diploma in ceramic technology second semester subject: … · 2020-05-21 · 5.0 structural geology...

Diploma in Ceramic Technology

Second Semester

Subject: Applied Geology

Contact Hrs / Week: 4 Contact Hrs/Semester : 64

Sl No Topics

Hours

1 Introduction to geology

03

2 Study of Earth 05

3 Petrology 12

4 Mineralogy

10

5 Structural geology 08

6 Physical geology 07

7 Crystallography 10

8 Economic geology 05

9 Test and revision 04

CONTENTS

1. Introduction to geology –Definition, Different branches of geology,

Importance of geology

2. Study of Earth-Our solar system, parts of earth, age of earth.

3. Petrology- Definition of a rock, Classification of rocks based on their origin,

igneous rock, Sedimentary rock, metamorphic rock, its formation,

classification, texture & structure, Forms of igneous rock, Uses.

4. Mineralogy- Definition, Physical properties of minerals such as habit, color,

streak, crystal system, luster, cleavage, fracture, hardness, specific

gravity,magnetism,Description of minerals such as quartz, feldspar,

mica,,asbestose,augite,bauxite,chromite,dolomite,corundum,diamond,flurite,g

alena,gold,graphite,gypsum,haematite,hornblende,pyrite,talc,topaz,zircon,silli

manite

5. Structural geology-Introduction, dip, apparent dip & true dip, strike,

definition, parts & types of folds, faults & joints.

6. Physical geology-Introduction, weathering, landslides, earthquakes, its causes,

effects, world distribution of earthquake.

7. Crystallography-Definition of crystal, elements of crystal, crystallographic

axes, axial & symmetry character, interfacial angle, crystal system.

8. Economic geology- Definition & its importance, classification of mineral

deposits, Important economic mineral deposits of India such as gold, copper,

alluminium,iron,manganese,chromium,lead,zinc,coal,petroleum,mica,kyanite,

asbestose & radioactive minerals.

General objectives

1.0 Introduction to geology

1.1 Know the deferent branches of geology

1.2 Under stand the importance of geology.

2.0 Study of Earth

2.1 Known the age of earth

2.2 Understand solar system

2.3 Known the different part of the earth

3.0 Petrology

3.1 Known the definition of rock, its classification

3.2 Formation, classification, structure, texture of igneous, sedimentary and

metamorphic rock

4.0 Mineralogy

4.1 Know the definition of minerals

4.2 Known the physical properties of minerals

4.3 Known the description of minerals

5.0 Structural geology

5.1 Understand the outcrop

5.2 Known the dip and strike

5.3 Understand the folds, fault and joint

6.0 Physical geology

6.1 Known the weathering process

6.2 Known the causes and effects of earth quakes

7.0 Crystallography

7.1 Known the definitions and elements of crystal

7.2 Understand the crystallographic axis

7.3 Known the axial and symmetric characters in crystal systems

8.0 Economic geology

8.1 Know the definition & its importance.

8.2 Know the classification &study of iomprtant economic mineral deposits of

India.

SPECIFIC OBJECTIVES

1.0. Introduction to geology

1.1 Definition of geology

1.2. Study of different branches of geology

1.3 Study of importance.

2.0. Study of Earth

2.1. Study of age of earth

2.2 Study of solar system

2.3 Know the different branches of earth

3.0 Petrology

3.1 Definition of rock & its classification based on origin.

3.2 Explain the formation, structure, texture & uses of igneous, sedimentary &

metamorphic rock

4.0 Mineralogy

4.1 Definition of mineral with example

4.2 Describe the physical properties of mineral such as habit, color, streak,

luster, cleavage, fracture, hardness, specific gravity, diaphaneity, magnetism

4.3 Study of minerals

4.4 uses of mineral

5.0 Structural geology

5.1 Explain the structural features like outcrop, dip, types of dip such as true

&apparent dip

5.2 Study of strike

5.3 Describe the parts & types of fold, fault & joint

6.0 Physical geology

6.1 Study of weathering

6.2 Explain the definition, causes & effects of earthquake

7.0 Crystallography

7.1 Definition of crystal

7.2 Study of elements of crystal & crystallographic axes

7.3 Explain the axial & symmetry character in cubic, tetragonal, hexagonal,

orthorhombic, monoclinic & triclinic system

8.0 Economic geology

8.1 Definition & classification

8.2 Explanation of important economic mineral deposits of India such as gold,

copper, alluminium,iron,manganese,chromium,lead,zinc,coal,petroleum,mica,

asbestose,kyanite,radioactive minerals.

REFFERENCE BOOK:1) A TEXT OF GEOLOGY BY P.K MUKERJEE

2)A TEXT OF GEOLOGY BY PARBINSINGH

3) FUNDAMENTALS OF ENGINEERING

GEOLOGY BY R.S KURMI

4)A TEXT OF GEOLOGY BY H.H REED

MODEL QUESTION PAPER

APPLIED GEOLOGY

TIME:3 HRS MAX MARKS:100

Note: 1) Section I is compulsory.

2) Answer any two full questions from each of sections-II, III&IV.

3) Each questions of sections sections- II, III &IV carries 15 marks.

SECTION-I

I.a.) Fill in the blanks with appropriate words.

i)The chemical formula of hematite is -----

ii) Quartz crystallizes under ----- system. 1x5

iii) Calcite reacts with dilute acid due to the presence of ------

iv) Relative displacement of rock is called-----

v) Dip & strike are measured by using -----

b) What is a mineral? Explain with example. (5)

SECTION-II

2. a)Describe the physical properties of a mineral with suitable example? (8)

b) What is a crystal? What are the elements of crystal? (4)

c) Define the streak in mineral? (3)

3.a)What are igneous rocks? How are they formed? (4)

b) What are dip & strike? (4)

c) Explain texture in igneous rock? (7)

4.a)Write the classification of metamorphic rock with example. (5)

b) Describe the axial 7 symmetry characters of isometric system. (7)

c) Write a short note on landslide. (3)

SECTION-III

5.a)Describe the physical properties , chemical composition & uses of plagioclase

feldspar & mica. (7)

b)Define plane of symmetry & axis of symmetry in a crystal (4)

c) Write a note on amygdaloidal structure. (4)

6.a)What are faults? Explain the important types of faults with neat diagrams. (9)

b) Write a note on earthquake. (3)

c) Write a note on landslide. (3)

7.a)Explain the geological distribution of ceramic raw materials. (6)

b)Explain chemical weathering of rocks. (4)

c)Describe the physical properties & uses of limestone. (5)

SECTION-IV

8. a) Write a short note on crystallographic axes. (4)

b) Explain interfacial angle in brief. (4)

c) What are concordant & discordant bodies? Explain (7)

9. a) Describe the different parts of earth. (6)

b) Mention the classification of rock on the basis of origin. (4)

c) How metamorphic rocks are formed? (5)

10.a) Write a note on erosion.(4)

b) What are intrusive & extrusive?(5)

c) Describe the axial & symmetry character in hexagonal system. (6)


First Semester

Subject: Basics of Ceramics


Sl No. Topic Hours Allotted

1. Introduction to Ceramics 06

2. White Wares & Heavy Clay wares 10

3. Refractories & Abrasives 06

4. Cement & Lime 14

5. Enamels 10

6. Glass 12

7. Revision & Test 06

Total Hours 64

Contents 1. Introduction to Ceramics: 6 Hrs

Definition of ceramics, birth , brief history and development of c eramics.

2. White wares & Heavy Clay wares 10 Hrs

Classification of wares: - white wares, heavy clay wares,

Raw materials, properties & Applications of white wares and heavy clay wares

Terracotta, majolica, earthenware‘s, stoneware, sanitary wares, table wares,

ceramic wall and floor tiles, electrical insulators etc.

Shaping methods: types 1) Soft mud process a) Wooden mould b)Metal mould c)

Jiggering d) Potters wheel 2)Stiff mud process- a) Extrusion b) Pressing

3) Slip casting- a) Plaster moulds b) Gel casting

3. Refractories and Abrasives 6 Hrs

Definition, classification of Refractories, raw materials and their occurrences.

Selection of raw material, body preparation, shaping methods, drying and firing of

wares.

Different refractory wares - crucibles, saggers, muffles, insulation bricks etc.

Abrasives, definition, types, various abrasive materials and their applications.

4. Cement & Lime 14 Hrs

Introduction and definition of cement, raw materials, classification, properties and

application of ordinary cement.

Manufacturing process of ordinary cement. Composition, Dry and Wet methods,

firing process of ordinary cement by using rotary kiln, Sketch of rotary kiln, flow

charts of cement manufacture.

Verities of cement, blast furnace cement, colored cement, high alumina cements,

acid resistant cement, quick setting cement, white cement, dental cement, Their

properties and uses.

Lime – types, raw materials, preparation of Quick lime & Fat Lime.

Differences properties and applications.

5. Enamels 10Hrs

Definition of enamel, classification, Raw materials used in enamel making, frit,

colors, composition of enamels, properties of enamels, application of enamels. Base

preparation, preparing the surface by various methods, importance of cleaning.

Different methods of applying of base coat & final coat - Spraying, brushing &

dipping with advantages and disadvantages in each methods.

6. Glass: 12Hrs

Introduction and definition of glass, origin and history of early glass,

classification of glass, soda lime, potash lime, potash lead glass and common glass.

Physical properties and chemical properties and uses.

Glass making process: Raw materials, Composition, firing, Annealing.

Fabrication Methods: Pressing, Blowing and rolling.

The various verities of glass products e.g. Laboratory glass wares, sheet glass,

optical glass, bullet proof glass etc.

Industrial applications of glass.

Sketches & Difference of tank furnace and pot furnace.

General Objectives

On completion of course the student should able to

1. Understand history and development of ceramics

2. Understand various types of ceramics

3. To know the traditional and advanced ceramics

4. To know the different shaping methods of white wares and heavy clay wares.

5. Understand the manufacturing process of cement, glass, Refractories and white

wares, enamels, frit etc.

6. To know the safety precautions to be taken in firing of enamel wares

7. To know the ceramic raw materials, machineries and furnaces.

8. To know industrial application of glass.

9. To understand the manufacturing process of lime.

10. To know various abrasive materials and their applications.

Specific Objectives

1.0 Introduction to Ceramics

1.1 Know and understand about ceramics.

1.2 Know the birth and history.

1.3 Know and understand the developments of ceramics about its role in various

applications.

1.4 Know the various classification of wares

1.5 Know the raw materials.

1.6 Understand the physical and chemical properties and its applications.

1.7 Know the terracotta, majolica, earthenware‘s, stoneware‘s, sanitary ware,

table ware, ceramics wall and floor tiles, electrical insulators.

1.8 Know their physical properties and application.

2.0 White wares & Heavy clay wares

2.1 Define white wares and heavy clay wares.

2.2 Write the properties and applications of earthen ware, majolica, terracotta,

stone wares, sanitary wares and table wares.

2.3 Write the uses properties & differences between wall and floor tiles, high

tension and low tension insulators.

2.4 Describe the shaping methods of white wares and heavy clay wares.

2.5 Definition of Pressing, extrusion, Jiggering, slip casting etc

2.6 Write the classification of wares and shaping methods.

3.0 Refractories and abrasives.

3.1 Know the definition of Refractories.

3.2 Know the classification of refractory materials with examples.

3.3 To study the features of acidic, basic and neutral Refractories with examples,

and their application in industry.

3.4 Know the preparation of refractory body mass with binders and water.

3.5 To know the general outline of production methods.

3.6 To study the various methods adopted for shaping, drying, firing and cooling

of refractory wares.

3.7 Know the advantages and disadvantages of each method of shaping, drying

and firing of Refractories.

3.8 Know the definition of abrasives.

3.9 Know the classification of abrasive with examples.

3.10 To know and understand various abrasive materials.

3.11 To study the various industrial applications of abrasives

4.0 Cements & Lime

4.1 Know the introduction and definition.

4.2 Know the elementary knowledge of raw materials.

4.3 Know the classification of cement.

4.4 Understand composition, properties and applications.

4.5 Know the manufacturing process of both dry and wet process of ordinary

Portland cement.

4.6 To draw the neat sketch of Rotary Kiln and mention its parts.

4.7 Know the verities of cements.

4.8 Understand the properties and uses.

4.9 Definition of lime

4.10 To know the classification, raw material, properties and application of limes.

5.0 Enamels

5.1 Know the definition of enamels.

5.2 Know the types of enamels.

5.3 Know how enamels come into existence.

5.4 Know the various advantages of ceramic enamels & applications.

5.5 Know various required ingredients in enamel composition. With special

preference to coloring oxides, frits and binders.

5.6 Know the preparation & application of enamels.

5.7 Know the applying of base coat, final coat by various methods.

5.8 Know the spraying, brushing and dipping with advantages and

disadvantages.

5.9 Know the drying and firing of enamels.

5.10 Know the methods of firing and the safety precautions that are to be taken

during firing wares.

6.0 Glass

6.1 Know the introduction and definition of glass.

6.2 Know the origin and history of early glass.

6.3 Know the classification of glass.

6.4 Know the physical and chemical properties.

6.5 Understand the glass making process.

6.6 Know the raw materials, composition, firing and annealing.

6.7 Know the fabrication methods: Pressing, Blowing & Rolling.

6.8 Know various verities of glass products. E.g. Laboratory glassware‘s, Sheet

glass, Bullet proof glass etc.

6.9 Know the industrial applications of glass.

Reference: 1. Engineering materials ----by Rangawala

2. Fuels Furnace & Refractory---by O.P.Guptha

3. Engineering Chemistry—by Jain & Jain

4. White ware---by Sudheer Sen

Model Question Paper

Basics of ceramics

Time: 3hrs [Max marks:100]

Instructions: i) Section I is compulsory

ii)Answer any two full questions each from the remaining sections.

Section –I

1. a) Fill in the blanks with appropriate word/ words: 5X1=5

i) ----------Refractories have a very high refractoriness value .

ii) ----------treatment is done to raw quartz to make it brittle.

iii) ---------treatment is done to metallic surfaces to remove scaling.

iv) --------- Kiln is widely used for burning the cement clinkers.

v) ----------treatment is done to burn out excess gases in the glaze.

b) Briefly write a note on fluxes.

Section- II

2. a) State the role of ceramics in various industrial applications. 9

b) State the classification of ceramic wares with examples. 3

c) Define the term ‗plasticity‘ 3

3. a) State the classification of Refractories with examples. 3

b) State the role of Refractories in industrial applications 8

c) Write note on ―Kiln –furniture‘s‖. 4

4. a) Describe in detail the manufacturing process for making ‗glass‘ . 9

b) Define the term ‗glass‘ 3

c) State the role and uses of glasses. 4

Section - III

5. a) state the various raw materials used for making ‗Portland cement‘ 3

b) Describe the manufacturing of Portland cement by ‗Dry mix‘ method 9

c) State the physical tests done for cement. 3

6. a) Describe in detail how enamel slip is prepared. 8

b) Stare the various methods of enamel application. 4

c) State the advantages of enameling. 3

7. a) define the term ‗Drying‘ 3

b) State the classification of dryers 4

c) Describe in detail the working principles of a ‗tunnel Drier‘. 8

Section - IV

8 a) State the various raw materials used for making ‗white wares‘ 3

b) Describe the manufacturing methods for making ‗sanitary wares‘ 8

c) State the role of ‗dental porcelain‘. 4

9. a) State the role of ‗abrasive in various industrial applications. 4

b) State the various abrasive materials 4

c) Describe the fabrication methods for making abrasives. 7

10. a) Define the term ‗calcinations‘ 3

b) State the classification of clays with examples 3

c) Describe the role of clays 9


Page 1 of 10


Second Semester

Subject: Applied Physics


Sl No. Topic Hours Allotted

1. Units Dimensions & Measurements 06

2. General Physics 10

3. Force and Linear motion & Newton’s Law of motion 15

4. Heat & Temperature 10

5. Light 8

6. Sound 6

7. Electromagnetism 5

Revision & Test 04

Total Hours 64


Page 2 of 10

1. Units, Dimensions & Measurements

MKS, CGS, FPS & SI systems, fundamental and derived units, dimensions, use of

dimensional analysis.

Measurement of length, absolute and percentage error. Vernier scale, vernier caliper,

screw gauge.

2. General Physics

Destinction between solids, liquids and gases. Inertia; moment of inertia of regular solid

bodies. Archimedes principle. Measurement of density and specific gravity.

Elasticity, stress and strain, hooks law. Youngs modulus, bulk modulus and modulus of

rigidity.

3. Force and linear motion & Newtons laws of motion

Velocity, acceleration, force – rectilinear, centripetal and centrifugal; momentum friction.

Composition and resolution of vectors.

Newton’s Laws of motion; Kinetic equations, work, energy, power. Their units, concept

of kinetic and potential energy. Different forms of energy – Mechanical, thermal, electrical,

chemical etc.

Conservation of energy. Equivalence of different forms

4. Heat & Temperature

Linear, surface and volume expansions; isothermal and adiabatic expansion of gases.

Variation of density of water with temperature.

Thermometry and calorimetry. Units of heat and temperature, Celsius and Kelvin scale,

absolute zero, heat capacity, specific heat, latent heat of fusion and vaporization.

Transmission of heat – conduction, convection and radiation.

Boyle’s and Charl’s law, kinetic theory of gases, concept of specific heat capacities of

gases and degree of freedom. Simple problems of engineering applications.

5. Light

Nature of propagation of light. Electromagnetic spectrum, visible range of spectrum,

velocity of light.

Refraction at plane surface, Dispersion by prism, total internal reflection. Application.

Reflection by plane and curved mirrors. Refraction by concave and convex lens,

formation of image.

Calculation involving position and nature of image and magnification.

6. Sound

Simple harmonic motion. Nature and velocity of propagation of sound. Effect of

pressure, temperature, density and relative humidity on velocity of sound. Sound as wave

motion, frequency, wave length, amplitude, pitch, audible range, dB-notation, principle of

sound insulations

Vibration of strings and pipes. Reflection of sound (echo). Interference of sound beats

7. Electromagnetism

Solenoid, Mutual Inductance, Modes of magnetization, electron theory of magnetism,

weber elements.

Permeability, retentivity, coercivity, dia-magnetism, para-magnetism, ferro-magnetism &

Ferrites.


Page 3 of 10

General Objectives

1. Units, Dimensions & Measurements

a. To understand the concept of physical quantities, their units

b. To know the meaning and to write dimensions for different physical quantities

c. To understand and to use slide calipers for measurements

d. To understand and use screw gauge for measurements

2. General Physics a. To understand the properties of solids

b. To understand the properties of liquids

3. Force and Linear motion & Newton’s Law of motion a. To understand the types of motion with examples

b. To understand various physical quantities related to linear motion

c. To study and apply equations of motion

d. To study Newton's laws of motion

e. To understand friction

f. To study he concept of work

g. To understand the concept of power

h. To understand the concept of energy


a. To understand heat and its modes of transmission

b. To study gas laws

c. To study solar energy

d. To know the conservation of heat

e. To know different temperature scales and the relation between them

f. To know the units of heat and temperature.

5. Light

a. To understand light properties

b. To know the propagation of light

c. To know the electromagnetic propagation.

d. To know refraction, reflection and dispersion

e. To understand the refraction by concave and convex lens.

f. To understand the formation of image.

g. To find the refractive index of glass.

6. Sound a. To understand Simple harmonic motion

b. To understand wave motion

c. To study transverse vibrations of stretched strings

d. To know musical notes

e. To study acoustics of buildings

7. Electromagnetism

a. To know magnetism & inductance (self & mutual)

b. To know the modes of magnetism

c. To know the theory of magnetism

d. To know different parameters of magnet


Page 4 of 10

Specific Objectives

1. Units, Dimensions & Measurements a. Explain physical quantity with examples

b. Distinguish between fundamental and derived physical quantities

c. Define unit of a physical quantity

d. State different systems of units

e. List the base and supplementary quantities

f. Write the SI units of base and supplementary quantities

g. List the prefixes to denote multiple and sub multiple units in SI system

h. Define dimensions of a physical quantity

i. Write down dimensions for various physical quantities

j. Write dimensional equations for few physical quantities

k. List the applications of dimensional analysis

l. List the limitations of dimensional analysis

m. State the principle of vernier

n. Know the importance of slide calipers for accurate measurement

o. Draw a diagram of slide calipers

p. Identify different parts of slide calipers

q. Learn the zero error and zero correction

r. Define least count

s. Learn to read MSR and VSR (CVD)

t. Learn the usage of slide calipers

u. Solve problems on slide calipers

v. State the principle of the screw guage.

w. Draw a diagram of screw gauge

x. Identify the different parts of screw gauge

y. Explain zero error and zero error correction

z. Define pitch and least count

aa. Learn the use of screw gauge

bb. Solve the problems on screw gauge 2. General Physics

a. Explain solid as a state of matter

b. Explain the meaning of "deformation" with examples

c. Define elastcity with examples

d. Explain the meaning of elastic limit

e. Define plasticity with examples

f. Define stress

g. Write SI unit and dimensions of stress

h. Define different forms of stress with examples

i. Write SI unit and dimensions of different forms of stress

j. Define strain

k. Define different forms of strain with examples

l. State Hook's law and explain its limitations

m. Explain stress vs strain graph

n. Define modulus of elasticity and write its formula

o. Define Young's modulus of elastcity with examples


Page 5 of 10

p. Write the formula its SI unit and dimensions

q. Define Bulk modulus of elasticity with examples

r. Write the formula its SI unit and dimensions

s. Define shear modulus of elasticity with examples

t. Write the formula its SI unit and dimensions

u. Explain factor of safety and give its formula

v. Determine "Y" experimentally by Searle's method

w. Solve problems

x. Explain liquid as a state of matter

y. Define pressure at a point inside a liquid

z. Write its SI unit and dimensions

aa. Derive an expression for the pressure at a point inside a liquid

bb. Solve problems

cc. Define adhesion, cohesion with examples

dd. Explain the nature of meniscus with examples

ee. Define angle of contact with examples

ff. Define capillarity and write its applications

gg. Explain surface tension on the basis of molecular theory and define it

hh. Write the formula SI unit and dimensions of it

ii. Explain the factors affecting surface tension

jj. Write the applications

kk. Describe an experiment to determine surface tension by capillary rise method

ll. Solve problems

mm. Explain concept of friction in a liquid flow

nn. Explain viscous force

oo. Define viscosity and coefficient of viscosity

pp. Write the formula SI unit and dimensions of coefficient of viscosity

qq. Discuss the effect of temperature on viscosity of liquids and gases

rr. List the applications of viscosity

ss. Solve problems

3. Force And Linear Motion & Newton’s Law of motion

a. Know different types of motion with examples

b. Learn linear motion with examples

c. Define displacement, speed, velocity - uniform variable, average velocity,

acceleration - uniform variable, retardation

d. Write SI units and dimensions of the above physical quantities

e. Recapitulate equations of motion. Apply them for motion under gravity

f. Derive Sn = U + a/2 (2n - 1)

g. Solve problems on equations of motion

h. State and explain Newton's I law

i. Define force and inertia

j. Define momentum. Write SI unit and dimensions

k. State and explain Newton's II law of motion

l. Recall F = ma

m. Write SI unit and dimensions of force

n. Define one Newton


Page 6 of 10

o. Define impulse. Write SI units and dimensions

p. State and explain Newton's III law with examples

q. State and prove the law of conservation of momentum

r. Solve problems on Newton’s laws of motion

s. Know the concept of friction

t. Learn the types of friction

u. Know the advantages and disadvantages of friction

v. Know lubrication to reduce friction - give examples of lubricants

w. Explain the meaning of work in physics

x. Define work

y. Explain W = F X S X cos theta when theta = 0, = 90 & 0 less than theta less than 90

z. Write SI unit and dimensions of work

aa. Solve problems

bb. Explain the meaning of power and define it

cc. Write SI unit and dimensions

dd. Define Horse Power

ee. Write relation between HP and watt

ff. Solve problems

gg. List different forms of energy

hh. Mention different kinds of Mechanical energy

ii. Explain and define Kinetic energy with examples

jj. Derive an expression for Kinetic Energy

kk. Explain and define Potential Energy with examples

ll. Derive an expression for Potential Energy

mm. State and Explain the law of conservation of energy

nn. Illustrate this law in case of freely falling body and simple pendulum

oo. Solve problems


a. Differentiate between heat and temperature with examples

b. Explain and define conduction, convection & radiation with examples

c. Explain heat insulation with examples

d. Define specific heat of a substance

e. Write SI unit for specific heat

f. Define specific heat of a gas at constant pressure (Cp)

g. Define specific heat of a gas at constant volume (Cv)

h. Write the relation between Cp and Cv (No derivation)

i. State and explain first and second laws of thermodynamics

j. State and explain Boyle's law

k. Write mathematical expressions of Boyle's law

l. State and explain Charle's law when the pressure is constant and the volume is

constant

m. Write relevant mathematical expressions

n. Explain Absolute (Kelvin) scale of temperature

o. Give the conversion formula of temperature from deg Absolute to deg. C and

vice-versa p. Derive perfect gas equation


Page 7 of 10

q. Write the value of R in SI system

r. Solve problems on gas laws

s. Explain solar energy as non conventional, renewable, pollution free and

t. eco-friendly energy

u. Write the applications of solar energy

v. List the advantages and limitations of solar energy

5. Light

a. Definition of light

b. Explain the propagation of light

c. Explain the light spectrum.

d. State Velocity of light

e. Write note on reflection of light at a plane surface.

f. Explain the dispersion of light by prism

g. Find out refractive index of given glass prism

h. Refraction of light by concave and convex lens

i. Explain the formation of image by lens

j. Explain the magnification of image by lens

k. List out the application of lens.

