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06ME32A -MATERIAL SCIENCE & METALLURGY

MATERIAL SCIENCE & METALLURGY Sub Code: 06ME32A IA Marks: 25 Hrs/week: 05 Exam Hours: 03 Total Lecture Hrs: 62 Exam Marks: 100

PART – A UNIT 1: Structure of crystalline solids: Fundamental concepts of unit cell space lattice, Bravaias space lattices, unit cells for cubic structure & HCP, study of stacking of layers of atoms in cubic structure & HCP, calculations of radius, Coordination Number and Atomic Packing Factor for different cubic structures. Crystal imperfections-point, line, surface & volume defects. Diffusion, Diffusion Mechanism, Fick’s laws of diffusion. 7 Hours UNIT 2: Concepts of stress & strain, tensile properties, true stress & strain, Hardness, Rockwell, Vickess & Brinell Hardness testing. Plastic deformation, slip & twinning. 6 Hours UNIT 3: Fracture: types, stages in cup & cone fracture, Griffith’s criterion. Fatigue: fatigue tests, S-N curves, Factors affecting fatigue life and protection methods. Creep: The creep curves, Mechanisms of creep. Creep-resistant materials. 7 Hours UNIT 4: Solid solutions, Types, Rules of governing the formation of solids solutions. Phase diagrams: Basic terms, phase rule, cooling curves, construction of phase diagrams, interpretation of equilibriums diagrams, Types of phase diagrams. Lever rule. 6 Hours

PART – B UNIT 5: Iron carbon equilibrium Diagram, phases in the Fe–C system, Invariant reactions, critical temperatures, Microstructure of slowly cooled steels, effect of alloying elements on the Fe-C diagram, ferrite & Austenite stabilizers. The TTT diagram, drawing of TTT diagram, TTT diagram for hypo-& hypereutectoid steels, and effect of alloying elements, CCT diagram. 7 Hours UNIT 6: Annealing, and its types, normalizing, hardening, tempering, martemering, austempering, surface hardening like case hardening, carburizing, cyaniding, nitriding Induction hardening, hardenabilty, Jominy end-quench test, Age hardening of Al & Cu alloys. 6 Hours UNIT 7: Engineering Alloys: Properties, composition and uses of low carbon, mild medium & high carbon steels. Steel designation & AISI –SAE designation. Cast irons, gray CI, white CI, malleable CI, SC iron. Microstructures of cast iron. The light alloys, Al & Mg & Titanium m alloys. Copper & its alloys: brasses & bronzes. 7 Hours

UNIT 8: Corrosion & Its Prevention: Galvanic Cell, The Electrode Potentials, Polarization, Passivation, General methods of Corrosion Prevention, Cathodic Protection, Coatings, Corrosion Prevention by Alloying, Stress Corrosion Cracking.

6hours Text Books: 1. “Materials Science & Engineering- An Introduction”, William D.Callister Jr. Wiley India Pvt. Ltd. 6th Edition, 2006, New Delhi. 2. “Essentials of Materials For Science And Engineering” , Donald R. Askeland, Pradeep P.Phule Thomson-Engineering, 2006. Reference Books: 1. “Introduction to Material Science for Engineering” , 6th edition James F. Shackel ford. Pearson, Prentice Hall, New Jersy, 2006. 2. “Physical Metallurgy, Principles & Practices”, V Raghavan.PHI 2nd Edition 2006, New Delhi. 3. “Foundation of Material Science and Engineering”, Smith, 3rd Edition McGraw Hill, 1997. Scheme of Examination: One Question to be set from each chapter. Students have to answer any FIVE full questions out of EIGHT questions, choosing at least 2 questions from part A and 2 questions from part B.

LESSON PLAN

I.A. Marks: 25 Hours / Week: 05 Sub Code: 06ME32A Total Hours: 62 Subject: Material science & metallurgy Sem:III

Hour. No TOPICS TO BE COVERED

1. Structure of crystalline solids: Fundamental concepts of unit cell space lattice, 2. Bravaias space lattices, unit cells for cubic structure & HCP 3. Study of stacking of layers of atoms in cubic structure & HCP 4. Calculations of radius, Coordination Number and Atomic Packing Factor for

different cubic Structures

5. Crystal imperfections-point, line, surface & volume defects 6. Revision/quiz/surprise test. 7. Diffusion, Diffusion Mechanism 8. Fick’s laws of diffusion. 9. Concepts of stress & strain. 10. Tensile properties. 11. True stress & strain 12. Rockwell Hardness, Testing 13. Revision/quiz/surprise test. 14. Vickers & Brinell Hardness testing 15. Plastic deformation 16. Slip &twinning. 17. Fracture: types, stages in cup & cone fracture, 18. Brittle Fracture. 19. Griffith’s criterion 20. Revision/quiz/surprise test. 21. Fatigue: fatigue tests, S-N curves, 22. Factors affecting fatigue life and protection methods 23. Creep: The creep curves, Mechanisms of creep 24. Creep-resistant materials. 25. Solid solutions, Types 26. Rules of governing the formation of solids solutions 27. Revision/quiz/surprise test. 28. Phase diagrams: Basic terms, phase rule, cooling curves 29. Construction of phase diagrams, 30. Interpretation of equilibriums diagrams 31. Types of phase diagrams. Lever rule. 32. Iron carbon equilibrium Diagram,. 33. Phases in the Fe–C system, 34. Revision/quiz/surprise test.

35. Invariant reactions, critical temperatures 36. Microstructure of slowly cooled steels, effect of alloying elements on the Fe-C

diagram 37. Ferrite & Austenite stabilizers. The TTT diagram, drawing of TTT diagram 38. TTT diagram for hypo-& hypereutectoid steels 39. Effect of alloying elements, CCT diagram 40. Revision/quiz/surprise test. 41. Annealing, and its types, 42. Normalizing, hardening, tempering, martemering, austempering 43. Surface hardening like case hardening, carburizing, 44. Cyaniding, nitriding 45. Induction hardening, hardenabilty, Jominy end-quench test 46. Revision/quiz/surprise test. 47. Age hardening of Al & Cu alloys. 48. Engineering Alloys: Properties, 49. Composition and uses of low carbon, mild steels. 50. Composition and uses of medium & high carbon steels 51. Revision/quiz/surprise test. 52. Steel designation & AISI –SAE designation 53. Cast irons, gray CI, white CI, malleable CI, SC iron 54. Microstructures of cast-iron. 55. The light alloys, Al & Mg & Titanium m alloys 56. Copper & its alloys: brasses & bronzes. 57. Revision/quiz/surprise test. 58. Corrosion & Its Prevention: Galvanic Cell, 59. The Electrode Potentials, Polarization, Passivation, 60. General methods of Corrosion Prevention, Cathodic Protection, Coatings 61. Corrosion Prevention by Alloying, Stress Corrosion Cracking. 62. Revision/quiz/surprise test.

QUESTION BANK

Unit-1

1. Define the term Unit cell, Lattice Parameter, Co ordination, Atomic packing factor with respect to crystal structure

2. With neat sketch explain Edge dislocation & screw Dislocation & compare them 3. From fundamentals, calculate the atomic packing factor for a BCC crystal 4. Explain Plastic deformation of metals & the mechanisms that contributes to it 5. Calculate basic atoms (Average atoms per unit cell relationship between lattice constant (a),

Atomic radius(r), & atomic packing Factor for BCC & FCC crystal structure 6. Draw a Unit Cell HCP & Find the effective No. Of atoms in the unit cell & its atomic

packing factor 7. Define Diffusion. Name the factors, which control the coefficient of diffusion.

Unit-2

1. With neat sketches, Explain the difference between slip & Twinning 2. Sketch the Stress-Strain diagram for perfect Ductile & Brittle Materials 3. Explain the mechanism of ductile – brittle transition. 4. Write briefly about Dislocation & their role in Plastic deformation 5. Distinguish between Brinell & Rockwell hardness test 6. Distinguish between Charpy & Izod’s Impact testing

Unit-3 1. Define Fatigue. Name the factors, which control the fatigue. 2. Explain fatigue testing. 3. Define fracture and explain all types of fracture. 4. Define creep and explain three stags in creep with fatigue testing 5. Explain Factors affecting fatigue life and protection methods

Unit-4

1. Compare between Homogenous & heterogeneous Nucleation 2. Write briefly about constitutional cooling 3. Write briefly about eutectic solidification 4. Explain briefly the process of Nucleation & growth of Pure Metals 5. Define & Explain the Linear elastic properties of metals 6. From the concept of free energy and with the help of cooling curve explain how

solidification process begins in pure metals. 7. Explain briefly the solidification of Alloys 8. Describe the Structures of cast metals with neat sketches 9. Define Solid solution. Compare between Interstitial & substitutional solid solution 10. With example 11. Draw the following type of Phase Diagrams- Eutectic, Eutectoid and Peritectic. 12. At Eutectic temperature three phase, liquid of 61%B solid α of 10% B and solid βof 95%

are in equilibrium for a binary alloy of A & B. Find the ratio of α & β phases in the eutectic phase.

13. Two Metals A & B of melting point 650 °C & 450 °C respectively. When alloyed together they do not form any compound or intermediate phase but form a eutectic at 300 °C of composition of 40% A. The maximum solid solubilities of B in A & A in B occurring at 300 °C, are 10% B & 8% A respectively and they reduce to 5% B & 4% A respectively at 0 °C. Assume that the solidus, liquidus & solvus lines to be straight.

a. Draw the phase diagram of the series and mark all salient regions b. Find the temperature at which an alloy with 30% B starts & ends Solidification c. Find the relative amounts, percentage, composition, number, type & distribution of

the phases in the above alloy at 0° C 14. Write briefly about Gibb’s Phase rule & how it can be applied for unary phase diagram? 15. What criteria favoring the formation of substitution solid solutions. Explain clearly. 16. Explain Hume-Ruthary rules giving examples 17. Explain the method of construction of a phase diagram for general A-B system with the

following data i. A & B are mutually soluble in liquid state ii. A & B are partially soluble in liquid state iii. A & B form an Eutectic

18.Two metals A & B have 100% mutual solubilities in the liquid and solid states .The melting point of pure metal A & B are 800 °C& 600 °C respectively. Details of start and end of solidification of various alloys in the series are as follows:

Alloy of Composition Temp. at start of solidification

Temp at end of solidification

90 % A + 10% B 798 °C 750 °C 70% A + 30%B 785 °C 705°C 50% A+ 50% B 757°C 675°C 30% A + 70% B 715°C 645°C 10% A + 90%B 650°C 615°C

i) Draw the phase diagram of the series if there are no solid state reactions & label all

regions ii) Predict the number, type, relative amounts & concentration of phases present in an alloy

of 40% A & 60% B at 700°C & 20 °C. 19.Two metals A and B are used to form an alloy containing 75% A and 25 % B. A melts at 750°C and B at 550°C. When alloyed together A and B do not form any compound or intermediate phase. The solid solubility of metal A in B do not form any compound or intermediate phase. The solid solubility of metal A in B and B in A are negligible. The metal pair forms a eutectic at 40%A and 60%B which solidifies at 300°C. Assume the liquidus and solidus lines to be straight. Draw the phase diagram for the alloy series and find

a. The temperature at which the alloy starts and completes solidification. b. The percentage of eutectic in the alloy at room temperature.

