIKETSU and

SHITSUKE – needs and objectives – effective implementation of 5S concepts in

an organisation - Housekeeping – Kaizen. Seven tools of quality control (Q-7 tools)

– Check sheet – Types of check sheet – Histogram – Cause and effect diagram

- Pareto diagram – Stratification Analysis – Scatter diagram-Graph/run charts –

Control charts - Construction of above diagrams. Quality circle - concept of

quality circle - Organisation of Quality circle and objectives of Quality circle.

UNIT III STATISTICAL FUNDAMENTALS

Types of Data – Collection of Data – Classification of Data –Tabular

presentation of Data – Graphical representation of a frequency distribution –

Comparison of Frequency distribution –Mean – Median – Mode – Comparison

of measures of central tendency – Introduction to measures of dispersion –

Sample –sampling - Normal curve – Sigma – Concept of six sigma –

Principles – Process- Problems.

UNIT IV CONTROL CHARTS

Control chart – Types of control charts – Control chart for variables – Construction

of X and R charts – control limits Vs specification limits – Process capability

– Method of doing process capability Analysis – Measures of process capability –

Problems. Attributes – Control charts – P chart – np chart – c chart – u chart –

Construction of above diagrams – Problems - Comparison between variable chart and


86

Attribute chart.

UNIT V MANAGEMENT PLANNING TOOLS & BENCH MARKING

Affinity diagram – Radar Diagram - Inter Relationship diagram (Inter

Relationship diagram) – Tree diagram - Prioritization matrix – Matrix diagram –

Decision tree – Arrow diagram – Matrix data analysis diagram - Construction of

above diagrams.Bench marking – Objectives of bench marking – Types –

Bench marking process - Benefits of Bench marking – Pit falls of Bench

marking-Just In Time(JIT) concepts and its objectives - Total Productive

Maintenance(TPM) - Introduction, Objectives of TPM -steps in implementing

TPM.

REFERENCE BOOKS


1. Total Quality Management B.Senthil

J.Praveen Paul SCITECH

2. Total Quality Management Prof.G.Arumugam

Srin ivasa Gupta

CBT Package

Sona Version

3. Total Quality Management

V.K.Kanna

Prem Vrat

B.S.Sahay

Ravisankar

NewAge International

Publishers

4. TQM & ISO 14000 Dr.K.C.Arora S.K.Kataria & Sons

Delhi

Online Resources:

1. www.faculty.mu.edu.sa


3. www.srividyaengg.ac.in

Course outcome:

Understand the quality and appreciate its signature.

Understand the concept of TQM.

Understand the usage of PDCA cycle for continuous improvement.

Determine the process capability of a manufacturing process.

Practice on management planning tools.

Use Bench Mark and JIT concepts.


87

3E 5307 AUTOMOBILE ENGINEERING PRACTICAL

RATIONALE

Mechanical engineering diploma holders are placed in the supervisor category at the

automotive industries. The study of mechanic tools and hands on experience in dismantling,

overhauling and assembling of all components will enhance their performance in the

manufacturing and service sectors of automobile.

OBJECTIVES

Identify the various tools and their applications used in Automobile.

Dismantle and assemble parts of petrol engine.

Dismantle and assemble parts of diesel Engine.

Service oil pump and water pump.

Service AC fuel pump.

Service carburetor.

Dismantle and assemble fuel injection pump.

Dismantle and assemble of power transmission and differential system.

Overhauling of starter motor and dynamo.

Troubleshoot the Electrical circuit in automobile.


Exercises:

1. Study of mechanics tools—double ended, spanner, ring spanner, sockets,

screwdrivers, torque wrench, feeler gauge, cutting pliers, etc. Study of gauges -

height gauge, bore gauge, inside and outside micrometers.

2. Engine dismantling, overhauling and assembling (Both S.I. and C.I. engines).

3. Adjusting valve clearance of ‘I’ head and ‘L’ type engines.

4. Removing, overhauling and replacing of Lubrication oil pump.

5. Removing, overhauling and replacing of water pump.

6. Dismantling, overhauling, assembling and testing of mechanical fuel pump.

7. Dismantling, inspecting and re-assembling of single cylinder F.I. pump and injectors

(Different types).

8. Dismantling, overhauling and assembling of Solex carburetor.

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

5307 - 6 3 60 3 25 75 100


88

9. Dismantling, overhauling, assembling and adjusting of clutches, use of clutch

adjusting fixture.

10. Dismantling, overhauling and assembling of sliding mesh, constant mesh and

synchromesh gearboxes.

11. Dismantling, overhauling, assembling of propeller shaft (universal joint and slip joint)

and adjusting backlash, correct teeth contact of crown and pinion of differential unit.

12. Removing rear axle and hub assembly, re-greasing, assembling and adjusting axle and

hub endplay.

13. Dismantling, overhauling, assembling and adjusting steering gears and checking

steering column and play, cross shaft end play and backlash of different types of

steering gears.

14. Dismantling, overhauling, assembling and bleeding of hydraulic brake system.

15. Removing, overhauling, replacing and adjusting of ignition distributor setting and

ignition timing.

16. Dismantling, testing and assembling of starter motor.

17. Dismantling, inspecting, overhauling and assembling of alternator.

18. Dismantling, inspecting, testing and charging the battery (Specific gravity test, high

rate discharge test).

19. Dismantling, inspecting, overhauling and replacing and adjusting of ignition

distributor and spark plugs setting-ignition timing.

20. Garage equipment-Hydraulic lift, Wheel balancing equipments, tyre changer, Auto

scrubbers and High pressure jet cleaner.

Course outcome:

Understand the various tools and their applications used in Automobile.

Dismantle and assemble parts of petrol engine.

Dismantle and assemble parts of diesel Engine.

Service oil pump and water pump.

Service AC fuel pump.

Dismantle and assemble fuel injection pump.

Dismantle and assemble of power transmission and differential system.

Overhauling of starter motor and dynamo.


89

3E 5403 SPECIAL MACHINES PRACTICE

OBJECTIVES:


Comprehend the need of various Machine Tools in the workshop.

Demonstrate observance of the safety consciousness and good housekeeping in the

workshop.



Operate & control different machine tools and equipment.

Select proper instruments for measuring.

Use of various types of tools, instruments for different types of operations.

Select and use appropriate Tool materials for various types of materials.


Produce jobs as per specified dimensions.


ALLOCATION OF MARKS

Job preparation / Marking 15 Setting / Operations 30 Dimensions / Finish 25 Viva voice 5 Total 75

MAJOR DIVISIONS:

Machine Tools practice

Shaper.

Planer.

Slotter.

Milling.

TOPICS


Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

5403 - 6 3 90 3 25 75 100


90


Need of Machine Tools practice.

Study about layout of the Machine shop.

Industrial application of the above sections.



tools & equipment in the above sections.

Safety precautions to be taken in the above sections.

Care & maintenance of tools and equipment used in the above sections.


Identify a Shaper, Planer, Slotter and Milling machine tool.

Safety precautions, Machine cleaning, checking, making ready for operation.

Selection of tools, preparing it in ready condition (tool sharpening).

Know the machinability of the materials.

Speed, Cutting speed, Feed, Depth of cut etc.,

Understand types of Cutting Tools.

Understand various types of work holding devices used in the above Machine Tools.


1. SHAPER

Introduction to Shaper machine tool and its parts.

a) V-Block (to an accuracy of ± 0.2mm).

b) Stepped Block with angle machining (to an accuracy of ± 0.2mm).

2. PLANER

Introduction to Planer machine tool and its parts.

a) V-Block (to an accuracy of ± 0.2mm).

b) Chamfering on both side (to an accuracy of ± 0.2mm).

3. SLOTTER

Introduction to Slotter machine tool and its parts.

a) Concave or convex machining (to an accuracy of ± 0.2mm).

b) Spline (to an accuracy of ± 0.2mm).

4. MILLING

Introduction to milling machine tool and its parts.

Using the attachment of simple indexing / differential indexing.

Method of indexing by dividing head.


91

a) Square, Hexagon and Spline machining. (In single work piece).

b) V-Block milling

c) Spur gear – Simple indexing.

d) Spur gear – Differential indexing.

e) Helical gear– Simple indexing.

DEMO PRACTICE:

1. Dovetail – Shaper.

2. Rack cutting – Milling.

3. Castle nut – Milling.

SERVICING OF MACHINE TOOL:

1. Dismantling and reconditioning of quick return motion of Shaper and Slotter.

2. Dismantling and reconditioning of any one

a) Tailstock on lathe b) Apron Mechanism. c) Lathe Chuck

3. List the faults associated with the above four machine tools and its remedies.

4. Scrapping practice.

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

select by a lot. Record note book must be submitted for the examination.

Course outcome:


workshop.

Understand the uses of various types of tools, instruments for different operations.

Identify machine tools for manufacturing different components.

Understand the manufacturing accuracy of machine tools.

Understand the maintenance of the machine components.


92

3E 5308 LIFE AND EMPLOYABILITY SKILLS RATIONALE:

Against the backdrop of the needs of the Industries, as wells as based on fulfilling

the expectations of the Industries, the Diploma Level students have to be trained directly and indirectly in toning up their competency levels. Proficiency in Communication only, equips them with confidence and capacity to cope with the employment. Hence, there is a necessity to focus on these in the curriculum. At the end of the Course, the student is better equipped to express himself in oral and written communication effectively.

SPECIFIC INSTRUCTIONAL OBJECTIVES: 1. Emphasize and Enhance Speaking Skills

2. Increase Ability to Express Views & Opinions

3. Develop and Enhance Employability Skills

4. Induce Entrepreneurship and Plan for the Future

5. Expose & Induce Life Skills for Effective Managerial Ability

Scheme of Instructions and Examination No. of Weeks per Semester: 15 Weeks

Subject

Instruction Examination

Hours/ Week

Hours/ Semester

Marks

Internal

assessment Board Examination

Total Duration

Life and Employability

Skills 4 Hours 60 Hours 25 75 100 3 Hours

SYLLABUS

Sl.No SECTION SKILLS TO BE

ACQUIRED ACTIVITY

NO,OF HOURS

1.

PART-A LISTENING ACTIVITY TOPICS: 1. Global Warming, 2. Pollution, 3. Environment,Communal Harmony

Deductive/reasoning skills Cognitive Skills Retention Skills

Talking down notes/hints Answering question Fill in the blanks the exact words heard Brief the read out passage

04 04 02 02


93

2.

PART-B SPEAKING ACTIVITY TOPICS: COMMUNICATION: Behavioural skills; Productivity, Occupational safety, Health Hazards,Accident &safety,First-aid,descriptive skillsFAQ in personal interview Various situational dialogues and telephonic conversation

Personality/psycholo-gical skills Pleasing &Amiable Skills Assertive skills Expressive skills Fluency/compatibility skills Leadership/team Spirit skills Interview skills(FAQ)

Instant sentence making Say expression/phrases Self introduction/ another higher official in company Describe/explain products Dialogues on technical ground discuss &interact Group Discussion

02 02 04 06 06 08

3.

