3rd sem course diary

7/29/2019 3rd Sem Course Diary

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BB..EE.. AAEERROONNAAUUTTIICCAALL EENNGGIINNEEEERRIINNGG

CCOOUURRSSEE DDIIAARRYY(ACADEMIC YEAR 2011-12)

IIIIII SSEEMMEESSTTEERR

Name : _____________________________________________

USN : _____________________________________________

Semester & Section : _____________________________________________

The Mission

The mission of our institutions is to provide

world class education in our chosen fields and

prepare people of character, caliber and vision

to build the future world


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INDEX

S.No. Contents

1 Schedule of Events

2 Engineering Mathematics-III

3 Material Science and Metallurgy

4 Basic Thermodynamics

5 Mechanics of Materials

6 Manufacturing Processes

7 Computer Aided Machine Drawing

8 Metallography and Material testing Lab

9 Foundry and Forging Lab

SCHEDULE OF EVENTS (2011 2012)


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B.E. (Aero) III Semester

THIRD SEMESTER

Commencement of Semester 01 Aug 2011

Internal Test Schedule

First Test Second Test Third Test

End of Semester

Commencement of Practical Examinations

Commencement of Theory Examinations

Commencement of EVEN Semester

OTHER MAJOR EVENTS

MVJ Memorial Cricket Tournament

TECH FEST Sep2011

Volley Ball Tournament

III SEMESTER


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Sl

No

Subject

CodeTitle

Teachin

g Dept.

Teaching

Hours /

week

Examination

Th

. Pr. Duration

I.A

Marks

Theory/

Practical

Total

Marks

1 10MAT31Engineering

Mathematics-IIIMaths 04 -- 03 25 100 125

2*10ME32A/

10ME32B

Material Science and

Metallurgy/Mechanic

al Mesurements &

Metrology

ME/AE 04 -- 03 25 100 125

3 10ME33Basic

ThermodynamicsME/AE 04 -- 03 25 100 125

4 10ME34 Mechanics ofMaterials ME/AE 04 -- 03 25 100 125

5 10AE35Manufacturing

ProcessesME/AE 04 -- 03 25 100 125

610ME36A/

10ME36B

Computer Aided

Machine Drawing/Fluid Mechanics

ME/AE 01 03 03 25 100 125

7*10MEL37A

10MEL37B

Metallography &

Material Testing

Lab/ Mechanical

Measurements &

Metrology Lab

ME/AE -- 03 03 25 50 75

8*10MEL38A/

10MEL38B

Foundry & Forging

Laboratory/

Machine shop

ME/AE -- 03 03 25 50 75

Total 21 09 24 200 700 900

III SEMESTER

ENGINEERING MATHEMATICS III

Sub Code : 10MAT31 IA Marks : 25

Hrs/ Week : 04 Exam Hours : 03


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Total Hrs. : 52 Exam Marks : 100

PART-A

UNIT-1

Fourier seriesConvergence and divergence of infinite series of positive terms, definition and illustrative

examples* . Periodic functions, Dirichlets conditions, Fourier series of periodic functions

of period 2 and arbitrary period, half range Fourier series. Complex form of Fourier series.

Practical harmonic analysis 7 Hours

UNIT-2

Fourier TransformsInfinite Fourier transform, Fourier Sine and Cosine transforms, properties, Inverse transforms

6 Hours

UNIT-3Application of PDE

Various possible solutions of one dimensional wave and heat equations, two dimensional

Laplaces equation by the method of separation of variables, Solution of all these equations

with specified boundary conditions. DAlemberts solution of one dimensional wave equation.

6 Hours

UNIT-4

Curve Fitting and OptimisationCurve fitting by the method of least squares- Fitting of curves of the form

y =ax+b, y=ax2+ bx + c, y=a e

bx, y= a x

b

Optimization: Linear programming, mathematical formulation of linear programming

problem (LPP), Graphical method and simplex method. 7 Hours

PART-B

UNIT-5

Numerical Methods - 1

Numerical Solution of algebraic and transcendental equations: Regula-falsi method,

Newton - Raphson method. Iterative methods of solution of a system of equations:

Gauss-seidel and Relaxation methods. Largest eigen value and the corresponding

eigen vector by Rayleighs power method. 6 Hours

UNIT-6

Numerical Methods 2

Finite differences: Forward and backward differences, Newtons forward and

backward interpolation formulae. Divided differences - Newtons divided difference

formula, Lagranges interpolation formula and inverse interpolation formula.

Numerical integration: Simpsons one-third, three-eighth and Weddles rules(All formulae/rules without proof). 7 Hours

UNIT-7


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Numerical Methods 3Numerical solutions of PDE finite difference approximation to derivatives, Numerical

solution of two dimensional Laplaces equation, one dimensional heat and wave equations7 Hours

UNIT-8Difference Equations and Z-Transforms

Difference equations: Basic definition; Z-transforms definition, standard Z-transforms,

damping rule, shifting rule, initial value and final value theorems. Inverse Z-transform.

Application of Z-transforms to solve difference equations . 6 Hours

Note: * In the case of illustrative examples, questions are not to be set.

TEXT BOOKS:1. B.S. Grewal, Higher Engineering Mathematics, Latest edition, Khanna Publishers.2. Erwin Kreyszig, Advanced Engineering Mathematics, Latest edition, Wiley Publications.