Unit-5

1. Draw Iron-Iron Carbide phase diagram & indicate the temperature compression and phases on it. Elaborate the invariant reactions involved in it

2. Explain the equilibrium coding of a Hypo eutectoid steel from liquid-state with phase transformation that takes place

3. Compare the microstructure of steels & cast irons 4. What is TTT diagram? How is it different from phase diagram? 5. Describe the various transformed products of Austenite on cooling 6. Draw a neat Fe-Fe3C equilibrium diagram, label all the salient fields, temperatures &

compositions on it & explain the mode of solidification, solid state reaction & room temperature microstructure of the following alloy: cast iron with 3.5% carbon.

7. Explain clearly the three invariants reactions in the above question 8. Define the following with respect to steel: Pearlite, Ferrite, Ledubrite, Cemenite, Austenite 9. Draw the Fe-Fe3Cphase diagram & label all temperatures (in 0°C), compositions & phases. 10. Sketch the microstructure of eutectoid steel & S G iron & identify the phases in it 11. Differentiate between plain carbon steel & alloy steels 12. Explain general classification of steel 13. Explain briefly CCT Curve with neat diagram 14. Discuss the chemical composition, properties & engineering applications of Grey Cast Iron &

S G Iron 15. Describe how TTT diagrams are constructed How is different from phase diagram

Unit-6

1. Explain the difference between annealing & Normalizing and the need for each. 2. Write briefly about Critical cooling rate & precipitation Hardening 3. Using the relevant portion of the Fe-Fe3 equilibrium diagram & the TTT diagram with

cooling curve super imposed on it discuss the normalizing heat treatment of a 1.5%, plain carbon Steel with respect to the process, Micro structural changes & its properties. Changes due to the process.

4. Explain briefly the metmorphing process & its advantages over traditional Quench Hardening 5. Describe the various transformed products of Austenite on cooling 6. Define heat treatment of steel. What are the steps involved in it & its purpose 7. Describe the following heat treatment process of steels with regard to thermal cycle involved,

microstructure and properties aimed i) Annealing ii) hardening iii) Spheroidising 8. Distinguish between Aus tempering & Mar tempering with neat diagram. What are the

practical difficulties in these treatments? 9. Write short note on Surface Heat treatment (Case Hardening, Nitriding, Cyaniding) 10. Explain the process of flame hardening and induction hardening with neat sketch. 11. Explain Jominy end –quench test.

Unit-7

1. Mention the properties, Composition & applications of following steels i) Low-Carbon steel ii) High Carbon steel iii)18/8 Stainless steel iv) 18/4/1 HSS

2. Compare the composition, microstructure, properties & applications of Gray C I & S G Iron with neat diagram

3. Discuss the importance of aluminum alloys in engineering field & name few Alloys 4. Mention the composition & properties of Bronze, Brass & Al-Si alloy.

5. Write a short note on Age Hardening. 6. Write a note on a)light alloys like Al & Mg & Titanium alloys

b)Copper & its alloys,brasses & Bronzes Unit -8

1. What do you mean by corrosion how to prevent it . 2. Explain general methods of preventing corrosion. 3. Explain cathodic protection. 4. Explain concept of Stress corrosion cracking. 5. Explain corrosion prevention by alloying.

SHORT NOTES ON:

1. Crystal Imperfections 2. BIS designation of Steels 3. Alloy Steels 4. Ductile & Brittle Fracture 5. Lever Rule applied to Eutectoid steel 6. Microstructures of Eutectoid steel & grey cast iron 7. Difference between Annealing & Normalizing 8. Effects of Chromium & Nickel as alloy7ing elements in steel 9. Laminated Composites 10. Fick’s law of Diffusion 11. Nucleation & Growth 12. Ceramics as insulators 13. Izod impact test 14. Gibb’s phase rule 15. Age Hardening 16. Case Hardening.

06ME33-BASIC THERMODYNAMICS

BASIC THERMODYNAMICS Sub Code: 06ME33 IA Marks: 25 Hrs/week: 05 Exam Hours: 03 Total Lecture Hrs: 62 Exam Marks: 100

PART - A UNIT 1: Fundamental Concepts & Definitions: Thermodynamics; definition and scope. Microscopic and Macroscopic approaches. Engineering Thermodynamics Definition, some practical applications of engineering thermodynamic. System (closed system) and Control Volume (open system); Characteristics of system boundary and control surface, examples. Thermodynamic properties; definition and units, intensive and extensive properties. Thermodynamic state, state point, state diagram, path and process, quasi-static process, cyclic and non-cyclic processes; Thermodynamic equilibrium; definition, mechanical equilibrium; diathermic wall, thermal equilibrium, chemical equilibrium- Zeroth law of thermodynamics, Temperature; concepts, scales, measurement. Internal fixed points. 7 Hours UNIT 2: Work & Heat: Mechanics, definition of work and its limitations. Thermodynamic definition of work; examples, sign convention. Displacement work; at part of a system boundary, at whole of a system boundary, expressions for displacement work in various processes through PV diagrams. Shaft work; Electrical work. Other types of work. Heat; definition, units and sign convention, what heat is not. 6 Hours UNIT 3: First Law of Thermodynamics: Joule’s experiments, equivalence of heat and work. Statement of the First law of thermodynamics, extension of the First law to non -cyclic processes, energy, energy as a property, modes of energy, pure substance; definition, two-property rule, Specific heat at constant volume, enthalpy, specific heat at constant pressure. Extension of the First law to control volume; steady state-steady flow energy equation, important applications, analysis of unsteady processes such as filling and evacuation of vessels with and without heat transfer. 6 Hours UNIT 4: Second Law of Thermodynamics: Devices converting heat to work; (a) in a thermodynamic cycle, (b) in a mechanical cycle. Thermal reservoir. Direct heat engine; schematic representation and efficiency. Devices converting work to heat in a thermodynamic cycle; reversed heat engine, schematic representation, coefficients of performance. Kelvin -Planck statement of the Second law of Thermodynamic; PMM I and PMM1I. Clasiu's statement .of Second law of Thermodynamic; Equivalence of the two statements; Reversible and irreversible processes; factors that make a process .irreversible, reversible heat engines, Carnot cycle, Carnot principles. Thermodynamic temperature scale. 7 Hours

PART – B UNIT 5: Entropy : Clasiu’s inequality; statement, proof, application to a reversible cycle. QR/T as independent of the path. Entropy; definition, a property, principle of increase of entropy, entropy as a quantitative test for irreversibility, calculation of entropy using Tds relations, entropy as a coordinate. Available and unavailable energy. 7 Hours

UNIT 6: Availability and Irreversibility: - Maximum Work, maximum useful work for a system and a control volume, availability of a system and a steadily flowing stream, irreversibility. Second law efficiency. 6 Hours UNIT 7: Pure substances: P-T and P-V diagrams, triple point and critical points. Sub- cooled liquid, saturated liquid, mixture of saturated liquid and vapor, saturated vapor and superheated vapour states of a pure substance with water as example. Enthalpy of change of phase (Latent heat). Dryness factor (quality), T-S and h-s diagrams, representation of various processes on these diagrams. Steam tables and its use. Throttling calorimeter, separating and throttling calorimeter.

6 Hours UNIT 8: Real and ideal gases: Introduction; Vander Waal's Equation Van der Waal's constants in terms of critical properties, law of corresponding states, compressibility factor; compressibility)" chart. Ideal gas; equation of state, internal energy and enthalpy as functions of temperature only, universal and particular gas constants, specific heats, perfect and semi-perfect gases. Evaluation of heat, work, change in internal energy, enthalpy and entropy in various quasi-static processes. Ideal gas mixture; Dalton's law of additive pressures, Amagat's law of additive volumes, evaluation of properties. Analysis of various processes. 7 Hours Text Books: 1. “Basic and Applied Thermodynamics” by P .K. Nag, Tata McGraw Hill, 3rd Edi. 2002 2. “Thermodynamics an engineering approach”, by Yunus A. Cenegal and Michael A. Boles. Tata McGraw hill Pub. 2002 Reference Books: 1. Engineering Thermodynamics. By Rajput, Laxmi Publications pvt ltd., 3rd Edi. 2007. 2. Engineering Thermodynamics by J.B. Jones and G.A.Hawkins, John Wiley and Sons. 3. Thermo Dynamics by S.C.Gupta, Pearson Edu. Pvt. Ltd., 1st Ed. 2005. Scheme of Examination: One Question to be set from each chapter. Students have to answer any FIVE full questions out of EIGHT questions, choosing at least 2 questions from part A and 2 questions from part B.

LESSON PLAN I.A. Marks: 25 Hours / Week: 04 Sub Code: 06ME33 Total Hours: 62 Subject: Basic Thermodynamics Sem:III

Hrs. No Topics to be covered

1. Thermodynamics, definition and scope. Microscopic and macroscopic approaches.

2. Engineering thermodynamics definition, some particle application of engineering thermodynamics.

3. System and control volume characteristics of system boundary and control surface examples; thermodynamics property definition and units. Intensive and extensive properties.

4. Thermodynamics state, state point, state diagram, path and process, quasi-static process, cyclic and non-cyclic processes.

5. Thermodynamic equilibrium; definition, mechanical equilibrium, diathermic wall thermal equilibrium, chemical equilibrium

6. Revision/quiz/surprise test. 7. Zeroth law of thermodynamics temperature concepts scales measurement

internal fixed points. 8. Numericals 9. Mechanics definition of work and its limitations, thermodynamics definition of

work; 10. Examples of sign convention 11. Displacement work at part of a system boundary at whole of a system boundary 12. Revision/quiz/surprise test. 13. Expressions for displacement work in various processes through p-v diagrams. 14. Shaft work electrical works other types of work heat definition units and sign

convention, what heat is not. 15. Numericals 16. Numericals 17. Joule’s experiments equivalence of heat and work statement of the first law of

thermodynamics 18. Revision/quiz/surprise test. 19. Extension of the first law to non-cyclic process energy energy as a property

modes of energy pure substance. 20. Revision/quiz/surprise test. 21. Definition two property rules specific heat and constant volume enthalpy 22. Specific heat constant pressure extension of first law to control volume steady

state flow energy equation 23. Revision/quiz/surprise test. 24. Important applications analysis and unsteady process such a filling and

evacuation of vessels with and without heat transfer 25. Numericals 26. Numericals

27. Second law of thermodynamics devices converting heat into work (a) Thermodynamics cycle (b) Mechanical cycle.

28. Thermal reservoir, direct heat engine, schematic representation and efficiency. Devices converting work to heat in a thermodynamics cycle.