6. Sound

a. Explain oscillatory motion with examples

b. Explain periodic motion with examples

c. Explain and define SHM

d. Define period frequency and amplitude for a vibrating body

e. Write the relation between period and frequency

f. Obtain the expression for displacement, velocity and acceleration of a particle

executing SHM

g. Explain mechanical and electromagnetic waves with examples

h. Explain wave and wave motion with an example

i. Define wave frequency, wave period, wave length, wave velocity, wave amplitude

or a wave

j. Derive the relation V = n X lambda & Solve problems

k. Explain types of mechanical waves - transverse and longitudinal

l. Define transverse wave with examples

m. Define longitudinal wave with examples

n. List the differences between transverse and longitudinal waves

o. Explain propogation of sound in air

p. Explain interference, polarisation and diffraction with examples

q. Explain Newton's assumptions for the velocity of sound in a gas and write formula

r. Calculate the value of velocity of sound in air using Newton's formula

s. Explain Laplace's assumptions for the propogation of sound in a gas

t. Write Newton - Laplace formula for the velocity of sound in a gas

u. Discuss the effect of pressure, temperature, density and humidity on the

v. velocity of sound

w. Solve problems

x. Explain and define stationary waves with examples

y. List the characteristics of stationary waves


Page 8 of 10

z. Explain free and forced vibrations with examples

aa. Explain and define resonance

bb. Write practical examples of resonance

cc. Describe an experiment to determine velocity of sound in air at room temperature and

at 0 deg C using resonance air column apparatus

dd. Solve problems

ee. Explain and define beats

ff. Define beat frequency

gg. Solve problems

hh. Explain vibrations in a stretched string

ii. State three laws of transverse vibration in a stretched string and write their

jj. relevant formula

kk. Explain the quantities involved in the formula

ll. Describe the experiments to determine the unknown frequency of the given

mm. tuning fork using sono-meter by comparison method and absolute method

nn. Solve problems

oo. Explain the difference between noise and musical note

pp. Explain the characteristics of musical note

qq. Explain the meaning of acoustics

rr. Explain and define echo, reverberation and reverberation time

ss. Explain absorptive power of a surface with examples like glass, open window etc.

tt. Write Sabine's formula and explain the quantities involved in the formula

uu. Explain the remedies for the above acoustical defects

7. Electromagnetism

a. Explain Solenoid

b. Explain inductance, self inductance & mutual inductance.

c. Differentiate between self and mutual inductance.

d. Explain electron theory of magnetism

e. Explain weber elements

f. Write definition of permeability, retentivity, coercivity.

g. Explain dia-magnetism, para-magnetism, ferro-magnetism

h. Differentiate between dia-magnetism, para-magnetism, ferro-magnetism

i. Explain what are ferrites.

8. Tests and revisions


Page 9 of 10

Second Semester Diploma in Ceramic Technology MODEL QUESTION PAPER

APPLIED PHYSICS(CERAMICS)

Time :3 Hours] [Max.Marks :100]

Note:

i. Section I is compulsory.

ii. Answer any two full questions from rest of each sections

SECTION I

1. Fill in the blanks with appropriate word/words:

A.

a) The SI unit of impulse is…………………… .

b) The rise of oil in a capillary tube due to ………………….

c) The acceleration of a moving body is zero. Its velocity is………..

d) The distance between two consecutive threads of a screw gauge is called……

e) The refractive index of air is …………….

B. Explain newton’s third law of motion

SECTION II

2. a ) What are the dimensions of aphysical quantity? State 3 limitations of dimensional manalysis.

b) Write a neat diagram of screw gauge and name its parts.

c) In a screw gauge , there are 50 HSD . while measuring the diameter of a thin wire , the

following observations are made :ZE=-5HSD. Distance moved by the screw for 6 rotation is

3mm , HSR=23, PSR=0.5mm. Calculate the observed diameter and corrected diameter of the

wire.

3. a) Define centripetal force. Write its SI unit. Write any two practical examples to indicate the

existence of centripetal force.

b) A 10 g piece of wax is sticking to the rim of a flywheel with a force of 100 N . If the radius of

flywheel is 1m , what max, number of revolutions per second can the flywheel make without

the wax getting detached ?

c) state Newton’s first law of motion

4. a) Define uniform velocity , an arrow is shot vertically up with a speed of 49m/sec. Find the

maximum height reahced and the total time for which the arrow was in air.

b) Define specific gravity of a substance . Describe an experiment to determine the specific

gravity of lead.

c) Define coefficient of elasticity.

SECTION III

5. a) Define Strain, explain three different types of strain and give example for each.

b) A wire of 3 mts long and 0.625mm2 is found to stretch 3mm under tension of 1.2ton rate.

What is the young’s modulus of material of the wire.

6. a) Define pressure of a point in a liquid. Obtain an expression for pressure at a point of depth ‘h’

in a liquid of density ‘d’.

b) define surface tension

c) A cylinder of 35cm long 8cm2 in cross section is filled with water. Calculate thrust exerted by

water on the bottom of the cylinder. Given that g=980m/sec2.


Page 10 of 10

7. a) Distinguish between heat and temperature.

b) Mention different scale of temperature and write the relation among them.

c) State charle’s law and explain briefly

SECTION IV

8. a) What are stationary waves? Write 4 charecteristics of stationary waves.

b) explain the factors which affects the velocity of sound in gas

9. a) What are lasers, write any four applications of laser

b) State the laws of vibration of stretched strings with relevant equations.

10. a) Mention the principles of electromagnetic induction

b) what are solenoids? Explain their application

c) Differentiate between mutual and self induction

Diploma Course in Ceramic Technology

FIRST SEMESTER

SUBJECT:Applied Chemistry(Ceramics)

No. of Hrs/Week: 04 Hrs Total No. of Hrs: 64

Sl.

No.

TOPIC HRS

ALLOTED

1 General ideas of 07

2 Structure of atom 08

3 Periodic priorities of elements 08

4 Acids, bases and salts 05

5 Thermodynamics 05

6 Chemical bonds 04

7 Electrochemistry 05

8 Metals and alloys 05

9 Corrosion 05

10 Water 03

11 Organic chemistry 05

12 Environmental pollution 04

Total 64 Hrs

COURSE CONTENT

1.0. GENERAL IDEAS OF

1.1. atoms, molecules, atomic and molecular weight, symbols, formula and

equation Dalton’s atomic theory, Avogadro’s hypotheses, laws of chemical

combination.

2.0. STRUCTURE OF ATOM

2.1. Rutherford model of the structure of an atom. Bohr’s theory of electrons.

Quantum numbers and their significance, electronic configuration-meaning

and use. Isotopes. Lattice structure, crystalline and amorphous solids.

3.0. PERIODIC PRIORITIES OF ELEMENTS

3.1. Periodic law, periodic table, periodicity in properties like atomic radius and

volume, ionic radii, ionization energy and electronic affinity.

4.0. ACIDS BASES AND SALTS

4.1. Concept of PII scale, determination of PII value, role of PII in industrial

processes.

5.0. Thermodynamics

5.1 Basics terms Laws of thermodynamics, Enthalpy of reaction .

6.0. CHEMICAL BONDS

6.1. Electrovalent, covalent and co-ordinate bonds and their properties, hydrogen

bonds, metallic bonding properties such as texture, conductance, luster,

ductility and malleability.

7.0. Electrochemistry

7.1. Definition.Electrorefining, electroplating, anodisation process.

8.0 METALS AND ALLOYS

8.1.Cast iron, mild steel, aluminum and their properties, elementary

knowledge of heat treatment of steel hardening, tempering, annealing,

normalizing and case hardening, composition, properties and uses of steel

micro-alloyed steel alloys of iron, copper and aluminum.

09. CORROSION

91. Definition, Electro chemical theory of corrosion, factors affecting corrosion

rate, rusting of iron, methods of preventing corrosion, modification by alloying

and changes of environment and non-metallic coatings.

10.0. WATER

12.1. Impurities in water, methods of their removal. Hard and soft water,

disadvantages of using hard water in boilers, methods of removal of

hardness. PH value and its determination. Role of PH in industrial

processes.

11.0. ORGANIC CHEMISTRY

11.1. Homologous series saturated and unsaturated compounds-preparations,

properties and industrial applications. Preparation and uses of methy1

and ethy1 alcohol1

11.2. Plastics and polymers: polymerization, macromolecules. Thermoplastics

and thermosetting plastics, PVC, perspex, polystyrene, nylon, synthetic

rubber and phenol, formaldehyde, resin, their application in industry.

12.0. ENVIRONMENTAL POLLUTION-BASIC CAUSES OF POLLUTION

12.1. Water pollution-Treatment of industrial effluents

12.2.Air pollution-control of poisonous emissions of oxides of sulphur, nitrogen

carbon, hydrocarbons. Control of engine exhaust and power house emissions.

Control of smoke pollution in ceramic industry.

REFERENCE BOOK:1) Standard Books for 10+2 course.

2)Engineering chemistry by JAIN & JAIN.

3)Inorganic chemistry by Puri & Sharma

General Objectives

1.0. General ideas of

1.1. Understand the basic ideas of atoms, molecules. Atomic and molecular weight,

symbol, formula &

Equation

1.2. Know the Dalton’s atomic theory, Avogadro’s hypothesis & laws of chemical

combination.

2.0. Structure of an atom

2.1. Know the Rutherford’s &Bohr’s model of an atom, Quantum numbers, electronic

configuration.

2.2. Understand the meaning of isotopes, lattice structure, solids.

3.0. Periodic priorities of elements

3.1. Understand the periodic law, periodic table, atomic radius & volume, ionic radii,

ionization energy, &electronic affinity.

4.0. Acids, bases &salts.

4.1. Understand the concept of pH scale, its determination & application.

5.0. Thermodynamics.

5.1. Basic terms involved in thermodynamics, laws of thermodynamics.

5.2. Know the enthalpy of reaction,

6.0. Chemical bonds.

6.1. Know the electrovalent (ionic), covalent, co-ordinate, hydrogen bond & their

properties.

6.2. Know the properties of metallic bond such as texture, conductance, luster, ductility &

malleability.

7.0. Electrochemistry.

7.1. Understand the meaning of electro refining, electroplating & anodisation process.

8.0. Metals & Alloys.

8.1. Know the cast iron, mild steel, aluminum & their properties.

8.2. Know the heat treatment of steel, Uses of steel, alloys of steel, iron, copper &

aluminum.

9.0. Corrosion.

9.1. Know the definition, electrochemical theory, factors &rusting of iron, methods of

prevention.

10.0. Water.

10.1Know the impurities in water, methods of removal, hard & soft water, disadvantages

of hard water & methods of removal.

11.0. Organic chemistry.

11.1. Understand the meaning of homologous series, saturated 7 unsaturated compounds,

their properties & application .Preparation & uses of methyl &ethyl

alcohol…………………………………….

11.2. Know the meaning of plastics, polymers, polymerization, thermoplastics &

thermosetting plastics.

12.0. Environmental pollution.

12.1. Understand the water pollution, air pollution, smoke pollution, causes &effects.

Specific objectives

1.0.General ideas of

1.1.General study of atoms, molecules, atomic & molecular weight, symbols,

formula & equation.

1.2.Study of Dalton’s atomic theory, Avogadro’s hypothesis & laws of

chemical combination.

2.0.Structure of an atom.

2.1.Explain the Rutherford & Bohr’s theory of model of an atom.

2.2.Describe quantum number 7 their significance in brief.

2.3.Know the electronic configuration, isotopes & lattice structure.

3.0.Periodic priorities of elements.

3.1.State modern periodic law.

3.2.Study of periodic table, properties like atomic radius, volume, ionic radii,

Ionization energy & Electronic affinity.

4.0. Acids, Bases & Salts.

4.1. Understand the concept of pH scale& its determination.

4.2. Study the role of pH in industrial processes.

5.0. Thermodynamics.

5.1. Study of basic terms involved in thermodynamics.

5.2. State first law of thermodynamics.

5.3. Study of enthalpy of reaction.

6.0. Chemical bond.

6.1. Definition & explanation of electrovalent, covalent, co-ordinate & hydrogen bond.

6.2. Study of metallic bond & their properties like texture, conductance, luster, ductility

& malleability.

7.0. Electrochemistry.

7.1. Definition. Explanation.

7.2. Study of electro refining, electroplating & anodisation process.

8.0. Metals & Alloys.

8.1. Brief explanation of cast iron, mild steel, aluminum & its properties.

8.2. Know the heat treatment of steel.

8.3. Study of properties & uses of steel, alloys of steel, iron, copper & aluminum.

9.0. Corrosion.

9.1. Definition, Electrochemical theory of corrosion. --------------------------------------------

---

9.2. Factors affecting corrosion rate

9.3. Study of Rusting of Iron, Methods of prevention

10.0. Water

10.1 Discuss about impurities in water, methods of removal

10.2. Study of hard & soft water, disadvantages of using hard water in boilers

11.0. Organic chemistry

11.1. Study of homologous series, saturated & unsaturated compounds

11.2. Preparation & uses of methyl & ethyl alcohol

11.3. Discuss about plastics & polymers

11.4. Study of thermoplastics & thermosetting plastics

11.5 Discuss about PVC, Perspex, polystyrene, nylon, synthetic rubber, phenol

formaldehyde resin

12.0 Environmental pollution

12.1 Study of water pollution, causes, treatment

12.2 Study of air pollution, control of poisonous emissions of oxides of sulphur, nitrogen

carbon & hydrocarbons

12.3 Control of engine exhaust & power house emission

12.4 Control of smoke pollution in ceramic industry

REFERENCE BOOK:

1. Standard books for 10+2 course

2. Engineering chemistry by JAIN & JAIN

3. Inorganic chemistry by Puri & Sharma


APPLIEDCHEMISTRY (CERAMICS)

TIME:- 3 HOURS MAX MARKS:100

NOTE: 1) SECTION I IS COMPULSORY.

2) ANSWER ANY TWO FULL QUESTIONS FROM EACH OF

SECTIONS-II, III &IV

3) EACH QUESTION OF SECTIONS –II, III &IV CARRIES 15

MARKS.

SECTION-I

I. a) Fill in the blanks with appropriate word

i) The neutral fundamental particle in an atom is ----- (5)

ii) The general electronic configuration of p-block element is -----

iii) Functional group of alcohol is -----

iv) The pH value equation is -----

v) Brass is an alloy of ----- metal.

b) Define ionization energy. Discuss the variation of ionization energy in the periodic

table.

SECTION-II

2. a) State Avogadro’s hypothesis. ( 2)

b) Explain the postulates of Bohr’s model of an atom. (5)

c) What are isotopes? Give any two examples. (4)

d) What is ionic bond? How is an ionic bond formed? (4)

3. a) What is pH value? How is p

H useful for the determination of p

H value in industry?

(6)

b) Explain electrochemical theory of rusting of iron? (5)

c) Write the characteristics of covalent compounds. (4)

4. a) State first law of thermodynamics.(2)

b) Explain anodization of aluminum? (4)

c) Discuss the elementary knowledge of heat treatment of steel. (5)

d) What are different types of impurities present in water? What are soft &hard water.

SECTION-III

5. a) What is a polymer? Distinguish between thermoplastics and thermosetting plastics

Give example. (7)

b) Mention the important uses of aluminum alloys (4)

c) Write a note on control of smoke pollution in ceramic industry.(4)

6. a) Explain the preparation of ethyl alcohol . Write any four uses of ethyl alcohol. (7)

b) What is e.c.e of metal? Explain in brief. (4)

c) What is atomic weight & molecular weight? (4)

7. a) What is metallic bond? Explain conductance &malleability with an example (6)

b) What are the factors affecting corrosion rate? (4)

c) Mention the disadvantages of using hard water in boilers. (5)

SECTION-IV

8. a) What is homologous series? Mention the characteristics of homologous series. (5)

b) What are the postulates of Rutherford’s model of an atom?(5)

c) Mention the four quantum numbers.Give their importance. (5)

9. a) Mention the methods by which temporary & permanent hardness can be removed.

(6)

b) What is meant by pollution? Mention the air pollutants. What are the controlling

measures for engine exhaust? (6)

c) Write a note on electron affinity. (3)

10. a)What are saturated & unsaturated hydrocarbons? (4)

b) State modern periodic law. Describe the classification of elements in the long form

of periodic table? (5)

c) Write the specific uses of PVC, polystyrene & nylon. (6)


First Semester

Subject: Basic Ceramics Lab


Sl No. Topic

1. Identification of different ceramic raw materials and wares. 6

2. Determination of cumulative percentage residue. 9

3. Determination of percentage moisture content. 9

4. Determination of percentage water of plasticity 9

5. Determination of percentage pore water of clay sample 9

6. Determination of Shrinkage water of clay sample 12

4. Determination of percentage of linear drying shrinkage 9

5. Determination of percentage of volume drying shrinkage 9

6. Determination of Bulk density of unfired and fired sample 12

7. Determination of specific gravity of plastic and non plastic sample. 12

Total:-- 96

Diploma course in ceramic technology

Applied Geology lab

II SEM Total no hrs:96

List of Experiments

1) Identification of minerals in hand specimens

2) Identification of igneous rocks in hand specimens

3) Identification of sedimentary rocks in hand specimens

4) Identification of metamorphic rocks in hand specimens

5) Study of symmetry character in crystals

6) Study of axial & symmetry character in cubic, tetragonal,

hexagonal, orthorhombic, monoclinic & triclinic system

7) Study of optical properties of minerals

8) Study of elements of crystal in crystal models


Ceramic Chemistry Lab Page 1 of 1

Diploma Course in Ceramic Technology

First Semester

SUBJECT: Applied Chemistry LAB

Contact Hrs / Week: 6 Contact hrs / Semester: 96

1. Study of chemical apparatus& its uses.

2. Determination of melting, boiling point of Organic compounds.

3. Determination of viscosity of water By Poiseuilleis method.

4. Determination of Viscosity of liquid by using Ostwald’s viscometer.

5. Determination of refractive index of water by shift method.

6. Determination of PH value.

7. Qualitative analysis of mixture with basics oxides and silicates.

8. Acid base titration method.

9. Study of chemical balance.

10. Determination of heat of neutralization of strong acid with strong base.

11. Purification of organic compounds.

12. Determination of E.C.E. of copper.


Second Semester

Subject: Applied Physics Lab


Sl No. Topic

1. Use of Vernier caliper, Screw gauge

2. Verification of laws of simple pendulum. & determination of

value of g.

3. Verification of Archemide’s principle.

4. Verification of Hooks law, determination of Young’s modulus.

5. Determination of coefficient of viscosity of given liquid.

6. Determination of specific heat of solids and liquids

4. Determination of latent heats of ice and steam

5. Determination of thermal conductivity of metal by searle’s

method

6. Determination of focal length of mirrors & lens

7. Determination of velocity of sound by resonance tube method

8. Determination of of surface tension of water

9. Experiment on sonometer to find frequency.

bcs_geos_sios

Contact hrs/Week: 04 Total Contact Hrs / Sem.: 64

General Educational Objectives :

After the completion of the study of this subject students should be able to

1. Recognize the various models of computer system

2. Recognize the various parts, physical components of a computer

3. Understand the cable connections and booting steps

4. Know the various I/O devices

5. Understand the need of Operating System

6. Use the various DOS commands

7. Understand the use of mouse buttons

8. Appreciate working under windows environment

9. Appreciate the use of Windows Explorer

10. Create any document

11. Know to format the document and take a printout

12. Create a worksheet in

13. Use functions and formulas

14. Know to format the worksheet and take a printout

15. Create a database

16. Create view,form,table,query and report

17. Know to take the printout of the report

18. Create a presentation using Powerpoint

19. Know to Insert Slides into the presentation

20. Understand various slide transitions

21. Demonstrate the slide show

22. Know to print the handouts

23. Understand the basics of Internet

24. Create an e-mail account

25. Know to send and receive mails

26. Use search engine while browsing

27. Use any Kannada Software package

Specific Instructional Objectives:

1 Concepts of Hardware and Software

1.1 Identify the models of computers - Tower, Desktop, Laptop, Palmtop

1.2 Identify and understand front panel switches and back panel connectors of

a computer system.

1.3 Identify and Understand the physical components of computer :

1.3.1 Motherboard (System Board)

1.3.2 Processor chip

1.3.3 Memory

1.3.4 HDD

1.3.5 FDD

1.3.6 CDD(R/W)

1.3.7 SMPS

1.3.8 Ports (Serial,Parallel & USB)

1.3.9 VGA/SVGA/AGP

1.3.10 Sound card

Diploma Course in Ceramic Engineering

I Semester

Subject: Basic Computer Skills

Page 1 of 5

bcs_geos_sios

1.3.11 Network Card

1.3.12 MODEM Card (internal and External)

1.3.13 Input devices - Keyboard,Mouse,Scanner,Joystick,Floppy,Compact Disk,etc

1.3.14 Output devices - Monitor, Printer, Plotter, etc.

1.4 Understand the need of an Operating system

1.5 Differences between command line and graphical user interface

1.6 Understand the meaning of the following terms :

1.6.1 Single user single tasking

1.6.2 Single user multi tasking

1.6.3 Multi user multi tasking

1.6.4 Batch processing

1.6.5 Real time Processing

1.6.6 Distributed processing

1.7 Do the connections of the system, switch on and understand the booting steps

1.8 Understand the concept of file and directory, naming rules for files / directories,

types of files

1.9 Basic DOS commands - CLS,DIR, Date, Time, Version, MD,CD,RD,Del,

Copy,Ren,Volume; Use of wild characters,Format,Path, Type

1.10 Getting started with

1.10.1 Windows

1.10.2 Desktop

1.10.3 Icons

1.10.4 Mouse operations - single click, double click, click & drag

1.10.5 Shortcuts

1.10.6 Popup Menus

1.10.7 Start button

1.10.8 Keyboard operations in window

1.10.9 Task Bar

1.10.10 Customizing the desktop

1.11 Exposure to Windows Operating System

1.11.1 Logging on to Windows

1.11.2 Starting and closing a program

1.11.3 Switching between programs,documents

1.11.4 Re-sizing windows - Maximize, Minimize and restore

1.11.5 Find - file, folders, etc.

1.11.6 Run - starting a program using run command

1.11.7 Shutdown - shutdown / restart computer

1.12 Practice Windows Explorer - through My computer, Icon and shortcut entry

1.13 Creating/opening a document

1.14 Understand clipboard concept for copy,cut and paste

1.15 Editing and saving the document in Floppy/ Hard disk

1.16 Study and understand Windows utilities -notepad, wordpad, paint, calculator,etc

1.17

Study and understand Windows system tools - scandisk,backup,system info, winzip,

etc

Page 2 of 5

bcs_geos_sios

2 Utilities

2.1 WORD PROCESSING

2.1.1

2.1.2 Create a new document - edit, save, close

2.1.3 Page setup (Layout)

2.1.4

2.1.5 Creating documents with Multiple columns

2.1.6 Inserting symbols,file, hyperlink,cliparts and pictures into the document

2.1.7

2.1.8

2.1.9 Creating drawings and charts using drawing toolbar

2.1.10 Creating tables and borders

2.1.11 Creating templates, envelopes & labels

2.1.12 Object Linking and Embedding (OLE)

2.1.13 Taking printout of the document

2.1.14 Mail-merging

2.1.15 Creating Macros and customizing Word

2.1.16 Exiting Word

2.2 SPREADSHEET AND CHARTS

2.2.1

2.2.2 Creating an excel book

2.2.3

2.2.4 Entering data - numeric, text and formula

2.2.5

2.2.6 Formatting rows and columns

2.2.7 Understand Filling series

2.2.8 Selecting cells, rows or columns

2.2.9 Clearing contents and formats of the cells selected

2.2.10 Creating different types of graphs for given data

2.2.11 Formatting charts

2.2.12 Dealing with formulas, functions related with text, logical, mathematical, etc

2.2.13 Manipulating Data - Sorting, filtering, validation, importing & exporting data

2.2.14 Working with windows - Splitting, freezing and setting the print area

2.2.15 Creating an excel report

2.2.16 Printing an excel sheet/part of an excel sheet

2.2.17 Object Linking and Embedding (OLE)

2.2.18 Creating Macros and customizing Excel

2.2.19 Exiting Excel

2.3 DATAPROCESSING

2.3.1

2.3.2 Creating a database,tables,view,forms,query,report,index,etc

2.3.3 Use of wizards to create tables

2.3.4 Create a report and take the printout

2.3.5 Creating Macros and customizing Access

2.3.6 Exiting Access

2.4 PRESENTATION

Page formatting - Inserting page numbers, date,time, fields,header and

footer,footnote, comments,etc

Practicing the utilities like find, replace, goto, spell check, grammer check, thesaurus,

wordcount,autotext and autocorrect

Understanding the excel sheet,cell,rows&columns, sheet size, navigating the

workbook

Formatting a cell - number, date,time,text, alignment, border, font,pattern, protection,

etc.

Invoking word application and understand the different parts -

titlebar,Menubar,Toolbar,Scrollbar,Control button, etc

Text formatting - Selection of Fonts, fontsize, alignments, line spacing, paragraph

alignment, indents & tabs

Invoking Excel application and understand the different parts - titlebar, Menubar,

Toolbar, Scrollbar, control window, etc

Starting Access and understanding the concept of data,field, record, table and

database

Page 3 of 5

bcs_geos_sios

2.4.1

2.4.2

2.4.3 Opening, saving,closing a presentation

2.4.4

2.4.5 Slide show - manual, auto

2.4.6 Printing handouts

2.4.7 Creating Macros and customizing Powerpoint

2.4.8 Exiting Powerpoint

3 INTERNET

3.1 Understand the meaning of :

3.2

3.3

3.4 Chatting

4 Practice on any Kannada Software Package

WORD PROCESSING

1. Create a business or personal letter

2. Create a company letterhead

3. Create a simple newsletter

4. Create a memo

5. Create a resume

6. Create an Invitation/Greeting Card

7. Create the cover page of a project report

8. Create a mailmerged letter/Invitation

9. Create a Macro which inserts a picture and formats the text

SPREADSHEET

1. Create a worksheet with 4 columns. Enter 10 records and find the sum

of all columns

2. Create a report containing the pay details of the employees

3. Create a results sheet containing Candidate's Register No., Name, Marks

for all subjects, Total and result.

Total and result must be calculated as below:

Total is sum of marks in all subjects

Result is Distinction if Total >= 70 %

First Class if Total > = 60 % and < 70 %

Second Class if Total >= 50 % and < 60 %

Pass if Total >= 35 % and < 50 %

provided the candidate has secured atleast 35 marks in each

subject. Fail otherwise.

4. Create a simple Bar chart to highlight the sales of a company for

3 different periods

5. Create a pie-chart - give legends

6. Create a worksheet importing data from a database and calculate sum of

all the columns

7. Create a Macro which creates a line chart using the data in the worksheet

DATABASE

SAMPLE EXERCISES

Creating an E-Mail ID, Sending and Receiving E-Mails, voicemail,video mail, video

conferencing, etc

Creating a presentation using auto context wizard, Design Templates and Blank

presentation

Working with slides - Inserting pictures, tables,sound files, outline,slide transitions

Network,Internet,intranet,internet server, internet browser,Webpage, Website,URL's,

Search engines, http,www,HTML,DHTML and Outlook

Logging on to internet, browsing the net, using search engines, Downloading a file

Invoking Powerpoint application and understand -

titlebar,Menubar,Toolbar,Scrollbar,control window, etc

Page 4 of 5

bcs_geos_sios

1.Create a simple table for result processing

2.Design a query table for the same table

3.Design a form to update/modify the table contents

4.Design a report to print the result sheet and marks card for the above table.