PART-C READING AND WRITING ACTIVITY TOPICS: Facing interviews; entrepreneurship and Project Preparation

Creative & Reasoning Skills Creative &Composing Skills Attitude& Aim Skills Entrepreneurship Skills

Frame New words with the given words/Phrases Prepare an outline of a project to obtain loan from bank in becoming an entrepreneurship

02 02 02 02

4 PART-D Google search and presentation in record note(for continuous Assessment on any five topics) PROJECT TOPICS: 1. Loan application 2. Laboratory installation 3.Small scale industry 4. Site visit 5.construction of room 6. Lath setting 7.installation of a computer lab 8.consealed wiring of a complex building 9.Manufacturing of paper and pulp materials 10. Upgradation of technical needs.

Cognitive Skills Presentation Skills &Interactive Skills

Search in the website Prepare a presentation Discuss &Interact records as assignment

12


94

LABORATORY REQUIREMENTS: 1. An echo-free room 2. Necessary furniture and comfortable chairs 3. A Computer with internet access 4. English newspapers with equivalent Tamil news papers 5. A minimum of Three Mikes with or without cords 6. Colour Television with DTH 7. DVD/VCD Player with Home Theatre speakers 8. Projector Suggested Reading:

1. Production and Operations Management by S.N. Chary, TMH

2. Essentials of Management by Koontz & Weihrich, TMH 3. Modern Production / Operations Management by E.S. Buffa and R.K. Sarin, John Wiley & Sons 4. Production Systems: Planning, Analysis and Control by J.L. Riggs, 3rd ed., Wiley. 5. Productions and Operations Management by A.Muhlemann, J. Oakland and K. Lockyer, Macmillan 6. Operations Research - An Introduction by H.A. Taha, Prentice Hall of India 7. Operations Research by J.K. Sharma, Macmillan 8. Business Correspondence & Report Writing by R.C. Sharma and K. Mohan, TMH 9. How to prepare for Group Discussion & Interview (With Audio Cassette) by Prasad,

TMH 10. Spoken English – A self-learning guide to conversation practice (with Cassette) 11. Introduction to Environmental Engineering by Mackenzie, L. Davis and A. David, Cornwell, McgrawHill, 3rd Ed.

12. Environmental Engineering by Peary, Rowe and Tachobanoglous, McgrawHill

13. Total Quality Management – An Introductory Text by Paul James, Prentice Hall 14. Quality Control and Applications by Housen & Ghose 15. Industrial Engineering Management by O.P. Khanna LEARNING STRUCTURE 100 Marks

Focus more on Speaking & Listening Skills

Attention less on Reading & Writing Skills

Apply the skills in fulfilling the Objectives on Focused Topics

a) Listening 25 Marks

1. Deductive Reasoning Skills (Note taking, summarizing, 10

2. Cognitive Skills (answering questions) 10

3. Retention Skills (filling in blanks with exact words heard) 05

b) Speaking Extempore/ Prepared 30 Marks

1. Coherence Skills (story telling) 05 2. Interview Skills (FAQ in interviews) 05


95

3. Assertive Skills (introducing oneself/others) 05 4. Expressive Skills (describe/explain things) 05 5. Fluency/Compatibility Skills (dialogue) 05 6. Leadership/Team Spirit Skills (group discussion) 05

c) Writing & Reading 20 Marks

1. Creative & Reasoning Skills (frame questions on patterns) 05

2. Creative & Composing Skills (make sentences on patterns) 05

3. Attitude & Aim Skills (prepare resume) 05 4. Entrepreneurship Skills (prepare outline of a project) 05

d) Continuous Assessment (Internal Marks) 25 Marks (search, read, write down, speak, listen, interact & discuss)

1. Cognitive Skills (Google search on focused topics)

2. Presentation Skills& Interactive Skills (after listening,

discuss) Total Marks: 100 Marks

Continuous Assessment (Internal Marks) I LISTENING (3 exercises), SPEAKING (6 exercises) and 10 Marks

READING & WRITING (4 exercises). All activities shall be recorded in the Record note. 13 exercises x 10 marks = 130 marks. Reduced to 10 marks

II Present in the Record Note on any 5 topics prescribed in syllabus as Assignments 10 Marks

Topics

5 Assignments x 10 Marks = 50 marks. Average of 5 Assignments is 10 marks

III Attendance 5 Marks Total 25 Marks


96

VI TERM


97

3E 6309 INDUSTRIAL ENGINEERING AND MANAGEMENT

RATIONALE

In the Indian Economy, Industries and enterprises always find prominent place. After

globalization, the government of India has announced liberalization policy of starting an

enterprise which is resulted in the mushroom growth of industries. The present day students

should be trained not only in manufacturing processes but also in managing activities of

industries. Training must be imparted to students not only to shape them as technicians but

also as good managers.

The knowledge about plant, safety, work study techniques, personnel management

and financial management will definitely mould the students as managers to suit the

industries. Due to the presence of such personalities the industries will leap for better

prosperity and development.

OBJECTIVES

Explain the different types of layout and compare them.

Appreciate the safety aspects and its impacts on an organization.

Compare different productivity improvement technique.

Explain different work measurement techniques.

Estimate standard time for a job.

Explain production planning and control and its functions.

Study the role of PPC as a tool for cost control.

Prepare process control charts.

Explain the principles of management and functions of management.

Compare different organizational structure.

Explain the selection and training of staff.

Create an awareness about the social responsibilities of students.




Unit I Plant engineering and plant safety 13 15

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E 6309 6 - 6 75 3 25 75 100


98

Unit II Work study, method study and work measurement 13 15

Unit III Production planning and quality control 13 15

Unit IV Principles of management and personnel management 13 15

Unit V Material Management and Professional Ethics 13 15

Revision 3

Cycle tests and model examination 7

Total 75 75

DETAILED SYLLABUS

3E 6309 INDUSTRIAL ENGINEERING AND MANAGEMENT

UNIT I PLANT ENGINEERING AND PLANT SAFETY

(i)Plant Engineering: Plant - Introduction—Selection of a site of industry - Plant

Layout - Principles of good layout – Types – Process, product fixed position layout

- Techniques to improve layout - Principles of material handling equipment - Plant

maintenance – Importance - Breakdown maintenance, Preventive maintenance and

Scheduled maintenance.

(ii)Plant Safety: Importance – accident – causes and cost of an accident – accident

proneness – Personal factors – prevention of accidents – safety awareness

measures - industrial disputes – settlement of industrial disputes – Collective

bargaining, Conciliation, Meditation, arbitration – Indian Factories act 1948 and its

provisions related to health, welfare and safety.

UNIT II WORK STUDY, METHOD STUDY AND WORK MEASUREMENT

(i)Work Study: Productivity – Standard of living – method of improving

productivity – objectives – Importance of good working conditions.

(ii)Method study: Definition – objectives –selection of job for method study –

Basic procedure for conduct of method study-Tools used – Operation process chart,

Flow process chart, two handed process chart, Man machine chart, string diagram

and flow diagram. Process Orientation, Various Stages in process, Overall

Management.

(iii)Work measurement: Definition - Basic procedure in making a time study –

employs rating factor – Application of time allowances – Rest, Personal, Process,

Special and Policy allowances – Calculation of standard time – Problems – Basic

concept of production study - Techniques of work measurement – Ratio delay

study, Synthesis from standard data, analytical estimating and pre-determined

motion time system(PMTS).

UNIT III PRODUCTION PLANNING AND QUALITY CONTROL

(i)Production planning and control: Introduction - Major functions of production

planning and control—Pre-planning – Methods of forecasting - Routing and


99

Scheduling- Dispatching and controlling - Concept of Critical path method (CPM)

Description only. Production –types - Mass production, Batch production and job

order production - Characteristics – Economic Batch Quantity (EBQ) - break even

analysis - Principle of product and process planning - make or buy decision -

problems.

(ii)Quality Control: Definition – Objectives – Types of inspection – First piece,

Floor and centralized inspection – Advantages and disadvantages. Quality control –

statistical quality control – types of measurement – method of variables – Method

of attributes - uses of X, R, p and c charts – operating characteristics curve (o.c

curve) – Sampling inspection – single and double sampling plan - concept of

reliability, reliability vs quality reliability frequency, MTBF, MTTR availability –

bath tub curve – Concept of ISO 9001:2008 Quality management system

registration / Certification procedure – Benefits of ISO to the organization. TQM,

FMEA., Continuous Improvement Process.

UNIT IV PRINCIPLES OF MANAGEMENT AND PERSONNEL MANAGEMENT

(i)Principle of Management: Definition of management – Administration –

Organization – F.W.Taylor’s and Henry Fayol’s Principles of Management –

Functions of manager – Types of organization – Line, staff, Taylor’s pure

functional types – Line and staff and committee type – Directing – Leadership –

Styles of Leadership – Qualities of a good leader – Motivation – Positive and

negative motivation – Modern management techniques – Just in time – Total

quality management(TQM) – Quality circle – Zero defect concept - 5S concept –

Management information systems.

(ii)Personnel Management: Responsibility of human resource management –

selection procedure – Training of workers – Apprentice training – On the job

training and vestibule school training – Job evaluation and merit rating – Objectives

and importance – Wages and salary administration – Components of wages – Wage

fixation – Type of wage payment – Halsey’s 50% plan, Rowan’s plan and

Emerson’s efficiency plan – Problems

UNIT V MATERIAL MANAGEMENT AND PROFESSIONAL ETHICS

(i)Material Management: Objectives of good stock control system – ABC

analysis of inventory – Procurement and consumption cycle – Minimum stock,

Lead time, Reorder Level – Economic order quantity problems – supply chain

management – Introduction – Purchasing procedure – store keeping – Bin card.

(ii)Professional Ethics: Basic human values – truth, right conduct, love, non

violence and peace – humanity and character.

(iii)Core areas of ethics: social ethics, personal ethics integrity and trust-

worthiness, honesty, loyalty.

(iv)Character : definition, individuality of a person from ‘good’ and bad qualities.

(v)Traits of good character: Sense of duties and obligation to one’s own

profession. Adherence to truth and principle, excellence team work with a good


100

rapport with teachers, colleagues and subordinate.

Self discipline, responsibilities and accountabilities, selflessness.