29. Revision/quiz/surprise test. 30. Reversed heat engine, schematic representation, COP. 31. Kelvin Planck statement of second law of thermodynamics PMM-I and PMM-

II. 32. Clasius statement of second law of thermodynamics equivalence of two

statement reversible and irreversible process 33. Factors that make process a to irreversible. Reversible heat engine, carnot cycle,

carnot principles, thermodynamics temperature cycle. 34. Numericals 35. Revision/quiz/surprise test. 36. Numericals 37. Entropy Clasius inequality statement proof 38. Application to a reversible cycle as independent of path 39. Entropy definition a property, principle of increases of entropy 40. Revision/quiz/surprise test. 41. Entropy as a quantitative test for irreversibility, 42. Calculation of entropy using Tds relations 43. Entropy as co ordinate available and unavailable energy. 44. Maximum work, maximum useful work for a system and a control volume 45. Availability of a system and a steadily flowing stream 46. Revision/quiz/surprise test. 47. Irreversibility, second law efficiency 48. Pure substance P-T and P-V diagrams, triple point and critical points 49. Sub cooled liquid, saturated vapor, and superheated vapor, 50. Enthalpy of Change of phase, dryness factors, 51. Revision/quiz/surprise test. 52. States of pure substance with water as example... 53. TS and HS diagrams, representation of various process on this diagrams. Steam

tables and its use 54. Throttling calorimeter, Separating and throttling calorimeter 55. Introduction of availability and irreversibility 56. Real & ideal gases – introduction, Vander waal’s equation Vander waal’s constant

in terms of critical properties. 57. Law of corresponding states, compressibility chart. Ideal gas equation of state,

internal energy and enthalpy as functions of temperature only. 58. Numericals 59. Universal and particular gas constant, specific heat, perfect and semi-perfect gases.60. Evaluation of heat, work, change in internal energy, enthalpy and entropy in

various quasi-static processes. 61. Ideal gas mixture, Dalton’s law, Amagat’s law of additive volume. 62. Evaluation of Properties, Analysis of Various processes.

QUESTION BANK

CHAPTER 1: FUNDAMENTAL CONCEPTS

1. Define the following terms with reference to thermodynamics a) System b) property c) process d) cycle e) thermodynamic equilibrium 2. Define Zeroth law of thermodynamics and Prove that T(K)=T(C) +273 3. Distinguish between i) open and closed system ii) Intensive and Extensive Properties.

iii) Mechanical and thermal equilibrium. 4. Explain thermodynamic system. Whether the following systems are open (or) closed i) a scooter engine ii) Centrifugal water pump iii) An electric fan iv) A

motor car battery 5. Fahrenheit and centigrade thermometers are both immersed in a fluid. Fahrenheit reading is

numerically twice that of the centigrade reading. What is temperature of The Fluid expressed as R and K

6. A temperature T on a thermometric scale is defined in terms of property P by Relation T= a log e p + b Where A and B are constants. The temperature at ice point and steam points are 00c and 100 0c respectively. An instrument gives values of P as1.86 and 6.81 at ice and steam point respectively. Evaluate temperature Corresponding to a reading of p =2.5.

7. The normal body temperature is 96.6 0F. What is the temperature in 0c, K and R? CHAPTER 2: WORK AND HEAT

1. Define Work and Heat from the thermodynamic point of view. 2. Define point function and path function. Prove that heat is a path function. 3. Differentiate between Work and Heat. 4. What is meant by displacement work? Explain the same with reference to different

Quasistatic processes. 5. A home cooler has fan of 170 watts rating .If the cooler operates for 10 hrs. Find the energy

consumed by the cooler. 6. A battery is charged with a battery charger. The charger operates 1 hour at 15v and a current of 30 Amps. Ccalculate the work done on the battery. 7. Aspherical balloon has a diameter of 20cm and contains air at 1.5 bars. The diameter of the

balloon increases to 30cm in a certain process during which pressure is proportional to the diameter. Calculate the work done by the air inside the balloon during the process.

8. A gas in the cylinder and piston arrangement comprises the system. It expands from 1m3 to 2m3 while receiving 200kJ of work from a paddle wheel. The pressure on the gas remains constant at 5 bars. Determine the network done by the system

CHAPTER 3: FIRST LAW OF THERMODYNAMICS

1. Derive an expression for displacement work for polytropic process 2. Write a brief note on perpetual motion machines. 3. Define internal energy and prove that it is a property

4. State first law of thermodynamics for a closed system undergoing a cyclic process. Show that internal energy is property of the system.

5. Explain the word “Enthalpy” of a system and the term pV with reference to an open system. 6. A cylinder containing the compressor the system cycle is completed as follows. 1) 8200N-m

of work is done by the piston on the air during compression stroke and 45 kJ of heat are rejected to the surroundings.2) During expansion stroke 1000N-m of work is done by the air on the piston. Calculate the quantity of heat added to the system

7. One kg of air having an initial volume of 0.3m3 is heated at constant pressure of 3.2 bar until the volume is doubled. Calculate (a) initial and final temperature of air, (b) work done (c) Heat added Take Cp = 1.003kJ/kg K, R = 0.2927 kJ/kg K

8. A tank contains 12 kg of water used for determining mechanical – thermal energy equalities. The total work input is 40Nm. assuming the system is adiabatic find the change in specific and total internal energy. If a heat loss of 0.1J/kg is noted, what is the internal energy change?

9. An engine cylinder of diameter 22.5 cm has a stroke length of 37.5 cm. The swept volume is 4 times the clearance volume. The pressure of gases at the beginning of expansion stroke is 1569 kPa. Find the work done during expansion stroke assuming the process as reversible adiabatic Take, γ = 1.4

10. A cylinder contains 1 kg of certain fluid at an initial pressure of 20 bar. The fluid is allowed to expand reversible behind a piston according to law pV2 = constant until the column is doubled. The fluid is then cooled reversibly at constant pressure until the piston regains its original position. Heat is then supplied reversibly with the piston firmly licked in position initial the pressure raises to the original value of 200 bar. Calculate the net work done by the fluid for an initial volume of 0.5 m3

11. Derive steady flow energy equation stating the assumption made 12. Apply the steady flow energy equation for the following system a) Gas turbine b) Nozzle c)

Condenser d) Throttle valve 13. A steam turbine operating under steady flow conditions receives 4500kg of steam per our.

The steam enters the turbine at a velocity of 42 m/s at the elevation of 4m and a specific enthalpy of 2800kJ/kg. It leaves the turbine at a velocity of 9.4m/s at an elevation of 1m and specific enthalpy of 2262kJ/kg. The heat losses from the turbine to the surroundings amounts to 16780kJ/hr. determine the power output of the machine.

14. A centrifugal pump delivers 60kg of water per second. The inlet and outlet pressure are 10 kPa and 400 kPa respectively. The suction is 2 m below and delivery is 8 m about the centerline of the pump. The suction and delivery pipe diameter are 20cm and 10cm respectively. Determine the capacity of the electric motor to run the pump.

CHAPTER 4: SECOND LAW OF THERMODYNAMICS

1. Write the Kelvin- Plancks and Clausius statement of second law of thermodynamics and prove that they are equivalent.

2. Define irreversibility and mention at least 3 factor which render a process irreversible. 3. state carnot’s theorem 4. Show that C O P of the heat pump minus C O P of a refrigerator is unity. 5. Define the term source, sink, and heat reservoir 6. Define heat engine and differentiate between heat engine and a reversed heat engine.

7. There are 3 reservoirs at temperature 8270C, 1270C and 270C parallel. A reversible heat engine operates between 8270C &1270C and a reversible refrigerator operates between 27 and 1270C respectively. 502kJ of heat are extracted for the reservoir at 8270C by the heat engine and the refrigerator from the reservoir at 270C abstracts 251 kJ of heat. Find the net amount of heat delivered to the reservoir at 1270C. Can the heat engine drive the refrigerator and still delivers some net amount of work? IF so how much

8. A heat engine working on Carnot cycle converts one-fifth of the heat input into work. When the temperature of the sink is reduced by 800C the efficiency gets doubled. Calculate for the temperature of source and sink.

9. The working substance in a carnot engine is 0.05kg of air. The maximum cycle temperature is 940 K, and the maximum pressure is 8.4 x 103 kPa. The heat added per cycle is 4.2 kg. Determine the maximum cylinder volume if the minimum temperature during the cycle is 300k

10. A reversible engine operates between 3 heat reservoirs 1000K, 800K & 600K and rejects heat to a reservoir at 300K, the engine develops 10kW and rejects 412kJ/min. If heat supplied by the reservoir at 1000K is 60% of heat supplied by the reservoir at 600 K, find quantity of heat supplied by each reservoir

11. An inverter claims to have developed a refrigerator, which maintains the refrigerated space at –100 c, and it has a cop of 8.5. How would you evaluate his claim as patent officer?

12. A reversible engine works between temperature limits of 2600 C and 600 C., which is preferable? Raising the source temperature to 3000 C or lowering the sink temperature to 300 C.

CHAPTER 5: ENTROPY AND

1 Define entropy and show that entropy is a property of a system. 2. Explain the principle of increase of entropy. 3. Derive an expression for entropy 4. Explain availability of a system with heat transfer. 5. What do you mean by available and non –available energy. 6. Derive an expression for decrease in available energy and unavailable energy. 7. Write short note on Helmholtz and Gibb function. 8. 0.5 kg of air initially at 250C is heated reversibly at constant volume until pressure is doubled,

for the total path determine the work transfer, the heat transfer and the change in entropy. 9. A 30 kg of steel ball at 4270 C is dropped in 150kg oil at 270 C, the specific heat of steel and

2.5kj/kg k respectively. Estimate the entropy change of steel, oil and that of system Containing oil and steel.

10. One kg of air at 1bar pressure and 150C is heated in a cylinder under constant pressure Conditions to 150 0C. Find the volume, the work done and the changes in internal energy, enthalpy and entropy.

11. 10gms of water at 200 C is converted into ice at –100c at constant pressure, assuming the specific heat of liquid water to remain constant at 4.2kj /kg k and that of ice to be half of this value and taking the latent heat of fusion of ice at 00 c to 335j/g, calculate the total entropy.

CHAPTER –6: AVAILABILITY AND IRREVERSIBILITY

1. A System receives 10000KJ of heat at 500 K from a source at 1000K.

the temperature of the surroundings is 300 K .Assume that the temperature

of the system and source remains constant during heat transfer,

Find :

i. The entropy production due to above mentioned heat transfer,

ii. Decrease in available energy

2. Determine the availability per unit mass for combustion products (say air) in an engine Cylinder at 11870 C and 15Mpa. Assume the environmental at 0.101Mpa and T0 =250 C.

3. Making use of a availability equation, determine the maximum thermal efficiency of a heat

engine operating between a high reservoir at Th and a low –temperature heat reservoir at TL.40kg of water at 1400 C mix 50kg of water at 550 C at constant pressure. If the Surroundings were at temperature 270 C, calculate the decrease in available energy.

4. a liquid of specific heat 6.3 KJ/Kg K is heated at approximately constant pressure from150 C.

to 700 C. by passing it through tubes which are immersed in furnace. the furnace temperature is constant at 14000 C. Calculate the effectiveness of the heating process when the atmospheric temperature is 100 C.

5. Differentiate between availability function and Gibbs energy function

6. Derive a general expression for irreversibility in Non flow process and Steady flow process

CHAPTER –7: PURE SUBSTANCES

1. Define the following terms with reference to pure substances i) Heat of fusion ii) Sensible heat iii) Wet steam iv) Triple point v) Enthalpy vi) Critical point vii) Dryness fraction viii) Sensible heat

2. Explain with neat sketch the method of estimating quality of steam by throttling calorimeter. 3. Explain with neat sketch the method of determining the quality of steam by combined

separating and throttling calorimeter. 4. Draw a P-T diagram for pure substance and indicate all the necessary points on it. 5. A pressure cooker contains 1.5 kg of saturated steam at 5 bar. Find the quantity of heat which

must be rejected so as to reduce quality to 60 % dry. Determine the pressure and temperature at the new state.