PRESENTATION

1.Create a simple presentation to list simple DOS commands,Hardwares,

Softwares etc.

INTERNET BASICS

1.Practice browsing of different sites using search engine

2.Practice Understanding different e-mail services-Outlook, Yahoomail, rediffmail

etc.

3.Practice creating e-mail account, Sending Receiving & Storing of mails

Duration: 3 Hrs Max Marks 100

1 Record 5

2 Viva 20

3 One question each on any two of the following 30 x2 =60

3.1 M S Word

3.2 M S Excel

3.2 M S Access

3.4 M S Power Point

4 Internet Basics 15

Total 40

1 Record 5

2 Viva 10

3 One question to be set from any 2 of the 4 combination

3.1 Writing 10

3.2 Execution 15

3.3 Printout 5 30x 2=60

4 Two or Three Questions to be asked on Internet Basics 15

Total 100

Reference Books

1. Basic Computer Skills By Dr M A Jayaram & D S Rajendra Prasad. Sapna Publications.

Scheme of Examination

Scheme of Evaluation

Page 5 of 5

Contact hrs/week : Contact hrs. / Sem:96

(2 Slots of 3Hrs each/Week)

Sl. No. Topics hrs alloted

1 Introduction to Engineering Graphics

2 Dimensiong

3 Projection of Points 8

4 Projection of Lines 12

5 Projection of Planes 14

6 Projection of solids 18

7 Conversion of Isometric View to orthographic views 22

Tests 6

Total 80

Subject Contents

1 Introduction to Engineering Graphics

Definition of the drawing-technical drawing

Engineering Instruments

Drawing Board, sheet - their standards sizes

Title Block, layout, Symbols,

types of lines, conventions, standards

applications of different types of lines

2 Dimensioning

Definiton and importance

Dimensioning components:

Dimension line, extension line, arrow head, leader, dimensional figure, symbol,scale and units

Systems of dimensioning

aligned system

unidirectional system

Arrangement of dimensioning

chain, parallel, progressive, combined, co-ordinate, equal and equi-distant…

Dimensioning common features

Circular, fillets, chamfers, rounds, curved surface, spherical, angles, tapers, threads, and knurls

3 Projection of Points

Four quadrants ,principal planes ,profile planes

Projection of points in all the four quadrants

Projection of points- front view,top view and side views

4 Projection of lines

Projection of line when parallel to both the planes

Projection of line parallel to one plane and perpendicular to other plane

Projection of line inclined to one plane and parallel to other plane

(Side views for above cases)

Diploma Course in Mechanical Engineering

First Semester

Subject Title: Engineering Graphics

Projection of line inclined to the both the planes

5 Projection of planes

Meaning of the planes like square, rectangular,pentagonal,hexagonal,and

circular

Solving the problems using change of position method only

6 Projection of solids

(All problems should be taught considering solids should be resting on HP)

Projection of cube, triangular prism, square prism, rectangular prism

pentagonal prism, hexagonal prism, pyramids like square, rectangular, pentagonal and

hexagonal, Cone and cylinder in different positions using first angle projection method

7 Projection of Isometric View to orthographic views

Projection of orthographic views of solids like prism, pyramid, cube, cylinder, cone,

Sphere, machine components etc

Tests

Total

Scheme of Examination

1 Chapter 1 is only for practice and internal assessment and not for examination

2 Three questions must be set as per the following pattern

Q. No. From Chapters

1 introduction

2 Dimensiong

3 Points

4 Lines

5 Planes

6 Solids

7 Iso to Ortho

Reference books

1 Elementary engineering drawing : N.D.Bhatt

2 Engineering Drawing : K.R. Gopal krishna

3 Fundamentals of engineeing drawing : R.K. Dhawan

6 Engineering Drawing : I.S. Morries

7 Step by step engineering drawing : Vee Ess

8 Engineering graphics : Verges

9 Engineering drawing by Venugopal

Question paper can be set as per reqular M08 standards

Total 140

10

10

20

30

30

30

Marks Alloted

10

Drawing the three views of the planes in different positon using first angle projection

method

9

12

Dimension line, extension line, arrow head, leader, dimensional figure, symbol,scale and units

Circular, fillets, chamfers, rounds, curved surface, spherical, angles, tapers, threads, and knurls

9

15

15

18

12

6

96

ENGLISH COMMUNICATION

TABLE OF SPECIFICATIONS

Sl NO

Ability

Content

Knowledge

Comprehension

Application

Analysis Total

1 Lessons 5 25 10 40

2 Parts of speech 2 02

3 Countable & Uncountable nouns 2 2

4 Use of some, any etc. 6 6

5 Main & Aux. verbs 2 2

6 Uses of Tenses 8 8

7 Voice 4 4

8 Interrogatives 2 2

9 Negatives 2 2

10 Prepositions 4 4

11 Question tags 2 2

12 Use of adverb too 2 2

13 Use of idioms & phrases 4 4

14 Story from outlines 5 5

15 Developing notes into a paragraph 5 5

16 Comprehension of unseen passage 5 5

17 Summarising 5 5

Total 13 32 40 15 100

Department of Technical Education

All Diploma Courses in Engineering and Technology Streams

First or Second Semester

ENGLISH COMMUNICATION

Contact Hrs./Week: 4 Contact Hrs. / Semester: 64

GOAL: IMPROVEMENT OF ENGLISH COMMUNICATION SKILLS OF I OR II SEMESTER

STUDENTS OF DIPLOMA COURSES IN ENGINEERING AND TECHNOLOGY.

SPECIFIC INSTRUCTIONAL OBJECTIVES:

1 READING SKILL

The student is able to :

1.1 Understand the difficult words and phrases in the lesson

1.2 Use the words and phrases correctly in his own sentences

1.3 Read the lesson properly without mistakes

1.4 Read the given passage correctly.

2 WRITING SKILL

The student is able to

2.1 Write the answers correctly to the questions on the lessons

2.2 Write personal letters in the proper format without mistakes

2.3 Use words and phrases in his own sentences

2.4 write grammatically correct sentences.

3 PRACTICAL KNOWLEDGE OF GRAMMAR

The student is able to

3.1 Use verbs correctly

3.2 Use various phrases appropriately

3.3 Use interrogatives and negatives

3.4 Convert active voice into passive and vice versa

3.5 Frame questions, question tags and give short form answers correctly

3.6 Use prepositions appropriately

4 COMPREHENSION

4.1 The student is able to read and understand the seen & unseen passages

and answer the questions given

5 CREATING AWARENESS

5.1 The student becomes aware of current environmental issues and

about his responsibilities toward environment factors.

5.2 Awareness about Right to Information Act

CONTENT

1 TEXT BOOK

“ENGLISH COMMUNICATION FOR POLYTECHNICS” By NITTTR, Chennai and Published by Orient BlackSwan Pvt Ltd, Hyderabad.

2 GRAMMAR

2.1 PARTS OF SPEECH

2.2 COUNTABLE, UNCOUNTABLE AND PROPER; NOUNS

2.3 USE OF SOME, ANY, MUCH, MANY, A LOT OF, ETC.,

2.4 MAIN AND AUXILIARY VERBS

2.5 USES OF TENSES

2.6 ACTIVE AND PASSIVE VOICE

2.7 INTEROGATIVES

2.8 NEGATIVES

2.9 PREPOSITIONS

3.1 QUESTION TAGS

3.2 USE OF ADVERB TOO

3.3 USING PHRASES IN OWN SENTENCES

3 COMPOSITION & COMPREHENSION

3.1 WRITING RESPONSE TO PICTURE

3.2 STORY FROM GIVEN OUTLINES

3.3 EXPANDING OUTLINES INTO PARAGRAPH

3.4 PARAGRAPH WRITING USING HINTS

3.5 COMPREHENSION OF UNSEEN PASSAGE

3.6 NOTE MAKING

3.7 DEVELOPING NOTES INTO PARAGRAPHS

3.8 SUMMERISING

MONTHLY TESTS

READING AND COMPREHENSION EVALUATION

BOARD OF TECHNICAL EXAMINATION – KARNATAKA

SUBJECT: APPLIED MATHEMATICS – I

For I- semester

DIPLOMA COURSES OF ALL BRANCHES

Contact hour per week: 04 Contact hour per Semester: 64

UNIT NO. CHAPTER TITLE CONTACT

HR.

ALGEBRA

1 DETERMINANTS 2

2 MATRICES 4

3 BINOMIAL THEOREM 3

4 LOGARITHMS 2

5 VECTOR ALGEBRA 6

TRIGONOMETRY

6 UNITS AND MEASUREMENT OF AN ANGLE 3

7 TRIGONOMETRIC RATIOS OF ACUTE

ANGLE AND STANDARD ANGLES

6

8 TRIGONOMETRIC RATIOS OF ALLIED

ANGLES

4

9 HEIGHTS AND DISTANCES 2

10 COMPOUND ANGLES 4

11 MULTIPLE AND SUB MULTIPLE ANGLE 2

12 TRANSFORMATION FORMULAE 4

13 PROPERTIES AND SOLUTIONS OF

TRIANGLES

4

14 INVERSE TRIGONOMETRIC FUNCTIONS 2

ANALYTICAL GEOMETRY

15 BASIC CONCEPTS OF ANALYTICAL

GEOMETRY

6

16 STRAIGHT LINES 6

17 TESTS AND ASSIGNMENTS 4

TOTAL HOUR 64

REFFERENCE BOOKS: 1.Applied Mathematics -I By W.R Neelakanta Sapna Publications.

2. Applied Mathematics -I By Dr. D S Prakash S Chand Publications

3. Text book of mathematics for P U C

QUESTION PAPER BLUE PRINT

FOR APPLIED MATHEMATICS – I

UN

IT N

O.

HO

UR

Questions

to be set

(2 Marks)

PART- A

Questions

to be set

(5 Marks)

PART- B

Questions

to be set

(5 Marks)

PART- C

Questions

to be set

(5 Marks)

PART- D

1 2 1 1 - -

2 4 1 2 - -

3 3 1 1 - -

4 2 - 1 - -

5 6 2 3 - -

6 3 - - 1 - 7 6 1 - 2 -

8 4 1 - 2 -

9 2 - - 1 -

10 4 1 - 1 -

11 2 1 - 1 -

12 4 1 - 1 -

13 4 1 - 2 -

14 2 1 - 1 -

15 6 1 - - 2

16 6 2 - - 2

TOT

AL

64 15 8 12 04

Questions to

be answered

10 5 8 3

APPLIED – MATHEMATICS – I

Marks No. of Questions No. of Questions

to be set to be Answered

Part A 2 X 10 = 20 15 10

Part B 5 X 05 = 25 08 05

Part C 5 X 08 = 40 12 08

Part D 5 X 03 = 15 04 03

Total = 100

CONTENTS OF APPLIED MATHEMATICS – I

ALGEBRA

UNIT – 1: DETERMINANTS. 2 Hr.

Definition, Order, Expansion of 2nd

& 3rd

order Determinants by means of

examples. Problems on finding unknown quantity in a 2nd

& 3rd

determinant using using

expansion. Solving simultaneous linear equations by determinant method ( Cramer’s

rule). Problems.

UNIT – 2: MATRICES. 4 Hr.

Determinant value of a square matrix. Singular and non singular matrices with

examples. Minor and co factor of an element of a matrix. Adjoint of a matrix. Problems.

Characteristics equations of a square matrix and its roots. Problems. Cayley – Hamilton’s

theorem (statement only). Problems. Find inverse of a matrix using the theorem.

UNIT – 3: BINOMIAL THEOREM. 3 Hr.

Meaning of nCr and its value. Binomial theorem for (x + a)

n, where n ia a positive

integer. Expansion. Finding constant term, co-efficient of xn , particular term and middle

term(s). Problems.

UNIT – 4: LOGARITHEMS. 2 Hr.

Defination of common and natural logarithems. Laws of logarithems. Problems

on laws.

UNIT – 5: VECTOR ALGEBRA. 6 Hr.

Defination of vector. Representation of a vector as a directed line segment.

Magnitude of a vector. Types of vectors. Position vector. Vector can be expressed in

terms of end points of position vector. Addition and subtraction of vector in terms of line

segment. Vector in a plane and vector in a space in terms of unit vector i, j and k

respectively. Product of vectors. Scalar and vector product. Geometrical meaning of

scalar and vector product. Applications of dot(scalar) and cross(vector) product:

Projection of a vector on another vector. Area of parallelogram and area of triangle. Work

done by a force and moment of force

TRIGONOMETRY

UNIT – 6: UNITS AND MEASUREMENT OF AN ANGLE 3 Hr

Defination of an angle. Systems of unit of an angle. Defination of radian. Radian

is a constant angle. Relation between degree & radian and problems. Derivation of l = rθ

& A = ½ r2θ. Problems.

UNIT –7: TRIGONOMETRIC RATIOS OF AN ACUTE ANGLE. 6 Hr

Defination of Trigonometric ratios in terms of sides of a triangle for an acute

angle. Proof of Trigonometric identities. Trigonometric ratios of standard angles: The

numerical value of trigonometric ratios of standard angles like 00, 30

0, 45

0, 60

0 and 90

0.

Problems.

UNIT – 8: ALLIED ANGLES. 4 Hr.

Angle of any magnitude, sign of the trigonometric ratios. Meaning of allied

angles. Trigonometric ratios of allied angles in terms of θ. Problems. Complimentary

angles and relation between trigonometric ratios of complimentary angles. Problems.

UNIT – 9: HEIGHTS AND DISTANCES. 2 Hr.

Defination of angle of elevation and depression. Problems.

UNIT -10: COMPOUND ANGLES. 3 Hr.

Geometrical proof of Sin( A + B) and Cos(A + B). Find Tan( A + B) using

Sin( A + B) and Cos(A + B). Write the formulae for Sin( A - B), Cos(A - B) and tan( A -

B). Problems.

UNIT -11: MULTIPLE ANGLES. 3 Hr.

Derive ratios of multiple angles of 2A and 3A. Problems. Obtain sub multiple

angle formulae. Problems.

UNIT-12: TRANSFORMATION FORMULAE. 4 Hr.

Express sum or difference of Sine and Cosine of an angles in to product form.

Express product of Sine and Cosine of angles in to sum or difference form. Problems.

UNIT-13: PROPERTIES AND SOLUTION OF TRIANGLES. 4 Hr.

The relation between sides of a triangle and Sines, Cosines and Tangents of any

angle(Sine rule, Cosine rule and Tangent rule), Projection rule. Half angle formulae in

terms of sides of a triangle. Problems. Problems on solution of triangles (four types).

UNIT- 14: INVERSE TRIGONOMETRIC FUNCTIONS. 2 Hr.

Defination. Principle values of inverse trigonometric functions. Derivation of

results like sin-1

x + cos-1

x =Л/2 =tan-1

x + cot-1

x = cosec-1

x + sec-1

x, tan-1

x + tan-1

y = tan-1

Problems.

ANALYTICAL GEOMETRY

UNIT-15: BASIC CONCEPTS OF ANALYTICAL GEOMETRY. 6 Hr.

Defination of a point in a plane, Specification of a point using co-ordinate system.

Points on X-axis and Y-axis. Derivation of distance formula. Problems. Section formulae.

Derivation of co-ordinate of a point which divide the line internally in the given ratio( No

derivation for external division). Mid point formula. Problems. Centroid, area of a

triangle and collinear points. Problems. Locus of a point with respect to a fixed point and

with respect to two fixed points and its equations. Problems.

UNIT-16: STRAIGHT LINES. 6 Hr.

Inclination of a line with horizontal line and its slope. Intercept of a straight line.

Slope of a line parallel to X-axis and Y-axis. Derivation of conditions for two lines to be

parallel and perpendicular. Problems. Derivations equations of straight lines y = mx + c,

y – y1 = m (x – x1 ), y – y1 = (y2 – y1 / x2 – x1 ) (x – x1 ), (x / a ) + (y / b) = 1 and

x cosα + y sinα = P. General equation of a line ax +by + c = 0 and problems. Equation of

lines through a point and parallel or perpendicular to a given line. Problems. Angle

between two lines. Problems. Point of intersection of lines. Equation of a line through the

point of intersection which is parallel or perpendicular to the given line. Problems.

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

GENERAL AND SPECIFIC OBJECTIVES

ALGEBRA

UNIT – 1: DETERMINANTS. 2 Hr

GENERAL OBJECTIVES.

1.1 To understand meaning of determinants and evaluation of 2nd

& 3rd

order

determinants.

1.2 To understand the solution of linear equations by Cramer’s rule.

SPECIFIC OBJECTIVES.

1.1.1 Definition of Determinant by means of Algebraic Expression and order in terms of

Rows and Columns.

1.1.2 Evaluate Determinants of 2nd

& 3rd

order --- Problems.

1.1.3 Solve the problems to find unknown quantity in a determinant.

1.2.1 Solve the linear equations of 2 nd

or 3 rd

unknowns using determinants. Problems

UNIT – 2: MATRICES. 4 Hr

GENERAL OBJECTIVES.

2.1 To understand Minors and co-cofactors, adjoint and inverse of a matrix.

2.2 To know the characteristic equation for 2 x 2 matrix.


2.1.1 Define singular and non singular square matrix.

2.1.2 Find the minors and cofactors of each elements of matrix

2.1.3 Define adjoint of a square matrix.--- Problems.

2.1.4 Define inverse of a square matrix --- Problems.

2.2.1 Explain characteristic equation of a 2 x 2 matrix and its roots --- Problems.

2.2.2 State Cayley – Hamilton’s theorem for 2nd

order (Statement only) --- Problems.

2.2.3 Apply it to find inverse of the matrix --- Problems.

UNIT – 3: BINOMIAL THEOREM. 3 Hr

GENERAL OBJECTIVES.

3.1 To recognise the meaning of nCr & to compute the values

nC0,

nCn,

nC1,

nC2…..

Cr

3.2 To prove nCr =

nCn-r by demonstration.

3.3 To know the statement of (x+a)n for positive integral Index n.


3.1.1 Meaning of nC r and value of

nCr .

3.2.1 Use of nCr in the expansion (x + a)

n , where n is positive integer.

3.3.1 Expansion of (x + a)n

, where n is positive integer. (only statement).

3.3.2 Solve the problems of the following types

(a) expansion of type (2x +y)6 , (√3 +2)

4, (x

2 – 1/√x )

8

(b) To simplify (√2 +1)

5 + (√2 -1)

5

(c) To find middle term(s)

(d). To find the coefficient of xn and constant terms in (x+a)

n

UNIT – 4: LOGARITHMS 2 Hr

GENERAL OBJECTIVES.

4.1 To understand logarithm, common logarithm and natural logarithm.

4.2 To comprehend laws of logarithem.


4.1.1 Define logarithm,common logarithm and natural logarithm.

4.2.1 Derive the laws of logarithm

(a) loga mn = loga m + loga n

(b) loga m/n = loga m - loga n

(c) loga xk

= k loga x

(d) loga b = logc b / logc a (CHANGE OF BASE)

4.2.2 Solve problems on laws of logarithms

UNIT – 5: VECTOR ALGEBRA 6 Hr

GENERAL OBJECTIVES.

5.1 To understand vectors.

5.2 To understand vector operations.


5.1.1 Define a vector and represent a vector geometrically.

5.1.2 Name a directed line segment as a vector.

5.1.3 Write different types of vectors.

5.1.4 Write addition and subtraction of vectors in terms of the segment.

5.1.5 Explain the position vector of a point with reference to a point.

5.1.6 Write the conclusion of difference of two vectors with same initial point as position

vector of a point.

5.1.7 Define vector in a plane and vector in a space in terms of unit vectors

i, j and k respectively.

5.2.1 Write types of vector product (a)Scalar product (b)Vector product

5.2.2 Define scalar product and vector product.

5.2.3 Interpret product of vectors geometrically.

5.2.4 Design the product of vectors to find angle between them and unit vector

5.2.5 Apply product of vectors to find ( i.) projection of a vector on another vector

(ii) Area of triangle and parallelogram (iii) work done by a Force (application of

scalar product) (iv) moment of a force (application of vector product)

TRIGONOMETRY

UNIT – 6: UNIT AND MEASUREMENT OF ANGLE 3 Hr

GENERAL OBJECTIVES.

6.1 To understand the concept of angle, unit and its measurement.


6.1.1 Define an angle.

6.1.2 Define a right angle in different systems.

6.1.3 Define radian.

6.1.4 Obtain relations between radian and degree.

6.1.5 Solve problems.

6.1.6 Prove the radian as a constant angle.

6.1.7 Derive l = rө

6.1.8 Derive area of sector = (r2ө ) /2.

6.1.9 Solve related problems.

UNIT – 7: TRIGNOMETRIC RATIOS 4 Hr

GENERAL OBJECTIVES.

7.1 To understand trigonometric ratios.

7.2 To comprehend trigonometric ratios of standard angles.


7.1.1 Define trigonometric ratios for an acute angle.

7.1.2 Derive important formulae (identities)

7.1.3 Solve problems using identities.

7.1.4 Obtain trigonometric ratios of standard angles 0°, 30° , 45° , 60°,90°

7.1.5 Solve problems using standard values.

UNIT – 8: ALLIED ANGLES 4 Hr

GENERAL OBJECTIVES.

8.1 To understand allied angles of the type ( nπ/2 ± ө).


8.1.1 Define positive and negative angles.

8.1.2 Give examples to differentiate positive and negative angles.

8.1.3 Explain trigonometric ratios in different quadrants and assign signs.

8.1.4 Define allied angles in different quadrants.

8.1.5 Write formulae of 90± Ө, 180± Ө, 270± Ө, 360± Ө and (-Ө)

8.1.6 Solve problems on allied angles.

UNIT - 9: HEIGHTS AND DISTANCES 2 Hr

GENERAL OBJECTIVES.

9.1 To understand the measurement of Heights and Distances using

trigonometry.


9.1.1 Define angle of elevation and angle of depression.

9.1.2 Define the “Height” and “Distance”

9.1.3 Solve problems on height and distance.

UNIT – 10: COMPOUND ANGLES 3 Hr

GENERAL OBJECTIVES.

10.1 To understand compound angles.


10.1.1 Define a compound angle.

10.1.2 Give examples for compound angles.

10.1.3 Derive the formula of sin(A+B) and cos(A+B) geometrically.

10.1.4 Obtain tan(A+B) interms of tanA and tanB using sin(A+B) and

cos(A+B).

10.1.5 Obtain formula for sin(A-B) ,cos(A-B) and tan(A-B).

10.1.6 Solve the problems on compound angles.

UNIT – 11: MULTIPLE AND SUBMULTIPLE ANGLES. 3 Hr

GENERAL OBJECTIVES.

11.1 To understand multiple and sub multiple angles.


11.1.1 Define multiple and submultiple angle with example.

11.1.2 Derive the formulae for trigonometric ratios of 2A and 3A

using compound angle formulae.

11.1.3 Deduce half angle formulae from the ratio of 2A formulae.


UNIT – 12: TRANSFORMATION FORMULAE 4 Hr

GENERAL OBJECTIVES.

12.1 To understand transformation formulae.


12.1.1 Obtain expressions for sinC ± sinD and cosC ± cosD interms of Product of

trigonometric ratios.

12.1.2 Derive expressions for sinAcosB, cosAsinB, cosAcosB and

sinAsinB interms of the sum and difference of trigonometric ratios.


UNIT – 13: PROPERTIES AND SOLUTIONS OF TRIANGLES 4Hr

GENERAL OBJECTIVES.

13.1 To understand the properties of triangles in order to solve them.


13.1.1 Obtain sine rule ,cosine rule and tangent rule for any angle of a triangle.

13.1.2 Write half angle formulae interms of sides of a triangle (no proof).

13.1.3 Solve simple problems on above rules.

13.1.4 Find the solution of a a triangle in the following cases when (i) all sides are given

(ii)two sides and included angle is given (iii) two angles and one side is

given.(iv)two sides and non included angle is given.

UNIT – 14: INVERSE TRIGNOMETRIC FUNCTIONS. 2 Hr

GENERAL OBJECTIVES.

14.1 To understand inverse trigonometric functions.


14.1.1 Define inverse trigonometric function.

14.1.2 Write principal values of trigonometric functions.

14.1.3 Prove standard results like

1. sinˉ1 x + cos

– 1 x

= tan

–1x

+ cot

–1x

= cosec

–1x

+ sec

–1x

= π/2,

xy

y

1

x tan=y tanx ± tan2. 1-1-1-

14.1.4 Solve the problems on inverse functions.

ANALYTICAL GEOMETRY

UNIT – 15: BASIC CONCEPTS OF POINT AND LOCUS 6 Hr

GENERAL OBJECTIVES.

15.1 To understand the basic concepts of point and locus.


15.1.1 Define coordinates in two dimensional space.

15.1.2 Define a point in terms of coordinates.

15.1.3 Obtain equation for the distance between two points in terms of co ordinates.

15.1.4 Solve problems on above formula.

15.1.5 Explain the section of a straight line.

15.1.6 Derive section formula for internal division.

15.1.7 Write section formula for external division.

15.1.8 Write formula for mid point of a line.

15.1.9 Solve problems on internal and external division.

15.1.10 Define locus of a point.

15.1.11 Solve problems on locus of a point.

UNIT – 16: STRAIGHT LINES 6 Hr

GENERAL OBJECTIVES.

16.1 To understand straight lines.


16.1.1 Define angle of inclination.

16.1.2 Define slope of a straight line.

16.1.3 Define x and y intercepts for straight line.

16.1.4 Write

12

12

1tan

mm

mm

16.1.5 Write angle between two straight lines in terms of

12

12

1tan

mm

mm

16.1.6 Write the conditions for two lines to be parallel and to be perpendicular to each

other.


16.1.8 Derive the slope-intercept form of an equation of a straight line y = mx + c

16.1.9 Obtain the point – slope form equation to the straight line )( 11 xxmyy

16.1.10 Obtain two point form of the equation to a straight line )( 1

12

121 xx

xx

yyyy

16.1.11 Obtain intercepts form of the equation to a straight line, 1b

y

a

x

16.1.12 Derive the normal form of equation to a straight line,xcos α + ysin α = p

16.1.13 Write the general form of equation to a straight line, ax +by+c=0

16.1.14 Solve problems on different forms of equation.

16.1.15 Solve problems to find an equation of a straight line passing through the given

point and parallel to the given line.