Reference Books :


1. Industrial Engineering

and Management O.P.Khanna

Revised Edition publications (P)

Ltd -2004, New Delhi – 110002

2. Engineering Economics

and Management

T.R.Banga &

S.C.Sharma Mc graw Hil, New Delhi

3. Management, A global

perspective

Heinz Weihrich,

Harold Koontz McGraw Hill, New Delhi

4 Essentials of

Management Joseph L.Massie

Prentice – Hall of India, New

Delhi

Online Resources:

1. www.unaab.edu.ng

2. www.university.youth4work.com

3. www.industrialengineeringnotes.blogspot.in

Course Outcomes:

Understand the different types of layout and compare them.

Compare different productivity improvement technique.

Knowledge of different work measurement techniques.

Evaluate standard time for a job.

Understand production planning and control and its functions.

Understand the principles of management and functions of management

Evaluate different organizational structure.

Understand the selection and training of staff.

Acquire social responsibilities by the students.


101

3E 6310 MECHATRONICS

RATIONALE

Today the technical field seeks interdisciplinary approach for all engineering

applications. This subject imparts knowledge on different input, Processing, output devices

with examples, automated systems so that a student can solve any interdisciplinary problems

in most efficient manner by interlinking all disciplines.

OBJECTIVES

Define Mechatronics and state its role in industries.

Compare the different types of sensors/transducers.

Explain the importance of signal conditioning and data presentation systems.

Describe the basic actuation systems and their importance.

Describe various basic Mechanical and Electrical actuation systems.

Explain the various basic pneumatic and hydraulic actuation systems.

Interfacing with peripheral devices.

Explain the structure of PLC and its functions.

Write PLC program for simple applications.

Apply Mechatronics design to real life case studies.



Unit I Introduction, sensors & transducers 13 15

Unit II Signal Conditioning &Data Presentation Systems 13 15

Unit III Actuation systems (mechanical, electrical, pneumatic

&hydraulic 13 15

Unit IV Programmable logic controller (plc) 13 15

Unit V Interfacing & Design examples 13 15

Revision 3

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E 6310 5 - 5 75 3 25 75 100


102


Total 75 75

DETAILED SYLLABUS

3E 6310 MECHATRONICS

UNIT I INTRODUCTION, SENSORS & TRANSDUCERS

Introduction – Systems – Measurement Systems – Control Systems –

Microprocessor Based Controllers Examples – Mechatronics approach.

Measurement System terminology – placement, Position & Proximity Sensors –

Velocity and Motion Sensors – Force Sensors – Fluid Pressure Sensors – Flow

Sensors – Liquid Level Sensors – Temperature Sensors – Light Sensors –

Selection of Sensors.

UNIT II SIGNAL CONDITIONING AND DATA PRESENTATION SYSTEMS

Signal Conditioning; Introduction-Signal Conditioning Processes,

Operational Amplifier-Inverting Amplifier, summing amplifier, integrating

amplifier, differential amplifier and comparator. Amplification Errors.

Protection- Filtering-Wheatstone Bridge. Digital Signals-Analogue to Digital

Conversion, Digital to Analogue Conversion. Multiplexers-Digital

Multiplexers, Time Division Multiplexing.

Data Presentation: Introduction- Data Presentation Elements –Analogue to

Digital Meters, Analogue Chart Recorders-Cathode Ray Oscilloscope. Visual

Display Unit. Printers-Magnetic Recording-Magnetic Disks. Light Indicators-

LED displays, Liquid Crystal Displays, Data Loggers

UNIT III ACTUATION SYSTEM

(i)Mechanical actuation systems: Introduction – type of motion – freedom

and constrains. Kinematic chain – the four – bar chain – the slider crank

mechanism, mechanical aspects of motor selection.

(ii)Electrical systems: Introduction – Mechanical switches – relays, solid –

state switches – diodes, thyristors and triacs, bipolar transistors, solinoids.

D.C.Motor – brushless permanent magnet D.C.Motors, A.C.Motors – stepper

motor – specifications.

UNIT IV PROGRAMMABLE LOGIC CONTROLLER (PLC)

Definition – Basic block diagram and structure of PLC – Input/

Output processing – PLC Programming: Ladder diagram, its logic functions,

latching and sequencing – PLC mnemonics –Timers, internal relays and

counters – Shift registers – Master and jump controls – Data handling –Analog

input/output – Selection of PLC.

UNIT V INTERFACING & DESIGN EXAMPLES


103

Interfacing Input/output ports – Interface requirements: buffers,

handshaking, poling and interrupts, serial interfacing – introduction to PIA –

serial communications interface – example of interfacing of a seven – segment

display with a decoder.

Design process stages - Traditional Vs Mechatronics designs - Possible

design solutions: Timed switch, Wind-screen wiper motion, Bath room scale -

Case studies of mechatronics systems: A pick- and-place robot, Car park

barrier, Car engine management system, Automatic Camera and Automatic

Washing Machine only. Introduction to Vehicle Mechatronics.

Reference Books :


1. Introduction to

Mechatronics V.Bolton

Addsion Wesley Longman

Inc.

2. A Text Book of

Mechatronics R.K.Rajput Tata mcgraw Hil

3. Mechatronics System

Design

Devdas Shetty &

Kolk Pws publishing co

4. Electro mechanics James H.Harter Prentice-Hall of India

5. Control system Engineering Colin D.Simpson, Prentice Hall of India

Online Resources:


2. www.iannauniversity.com

3. www.nptel.ac.in

Course Outcomes :

Understand different types of sensors/transducers.

Knowledge of signal conditioning and data presentation systems.

Identify the basic actuation systems and their importance.

Understand various basic Mechanical and Electrical actuation systems, pneumatic and

hydraulic actuation systems.

Interfacing with peripheral devices.

Understand the structure of PLC and its program, simple applications.

Apply Mechatronics design to real life case studies.


104

ELECTIVE THEORY-II

3E 6311.1 WELDING TECHNOLOGY

RATIONALE

Diploma technicians have a wide scope in fabrication industries. The knowledge

about welding equipments, processes, weld metallurgy, nonferrous metal joining processes

and testing of weldments are pre requests for the fabrication industries.

OBJECTIVES

Explain the different types of welding process and equipments.

Appreciate the safety aspects of welding.

Compare different welding technique.

Study the special welding process.

Explain heat flow and temperature distribution around weldment.

Explain heat affected zone and grain size control.

Study the welding economy and principles of weld design.

Explain the defects in welds.

Compare various non-destructive testing methodologies.

Analyze quality control for quality assurance.




Unit I Welding Processes and Equipment 13 15

Unit II Special Welding Processes 13 15

Unit III Metallurgy of Welding 13 15

Unit IV Weldability of Ferrous and Non – Ferrous Metals 13 15

Unit V Welding Economy, Applications and Testing 13 15

Revision 3


Total 75 75

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

6311.1 5 - 3 75 3 25 75 100


105

DETAILED SYLLABUS

3E 6311.1 WELDING TECHNOLOGY

UNIT I WELDING PROCESSES AND EQUIPMENTS

Classification of welding processes - Gas welding –oxy –acetylene welding–

gas welding techniques – gas welding equipment –– welding torch – types. Cutting

torch – types. Manufacturing of oxygen gas and acetylene gas – Arc welding – Arc

stability – Arc blow- mechanism of arc blow - factors affecting arc blow - Arc

welding power sources – Phenomenon of arching - arc voltage – characteristics of

welding power source.

Resistance welding – spot welding – seam welding – projection welding -

Gas cutting , Plasma cutting, Gouging - Brazing – Soldering. Welding safety –

safety recommendations for installation and operation of arc welding and cutting

equipment, gas welding and cutting equipment.

UNIT II SPECIAL WELDING PROCESSES

Submerged arc welding –TIG welding –MIG welding –CO2 welding –

Comparison between MIG and MAG welding - Electro slag welding –Electro gas

welding - Plasma arc welding –Friction welding – Friction stir welding - Principle

of operation –equipment –merits and demerits – applications. Ultrasonic welding –

explosive welding - atomic hydrogen welding – electron beam welding -laser

beam welding –definition, concept principle of operation and applications. Under

water welding.

UNIT III METALLURGY OF WELDING

Welding arc – Heat flow and temperature distribution in and around weld

metal –temperatures zones –metallurgical effects of welding –weld metal

solidification – absorption of gases by welds and their effects- gas metal reactions –

porosity in welds – thermal effects of welding on parent metal – heat affected

zones – grain size control –weld cracking – types. Corrosion of welds, weld decay,

dilution. Residual stresses – types – causes –effects of thermal stresses-control of

thermal stresses. Stress relief heat treatment- need for treatment .

UNIT IV WELDABILITY OF FERROUS AND NON – FERROUS METALS

Concept of weldability – Welding Processes used for welding wrought

iron – welding of grey cast iron , malleable cast iron, nodular cast and alloy cast

iron - Welding of low carbon steels, high carbon steels – welding of steel castings

– welding of alloy steels , stainless steels. Welding of Aluminium and its alloys,

copper and its alloys, magnesium and its alloys – welding of Inconel , cadmium –

welding of dissimilar metals – welding of plastics.

UNIT V SITE WELDING AND TESTING OF WELDS

Welding at open site. Site welding - Site welding Vs. Shop welding -

Environmental effects in site welding - Site welding Quality control.

Defects in welds –causes and remedies – welding distortion – control of


106

welding distortion.

Testing of welds – stages of weld inspection and testing – inspection

before welding, during welding and after welding - Destructive testing of weld –

tensile test, bend test, impact test, nick break test , hardness test, etch test – Non –

destructive testing of weld – visual inspection, leak test, radiography inspection,

magnetic particle inspection, liquid penetrant inspection, ultrasonic inspection,

eddy current testing.

Reference Books :


1. AWS Welding handbook Vol I &

Vol II Arthur L. Phillips

American welding

society

2. Arc Welding R.J Sacks American welding

society

3. Welding Methods Metallurgy Jackson Griffin publisher

4. Welding Technology O.P Khanna. Dhanpat Rai & Sons

5. Welding Technology Richard L. Little. McGraw Hill

Publishers

Online Resources:

1. www.nptel.ac.in

2. www.me.emu.edu.tr/me364/ME364_combining_fusion.pdf


Course Outcomes :

Understand the different types of welding process and equipments, special welding

process.

Compare different welding technique.

Understand the concepts of heat flow and temperature distribution around weldment,

heat affected zone and grain size control.

Knowledge ofdefects in welds.

Compare various non-destructive testing methodologies.


107

ELECTIVE THEORY-II

3E 6311.2 REFRIGERATION AND AIR CONDTIONING

RATIONALE

Refrigeration and air conditioning is one of the most meaningful job areas for diploma

holders in mechanical engineering. Considering the wide and increasing use of refrigeration

and air conditioning for domestic, commercial and industrial applications and the challenges

put by the use of refrigeration and air conditioning equipment in existing stage, it is

absolutely necessary that diploma engineers should learn this course.

OBJECTIVES

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

Describe the working and construction of compressors used for air conditioning.

Explain vapour compression refrigeration system.