REFERENCE BOOKS:

1. B.V. Ramana, Higher Engineering Mathematics, Latest edition, Tata Mc.

Graw Hill Publications.

2. Peter V. ONeil, Engineering Mathematics, CENGAGE Learning India

Pvt Ltd.Publishers

MATERIAL SCIENCE AND METALLURGY

Subject Code : 10ME32A /42A IA Marks : 25

Hours/Week : 04 Exam Hours : 03

Total Hours : 52 Exam Marks : 100

PART A

UNIT - 1

Crystal Structure: BCC, FCC and HCP Structures, coordination number and


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atomic packing factors, crystal imperfections -point line and surface imperfections.Atomic Diffusion: Phenomenon, Ficks laws of diffusion, factors affecting diffusion.

06 Hours

UNIT - 2

Mechanical Behaviour: Stress-strain diagram showing ductile and brittle behaviourof materials, linear and non linear elastic behaviour and properties, mechanical properties

in plastic range, yield strength offset yield strength, ductility, ultimate tensile strength,

toughness. Plastic deformation of single crystal by slip and twinning. 06 Hours

UNIT - 3

Fracture: Type I, Type II and Type III.

Creep: Description of the phenomenon with examples. three stages of creep, creep

properties, stress relaxation.

Fatigue: Types of fatigue loading with examples, Mechanism of fatigue, fatigue properties,

fatigue testing and S-N diagram. 07 Hours

UNIT - 4

Solidification: Mechanism of solidification, Homogenous and Heterogeneous

nucleation, crystal growth, cast metal structures. Phase Diagram I: Solid solutions

Hume Rothary rule substitutional, and interstitial solid solutions, intermediate phases,Gibbs phase rule. 07 Hours

PART - B

UNIT - 5

Phase Diagram II: Construction of equilibrium diagrams involving complete and

partial solubility, lever rule. Iron carbon equilibrium diagram description of phases,

solidification of steels and cast irons, invariant reactions. 06 Hours

UNIT - 6

Heat treating of metals: TTT curves, continuous cooling curves, annealing and

its types. normalizing, hardening, tempering, martempering, austempering, hardenability,

surface hardening methods like carburizing, cyaniding, nitriding, flame hardening andinduction hardening, age hardening of aluminium-copper alloys. 07 Hours

UNIT - 7

Ferrous and non ferrous materials: Properties, Composition and uses of

Grey cast iron, malleable iron, SG iron and steel

Copper alloys-brasses and bronzes.

Aluminium alloys-Al-Cu,Al-Si,Al-Zn alloys.06 Hours


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UNIT - 8Composite Materials: Definition, classification, types of matrix materials &

reinforcements, fundamentals of production of FRP's and MMC's advantages andapplication of composites. 07 Hours

TEXT BOOKS:1. Foundations of Materials Science and Engineering, Smith, 4th Edition

McGraw Hill, 2009

2. Materials Science, Shackleford., & M. K. Muralidhara, Pearson Publication 2007.

REFERENCE BOOKS:

1. An Introduction to Metallurgy; Alan Cottrell, Universities Press India OrientalLongman Pvt. Ltd., 1974.

2. Engineering Materials Science, W.C.Richards, PHI, 1965

3. Physical Metallurgy; Lakhtin, Mir Publications

4. Materials Science and Engineering, V.Raghavan , PHI, 20025. Elements of Materials Science and Engineering, H. VanVlack, Addison- WesleyEdn., 1998

6. Materials Science and Engineering,William D. Callister Jr., John Wiley & Sons. Inc,

5th Edition, 2001.

7. The Science and Engineering of Materials, Donald R. Askland and Pradeep.P. Phule,Cengage Learning, 4lh Ed., 2003.

QUESTION BANK

Unit-1

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

2. With neat sketch explain Edge dislocation & screw Dislocation & compare them3. From fundamentals, calculate the atomic packing factor for a BCC crystal4. Explain Plastic deformation of metals & the mechanisms that contributes to it5. 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 atomicpacking 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


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2. Sketch the Stress-Strain diagram for perfect Ductile & Brittle Materials3. Explain the mechanism of ductile brittle transition.4. Write briefly about Dislocation & their role in Plastic deformation5. Distinguish between Brinell & Rockwell hardness test6. Distinguish between Charpy & Izods Impact testing

Unit-31. 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 testing5. Explain Factors affecting fatigue life and protection methods

Unit-4

1. Compare between Homogenous & heterogeneous Nucleation2. Write briefly about constitutional cooling3. Write briefly about eutectic solidification4. Explain briefly the process of Nucleation & growth of Pure Metals5. Define & Explain the Linear elastic properties of metals6. 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 Alloys8. Describe the Structures of cast metals with neat sketches9. Define Solid solution. Compare between Interstitial & substitutional solid solution10.With example11.Draw the following type of Phase Diagrams- Eutectic, Eutectoid and Peritectic.12.At Eutectic temperature three phase, liquid of 61%B solid of 10% B and solid of 95%

are in equilibrium for a binary alloy of A & B. Find the ratio of & phases in the eutecticphase.