16.1.16 Solve problems to find an equation of a straight line passing through the given

point and perpendicular to the given line.

16.1.17 Solve problems to find an equation of straight line passing through the

intersection of given lines.

16.1.18 Obtain the condition for the intersection of three lines express in general in the

determinant form.

16.1.19 Solve the problems on the above condition.

REFERENCE BOOKS:

1. First and Second PUC mathematics Text Books of different authors.

2. Text Book of mathematics –I for polytechnic-by different authors

3. Text Book of mathematics-II for polytechnic- by different authors

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

BOARD OF TECHNICAL EXAMINATION – KARANATAKA

MODEL QUESTION PAPER Code:

APPLED MATHEMATICS –I ( FOR ALL COURSES)

Time: 3 Hrs Max.m marks:100

NOTE: i) Answer any 10 questions in section A, 5 questions in section B

8 questions in section C, & 3 questions in D

ii) Each question carries 2 marks in section A

ii) Each question carries 5 marks in remaining section

SECTION – A

1. Find x if

1 2 3

4 5 0

7 8 9

x

2. If A = 1 2

3 5

, Find A. adj(A)

3. Find the 5th

term in 83

xx

4. If a

= 2i + 3 j – 2 k and b

= i + 2k, find .a

b

5. If p

= i + J -2k, Find unit vector in the direction of p

6. If sinθ + cosecθ = ½ , find sin2θ + cosec

2θ

7. If sec θ = cosec3θ, find θ.

8. Find the value of tan15° without using table or calculator.

9. Show that tan2

=

sin

1 cos

10. Show that cos17 sin17

tan 28cos17 sin17

11. Show that ( ) ( )

tan2 ( )

A s b s c

s s a

12. Show that 1 1cos ( ) cosx x

13. Find the locus of a point which moves at a equal distances from the axis

14. Find the inclination and Y-intercept of the line √3x + y = 3

15. Find the angle between the lines who’s slopes are √3 and 1/√3

SECTION – B

1. Solve the following equations by cramer’s rule

2x + y = 1, y + 2z = 7 and 3z – 2x =11

2. Find the inverse of the matrix A =

1 2 5

0 1 3

3 1 2

3. Verify Caylay-Hamilton Theorem for the matrix A = 2 1

1 5

4. Find the co-efficient of x18

in

15

2 3ax

x

5. If loga (bc) = x , logb (ac) = y and logc(a b) = z. Show that 1 1 1

11 1 1x y z

6. Find the sin of the angle between the vectors ( 3,2,-1) and ( 2,-1,4)

7. If the position vectors of A, B,C are respectively i + 2j + 3k, 2i + 5j – k and –i + j +2k,

find the area of triangle ABC

8. Find the projection of vector 2i + 3j + 2k on 4i + 5j + 3k

SECTION – C

1. Circular wheel is rotating at the rate of 450 r.p.m. If the radius of the wheel 70cm, find

the distance covered by a point on the rim in 1 second.

2 Prove that tan sec 1 1 sin

tan sec 1 cos

3. Show that sin 1 cos

2cos1 cos

ecsin

4. Show that sin420°cos390° + cos(- 300°) sin(- 330°) = 1

5. Simplify cos( )sec( ) tan( )

2

sec(2 )sin( )cot( )2

6. The angles of elevation of the top of a tower from the base and top of building are

60° and 45°. The building is 20m high. Find the height of the tower.

7. Prove that sin( )

sin sin

A B

A B

= 0

8. Prove that cos3 sin3

cos sin

A A

A A

= 1 + sin2A

9.Prove that sin sin3 sin5 sin 7

cos cos3 cos5 cos7

A A A A

A A A A

= tan4A

10.In a triangle ABC show that 2 2 2 2

cos 2 cos 2 1 1A B

a b a b

11. Solve the triangle ABC if a = 2 , C = √3 – 1 , B = 120°

12. Prove that 1 1 11 1 12 tan tan 2 tan

8 7 5 4

SECTION – D

1. Find the point on the x-axis which is equidistant form the points (7,6) and (–3,4)

2. Find the co-ordinates of the point of trisection of the median AB of the triangle ABC

whose vertices are A(– 2, 2 ) ,B (– 1, –3 ) and C (5,7)

3. Find the equation of the line passing through (– 2, 6 ) and the sum of intercepts on the

co-ordinate axes is 5.

4. Find the equation of the line perpendicular to 3x – 2y + 1 = 0 and passes through(1,–2).

0-o-0-o-0-o-0-o-0-o-0-o-0-o-0-o-0-o-0-o-0

Applied Mathematics – II Page 1 of 11

BOARD OF TECHNICAL EXAMINATION –

KARNATAKA

SUBJECT: APPLIED MATHEMATICS – II

For II - Semester

DIPLOMA COURSES OF ALL BRANCHES

Contact hour per week: 04 Contact hour per Semester: 64

UNIT NO. CHAPTER TITLE CONTACT

HR.

DIFFERENTIATION CALCULUS 1 LIMITS 6

2 DIFFERENTIATION 16

3 APPLICATIONS OF DIFFERENTIATION 6

INTEGRAL CALCULUS

4 INDEFINITE INTEGRATION 14

5 DEFINITE INTEGRATION 4

6 APPLICATIONS OF DEFINITE INTEGRATION 2

7 DIFFERENTIAL EQUATIONS 12

8 TESTS AND ASSIGNMENTS 4

TOTAL HOUR 64

REFFERENCE BOOKS: 1. Applied Mathematics –II By W.R Neelakanta. Sapna Publications.

2. Applied Mathematics –II By Dr. D S Prakash S Chand Publications

3. Text Books of PUC-2 mathematics.

4. Applied Mathematics –II for Polytechnics- By different Authors.

5. Engineering Mathematics.


QUESTION PAPER BLUE PRINT

FOR APPLIED MATHEMATICS – II

UN

IT N

O.

HO

UR

Questions

to be set (2

Marks)

PART- A

Questions

to be set (5

Marks)

PART- B

Questions

to be set (5

Marks)

PART- C

Questions

to be set (5

Marks)

PART- D

1 6 2 2 - -

2 16 4 6 - -

3 6 2 2 - -

4 14 4 - 6 -

5 4 3 - 1 -

6 2 - - 1 - 7 12 - - - 6

TOTA

L

64 15 10 08 06

Questions to

be answered 10 07 05 04

APPLIED – MATHEMATICS – II

Marks No. of Questions No. of Questions

to be set to be Answered

Part A 2 X 10 = 20 15 10

Part B 5 X 07 = 35 10 07

Part C 5 X 05 = 25 08 05

Part D 5 X 04 = 20 06 04

Total = 100


Diploma Courses of All Engineering Branches

II Semester

Sub: Applied Mathematics II

CONTENTS

UNIT – 1: LIMITS. 6 Hr.

Variables and Constants. Definition of function. Types of function: Direct and

Inverse functions, Explicit and implicit function, Odd and even functions (Definition

with examples). Concept of x tends to ‘a’. Definition of limit of a function. Problems

on limit of a function by factorization, rationalization when x tend to ‘0’, when x tend

to ‘∞’ and x tend to ‘a’. Derivations of algebraic and trigonometric limits. Problems.

Standard limit (only statement)

enenx

ea

x

an

n

n

n

x

xe

x

x

1

0001lim 4.

11lim3. 1

1lim.2 log

1lim.1

Simple problems on standard limits.

UNIT – 2: DIFFERENTIAL CALCULUS. 16 Hr.

Definition of increment and increment ratio. Definition of derivative of a

function. Derivatives of functions of xn, sinx, cosx and tanx with respect to ‘x’ from

first principle method. List of standard derivatives. Rules of differentiation: Sum,

product and quotient of functions. Problems on rules. Derivatives of function of a

function (Chain rule). Derivatives of inverse Trigonometric functions, Hyperbolic

functions and inverse of hyperbolic functions, Implicit functions, Parametric

functions. Problems. Logarithmic differentiation. Problems. Successive differentiation

up to second order. Problems.

UNIT – 3: APPLICATIONS OF DIFFERENTIATION. 6 Hr.

Geometrical meaning of derivative. Equation of tangent and normal to the

curve y = f(x) at a given point. Derivative as a rate measure. Definition of increasing

and decreasing function. Maxima and minima of a function.

UNIT – 4: INTEGRAL CALCULUS. 14 Hr.

Definition of Integration. List of standard integrals. Rules of integration (only

statement)

problems. Integration by substitution method. Problems. Integrals of functions

involving a2 + x

2 , a

2 – x

2 and their radicals. Some important integrals of the type

g(x)dxf(x)dxdxg(x)f(x) 2. .)()(.1 dxxfkdxxkf


proof. with sin 2. tan1

.1 1

22

1

22c

a

x

xa

dxc

a

x

aax

dx

proof) no 7 to3 ( sec1

7.

cosh 6. .0 a if log2

1 5.

.0 x if log2

1 4. sinh.3

1

22

1

2222

22

1

22

ca

x

aaxx

dx

ca

x

ax

dxxc

xa

xa

axa

dx

acax

ax

aax

dxc

a

x

xa

dx

Integrals of the forms:

Problems. dx. ,dx , ,

2222cbxax

qpx

cbxax

qpx

cbxax

dx

cbxax

dx

Integration by parts. Rule of integration by parts. Problems.

Integration of the forms: Problems. dx)(ff(x) 1x

xe

UNIT – 5: DEFINITE INTEGRALS. 4 Hr.

Definition of Definite integral. Theorems on definite integrals. Problems.

Definite integrals of the type Problems. tan1

1 ,

tan1

12

0

2

0

dxx

dxx

UNIT – 6: APPLICATIONS OF DEFINITE INTEGRALS. 2 Hr.

Find area, volume and r m s value of a function. Problems.

UNIT – 7: DIFFERENTIAL EQUATIONS. 12 Hr.

Definition, example, order and degree of differential equation with examples.

Formation of differential equation by eliminating arbitrary constants up to second

order. Solution of D E of first degree and first order by variable separable method.

Solution of differential equations reducible to variable separable form. Linear

equations and its solution. Solution of differential equations reducible to linear form-

Bernoulli’s form. Homogeneous form and its solution. Solution of differential

equations reducible to homogeneous form. Exact differential equation and its solution.

Solutions of differential equation of a type

problems. Simple constants. are c b, a, where,02

2

cydx

dyb

dx

yda


GENERAL AND SPECIFIC OBJECTIVES

UNIT – 1: LIMITS. 6 Hr.

GENERAL OBJECTIVES.

1.1 To understand variables, constants and functions.

1.2 To know the indeterminant form and evaluation of limit of a given function.


1.1.1 Explain calculus as calculation of Infinitesimal values.

1.1.2 Define Independent, dependent variable and constants with examples.

1.1.3 Define a function.

1.1.4 List types of functions.

1.1.5 Define 1. Direct and inverse functions 2. Explicit and Implicit function

3.Odd and even function with examples.

1.2.1 Explain the concept of x tends ‘a’.

1.2.2 Define limit of a function.

1.2.3 Solve problems on limit of a function by factorization.

1.2.4 Solve problems on limit of a function by rationalization.

1.2.5 Solve problems on limit of a function when x tends INFINITY.

1.2.6 Deduce

radiansin is where1sin

lim

number. rationalany for lim

0

1

nnn

axna

ax

ax

1.2.7 Solve problems on above results.

1.2.8. Write formula for standard limits(statement only).

n

nx

e

x

nenx

ea

x

a 1

0nn0x0x1lim

11lim 3. 1

1lim 2. log

1lim1.

1.2.9 Solve simple problems on above results.

UNIT – 2: DIFFERENTIAL CALCULUS. 16 Hr.

GENERAL OBJECTIVES.

2.1 To understand the differentiation of a function in terms of limit of a function.

2.2 To know different methods of differentiation.

2.3 To know the derivatives of higher order up to second order.



2.1.1 Define increment and increment ratio.

2.1.2 Define differentiation.

2.1.3 Derive the differential co-efficient (dy/dx).

2.1.4 Derive differentiation of a functions from first principle method xn , Sinx, Cosx

and Tanx with respect to ‘x’.

2.1.5 State derivative of ex and log x.

2.2.1 State rules of differentiation: Derivatives of Sum, Product and quotient of

function.

2.2.2 Solve problems on rules of differentiation.

2.2.3 Obtain the derivatives of function of a function (Chain Rule), Inverse T-

functions, Implicit functions & Parametric functions

2.2.4 Solve problems on above types.

2.2.5 Carry out logarithmic Differentiation

2.2.6 Solve problem of the type xx , a

x , x

Sin x, x

1/x etc.,

2.3.1 Obtain the second derivative of a function.

2.3.2 Solve problems on Successive differentiation.

UNIT -3: APPLICATIONS OF DIFFERENTIATION. 6Hr.

GENERAL OBJECTIVES.

3.1 To understand dy/dx as slope of a tangent.

3.2 To illustrate dy / dx as a rate measure.

3.3 To understand maxima and minima of a function.


3.1.1 Explain geometrical meaning dy / dx as a slope of tangent.

3.1.2 Find equation of tangent and normal to a curve y = f(x) at a given point.

3.1.3 Solve problems on tangent and normals.

3.2.1 Explain derivative as a rate measure.

3.2.2 Obtain velocity and acceleration for a moving body whose equation of motion

is given.

3.2.3 Solve problems on rate measure including variation of area, volume etc.,

3.3.1 Define increasing and decreasing function.

3.3.2 State the condition for maxima and minima of a function, no proof.

3.3.3 Find maximum and minimum values of a function.

UNIT – 4: INTEGRAL CALCULUS. 14 Hr.

GENERAL OBJECTIVES.

4.1 To know integration as converse process of differentiation.

4.2 To understand indefinite integral.


4.1.1 Define integration as anti derivative.

4.1.2 List of standard integrals.

4.1.3 State rules of Integration.


4.1.4 Solve the problems on rules of integration.

4.2.1 Explain integration by substitution method.

4.2.2 Solve problems on substitution method.

4.2.3 Derive . sin 2. tan1

.1 1

22

1

22c

a

x

xa

dxc

a

x

aax

dx

4.2.4 Write

proof) no 7 to3 ( sec1

7.

cosh 6. .0 a if log2

1 5.

.0 x if log2

1 4. sinh.3

1

22

1

2222

22

1

22

ca

x

aaxx

dx

ca

x

ax

dxxc

xa

xa

axa

dx

acax

ax

aax

dxc

a

x

xa

dx


4.2.5 Write

dx. ,dx , ,

2222cbxax

qpx

cbxax

qpx

cbxax

dx

cbxax

dx


4.2.6 Explain the rule integration by parts.

4.2.7 Solve problems of the type x sinx, x2 Cos x, (ax + b) e

x, x sin

2x, log x, e

x sinx,

x log x etc.,

4.2.8 Solve problems of the type dx)(ff(x) 1x

xe

UNIT – 5: DEFINITE INTEGRALS. 4 Hr.

GENERAL OBJECTIVES.

5.1 To understand the concept of definite integral to eliminate constant of

integration.


5.1.1 State, a b f(x) dx as a definite integral.

5.1.2 State theorems on definite integrals.

5.1.3 Solve the problems of the same type as in indefinite integral using limits of

integration.

5.1.4 Solve definite integrals of the type tan1

1 ,

tan1

12

0

2

0

dxx

dxx

UNIT – 6: APPLICATIONS OF DEFINITE INTEGRALS. 2 Hr.

GENERAL OBJECTIVES.


6.1 To understand definite integral as a tool to find area under the curve, volume

of solid of revolution and r m s value of a function.


6.1.1 Explain definite integral as a limit of sum (statement).

6.1.2 Write the formulae for finding area, volume and r m s value of a function.

6.1.3 Solve problems on above applications.

UNIT – 7: DIFFERENTIAL EQUATIONS. 12 Hr.

GENERAL OBJECTIVES.

7.1 To understand the concept of differential equation.

7.2 To solve differential equation for unknown functions.


7.1.1 Define differential equation with examples.

7.1.2 Define Order and Degree of D E with examples.

7.1.3 Formation of D E by eliminating arbitrary constants.

7.2.1 Obtain the solution of D E by variable separable method.

7.2.2 Solve problems on variable separable method.

7.2.3 Obtain the solution of D E by Reducible to variable separable method – Solve

problems.

7.2.4 Obtain the solution of linear D E of the type QPydx

dy --solve problems.

7.2.5 Obtain the solution of D E by Reducible to linear form (Bernoulli’s form) –solve

problems.

7.2.6 Obtain the solution of D E by Homogeneous form – solve problems.

7.2.7 Obtain the solution of D E by Reducible to homogeneous form – solve problems

7.2.8 Obtain the solution of Exact D E --- solve problems.

7.2.9 Obtain the solution of D E of the type ,02

2

cydx

dyb

dx

yda -- Solve simple

problems only.

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


BOARD OF TECHNICAL EXAMINATION – KARANATAKA


Code:

APPLED MATHEMATICS –II ( FOR ALL COURSES)

Time: 3 Hrs

Maximum marks:100

NOTE: i) Answer any 10 questions in section A, 7 questions in section B

5 questions in section C, & 4 questions in D

ii) Each question carries 2 marks in section A

iii) Each question carries 5 marks in remaining section

SECTION – A

1. Evaluate 2

20

sin 3lim

tan 4x

x

x

2.Evaluate3

42

8lim

16x

x

x

3. Find dy

dx if y = 1 –cos4x

4. Find dy

dx if x

2 + y

2 = a

2

5. Find dy

dx if x = a sinθ and y = a cosθ

6. Find the slope of a tangent to the curve y = x2+6x – 7 at point ( 1, –2)

7. If s = 4t2 – 4t + 6 then find velocity when t = 2second

8. Evaluate tanx xe e dx

9. Evaluate 2sin xdx

10 Evaluate cos (1 4 )ec x dx

11. Evaluate

4

0

1dx

x

12. Evaluate2

0

sin x dx


13. Evaluate 2

2

0

tan x dx

14. Evaluate2

sin

cos

xdx

x

15. Show that( )xd a

dx = a

x loge a

SECTION – B

1. Prove geometrically 0

sinlim

2. Evaluate0

3sin 2 5lim

4 tanx

x x

x x

1 xdy

edx

3. Find the derivative of tanx w.r.to x form the first principle

4. If y = ex ( sinx – cosx ), find dy/dx.

5. If y = 2 3sinh

3 2cosh

x

x

, find dy/dx

6. If xcoy + ysin(x/y) = k find dy/dx.

7. Find dy/dx if x = a(cosθ + θ ) and y = a ( 1 – sinθ )

8. If y = sinx cosx

, find dy/dx.

9. Find the equations of tangent and normal to the curve y2 = 9x at ( 1, - 3 )

10. Find the maximum and minimum value of the fuction 2x3 - 12 x

2 + 18x + 5.

SECTION – C

1. Evaluate 3sin xdx

2. Evaluate 2 6 13

dx

x x

3. Evaluate 2 sinx xdx

4. Evaluate 2

2 3

8 2

xdx

x x

5. Evaluate 2

3

0

cos x dx


6. Evaluate .logx xdx

7. Evaluate 4

2 1

xdx

x

8. find the area bounded by the curve y = 4x – x2 – 3 and x-axis.

SECTION – D

Solve the following equations;

1.sec2x tany dx + sec

2y tanx dy= 0

2. y (1 + x) dx + x (1 + y) dy = 0

3. (y3 – 3x

2y ) dx – (x

3 – 3xy

2 ) dy = 0

4. ( 3y – 7x + 7 ) dx + ( 7y – 3x + 3 ) dy = 0

5. ( 2x + y + 1 ) dx + ( x + 2y + 1 ) dy = 0

6. ey 1 xdy

edx

0-o-0-o-0-o-0-o-0-o-0-o-0-o-0-o-0-o-0-o-0

me_science

Contact hrs/week : 4 Contact hrs. / Sem: 64

Sl. No. Topics Hrs alloted

1 Sources of energy 3

2 Properties of metals 3

3 Ferrrous metals 8

4 Non ferrous metals 6

5 Heat treatment of steels 6

6 Friction and lubrication 6

7 Transmission of power 8

8 Fasteners 6

9 Bearings 6

10 Welding, Soldering and Brazing 8

11 Tests and revisions 4

Total 64

1 Sources of Energy 3

1.1 renewable & non-renewable energy sources

1.2 solar energy, wind energy, hydro energy, tidal energy, geo thermal energy


2.1

2.2 Ductility, hardness, toughness, brittleness, impact, mallealibility ,elastisity,plastisity etc

3 Ferrous metals 8

3.1 Principal ferrous metals

3.2 Cast iron and steel

3.3 Cast iron - manufacturing using cupola

3.4 Types of cast iron, composition, properties and uses

3.5 Steel - grades of steel and their composition

3.6 Manufacturing of steel using bessemer convertor process

3.7 Alloying of steel and its purpose

3.8

Composition and uses of - Nickel steel, 18/8 stainless steel,

HSS, Manganese steel

4 Non Ferrous metals 6

4.1 principal non-ferrous metals

4.2 properties and uses of non-ferrous metals- copper, aluminium,

zinc, tin, lead, cobalt, nickel, chromium

4.3 composition, properties & uses

4.3.1 copper alloys- brass & bronze

4.3.2 brass- montz metal, white brass, yellow brass

4.3.3 bronze- bell metal, gun metal & phosphor bronze

4.3.4 aluminium alloys- aluminium bronze, duralumin

4.3.5 magnesium alloys- dove metal & electron metal

4.3.6 nickel alloys- monel metal, nichrome

4.3.7 lead base alloys

Diploma Course in Ceramics

Second Semester

Subject Title: Mechanical Engineering Science

Subject Content

Meaning of chemical, thermal, electical, magnetic and mechanical properties of metals

Page 1 of 7

me_science

4.3.8 tin base alloys- babitt metal

4.3.9 zinc base alloys- bearing metals


5.1 purpose of heat treatment

5.2 heat treatment processes- annealing, normalising, hardening,

tempering, nitriding, cyaniding

5.3 engineering applications of the above processes

6 Friction & Lubrication 6

6.1 introduction

6.2 definition & types of friction

6.3 coefficient of friction

6.4 angle of friction & friction angle

6.5 laws of solid friction

6.6 effect of friction

6.7 necessity of lubrication

6.8 properties of different types of lubricants

6.9 methods of lubrication

6.10 splash, wick, screw cap & needle lubricators

7 Transmission of Power 8

7.1 introduction

7.2 types of power transmission

7.3 flat belt drives- open & cross belt drives

7.4 velocity ratio, slip & creep

7.5 simple problems

7.6 fast & loose pulley

7.7 cone or stepped pulley, jockey or idler pulley

7.8 v belt drive-advantages & limitations

7.9 rope drive- advantages & limitations

7.10 chain drive- advantages & limitation

7.11 gear drive

7.12 types of gears-spur, helical, bevel, worm & worm wheel, rack & pinion

8 Fasteners 6

8.1 Intorduction

8.2 classification

8.3 screw thread terminology

8.4 V- threads,square threads, Metric threads,Acme Threads

8.5 single & Multistart threads

8.6 Right & Lefthand threads

8.7 Bolts & Nuts

8.8 LockNut

8.9 Locking devices- split pin,Screw pin,plate & spring washer

9 Bearing 6

9.1 Need of bearings

9.2 Types- Bush,Pedestal, Footstep bearings

9.3 Ball and roller bearings-needle bearing, thurst bearing

9.4 Advantages and disadvantages of ball and roller bearings

10 Welding , Soldering and Brazing 8

10.1 Introduction to Welding

Page 2 of 7

me_science

10.2 Classification of welding

10.3 Applications of welding

10.4 Arc welding

10.5 Gas welding

10.6 Introduction to Soldering and Brazing

10.7 Comparison of welding with Soldering and Brazing

General Objectives

1 To know the different solar energy sources and their applications

2 To know the different uses of metals with their properties

3 To know ferrous metals and their preparation and types

4 To know the different nonferrous metals and their types with applications

5 To know the importance of heat treatment and its proceses

6 To know about the friction and lubrication proceses

7 To know the diferent modes of transmission of power and applications

8 To know the different fastening members and their applications

9 To know the importance of bearings and their types

10 To understand the proceses of welding, brazing and solding and their applications

1 appreciate the uses of different sources of energy

1.1 define renewable and non- renewable energy sources

1.2 differentiate renewable and non-renewable sources of energy

1.3 list the advantages and limitations of the above

1.4 explain solar energy

1.5 state application of solar energy

1.6 explain wind energy and state its application

1.7 list advantages and disadvantages of wind energy

1.8 explain the application of hydro energy

1.9 explain the application of tidal energy

1.10 expalin the application of geo- thermal energy

2

2.1 name the metals used in industries

2.2

2.3 know the importance of the above properties

3 appreciate the use of ferrous metals in industries

3.1 list the principal ferrous metals

3.2 sketch and explain cupola

3.3 know the manufacturing of cast iron3.4

3.5

know the manufacturing of steel by Bessemmer converter

process

3.6 state the composition and uses of various grades of steel

3.7 define alloying and state its purpose

3.8

4 appreciate the use of non-ferrous metals in industries

4.1 list different non-ferrous metals used in industries

4.2

4.3 state the composition, properties & uses of

specific instructional objectives:

state the composition, properties and uses of nickel steel, chromium steel, 18/8

state the properties and uses of copper, zinc, aluminium, lead, tin, cobalt, nickel and

appreciate the use of different metals in mechanical engineering

define chemical, magnetic, electrical, thermal & mechanical properties of metals

list the types of cast iron with composition, properties and uses

Page 3 of 7

me_science

4.3.1 copper alloys- brass & bronze

4.3.2 brass- montz metal, white brass, yellow brass

4.3.3 bronze- bell metal, gun metal & phosphor bronze

4.3.4 aluminium alloys- aluminium bronze, duralumin

4.3.5 magnesium alloys- dove metal & electron metal

4.3.6 nickel alloys- monel metal, nichrome

4.3.7 lead base alloys

4.3.8 tin base alloys- babitt metal

4.3.9 zinc base alloys- bearing metals

4.3.10

5 state the objectives of heat treatment of steel

5.1

6 know the role of friction and lubrication in machine elements

6.1 define force of friction

6.2 state laws of solid friction

6.3 identify the need for lubrication

6.4 list types of lubrication

6.5 list the properties of lubricants

6.6 list the types of lubricators

6.7

7 understand transmission of power in machines

7.1 list the types of transmission of power

7.2 explain open and cross belt drive

7.3 define velocity ratio

7.4 state the effect belt thickness and slip on velocity ratio

7.5

7.6 explain the advantages of v-belt drive over flat belt drive

7.7 list the advantages and disadvantages of rope drive

7.8 list the advantages and disadvantages of chain drive

7.9 list the types of gear drives

7.10

7.11

8 appreciate the application of fasteners

8.1 define fastener and fastening

8.2 classify fasteners

8.3 classify threaded fasteners

8.4 explain screw thread terminology

8.5

8.6 explain single and multi start thread

8.7 explain right and left hand thread

8.8 explain the principle of lock nut

8.9

9 discuss the importance of bearings in industries

9.1 classify bearings

9.2 explain bush bearings and state its industrial application

9.3 explain plummer block and state its industrial application

explain wick lubricator, splash lubrication, screw cap lubricator, needle lubricator

explain the use of cone pulle, idler pulley and fast & loose pulley in belt drive

explain annealing, normalising, hardening, tempering, nitriding, cyaniding with its

expain the use of spur, helical, bevel, worm & worm wheel, rack & pinion types of gear

drives

solve simple problems on velocity ratio and slip in flat belt drives

explain application of v -thread, metric thread, square thread & acme thread in the

field of engineering

explain the locking of nut using split pin, screw pin, plate and spring washer

discuss the engineering application of the above non-ferrous alloys

Page 4 of 7

me_science

9.4 explain foot step bearing

9.5

10 Explain the welding and its concepts

10.1 Classification on the basis of fusion and non fusion ,pressure and non pressure .

10.2 Different areas of use of welding

10.3 Principle of Arc welding(with sketch) including all equipments ,preparation ,precautions and procedure

10.4 Principle of Gas welding(with sketch) including all equipments ,preparation ,precautions and procedure

10.5 Explain the clear concepts of soldering and brazing

10.6 Comparison of welding ,soldering and brazing

Text Books: 1. Mechanical Engineering Science By R K

Hegde and Niranjan Murthy -Sapna Publications.