Explain vapour absorption refrigeration system.

Compare the properties and applications of various refrigerants.

Define the parameters used in psychrometry.

Use Psychrometry chart

Describe the equipment used for air conditioning.

Estimate the cooling load for the given requirement.

Explain the industrial application of refrigeration.




Unit I Refrigeration system & Refrigeration equipment 13 15

Unit II Vapor compression refrigeration system,

Vapor absorption refrigeration system & Cryogenic systems 13 15

Unit III Refrigerant flow controls, refrigerants and lubricants

Applications of refrigeration 13 15

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

6311.2 5 - 3 75 3 25 75 100


108

Unit IV Psychrometry and comfort air conditioning 13 15

Unit V Air conditioning systems Cooling load calculations 13 15

Revision 3


Total 75 75

DETAILED SYLLABUS

3E 6311.2 REFRIGERATION AND AIR CONDTIONING

UNIT I (i)REFRIGERATION SYSTEM

Thermodynamic state of a pure substances, modes of heat transfer –

laws of heat transfer - mechanisms of production of cold - unit of refrigeration

–types of refrigeration –reversed Carnot cycle - C.O.P of heat engine-heat

pump- refrigerating machine – principle of working of open and closed air

system of refrigeration – advantages and disadvantages –problems.

(ii)REFRIGERATION EQUIPMENTS

Compressor – principle of working and constructional details of

reciprocating and rotary compressors, hermetically and semi hermetically

sealed compressors- condensers-principle of working and constructional details

of air cooled and water cooled condensers, evaporative condensers- advantages

and disadvantages - natural and forced draught cooling towers. Evaporators-

natural circulation and forced circulation type – principle of working

constructional details.

UNIT II (i)VAPOUR COMPRESSION REFRIGERATION SYSTEM

Principle of working of vapour compression system – analysis of

vapour compression cycle using T-s diagram and p-H diagram- refrigerating

effect- compression work - C.O.P - effect of superheating and under cooling -

problems – effect of - evaporative pressure - condenser pressure - liquid –

vapour refrigeration heat exchangers - advantages and disadvantages of

superheating and under cooling –use of flash chamber and accumulator.

(ii)VAPOUR ABSORPTION REFRIGERATION SYSTEM

Simple absorption system – Electrolux system -NH3 and lithium

Bromide system -absorption system comparison with mechanical refrigeration

system.

UNIT III (i)REFRIGERANT FLOW CONTROLS, REFRIGERANTS AND

LUBRICANTS

Capillary tube-automatic expansion valve-thermostatic expansion

valve-solenoid valve-evaporator pressure regulator –suction pressure regulator-

selection of a refrigerant-properties and applications of following refrigerants


109

SO2 , CH4 , F11, F12 ,F22, and NH3 –lubricants used in refrigeration and their

applications-Cryogenics.

(ii)APPLICATIONS OF REFRIGERATION

Slow freezing –quick freezing- cold storage-frozen storage-freeze

drying –dairy refrigeration –ice cream cabinets-ice making – water cooler, milk

cooler, bottle cooler-frost free refrigeration. Cooling Laptops and other

electronic Gadgets

UNIT IV PSYCHROMETRY AND COMFORT AIR CONDITIONING

Definitions of dry air, moist air, water vapour, Avogadro’s law,

Dalton’s law of partial pressure - dry and wet bulb temperature - dew point -

humidity - specific and absolute - relative humidity - degree of saturation -

enthalpy of moist air- adiabatic saturation of air by evaporation of water-

psychometric chart and its uses – psychometric processes – sensible heating and

cooling - humidifying and heating - dehumidifying and cooling - adiabatic

cooling with humidification - total heating or cooling processes -sensible heat

factor - by pass factor with simple problems – governing optimum effective

temperature – comfort chart-design consideration.

UNIT V (i)AIR CONDITIONING SYSTEMS

Equipment for air conditioning and insulation factors – air purification

– temperature control – humidity control – dry and wet filters- centrifugal dust

collector – air washer humidifier – dehumidifier - fans and blowers – grills and

registers – summer and winter air conditioning, window type air conditioner –

central plant system – properties of ideal insulator, types of insulating materials

–air distribution and duct systems – tools and installation, servicing and

maintenance of R & AC systems.

(ii)COOLING LOAD CALCULATIONS

Different heat sources – conduction heat load – radiation load of sun –

occupants load – equipment load - infiltration air load – miscellaneous heat

sources –fresh air load - simple problems.

Reference Books :


1. Refrigeration and air conditioning P.L. Ballaney Khanna publishers

2. A course in refrigeration and air

conditioning Domkundwar

Dhanpat Rai Pub. Co.

New Delhi.

3. Principles of refrigeration Dossat Prentice Hall,

4. Home refrigeration and air

conditioning Edwin P Anderson

D. B.Taraporevala

publisher

5. Refrigeration and air conditioning C.P Arora Tata McGrawHill


110

Publication,

Online Resources:


2. www.universe.bits-pilani.ac.in

3. www.engineeringstudymaterial.net

Course Outcomes

Understand the working of open and closed air system of refrigeration, working and

construction of compressors used for air conditioning.

Acquiring knowledge on vapour compression/absorption refrigeration system.

Compare the properties and applications of various refrigerants.

Understand the parameters used in psychrometry.

Evaluate the cooling load for the given requirement.

Understand the industrial application of refrigeration.


111

ELECTIVE PRACTICAL II

3E 6312.1 INDUSTRIAL WELDING PRACTICE

OBJECTIVES:


Comprehend the need of various welding equipment in welding shop.

Demonstrate observance of the safety consciousness and good housekeeping in

welding shop.

Follow the standard procedure for welding shop.

Select appropriate welding method for joining various types of materials.

Use of various types tools, equipment for different operations in the welding shop.

Know the weldability of Engineering Materials like Metals, non-metals, ferrous

metals and non-ferrous metals.


SCHEME OF EVALUATION

Note: All the exercises have to be completed. Two exercises will be given for

examination. All the exercises should be given in the question paper and

students are allowed to select by a lot.

Record note book should be submitted during examination.

ARC / GAS Welding : 35 marks

Edge preparation - 10

Welding / Cutting - 10


Joint / Finish - 05

SPECIAL WELDING / CUTTING : 35 marks

Edge preparation - 10

Welding / Cutting - 10


Joint / Finish - 05

Viva-voce : 05 marks

Total : 75 marks

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

6312.1 2 4 4 75 3 25 75 100


112

List of Experiments

TOPICS:




Study about layout of Welding section.

Industrial application of welding operation.

Identify the various types of welding equipment.


tools & equipment in the Welding sections.

Safety precautions to be taken in Welding sections.

Care & maintenance of tools and equipment used in Welding sections.

Read and interpret job drawings and welding symbol.

Defects in weld components.

Welding of ferrous metal and non-ferrous metal.

Know the materials which can be welded and materials which cannot be welded.

I. GAS

Review about Gas welding equipment and its parts.

Demonstrations of back fires and trouble shooting.

Demonstration about types of flames.

The variants of brazing- braze welding.

The quality of gas weld compare with arc welding.


Practice of different methods of gas welding

1. Left hand welding and Right hand welding.

2. Vertical welding.

3. Welding of Thin section.

4. Tube Butt joint – 1G and 5G

BRAZING:

1. Square butt joint – D.H. position

2. Square butt joint Copper to brass or S.S. to MCS – by Brazing.

DEMO EXERCISES

1. Soldering the component made in the sheet metal section.

2. Brazing the component fabricated in the sheet metal section.

3. Preparation of pipe joints using gas welding

4. Repair of Steel, Aluminum alloy and Copper alloy.

II. ARC

Review about the various types Arc welding equipment and accessories.

Demonstration about selection of electrodes and setting the current, how to start an

arc.



113

1. Butt joints by both polarities to identify the weld difference.

2. Single V Butt welding – Down hand position.

3. Double V Butt welding – Down hand position.

4. Single V Fillet welding – Vertical position.

5. Fillet welding – Vertical position.

6. Butt welding – Overhead position.

7. Tube Butt joint – 1G.



10. Welding of Cast Iron / Aluminium / Stainless Steel.

11. Flare – V-groove butt weld (Two Rods).

12. Flare – bevel-groove butt weld (Rod over plate).

13. Repairing of defect weld bead by “Gouging” operation.

DEMO TOPICS:

1. Welding of High carbon steel.

2. Welding of dissimilar materials -SS and MS joints.

3. NDT testing LP, MP.

4. Discussion on X-ray samples.

III. MIGWELDING

Introduction to TIG welding equipment and its parts.


1. Square butt joint on position horizontal

2. Fillet weld outside & inside corner position vertical

3.Square butt joint – over head position.

IV.TIGWELDING

Introduction to TIG welding equipment and its parts.

Various gases used in TIG welding operations.


1. Square Butt joint – Down hand position.

2. Corner Butt joint –Vertical position.

3. Tube Butt joint – 1 G / 2 G / 5 G.

4. Square butt joint on aluminum sheet.

5. Welding of Stainless steel.

DEMO EXERCISES

1.Welding of High carbon steel by gas welding.

2.Repairing of C.I. shaft by ARC welding.

3.Spot welding.

4.Metal spraying.

5.Welding Simulation practice.

V. PROFILE

PROFILE CUTTING PRACTICE:

1. Gas cutting - Triangle


114

2. Plasma cutting - Half round, Step cutting.

3. C.I. cutting - Gas cutting process.

Course Outcomes

Identify appropriate welding method for joining various types of materials.

Knowledge of various types tools, equipment for different operations in the welding

shop.

Understand the weldability of Engineering Materials like Metals, non-metals, ferrous

metals and non-ferrous metals.


115

ELECTIVE PRACTICAL-II

3E 6312.2 REFRIGERATION AND AIR CONDITIONING PRACTICAL

RATIONALE:

Since the use of refrigerators and air conditioning systems for domestic, commercial

and industrial application increases day by day, diploma technicians are expected to know the

construction features, test procedures and service procedures of them.

OBJECTIVES

Identify the various tools used in R & AC.

Demonstrate the construction and working of window air conditioner

Demonstrate the construction and working of split type air conditioner.

Set parameters for comfortable operation of an air conditioner.

Determine the COP of an air conditioner.

Determine the capacity of a window air conditioner.

Describe the wiring of refrigerator and coolers.

Perform servicing on air conditioning system



1. BASIC REFRIGERATION WORKSHOP OPERATION:

(a) Copper and steel tubing

-To study the various sizes of copper and steel tubing.

-To study the various tools used for operations.

-To become familiar with various operations on copper and steel tubing –Flaring.