13.Two Metals A & B of melting point 650 C & 450 C respectively. When alloyed togetherthey do not form any compound or intermediate phase but form a eutectic at 300 C ofcomposition 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 regionsb. Find the temperature at which an alloy with 30% B starts & ends Solidificationc. Find the relative amounts, percentage, composition, number, type & distribution of

the phases in the above alloy at 0 C14.Write briefly about Gibbs 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 examples17.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 stateii. A & B are partially soluble in liquid state

iii. A & B form an Eutectic


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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 ofsolidification of various alloys in the series are as follows:

Alloy of CompositionTemp. at start of

solidification

Temp at end of

solidification

90 % A + 10% B 798 C 750 C70% A + 30%B 785 C 705C

50% A+ 50% B 757C 675C

30% A + 70% B 715C 645C

10% A + 90%B 650C 615C

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

ii) Predict the number, type, relative amounts & concentration of phases present in an alloyof 40% A & 60% B at 700C & 20 C.

19.Two metals A and B are used to form an alloy containing 75% A and 25 % B. A melts at 750Cand B at 550C. 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 300C. Assume the liquidus and solidus lines to be straight. Draw thephase 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 onit. Elaborate the invariant reactions involved in it

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

3. Compare the microstructure of steels & cast irons4. What is TTT diagram? How is it different from phase diagram?5. Describe the various transformed products of Austenite on cooling6. 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 question8. Define the following with respect to steel: Pearlite, Ferrite, Ledubrite, Cemenite, Austenite9. Draw the Fe-Fe3Cphase diagram & label all temperatures (in 0C), compositions & phases.10. Sketch the microstructure of eutectoid steel & S G iron & identify the phases in it11. Differentiate between plain carbon steel & alloy steels12. Explain general classification of steel13. Explain briefly CCT Curve with neat diagram14. 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


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Unit-6

1. Explain the difference between annealing & Normalizing and the need for each.2. Write briefly about Critical cooling rate & precipitation Hardening3.

Using the relevant portion of the Fe-Fe3 equilibrium diagram & the TTT diagram withcooling 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 Hardening5. Describe the various transformed products of Austenite on cooling6. Define heat treatment of steel. What are the steps involved in it & its purpose7. Describe the following heat treatment process of steels with regard to thermal cycle involved,

microstructure and properties aimedi) Annealing ii) hardening iii) Spheroidising

8. Distinguish between Aus tempering & Mar tempering with neat diagram. What are thepractical 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 HSS2. 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 Alloys4. 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 Imperfections2. BIS designation of Steels3. Alloy Steels4. Ductile & Brittle Fracture5. Lever Rule applied to Eutectoid steel6. Microstructures of Eutectoid steel & grey cast iron7. Difference between Annealing & Normalizing8. Effects of Chromium & Nickel as alloy7ing elements in steel9. Laminated Composites


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10. Ficks law of Diffusion11. Nucleation & Growth12. Ceramics as insulators13. Izod impact test14. Gibbs phase rule15. Age Hardening16.Case Hardening.


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BASIC THERMODYNAMICS

Subject Code : 10ME33 IA Marks : 25



PART-A

UNIT - 1

Fndamental Concepts & Definitions: Thermodynamics definition and scope, Microscopic andMacroscopic approaches. Some practical applications of engineering thermodynamic Systems,

Characteristics of system boundary and control surface, examples. Thermodynamic properties;

definition and units, intensive and extensive properties. Thermodynamic state, state point, statediagram, path and process, quasi-static process, cyclic and non-cyclic ;processes; Thermodynamic

equilibrium; definition, mechanical equilibrium; diathermic wall, thermal equilibrium, chemicalequilibrium, Zeroth law of thermodynamics, Temperature; concepts, scales, fixed points and

measurements. 06 Hours

UNIT - 2

Work and Heat: Mechanics, definition of work and its limitations. Thermodynamic definition of

work; examples, sign convention. Displacement work; as a part of a system boundary, as a whole of

a system boundary, expressions for displacement work in various processes through p-v diagrams.

Shaft work; Electrical work. Other types of work. Heat; definition, units and sign convention.

06 Hours

UNIT - 3

First Law of Thermodynamics: Joules experiments, equivalence of heat and work. Statement ofthe 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 controlvolume; steady state-steady flow energy equation, important applications, analysis of unsteady

processes such as film and evacuation of vessels with and without heat transfer.

07 Hours

UNIT - 4Second 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 Thermodynamics; PMM I and PMM II, Clausius statement of Second law of Thermodynamics,

Equivalence of the two statements; Reversible and irreversible processes; factors that make a

process irreversible, reversible heat engines, Carnot cycle, Carnot principles.

07 Hours


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PART-B

UNIT - 5

Entropy: Clasius inequality; Statement, proof, application to a reversible cycle. Entropy;definition, a property, change of entropy, principle of increase in entropy, entropy as a quantitative

test for irreversibility, calculation of entropy using Tds relations, entropy as a coordinate. Available

and unavailable energy. 06 Hours

UNIT - 6

Pure Substances: P-T and P-V diagrams, triple point and critical points. Sub-cooled liquid,

saturated liquid, mixture of saturated liquid and vapour, saturated vapour and superheated vapour

states of pure substance with water as example. Enthalpy of change of phase (Latent heat). Drynessfraction (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.