6. Find the enthalpy, specific volume and internal energy if the pressure of steam is 50 bar and temperature is 443 0C.

7. 0.5 Kg of steam has a dryness fraction of 0.8 initially. This steam is heated at constant pressure till it reaches 8 bar till the volume is double. Determine the final temp

8. Two boilers one with super heater and without super heater are delivering equal quantities of steam into a common main. The pressure in the boiler is 20bar. The temperature of steam from a boiler with a super heater is 3500C and temperature of the steam in the main is 2500C determine the quality of the steam supplied by other boiler take Cps=2.25KJ/Kg.

9. Steam from a boiler is delivered at 15 bar absolute and dryness fraction of 0.85 into a steam superheater where an additional heat is added at constant pressure. Steam temperature now increases to 573 K. Determine amount of heat added and change in internal energy for unit mass of steam

10. A piston cylinder assembly had steam at 100kPa with quality 20 percent wet. Temperature of steam rises to 3000C due to energy transfer. Determine the work done and heat supplied.

11. A pressure cooker contains 4 kg of steam at 6 bar and 0.96 dryness. Fine the quantity of heat which must be rejected so as the quality of steam becomes 0.7 dry

CHAPTER –8: REAL & IDEAL GASES.

1. Write short notes on : i) Vander Waals equation of state. ii) Law of corresponding states.

2. Show that entropy of an ideal gas is given by equation S2 – S1 = Cp ln V2 / V1 +CV ln P2 / P1 starting from the general property relations T.ds = du + pdv and T.ds = dh – vdp.

3. Show that for an ideal gas reversible adiabatic process is represented by pvγ = constant.

Where p[ is the pressure v is the volume and γ is ratio of specific heats of gas. 4. Using one of the T.ds relations, show that for restricted reversible polytropic n – γ T2

process the change in entropy is given by ∆S = Cv loge T1 . n – 1 5. A quantity of air at a pressure of 100 kpa, 270C occupying a volume of 0.5 m3 is

compressed to a pressure of 500 kpa and volume of 0.12 m3 according to the law pvn = constant. Find: 1) The value of index ‘n’ 2) The mass of air 3) Work transfer 4) Heat transferred during the process and 5) Change in entropy.

6. Derive expressions for gas constant and molecular weight of mixture of the three ideal gases A,B and C .

7. Explain the following: i) Compressibility factor ii) Reduced properties. iii) Law of corresponding states iv) Generalized compressibility chart.

8. Determine the specific volume of nitrogen gas at 10 Mpa and 150 K based on i)The ideal gas ii) Compressibility chart and iii) Vander waals equation.

9. Derive Vander Waals constants in terms of critical properties. 10. Define compressibility factor and explain its significance. 11. Distinguish between ideal gas and real gas. 12. Show that for an ideal gas undergoing reversible adiabatic process, the law for the process is

given by TVγ-1 = constant. 13. A mass of 0.25 kg of an ideal gas has a pressure of 300 kPa, a temperature of 800C and a

volume of 0.07 m3. The gas undergoes an irreversible adiabatic process to a final pressure of 300 kPa and final volume of 0.10 m3, during which the work done on the gas is 25 kJ. Evaluate the Cp and Cv of the gas and increase in endropy of gas.

06ME34 – MECHANICS OF MATERIALS

MECHANICS OF MATERIALS

Sub Code: 06ME34 IA Marks: 25 Hours / Week: 05 Exam Hours: 03 Total Hours: 52 Exam Marks: 100

PART A UNIT I. SIMPLE STRESS AND STRAIN: Introduction, stress, strain, mechanical properties of materials, Linear elasticity, Hooke’s law and poisson’s ratio, stress- strain relation – behavior in tension for mild steel and non ferrous metals. Extension/shortening of a bar, bars with cross sections varying in steps, bars with continuously varying cross sections (circular and rectangular), Elongation due to self-weight, Principle of super position. 07 hrs UNIT II STRESS IN COMPOSITE SECTION Volumetric strain, expression for volumetric strain, elastic constants, simple shear stress, shear strain, temperature stress (including compound bars). 06 hrs

UNIT III. COMPOUND STRESSES Introduction, plane stress, stress on inclined sections, principal stress and max shear stress, Mohr’s for plane stress. 07 hrs

UNIT IV. THICK AND THIN CYLINDERS: Stress in thin cylinders, change in dimensions of cylinders (diameter, length and volume), thick cylinders subjected to internal and external pressures (Lame’s equation), (Compound cylinders are not included). 06 hrs PART - B UNIT V. BENDING MOMENT AND SHEAR FORCE IN BEAMS Introduction, types of beams, load and reactions, shear force and bending moment, rate of loading, sign conventions, relationship between shear force and bending moments, shear force and bending moments, shear force and bending moment diagrams for different beams subjected to concentrated loads, uniform distributed load (udl) and couple for different types of beams,

06 hrs UNIT VI: BENDING AND SHEAR STRESSES IN BEAMS: Introduction, theory of simple Bending, assumptions in simple bending, relationship between bending Stresses and radius of curvature, relationship between bending moment and Radius of curvature, moment carrying capacity of a section, shearing stresses In beams, shear stress across rectangular, circular, symmetrical I and T Sections (composite / fletched beams not included). 7 Hrs

UNIT VII:

DEFLECTION OF BEAMS

Introduction, differential equation for deflection, Equations for deflections, slope and moments, double integration method for Cantilever and simply supported beams for point load, UDL, UVL and Couple, Macaulay’s method. 06 hrs UNIT VIII: Torsion of circular shafts and Elastic stability of columns : Introduction,pure torsion, assumptions, derivation of torsional equations, polar modulus, torsional rigidity / stiffness of shafts, power transmitted by solid and hollow circular shafts. Introduction to columns, Euler’s theory for axially loaded elastic long columns, derivation of Euler’s load for various end conditions, limitations of Euler’s theory, Rankine’s formula.

TEXT BOOKS: 1. “Mechanics of Materials” by R.C.Hibbeler, Printice Hall, Pearson Edu., 2005 2. “Mechanics of materials”, James.M.Gere, Thomson, Fifth edition 2004. 3. “Mechanics of materials”, S.I. Units, Ferdinand Beer & Russell Johnstan, TATA Mac GrawHill-2003.. REFERENCE BOOKS: 1. “Strength of Materials”, S.S.Bhavikatti, Vikas publications House – Pvt. Ltd., 2nd Ed., 2006. 2. “Mechanics of materials” K.V. Rao, G.C. Raju, First Edition,2007 3. “Engineering Mechanics of Solids” Egor.P. Popov, Pearson Edu. India, 2nd, Edition, 1998. 4. “Mechanics of Solids”, Mubeen, Pearson Edu. India, 2002 5. “Strength of Materials”, W.A. Nash, Sehaum’s Outline Series, Fourth Edition-2007.

LESSON PLAN

Sub Code: 06ME34 I.A. Marks: 25 Hours / Week: 05 Total Hours: 52 Subject: Mechanics Of Materials Sem:III

No. of hours

Topic to be covered

1. Introduction, stress, strain, mechanical properties of materials.

2. Hook's Law, definition of poisson's ratio and typical Stress - Strain diagram for steel and non-ferrous materials subjected to Static Tension Test.

3. Determination of axial deformation of prismatic bars subjected to Static axial load and solving of some numerical problems.

4. Solving some numerical problems on deformation of prismatic bars. Explaining the principal of Superposition for evaluation of total deformation of bars with stepped variation in cross section along its length.

5. Solving some numerical problems on evaluation deformations of bars with stepped variation in cross section by principal of super position concept.

6. Revision/quiz/surprise test.

7. Evaluation of expression for deformation of tapering bars of circular and rectangular cross sections.

8. Solving some numerical problems on deformation of tapering bars with circular and rectangular cross section.

9. Determination of deformation due to self- weight of the bar and solving some numerical problems.

10. Concept of composite bar action and evaluation stresses and deformation of composite bar subjected to axial force.

11. Solving some numerical problems on composite bar action. Explanation of Elastic constants and deriving the relation ship between various elastic constants.

12. Revision/quiz/surprise test.

13. Solving some numerical problems on elastic constants. 14. Concept of Thermal Stresses and its evaluation simple bars and compound bar. 15. Solving some numerical problems on evaluation of Thermal Stresses in simple bars.

16. Introduction to compound Stress and its importance in the design of Structural components.

17. Determination of Stress components on inclined planes for uni-axial Stress System. 18. Revision/quiz/surprise test.

19. Determination of Stress components on inclined planes for general two-dimensional Stress System.

20. Determination of principal planes and principal Stresses.

21. Introduction to thin and thick cylinders, stresses iron the walls of thin cylinder, Assumptions made in the analysis of thin cylinders

22. Relationship between hoop stress and longitudinal stress 23. Strains in thin cylindrical shells, problems on above 24. Revision/quiz/surprise test.

25. Derivation of Lame's equation, assumptions made in analysis of theory on thick cylinders

26. Problems concerned to thick cylinders 27. Problems concerned to thick cylinders

28. Determination of Bending moment and Shear force with salient values for over hanging beams.

29. Introduction to Bending stresses and Shear stress in Bending members . Assumption made in deriving pure Bending of Bernoulli's equation .

30. Revision/quiz/surprise test.

31. Derivation of Bernoulli's equation. And definition of modulus of rupture and section modulus.

32. Definition of flexural rigidity , derivation of expression form Shear stress in Beam's

33. Solving some numerical examples for determining bending stress and Shear stress for rectangular section Beams.

34. Solving some numerical examples for determining bending stress and Shear stress for I and T section Beams.

35. Introduction to deflection of Beams assumptions made in deriving diffraction equation for the Deflected curve Beam.

36. Revision/quiz/surprise test.

37. Derivation of second order deflection equation. sign convention for various loading cases

38. Use of Maccualay's method for evaluating the deflection of Beams.

39. Solving some numerical examples for evaluating the deflection of Beams by Maccualay's method.

40. Solving some numerical examples for evaluating the deflection of Beams by Maccualay's method.

41. Solving some numerical examples for evaluating the deflection of Beams by Maccualay's method.

42. Revision/quiz/surprise test. 43. Introduction to torsion, 44. Pure torsion, torsion equation of circular shaft 45. Strength and stiffness 46. Torsional rigidity and polar modulus 47. Power transmitted by a shift for solid and hollow circular sections. 48. Revision/quiz/surprise test. 49. Problems on above concepts 50. Problems on above concepts 51. Problems on above concepts

52. Introduction to column behaviour, differences between bulking and bending, and end conditions of column

53. Revision/quiz/surprise test.

54. Classification of columns, Assumptions made in Euler's theory, Euler's formula derivation for both end hinged condition.

55. Euler's formula derivation for both ends fixed, one end fixed other end hinged

56. Euler's formula derivation for one end fixed and other end free, Limitations of Euler's theory, Rankine's formula

57. Problems on above 58. Revision/quiz/surprise test.

59. Euler's formula derivation for one end fixed and other end free, Limitations of Euler's theory,

60. Rankine's formula 61. Problems on above 62. Problems on above

QUESTION BANK

1. Define Stress, Strain and State Hooke's Law. 2. Explain with an example the difference between lateral strain and longitudinal strain and

hence define Poisson's ratio. 3. A bar of diameter 20mm and length 100mm extends by 0.2 mm. If E of the materials of the

rod is 2x 105 N/mm2, what load and type of load applied to the rod? If an extension of 20% greater is required for the same load applied above, how the diameter of the bar need to be reduced.