reference books

1 mechanical Engineering science- K. R. Gopala Krishna

2

3 elements of mechanical engineering- K.R.Gopala Krishna

4 engineering materials- Hajra Choudary

5 engineering materials- Rangawala

6 engineering materials- Roy & Choudary

7 Materials & metallurgy- J.K. gupta

Sl. No. COURSES

Hrs

allote

d

Total marks

for questions

to be asked

Total marks

for questions

to be attempt

UNIT- I

four fill in the blanks has to be set, each carrying one mark 4 4

UNIT- II

1 Sources of energy 3


3 Ferrrous metals 8

4 Non ferrous metals 6

UNIT- III


6 Friction and lubrication 6

7 Transmission of power 8

UNIT- IV

8 Fasteners 6

9 Bearings 6

10 Welding, Soldering and Brazing 8 48 32

Total 148 100

discuss the types of antifriction bearings with engineering application

32

48

48

32

QUESTION PAPER PATTERN AND MARKS DISTRIBUTION

Subject Title: Mechanical Engineering Science

First Semester

elements of mechanical engineering- K.P. Roy & Hajra Choudary

Page 5 of 7

me_science

Board of Technical examinations,

Bangalore

Mechanical Engineering science

Duration: 3 Hrs

max marks

100

UNIT I

Fill in the blanks with appropriate word 1x4 = 1

1 ___________ is an example of renewable energy source

2 Welding has been classified as __________ type of fastener

3

________ pulley is being used to increase the velocity ratio of

the belt drive

4 Cupola furnace is used to manufacture _____________

UNIT II

1 3

b) Write short note on Wind energy 5

8

2 a) Define alloy and state the purpose 3

b) state the properties and uses of non ferrous metals 5

c) explain ductility, malleability, plasticity and elasticity 8

3 a) list various grades of steel 3

5

c) explain with neat sketch the manufacturing process of steel

by Bessemmer Convertor 8

UNIT III

4 a) List the need of heat treatment of steel 3

b) explain effect of belt thickness on velocity ratio 5

c) In a open belt drive, the driving pulley diameter is 0.6m and

is running at 1200rpm. The driven pulley diameter is 0.2m.

Determine speed of the driven pulley, velocity ratio if the

thickness of the belt is 10mm. 8

5 a) List the advantages of v belt over flat belt 3

b) List the properties of good lubricants 5

c) With neat sketch explain screw cap lubricator 8

6 a) list the advantages and disadvantages of chain drive 3

b) with neat sketch expalin rack and pinion 5

c) Explain annealing and tempering process 8

a) Differentiate between renewable and non-renewable energy sources

c) Sketch and explain Cupola Furnace

b) Write short note on copper

Model Question Paper

Answer Unit I and any two full questions from each of the remaining units

Page 6 of 7

me_science

UNIT IV

7 3

b) explain screw thread terminology 5

c) with neat sketch explain locking of nut using split pin 8

8 a) list the classification of bearings 3

b) explain bush block 5

c) with neat sketch explain different types of gas flame 6

9 a) List precautions to be followed in arch welding 3

b) explain different applications of gas welding 5

c) explain with neat sketch the princple of arc welding 8

a) define fastener and fastening

Page 7 of 7

Government of Karnataka

Directorate of Technical Education

Bangalore

REVISED CURRICULUM

2010-2011.

3rd

and 4th

Semesters

OF

DIPLOMA IN

CERAMICS TECHNOLOGY

N.ASWATHAIAH, H.O.D/Chairman of Ceramics Board

e-mail:[email protected]

S.J (Govt.) polytechnic Bangalore-01

MEMBERS

1. K. MARISWAMY

Resource person/ H.O.D. of Ceramics Technology

R. N. Shetty Rural Polytechnic Murudeshwar– 581350

e-mail: [email protected]

2. SANGEETHA.S.A

Lecturer, Dept. of Ceramics Technology

S.J (Govt.) Polytechnic Bangalore-01

e-mail:[email protected]

MEMBERS FROM INDUSTRIES

1. D. Suresh Kumar 2. Dr. C.D Madhusoodana

General Manager Sr.Manager, BHEL, CTI

Bhoruka Steels & Services Refractory division BHEL Malleshwaram

Refractory division Bangalore – 5600 12

Whitefield Road, Banagalore-48 e-mail: [email protected]

e-mail: [email protected] M.Ph.9449052806

M.Ph. 9845395330

3. M.G Ananda Kumar

Engg Officer, Materials Technology Division

Central Power Research Institute,

Bangalore – 80, e-mail- [email protected]

M.Ph. 9986318844

mailto:[email protected]



2

THIRD SEMESTER DIPLOMA IN CERAMICS TECHNOLOGY

Scheme of study and examination

Sl.

No SUBJECTS

Contact hours Exam

duratio

n

In

Hours

Scheme of

examination Total

max.

mark

s

Min

mark

s for

passi

ng

Th

eor

y

Pra

ctic

al

Tot

al

End Exam * I.A

Mar

ks

Max

mar

ks

Min

mar

ks

1 White wares 4 - 4 3 100 35 25 125 45

2 Coating technology 4 - 4 3 100 35 25 125 45

3 Ceramics Calculation 4 - 4 3 100 35 25 125 45

4

Basics Electrical &

Electronics for ceramics

4 - 4 3 100 35 25 125 45

5 Coating technology lab - 6 6 3 100 50 25 125 60

6 Ceramics Testing Lab - 6 6 3 100 50 25 125 60

7

Ceramics Forming

Practice

- 6 6 3 100 50 25 125 60

TOTAL 16 18 34 - 700 - - 875 360

No minimum marks for IA

For practical batch strength is limited to 20

3

FOURTH SEMESTER DIPLOMA IN CERAMICS TECHNOLOGY


Sl

No SUBJECTS

Contact hours

Exam

durati

on

in

Hours

Scheme of

examination

Total

max.

marks

Min

marks

for

passin

g

Theo

ry

Practica

l Total

End Exam * IA

Mark

s

Max

mark

s

Min

mark

s

1 Furnace technology 4 - 4 3 100 35 25 125 45

2 Refractories 4 - 4 3 100 35 25 125 45

3 Ceramics Machinery 4 - 4 3 100 35 25 125 45

4 Ceramics Cad Lab - 6 6 3 100 50 25 125 60

5 Refractories Lab - 6 6 3 100 50 25 125 60

6 Furnace technology Lab - 6 6 3 100 50 25 125 60

7 Ceramic Processing Lab - 6 6 3 100 50 25 125 60

Total 12 24 36 - 600 - - 750 330

No minimum marks for IA


4

DIPLOMA IN CERAMICS TECHNOLOGY

THIRD SEMESTER

Subject: White Wares

NO OF HRS/ WEEK: 04 Total no of Hrs: 64 Hrs

SL NO TOPIC

HRS ALLTD

1 Ceramics raw material 07

2 Batch preparation 08

3 Electro porcelain 09

4 Earthen ware 09

5 Stone ware 09

6 Plaster of Paris (pop) 06

7 Soft paste porcelains 08

8 Industrial visit & Guest Lecture 04

9 Test & Revision 04

Total 64

5

Details of Contents

1.0 CERAMICS RAW MATERAL

1.1 Mining Definition, Description, Introduction, Mining methods for

ceramics raw materials, Digging, Stripping, Breaking with hammer

and pick axe, Hydraulic mining, Quarrying by wedging and

Levering, Blasting, mining by dredges and mechanical shovels.

1.2 Underground mining, Advantages and disadvantages of Open cast

mining as Compared with underground mining. Ore dressing

methods mining tools.

2.0 BATCH PREPARATION

2.1 Definition of batch preparation, batch preparation, Dry mix, Wet mix

methods of body preparation, Formulae involved, Defects and

Remedy in wet mix and Dry mix, Tempering, pugging and souring,

Ageing and souring of body’s, Electrolytes casting slips.

3.0 ELECTRO PORCELAIN

3.1 Definition and Description,

3.2 Formation & Structure of Electro-porcelain.

3.3 Selection of body & glaze by Tri-axial method.

3.4 Raw materials ,Body preparation, Manufacturing

3.5 Drying, Firing specifications and sizes.

3.6 The influence of glaze on a technical characteristics of porcelain

insulator.

3.7 Methods of testing

4.0 EARTHEN WARE

4.1 Definition and classification, inferior or Rough Earthen ware,

Architectural

Faience Encaustic tiles, Enameled Faience.

4.2 Felspathic or Fine earthen ware, English Earthen ware compositions,

American Earthen ware bodies. Indian body’s and glazes, Shaping of

earthen ware by different methods and particularly jigger and jolly

machine methods, fettling the Ware by sponging and towing and

firing glazed wall tiles, tests for tiles, Auto clave test and thermal

shock test . Engobe: Definition of engobe, and engobe compositions

and properties.

5.0 STONE WARE

5.1 Definition, classification, raw materials and forming methods of

stone ware,Extrusion of pipes, Drying and glost firing, salt glazing.

6

common defects in stone Ware and their remedy. Tests on stone

ware hydraulic test, Absorption test, specification and sizes.

6.0 PLASTER OF PARIS (POP)

6.1 General explanation. And manufacturing process properties of

plaster mould, Porosity and absorption of mould building time

graphs for plaster of Paris, tests, sieve test, water test.

7.0 SOFT PASTE PORCELAINS

7.1 History ,classification of porcelain raw materials, Body composition,

Body preparation methods , flow sheet of body preparation of soft

paste porcelain, Drying, glazing and glost firing of s.p.p vitreous

china, sanitary ware, Bone china, Firing of s.p.p. body stains for s.p.p

and bone china.

Reference Books:

Indian Pottery by mirmira

White ware By sudhir sen

Industrial ceramics by Singer & singer

GENERAL OBJECTIVES

1.1 to understand mining of ceramics raw materials

1.2 to understand mining definition, introduction, history and mining

methods

1.3 to know the underground and open cast mining

1.4 to know the batch preparation of earthen ware

1.5 to understand the dry mix method and wet mix method

1.6 to know the definition of terracotta and description of raw materials

1.7 to know the definition of earthen ware and it’s classification

1.8 to know the definition of stone ware, it’s classification, and raw

materials, shaping methods

1.9 to understand plaster of Paris manufacture

1.10 to know the properties of plaster of Paris and it’s uses

1.11 to understand the definition of soft paste porcelain (spp) body

preparation manufacturing.

7

SPECIFIC OBJECTIVES

1.0 Study of mining ceramics raw materials.

1.1 Know and understand the mining definition.

1.2 knows and understands the description.

1.3 knows and understands the introduction and history of mining.

1.4 knows and understands the various digging process.

1.5 knows and understands the various stripping process.

1.6 knows and understands breaking with hammer and picks process,

hydraulic mining.

1.7 knows and understands quarrying by wedging and levering blasting,

dredges and mechanical Shovels.

1.8 knows and understands underground mining, open cast mining and their

advantages

1.9 knows and understands the dressing methods and mining tools.

2.0 Batch preparation.

2.1 know and understand the definition of batch preparation.

2.2 know and understand the dry mix and wet mix methods of body

preparation.

2.3 know and understand the formula involved.

2.4 know and understand defects and remedies in wet mix and dry mix.

2.5 know and understand methods of tempering, pugging, ageing and

souring of body.

2.6 know and understand the process of electrolytes casting slips.

3.0 Electro Porcelain:

3.1 Know and understand definition and description.

3.2 Know the formation & structure of electro porcelain

3.3 Know the Selection of body & glaze by Tri-axial method.

3.32 know and understand the raw material body preparation and

manufacturing of electro porcelain

3.4 know and understand the drying & firing of electro - porcelain.

3.5 know and understand specification and sizes of electro porcelain.

3.6 know and understand the influence of glaze on technical characteristics

of porcelain insulator.

3.7 know and understand the methods of testing on electro porcelain.

4.0 Earthenware.

4.1 know and understand definition and classification.

4.2 know and understand inferior or rough earthen ware, architectural

faience encaustic tiles, and enameled faience.

4.3 know and understand feldspathic or fine earthen ware, English earthen

ware composition.

8

4.4 know and understand American earthen ware bodies, Indian bodies and

glazes.

4.5 know and understand shaping of earthen ware by different methods and

particularly jigger and jolly machine method.

4.6 know and understand fettling the ware by sponging and towing and

firing glazed wall tiles, tests for files, auto clave test and thermal shock test.

4.7 know and understand engobe definition, application of engobe, and

engobe composition and properties.

5.0 Stone ware.

5.1 know and understand definition classification, raw materials and

forming methods of stone ware.

5.2 know and understand extrusion of pipes, drying and glost firing, salt

glazing common defects in stone ware and their remedy.

5.3 know and understand tests on stone ware hydraulic teat, absorption test,

specification and sizes.

6.0 plaster of Paris.

6.1 know and understand the general explanation and manufacturing

process.

6.2 know and understand properties of plaster mould, porosity and

absorption of mould blending time graphs for plaster of paris tests, sieve

test, water test.

7.0 Soft paste porcelains.

7.1 know and understand the history and classification of porcelain raw

materials.

7.2 know and understand body composition, body preparation methods.

7.3 know and understand flew sheet of body preparation for soft paste

porcelain.

7.4 know and understand drying, glazing and glost firing of spp vitreous

china, sanitary ware, bone china, firing spp, body stains for spp. and bone

china.

9

MARKS WEIGHTAGE TABLE

Sl.No Section Chapter Name Marks to be

allotted

Marks

allotted

1 I All Chapters 10 10

2

II

Ceramics Raw

Materials

20

45

Batch preparation

18

Electrolytes casting

slips.

07

3

III

Electro - Porcelain

18

45

Earthen ware

18

Engobe composition

and properties.

09

4

IV Stone ware

18

45 Plaster of paris (pop) 10

Soft paste porcelains 17

Total 145

10


WHITE WARES

Time: 3 Hours

Max. Marks: 100

Instructions-

1) Section-1 is compulsory.

2) From each remaining sections answer two questions. (Total 6 questions from section

II, III & IV).

SECTION 1

1. (a) fill in the blanks : 5 x 1 = 5

1. Chemical formula of gypsum is _____________

2. Hard paste porcelain is fired above ____________ oc

3. ___________ is an example for deflocculates.

4. Autoclave test was performed to find ___________

5. ____________ machine was used to shape the inner side of the cup.

(b) Write short note on Bone China. 5

SECTION 2

2. (a) What is mining? Explain open cast mining. 9

(b) Name different mining methods. 3

(c) Compare under ground open cast mining. 3

3. (a) Explain the wet method of body preparation. 7

(b) Compare advantages and limitations of dry and wet mix method of

body preparation. 4

(c) In short explain the need of electrolytes in preparation of casting

slip. 4

4. (a) what is pugging? Explain de airing pug mill with neat sketch. 8

(b) Explain ageing and weathering. 5

(c) Write short notes on Electro porcelain. 2

11

SECTION-III

5. (a) With neat flow diagram explain manufacturing of porcelain insulator. 9

(b) Name different products made with Electro Porcelain. 3

(c) Briefly explain the terms sponging and towing. 3

6. (a) With neat sketch explain jiggering and jollying. 7

(b) What is engobe? Explain. 4

(c) Write general properties and uses of earthen ware body. 4

6. (a) What is stone ware? Write a typical body composition of 5

stone ware body

(b) Write common defects and there remedies observed in stone ware. 4

(c) Name different shaping methods adopted for stone ware. 6

SECTION-IV

8. (a) Explain how plaster of paris is prepared? 9

(b) Give any three physical properties of gypsum. 3

(c) Mention different types of plaster of paris and their uses. 3

9. (a) write neat flow diagram explain making of soft past porcelain. 7

(b) Name the raw materials and composition of soft past porcelain. 4

(c) Give classification of stone ware. 4

10. (a) Explain salt glazing. 8

(b) Explain glost firing of bone china. 5

(c) What is I.S.T and F.S.T? Explain briefly. 2

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

12

CERAMICS TECHNOLOGY

III SEMESTER

COATING TECHNOLOGY

No of Hrs/Week: 04 Hrs Total no of Hrs: 64Hrs

SL

NO

TOPIC Hours Allotted

1. Introduction of Glazes 06

2. Raw Materials 06

3. Preparation of Glazes 05

4. Application of Glaze 05

5. Firing of Glazes 04

6. Glaze defects & Remedies 04

7. Colors & Decoration 06

8. Introduction of Enamels 05

9. Base Metal Preparation 04

10. Preparation & Application of Enamels 03

11. Firing & Defects in Enamel 04

12 Advanced Coating 04

13 Industrial Visit & Guest lecture 04


Total 64

13

DETAILS OF CONTENT

1.0 Introduction of Glaze

Definition, Similarities & Dissimilarities between glazes & Glasses.

Classification of glazes. Definition & Explanation of Raw glaze, Fritted glaze,

Lead glaze, leadless glaze, vapour glaze, opaque glaze, matt glaze &

crystalline glaze

2. Raw Materials

Clay: - China clay, Bentonite, Ball clay

Silica: - Quartz, Quartzite, flint, sand stone, silica sand & Explain effect of

silica

Fluxes: - Soda feldspar, Potash feldspar, cornwall stone, nephline syanite,

cullet

Amphotoric Oxide: - Alumina,

Alkalie materials:- Sodium Carbonate, Sodium Chloride, Sodium Nitrate,

Sodium Hydroxide, Sodium Silica fluoride, Potassium

Carbonate, Sodium Nitrate, litharge, red lead.

Alkaline earth materials:-Barium Carbonate, calcium carbonate, borax, boric

acid

Opacifiers: - Tin oxide, zirconia, zircon, antimony oxide, & calcium

fluoride.

Explanation of role of each glaze raw material

3. Preparation of glaze

Selection of Raw materials, Composition, Batch preparation, weighing,

mixing, grinding, quantity of water

Definition of frit, preparation of frit & importance of fritting.

Tests for raw glaze slip: Density, viscosity, particle size. Explain briefly.

4. Application of glaze

Dipping, brushing, pouring, & spraying [Mechanical, Air, Electrostatic&

Plasma Spraying], Explain each glaze application method.

5. Firing of glaze:-

Drying, placing precautions of glazed ware before firing of a glazed ware.

6. Glaze defects & Remedies:-

Types of defects. Discuss common defects in glazed articles like crazing,

crawling, peeling & pin holes with causes & remedies.

14

7. Colors & Decoration

Definition of colors, explanation of ceramics colors like manganese, cobalt,

chromium, iron, & copper. Definition & preparation of stains.

Decoration: Definition of under glaze, in glaze & on glaze decoration.

Describe Decoration methods like direct application [ Painting, banding & lining],

semi direct application [ Stamping & Stenciling] & indirect application[ Screen

printing, & Chromolithic graphic].

8. Introduction & Classification of Enamels

Definition & Brief history of enamels. Lacquer enamels & Paint enamels

Definition & Brief explanation of various types of enamels like vitreous, soft

art, hard porcelain, colored, iron & steel & jewellery enamels.

9. Base Metal preparation

Cleaning by organic detergents, chemical method, de greasing by heat

treatment & pickling

10. Preparation & Application

Enamel composition, Batching, grinding, & mill additives.

Define ground coat & cover coat enamel. Application of enamel by dipping &

spraying method

11. Firing & Defects in enamel

Enamel frit furnace, crucible frit furnace, firing cycle, diagram & working

process. Under fired, rolling, scaling, chipping, pinholes, crazing. Explain

causes & Defects of enamels.

12. Advance Coating

Diffusion, definition of diffusion, diffusion process by carburizing, nitridizing,

thin film coating- Nano material coating.

15

General Objectives

1.12 Know the classification of glazes.

1.13 Understand the concept of glaze preparation & applications methods.

1.14 Know the firing of glaze.

1.15 Understand the defects & remedies.

1.16 Know the colors & decoration.

1.17 Know the influence of glaze on mechanical strength.

1.18 Know the history & classification of enamels.

1.19 Understand the concept of metal preparation, application & enamel

firing.

1.20 Understand the diffusion process & thin film coating.

Specific Objectives

1.0 Introduction of Glaze

1.1 Know the definition of glaze.

1.2 State the classification of glaze

1.3 Know the definition & explanation of raw, fritted, lead, leadless, vapor,

opaque, matt, & crystalline glazes

1.4 Know the raw glaze & fritted glazes.

1.5 Understand glaze composition of lead glaze, leadless, vapor, opaque, matt,

crystalline & luster glazes.

1.6 Know the similarities & dissimilarities between glazes & glasses.

2.0 Raw materials

2.1 Know the clays, silica, fluxes, alkalis & opacifiers.

2.2 State the role of each glaze raw materials.

3.0 Preparation of glazes

3.1 Know the selection of raw materials composition weighing, mixing,

fritting, grinding, quantity of water.

3.2 Understand the viscosity & density of glaze slip.

4.0 Application of glaze

4.1 Know the methods of glaze applications.

4.2 Explanation of spraying, dipping & Brushing

5.0 Firing of glaze

5.1 Understand the firing process.

5.2 To know the placing precautions of glazed ware before firing.

5.3 Understand the pyrochemical reaction.

6.0 Glaze defects & remedies

6.1 To know the types of defects.

6.2 Understand causes & remedies in crawling, crazing, pinholes, peeling &

crazing.

16

7.0 Colors & Decoration

7.1 Definition of Colors

7.2 Explanation of ceramic colors

7.3 Know the definition & preparation of stains.

7.4 Know the definition & decoration method like painting, screen printing,

stenciling & chromolithography.

8.0 Enamels

8.1 Know the definition, brief history of enamels.

8.2 Understand lacquer & paints.

8.3 Able to understand classification of enamels.

8.4 Know definition & explanation of vitreous enamels, soft art enamel,

porcelain enamel, iron & steel, colored & jewelry enamels.

9.0 Metal preparation

9.1 Know preparation metal before applying the enamels.

9.2 Understand the chemical methods, organic detergents, decreasing by heat

treatment & pickling.

10.0 Preparation & Application

10.1 Understand the composition, batching, & grinding of enamels.

10.2 Know the mill additives.

10.3 Understand the ground coat & cover coat.

10.4 Know the dipping & spraying methods in enamels.

11.0 Firing & defects in enamels

11.1 Know the frit furnace, working principles & diagrams.

11.2 Know the crucible furnace.

11.3 Know the types of enamel defects.

11.4 Understand the under fired rolling, scaling, chipping, pinholes, crazing.

11.5 Know the causes & remedies of each defect.

12.0 Advanced Coating

12.1 Know the advanced coating.

12.2 Understand the diffusion.

12.3 Know the carburizing & nitridizing.

12.4 Understand the thin film coating, nano material coating

17



allotted

Marks

alloted


2

II

Introduction of Glazes

10

45

Raw Materials

15

Preparation & application

of Glazes 20

3

III Firing of Glazes 15

45 Glaze defects &

Remedies 15

Colors & Decoration,

Introduction of enamels 15

4

IV Metal Preparation 10

45 Preparation & Application

of Enamels

10

Firing & Defects in

Enamel, Advanced

Coating

25

Total 145

18


COATING TECHNOLOGY

Max.Marks : 100

Time: 3 Hrs INTRUCTIONS

1. Section no. 1 is compulsory.

2. Answer any 2 full questions from II, III & IV Sections (total Six full questions)

SECTION I

1. (a) Fill in the blanks: 5x1=5

i. Cobalt gives ___________ color. ii. Cullet acts as ___________ agent.

iii. The chemical formula of antimony oxide ___________.

iv. The fluidity of slip is increased by adding ___________

v. Firing of an article after application of glaze is known as ___________ firing.

b) Write a short note on Lacquers. 5

SECTION II

2. a) Define glaze. 2

b) Write the similarities & dissimilarities between glazes & glasses. 5

c) Explain lead glazes & fritted glazes. 8

3. a) Explain the effect of heat on silica from room temperature 7

to its melting temperature.

b) What are opacifiers? Give examples. 4

c) Explain the role of flux in glaze. 4

4. a) Define frit. 2

b) Explain why fritting is necessary. 6

c) Briefly explain preparation of raw glaze. 7

SECTION III

5. a) Explain how to maintain density & viscosity of glaze slip. 5

b) Name the various glaze application methods. 2

c) Explain plasma & electrostatic spraying. 8

6. a) What are the precautions to be taken while placing the glazed 4

ware for firing.

b) What is bentonite? State its use in glaze preparation.

c) Explain the pyro chemical reactions occurring during firing & glazed ware. 7

19

7. a) Explain crazing & peeling defect with causes & remedies. 6

b) Define stain explain how it is prepared. 4

c) Explain screen printing. 5

SECTION IV

8. a) Define vitreous enamel. 2

b) Explain colored & jewelry enamel. 6

c) Explain the base metal preparation before enameling 7

by chemical & pickling method.