(b) Soldering methods used in R & A.C

2. TO STUDY THE CONSTRUCTION FEATURES OF THE FOLLOWING :

(a) Domestic refrigerators (b) Water coolers (c) Window Air Conditioner

3. PROPER METHODS OF SETTING AND ADJUSTING OF

(a) Thermostats

(b) Low pressure and high pressure cut-outs

(c) Thermostatic expansion valve

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

6312.2 2 4 4 75 3 25 75 100


116

4. TEST PROCEDURES

1. To determine the refrigerating effect, C.O.P and the compressor capacity of a

open type system with

i) Thermostatic expansion valve

ii) Capillary tube

2. To determine the C.O.P of sealed system from electrical measurements

3. To determine the capacity of a window air conditioner.

4. To determine the efficiency of a cooling tower.

5. Wiring of refrigerator, water cooler, desert cooler, room air conditioner -

packaged air conditioner, panel board etc.

(a) SERVICE PROCEDURES

To change refrigerant into service cylinder from storage cylinder.

1. To evaluate the entire system.

2. To Pump down the system.

3. To Purge air from the system.

4. To locate the leaks in a system.

5. To charge the system .

6. To check the oil level in the compressor.

7. Tracing the common faults in R& A.C units and their remedies.

Resource Requirements:

Course Outcomes:

Identify the various tools used in R & AC.

Understand working of window air conditioner, split type air conditioner.

Evaluate the COP of an air conditioner.

Evaluate the capacity of a window air conditioner.

Understand the wiring of refrigerator and coolers.

Knowledge of servicing an air conditioning system


117

3E 6313 PROCESS AUTOMATION PRACTICAL

RATIONALE

The Automation is being the order of the day to improve the production with high quality consciousness. Such automation involves the use of programmable logic controllers. This course aims to impart knowledge about automatic operations using programmable logic controllers with pneumatic kits.

OBJECTIVES

Use PLC system and its elements for process control

Write ladder logic for logic controls such as AND, OR

Familiarize the working of function blocks in PLC

Use ON – Delay timer to control a motor.

Use OFF –Delay timer to control a motor.

Use counter function block( Up counter and Down Counter)

Control the automatic operation of pneumatic cylinder using PLC

Control Sequential operation of pneumatic cylinder using PLC

Sense the physical quantities by using sensors.


EXCERCISES

1. Study of PLC systems and its elements

Control of Process Using PLC

1. Direct operation of a motor using latching circuit.

2. Operation of a motor using ‘AND’ logic control.

3. Operation of a motor using ‘OR’ control.

4. On – Delay control of a motor.

5. Off – Delay control of a motor.

6. Automatic operation of a Double acting cylinder – single cycle

7. Automatic operation of a Double acting cylinder – Single cycle – forward, time delay,

return.

8. Automatic operation of Double acting cylinder – Multi Cycles.

9. Automatic operation of Double acting cylinder – N cycles (using counter functions

block).

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

6313 2 2 4 60 3 25 75 100


118

10. Sequential operation of a Double acting cylinder and a motor.

11. Sequential operation of a two double acting cylinders for the sequence A+,B+,B-,A-

12. Measurement of Temperature using sensors.

13. Measurement of Flow using sensors.

14. Measurement of Displacement using sensors.

Course Outcomes

Use PLC system and its elements for process control

Acquire the knowledge of different logic functions to control actuator using

PLC

Sense the physical quantities by using sensors.


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3E 6314 COMPUTER AIDED DESIGN AND MANUFACTURING PRACTICAL

RATIONALE

Today diploma engineers are placed in the supervisory level in industries. The

traditional manufacturing of components are replaced with new automation technologies

which use computers for manufacture. This course is coined to impart CNC part

programming and manufacturing of components with CNC machines.

OBJECTIVES:

Study of parametric modeling.

Understand the part modeling and assembly of parts

Create the views of the solid model and parts list.

Study the working principle of CNC machines

Study the datum points and offsets.

Differentiate incremental System with absolute system

Study the simulation software package.

Write program and simulate in the Lathe software and Milling software.

Prepare a part program, edit and execute in CNC Turning centre.

Prepare a part program, edit and execute in CNC Machining centre.

Produce components in the CNC Turning centre and CNC Machining centre.



PART A: Solid modelling

Introduction

Part modelling - Datum Plane – constraint – sketch – dimensioning – extrude

–revolve – sweep – blend – protrusion – extrusion – rib – shell – hole – round –

chamfer – copy – mirror – assembly – align – orient.

Exercises

3D Drawing

1. Geneva Wheel

2. Bearing Block

3. Bushed bearing

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

6314 1 5 3 90 3 25 75 100


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4. Gib and Cotter joint

5. Screw Jack

6. Connecting Rod

Note: Print the orthographic view and sectional view from the above assembled 3D

drawing.

PART B: CNC Programming and Machining

Introduction:

1. Study of CNC lathe, milling.

2. Study of international standard codes: G-Codes and M-Codes

3. Format – Dimensioning methods.

4. Program writing – Turning simulator – Milling simulator, IS practice -

commands menus.

5. Editing the program in the CNC machines.

6. Execute the program in the CNC machines.

Exercises

CNC Turning Machine Material: Aluminum / Acrylic fibre rod / Plastic

1. Using Linear and Circular interpolation - Create a part program and produce

component in the Machine.

2. Using Stock removal cycle – Create a part program for multiple turning operations and

produce component in the Machine.

3. Using canned cycle - Create a part program for thread cutting, grooving and


CNC Milling Machine Material: Aluminum flat or acrylic fibre or plastic

4. Using Linear interpolation and Circular interpolation – Create a part program for

grooving and produce component in the Machine.

5. Using canned cycle - Create a part program for drilling, tapping, counter sinking and


6. Using subprogram - Create a part program for mirroring and produce component in the

Machine.

Note: Print the part program from the simulation software and make the component in the

CNC machine.

Course Outcomes:

Study of parametric modeling.

Understand the part modeling and assembly of parts

Understand the working principle of CNC machines

Understand the simulation software package.

Prepare a part program, edit and execute in CNC Turning centre, and CNC Machining

centre

Production of components in the CNC Turning centre and CNC Machining centre.


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3E 6404 PROJECT WORK

RATIONALE

Project work aims at developing skills in the students whereby they apply the totality

of knowledge and skills gained through the programs in the solution of particular problem or

undertaking a project . The students have various aptitudes and strengths. Project work,

therefore, should mach the strength of the students. This course also aims to impart

knowledge to the students to become future entrepreneurs and also creates awareness on

environment and disaster management.


PROJECT WORK

The students of all the Diploma Programs (except Diploma in Modern Office Practice)

have to do a Project Work as part of the Curriculum and in partial fulfillment for the award of

Diploma by the State Board of Technical Education and Training, Tamilnadu. In order to

encourage students to do worthwhile and innovative projects, every year prizes are awarded

for the best three projects i.e. institution wise, region wise and state wise. The selection of

Project work should be taken up in V Term of study. The First Project review should be done

in 12th week of study in V Term. The Second Project Review should be done in the 8th

week of study in the VI Term.

a) Internal Assessment mark for Project Work & Viva Voce:

Project Review I (V Term) 05 marks

Project Review II (VI Term) 05 marks

Project Review III (VI Term) 10 marks

Attendance ------- 05 marks

Total 25 marks

b) Project Work & Viva Voce Autonomous Examination

The allocation of Mark:

Viva Voce 15 marks

Course

Code

Instruction

Periods/Week

Credits

Total

Periods

Per

Term



(hrs)

Internal

Assessment

Marks

End

Exam

Marks

Total

Marks

3E

6404 - 4 2 60 3 25 75 100


122

Project Report 25 marks

Demonstration 20 marks

Applicability of the Project 15 marks

Total 75 marks


123

Model Question papers


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MODEL QUESTION PAPER

Programme: Mechanical Engineering Max.marks: 75 Course: Strength of Materials Course code: 3E 3205 Term: III Time: 3 Hrs.

[Note: (1) Answer any FIVE questions in each PART – A and PART – B. Q.No. 8 in PART – A and Q.No. 16 in PART – B are compulsory. (2) Answer division (a) or division (b) of each question in PART – C. (3) Each question carries 2 marks in PART – A, 3 marks in PART – B and 10 marks in PART – C.]

PART –A

1) Define Stiffness.

2) What is temperature stress?

3) Define Modulus of resilience.

4) Define Moment of Inertia.

5) Define Slope.

6) Write down Bending equation.

7) Define – Column

8) When is a Shaft said to be in pure torsion?

PART - B

9) Define Bulk modulus.

10) Give the relationship among elastic constants.

11) Obtain a relation for the stress induced in a body, if a load P is applied suddenly.

12) Draw BMD for a cantilever beam carrying UDL over entire length.

13) Explain the term “ Polar modulus ”

14) Derive a relation for the Euler’s crippling load for a column when it has both ends

hinged.

15) What are helical springs? Differentiate between a closely coiled &openly coiled helical

spring.

16) State and Prove Perpendicular axis theorem.

PART – C

17) a) The following data refer to a mild steel specimen.

Diameter of specimen = 30mm;

Length of the specimen = 300mm;

Extension under a load of 15kN=0.05mm;

Load at yield point = 130kN;

Length of specimen after failure = 370mm. Determine Young’s modulus, Ultimate stress,

Percentage of elongation, Safe Stress when FOS is 2.

(Or)

b) Two vertical wires each of 3mm diameter and 3m long jointly support a load of 2kN.

One is of steel and other is of aluminum. If the wire stretches by 3mm, Find the load

taken by each and the values of young’s modulus for aluminum. Take E steel = 0.2 X 106

N/mm2.


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18) a)A rod 12.5mm in diameter is stretched 3.2mm under a steady load of 10kN. What

stress would be produced in the bar by a weight of 700N, falling through 75mm before

commencing to stretch, the rod being initially unstressed? Take E = 210 X 103Mpa.

(Or)

b) Determine the moment of inertia of a channel section about XX & YY axis having

overall dimensions of 200 X 200 X 50.

19) a)A beam is free supported over a span of 8meters. It carries point load of 3kN at 2m

from the left hand support and an UDL of 2kN/m run from the center to right hand

support. Construct SFD and BMD.

(Or)

b)(i) A cantilever 2m long carries a load of 40kN at the free end. Calculate the slope and

deflection at the free end. Take E=200 X 103 N/mm2 and I = 160 X 106 mm4.

(ii)A cantilever of length 2m carries a UDL of 1.5kN/m run over the whole length and a

point load of 2kN at a distance of 0.5m from the free end. Draw SF and BM diagram then

note salient points.

20) a)A rectangular beam 200mm deep and 100mm wide is simply supported over a span

of 8m and carries a central point load of 25kN. Determine the maximum stress in

beam.

(Or)

b)A 1.75m long steel column of rectangular cross-section 120 mm X 100 mm is rigidity

fixed at one end and hinged at other. Determine the buckling load on the column and

corresponding axial stress using Euler’s formula. Take E = 200Gpa.