4. What is proof stress? Explain the concept of proof stress with the help of a stress strain diagram.

5. Derive an expression for the elongation of a vertically Supported bar due to its self-weight. 6. Find the total elongation of a bar shown in Fig 1. Take E= 1.05 X 105 N/mm2.

7. Define Principal Plane and Principal Stress." All Principal Stresses are normal Stress, but all

normal Stresses are not Principle Stresses" State Whether this Statement is true or false Justify your answer.

8. Explain the step by step procedure for drawing Mohr's Circle diagram for an element under combined stresses as shown in fig 2, to find the principal stresses and principal planes.

9. An element is subjected to stresses as shown in fig. 3 Determine (i) Principal Stresses and their directions analytically. (ii) Find the normal and tangential Stress on the plane BC graphically.

10. What is abeam? How are they classified? What are the different types of loads a beam can carry or which can apply on it.

11. Enumerate the assumptions made in theory of pure bending. 12. Define Section modules of rupture. Derive an expression for the section of a hollow

rectangular Cross section as shown in Fig 5

13. A cast Iron test beam 25mm X 25mm Cross Section and 1 m long, supported at its ends fails

when a central load of 800 N is applied on it. What UDL will break a Cantilever of the same materials 50 mm Wide and 100mm deep and 2m long?

14. What is flexural rigidity? What are the different methods of finding the slope and deflection of beams? Find expressions for slope and deflection for a Cantilever beam with a point load P at its free end as shown in fig. 6, by double integral method.

15. A Cantilever beam of length 3m, Carries an UDL of 3000 N/m for a length of 1.5 m from its

fixed end and a point load of 1500 N at its free end. If the Cross Section of the beam is a rectangle of 150mm Wide and 300mm deep, find the deflection of the beam at its free end. Take E=1.05 X105 N/mm2.

16. Define torsional rigidity and polar modulus. 17. What are the assumptions made in the theory of pure tension? 18. Explain each term in the relation.

T/Ip = C/r = C@/1 with units.

19. A hollow shaft has an outside diameter 'd' and inside diameter half of it. Calculate the minimum Value of d, if it is to transmit 400kw at 100rpm with a working stress of 40 N/mm2. Determine the twist in a length of 15 times the external diameter, take C=1 X105 N/mm2.

20. What is meant by thin and thick Cylinders? Derive an expression for longitudinal and loop stress for a thin Cylinder of diameter 'd' thickness 't' under the influence of an internal pressure p.

21. A pipe of 500mm internal diameter and 75mm thick is filled with a fluid at a pressure of 6 N/mm2. Find the maximum and minimum hoop stress across the Cross Section of the Cylinder, Also Sketch the radial pressure and hoop stress distribution across its thickness.

22. Derive an expression to show the relationship between Young's modulus. Bulk modulus. Rigidity modulus and Poisson's ratio.

23. A steel rod is of 18m long at a temperature of 25% c. Find the free expansion of the length when the temperature is raised to 85% c. Also find the temperature stress produced.

(i) When the expansion is fully prevented. (ii) When the rod is permitted to expand by 4.5mm. Take a = 12x 106

per 0C, E = 200 KN/mm2. 24. Define Neutral axis and moment of resistance. Also mention the assumptions made in the

theory of pure bending. 25. A rolled steel joist of I section has the following dimensions:

Flange 250mm wide and 25mm thick. Web of 15mm thickness and has an overall depth of 650mm.

If this beam carries a UDL of 50 KN/m on a span of 6m. Calculate the maximum bending stress produced.

26. Derive an expression for the slope and deflection at the free end of a cantilever loaded by a UDL throughout its span.

27. A steel shaft transmits 125KW at 175 rpm. The diameter of shaft is 100mm. determine the torque on the shaft and the maximum shearing stress indeed. Also calculate the twist of the shaft in a length of 6m. Take C= 8.5 X 104 N/mm2.

28. A load of 270 KN is acting on a short RCC column of size 200mm X 200mm. The column is reinforced with 10 bars of 12mm diameter. Determine the stresses in steel and concrete if modulus of elasticity of steel is 16.5 times of that of concrete.

29. Draw the Mohr's circle for two unequal like principal stresses acting on a body. Get the expressions for normal and tangential stresses.

30. Differential between thin and thick cylinders. Also explain hoop stress and longitudinal stress in connection with thin cylinders. Draw neat sketches. Write the expression.

31. Derive an expression for Euler's formula for a column when one end is fixed and the other end is hinged.

32. Find the shortest length L for a pin ended steel column having a cross section of 70mm X 110mm for which Euler's formula applies. Take E = 2.1 X 105 N/mm2 and critical proportional limit is 250 N/mm2.

33. Derive an expression for the theory of pure torsion. 34. A steel bar of 2mm diameter is subjected to a tensile test. Determine stress. Strain, E %

Elongation from the following data. i. Gauge length 200mm ii. Extension at a load of 100KN = 0.140mm iii. Total Extension = 50mm.

Also determine the percentage decrease in area if the diameter of rod at failure is 16mm. Further determine the breaking load if ultimate stress of bar material is 600N/mm2.

35. Two vertical rods one of steel and the other of copper are each rigidly fixed at top and are 500mm apart. Diameter and length of each rod are 20mm and 3.5m respectively. A cross bar is fixed at the lower ends of the rods.

i. Determine the location of a 5000N load to be placed on the cross bar so than the cross bar remains horizontal. Calculate the corresponding stresses in both the rods.

06ME35-MANUFACTURING PROCESS-I

MANUFACTURING PROCESS – I

Sub Code: 06ME35 IA Marks: 25 Hrs/week: 05 Exam Hours: 03 Total Lecture Hrs: 62 Exam Marks: 100

PART – A

CASTING PROCESS UNIT 1: Introduction: Concept of Manufacturing process, its importance. Classification of Manufacturing processes. Introduction to Casting process & steps involved. Varieties of components produced by casting process. Advantages & Limitations of casting process. Patterns: Definition, functions, Materials used for pattern, various pattern allowances and their importance. Classification of patterns. Binder: Definition, Types of binder used in moulding sand. Additives: Need, Types of additives used. 6 Hours UNIT 2: Sand Moulding : Types of base sand, requirement of base sand. Types of sand moulds. Sand moulds: Moulding sand mixture ingredients (base sand, binder & additives) for different sand mixtures. Method used for sand moulding. Cores: Definition, Need, and Types. Method of making cores, Binders used. Concept of Gating & Risering. Principle involved. And types. Fettling and cleaning of castings. Basic steps involved. Casting defects - causes, features and remedies. Moulding machines: Jolt type; squeeze type, Jolt & Squeeze type and Sand slinger. 7 Hours UNIT 3: Special moulding Process :Study of important moulding processes Green sand, Core sand, Dry sand, Sweep mould, CO2 mould, Shell mould, Investment mould. Metal moulds : Gravity die-casting, Pressure die casting, centrifugal casting, Squeeze Casting, Slush casting, Thixocasting and continuous casting processes. 7 Hours UNIT 4: Melting Furnaces: Classification of furnaces. Constructional features & working principle of Gas fired pit furnace, Resistance furnace, Coreless Induction furnace, Electric Arc Furnace, Cupola furnace. 6 Hours

PART – B WELDING UNIT 5: Welding process: Definition, Principles, Classification, Application, Advantages & limitations of welding. Arc Welding: Principle, Metal Arc welding (MAW) , Flux Shielded Metal Arc Welding (FSMAW) , Inert Gas Welding (TIG & MIG) Submerged Arc Welding (SAW) and Atomic Hydrogen Welding processes. (AHW) Gas Welding: Principle, Oxy – Acetylene welding, Reaction in Gas welding, Flame characteristics, Gas torch construction & working. Forward and backward welding.

UNIT 6: Special type of welding: Resistance welding - principles, Seam welding, Butt welding, Spot welding and projection welding. Friction welding, Explosive welding, Thermit welding, Laser welding and Electron beam welding. 7 Hours UNIT 7: Metallurgical aspect in welding : Structure of welds, Formation of different zones during welding. Heat affected zone (HAZ). Parameters affecting HAZ . Effect of carbon content on structure and properties of steel. Shrinkage in welds & Residual stresses. Concept of electrodes, Filler rod and fluxes. Welding defects – Detection causes & remedy. 6 Hours UNIT 8: Principles of soldering & brazing: Parameters involved & Mechanism. Different Types of Soldering & Brazing Methods. Inspection Methods – Methods used for Inspection of casting and welding. Visual, Magnetic particle, Fluorescent particle, Ultrasonic, Radiography, Eddy current, Holography methods of Inspection. 6 Hours Text Books: 1. “Manufacturing & Technology : Foundry Forming and Welding”, P.N.Rao 2nd Ed., Tata McGraw Hill, 2003. 2. “Manufacturing Process-I”, Dr.K.Radhakrishna, Sapna Book House, 2nd Edition 2007. Reference Books: 1. “Manufacturing Technology”, Serope Kalpakjain, Steuen.R.Sechmid, Pearson Education Asia, 5th Ed. 2006. 2. “Process and Materials of Manufacturing :, Roy A Lindberg, 4th Ed. Pearson Edu. 2006. Scheme of examination: One Question to be set from each chapter. Students have to answer any FIVE full questions out of EIGHT questions, choosing at least 2 questions from part A and 2 questions from part B.