9. a) What are mill additives? Give examples. 4

b) Define ground coat & cover coat. 4

c) Draw a neat diagram of crucible frit furnace & explain its working. 7

10. a) Explain under fired & scaling defect in enamel with causes & remedies. 6

b) Explain diffusion by carburizing. 5

c) Write a note on thin film coating. 4

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

20

Diploma in Ceramics Technology

Third semester

Subject: Ceramics Calculation

Contact Hrs / Week: 4 Contact Hrs / Semester: 64

SL NO TOPIC HRS ALLTD

1 Units. accuracy and errors in result and calculation 05

2 Shortened method calculation 10

3 Dimensional Changes 10

4 Shrinkage Behavior in Firing 10

5 Mechanical strength 10

6 Blending and Specific Gravity of slip. 10

7 Glazes and frits Thorpes ratio, Lead glaze

calculation, air calculation for fuel burning.

10

8 Surface factor and analysis. 10

9 Industrial Visit & Guest Lectures 04


Total 64

DETAILS OF CONTENT

1.0 UNITS, ACCURACY AND ERRORS IN RESULTS AND CALCULATION

1.1 Definition, percentage and relative error

2.0 SHORTENED METHOD CALCULATION

2.1 Abridge method of division and multiplication

3.0 DIMENSIONAL CHANGES

3.1 Shrinkage, Firing shrinkage, volume shrinkage moisture content and

loss on Ignition

21

4.0 BURNING SHRINKAGE AND BEHAVIOR IN FIRING.

4.1 Definitions, solution to problem on Porosity water absorption, true

density. Apparent density volume to linear and vice-versa, volume of open pores,

Closed pores and total porosity, shrinkage water and pore water

5.0 MECHANICAL STRENGTH

5.1 Definition and solution to problems on.

5.2 Modulus of rupture, effective Modulus.

5.3 Crushing strength, tensile strength, compressive strength. Mean mode and

Median.

6.0 BLENDING AND SPECIFIC GRAVITY OF SLIP

6.1 Method of blending the raw material fixing of composition problem on the

percentage batch of wet to dry method.

6.2 Triaxial diagram (fixing of body composition).

7.0 GLAZES AND FRITS THORPES RATIO LEAD GLAZE Calculation: air calculation for fuel burring.

8.0 SURFACE FACTOR AND SIEVE ANALYSIS.

8.1 Definition, problem on: SSF and average diameter.

9.0 Suspensions of body composition (Dry & wet methods) specific gravity of liquids &

solids

REFERENCE BOOK

1. Calculation in ceramics - By R. GRIFFITHS & Radfard

2. Ceramics test & calculation - By A. I ANDREWS.

3. Hand Book of glaze MFG - By F.U. TOOLEY volume I & II Ogden

Flushing

GENERAL OBJECTIVES

1.0 know about units, Accuracy and errors in results and calculation

2.0 Understand Shortened Method Calculation

3.0 Have knowledge about Dimensional changes.

4.0 Understand Burning Shrinkage & Behavior in firing.

5.0 Know about mechanical strength.

6.0 Have knowledge of blending and specific of rarity of slip

7.0 Understand about glazes and frit

8.0 Know Thorpe’s ratio of lead glaze and calculation

9.0 Understand Air Calculation for fuel burning

10.0 know analysis of surface factor and Sieve analysis.

22

SPECIFIC OBJECTIVES

1.0 Units, Accuracy and Errors in Results and Calculation

1.1 Know and understand the Definitions

1.2 Know and understand the percentage and relative error

2.0 Shortened method calculation.

2.1 know about the Abridge method of Division

2.2 know about the Abridge method of Multiplication

3.0 Dimensional Changes

3.1 Understand about Shrinkages

3.2 know about Moisture content

3.3 Know and understand the Loss on Ignition

4.0 Burning Shrinkage and Behavior in Firing

4.1 know the definition

4.2 Understand solve the problem on porosity, Water absorption, true Density &

Apparent density.

4.3 Understand solve the problem on volume of Open pores and Closed pores

4.4 Understand solve the problem on total porosity, Shrinkage water, Pore water.

5.0 Mechanical Strength

5.1 Know and understand the definition

5.2 Solve the problems on Mechanical strength.

5.3 Know about Modulus of Rupture and Effective Modulus

5.4 Know about Tensile strength and Compressive strength

5.5 Understand mean median and mode

6.0 Blending and Specific gravity of Slip

6.1 Know about methods of blending the raw material

6.2 Understand fixing of composition.

6.3 Solve problems on percentage batch of Wet to Dry method

7.0 Glazes and Frit

7.1 Know and understand the definition.

8.0 Thorpe’s Ratio and Lead Glaze Calculation

9.0 Air Calculation for Fuel Burning

10.0 Surface Factor and Sieve Analysis

10.1 Know and understand the definition

23



allotted

Marks

alloted


2

II

Units. Accuracy and

errors in Result and

calculation

10

45 Shortened method

calculation

25

Drying & Firing

Shrinkage

10

3

III Dimensional Changes 15

45 Shrinkage and Behavior

in Firing

15

Mechanical strength

15

4

IV Blending and specific

Gravity of slip.

15

45

Glazes and frits Thorp’s

calculation, air

calculation for fuel

burning.

15

Surface factor and

analysis.

15

Total 145

24


CERAMICS CALCULATION

Time: 3HRS [Max. Marks: 100]

INSTRUCTIONS

1. Section No. 1 is compulsory.

2. Answer any two questions from II, III & IV sections (total six full questions)

SECTION I

1. a) Fill in the blanks 1x5=5

1) Unit of density___________

2) Other name of potash feldspar____________

3) Chemical formula of Quartz___________

4) Shrinkage is directly proportional to___________

5) Molecular weight of Silica__________

(b) Write a short note on accuracy and error. 5

SECTION II

2. a) A clay body shrinks 8.5 % on drying and 5% on burning (both plastic basis).We

wish to make a cylindrical jar holding 231 cc. we want the inside height to be

3 times the inside diameter. What must be the dimension of the inside of the jar

when moulded? 10

b) Calculate the SSF of the following if the specific gravity is 2.65. 3

c) Calculate the average diameter if SSF varies from 40 to 80 2

D.A. PERCENTAGE

0.0176 12.05

0.0134 7.40

0.0100 1.65

0.0062 10.90

0.0043 68.00

25

3. a) Find out all you can from the following: 8

Plastic volume 88.2cc

Dry volume 71.2cc

Plastic weight 182.6gm

Dry weight 121.0gm

b) Write a short note on

i) Percentage volume drying shrinkage 3

ii) Percentage water of plasticity 4

4. Calculate the %volume drying shrinkage, water of plasticity and pure water from the

following data: 15

SECTION III

5. a) Find out the dry content of the earthen ware glaze.

45.72 cm of ball clay at 2.4 kg/liter

27.94 cm of chine clay at 2.6 kg/liter

19.05 cm of flint at 3.20 kg/liter

11.43 of stone ware at is 2.50

b) What is the dry content of 30.4 liters of flint slip 161 gm (the specific gravity of dry

flint is 2.50) 3

c) Write a note on dry content. 2

6. a) calculate the formula from the following soda feldspar 7 Na2O 10.24

K2O 0.62

CaO 0.50

MgO 0.38

Fe2O3 0.27

Al2O3 18.31

SiO2 68.43

b) Find out the molecular weight of borax: Na2O. B4O7. 10H2O

Plastic weight 101.72gm

Dry weight 93.00gm

Plastic suspended weight 59.02gm

Saturated dry weight 93.00gm

Suspended weight 55.58gm

26

c) List RO, RO2, R2O3 group of material. 4

7. a) find out the tensile strength of a refractory brick from the following data 7

Load (Kg ) Length(cm ) Breadth (cm )

5000 2.30 2.30

4560 2.30 2.30

4410 2.30 2.30

4720 2.30 2.30

5050 2.30 2.30

b) Find out SSF of the following data. When the specific gravity is 2.56 4

Diameter Percentage

0.7076 12.05

0.0034 7.40

0.0030 3.45

0.0062 10.90

0.0043 68.00

c) Find out the average diameter if SSF varies from 100 to 120. 4

SECTION IV

8. a) calculate the modulus of rupture and effective modulus from the following data.

Length is 10cm in all the cases

Load (kg) Breadth (cm) Depth (cm)

30.5 2.45 2.40

32.4 2.45 2.40

34.3 2.45 2.40

31.1 2.45 2.40

29.6 2.45 2.40

28.7 2.45 2.40

27.8 2.45 2.40

26.1 2.45 2.40

Mark the mean, mode and medians.

9. a) calculate the recipe of the following glaze. 10 0.40 CaO

0.10 BaO

0.05 MgO

0.05 SrO

0.55 Al2O3

1.0 B2O3

2.30 SiO2

b) Convert percentage linear shrinkage 8.62% volume drying shrinkage. 2

c) A clay having 20% water of plasticity on testing had a plastic volume of 109.0cc a dry

volume of 80.00cc and dry weight 174.0gm.what is its

27

i) percentage shrinkage water ii)Its pore water? 3

10. a) Calculate what you can from the following: 8

Dry weight = 87.25 gm

Saturated weight = 94.42 gm

Suspended weight = 33.82 gm

100cc of kerosene oil weight 79.5 gm

b) Find out the average percentage linear drying shrinkage of the following data. 6 Plastic length (cm) Dry length (cm)

15.0 4.82

15.0 4.62

15.0 4.53

c) Define the term true specific gravity. 2

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

28


Third Semester

Subject: Basic Electrical and Electronics for Ceramics

Contact Hrs / Week: 4 Contact hrs / Semester: 64 Table of Specifications

Chapter Topic Hours

1 Electric Current And Circuits (DC) 7

2 Electrostatics 4

3 Electromagnetic Induction 4

4 AC Fundamentals 5

5 Transformers 5

6 Electronics Components and Their applications 12

7 Integrated Circuits 5

8 Measurement of Temperature 14

9 Lighting 2

10 Protective Devices 2

11 Tests and Revision 4

Total . 64

29

Details of Contents

1. Electric Current And Circuits (DC) a. Current, voltage and Resistance --- Definition, unit & measurement

methods

b. Ohm's law - limitations

c. Kirchhoff’s voltage and current laws.

d. Series and Parallel combination of circuits. Practical examples of these

circuits

e. Power, energy, units and their relation, how they are measured.

f. Measurement of Voltage & Current, Galvanometer, Voltmeters, ammeters,

2. Electrostatics

a. Electric charge, field, Permittivity

b. Coulomb’s law

c. Capacitance - Series and parallel combination

d. Meaning of charging and discharging of capacitors

3. Electro Magnetic Induction

a. Faraday’s laws and Lenz’s law

b. Self and mutual induction and emf

4. AC Fundamentals

a. Definition of sine wave. Equation of AC sine wave. Comparison with DC

b. Average value, maximum value, RMS value and form factor for sine wave

c. Types of reactance’s

d. Current and voltage in R,RL,RC and RLC circuits

e. define power factor

f. What is single phase & 3 phase, phase, phase difference and phase angle.

5. Transformers

a. Principle of operation of transformer

b. Turn ration, current and voltage ratios.

c. Losses in transformer

d. Types of transformers, core and shell type, step-up and step-down.

6. Electronic components and their applications

a. Conductors, semiconductors and insulators Electron emission, Types.

b. Semiconductor materials, P type and N type

c. Intrinsic and extrinsic Semiconductor.

d. PTC & NTC devices

e. PN Junctions

f. Light Emitting Diodes and their application & Seven segment displays.

g. Light Dependent Resistors, Photo Diodes, Photo voltaic cells, their uses in

industrial automation.

h. Brief idea like- types, symbols, specifications, general idea of

construction, characteristics and applications of Resistors, capacitors,

inductors, potentiometers, Relays and their types, switches

7. Integrated Circuits

a. Logic functions

b. Logic gates-NOT,AND,OR,NAND, NOR

30

c. Fundamentals of IC

d. Application of IC’s

e. Introduction to microprocessors and micro controllers with examples of

their application in general process control.

8. Measurement of temperature,

a. Temperature scales, Celsius, Fahrenheit, Kelvin, conversion from one to

another

b. Thermometers- different models.

c. Pyrometers - thermoelectric thermometers, thermocouples- seebeck

effect, peltier effect, thermocouple materials and color codes,

d. Resistance thermometers, resistance-temperature relation

e. Radiation thermometers - total Radiation pyrometers & optical pyrometers

9. Lighting

a. List electrical sources of light

b. Function and applications of

i. Incandescent lamp

ii. Fluorescent

iii. mercury vapour lamp

iv. sodium vapour lamp

c. Salient features of Industrial lighting.

10. Protective devices

a. Necessity of Protective devices

b. fuses - Rewirable & HRC, Breakers - MCB.

c. Necessity of electrical earthing

d. General electrical safety precautions.

11. Tests and revision

Reference Books :

1. Electrical Techology – B.L Thereja

2. Electronic Components - K Padmanabhan

3. Electronic Components - D V Prasad

4. Principles of Electronics - V K Mehta

5. Electronic Principles – Malvino

31

General Objectives

1.0 Electric Current & Circuits

1.1 Know the definition of current & Circuits

1.2 Understand the limitation of Ohm’s law & Kirchhoff’s law’s

1.3 Know the series & parallel combination of circuits & practical examples

1.4 Understand the power, energy, units & measurements

1.5 Know the measurement of voltage, current, galvanometer, voltmeter,

ammeters

2.0 Electro statics

2.1 Definition of electric charges, electric field, capacitance

2.2 Know the Coulomb’s law

3.0 Electro magnetic Induction

3.1 Understand the faraday’s law & Mutual Induction

4.0 AC Fundamentals

4.1 Know the definition of Sine waves, Average value, RMS value, reactance

& Power factors

5.0 Transformers

5.1 Know the principle operation of transformer

5.2 Understand the core & shell type, step-up & step down transformers

6.0 Electronic components & their applications

6.1 Definition of conductor, semi-conductors & insulators, electronic

emission, P&N type

6.2 Understand the PTC, NTC devices & PN junctions

6.3 To know the photo diodes, cells, symbols, relays& switches

7.0 Integrated Circuits

7.1 Understand the logic functions, logic gates

7.2 Know the application of IC & Microprocessors

8.0 Measurement of Temperature

8.1 Know the temperature scales, thermometers & Pyrometers

9.0 Lighting

9.1 Know the source of light, functions & applications of lamps

10.0 Protective Devices

32

10.1 Understand the necessity of protective devices

10.2 Understand the fuses, breakers, and earthings

10.3 Understand the general electrical safety precautions

SPECIFIC OBJECTIVES

1.1 Explanation of Ohm’s law & Kirchhoff’s law’s

1.2 Draw the series & Parallel circuits

1.3 Working principle of galvanometer, voltmeter & Ammeter

1.4 Solve the parallel & series problem

1.5 Know the Single phase & 3 phase circuits

1.6 Draw the sketches & function of transformers

1.7 Brief explanation of electronic components & their applications.

1.8 Brief explanation of logic functions, integrated circuits & microprocessor

1.9 Working principle & sketches of resistance thermometer, radiation thermometer &

optical Pyrometers

1.10 Salient features of electrical source of light & Industrial light

1.11 Brief explanation of electrical earthing

33



allotted

Marks

allotted


2

II

Electric Current And

Circuits (DC)

15

45 Electrostatics 15

Electromagnetic

Induction

15

3

III AC Fundamentals

15

45 Transformers 15

Electronics

Components and Their

applications

15

4

IV Integrated Circuits

15

45

Measurement of

Temperature

15

Lighting & Protective

devices

15

Total 145

34


Basic Electrical & Electronics for Ceramics


INSTRUCTIONS


2. Answer any two questions from II, III & IV sections (total six full questions)

SECTION I

1. a) Fill in the blanks 1x5=5

i.

ii

iii

iv

v

b) Write a short notes on logic-gates 5

Section II

2. a) Define current & Voltage. 3

b) Write the limitation of Ohm’s law? 4

c) Explain & draw the circuit Kirchhoff’s voltage & Current laws? 8

3. a) Define Power & Energy. 3

b) Explain the working principle of galvanometer & Voltmeter? 6

c) What is Capacitance? Write the series & parallel combination 6

of capacitance?

4. a) Define Coulomb’s law. 3

b) Explain faraday’s laws & Lenz’s law? 6

c) What is mutual induction & explain briefly. 6

Section III

5. a) Define Sine wave? 3

b) What is RMS – value? Explain average value & form factors? 6

c) Write the types of reactance & explain briefly? 6

6. a) Define power factor? 3

b) What is single phase & 3phase, explain briefly? 7

c) Draw the RC & RLC circuits. 5

7. a) What is transformer? 3

b) Write the classification of transformer & explain any one in detail? 8

c) Mention the losses in transformer. 4

35

Section IV

8. a) Define semi-conductor. 3

b) What is electron emission? Explain briefly. 7

c) What is insulators & explain NTC device. 5

9. a) Write the application of IC? 3

b) What is radiation thermocouple & Explain? 6

c) What is optical pyrometer & explain. 6

10. a) What are the salient features of industrial lighting? 4

b) Name the electrical source of light. 5

c) Write a short notes on:- i) Mercury vapor lamp 6

ii) Electrical earthing

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

36

Diploma Course in Ceramics Technology

Third Semester

Subject: Coating Technology Lab

Contact Hrs/ Week: 6 Contact

Hrs/ Semester: 96

1. Identification of glaze raw materials & chemicals: Borax, Boric acid, Lead

oxide, Red lead, White lead, Strontium carbonate, Chromium trioxide,

Antimony oxide, Cobalt oxide, Phosphor, Calcite, Sodium carbonate,

Manganese-di-oxide, Calcium oxide.

2. Preparation of fritted glazes. Sieving, Weighing & batch mixing of frit No.1

(at 1000oc)

Borax 65%

Feldspar 15%

Calcite 10%

NaCl 5%

Ball clay 5%

3. Preparation of glaze: Glaze No.1 at 1000oc on earthen ware body.

By using above frit No.1 55%

Ball clay (Images clay) 20%

Feldspar 20%

Quartz powder (Calcined) 3%

CaO 2%

Total 100%

4. Matching of the above glaze to earthen ware body & testing at 1000oc.

5. Matching of the above glaze to self vitrified body prepared & testing at

750oc–900

oc.

6. Application of glazes in various methods to represent the best method with the

available facilities.

7. To study the factors responsible for thickness of glaze on the article:

Viscosity, Dipping time, Porosity of article, Binding behavior of glaze on binders

content.

8. How different forms such as limes, rings, bows, matty finish could be got

with the glaze.

9. Application of stamping, stencil printing on wares-screen printing

technique.

10. Vapors deposition of glaze on article with colouring oxide vapors, salt

vapors etc.,

11. To assess the quality of glaze with respect to strength, porosity in

compression/ tension with the body.

37

Equipment List for Batch of 20 Students

Sl.No Name of the Equipment Quantity(Nos)

1 Brushes ( 5 mm) 20

2 Pestle & Mortars (9 inch diameter) 20

3 Basins (Steel) 20

4 Pot Mill Jars 10

5 Spraying Gun 01

6 Beaker (500 ml) 10

7 Measuring Jar (100 ml) 10

38

DIPLOMA COURSE IN CERAMICS TECNOLOGY

THIRD SEMESTER

SUBJECT: CERAMICS TESTING LAB

HRS/WEEK:06

CONTACT HRS/ SEMESTER: 96

DETAILS OF CONTENTS

1. To study the degree of vitrification in a product- stone ware, porcelain,

terracotta by conducting porosity to represent the relevant graphical presentation. 16

2. Compare the absorption ratio of terracotta roofing tiles and glazed

wall tiles, graphical presentation. 12

3. To study the flow character of casting of slip by electrolytes. 12

4. To study the setting behavior of plaster by varying water plaster ratio, particle size

setting time, strength, absorption. 18

5. Wet sieve analyses- to determine the percentage residue in the body slips, glaze

present the particle size and body on graph sheet. 14

6. Determine the percentage loss in inanition of ball clays and china clays,

magnesite, dolomite, calcite. 12

7. Determine the PH value of slips, water, distilled water. 12


Sl.No Name of the Equipment Quantity(Nos)

1 Steel body Water Bath(10 lts capacity) 02

2 Electronic Weighing Balance (0.001gm to

3000gm)

2

3 Ford Cup viscometer 10

4 Specific Gravity Bottle (25ml) 25

5 Steel Basin 10

6 Plastic Mugs (500 ml) 10

7 New system Digital PH Meter 01

39

DIPLOMA COURSE IN CERAMICS TECHNOLOGY

THIRD SEMESTER

SUBJECT: CERAMICS FORMING PRACTICE

CONTACT HRS / WEEK: 6

CONTACT HRS / SEMESTER: 96

DETAILS OF CONTENTS

1. Making a Uniform sized shaped, rings, discs, rods, plates etc., with clay mass / body

mass. 12

2. Practicing of using various forming tools, knife, wire, bamboo strip, pin, sponge,

watering the shaped ware and finishing clues and precautions for keeping the ware for

drying after shaping. 12

3. Attachment of different parts into one single unit and finishing and decorating

attractively. 12

4. To study the parts of pug mill, importance and cleaning of the pug mill after extruding

of one mass. 12

5. Extruding round, squares rods, hollow tubes, cutting technique. 12

6. To study of various forming equipment in lab with its importance, advantages and

disadvantages. 12

7. Preparation of body mass powder for dry pressing, pressing the ware with dry powder

mass and to study the properties of the product with all the parameters like moisture,

pressure, grain size etc., shall be trained on flat ware and bulky wares also. 12

8. On potters wheel (mechanical or manual) meddling of clay mass with suitable moisture

in the Mass and the requisite water lubricant, shaping some round shaped clay / body

mass articles. 12


Sl.No Name of the Equipment Quantity (Nos)

1 Wooden Mallet 10

2 Wooden Roller 10

3 Knife 12

4 Steel Scale (30 cm) 20

5 Metal Sheet 12

6 Plastic Buckets (5 liters) 12

40

FOURTH SEMESTER DIPLOMA IN CERAMICS

TECHNOLOGY


(Proposed -2010-2011)

Sl

No SUBJECTS

Contact hours Exam

durati

on

in

Hours

Scheme of examination

Total

max.

marks

Min

marks

for

passing Theor

y

Practi

cal Total

End Exam * IA

Mark

s

Max

mark

s

Min

mark

s

1 Furnace Technology 4 - 4 3 100 35 25 125 45

2 Refractories 4 - 4 3 100 35 25 125 45

3 Ceramics Machinery 4 - 4 3 100 35 25 125 45

4 Ceramics CAD Lab - 6 6 3 100 50 25 125 60

PRACTICAL

5 Refractory Lab. - 6 6 3 100 50 25 125 60

6 Furnace Technology Lab. - 6 6 3 100 50 25 125 60

7 Ceramics processing Lab - 6 6 3 100 50 25 125 60

Total 12 24 36 21 700 290 175 875 330

2. No minimum marks for IA

3. For practical batch strength is limited to 20

41

Third semester Diploma in Ceramics Technology Fourth Semester

Subject: Furnace Technology

Contact hrs/ Week :4 Contact hrs/Semester:64

Sl No. Topic Hours Allotted 1 Fuels & Classification 08

2 Fuel Properties 05

3 Fuel Calculation 05

4 Burners 05

5 Classification of Furnaces 08

6. Furnace and Kiln Accessories 05

7. Materials in Furnace Construction 05

8. Firing Practice 06

9 Pyroscopes 05

10 Furnace Maintenance 04

11. Industrial visit & Guest lecturer 04

12. Test & Revision 04

Total 64

Details of Contents

1. Fuels and Classification

Introduction to fuels, definition of fuels

Classification of Natural & Artificial fuels with examples

Solid Fuels

Types of Solid fuel

Peat, Lignite, Bituminous, Anthracite, Coal, Charcoal, Saw dust & Coke

Properties & uses

Liquid Fuels

Types of Liquid fuel

Properties and application of petroleum, petrol, diesel, kerosene & furnace oil.

Gaseous fuel

Types of Gaseous fuel, Explain the natural gas, bio-gas, coke oven gas.

Properties & application, Description of LPG & producer gas

Alternative Fuels: Solar, Microwave, RF, IR

2. Fuel Properties

Definition Thermal efficiency of fuel, flash point, fire point, flow point, viscosity

of fuel with explanation, Explain nation about the calorific value of fuel, Calorific

value, types, with definitions. Explain with sketch bomb calorimeter and gas

calorimeter. Flue gas analysis using Orsat apparatus.

Analysis of coal: proximate analysis like, moisture, ash, volatile, fixed carbon

Ultimate Analysis like Carbon, Hydrogen, Nitrogen, Sulphur and Oxygen, Gross

42

Calorific value.

3. Fuel Calculation

Analysis of coal, definition of proximate & ultimate analysis like moisture

content, ash content, volatile content, fixed carbon content & gross calorific

value.

4. Burners

Introduction to burners, Types of Burners, atomization of fuel with

definition and explanation.

5. Classification of furnaces

Furnace Classification by Heat Source, Furnace Classification by Batch or

Continuous, and by Method of Handling Material into, Through, and out of the

Furnace , Furnace Classification by Fuel, Furnace Classification by Recirculation

Furnace Classification by Direct-Fired or Indirect-Fired, Classification by Furnace

Use, Classification by Type of Heat Recovery ,Other Furnace Type Classifications .

Description of muffle furnace, shuttle kiln, pusher kiln, tank furnace, rotary,

Hoffman’s kiln. Shaft furnace, bull trench kiln with sketch.

6. Furnace and kilns accessories

Briefly explanation about fire box, chimney, crown, damper and stack, Definition, types

and mechanism of Draught, dampers.

7. Materials in furnace construction:

Refractory components for walls, roof, hearth, and it’s thermal and physical

properties, monolithic refractory, furnace construction with monolithic refractory,

coatings, mortars, cement, Metals for furnace components, Cast iron, carbon

steels, alloy steels

8. Firing practice:

Furnace loading: sagars, kiln furniture, principles of setting loading density and

pattern,

General principles: lighting up firing schedule in relation to the type of wares, seger

cones , kiln atmosphere, cooling

Furnace operation: operation and controls of intermittent and continuous kiln control

parameters, operating appliances, instrumentation,

Firing defects: warp age, bloating, visual defects, dunting.