21) a)A hollow shaft having an internal diameter 60% of its outer diameter is to replace a

solid shaft transmitting the same power at the same speed. Calculate the percentage

saving in material, if the material to be used is also the same.

(Or)

b)A closely coiled helical spring is to carry a load of 500N. Its mean coil diameter is to be

10 times of the wire diameter. Calculate these diameters if the maximum shear stress in

the material of the spring is to be 80N/mm2 .If the stiffness of the spring is 20N/mm and

modulus of rigidity=8.4 X 104N/mm2, find the number of turns in the helical spring.


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Programme: Mechanical Engineering Max.marks: 75 Course: Fluid Mechanics and Fluid Power Course code: 3E 3206 Term: III Time: 3 Hrs.

[Note: (1) Answer any FIVE questions in each PART – A and PART – B. Q.No. 8 in PART – A and Q.No. 16 in PART – B are compulsory. (2) Answer division (a) or division (b) of each question in PART – C. (3) Each question carries 2 marks in PART – A, 3 marks in PART – B and 10 marks in

PART – C.] PART – A

1. Distinguish between Gauge pressure and vacuum pressure?

2. What is the use of dead weight pressure gauge?

3. What is laminar flow?

4. Define co-efficient of contraction.

5. State the purpose of hydraulic brake in a pelton wheel.

6. What is cavitation?

7. What is the use of quick exhaust valve?

8. Define flash point of hydraulic fluid

PART – B 9. If a density of liquid is 840 kg/m3. Find its specific weight and relative density.

10. Calculate the head lost due to friction in a pipe of 0.5m diameter and 1000 m long.

The velocity of flow of water is 2 m/s and the friction factor is 0.02.

11. Mention minor losses that occur in flow through pipes.

12. Mention the elements of hydraulic system.

13. What is priming? Why it is necessary?

14. A jet of water 0.25m diameter is moving with a velocity of 30 m/s. Find the force exerted

by the jet if the plate is moving with a velocity of 12 m/s in the direction of the jet.

15. What is draft tube? State its functions.

16. Compare venturi meter with orifice meter

PART – C 17.(a) Explain the construction and working principle of diaphragm type pressure gauge with a simple sketch.

(or)

(b) Calculate the flow of water in liters per hour through 400mmx150mm venturimeter. when a differential gauge connected to the mouth and throat is 250mm of mercury. Assuming co-efficient of discharge of the meter is 0.98. 18.(a) Explain the working of Hydro-electric power plant with neat sketch.

(or)


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(b) A jet of water 60mm diameter moves with a velocity of 25m/sec and strikes on a Series of vanes moving with a velocity of 10m/sec. find (i) the force exerted by the jet (ii)work done by the jet (iii)efficiency of the jet (iv)vane velocity for maximum Efficiency. 19. (a) With a neat sketch explain the working of single stage centrifugal pump.

(or) (b) A single acting reciprocating pump has its plunger diameter 0.15m and a stroke of 0.3m. It discharges 300 liters of water per minute at 60 rpm. The suction and Delivery head are 6mand 14m respectively. Find (i) theoretical discharge (ii) Slip of the pump (iii) power required to drive the pump. if its efficiency is 70%. 20. (a) what is an FRL unit? Explain with neat sketch

(or) (b) Briefly explain the elements of pneumatic system with neat sketch.

21. (a) Explain the following with sketches: (i) Radial piston pump (ii) Pressure intensifier.

(or) (b) Explain the hydraulic circuit with ISO symbols for the table movement of surface grinding Machine.

______


128


Programme: Mechanical Engineering Max.marks: 75 Course: Manufacturing Processes Course code: 3E 3207 Term: III Time: 3 Hrs.



1. What is a pattern?

2. State any three casting defects.

3. What is plasma?

4. List out the equipments need for gas welding.

5. Define sintering.

6. What is composite material?

7. Name the characteristic of plastics.

8. Define accuracy.

PART – B 9. Name the pattern allowances?

10. List out the various casting processes.

11. What is electro slag welding? Give its applications.

12. Define (i) Blanking (ii) Piercing.

13. What are the design rules in powder metallurgy?

14. What are the factors influencing the selection of plastics?

15. Compare Thermo Plastics and Thermosetting Plastics.

16. What are the advantages and disadvantages of electrical comparator?

PART – C 17. (a) Explain green sand moulding with a neat sketch.

(or) (b) Explain hot chamber die casting with a neat sketch.

18. (a) Explain resistance welding with a neat sketch.

(or) (b) Explain oxy acetylene cutting with a neat sketch.

19. (a) Explain smith forging operations with a neat sketch.

(or) (b) Explain atomization process with a neat sketch.

20. (a) Explain twin screw extruders with a neat sketch.

(or) (b) Explain pultrusion process with a neat sketch.

21. (a) Explain nomenclature of twist drill with a neat sketch.

(or) (b) Explain mechanical comparator with a neat sketch.


129


Programme: Mechanical Engineering Max.marks: 75 Course: Machine Drawing Course code: 3E 3301 Term: III Time: 3 Hrs.

[N.B. 1.Answer any SEVEN questions in each PART A and answer division (a)

Or answer division (b) in PART B

2. Each question carries 5 marks in PART A, 40 marks in PART B

3. All questions are to be answered in the drawing sheet only]

PART A

1. Name the different types of section. Explain (i)full section and (ii) half section.

2. List the important points to be the considered while creating hatching lines.

3. Define the hole basis and shaft basis system .explain with sketch.

4. What are the types of fits? Illustrate transition fit using a neat sketch.

5. Explain surface roughness symbol and its notations.

6. Explain the direction of lay using symbols

7. Explain the nomenclature of screw thread.

8. Illustrate the types of keys. Draw a gib headed key with its proportions.

PART B

9. a) Assemble and draw the following views of PLUMMER BLOCK

Right half sectional elevation: 20

Plan : 15

Bill of materials : 05

(or)

b) Assemble and draw the following views of KNUCKLE JOINT

Full sectional front view : 20

Top view : 15

Bill of materials : 05


130


131


132


Programme: Mechanical Engineering Max.marks: 75 Course: Heat Power Engineering Course code: 3E 4211 Term: IV Time: 3 Hrs.

Note: (1) Answer any FIVE questions in each PART – A and PART – B. Q.No. 8 in PART – A and Q.No. 16 in PART – B are compulsory. (2) Answer division (a) or division (b) of each question in PART – C. (3) Each question carries 2 marks in PART – A, 3 marks in PART – B and 10 marks in PART – C.]

PART – A 1. State the second law of thermodynamics.

2. Define Air standard efficiency.

3. List out the uses of compressed air.

4. Draw the P-V diagram of otto cycle.

5. Define dryness fraction of steam.

6. Define control volume.

7. What are the purposes of boiler trail?

8. What is meant by throttling process?

PART – B 9. What are intensive and extensive properties? Give an example for each.

10. A closed system receives 120 KJ of heat and performs 150 KJ work.

Determine the Change in internal energy.

11. Derive the relationship between specific heats.

12. Write the steady flow energy equations for nozzle, condenser and

reciprocating air compressor.

13. Show the isentropic process of expansion of steam on h-s and T – s

diagrams.

14. State any three advantages of superheated steam.

15. Find the mass of 0.15m3 of wet steam at a 9 bar and 0.85 dryness fraction.

16. State the effects of intercooling.

PART – C

17. (a) (i) Explain closed cycle thermodynamics system with an example.

(ii) A mass of 2.25 kg of N2 Occupying 1.5m3 is heated from 250 C to 200 0 Cat

constant Volume. Calculate the initial and final pressure of the gas. Molecular weight of

nitrogen is 28.universal gas constant is 8314 J/kg mole K.

(or)

(b) 0.63 Kg of air at a pressure of 1.5bar occupies a volume of 0.4m3. If the air expands

Isothermally to a volume of 0.9m 3. Determine i) initial temperature ii)final temperature

iii)Work done, iv)Change in internal energy, v)Change in entropy. TakeR=0.29KJ/Kg.K.


133

18. (a) Steam enters a turbine at a velocity of 12 m/sec and a specific enthalpy is 2900

kJ/kg at the Exit of the turbine the steam velocity is 30 m/sec and the specific enthalpy is

2400 kJ/kg. the heat lost during the flow through the turbine is 20 kJ/kg and the steam

flow rate is 85 kg/sec. determine the power output from the turbine.

(or)

(b) Derive an expression for the air standard efficiency of otto cycle.

19. (a) Explain the working of a multistage air compressor with intercooling.

(or)

(b) Explain the working of a closed cycle gas turbine with a line sketch.

20. (a) In an experiment on wet steam in a barrel calorimeter the following reading were

taken Steam pressure =5.5 bar, Mass of copper calorimeter= 1 kg, Mass of copper

calorimeter=3.8 kg ,Mass of Copper calorimeter + steam =4 kg , Initial temperature of

water =100C,Final temperature of water= 50 0 C, Specific heat of copper =0.092 KJ/Kg K.

Calculate the Dryness fraction of steam

(or)

(b) Determine the specific volume and internal energy of 1kg of steam at a pressure

of 8 bars when steam is 90% dry and saturated and superheated ,the temperature of

superheated steam being 2000C.Assume CP for superheated steam as 2.25 KJ/kg K.

21. (a) With a neat sketch, explain the function, and working of BHEL high pressure

boiler

(or)

(b) The following observations refer to a boiler trial. Mean temperature of feed water

280C,water evaporated per hour 48000 kg, boiler pressure 14 bar absolute, quality of steam

90% dry, coal burnt per hour 4800 kg , calorific value of coal 34000 kJ/kg. Calculate

1. Equivalent evaporation in kg per kg of coal 2.boiler thermal efficiency.


134


Programme: Mechanical Engineering Max.marks: 75 Course: Special Machines Course code: 3E 4212 Term: IV Time: 3 Hrs.


PART – A 1. Write down the different parts of lathe.

2. Mention the names of different types of planer.

3. Mention the names of various operations performed in milling machine.

4. Mention various methods of indexing methods.

5. What is an abrasive process?

6. How metal is removed in ultrasonic machining process.

7. Define CNC.

8. What is ATC?

PART – B 9. Explain any one work holding device with a neat sketch used in planer

10. Write down the rules for differential indexing

11. Mention the advantages of gear planning.

12. Write down the specifications of a grinding machine.

13. Mention the advantages of Laser beam machining.

14. State the features of CNC machines.

15. Define in process probing.

16. Write down the important specifications of a lathe.

PART – C 17. (a) (i) Explain any two properties required for cutting tool.

(ii) Explain any one type of tool holder used in semiautomatic lathe.

(or) (b) Explain Tumbler gear mechanism with neat sketch. 18. (a) Explain with neat sketch crank and slotted link mechanism used in shaper.