LESSON PLAN

Sub Code: 06ME35 I.A. Marks: 25 Hours / Week: 05 Total Hours: 62 Subject: Manufacturing Process – I Sem:III

Hour. No TOPICS TO BE COVERED

1. Introduction: Concept of Manufacturing process, its importance. 2. Classification of Manufacturing processes Introduction to Casting process

&steps involved 3. Varieties of components produced by casting process. Advantages &

Limitations of casting process. 4. Patterns: Definition, functions, Materials used for pattern 5. Various pattern allowances and their importance. . Classification of patterns 6. Revision/quiz/surprise test. 7. Binder: Definition, Types of binder used in moulding sand. Additives: Need,

Types of additives used. 8. Sand Moulding: Types of base sand, requirement of base sand. Types of sand

moulds. 9. Types of sand moulds. Method used for sand moulding 10. Moulding sand mixture ingredients 11. Cores: Definition, Need, Types. Method of making cores, Binders used. 12. Revision/quiz/surprise test. 13. Concept of Gating & Risering. Principle involved. and types 14. Fettling and cleaning of castings. Basic steps involved Casting defects -causes,

features and remedies. 15. Moulding machines : Jolt type, squeeze type, Jolt & Squeeze type and Sand

slinger. 16. Special moulding Process :Study of important moulding processes Green

sand, Core sand, Dry sand 17. Study of important moulding processes Green sand, Core sand, Dry sand 18. Revision/quiz/surprise test. 19. Sweep mould, CO2 mould 20. Shell mould,Investment mould. 21. Metal moulds : Gravity die-casting, Pressure die casting 22. centrifugal casting, Squeeze Casting, 23. Slush casting, Thixocasting and continuous casting processes. 24. Revision/quiz/surprise test. 25. Melting Furnaces: Classification of furnaces. 26. Constructional features &working principle of Gas fired pit furnace 27. Resistance furnace, 28. Electric Arc Furnace 29. Coreless Induction furnace

30. 31. Cupola furnace. 32. Welding process: Definition, Principles, Classification, Application, 33. Advantages & limitations of welding. 34. Arc Welding : Principle, Metal Arc welding (MAW) 35. Flux Shielded Metal Arc Welding (FSMAW) , 36. Revision/quiz/surprise test. 37. Inert Gas Welding (TIG & MIG) Submerged Arc Welding (SAW) 38. Atomic Hydrogen Welding processes. (AHW) Gas Welding : Principle, Oxy –

Acetylene welding Reaction in Gas welding 39. Flame characteristics, Gas torch construction & working. Forward and

backward welding 40. Special type of welding: Resistance welding - principles, Seam welding, Butt

welding, Spot welding and projection welding. Friction welding, Explosive welding, Thermit welding, Laser welding and Electron beam welding

41. Spot welding and projection welding. 42. Revision/quiz/surprise test. 43. Friction welding 44. Explosive welding 45. Thermit welding 46. Laser welding and 47. Electron beam welding 48. Revision/quiz/surprise test. 49. Metallurgical aspect in welding : Structure of welds, 50. Formation of different zones during welding. Heat affected zone (HAZ). 51. Parameters affecting HAZ . Effect of carbon content on structure and properties

of steel. 52. Shrinkage in welds & Residual stresses 53. Concept of electrodes, Filler rod and fluxes 54. Revision/quiz/surprise test. 55. Welding defects – Detection causes & remedy. 56. Principles of soldering & brazing: Parameters involved & Mechanism.

Different Types of Soldering & Brazing Methods. Inspection Methods – Methods used for Inspection of casting and welding. Visual, Magnetic particle, Fluorescent particle, Ultrasonic, Radiography, Eddy current, Holography methods of Inspection.

57. Principles of soldering & brazing: Parameters involved & Mechanism 58. Different Types of Soldering & Brazing Methods 59. Inspection Methods – Methods used for Inspection of casting and welding 60. Revision/quiz/surprise test. 61. Visual, Magnetic particle, Fluorescent particle 62. Ultrasonic, Radiography, Eddy current, Holography methods of Inspection.

QUESTION BANK

Unit-1

1. Write the basic steps in the casting process. 2. Write the advantages of casting process. 3. Enumerate the applications of casting process. 4. Discuss the types of mould casting.(expendable, permanent and semi-permanent mould). 5. Discuss the following methods of sand mould casting process: Bench moulding, floor

moulding, and pit moulding. 6. Discuss the types of sand moulds. 7. Compare the different types of sand moulds. 8. Write the advantages of machine moulding. 9. With the help of diagrams, explain the following machine moulding methods: Squeeze

moulding, Jolt moulding and sand slingers. 10. Explain the function of a pattern in the casting process. 11. Write the requirements of a good pattern. 12. List the common pattern materials. 13. Write the advantages and limitations of different pattern materials. 14. Write the advantages of plastics as the pattern material. 15. Discuss the various pattern allowances. 16. With the help diagrams discuss the different types of patterns. 17. Why a colour scheme for patterns is needed? Illustrate a common colour scheme.

Unit -2 1. Name the various moulding materials used in foundry. 2. Name the essential constituents of moulding sand. 3. Write the advantages of silica sand as a moulding material. 4. What are the functions of a binder in moulding sand? 5. What is meant by sand “at temper”? 6. What are the functions of additives in moulding sand? 7. How the moulding sand is classified on the basis of clay matter it contains? 8. Discuss: natural sand, synthetic sand and chemically coated sand. 9. Discuss the various binders used in moulding sand. 10. Write on parting materials used in sand moulding. 11. Write about the following types of sands: Facing sands, Backing sand, system sand,

parting sand. 12. Discuss the various properties of moulding sand. 13. Discuss the essential qualities of a core. What is core sand? 14. What is a core dryer? 15. What is core venting? 16. Discuss synthetic resin core binders. 17. With the help of diagrams discuss the various types of cores used in sand mould casting.

18. Sketch a common gating system. Label it and explain the function of its various elements. 19. Explain functions of splash core, skim bob, runner and runner extension.

20. What is the function of riser? Write the requirements of good riser. 21. What is directional solidification? Explain it with the help of a diagram. 22. Discuss the various types of risers and shapes of risers? 23. Sketch and compare: parting line gate, top gate and bottom gate. 24. Sketch the various sand mould casting defects. Give their causes and remedies.

Unit-3

1. Differentiate between Pressure die casting and permanent mould casting. 2. What are the limitations and applications of pressure die casting method. 3. Write the steps for making a casting by die casting process. 4. Compare cold-chamber and hot-chamber methods of die casting. 5. Name the various types of die-casting dies. 6. List the materials commonly used to make permanent moulds. 7. Define gating ratio. Distinguish between pressurized & non-pressurized gating. 8. Discuss the mould coatings. 9. List the steps needed for permanent mould casting operation. 10. List the advantages and limitations of permanent mould casting method. 11. Define the method of centrifugal casting. 12. With the help of diagrams discuss the following casting methods with the advantages,

disadvantages and applications: a. True-centrifugal casting. b. Semi-centrifugal casting c. Centrifuge casting.

13. What is meant by “precision investment casting”/ 14. With the help of diagrams, discuss the shell moulding method. 15. Discuss the various methods of cleaning the surfaces of castings

Unit-4

25. Explain the construction details of cupola furnace. 26. Explain the different stages of melting in cupola. 27. Explain the advantages and disadvantages of cupola furnace. 28. Give classification of melting furnaces. 29. Explain with a neat sketch oil fired crucible furnace. 30. Explain with a neat sketch i)direct electric arc furnace ii)Indirect electric arc furnace

iii)core type induction furnace iv)coreless type induction furnace v) resistance furnace

Unit-5 1. Define the welding process. Give the applications of the welding process. 2. Write the advantages and drawbacks of the welding process. 3. How the welding process may be classified? 4. Sketch the various types of welds used in making a joint. 5. Sketch and write on the various edge preparations used for welded joints. 6. Sketch and write on the various welding positions. 7. What is meant by fluxing? Why it is done? What are the properties which a good flux

should possess?

8. Define “electric are welding”. 9. List the advantages and disadvantages of D.C. arc welding over A.C. arc welding. 10. Write on the different types of electrodes used in arc welding. 11. What is purpose of coating on an arc welding electrode? Write the constituents of a coating

and write the function of each. 12. Write on coding of electric arc electrodes. 13. Explain principle of oxy acetylene welding. 14. Explain on flame characteristics & gas torch construction. 15. Explain the following electric arc welding processes with the help of neat sketches:

a) SMAW b) FCAW c) GTAW d) GMAW

e) SAW

Unit-6

16. Explain the following electric arc welding processes a) Atomic-hydrogen welding b) Electron beam welding.

c)Laser beam welding d)Thermit welding.Define “Resistance welding process”.

17. Name six types of resistance welding methods. For what kind of production is resistance welding mainly employed?

18. With the help of a neat sketch explain the all types of resistance welding process. 19. How does seam welding differ from spot welding? 20. What are the special features of resistance projection welding? 21. With the help of neat sketches explain the following welding methods:

a. Ultra-sonic welding. b. Explosive welding c. Electron-beam welding d. Laser-beam welding e. Thermit welding. f. Friction welding

Unit -7 1. Discuss on metallurgical aspect of welding. 2. Discuss on residual stresses in welding. 3. Explain heat effected zone & formation of different zones during welding. 4. What is purpose of preheating a part to be welded? 5. Write briefly on “Testing and Inspection of welded joints”. 6. How do you classify the welding defects. List out the weld defects. 7. Explain concept of electrodes , filler rods & fluxes.

Unit -8 1. Write about the various fluxes used in brazing process. 2. Distinguish between brazing and braze welding. 3. Write about the filler materials used in brazing process. 4. Write a note on the various brazing methods. 5. Write the advantages and limitations brazing process.

6. Distinguish between soft solder and hard solder. 7. Write about the various soldering techniques used. 8. Give the reasons for weld defects and suggest the remedies. 9. Discuss the following methods of inspection and testing of castings:

a. Radio-graphic testing b. Magnetic particle testing c. Ultrasonic testing. d. Liquid penetrant testing

06ME36A– COMPUTER AIDED MACHINE DRAWING

COMPUTER AIDED MACHINE DRAWING

Sub. Code: 06ME36A IA Marks 25 Hours / Week: 4 Exam Hours: 3 Total Hours: 62 Exam Marks: 100

Introduction: Review of graphic interface of the software. Review of basic sketching commands and navigational commands. Starting a new drawing sheet. Sheet sizes. Naming a drawing. Drawing units, grid and snap. 2 Hrs

PART A UNIT 1: Section of Solids: Sections of prisms, pyramids, cylinders, cones and tetrahedrons resting only on their bases (No problems on axis inclinations, spheres and hollow solids)True shape of sections .

Orthographic Views: Conversion of Pictorial views into orthographic projections of simple machine parts with or without section. B.I.S conventions to be followed for the drawings. Hidden line conventions. Precedence of lines. 8 Hrs

UNIT 2: Thread Forms: Thread terminology, sectional view of threads. ISO metric (Internal and External), BSW (Internal and External), Square, Acme, Sellers thread and American Standard Thread

Fasteners: Hexagonal headed bolt and nut with washer (Assembly), square headed bolt and nuts with washer (Assembly), Simple assembly using stud bolts with nut and lock nut. Flanged nut, Slotted nut and Wing nut, Taper and Split pin for locking. Counter sunk head screw, Grub screw and Allen screw. 8 Hrs

PART B UNIT 3: Keys: Parallel key, Taper key, Feather key, Gib-head key, Woodruff key. Riveted Joints: Single and double riveted lap Joints, butt joints with single/ double cover straps (Chain and zigzag, using snap head rivets), Cotter joint (socket and spigot joint), Knuckle joint (pin joint) for two rods. 8 Hrs

UNIT 4: Couplings: Split muff coupling, Protected type flange coupling, pin (bush) type flexible coupling, Oldham’s coupling, Universal coupling (Hooks’ joint). 8 Hrs

PART C

Assembly Drawings (Part Drawings to be given)

1. Plummer block (Pedestal Bearing) 2. Petrol Engine piston 3. IC Engine connecting rod 4. Screw Jack (Bottle type) 5. Tailstock of lathe 6. Machine Vice 7. Tool head of a Shaper 18 hrs

Text Books: 1.‘A Primer on Computer Aided Machine Draiwng –2007’, Published by VTU, Belgaum. 2.‘Machine Drawing’, Sri. N.D. Bhat & V.M. Panchal 3.‘Machine Drawing’, N. Siddeshwar, P. Kanniah, v.V.S. Sastri, Tata McGraw Hill, 2006

Reference Book:

1. ‘A Textbook of Computer Aided Machine drawing’, S.Trymbaka Murthy, CBS Publishers, New Delhi, 2007

2. ‘Machine Drawing’ , Sri. K.R. Gopal Krishna, Subhas Publications, Bangalore 3. ‘Machine drawing with AutoCAD’, Goutam pohit & Goutam Ghosh, 1st Indian print, Pearson

Education, 2005 4. ‘AutoCAD, 2006, for Engineers and Designers’, Sham Tickoo, Dream Tech, 2005

Note: Internal Assessment: 25 marks All sheets should be drawn in the class using software. Sheet sizes should be A3 /A4. All sheets must be submitted at the end of the class by taking printouts. Scheme of Examination: Two questions to be set from each part: A, B & C Student has to answer one question from part A and part B for 20 marks each, and one question from part C for 60 marks.

i.e. Part A 1 x 20 = 20 marks Part B 1 x 20 = 20 marks Part C 1 x 60 = 60 marks

Total = 100 marks

LESSON PLAN

Sub. Code: 06ME36A IA Marks 25 Hours / Week: 04 Total Hours: 62 Subject: Computer Aided Machine Drawing

Sl.No. TOPICS TO BE COVERED

1. Introduction: Review of graphic interface of the software. Review of basic sketching commands and navigational commands.