9.Pyrometry & Pyroscope : Pyroscope such as Seger cones, holdcrafts bar, buller ring,

wedgewood cylinder, Pyrometers- optical pyrometer, Infrared, Resistance type,

thermocouples, thermopiles, wheatstone bridge etc.,

43

10. Furnace maintenance

Primary Air, Secondary Air, Air supply equipment maintenance, recuperative heat

exchangers and dilution air supply maintenance, exhortations.

REFRENCE BOOK

1. Fuel combustion and furnace by – j. Gris wold mc. Graw hill New York

2. Efficient solid, liquid, and gaseous- by j.s.s brame and j.g. king Edward

anrnold

3. Fuel and their combustion by – R.harlam & R.P. Russian Mc graw hill New

York

4. Fuels Furnace & Refeactories by OP Gupta, Khanna Publisher

Specific Objectives

3.0 Fuels & Classification:

3.1 Know the definition of fuels

3.2 Understand the classification of fuels

3.3 Define Natural & Artificial fuels

3.4 Understand Solid, Liquid & Gaseous fuels with examples

3.5 Know the properties & application of peat, lignite, bituminous, anthracite,

coal, coke & saw dust

3.6 Understand the properties & applications of petroleum, kerosene &

furnace oil

3.7 Know the types & examples of gaseous fuels

3.8 Description of natural gas, bio gas, LPG & producer gas

3.9 Know the types of alternative fuels.

1.0 Efficiency of Fuels:

1.1 Understand the thermal efficiency of fuels

1.2 Explanation of flash point, fire point, flow/pour point & viscosity

1.3 Definition of calorific value

1.4 Understand the lower & higher calorific values

1.5 Know the experimental procedure of bomb calorimeter, boys calorimeter

& Orsat apparatus

3.0 Fuel Classification:

3.1 Know the analysis of coal

3.2 Know the definition of Proximate & ultimate analysis

3.3 Calculate the proximate & ultimate analysis

3.4 Find the percentage of moisture, ash, volatile, fixed carbon & Gross

calorific value

4.0 Burners:

4.1 Know the types of burners

44

4.2 Understand the atomization of fuels

5.0 Classification of Furnaces:

5. Know the classification by heat source, by batch or continuous

5.2 Understand the method of handling materials into, through & out of

the furnace

5.3 Know furnace classification by direct fired & indirect fired

5.4 Description of Muffle furnace, Shuttle kiln, Pusher kiln with sketch

5.5 Know the working principle of Tank furnace, Rotary kiln, Hoffman

Kiln

5.6 Explanation with sketch of shaft furnace, bulls trench kiln.

6.0 Furnace & Kiln accessories

6.1 Know the fire box, chimney, crown, damper & stack.

6.2 Understand mechanism of draught.

6.3 Know the function of damper

7.0 Materials in furnace construction

7.1 Know the refractory materials used in furnace construction.

7.2 Understand refractory components for walls, roof, hearth.

7.3 Know the thermal & physical properties of refractory components.

7.4 Definition of monolithic refractory.

7.5 Know the furnace construction with using monolithic refractory.

7.6 Understand the coatings, mortars or cements.

7.7 Know metals for furnace components like cast iron, carbon steels & alloy

steels.

8.0 Firing Practice

8.1 Know the furnace loading

8.2 Understand the kiln furniture’s sagars.

8.3 Understand the general principles of lighting up, firing schedules

8.4 Know types of wares, cones, Kiln atmosphere & cooling’s.

9.0 Pyrometry & Pyroscope

9.1 Know the definition of Pyrometer

9.2 Know the diagram & working of thermocouple, thermopiles, Infrared

pyrometer, optical pyrometer & resistance pyrometer

9.3 Definition of pyroscope

9.4 Know the seger cone & buller ring

9.5 Know the hold crafts bar, & Wedgewood cylinder

10.0 Furnace maintenance

45

10.1 Know the primary air & Secondary air.

10.2 Know the maintenance of furnace equipments.

10.3 Understand the recuperate & dilution.

10.4 Know the exhortations & Air supply in furnace

GENERAL OBJECTIVES

1.1 Derive the natural & artificial fuels.

1.2 Recognize the special Solid, Liquid, Gaseous fuels with examples.

1.3 Write the properties & application of Solid, Liquid & Gaseous fuels.

1.4 Description of bomb calorimeters, gas calorimeter & orsat apparatus.

1.5 Calculate approximate & ultimate analysis of coal.

1.6 Know the atomization of fuels.

1.7 Know the detail classification of furnaces.

1.8 Explanation of kiln accessories.

1.9 Categorize the refractory components for wall, roof & hearth.

1.10 Furnace constructions know the furnace loading, operation & firing defects.

1.11 Know the furnace maintenance & Air supply equipment & exhortations.


Sl. No Section Chapter Name Marks to be

allotted

Marks

alloted 1 I All Chapters 10 10

2

II

Fuels & Classification

15

45

Fuel Properties

15

Fuel Calculation

15

3

III

Burners

15

45

Classification of Furnaces

15

Furnace and Kiln

Accessories

15

4

IV Construction of Furnace 15

45

Firing Practice

15

Pyrometry & Furnace

Maintenance

15

Total 145

46


Furnace Technology

Time: 3 hrs Max Marks: 100

Instructions 1. Section no. 1 compulsory.

2. Answer any two full question from II, III, & IV section (Total six full questions )

SECTION I 1. (a) Fill in blanks : 5x1=5

i. Orsat apparatus used for ________________ analysis.

ii. C.V of wood is ________________

iii. Conserve heat in the furnace ________________ refractory.

iv. Seger cone are ________________ types of pyroscope.

v. Carbon refractories are fired under ________________ kiln atmosphere.

SECTION II

2. a) Define fuel. 3

b) Write the classification of fuels with examples. 7

c) What is pectrolevens? Explain its properties & applications. 5

3. a) What is coke? 3

b) How to prepare the coke oven gas? Explain briefly. 6

c) Define thermal efficiency of fuel? And explain. 6

4. a) What is producer gas? Write the properties &application 6

of producer gas.

b) Define calorific value of fuel. 3

c) Draw the neat sketch of bomb calorimeters & mention the parts. 6

SECTION III

5. a) How to analyze the flue gas? Explain 6

b) Define approximate analysis of coal. 3

c) How to calculate the approximate analysis by experiment. 6

47

6. a) What is burner? Write the types of burners. 6

b) Define atomization of fuel? Explain. 4

c) Classify the furnace by heat source? 5

7. a) Classify the furnace by batch types? 3

b) Draw the neat sketch & working principle of muffle furnace? 7

c) Draw the neat sketch of rotary Kiln & mention the parts. 5

SECTION IV

8. a) Define damper? 3

b) Write the mechanism of dampers & draught. 6

c). Write notes on fire box & chimney. 6

9. a) What are refractory components? Explain. 6

b) What is Monolithic refractory? 3

c) Name the metals for components? & explain. 6

10. a) What are the firing defects in furnace? Explain any one. 5

b) Explain the operation & control of intermittent kiln? 6

c) Write short note on Pyroscope. 4

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

48


Fourth Semester

Subject: Refractories Contact hours/Week: 4 Contact hours/Semester: 64

Sl. No. Topics Hours

1 Introduction to refractory 05

2. Manufacture of refractories 20

3 Special refractories 08

4. Insulation refractories 05

5 Properties of refractory 06

6 Testing of refractory 06

7 Refractory mortars , castables and ramming masses 04

8 Phase equilibrium in refractory materials 05

9 Application of refractory in various industries 05

Details of Contents:

1. Introduction to refractory Definition of Refractory. Classification of refractory,

based on chemical nature, acid base, neutral, with definition and examples. History

of refractory.

2. Manufacture process of Silica, alumina-silicate,

Manufacture process high alumina, magnasite, dolomite, kyanite,

silimanite, mag–chrome, forsterite, & Carbon, Graphite. It’s raw materials,

composition, shaping methods, firing process and it’s flow charts etc. and also each

properties and applications.`

3. Special Refractory:

Silicon Carbide, Sialon, Electro cast refractory Monolithic refractory its

manufacturing, composition, shaping, firing process and its properties and applications.

4. Insulation refractory:

Raw materials, composition, flowchart, shaping and firing methods. Its properties

and applications.

5. Properties of refractories:

Mechanical strength (low and high temperature ); thermal expansion ;

conductivity ; stress; thermal shock resistance ; porosity ; bulk density ; permeability;

abrasion resistance, corrosions resistance

6. Testing

Cold crushing strength (CCS) modulus of rupture (MOR); Pyrometric Cone

equivalent (P.C.E.), Refractoriness under load (RUL), Hot modulus of rupture.

49

7. Refractory, mortars, castables and ramming masses: Castables (low cement &

non- cement); gunniting materials; compositions for welding refractory; refractory

mortars. Kiln furniture’s, crucibles, muffles, Rollers, sager, & glass melting pots.

8. Phase Equilibrium in Refractory materials: Interpretation of phase diagram

for choice of refractory, firing temperature &Firing schedule. Sintering,

vitrification and fusion, phase rule, double component system alumino silicate

system, Magnesium silicate system

Triple component systems ferrous alumino silicate system, lime alumino silicate

system

9. Application of Refractory in various industries

Iron and steel industry, hot metal mixer, blast furnace, BF stoves, LD converter, and

electric arc furnace. Open hearth furnace.ladles, Refractory in ferrous and non-ferrous

metal industries (copper, aluminum, zinc and lead); cement industries continuous casting

furnaces , electric furnaces.

Reference Books:

1. Refractories production and properties. J.H.Chesters.Ironand steel industry,

London.

2.Refractories by F.H.norton. Macgrew Hill.

3.Technology of ceramics and refractories.by P.P. Budnikov. M.T. Press ,

Cambridge.

4.Refractories : their manufacture , properties and uses by M.L Misra

BHU,Varanasi(UP).

5. Fuels furnace and refractories by O.P Gupta

6.handbook of refractory D.N.Nadi.

General Objectives :

On completion of the course the student is expected to know

1. The definition of Refractories and Historical background of invention of

refractories.

2. Understand the concepts for classification of Refractories.

3. Know the various raw materials used in Acidic, Basic, Neutral, Special

and Insulation refractories and the reasons for using the same.

4. Understand the different steps involved in Processing of Refractories.

5. Know the various size reduction methods.

6. Know the various Shaping methods.

7. Understand the principles involved in drying and firing of refractories.

8. Understand the principles involved in classification of Refractory Mortars,

Refractory Cements and Castables.

9. Know the processes involved in making a good mortar.

50

10. Know the influence of composition of refractory cements on their setting

properties

11. Know the different Properties of Refractories.

12. Know the universal Standard Tests for refractories

13. Understand the working knowledge of Refractory applications in Industry.

Specific Objectives:

1.0 Introduction, Definition and history of Refractories

1.1 Know the historical background of Refractories.

1.2 Know the definition of Refractories.

1.3 Know the difference between refractory metals, Cermets and Ceramics

Refractories

1.4 Know the usage of Refractories in various industries.

2.0 Classification of Refractories.

2.1 Know the concepts behind classification of Refractories.

2.2 Know the classification of Refractories according to service temperature.

2.3 Know the classification of Refractories according to physical attributes.

2.4 Know the classification of Refractories according to chemical composition.

2.5 Know the classification of Refractories according to raw materials used.

2.6 Know the classification of Refractories according to their chemical activity.

3.0 Acidic Refractories.

3.1 Know the Definition of Acidic Refractory.

3.2Know the different raw material grouping for Acidic Refractories.

3.3 Know the classification of clay group, alumino silicate and siliceous materials.

3.4 Know the different materials in clay group with their physical and chemical

properties.

3.5 Know the different materials in Alumino-silicate group with their physical and

chemical properties.

3.6 Know the different materials in siliceous group with their physical and

chemical properties.

3.7 Know the reasons for usage of Grog and methods of obtaining grog.

.

4.0 Basic Refractories.

4.1 Know the Definition of Basic Refractory.

4.2 Know the different raw materials for Basic Refractories.

4.3 Know the various methods of obtaining Dead Burnt magnesite and its

properties.

4.4 Know the different process involved in making Magnesite refractories,

chrome-magnesite and magnesite- chrome refractories.

4.5 Know the properties of Dolomite and the treatments required before usage as

refractory.

51

4.6 Know the different sources of Alumina, different crystalline forms of Alumina

and the process of making of alumina refractory.

4.7 Know the different sources of Zirconia, different crystalline forms of Zirconia

and the process of making of Zirconia refractory

5.0 Neutral Refractories

5.1 Know the Definition of Neutral Refractory.

5.2 Know the different raw materials for Neutral Refractories.

5.3 Know the various methods of obtaining Graphite and its properties.

5.4 Know the different process involved in making Graphite, Carbon-Chamotte,

and carbon impregnated refractories.

5.5 Know the different binders used in carbon refractory manufacture.

6.0 Special Refractories.

6.1 Know the Definition of Non oxide refractories.

6.11 Know the different materials classified as non oxide Refractories.

6.12 Know the definition of metalloid, non metalloid and intermediates.

6.13 Know the general properties of carbides.

6.14 Know the different carbides that are of engineering use.

6.15 Know the crystal structure and properties of silicon carbide.

6.16 Know the different process of obtaining silicon carbide.

6.17 Know the definition of clay bonded silicon carbide, self-bonded silicon

carbide, recrystallised silicon carbide and nitride bonded silicon carbide

and the process of making the same.

6.2 Know the general properties of Nitrides.

6.21 Know the different nitrides that are of engineering use.

6.22 Know the crystal structure and properties of silicon nitride.

6.23 Know the different process of obtaining silicon nitride.

6.24 Know the definition of pressureless sintered silicon nitride, hot pressed

silicon nitride and hot isostatically pressed silicon nitride and the process

of making the same.

6.3 Know the general properties of Boron Nitride, Silicon oxy nitride, silicon

aluminum oxy nitride and Aluminum oxy nitride.

6.4 Know the definition, property and usage of Tabular Alumina.

6.5 Know the definition, property and usage of Fused Alumina.

6.6 Know the definition, property and usage of oxide carbon refractories.

6.7 Know the definition, property and usage of Magnesia – Carbon refractories.

7.0 Insulation Refractories

7.1 Know the Definition of Neutral Refractory.

7.2 Know the different raw materials for Insulation Refractories.

7.3 Know the various methods of obtaining porosity in insulation bricks.

7.4 Know the manufacturing process involved in making Insulation bricks.

7.5 Know the difference hot face and cold face insulation.

52

8.0 Processing of Refractories

8.1 Know the various shaping methods employed in refractory manufacture.

8.2 Know the complete manufacturing process involved in making different

Refractory shapes.

8.3 Know the process involved in drying of ordinary refractories.

8.4 Know the process involved in drying of chemically bonded refractories

8.5 Know the process of firing of refractories.

9.0 Refractory Mortars, Cements and Castables.

9.1 Know the definition of Refractory mortar.

9.2 Know the difference between air setting mortars and hydraulic setting mortars.

9.3 Know the definition of Refractory cements.

9.4 Know the chemical composition of refractory cements and the role they play

in setting time as also the strength they provide at room temperature and high

temperatures.

9.5 Know the process of making refractory castables.

10.0 Standard Tests for Refractories.

10.1 Know the different tests prescribed by Indian Standards Institute for

refractories.

10.2 Know the method of testing refractories for Cold Crushing Strength,

Pyrometric cone equivalent, Refractoriness under load and Spalling Resistance.

10.3 Be aware of the importance of size tolerances, bulk density, porosity, slag

and metal wetting resistance and permeability.

11.0 Application of Refractories in Industry.

11.1 Be aware of refractory usage in various industries.

11.2 Know the qualitative and quantitative requirements of refractories in steel

making, cement industry, chemical industry, ceramics industry, paper industry etc.

53



allotted

Marks

alloted


2

II

Introduction, Definition

and history of

Refractories

10

45 Classification of

Refractories.

15

Acidic Refractories 20

3

III Basic Refractories 10

45 Neutral Refractories 10

Special & Insulation

Refractories

25

4

IV Processing of

Refractories

20

45 Refractory Mortars,

Cements and Castables

10

Standard Tests &

application for

Refractories

15

Total 145

54


REFRACTORIES


INSTRUCTIONS


2. Answer any two full questions from II, III & IV Section (Total Six Full Question)

SECTION I

1. (a) Fill in the blanks: 1X5=5

a) ____________bricks are very light.

b) Hematite is used for making ____________ bricks.

c) Major constituent of mullite is___________.

d) _______________ atmosphere is very much required for firing carbon

bricks.

c) P.C.E. if Bauxite Refractories is ___________

(b) Write short note’s on Grog 5

2. a) Define refractory. 3

b) Give the detail classification of refractories with examples. 6

c) What is grog? Explain its need. 6

3. a) Write a note on raw materials used for manufacturing silica refractories. 3

b) With a neat flow chart explain the manufacturing of silica refactories. 7

c) State the properties and uses of silica refractory. 5

4. a) What is calcination? 3

b) Give the important role of refractories in the following places. 6

i) Iron and steel industries, (ii0 Ceramic industries, (iii) cement.

c) Explain R.U.L. property of refractory in detail. 6

SECTION III

5. a) Write a note on silicon carbide refractory. 4

b) Explain the manufacturing process of dolomite refractories. 7

c) State the properties and uses of dolomite refractories. 4

55

6. a) What are carbon refractories? 3

b) What are the various tests conducted to satisfy of refractory bricks? 5

c) Explain any two in detail. 7

7. a) What are kiln furnitures? 3

b) Explain how you manufacture saggers. 7

c) State the properties and uses of saggers. 5

SECTION IV

8. a) What are mortars? 4

b) What is porosity? Explain how it influences mechanical strength of a

refractory body. 9

c) What is muffle? 2

9. a) Define refractory cement. 3

b) Explain in detail the manufacturing of graphite refractory crucible. 8

c) Explain the term “insulation bricks”. 4

10. a) What is spalling resistance? 3

b) Explain the spalling resistance test conducted for refractories. 6

c) Name the refectories used in different parts of blast furnace and LD 6

Convertor.

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

56


Fourth Semester

Subject: Ceramics Machinery

Contact Hrs / Week: 4 Contact hrs / Semester: 64

Chapter Topic Hours

1 Size Reduction 10

2 Size Separation 07

3 Body Making & Mixing Machinery 06

4 Pressing Machinery 08

5 Shaping Equipments 05

6 Driers 08

7 Testing Equipments 05

8 Handling of Raw Materials 07

9 Tests & Revisions 04

10 Industrial visit & Guest lecture 04

Total 64

DETAILS OF CONTENTS

1. Size Reduction

Definition of size reduction, Selection of Crushing & Grinding Equipment,

Definition of closed & open circuit operations. Classification of size reduction machinery.

Crushers – Single and double toggle jaw crushers, Blake Jaw Crushers, Gyratory

Crushers, Crushing rolls (toothed & Smooth), Hammer mill, edge runners.

Grinders – Ball mills, Tube mills, conical mills, Pot mills, vibro-energy mills etc

with their parts, quantity of balls, size of balls and other factors effecting grinding

efficiency.

Explain construction & working of each machine with neat sketch.

2. Size Separation

Wet classifiers, Air separators, Magnetic/ electromagnetic separators, Grizzles,

Flat Screens, Punched Screens, Trommel, Vibrating sieves, Shaking Screens,

cyclone separators, filter press, centrifugal de-watering, electro osmosis plant etc.


57

3. Body Making & Mixing

Pug mill, De-airing pug mill( single arc and double arc), Extruders, kneading

equipments, wet pan mill, Mixers – ribbon mixers, blunger, agitator etc.


4. Pressing Machines

Definition of pressing, important parameters of pressing[Die, Powder, &

Pressure] Toggle press, Screw press, friction press, Hydraulic press, Vibration

Compaction, Isostatic press, Hot isostatic press (HIP), Injection Moulding, Tape

casting etc


5. Shaping Equipments

Potters wheel, jiggering & Jollying, Batting machine, Semi and fully automatic

jiggers, Turning.


6. Driers

Introduction, classification, Batch dryer: Loft & Hot floor, periodic box drier

&chamber dryer, microwave drier. Continuous dryer: Humidity dryer, belt dryer,

pneumatic drier, rotary drier, tunnel drier and spray drier.


7. Testing Equipments

Vicat apparatus, Le-chatlier apparatus, Penetrometer, MOR Testing machine,

Autoclave machine, abrasion testing machine, infrared moisture balance.


8. Material handling equipments

Portable power driven machines, permanent installations, flight conveyors, belt

conveyors, screw conveyors, bucket elevators, fluidized bed conveyer (cement

industry), conveying through pipes, slurry pumps, and diaphragm pump.


8. Tests and Revisions

RECOMMENDED BOOKS

1. Industrial Ceramic by Singer & Singer, IBH Publisher.

2. Mineral Processing – S. K Jain, CBS Publisher

3. Mineral Processing Technology - Barry A. Wills, Tim Napier-Munn

4. A Concise Introduction to Ceramics by George C. Phillips, Amazon Publication

5. Ceramics, Mastering the Craft by Richard Zakin, American Ceramic Society Pub 1990

58

6. Advanced Ceramic Processing and Technology. Vol. 1, Jon G.P. Binner.

7. Ceramic Materials - Science and Engineering, C Barry Carter & M. Grant



allotted

Marks

alloted


2

II

Size Reduction

20

45 Size Separation

15

Body Making &

Mixing Machinery

10

3

III Pressing Machinery

20

45 Shaping Equipments

10

Driers

15

4

IV Testing Equipments

25

45 Handling of Raw

Materials

10

Slurry & Diaphragm

Pump

10

Total 145

59

General Objectives

1. Size Reduction

a. To study the size reduction methods

b. To know the mechanism of communation

c. Factors affecting selection of crushing & grinding machines.

d. To know the classification of crushing and grinding equipments based on

particle size of feed and discharge.

e. To know the classification – closed circuit and open circuit grinding.

f. To draw the sketch of Blake Jaw Crusher, working principle etc

g. To draw the sketch of Ball mill, Tube mill, Conical mill etc.

For all machineries – the student should be able to draw the sketch, label the parts,

explain its working, compare the products with similar products.

Specific Objectives

1.0 Size Reduction

1.1 To know & understand definition of Size reduction

1.2 To know the selection of crushing & grinding equipments.

1.3 To know the definition of close & open circuit operation.

1.4 To know the classification of size reduction machinery.

1.5 To know the diagrams & working principles of blake jaw, gyratory, roller

crushers. hammer mill & edge runner mill.

1.6 To know the diagram & working principle of ball mill, tube mill, conical mill,

pot mill & vibro- energy mill.

1.7 To understand the factors effecting grinding efficiency.

2.0 Size separation

2.1 To know the definition of wet classifier & air separator.

2.2 To know & understand the diagram & working of magnetic & cyclone

seperators, centrifugal de-watering & electro osmosis plant

2.3 To know the diagram & working of grizzles, flat, punched, tromel, vibrating

& shaking screens.

3.0 Body making & Mixing

3.1 To know & understand the diagram & working of De-airing pug mill,

kneading machine, wet pan mill, ribbon mixer, blunger & agitator.

60

4.0 Pressing Machines

4.1 To know the definition of pressing.

4.2 To understand the parameters of pressing.

4.3 To know the diagrams & working principles of toggle press, screw press,

friction press, hydraulic press, vibration compaction, isostatic press, hot

isostatic press, injection moulding & Tape casting.

5.0 Shaping Equipments

5.1 Understand the working & diagrams of potter’s wheel & batting machine.

5.2 To know jiggering & jollying.

5.3 To understand semi & fully automatic jiggers.

5.4 To understand the working of turning machines.

6.0 Dryers

6.1 To know the classification of dryer

6.2 Explaination of batch type dryer like loft & hot floor, chamber, microwave

dryer.

6.3 Understand the diagram & working of continuous dryers like belt dryer,

humidity dryer, pneumatic dryer, rotary dryer & spray dryer.

7.0 Testing Equipments

7.1 Know the working principles of vicat apparatus, le-chatlier apparatus,

peneterometer, & MOR testing machine.

7.2 Know the procedures with sketches of autoclave machine, abrasion testing

machine & infrared moisture balance.

8.0 Material Handling Eqipments

8.1 Know the portable power driven machines, permanent installations & flight

conveyers

8.2 Understand the working principles of belt conveyers, screw conveyers &

fluidized be conveyers.

8.3 Able to understand the conveying through piped, slurry pumps & diaphragm

pump.

61


Ceramics Machinery

Time: 3 hrs Max Marks: 100

Instructions 1. Section no. 1 compulsory.

2. Answer any two full question from II, III, & IV section (Total six full questions )

SECTION I

1. (a) Fill in blanks : 5x1=5

i. Thin & Complicated articles are prepared by ___________ pressing.

ii. The leather hard articles have ___________ % moisture.

iii. The speed of the blunger is ___________ than the agitators.

iv. Critical speed of the mill is found by ___________ formula.

v. ___________ size grinding media are used in ball mill.

b) Write a short note on Cyclone separator. 5

SECTION II

2. a) Define size reduction. 2

b) Give the classification of size reduction. 4

c) Explain with a neat sketch working of blake raw crusher? 9

3. a) Draw a neat sketch of Hammer mill & label its parts. 5

b) State the advantages of hammer mill over roller crusher. 5

c) Explain the effect of speed on the grinding efficiency. 5

4. a) Explain with diagram electro osmosis plant. 6

b) Define De-airing. 2

c) Draw a neat sketch of conical mill & explain its working.

SECTION III

5. a) Define extrusion. 2

b) Explain how pugging is done in de-airing pug mill. 7

c) Explain the importance of die, powder & pressure for sound pressing 6

6. a) Write the advantages & disadvantages of iso-static pressing. 5

b) Draw a neat sketch of injection moulding 7 explain its working. 7

c) Draw a neat sketch of pan mill & label the parts. 3

62

7. a) Explain the shaping of flat wares by jigger machine. 6

b) State the advantages of screw press over toggle press. 4

c) Explain Turning. 5

SECTION IV

8. a) Give the classification of driers. 4

b) Explain Micro wave drying. 6

c) Differentiate between batch type & continous type. 5

9. a) Draw a neat sketch of spray drier & explain its working. 6

b) Differentiate between rotary drier & tunnel drier. 4

c) Find the green density of tiles by using penitrometer. 5

10. a) Explain how the soundness of cement is determined. 5

b) Name the different types of conveyers. 2

c) Explain screw conveyors & bucket elevators. 8

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


Subject: Ceramics Cad Lab.