07 HoursUNIT - 7

Thermodynamic relations: Maxwell relation, Clausius Clayperon's equation. Ideal gas; equationof 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. 07 Hours

UNIT - 8

Ideal gas mixture: Ideal gas mixture; Dalton's laws of partial pressures, Amagat's law of additive

volumes, evaluation of properties, Analysis of various processes. Real Gases: Introduction. Van-der

Waal's Equation of state, Van-der Waal's constants in terms of critical properties, Law of

corresponding states, compressibility factor; compressibility chart 06 Hours

Data Handbooks :

1. Thermodynamic data hand book, B.T. Nijaguna.2. Properties of Refrigerant & Psychometric (tables & Charts in SI Units),

Dr. S.S. Banwait, Dr. S.C. Laroiya, Birla Pub. Pvt. Ltd., Delhi, 2008

TEXT BOOKS:

1. Basic Engineering Thermodynamics, A.Venkatesh, Universities Press, 2008

2. Basic and Applied Thermodynamics, P.K.Nag, 2nd Ed., Tata McGraw Hill Pub. 2002

REFERENCE BOOKS:1. Thermodynamics, An Engineering Approach, Yunus A.Cenegal and Michael A.Boles, Tata

McGraw Hill publications, 2002

2. Engineering Thermodynamics, J.B.Jones and G.A.Hawkins, John Wiley and Sons..

3. Fundamentals of Classical Thermodynamics, G.J.Van Wylen and

R.E.Sonntag, Wiley Eastern.

4. An Introduction to Thermodynamcis, Y.V.C.Rao, Wiley Eastern, 1993,

5. B.K Venkanna, Swati B. Wadavadagi Basic Thermodynamics, PHI, New Delhi, 2010


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LESSON PLANS

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 surfaceexamples; thermodynamics property definition and units. Intensive and extensive

properties.

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

5. Thermodynamic equilibrium; definition, mechanical equilibrium, diathermic wallthermal equilibrium chemical equilibrium

6.

Zeroth law of thermodynamics temperature concepts scales measurement internalfixed points.

7. Numericals8. Mechanics definition of work and its limitations, thermodynamics definition of

work;

9. Examples of sign convention10. Displacement work at part of a system boundary at whole of a system boundary11. Expression for displacement work in various process through p-v diagrams.12. Shaft work electrical works other types of work heat definition units and sign

convention what heat is not.

13. Numericals14. Numericals15. Joules experiments equivalence of heat and work statement of the first law of

thermodynamics

16. Extension of the first law to non-cyclic process energy energy as a property modesof energy pure substance.

17. Definition two property rules specific heat and constant volume enthalpy18. Specific heat constant pressure extension of first law to control volume steady state

flow energy equation

19. Important applications analysis and unsteady process such a filling and evacuationof vessels with and without heat transfer

20. Numericals21. Numericals22. Second law of thermodynamics devices converting heat into work (a)

Thermodynamics cycle (b) Mechanical cycle.

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

24. Reversed heat engine, schematic representation, COP.25. Kelvin Planck statement of second law of thermodynamics PMM-I and PMM-II.26. Clasius statement of second law of thermodynamics equivalence of two statement

reversible and irreversible process

27. Factors that make process a to irreversible. Reversible heat engine, carnot cycle, carn


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principles, thermodynamics temperature cycle.

28. Numericals29. Numericals30. Entropy Clasius inequality statement proof31. Application to a reversible cycle as independent of path32. Entropy definition a property, principle of increases of entropy33. Entropy as a quantitative test for irreversibility,34. Calculation of entropy using Tds relations35. Entropy as co ordinate available and unavailable energy.36. Maximum work, maximum useful work for a system and a control volume37. Availability of a system and a stadily flowing stream38. Irreversibility, second law efficiency39. Pure substance P-T and P-V diagrams, triple point and critical points40. Sub cooled liquid, saturated vapor, and superheated vapor,41. Enthalpy of Change of phase, dryness factors,42. States of pure substance with water as example...43. TS and HS diagrams, representation of various process on this diagrams.Steam

tables and its use

44. Throttling calorimeter, Separating and throttling calorimeter45. Introduction of availability and irreversibility46. Real & ideal gases introduction, Vander waals equation van der waals consta

in terms of critical properties.

47. Law of corresponding states, compressibility chart.48. Ideal gas equation of state, internal energy and enthalpy as functions of temperat

only.

49. Universal and particular gas constant, specific heats, perfect and semi-perfectgases.

50. Evaluation of heat, work, change in internal energy, enthalpy and entropy invarious quasi-static processes.

51. Ideal gas mixture, Daltons law of additive pressure, Amagats law of additivevolume.

52. Evaluation of Properties, Analysis of Various processes.


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QUESTION BANK

CHAPTER 1: FUNDAMENTAL CONCEPTS

1. Define the following terms with reference to thermodynamicsa) System b) property c) process d) cycle e) thermodynamic equilibrium

2. Define Zeroth law of thermodynamics and Prove that T(K)=T(C) +2733. 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) closedi) a scooter engine ii) Centrifugal water pump iii) An electric fan iv) A

motor car battery5. 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 K6. 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 are00c 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 energyconsumed by the cooler.

6. A battery is charged with a battery charger. The charger operates 1 hour at 15v anda 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 theballoon increases to 30cm in a certain process during which pressure is proportional to thediameter. 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 to2m3

while receiving 200kJ of work from a paddle wheel. The pressure on the gas remainsconstant 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 process2. Write a brief note on perpetual motion machines.3. Define internal energy and prove that it is a property4. 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.