(or) (b) (i)Explain any two work holding devices used in slotter. (ii)Explain any one broaching operation with neat sketch.

19. (a) Sketch and explain column and knee type milling machine. (or)

(b) Sketch and explain Gear shaping process. 20. (a) Explain with a neat sketch cylindrical grinding machine.

(or) (b) Sketch and explain Electrical Discharge Machining (EDM).

21. (a) Explain the working principle of a CNC system with a neat sketch. (or)

(b) Explain the recirculating ball screw and nut mechanism in CNC machine with neatsketch. State it merits also.


135


Programme: Mechanical Engineering Max.marks: 75 Course: Electrical Drives & Control Course code: 3E 4401 Term: IV Time: 3 Hrs.


PART – A 1. What is resistance and mention its unit?

2. What is the advantage of 4- point starter when compared with 3- point starter?

3. Write the application of capacitor start induction motor.

4. Compare squirrel cage and slip ring induction motor.

5. What are the application of servo motor?

6. What is earthing ?

7. What is positive and negative logic?

8. What is circuit breaker?

PART – B 9. State Kirchoff’s current law.

10. Define power.

11. Write the types of alternator.

12. What is the formula for power in single phase circuit?

13. What is group drive?

14. What is electric shock?

15. What is positive and negative logic?

16. Write the necessity of Fuses?

PART – C 17 (a) Derive and Expression for series parallel circuit with neat diagram. (OR) (b) Draw the circuit of Three point starter and explain its working 18 (a) Derive the relationship between phase current, line current, phase voltage and line voltage in delta connection (OR) (b) Derive the EMF equation of transformer. 19 (a) Explain the construction and working principle of stepper motor with neat diagram

(OR) (b) what is electric shock? What are precaution against electric shock.

20) (a) Explain the working principle of Bridge rectifier with suitable diagram & wave form

(OR) (b) Construct a following gates using NOR gate – any 3 gates 21 (a) Explain the working principle of inductive proximity sensors.. (OR)

(b) With neat diagram, explain the working of ELCB


136


Programme: Mechanical Engineering Max.marks: 75 Course: DESIGN OF MACHINE ELEMENTS Course code: 3E 5304 Term: V Time: 3 Hrs. NOTE : Answer all the questions by either or choice

Each question carries 15 marks. Approved Data book, P.S.G. Data book may be permitted

1. A. i) What is meant by working stress and how it is calculated for

ductile and brittle materials? (05) ii) A knuckle joint is subjected to a pull of 80 KN. If the maximum

permissible tensile stress in the rods is 100 N/mm2 and the permissible

shear stress in the pin is 80 N/mm2, calculate the diameter of the rods and that of the pin. (10)

OR B. Two shafts are connected by means of coupling to transmit 3.56 KW at 1200

RPM. The flanges of the coupling are fastened by means of 3 bolts at a pitch circle radius of 25 mm. Design the bolt if permissible shear stress in the bolt is 30 N/mm2. (10)

2. A. i) Explain the types of failures in keys. (05) ii) A shaft made of mild steel is required to transmit 100 KW at 300 rpm.

The supported length of the shaft is 3 m. It carries two pulleys each weighing 1500 N, supported at a distance of 1 m from each ends respectively. Assume the safe value of stress as 60 N/mm2. Determine the diameter of the shaft. (10)

OR B. Design a protective type flange coupling to connect two shafts to transmit 7.5

KW at 720 rpm. The permissible shear stress for the shaft, bolts and key

materials is 33 N/mm2, permissible crushing strength for bolt and key material

is 60 N/mm2 and permissible shear stress for cast iron is 15 N/mm2. (15)

3. A. i) What do you mean by ply in flat belts? When a V-belt is preferred over

flat belt? (05) ii) Select a crossed flat belt drive from the manufacture’s catalogue to

transmit a power of 25 KW at 960 rpm. The speed of the driven pulley is 500 rpm. Centre distance between shafts is 1.5 m. Take intermittent load. (10)

OR

B. Design a V-belt drive if the power to be transmitted is 75 KW, speed of driving wheel is 1440 rpm, speed of the driven wheel is 400 rpm, diameter of driving wheel is 300 mm and centre distance is 2500 mm. Assume small pulley factor Kd = 1.14, service factor Ks=1.3 and correction factor for length Kt=1.07 (15)


137

4. A. i)State the factors to be considered in the selection of bearings. (05) ii)A 150 mm diameter shaft supporting a load of 10 KN has a speed of 1500

rpm. The shaft runs in a bearing whose length is 1.5 times the shaft diameter. If the diametral clearance of the bearing is 0.15 mm and the absolute viscosity of the oil at the operating temperature is 0.011 kg/m-s, find the power wasted in friction (10)

OR B. Design a suitable journal bearing for a centrifugal pump from the following

data: Load on the bearing=13.25 KN

Diameter of the journal=80 mm Speed=1440 rpm

Bearing characteristic number=30 x 10-6

Permissible bearing pressure=0.7 to 1.4 N/mm2

Average atmospheric temperature=30 C Calculate the cooling requirements and friction coefficient. Assume

L/D=2, Average temperature of oil, to=75 C, Coefficient of heat

dissipation K=0.2730 C/m2/W for heavily constructed bearing.

Temperature rise to=6 C (15)

5. A. Design a spur gear drive to connect an electric motor to reciprocating pumps both being mounted on the same bed. Speed of the motor is 1440 rpm. Speed reduction designed is 10:1. Motor power is 36.8 KW.

The gears are to have 20 pressure angle. The minimum number of teeth on the pinion is 24. Material used for both pinion and wheel is steel hardened to 400 BHN. Service/Shock factor Ko=1.25, static

stress permissible=210 N/mm2. Velocity factor V=6/(6+V) where V is velocity in m/s. Face width b=3 x circular pitch. Fatigue stress factor,

K=2.553 N/mm2. Deformation factor, C=285 KN/m. (15) OR

B. Design a hand lever of rectangular section subjected to a maximum load of 250 N at the end of moment’s arms of 1.2 m. The thickness of lever is constant and is equal to 0.375 times the width of lever near the

boss. Permissible shear stress for the shaft material is 40 N/mm2 and

permissible bending stress for the lever material is 80 N/mm2.(15) -------------


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Programme: Mechanical Engineering Max.marks: 75 Course: Automobile Engineering Course code: 3E 5304 Term: V Time: 3 Hrs.

Model Question Paper [Note: (1) Answer any FIVE questions in each PART – A and PART – B. Q.No. 8 in PART – A and Q.No. 16 in PART – B are compulsory. (2) Answer division (a) or division (b) of each question in PART – C. (3) Each question carries 2 marks in PART – A, 3 marks in PART – B and 10 marks in PART – C.]

PART – A

1. What are the different components in IC Engines?

2. What are the functions of Piston Rings?

3. What is the purpose of PCV Valve and where it is located ?

4. What is the purpose of Cushioning springs and where it is located ?

5. What are different types of steering systems?

6. What is air suspension?

7. What are the components of Ignition system?

8. Brief MPFI?

PART – B

9. Brief different Valve Head Arrangements

10. State the effects of overheating of engine parts.

11. Explain Vapour Lock Tendancy.

12. What causes emission of Nitrogen oxides from an automobile?

13. What is the function of synchro meshing device?

14. What are the important elements used in Pneumatic Brake System?

15. Draw the sketch of Injector.

16. What are the different sensors used in IC Engines?

PART – C

17. (a) Explain Pressure Lubrication System with neat sketch. (OR)

(b) What are different forms of liquid cooling and explain any two with neat sketch? 18. (a) Explain Jerk type Fuel Injection Pump with neat sketch.

(OR) (b) Explain Pneumatic Governor with neat sketch. 19. (a) Explain constant mesh gear box with neat sketch.

(OR) (b) Explain construction and operation of Differential with neat sketch. 20. (a) Explain different forms of Independent Suspension with neat sketch.

(OR) (b) Explain hydraulic brake system with neat sketch. 21. (a) Explain construction Bendix drive with neat sketch.

(OR) (b) Explain Current Regulator, Voltage Regulator and Cut out Relay with neat sketch.


139


Programme: Mechanical Engineering Max.marks: 75 Course: Computer aided Design and Manufacturing Course code: 3E 5305 Term: V Time: 3 Hrs.


PART - A

1. What is a graphic standard? 2. What is Group Technology? 3. What is generative CAPP? 4. What is zero point? 5. What is meant by proximity sensor? 6. What is sequential engineering? 7. What is Value Engineering? 8. What is Flexible Transfer Line?

PART - B 9. What are the operators used in C-rep? 10. List any three advantages of Finite Element Analysis. 11. What is Just-In-Time manufacturing philosophy? 12. Write any three preparatory functions. 13. What is Rapid prototyping? 14. List any three benefits of CIM. 15. What is Proximity and Tactile sensors? 16. List any three applications of Augmented Reality.

PART - C 17. a) Explain the Shigley design process.

(OR) b) Explain the Wire Frame Model with linear and curvilinear edge.

18. a) Explain the OPTIZ classification system. (OR)

b) Explain the functions of CAM. 19. a) Explain CNC program procedure.

(OR) b) Explain 3D printing.

20. a) Explain the integrated CAD/CAM.

(OR) b) Explain the working principle of AGV.

21. a) Explain the Steps involved in Failure Modes and Effects Analysis.

(OR) b) Explain Product Development Cycle.


140


Programme: Mechanical Engineering Max.marks: 75

Course: Renewable Energy Sources and Energy Conservation

Course code: 3E 5306.1

Term: V Time: 3 Hrs. [Note: (1) Answer any FIVE questions in each PART – A and PART – B. Q.No. 8 in PART – A and Q.No. 16 in PART – B are compulsory. (2) Answer division (a) or division (b) of each question in PART – C. (3) Each question carries 2 marks in PART – A, 3 marks in PART – B and 10 marks in PART – C.]

PART – A 1. What is the effect of electromagnetic radiation on humans? 2. What is a PV hybrid system? 3. What do you mean by variable speed WEG? 4. What is ‘bio-fouling’ in OTEC system? 5. What is a tide? 6. What do you understand by the term ‘bio-diesel’? 7. What is a fuel cell? 8. What is Global warming?

PART – B

9. How nuclear fission is different from nuclear fusion 10. What is the difference between energy conservation and energy efficiency 11. What is meant by Kyoto Protocol? 12. What are bio-fuels? 13. State the difference between active and passive solar heating system. 14. What are the limitations of wave energy? 15. What is a greenhouse? 16. What do you mean by ‘co-generation’?

PART – C

17. (a) Discuss the power scenario in India. (or)

(b) With the help of neat sketch, discuss the different types of wind turbines. 18. (a) Discuss the parameters governing the performance of flat plate solar collectors.