2. Starting a new drawing sheet. Sheet sizes. Naming a drawing. Drawing units, grid and snap.

3. Section of Solids: Section of Regular Prisms and their true shapes. 4. Section of Regular Pyramids and their true shapes. 5. Section of tetrahedrons and their true shapes. 6. Section of Regular cone and Cylinder and true shapes 7. Revision/quiz/surprise test. 8. Orthographic Views: Conversion of Pictorial views into orthographic

projections of simple machine parts with section 9. Conversion of Pictorial views into orthographic projections of simple machine

parts without section. B.I.S conventions to be followed for the drawings. 10. Hidden line conventions. 11. Precedence of lines 12. Thread Forms: Thread terminology, sectional view of threads. ISO metric

(Internal and External) 13. Revision/quiz/surprise test. 14. BSW (Internal and External) 15. Square, Acme, Sellers thread 16. American Standard Thread 17. Fasteners: Hexagonal headed bolt and nut with washer (Assembly), 18. Square headed bolt and nuts with washer (Assembly), 19. Simple assembly using stud bolts with nut and lock nut. 20. Revision/quiz/surprise test. 21. Flanged nut, Slotted nut and Wing nut, 22. Taper and Split pin for locking. 23. Counter sunk head screw, Grub screw and Allen screw. 24. Keys: Parallel key, Taper key 25. Feather key, Woodruff key 26. Gib-head key 27. Revision/quiz/surprise test. 28. Riveted Joints: Single and double riveted lap Joints, 29. Butt joints with single cover straps (Chain and zigzag, using snap head rivets), 30. Butt joints with double cover straps (Chain and zigzag, using snap head rivets) 31. Cotter joint (socket and spigot joint), 32. Knuckle joint (pin joint) for two rods. 33. Couplings: Split muff coupling

34. Revision/quiz/surprise test. 35. ,, 36. Protected type flange coupling 37. ,, 38. Pin (bush) type flexible coupling 39. ,, 40. Oldham’s coupling, 41. Revision/quiz/surprise test. 42. Universal coupling (Hooks’ joint). 43. Plummer block (Pedestal Bearing) 44. ,, 45. Petrol Engine piston 46. ,, 47. IC Engine connecting rod 48. Revision/quiz/surprise test. 49. ,, 50. Screw Jack (Bottle type) 51. ,, 52. Tailstock of lathe 53. ,, 54. Machine Vice 55. Revision/quiz/surprise test. 56. ,, 57. Tool head of a Shaper 58. ,, 59. Repitation 60. Repitation 61. Repitation 62. Repitation

QUESTION BANK

SECTIONS OF SOLIDS

1) A cube of 30 mm edges rests with one of its square faces on HP such that one of its vertical square faces is inclined at 300 to VP. A section plane perpendicular to VP and inclined at 600 to HP passes through a point on the vertical axis 5mm below its top end. Draw its sectional top view, front view and the true shape of section.

2) A cube of 40 mm edges rests with one of its faces on HP such that one of its vertical square faces is inclined at 300 to VP. A section plane perpendicular to HP and inclined at 600 to VP passes through the cube such a square face making 300 with VP is cut into two halves. Draw the sectional front view and the true shape of section.

3) An equilateral triangular prism of side of base 50 mm and axis 70 mm long rests with its base on HP such that two of its rectangular faces being inclined to VP at 450 and 750 . If a section plane, inclined at 600 to HP cuts the axis of the prism at a height of 50 mm, draw the sectional top view, front view and true shape of section.

4) A square prism, side of square faces 50 mm and height 80 mm rests with its base on HP such with two of its vertical faces equally inclined to VP. A section perpendicular to VP & inclined to HP at 600 cuts the prism so as to pass through a point on the axis 10 mm below its top end. Draw the sectional top view & the auxiliary view showing the true shape of section. Add the profile view showing the sectioned surface.

5) A square pyramid of side of base 40 mm and height 80 mm stands on its base with the sides of the base inclined at 450 to VP. It is cut by a plane equally inclined to both HP and VP passing through the midpoint of its axis. Draw the sectional views and the true shape of section.

6) A right regular hexagonal pyramid with edge of base 40 mm and height 100 mm stands with its base on HP with two of its base edges parallel to VP. It is cut by a plane passing through a point on the axis 50 mm from the base and inclined at 200 to the horizontal plane & perpendicular to the profile plane. Project the sectional view and the true shape of section.

7) A cylinder base 50 mm diameter and axis 75mm has a square hole of 25 mm cut through it so that the axis of the hole coincides with that of the cylinder. The faces of the hole are equally inclined to VP. The cylinder is lying with its base on ground . It is cut by two section planes which are perpendicular to VP and intersect each other at the top end of the axis. The cutting planes cut the cylinder on opposite sides of the axis and are inclined at 300 and 450 respectively to it. Draw the sectional top view and auxiliary top views on the planes parallel to the two section planes.

8) A cylinder 60 mm diameter and 80 mm long stands with its circular base on HP. A section perpendicular to VP & inclined to HP at 600 cuts the axis at a point 28 mm below its top end. Draw the sectional top & right views & the true shape of section.

9) A cone diameter of base 60 mm & axis 70 mm stands with its base on HP. A section plane perpendicular to HP and parallel to VP cuts the cone at a distance of 10 mm from the axis. The section plane is passed in front of the axis of the cone. Draw the sectional front view and the top view. Name the true shape of the curve.

i. A right circular cone of base 50 mm diameter & height 75 mm stands with its base on HP. A cutting plane perpendicular to HP and inclined at 450 to VP cuts the cone at a

distance of 5 mm from the axis of the cone & in front of it. Draw the apparent and true shape of sections.

CONVERSION OF PICTORIAL VIEWS INTO ORTHOGRAPHIC PRO JECTIONS with SECTIONS

Pictorial view of a dove tail stock is shown in Fig above draw to scale 1:1 the follwing views of the Dove Tail Stock

i) Sectional views from the front looking in the direction F ii) View from above looking in the direction T iii) Right view looking in the directions R

Indicate all the dimensions on the views. Do not show the invisible edges on the sectional view Print the title and scale of the drawing name the views

The Pictorial view of a machine part is shown in Fig Draw the following views i) Sectional front view along the axis of symmetry ii) Top view iii) Right View State the convenitions employed in the sectional view Indicate the section plane on the appropriate view Show the invisible edges in the top and right views Distribute the dimensions judiciously on all the three views All holes are through holoes

The Pictorial view of a machine part is shown in Fig Draw the following views i) Front view looking in the direction F ii) Sectional left view for the sectional plane SS looking in the direction L iii) Top View State the convenitions employed in the sectional view

The Picture view of a machine part is shown in Fig Draw the following views i) Front view taking section AA along the axis of symmetry ii) Top view iii) Right View

THREAD FORMS, BOLTS, NUTS AND SCREWS, JOINTS & COUPLINGS, BEARINGS 1. Draw the profile of ISO screw thread of pitch 40 mm. Indicate all the proportions &

dimensions.

2. Sketch neatly any three types of profiles of V-thread of pitch 50 mm. Indicate the angle & depth of the thread.

3. Draw the dimensional sketches of the following:

a) Square thread b) Trapezoidal thread c) Knuckle thread

4. Draw three views of hexagonal nut for a 20 mm diameter bolt. Indicate the empirical proportions & the calculated dimensions.

5. Draw the three views of the square headed bolt with a hexagonal nut. Show the bolt head and the nut across corners in the front view. The nut is screwed on the bolt. The bolt is 20 mm diameter, 120 mm long with a thread length of 50 mm. The end of the bolt is chamfered to 450.

6. Draw neat-dimensioned sketches of any three types of the nuts.

7. Show the method of locking a nut by a) set screw, b) split pin, c) Washer.

8. Sketch a countersunk screw & any two types of grub screws.

9. Sketch the sectional front view, top view and right view of a cotter joint with sleeve. Show all the dimensions.

10. Sketch the sectional front view, top view and right view of a knuckle joint to connect two shafts 25 mm diameter. Show all the dimensions.

11. Sketch the sectional front view & side view of a flanged coupling to connect two shafts of 25 mm diameter. Show all the dimensions.

12. Sketch the front view and right view of a Universal coupling. Show all the dimensions.

13. Draw to 1:1 scale the top and front views of a single riveted lap joint. The thickness of the plates is 9mm show atleast three rivets indicate all the dimensions. Use snap head revets.

14. Draw to 1:1 scale The top and sectional front views of a double riveted lap joint with chain and Zig Zag riveting the thickness of the plates is 9 mm Show atleast three rivets in each row indicate the dimensions use snap head rivets

ASSEMBLY DRAWINGS Views of the parts of a PLUMMER BLOCK are shown in the figure below. Draw to 1:1 scale the following views of the bearing.

a) Front view showing right half in section. b) Top view with right half in section. c) Right view.

The figure1 below shows the details of a PETROL ENGINE PISTON. Assemble all the parts and draw the following views of the assembled piston with its axis horizontal to 2:1 scale.

a) Front view

b) Top view showing one half in section c) End view in section, the section plane is passed along AA.

Figure below shows the different parts of a CONNECTING ROD. Assemble all the parts and draw the following views of the assembly.

a) Front view in half section b) Top view. c) View looking from the big end.

Figure below shows the different parts of a SCREW JACK. Assemble all the parts and draw the following views of the assembly when the top face of the load-bearing cup is raised to a height of 350 mm above the bearing surface of the body.

a) Front view in half section b) Top view

METALLOGRAPHY & MATERIAL TESTING LABORATORY

Sub Code: 06MEL37A IA Marks: 25 Hrs /week: 03 Exam Hours: 03 Total Lecture Hrs: 42 Exam Marks: 100

PART A 1. Preparation of Specimen for metallgraphic examination of different engineering materials.