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6. A cylinder containing the compressor the system cycle is completed as follows. 1) 8200N-mof work is done by the piston on the air during compression stroke and 45 kJ of heat arerejected 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 system7. 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 is4 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, = 1.410. 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 isdoubled. 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 m311. Derive steady flow energy equation stating the assumption made12. 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 specificenthalpy 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 10cmrespectively. 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 andprove that they are equivalent.

2. Define irreversibility and mention at least 3 factor which render a process irreversible.3. state carnots theorem4. 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 reservoir6. 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 &127

0C and a reversible refrigerator operates between 27

and 1270C respectively. 502kJ of heat are extracted for the reservoir at 8270C by the heat


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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. Whenthe 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 temperatureis 940 K, and the maximum pressure is 8.4 x 10

3kPa. 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 rejectsheat to a reservoir at 300K, the engine develops 10kW and rejects 412kJ/min. If heatsupplied 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 at100 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 ispreferable? Raising the source temperature to 3000 C or lowering the sink temperature to 300

C.

CHAPTER 5: ENTROPY

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

0

C. 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 totalentropy.

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


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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 anengine Cylinder at 1187

0C 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 heatengine 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 theSurroundings 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 70

0C.

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 function6. 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 fusionii) Sensible heatiii) Wet steamiv) Triple pointv) Enthalpyvi) Critical pointvii) Dryness fractionviii) 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.


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

0C.

7. 0.5 Kg of steam has a dryness fraction of 0.8 initially. This steam is heated at constantpressure 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 ofsteam 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 250

0C

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 steamsuperheater 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 steam10. 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 heatwhich must be rejected so as the quality of steam becomes 0.7 dry


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MECHANICS OF MATERIALS

Subject Code : 10ME34 IA Marks : 25



PART-A

UNIT 1:

Simple Stress and Strain: Introduction, Stress, strain, mechanical properties of materials, Linear

elasticity, Hooke's Law and Poisson's ratio, Stress-Strain relation - behaviour in tension for Mild

steel, cast iron and non ferrous metals. Extension / Shortening of a bar, bars with cross sectionsvarying in steps, bars with continuously varying cross sections (circular and rectangular),

Elongation due to self weight, Principle of super position 07 Hours

UNIT 2:

Stress in Composite Section: Volumetric strain, expression for volumetric strain, elastic constants,simple shear stress, shear strain, temperature stresses (including compound bars). 06 Hours

UNIT 3:

Compound Stresses: Introduction, Plane stress, stresses on inclined sections, principal stresses andmaximum shear stresses, Mohr's circle for plane stress. 07 Hours

UNIT 4:

Energy Methods: Work and strain energy, Strain energy in bar/beams, Castiglinios theorem,

Energy methods.Thick and Thin Cylinder Stresses in thin cylinders, changes in dimensions of cylinder (diameter,

length and volume). Thick cylinders Lames equation (compound cylinders not included).

06 Hours

PART-B

UNIT 5:

Bending Moment and Shear Force in Beams: Introduction, Types of beams, loads and reactions,

shear forces and bending moments, rate of loading, sign conventions, relationship between shear

force and bending moments. Shear force and bending moment diagrams for different beams

subjected to concentrated loads, uniformly distributed load, (UDL) uniformly varying load (UVL)and couple for different types of beams. 07 Hours

UNIT 6:

Bending and Shear Stresses in Beams: Introduction, Theory of simple bending, assumptions in

simple bending. Bending stress equation, relationship between bending stress, 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 / notched beams not included). 07 Hours


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UNIT 7:

Deflection of Beams: Introduction, Differential equation for deflection. Equations for deflection,slope and bending moment. Double integration method for cantilever and simply supported beams

for point load, UDL, UVL and Couple. Macaulay's method 06 Hours

UNIT 8:

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

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. 06 Hours

TEXT BOOKS:1. "Mechanics of Materials", by R.C.Hibbeler, Prentice Hall. Pearson Edu., 2005

2. "Mechanics of materials", James.M.Gere, Thomson, Fifth edition 2004.3. "Mechanics of materials", in SI Units, Ferdinand Beer & Russell Johston, 5th Ed.,

TATA McGraw Hill- 2003.

REFERENCE BOOKS:

1. "Strength of Materials", S.S. Rattan, Tata McGraw Hill, 20092. "Strength of Materials", S.S.Bhavikatti, Vikas publications House -1 Pvt. Ltd., 2nd Ed., 2006.

3. "Mechanics of Materials", K.V. Rao, G.C. Raju, First Edition, 2007

4. "Engineering Mechanics of Solids", Egor.P. Popov, Pearson Edu. India, 2nd, Edition, 1998.

5. "Strength of Materials", W.A. Nash, 5th Ed., Schaums Outline Series, Fourth Edition-2007.


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LESSON PLAN

Sub Code: 10ME34 I A Marks: 25

Hours / Week: 04 Exam Hours: 03Total Hours: 52 Exam Marks: 100Subject: Mechanics of Materials

No. of

hoursTopic 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 steeland non-ferrous materials subjected to Static Tension Test.

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

4. Solving some numerical problems on deformation of prismatic bars. Explaining theprincipal of Superposition for evaluation of total deformation of bars with steppedvariation in cross section along its length.