(or) (b) Write short notes on various solar thermal energy storage systems.

19. (a) Explain the different types of solar cells on the basis of the type of junction Structure.

(or) (b) Discuss the limitations of tidal power projects.

20. (a) With a neat diagram, discuss the biomass gasification method (or)

(b) Discuss the method of power generation from liquid waste.

21. (a) Write your views on energy options for India considering socio-economic problems.

(or) (b) Write notes on energy conservation and energy efficiency.


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Course: Total Quality Management Course code: 3E 5306.2

Term: V Time: 3 Hrs.


PART – A

1. Define Quality.

2. What is customer delight?

3. What are the factors make continuous process improvement?

4. What are the “Cause and Effect Diagram”?

5. Define standard deviations.

6. Define control chart.

7. What is meant by process capability?

8. What is the objective of bench marking?

PART – B

9. Write basic concept of TQM?

10. Describe the Deming Philosophy.

11. What is the benefit of Kaizen?

12. What is the benefit of Quality circle?

13. Define mean, median and mode.

14. What are the concepts of six sigma?

15. Describe the control chart for variables.

16. What is the concept of just in time?

PART – C

17. (a) (i) Explain at least five steps in strategic planning. (ii) What are the obstacles to TQM implementation?

(or) (b) Elaborate ISO 9001 : 2008 quality management system requirement and implementation.

18. (a) Explain in detail about 5S concept. (or)

(b) Explain in detail about seven tools of quality control.

19. (a) What are the characteristics of a normal curve? (or)

(b) Find out Arithmetic mean, Median, Mode, Range and Standard Deviation for the weight of people. Their weights are 83, 91, 78, 80, 83, 85 and 87 Kgs respectively.


142

20. (a) List down in a detail manner the steps involved in the construction of chart. (or)

(b) Compare P-chart and C-chart. 21. (a) Explain in detail the steps involved in the construction of affinity diagram with

example and its applications (or)

(b) Explain in detail the steps involved in the “Bench marking process” and state what are the benefits.


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Course: Industrial Engineering and Management Course code: 3E 6309

Term: VI Time: 3 Hrs. [Note: (1) Answer any FIVE questions in each PART – A and PART – B. Q.No. 8 in PART – A and Q.No. 16 in PART – B are compulsory. (2) Answer division (a) or division (b) of each question in PART – C. (3) Each question carries 2 marks in PART – A, 3 marks in PART – B and 10 marks in PART – C.]

PART – A 1. Write any four factors to be considered for the selection of site. 2. What are the causes for an accident? 3. What are the methods of improving productivity? 4. What are the techniques used for work measurement? 5. What are the documents used in dispatching? 6. Write any four types of organizations? 7. What are the methods followed for calculating depreciation? 8. What are the effects of good rapport with teachers?

PART – B 9. Write at least six advantages good plant layout. 10. What are the methods to settle industrial dispute? 11. What are the objects of method study? 12. What is analytical estimation? 13. Differentiate quality control and inspection. 14. Why authority and responsibility go hand in hand explain short? 15. What are the function of human resource manager? 16. How self disciplines improve the development of the nation?

PART – C 17. (a) (i) what are the important factors to considered in selection of good plant layout?

(ii) List out the benefits of industrial act 1948. (or)

(b) What is an Industrial dispute? Discuss the causes of it. 18. (a) Briefly explain each step the basic procedure followed for conducting method

study. (or)

(b) (i) What is man machine chart? Explain with example. (ii) Write short notes on ratio delay study.

19. (a) What is fore casting? Explain different techniques applied. (or)

(b) (i) Write short notes on double sampling plan. (ii) Explain operating characteristics curve.

20. (a) Explain Taylor’s pure functional organization with chart. State its merits and demerits.

(or) (b) Explain all wages system implemented in factory.

21. (a) (i) Explain function of a store. (ii) Explain purchasing procedure.

(or) (b) Discuss the individuality of a person from “Good and Bad” qualities.


144



Course: Mechatronics Course code: 3E 6310

Term: VI Time: 3 Hrs.


PART – A 1) What is sensitivity? 2) Brief operational amplifier. 3) What is VDU? 4) Brief mechanism with one example 5) What is relay? 6) What are operations performed in data handling? 7) What is buffer? 8) What is counter?

PART – B 9) Brief measurement system. 10) What is data logger? 11) What are freedom and constraints? 12) Brief any two stepper motor specifications. 13) What is master and jump control? 14) What is mass input/output copying? 15) What is Peripheral interface adapter? 16) Brief thermocouple.

PART – C 17) (a)Explain Differential transformer with neat sketch.

(Or) (b)Explain Pyro electric sensor with neat sketch.

18) (a)Explain Comparator with neat sketch. (Or)

(b)Explain DAC with one example.

19) (a)Explain Slider crank mechanism with neat sketch. (Or)

(b)Explain different types of stepper motor with neat sketch.

20) (a)Explain different types of timers with neat sketch (Or)

(b)Explain Sequencing with neat sketch

21) (a)What are different interface requirements? (Or)

(b) Explain how car park barrier can be operated using PLC.


145



Course: Welding Course code: 3E 6311.1




1. What are types of welding torches?

2. What is gouging?

3. State the features of electro slag welding.

4. What are the merits of friction stir welding?

5. What is weld metal solidification?

6. State any two measures to control thermal stresses in welding.

7. Define weldability.

8. What is ‘weld distortion’?

PART – B 9. State and briefly explain the different types of flames in gas welding. 10. State the factors affecting arc blow. 11. Compare MIG and MAG welding processes.

12. Write short notes on ‘under water welding’. 13.Briefly explain the metallurgical effects of welding. 14. Write short notes on ‘weld decay’ 15. State the welding processes used for welding wrought iron. 16. Distinguish between site welding and shop welding

PART – C 17. (a) List the safety recommendations for installation and operation of arc welding

equipments. (or)

(b) Explain any two resistance welding processes with neat sketches.

18. (a) Explain CO2 welding process with a neat sketch. State its applications

(or)

(b) Explain the principle and operation of laser beam welding with a neat sketch.

19. (a) Explain the heat flow and temperature distribution in and around weld metal.

(or)

(b) Briefly explain (a) corrosion of welds (b) Dilution.

20. (a) Explain the welding of aluminium and its alloys.

(or)

(b) Describe the welding of plastics.

21. (a) Explain any two defects in welds , causes for them and remedies

(or)

(b) Explain the magnetic particle inspection method of testing for welds


146



Course: Refrigeration and Air Conditioning Course code: 3E 6311.2



PART – C.] PART - A

1. Define Refrigeration. 2. State Newton’s law of cooling of heat convection. 3. What is the function of an accumulator? 4. Define slow freezing. 5. Define Relative humidity. 6. Define By-pass factor. 7. Define Induced draft fan. 8. Write any two effects of sub-cooling the liquid?

PART - B

9. State and explain Fourier’s law of heat conduction. 10. Draw and explain p-v diagram for reversed Carnot cycle. 11. What is the effect of superheating and undercooling? 12. What are the limitations of Vapor Absorption System? 13. State any three properties of good Lubricating oil. 14. What are the desirable properties of an ideal refrigerant? 15. State Dalton’s law of partial pressure. 16. Brief about Gas-bulb thermostat.

PART - C 17. a) A refrigeration plant is required to store 15 tonnes of fish. The fish is supplied at a

temperature of 300C. The specific heat of fish above freezing point is 2.9 KJ/Kg.K. The specific heat of fish below the freezing point is 1.26 KJ/Kg.K. The fish is maintained at -80C. If the plant requires 60kW to drive it, find (a) the capacity of the plant & (b) the time taken to achieve cooling. Assume actual C.O.P of the plant as 0.3 of the Carnot C.O.P.

(OR) b) Explain the construction and working principle of Reciprocating Compressor.

18. a) Explain the working of vapor compression refrigeration system.

(OR) b) Explain the construction & working of Lithium-Bromide Absorption system.


147

19. a) Explain the construction and working of Thermostatic Expansion Valve.

(OR) b) Explain the working of Slow Freezing and Quick Freezing.

20. a) The values obtained from a sling Psychomotor are DBT=300C & WBT=200C. The barometric reading is 740mm of Hg. Calculate (i) Dew point temperature & relative humidity (ii) degree of saturation (iii) Specific humidity (iv) Specific volume (v) Specific enthalpy.

(OR) b) Explain the various Psychrometric process in detail with the Psychrometric chart.

21. a) Explain the construction and working of Central Plant Air conditioning system.

(OR) b) Explain the condition for Design of Air conditioning system.


148

EQUIVALENT PAPERS FOR D-SCHEME IN E-SCHEME TERM III

SL.

NO D-SCHEME E-SCHEME

1 Mechanics of Materials Strength of Materials

2 Fluid Mechanics and Fluid Power Fluid Mechanics and Fluid Power

3 Manufacturing Technology - I Manufacturing Processes

4 Material science -

5 Machine drawing Machine drawing

6 Mechanics of Materials & Fluid

Mechanics Laboratory

Strength of Materials & Fluid

Mechanics Practical

7 Foundry ,Smithy and Welding Practice Foundry, Smithy and Welding Practical

TERM IV

SL.

NO D-SCHEME E-SCHEME

1 Manufacturing Technology - II Special Machines

2 Thermal Engineering - I -

3 Electrical Drives and Control Electrical Drives and Control

4 Thermodynamics Laboratory Heat Power Engineering Practical

5 Computer Aided Machine Drawing Computer Applications and CAD

Practical

6 Machining & Measuring Practice Machining, Machine Tool Testing and

Maintenance Practical

7 Electrical control and drives

laboratory Electrical Drives and Control Practical


149

TERM V

SL.NO

D-SCHEME E-SCHEME

1 Design of Machine Elements Design of Machine Elements

2 Thermal Engineering-II -

3 Computer Integrated manufacturing Computer Aided Design and

Manufacturing

4 Automobile Technology Automobile Engineering

5 Automobile Technology practical Automobile Engineering Practical

6 Communication and life skills practical

Life and employability skills practical

7 Special Machining Practice Special Machines Practical

TERM VI

S.N

O D-SCHEME E-SCHEME

1 Industrial Engg. And Management Industrial Engg. And Management

2 Mechatronics Mechatronics

3

Elective - II Theory

1.Welding Technology


Elective - II Theory

1.Welding Technology


4 Computer integrated manufacturing

practice Computer Aided Design and Manufacturing practical

5 Industrial automation Laboratory Process Automation Practical

6

Elective - II Practical

1.Industrial welding practice

2.Refrigeration and Air conditioning laboratory

Elective - II Practical

1.Industrial welding practice

2.Refrigeration and Air conditioning laboratory

7 Project work Project work

trichy - prefacesittrichy.in/admin/filefolder/applications/151.pdfsit: department of mechanical...

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