Identification of microstructures of plain carbon steel, tool steel, gray C.I. SG iron, brass, bronze & Composites

2. Heat treatment: Annealing, normalizing, hardening and tempering of steel, hardness studies of heat-treated samples.

3. To study the wear characteristics of ferrous, non-ferrous and composite materials for different parameters.

4. Non destructive test experiments like, a. Ultrasonic flaw detection b. Magnetic crack detection c. Dye penetration testing to study the defects pf casted and welded specimens

PARTB

1. Tensile shear and compression tests of metallic and non metallic specimens using a universal testing machine

2. Torsion tests 3. Bending test on metallic and non nonmetallic specimens 4. Izod and Charpy tests on MS specimen 5. Brinell, Rockwell and Vicker’s Hardness test 6. Fatigue test

Scheme of examination: One question from Part-A 20 Marks One question from Part-B 20 Marks Viva Voce: 10 Marks Total Marks 50 Marks

LESSON PLAN

Sub Code: 06MEL37A Hrs/week: 03 Total Lecture Hrs: 42 Exam Marks: 100 Subject: Metallography & Material Testing Lab Sem:III

Sl No Topics to be covered 1. Introduction to Material Testing Lab 2. Metallographic examination of & Study of Microstructure of Plain carbon Steel,

& tool steel 3. Conduction of Tensile test of Mild steel specimen by UTM. 4. Conduction of shear test of Mild steel specimen by UTM 5. Conduction of compression test of Mild steel specimen by UTM 6. Conduction of Torsion test of Mild steel specimen by Torsion testing machine 7. Conduction of Izod & Charpy Impact test on Mild steel specimen. 8. Brinell hardness test of MS, Brass and Aluminum 9. Rockwell hardness & Vickers hardness test of MS, Brass, Aluminium. 10. Introduction to Metallographic, preparation of specimen for metallographic

examination 11. Metallographic examination of & Study of Microstructure of Plain carbon Steel,

& tool steel 12. Metallographic examination of & Study of Microstructure of Gray cast iron &

SG iron 13. Metallographic examination of & Study of Microstructure of Brass , & Bronze 14. Conduction of Heat Treatment: annealing , normalizing, Hardening, &

Tempering of steel. 15. Study of wear characteristics of Ferrous , nonferrous & Composite materials for

different parameters. 16. Demonstration of non destructive testing: Magnetic crack detector, Dye pen

entrant testing

VIVA QUESTIONS

1. Define the term Unit cell. 2. Define the term Lattice Parameter. 3. Define the term Co ordination. 4. Atomic packing factor with respect to crystal structure 5. What is Edge dislocation & screw Dislocation & compare them. 6. What is atomic packing factor a crystal? 7. Define Diffusion. Name the factors, which control the coefficient of diffusion. 8. Explain the difference between slip & Twinning 9. Sketch the Stress-Strain diagram for perfect Ductile. 10. Sketch the Stress-Strain diagram for perfect Brittle Materials. 11. What is Dislocation & mention its role in Plastic deformation. 12. Distinguish between Brinell & Rockwell hardness test. 13. Distinguish between Charpy & Izod’s Impact testing. 14. Define Fatigue. Name the factors, which control the fatigue. 15. Why is fatigue testing required? 16. Define fracture and mention all types of fracture. 17. Define creep and mention three stages in creep with fatigue testing 18. Mention Factors affecting fatigue life and protection methods 19. Mention mechanical properties of metals 20. Define Solid solution. Compare between Interstitial & substitution solid solution 21. Write briefly about Gibb’s Phase rule & how it can be applied for unary phase diagram? 22. What criteria favoring the formation of substitution solid solutions. Explain clearly. 23. State Hume-Ruthary rules giving examples 24. Compare the microstructure of steels & cast irons 25. What is TTT diagram? How is it different from phase diagram? 26. What are the three invariants reactions 27. Define the following with respect to steel: Pearlite, Ferrite, Ledubrite, Cemenite, Austenite 28. Sketch the microstructure of eutectoid steel & S G iron & identify the phases in it 29. Differentiate between plain carbon steel & alloy steels 30. Discuss the chemical composition, properties & engineering applications of Grey Cast Iron

& S G Iron 31. Distinguish between annealing & Normalizing and the need for each. 32. Write briefly about Critical cooling rate & precipitation Hardening 33. Define heat treatment of steel. What are the steps involved in it & its purpose 34. What is i) Annealing i) hardening iii) Spheroidising 35. Distinguish between Aus tempering & Mar tempering 36. Mention various Surface Heat treatment processes 37. What do you know about flame hardening and induction hardening? 38. Explain Jominy end –quench test. 39. Mention the properties, Composition & applications of following steels 40. Low-Carbon steel ii) High Carbon steel iii)18/8 Stainless steel iv) 18/4/1 HSS 41. Discuss the importance of aluminum alloys in engineering field & name few Alloys 42. Mention the composition & properties of Bronze, Brass & Al-Si alloy.

43. What is Age Hardening? 44. What is hardenability? 45. What do you mean by corrosion how to prevent it. 46. What are general methods of preventing corrosion? 47. What is cathodic protection? 48. What is Stress corrosion cracking? 49. What is Crystal Imperfection? 50. What do you about Ductile fracture & Brittle Fracture 51. What is Annealing? 52. What is Normalizing? 53. Difference between Annealing & Normalizing 54. Effects of Chromium & Nickel as alloying elements in steel. 55. What are Laminated Composites? 56. State Fick’s law of Diffusion 57. State Gibb’s phase rule 58. What is Hardness? How you find it. 59. What is factor of safety? 60. What is working stress? 61. What is proof stress? 62. State Hook’s Law. 63. Define Young’s Modulus. 64. What is Bulk Modulus? 65. What is difference between stress & pressure? 66. What is stress concentration? 67. What is rigidity? 68. What is Toughness? 69. Define shear stress. 70. What is the difference between shear stress & normal stress? 71. What is the difference between True stress & Engineering stress? 72. What is stiffness? 73. What is resilience? 74. Mention the various methods of NDT. 75. What is the principle of MPI? 76. What are methods of magnetization? 77. What are the advantages of MPI? 78. What is the Principle of dye penetrant test? 79. What is the principle of Ultrasonic flaw detection method?

FOUNDRY AND FORGING LABORATORY

Sub Code: 06MEL38A IA Marks: 25 Hrs /week: 03 Exam Hours: 03 Total Lecture Hrs: 42 Exam Marks: 100

PART – A

1. Testing of Moulding sand and Core sand Preparation of sand specimens and conduction of the following tests:

1. Compression, Shear and Tensile tests on Universal Sand Testing Machine. 2. Permeability test 3. Core hardness & Mould hardness tests. 4. Grain fineness number tests (Sive Analysis test) 5. Clay content test. 6. Moisture content test.

PART – B

2. Foundry Practice Use of foundry tools and other equipments.

1. Preparation of moulds using two moulding boxes using patterns or without 2. Patterns. (Split pattern, Match plate pattern and Core boxes). 3. Preparation of one casting (Aluminum or cast iron-Demonstration only)

PART – C

3. Forging Operations 1. Preparing minimum three forged models involving upsetting, drawing and bending

operations. 2. Out of these three models, at least one model is to be prepared by using Power Hammer.

Scheme of Examination: One question is to be set from Part-A: 10 marks One question is to be set from either Part-B or Part-C: 30 marks Viva-Voce: 10 marks. Total: 50 marks.

LESSON PLAN

Sub Code: 06MEL38A Hrs/week: 03 Total Lecture Hrs: 42 Exam Marks: 100 Subject: Foundry And Forging Laboratory Sem:III

Hour. No TOPICS TO BE COVERED

PART A

1. Introduction 2. Compression, Shear and Tensile tests on Universal Sand Testing machine. 3. Permeability test 4. Core hardness & Mould hardness tests. 5. Grain fineness number tests (Sive Analysis test) 6. Clay content test. 7. Moisture content test. PART - B 8. Introduction

9. Preparation of moulds using two moulding boxes using patterns or without patterns. (Split pattern, Match plate pattern and Core boxes)

10. Preparation of one casting (Aluminum or cast iron-Demonstration only) PART - C 11. Introduction

12. Preparing minimum three forged models involving upsetting, drawing and bending operations.

13. Out of these three models, at least one model is to be prepared by using power Hammer.

Viva Questions

1. Write the basic steps in the casting process. 2. Write the advantages of casting process. 3. Enumerate the applications of casting process. 4. Discuss the types of mould casting.(expendable, permanent and semi-permanent mould). 5. Discuss the following methods of sand mould casting process: Bench moulding, floor

moulding, and pit moulding. 6. Discuss the types of sand moulds. 7. Compare the different types of sand moulds. 8. Write the advantages of machine moulding. 9. With the help of diagrams, explain the following machine moulding methods: Squeeze

moulding, Jolt moulding and sand slingers. 10. Explain the function of a pattern in the casting process. 11. Write the requirements of a good pattern. 12. List the common pattern materials. 13. Write the advantages and limitations of different pattern materials. 14. Write the advantages of plastics as the pattern material. 15. Discuss the various pattern allowances. 16. With the help diagrams discuss the different types of patterns. 17. Why a colour scheme for patterns is needed? Illustrate a common colour scheme. 18. Name the various moulding materials used in foundry. 19. Name the essential constituents of moulding sand. 20. Write the advantages of silica sand as a moulding material. 21. What are the functions of a binder in moulding sand? 22. What is meant by sand “at temper”? 23. What are the functions of additives in moulding sand? 24. How the moulding sand is classified on the basis of clay matter it contains? 25. Discuss: natural sand, synthetic sand and chemically coated sand. 26. Discuss the various binders used in moulding sand. 27. Write on parting materials used in sand moulding. 28. Write about the following types of sands: Facing sands, Backing sand, system sand, parting

sand. 29. Discuss the various properties of moulding sand. 30. Discuss the essential qualities of a core. What is core sand? 31. What is a core dryer? 32. What is core venting? 33. Discuss synthetic resin core binders. 34. With the help of diagrams discuss the various types of cores used in sand mould casting. 35. Sketch a common gating system. Label it and explain the function of its various elements. 36. Explain functions of splash core, skim bob, runner and runner extension. 37. What is the function of riser? Write the requirements of good riser. 38. What is directional solidification? Explain it with the help of a diagram. 39. Discuss the various types of risers and shapes of risers? 40. Sketch and compare: parting line gate, top gate and bottom gate. 41. Sketch the various sand mould casting defects. Give their causes and remedies.

42. Differentiate between Pressure die casting and permanent mould casting. 43. What are the limitations and applications of pressure die casting method. 44. Write the steps for making a casting by die casting process. 45. Compare cold-chamber and hot-chamber methods of die casting. 46. Name the various types of die-casting dies. 47. List the materials commonly used to make permanent moulds. 48. Define gating ratio. Distinguish between pressurized & non-pressurized gating. 49. Discuss the mould coatings. 50. List the steps needed for permanent mould casting operation. 51. List the advantages and limitations of permanent mould casting method. 52. Define the method of centrifugal casting. 53. With the help of diagrams discuss the following casting methods with the advantages,

disadvantages and applications: a) True-centrifugal casting. b) Semi-centrifugal casting c) Centrifuge casting.

54. What is meant by “precision investment casting”/ 55. With the help of diagrams, discuss the shell moulding method. 56. Discuss the various methods of cleaning the surfaces of castings. 57. Explain the construction details of cupola furnace. 58. Explain the different stages of melting in cupola. 59. Explain the advantages and disadvantages of cupola furnace. 60. Give classification of melting furnaces. 61. Explain with a neat sketch oil fired crucible furnace. 62. Explain with a neat sketch i)direct electric arc furnace ii)Indirect electric arc furnace

iii)core type induction furnace iv)coreless type induction furnace v) resistance furnace