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

6. Evaluation of expression for deformation of tapering bars of circular and rectangularcross sections.

7.Solving some numerical problems on deformation of tapering bars with circular and

rectangular cross section.

8. Determination of deformation due to self- weight of the bar and solving somenumerical problems.

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

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

11. Solving some numerical problems on elastic constants.12. Concept of Thermal Stresses and its evaluation simple bars and compound bar.13. Solving some numerical problems on evaluation of Thermal Stresses in simple bars.14.

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

components.15. Determination of Stress components on inclined planes for uni-axial Stress System.16. Determination of Stress components on inclined planes for general two-dimensional

Stress System.

17. Determination of principal planes and principal Stresses.18. Introduction to thin and thick cylinders, stresses iron the walls of thin cylinder,

Assumptions made in the analysis of thin cylinders

19. Relationship between hoop stress and longitudinal stress20. Strains in thin cylindrical shells, problems on above21. Derivation of Lame's equation, assumptions made in analysis of theory on thick


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cylinders

22. Problems concerned to thick cylinders23. Problems concerned to thick cylinders24. Determination of Bending moment and Shear force with salient values for over

hanging beams.

25. Introduction to Bending stresses and Shear stress in Bending members . Assumptionmade in deriving pure Bending of Bernoulli's equation .

26. Derivation of Bernoulli's equation. And definition of modulus of rupture and sectionmodulus.

27. Definition of flexural rigidity , derivation of expression form Shear stress in Beam's28. Solving some numerical examples for determining bending stress and Shear stress for

rectangular section Beams.

29. Solving some numerical examples for determining bending stress and Shear stress for Iand T section Beams.

30. Introduction to deflection of Beams assumptions made in deriving diffraction equationfor the Deflected curve Beam.

31. Derivation of second order deflection equation. sign convention for various loadingcases

32. Use of Maccualay's method for evaluating the deflection of Beams.33. Solving some numerical examples for evaluating the deflection of Beams by

Maccualay's method.

34. Solving some numerical examples for evaluating the deflection of Beams byMaccualay's method.

35. Solving some numerical examples for evaluating the deflection of Beams byMaccualay's method.

36. Introduction to torsion,37. Pure torsion, torsion equation of circular shaft38. Strength and stiffness39. Torsional rigidity and polar modulus40. Power transmitted by a shift for solid and hollow circular sections.41. Problems on above concepts42. Problems on above concepts43. Problems on above concepts44. Introduction to column behaviour, differences between bulking and bending, and end

conditions of column

45. Classification of columns, Assumptions made in Euler's theory, Euler's formula

derivation for both end hinged condition.46. Euler's formula derivation for both ends fixed, one end fixed other end hinged47. Euler's formula derivation for one end fixed and other end free, Limitations of Euler's

theory, Rankine's formula

48. Problems on above49. Euler's formula derivation for one end fixed and other end free, Limitations of Euler's

theory,

50. Rankine's formula51. Problems on above52. Problems on above


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QUESTION BANK

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

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 allnormal 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 undercombined 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 andtheir directions analytically. (ii) Find the normal and tangential Stress on the plane BC

graphically.


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10.What is abeam? How are they classified? What are the different types of loads a beam cancarry 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 failswhen 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 deflectionof 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.


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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 arectangle 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 theminimum 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 X10

5

N/mm2.

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

21.A pipe of 500mm internal diameter and 75mm thick is filled with a fluid at a pressure of 6N/mm2. Find the maximum and minimum hoop stress across the Cross Section of theCylinder, 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 lengthwhen 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 themaximum bending stress produced.

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


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27. A steel shaft transmits 125KW at 175 rpm. The diameter of shaft is 100mm. determine thetorque on the shaft and the maximum shearing stress indeed. Also calculate the twist of theshaft 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 columnis 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 theexpressions for normal and tangential stresses.

30. Differential between thin and thick cylinders. Also explain hoop stress and longitudinalstress 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 otherend is hinged.

32. Find the shortest length L for a pin ended steel column having a cross section of 70mm X110mm for which Euler's formula applies. Take E = 2.1 X 10

5N/mm

2and 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 200mmii. 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 are500mm 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.


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Manufacturing Processes

Sub Code: 10AE35 IA Marks: 25Hrs/ Week: 04 Exam Hours: 03

Total Hours: 52 Exam Marks: 100

PART A

Unit 1: 6 Hours

Casting Process: Introduction: Concept of Manufacturing process, its importance. Classification

of Manufacturing processes. Introduction to Casting process & steps involved. Varieties ofcomponents produced by casting process. Advantages & Limitations of casting process.

Patterns: Definition, functions, Materials used for pattern, various pattern allowances and theirimportance. Classification of patterns.

Binder: Definition, Types of binder used in moulding sand.

Additives: Need, Types of additives used.

Unit 2: 7 Hours

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 sandmixtures. 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.

Unit: 3 7 Hours

Moulding machines: Jolt type; squeeze type, Jolt & Squeeze type and Sand slinger. 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

Unit4:

Welding 6 Hours

Welding process: Definition, Principles, Classification, Application, Advantages & limitations of

welding.

Gas Welding: Principle, Oxy Acetylene welding, Reaction in Gas welding, Flame characteristics,

Gas torch construction & working. Forward and backward welding.

Arc Welding: Principle, Metal Arc welding (MAW), Flux Shielded Metal Arc Welding

(FSMAW), Inert Gas Welding (TIG & MIG)


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PART B

Unit 5: 6 HoursPrinciples of soldering & brazing: Parameters involved & Mechanism. Different Types ofSoldering & 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.

Unit 6: 7 Hours

Theory of metal cutting: Single point cutting tool nomenclature, geometry of single point cutting

tool. Merchants circle diagram and analysis, Ernst-Merchants solution, Shear angle relationship,

Problems on Merchants analysis, Tool wear & tool failure, Tool life, Effects of cutting parameterson tool life, Tools failure criteria, Taylors tool life equation, Problems on tool life evaluation.

Unit 7: 7 HoursCutting tool materials: Desired properties, types of cutting tool materials- HSS carbides, coated

carbides, ceramics, cutting fluids, desired properties, types and selection, Heat generation in metalcutting, factors affecting heat generation. Heat distribution in tool and w/p. Measurements of tool

tip temperature.

Unit 8: 6 Hours

Non-Traditional Machining Process: Principle, need, equipment, operation and applications of

LBM, Plasma Arc Machining, Electro chemical machining, Ultrasonic Machining, Abrasive jet

machining, Water jet machining

Text Books:

1. Workshop Technology, Hajra Choudhry Vol- I and II, Media Promoters and Publishers Pvt.Ltd., 2004.

2. Production Technology, R.K. Jain, Khanna Publications, 2003.Reference Books:

1. Manufacturing Technology, Serope Kalpakjain, Steuen.R.Sechmid, Pearson EducationAsia, 5th Ed. 2006.

2. Process and Materials of Manufacturing :, Roy A Lindberg, 4th Ed. Pearson Edu. 2006.3. Manufacturing Science, Amitabha Ghosh and Mallik, Affiliated East-West Press, 2003.4. Fundamentals of Metal Machining and Machine Tools, G. Boothroyd, McGraw Hill, 2000

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.


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COMPUTER AIDED MACHINE DRAWING

Subject Code :10ME36A/10ME46A IA Marks : 25

Hours/Week : 04(1 Hrs. Theory &

3 Hrs Practical) Exam Hours: 03

Total Hours : 52 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. 02 Hours

PART-A

UNIT - 1

Sections of Solids: Sections of Pyramids, Prisms, Cubes, Tetrahedrons, Cones and Cylindersresting 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. (Bureau of Indian Standards conventions are to be followedfor the drawings) Hidden line conventions. Precedence of lines. 08 Hours

UNIT - 2

Thread Forms: Thread terminology, sectional views of threads. ISO Metric (Internal & External)

BSW (Internal & External) square and Acme. Sellers thread, American Standard thread.Fasteners: Hexagonal headed bolt and nut with washer (assembly), square headed bolt and nut with

washer (assembly) simple assembly using stud bolts with nut and lock nut. Flanged nut, slotted nut,

taper and split pin for locking, counter sunk head screw, grub screw, Allen screw.08 Hours

PART-B

UNIT - 3

Keys & Joints: Parallel key, Taper key, Feather key, Gibhead key and 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), knuckle joint (pin joint)

for two rods. 08 Hours

UNIT - 4

Couplings:

Split Muff coupling, Protected type flanged coupling, pin (bush) type flexible coupling, Oldham's

coupling and universal coupling (Hooks' Joint) 08 Hours


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PART - C

Assembly Drawings

(Part drawings should be given)

1. Plummer block (Pedestal Bearing)2. Rams Bottom Safety Valve

3. I.C. Engine connecting rod

4. Screw jack (Bottle type)

5. Tailstock of lathe

6. Machine vice

7. Tool Head of a shaper 18 Hours

TEXT BOOKS:

1. 'A Primer on Computer Aided Machine Drawing-2007, Published by VTU, Belgaum.

2. 'Machine Drawing', N.D.Bhat & V.M.Panchal

REFERENCE BOOKS:1. 'A Text Book of Computer Aided Machine Drawing', S. Trymbaka Murthy, CBS Publishers,

New Delhi, 2007

2. 'Machine Drawing, K.R. Gopala Krishna, Subhash Publication.

3. 'Machine Drawing with Auto CAD', Goutam Pohit & Goutham Ghosh,1st Indian print Pearson Education, 2005

4. 'Auto CAD 2006, for engineers and designers', Sham Tickoo. Dream tech 2005

5. 'Machine Drawing', N. Siddeshwar, P. Kanniah, V.V.S. Sastri, published by Tata McGraw

Hill,2006

NOTE:

Internal assessment: 25 MarksAll the 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, Part-B and Part-C Student has to answer one question

each 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


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LESSON PLAN

Sub. Code: 10ME36A Hours / Week: 04

I.A. Marks: 25 Total Hours: 52Subject:Computer Aided Machine Drawing

Sl.No. TOPICS TO BE COVERED

01 Introduction: Review of graphic interface of the software. Review of basic

sketching commands and navigational commands.

02 Starting a new drawing sheet. Sheet sizes. Naming a drawing. Drawing units,

grid and snap.

03 UNIT 1: Section of Solids: Section of Regular Prisms and their true shapes.

04 Section of Regular Pyramids and their true shapes.

05 Section of tetrahedrons and their true shapes.06 Section of Regular cone and Cylinder and true shapes

07 Orthographic Views: Conversion of Pictorial views into orthographic

projections of simple machine parts with section

08 Conversion of Pictorial views into orthographic projections of simple machine

parts without section. B.I.S conventions to be followed for the drawings.

09 Hidden line conventions.

10 Precedence of lines11 UNIT 2: Thread Forms: Thread terminology, sectional view of threads. ISO

metric (Internal and External)

12 BSW (Internal and External)

13 Square, Acme, Sellers thread14 American Standard Thread

15 Fasteners: Hexagonal headed bolt and nut with washer (Assembly),

16 Square headed bolt and nuts with washer (Assembly),

17 Simple assembly using stud bolts with nut and lock nut.

18 Flanged nut, Slotted nut and Wing nut,19 Taper and Split pin for locking.

20 Counter sunk head screw, Grub screw and Allen screw.

21 UNIT 3: Keys: Parallel key, Taper key

22 Feather key, Woodruff key

23 Gib-head key

24 Riveted Joints: Single and double riveted lap Joints,25 Butt joints with single cover straps (Chain and zigzag, using snap head rivets),

26 Butt joints with double cover straps (Chain and zigzag, using snap head rivets)

27 Cotter joint (socket and spigot joint),28 Knuckle joint (pin joint) for two rods.

29 UNIT 4: Couplings: Split muff coupling

30 ,,

31 Protected type flange coupling

32 ,,

33 Pin (bush) type flexible coupling

34 ,,


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35 Oldhams coupling,

36 Universal coupling (Hooks joint).37 Plummer block (Pedestal Bearing)

38 ,,39 Petrol Engine piston

40 ,,

41 IC Engine connecting rod

42 ,,

43 Screw Jack (Bottle type)

44 ,,

45 Tailstock of lathe

46 ,,47 Machine Vice

48 ,,

49 Tool head of a Shaper50 ,,

51 Revision52 Revision


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QUESTION BANK

SECTIONS OF SOLIDS1) 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 60 0

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 squarefaces is inclined at 30

0to VP. A section plane perpendicular to HP and inclined at 60

0to 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 baseon HP such that two of its rectangular faces being inclined to VP at 45

0

and 750

. If a sectionplane, inclined at 60

0to 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 suchwith 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 ofthe base inclined at 45

0to 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 withits base on HP with two of its base edges parallel to VP. It is cut by a plane passing through apoint on the axis 50 mm from the base and inclined at 20 0 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 sothat 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 cuttingplanes 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 planeperpendicular 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 itsbase on HP. A cutting plane perpendicular to HP and inclined at 45

0to VP cuts the cone at a


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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 PROJECTIONS with

SECTIONS

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

i) Sectional views from the front looking in the direction Fii) View from above looking in the direction Tiii) Right view looking in the directions R

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


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The Pictorial view of a machine part

is shown in Fig Draw the followingviews

i) Sectional front view along the axisof 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 topand right views

Distribute the dimensions judiciously

on all the three viewsAll 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 axisof symmetry

ii) Top view

iii) Right View


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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 threadb) Trapezoidal threadc) Knuckle thread

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

5. Draw the three views of the square headed bolt with a hexagonal nut. Show the bolt head andthe nut across corners in the front view. The nut is screwed on the bolt. The bolt is 20 mmdiameter, 120 mm long with a thread length of 50 mm. The end of the bolt is chamfered to 45 0.

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 twoshafts 25 mm diameter. Show all the dimensions.

11.Sketch the sectional front view & side view of a flanged coupling to connect two shafts of 25mm 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 chainand 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


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b) Top view showing one half in sectionc) 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 sectionb) 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 sectionb) Top view


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METALLOGRAPHY AND MATERIAL TESTING LABORATORY

Subject Code : 10MEL37A / 47A IA Marks : 25



PART A

1. Preparation of specimen for Metallograpic examination of different engineering

materials. Identification of microstructures of plain carbon steel, tool steel, grayC.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 of Cast and Welded specimens

PART B

1. Tensile, shear and compression tests of metallic and non metallic specimens using

Universal Testing Machine2. Torsion Test

3. Bending Test on metallic and nonmetallic specimens.

4. Izod and Charpy Tests on M.S, C.I Specimen.5. Brinell, Rockwell and Vickerss Hardness test.

6. Fatigue Test.


ONE question from part -A: 20 Marks

ONE question from part -B: 20 Marks

Viva -Voice: 10 Marks

Total : 50 Marks


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FOUNDRY AND FORGING LABORATORY

Subject Code : 10MEL38A / 48A IA Marks : 25



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 Sieve Analysis to find Grain Fineness number of Base Sand

5 Clay content determination in Base Sand

PART B2. Foundry Practice

Use of foundry tools and other equipments.Preparation of moulds using two moulding boxes using patterns or without patterns.

(Split pattern, Match plate pattern and Core boxes).

Preparation of one casting (Aluminum or cast iron-Demonstration only)

PART C

3. Forging Operations :

Calculation of length of the raw material required to do the model. Preparing minimum three forged models involving upsetting, drawing and bending operations.

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


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

Calculation part in case of forging is made compulsory

Calculation + Foundry = 05 +25 = 30 Marks

(Forging) Model

Calculation + Forging = 05 +25 = 30 Marks

3rd sem course diary

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