Contact Hrs / week: 6 Contact Hrs/ semester: 96

Sl.No Contents Hours Alloted

1 Basics of Auto CAD 10

2 Basics Drawing 10

63

3 Introduction to modify commands & tools 12

4 Advanced Drawing techniques 08

5 Text Creation 08

6 Construction of 2D Ceramics Drawing 12

7 Intrroduction to 3D Ceramics Drawing 15

8. Creation of realistic ceramics material & product 15


Total 96

DETAILS OF CONTENTS

1. Basics Auto CAD

a. Starting of Auto CAD

b. Main menu bar

c. Basics CAD commands

2. Basics Drawing

Draw the line, ray, circle, arc, square, rectangle & Triangle by using CAD

commands.

3. Introduction to modify commands & tools

Erase, move, copy, Rotate, Break, Trim, Scale, Streatch, Lengthen, extend, offset,

mirror, zoom & hatch.

4. Advance Drawing Techniques.

To change colors, line type & thickness.

5. Text Creation

Text plays an important part in ceramics drawing. It is used for title block to

label the parts of the drawing to give the specification by using test commands

Ex. Ceramics tiles, Refractory brick, Cement blocks.

6. Construction of 2D Ceramics drawing

Block Diagrams, plant layout, ball mill, rotary kiln & blast furnace

7. Introduction to 3D Ceramics drawing

Construction of 3D ceramics ware. E.g. Ceramics glazed tile, stone ware pipe,

bullers ring, seger cone, refractory brick & Ceramics insulator

8. Creation of realistic ceramics material & Product

Granite, marble, glazed tile, refractory brick, terracotta tile, cement block.


Subject: Refractories Lab

Contact Hrs / week: 6

Contact Hrs/ semester: 96

1. Sieving and grading of grogs. 6

2. Preparation of following refractory mixture for standard brick. 15

(e. g. Fireclay, Silica, Insulation bricks etc)

-20 + 40 -40 + 60 -60 +100

64

A 50% 25% 25%

B 40% 30% 30%

C 25% 50% 25%

3. Study of linear drying shrinkage.

4. Porosity by boiling in water. 6

5. Study of volume drying shrinkage. 6

6. Determination of CCS 9

7. Making of refractory crucible and study the properties. 9

8. Making of refractory candle for water filter and study the properties. 9

9. Determination of thermal conductivity by heated wire and by plate

method 9

10. Prepare a polished specimen and study the micro structure by 12

Ceramographic Microscope.

11. Revision

Equipment List for a batch of 20 Students

Sl. No Name of the Equipment Quantity (Nos) 1 U.T.M Machine (CCS) 01

2 Metal Bricks Mould 10

3 Lab Furnace 01

4 RUL – Apparatus 01

5 PCE – Apparatus 01

6 Sieve Shaker 01

7 40 mesh, with square steel / wooden frame.

I5x15x4 inches ( lxbxh)

10

8 90 mesh with square steel frame 15x15x4 inches

(lxbxh)

15

DIPLOMA COURSE IN CERAMICS TECHNOLOGY

Fourth Semester

Subject: Furnace Technology Lab

Contact Hrs / week: 6 contact Hrs/ semester: 96

1. Preparing the furnace for firing by 3

(a). Cleaning the Fire box.

(b). Flue channel.

65

(c). Ash pit.

8.0 Inspecting the furnace for fitness, to study the damages, on Refractories, 3

Lining inspection, Inspecting the peep hole, Dome chimney tightening and locking

M.S. bands of the kiln structure.

9.0 Inspection of burners, cleaning the burners for probable choking of fuel 3

Impurities setting the air fuel ratio inspection of bluer exhaust fans bearing and free

movement of damper.

10.0 Inspection of pusher machine, kiln cars and suitability of stroke fitness

of cars for firing.

11.0 Points to record such a initial stock of fuel room temperature, pressure in

3

the kiln before starting (mono-meter recording). Fuels pour point, calorific value and

flash point of fuel.

7. Clean the oil filter in the stammer box in the oil circuit. 3

12.0 Determine the moisture content in fire wood sulphur, content in coal

3

and to take appropriate precautions to avoid defects in firing because of impurities in

fuel.

13.0 Determine the flue gas content during operation of kiln & is control for

3

efficient burning and economy of fuel.

14.0 Arranging of pyroscope-process selection and number accessibility of

3

pyroscope during the process of firing for temperature measurements loading of

articles in the kiln by taking care of sticking damaging the articles to be fired and

being damaged by the article for the parts of furnace, with special reference electric

glob rods heating element furnace.

15.0 Closing of the door with necessary precautions to avoid heat and gases

being leaked out

13. Determination of moisture content in coal and sawdust. 3

14. Determination of fusion point in coal ash. 3

15. Determination of volatile content and fixed carbon content of coal

16. Determination of calorific value of coal by using bomb calorie meter. 3

17. Determination of calorific value of liquid fuels. 3

18. Determination of viscosity of liquid fuels. 3

19. Determination of flash and fire point. 6

66

20. Determination of pour point. 3

21. Find out the flue gas analysis by Orsat’s apparatus. 3

22. Demonstration and operation of optical and radiation pyrometers. 3

23. To ascertain the fitness of electrical furnace by checking the electrical 3

continuity. In Inspection of heating elements and continuity of glow bars,

ascertain the functioning of limit safety switch in door and its importance.

Precaution to take such that the heating elements will not be damaged.

24. How to raise-the temperature when solid liquids, gaseous or electrical 3

fuel are used. How salting being done to give vapour glaze for products (stone

wares).

25. How to create reducing atmosphere in the kiln during firing to get the 3

desired dark colour of the glazes and to meddle the annealing process.

26. To record initial reading of energy meters oil flow/gas flow meters. 3

Calculate the cost per unit of firing at various temperatures from 800o C, 900

o C,

1000o C, 1100

oC and 1200

o C.

27. When the required temperature is reached in the kiln how soaking 3

to be done? Care / precautions to do so.

28. How to start firing in Electric/coal/oil/gas fired kilns. The cooling 3

Process adopted in kiln with utmost care to avoid any firing defects to dry wares

fired in kiln.

29. Revision


Sl.No Name of the Equipment Quantity (Nos)

1 Drier 01

67

2 Oven 01

3 2 inch diameter porcelain Crucibles with lid 20

4 Red wood Viscometer 02

5 Cleveland Open Cup apparatus 01

6 Abel Closed Cup apparatus 01

7 Bomb Calorimeter 01

8 Boys/Junkers calorimeter 01

9 4 inch diameter porcelain Crucibles with lid 20

10

Orsat apparatus for flue gas analysis

01


Subject: CERAMICS PROCESSING LAB

Contact Hrs / week: 6

Contact Hrs/ semester: 96

1. MOULDING BY WAX 18

a. Preparation of core model, mould for core model, casting the wax,

finishing the cast using tools.

b. Making of candle, casting the wax and finishing the product.

68

2. CASTING PROCESS 18

a. Using plaster moulds and ceramic body slip by varying the thickness , wall

thickness of the ware, achieving the best mechanical strength of the casted ware,

joining the extra parts by individual castings such as handles, spouts, rings.

Study calibrating the strength of casted ware.

b. Making the number of wares using plaster moulds and ceramic body slips by

varying the slip thickness, wall thickness of ware to achieving the best strength of

the casted wares.

c. To join the extra parts by individual castings such as handles rings etc.

3. FORMING OF WARES 18

a. By using metallic moulds, wooden moulds, plastic molds, and rubber moulds by

pressing in fly press, toggle press, isostatic press, calibration of best particle size/

grain size distribution and moisture content in the body. Study on best

moisture/pressure content relationship for best pressed product. Designing and

making a mould for pressing by using a metal, wood and plastics.

4. MAKING A PLASTER – MOTHER MOULDS 18

Preparation of plaster of Paris moulds leading to.

a. Single piece mould.

b. Two piece mould.

c. Three piece mould.

d. Four piece mould.

5. PRESSING METHODS 18

a. Making of tile from using clays and metallic moulds by pressing in fly press

machine.

b. Making of rectangle test piece from using clays and metallic moulds by

pressing in fly press machine and hydraulic press machine.

6. Revision 6


Sl. No Name of the Equipments Quantity (Nos)



3 Plastic Mugs (1000 ml) 10

4 Metal Models 10

69

5 Hak saw blades 10

6 Metal sheets 12

7 Enamel Basins 12

.

PROPOSED EQUIPMENTS LIST 2010-2011 SL

NO

NAME OF THE EQUIPMENT QUANTITY

1 Brushes (5mm) 20

2 Pestle and mortars (9 inches diameter) 20

3 Steel basins 20

4 Pot mill jars 10

5 Spraying gun 01

6 Beaker (500ml) 10

7 Measuring jar (100ml) 10

8 Steel body water bath (10 liters capacity) 02

9 Electronic weighing balance(0.001gm to3000gm) 02

70

10 Ford cup viscometer 10

11 Specific gravity bottle (25 ml) 25

12 Plastic mugs (500 ml) 10

13 New system digital PH meter 01

14 Wooden mallet 10

15 Wooden roller 10

16 Knives 12

17 Steel scale 20

18 Metal sheet 20

19 Plastic buckets (5 liters) 12

20 Universal testing machine ( U.T.M) 01

21 Metal bricks mould 10

22 Lab furnace 01

23 R.U.L apparatus 01

24 P.C.E apparatus 01

25 Drier 01

26 Oven 01

27 2 inch diameter porcelain crucibles with lid 20

28 Red wood viscometer 01

29 Cleveland open cup apparatus 01

30 Abel closed cup apparatus 01

31 Bomb calorimeter 01

32 Boys / Junkers calorimeter 01

33 4 inch diameter porcelain crucibles with lid 20

34 Orsat apparatus 01

35 Plastic bucket (10 liters) 10

36 Plastic buckets (15 liters) 10

37 Plastic mugs (1000 ml) 10

38 Metal models 10

39 Enamel basin 12

40 Sieve Shaker 01

41 40 mesh with steel / wooden frame 15x15x4 inches (lxbxh) 10

42 90 mesh with steel frame 15x15x4 inches (lxbxh) 15

1

Government of Karnataka

Directorate of Technical Education

Bangalore

REVISED CURRICULUM

2011-2012.

5rd and 6th Semesters

OF

DIPLOMA IN

CERAMICS TECHNOLOGY N.ASWATHAIAH, H.O.D/Chairman of Ceramics Board

e-mail: [email protected] S.J (Govt.) polytechnic Bangalore-01

MEMBERS 1. K. MARISWAMY

Resource person/ H.O.D. of Ceramics Technology R. N. Shetty Rural Polytechnic Murudeshwar– 581350

E-mail: [email protected]

2. SANGEETHA.S.A 3.shantkumar Biradar Lecturer, Dept. of Ceramics Technology Lecturer, Dept. of Ceramics Technology S.J (Govt.) Polytechnic Bangalore-01 R. N. Shetty Rural Polytechnic Murudeshwar e-mail:[email protected] E-mail:[email protected]

MEMBERS FROM INDUSTRIES

1. D. Suresh Kumar 2. Dr. C.D Madhusoodana General Manager Sr.Manager, BHEL, CTI

Bhoruka Steels & Services Refractory division BHEL Malleshwaram Refractory division Bangalore – 5600 12

Whitefield Road, Banagalore-48 e-mail: [email protected] E-mail: [email protected] M.Ph.9449052806 M.Ph. 9845395330

3. M.G Ananda Kumar Engg Officer, Materials Technology Division

Central Power Research Institute, Bangalore – 80, e-mail- [email protected]

M.Ph. 9986318844

FIFTH SEMESTER DIPLOMA IN CERAMICS TECHNOLOGY






2

(2011- 2012)

Sl

N

o

SUBJECTS Q P

Code

Contact hours

Exam

duration

In Hours


Total

max.

marks

Min

marks

for

passing

with I.A

Marks

Theory Practical Total

End Exam

I.A

Marks Max

marks

Min

marks

1 Cement Technology. 9CR51 4 - 4 3 100 35 25 125 45

2 Glass Technology. 9CR52 4 - 4 3 100 35 25 125 45

3 Ceramics Processing

Technology. 9CR53 4 - 4 3 100 35 25 125 45

4 Cement & Ceramics Testing

Lab. 9CR54P - 6 6 3 100 50 25 125 60

5

Glass Work Shop Practice &

Ceramics Testing. 9CR55P - 6 6 3 100 50 25 125 60

6

CASP

Communication & Analysis

Skill Development Program.

9CR56P - 6 6 3 50 25 75 125 60

7 Ceramics Processing lab -2 9CR57P - 6 6 3 100 50 25 125 60

8 Project work & Industrial

visit. 9CR58P 3 3 3 - - 25 25 -

TOTAL 12 27 39 - 650 - 250 900 375

1. No End exam for project work in 5th sem. 2.For practical batch strength is limited to 20

3

SIXTH SEMESTER DIPLOMA IN CERAMICS TECHNOLOGY


(Proposed 2011-2012)

Sl

N

o

SUBJECTS

Q P

Code

Contact hours

Exam

duration

in Hours


Total

max.

marks

Min marks

for passing

with IA

marks

Theory Practic

al Total

End Exam

IA

Marks

Max

marks

Min

marks

1 Basic Management Skills & Indian

Constitution. 9ME51 4 - 4 3 100 35 25 125 45

2 Raw materials technology. 9CR61 4 - 4 3 100 35 25 125 45

3 Advanced ceramics. 9CR62 4 - 4 3 100 35 25 125 45

4 Electives:

4 - 4 3 100 35 25 125 45

i) Ferrite & Technical Ceramics. 9CR63EA

ii)Bio & dental ceramics. 9CR63EB

iii) Special refractories

&management. 9CR63EC

iv) Vitrified and glazed Tile

Ceramics. 9CR63ED

v) Composite & chemical

Ceramics. 9CR63EE

vi) Graphite & Carbon Ceramics. 9CR63EF

5 Raw Materials Testing Lab. 9CR64P - 6 6 3 100 50 25 125 60

6 Product Testing lab 9CR65P - 6 6 3 100 50 25 125 60

7 Project work. 9CR66P - 6 6 3 100 50 25 125 60

Total 16 18 34 - 700 - 175 875 360


4


FIFTH SEMESTER

Subject: Cement Technology

NO OF HRS/ WEEK: 04hrs. Total no of Hrs: 64 Hrs.

SL. NO TOPIC HOURS ALLOTTED

1 Introduction of cement 04

2 Raw materials 05

3 Calculations 05 4 Manufacturing of cement 06

5 Burning 05

6 Grinding of clinker 05

7 Coolers 05 8 Hydration 05

9 Testing of cement 05

10 Types of cement 06

11 Phase diagrams 03

11 Environmental awareness in cement plant 06

12 Tests and revision 04

TOTAL 64

CONTENTS IN DETAILS

1.0 Introduction of cement:

Definition, history of cements, applications of cement and properties of cement.

2.0 Raw Materials : Lime, sources of lime, calcinations of limestone, slaking of lime, types of lime.

Silica, alumina, Iron oxide – their sources and role of each raw material in the manufacture and properties of cement. 3.0 Calculations:

Batch calculations, calculation of LSF, Alumina Modulus, Silica modulus and their importance.

Various phases present in cement – their composition and role in cement.

4.0 Manufacturing of Cement: Dry Process, Wet Process, Semi Dry Process, advantages and disadvantages of Different processes. 5.0 Burning: Constructional aspects of rotary kiln, types of Pre-calciners, Sketch Showing, and Cyclone Separators, Pre-heaters. Refractories used, Burner pipes, Shape of the Flame,

5

Secondary Air, Importance of Coating formation, Reactions occurring in different Zones of Rotary kiln And Reactions during burning and fuel used.

6.0 Grinding of Clinker: Closed circuit and Open circuit operations, Ball mill and tube mill.

7.0 Coolers:

Importance of cooling, various types of coolers like rotary coolers, grate coolers and planetary coolers

8.0 Hydration:

Hydration of cement and its various phases, heat of hydration, set retarders, set accelerators, flash set or quick set and false setting.

9.0 Testing of Cement : Chemical Testing: Determination of various oxides in cement, - CaO, SiO2, Al2O3, Fe2O3,

MgO, SO3, Insoluble residue and Loss on Ignition.

Physical Testing – water consistency, Setting time – Initial and final setting,

compressive strength, Soundness – Le-chatelaines or autoclave method and Fineness.

10.0 Types of Cement: Ordinary Portland cement – 33, 43 & 53 grade cement. Blended cement: Portland Pozzolona cement, Portland slag cement, advantages of blended cement. White cement, Sulphate resisting cement, Oil well cement, Rapid hardening Cement, Masonry cement, High alumina cement, Low heat cement, quick setting Cement, hydrophobic cement and IRS-T special grade Cement (53 S cement). 11. Phase diagrams: 11.1 Definition of phase diagram, phase rule 11.2 Classification, Binary (cao-Al2o3 etc), ternary (cao-al2o3-sio2 etc) phase diagrams. 12. Environmental engineering in cement plant: 12.1 Role of the pollution control in cement industry. 12.2 control devices for particulate contaminants like cyclone dust collector, Bag filters, Electrostatic precipitators (ESP’S), Scrubbers or wet collectors. 12.3 Control devices for gaseous contaminants like multiple fixed bed absorber, Tray tower, packed tower, surface condenser, contact condenser.

GENERAL OBJECTIVES

1 Know the definition, history properties and application of cement.

2 Study the raw materials of cement.

6

3 Understand the batch calculations, LSF, Silica modulus, Alumina Modulus.

4 Know the Portland cement- raw materials, manufacturing process and properties.

5 Know the Wet and dry methods of clinker burning.

6 Understand Burn ability and Clinkerization of cement raw mix.

7 Know the Rotary kiln-diagram, zones and Refractories used.

8 Understand Crushing and grinding processes.

9 Study the tests on cement

10 Study the types of cements.

11 Study and understand the phase rule and phase diagrams of binary and ternary.

12 Know and understand the cause, control, of pollutants in cement industry.

SPECIFIC OBJECTIVIES

1. Introduction of cement:

1.0 Know the definition of cement. 1.1 Study the history of cement. 1.2 Understand the properties and applications of cement. 2. Raw materials:

2.0 Know the Composition of Cement. 2.1 Understand the Occurrence of Cement Raw Materials. 2.2 Know the sources of lime, calcinations of limestone, slaking of lime, types of lime.

2.3 Understand the Silica, alumina, Iron oxide – their sources and role of each raw material in the manufacture and properties of cement.

3. Calculations: 3.0 Know the batch calculations. 3.1 Understand calculation of LSF, Alumina Modulus and Silica modulus.

3.2 Study various phases present in cement – their composition and role in cement. 4. Manufacturing of Cement: 4.1 Know the Raw Materials. 4.2 Know the Process Flow Chart, manufacturing by dry, semi dry and wet process. 4.3 Study the advantages and the disadvantages of different processes. 5. Burning:

5.1 Study the constructional aspects of rotary kiln. 5.2 Know the refractories used and burner types. 5.3 know the Secondary Air, Importance of Coating formation. 5.4 Study the reactions occurring in different zones of Rotary kiln.

5.5 Understand the Reactions during burning and fuels used. 5.6 Know the types of Pre-Calciners, Sketch Showing, and Cyclones

7

Pre- heaters.

6. Grinding of Clinker: 6.1 Know the Closed circuit and Open circuit operations. 6.2 understand the grinding of clinker in ball mill and tube mill. 7. Coolers: 7.0 Know the importance of coolers.

7.1 Study the various types of coolers like rotary coolers, grate coolers and planetary coolers. 8. Hydration: 8.0 Understand the hydration of cement and its various phases. 8.1 Study the heat of hydration. 8.2 Know the set retarders, set accelerators. 8.4 Know the definition of flash set and false set. 9. Testing of Cement: 9.1 Know the chemical tests and loss on ignition. 9.2 Study the physical tests like water consistency, Setting time – Initial and final setting, compressive strength, Soundness – Le-chateliers or autoclave method and Fineness.

10. Types of Cement: 10.1 Study the various types of cements like Ordinary Portland cement – 33, 43 & 53 grade cement. Blended cement: Portland Pozzolona cement, Portland slag cement, advantages Of blended cement. White cement, Sulphate resisting cement, Oil well cement, Rapid hardening Cement, Masonry cement, High alumina cement, Low heat cement, Quick setting Cement, Hydrophobic cement and IRS-T special grade Cement (53 S cement). 11. Phase diagrams: 11.1 Know the definition of phase diagram. 11.2 Know the classification of phase diagram. 11.3 Know the Binary and Ternary phase diagram.

12. Environmental awareness in cement plant: 12.1 Know the environmental pollution control aspects. 12.2 Know the different control devices of pollution. 12.3 Know the different devices used for controlling particulates. 12.4 Know the different devices used for gaseous control.

References:

1. Engineering materials by Rangwala

8

2. Cements by Fedar gladkov,A.S Arthur and C Ashleigh

3. Cement Chemistry by H.F.W.Taylor

4. Cement by W.A Becker

5. Cement by Heiner Muller and Helen fehervary

6. Cement and concrete by Mary. s.j Gani

7. Advances in Cement technology by S.N Ghosh

8. Oragnisational management by Shivaprakash.V.M


allotted

Marks allotted


2

II

Introduction of cement 10

45

Raw materials and

Calculations

20

Manufacturing of

cement

15

III Burning, Grinding of

clinker

18

9

WEIGHTAGE TABL

E

3

Coolers 15

45

Hydration 12

4

IV Testing of cement and

types of cement

25

45 Phase diagrams

08

Environmental

awareness in cement

plant

12

Total 145

10


CEMENT TECHNOLOGY

Times: 3hrs Max. Marks: 100

INSTRUCTIONS:

1. Section-I is compulsory 2. Answer any Two full questions from II, III & Iv sections (total six full questions)

SECTION-I

1. (a) Fill in the blanks: 5x1=5

I. Joseph Aspidian invented cement in the year (Ans. 1848)

ii. Phase is responsible for early strength in cement. (Ans.C3S)

iii. IST and FST of cement can be determined by using apparatus.

iv. Excess magnesia content causes of cement.( ANS. Un Soundness)

v. Chemical composition of lime stone is (Ans. Ca Co3 )

b) Write short notes on calcinations of lime stone 5

SECTION - II

2. a) Define cement. Why it is called Portland cement? 6 b) Explain briefly how the cement has grown both in terms of quality and Production. 9

3. a) What are the various raw materials used in the manufacturing of cement? Explain briefly. 6 b) Calculate the phase composition of cement from the given raw material Composition 9 CaO - 64.6%

SiO 2 - 21.75%

Al2 O3 - 4.65%

Fe2 O3 - 3.26%

MgO - 0.19%

11

S O3 - 2.35%

TiO2 - 0.24%

Alkalis - 1.18%

4. a) What are the various phases present in cement? 4 b) Explain lime saturation factor and silica modulus. 5 c) Give an oxide composition of Portland cement. 6

SECTION - III

5. a) With a neat flow chart explain the manufacturing process of cement by dry

process method. 10 b) What are the advantages of dry process method over wet process method? 5

6. a) What are the constructional features of rotary kiln? Explain. 6 b) What is secondary air temperature? What is its importance? 6 c) What is the importance of clinker coolers? 3

7. a) What is heat of hydrations? Explain. 4 b) What are the chemical reactions taking place in rotary kiln? Explain in order of phase formation. 7 c) Explain briefly about coal used for burning.

SECTION - IV

8. a) What are the physical tests conducted on cement? Mention. 3

b) Explain how fineness is determined using blains air permeability method. 7 c) Explain Le – Chateleirs method of testing soundness of cement. 5

9. a) Define initial and final setting time of cement. 5 b) Explain the phase rule and phase diagram c) What is the IS standard for initial and final setting time? 2

10. a) What are the different types of cement? 3 b) What are blended cements? Explain. 6 c) Define briefly the aspects of control of pollution in cement industry? 6 ***********************

DIPLOMA IN CERAMICS TECHNOLOGY FIFTH SEMESTER

Subject: Glass Technology

NO OF HRS/ WEEK: 04 Total no of Hrs: 64 hrs

12

SL. NO TOPIC HOURS ALLOTTED 1 Introduction and General properties of glasses. 03

2 Classification of glasses. 03

3 Raw materials. 03

4 Glass compositions 03 5 Batch and batch calculation. 06

6 Glass melting furnaces. 07

7 Feeding devises and moulds. 06

8 Manufacturing process of bottle, sheet and optical glasses.

07

9 Annealing. 04 10 Defects in glass. 02

11 Different properties of glass. 05

12 Testing of glass ware. 04

13 Environmental awareness in glass plant. 06

14 Layout of a Modern glass Plant. 01

15 Tests and Revision. 04

Total 64

CONTENTS IN DETAIL

1. Introduction:

Brief History of Glass, Definition of Glass, General Properties of Glass, Crystalline V/s

Amorphous Solids, Structure of Silicates, Periodic, Criteria for Glass Formation, Glass Structure,

2. Classifications:

13

Definition, Soda Lime Glass, Potash Lime Glass, Potash Lead Glass, Borosilicate Glass,

Phosphate Silicate Glass, White & Colored Glass, Optical Glass, Fiber Glass. Each definition,

properties & applications.

3. Raw materials:

Glass forming oxides , etc. Silica, Boric oxide, Sodium oxide, Potassium oxide, Alumina,

Lead oxide, Zinc oxide, Cullet. Fluxes, Oxidizing agents, Reducing agents, Fining agents, Coloring

agents, De- coloring agents, De-Scumming agents & Melting aids. De-colorizing agents,

opacifying agents and Various Coloring agents or Oxides.

4. Glass compositions:

Soda lime Glass, Potash lime Glass, Potash Lead Glass, Borosilicate Glass, Optical Glass,

Etc.

5. Glass batch preparations and batch calculations:

Storage of glass raw materials , Weighing and Mixing, Batch & Batch calculations.

6. Glass melting furnaces:

Pot Furnace, Tank Furnace, Recuperative furnace, Regenerative end Port type Furnace,

Regenerative Side Port type Furnace, Comparison of Pot and Tank Furnace.

7. Melting:

Charging of batch, tank temperature, convection current, mechanism of melting, fining.

8. Feeding devices:

Definition, Miller Gob feeder, Homer Brooke flow feeder, Hontford Fairmont feeder.

9. Moulds:

Moulds used for blowing and pressing, Carbon Moulds, Caste Iron Moulds, Chromium

Moulds.

10. Manufacture and fabrication of glass:

Manufacture of Bottles by Blowing method, Manufacture of Sheet glass by Machine

Drawing process, Manufacture of Optical glass, the Lens manufacture involves

a) Cutting, b) Grinding c) Polishing d) Shaping.

11. Annealing:

14

Definition, Chamber furnace & Lehr.

12. Defects in glass wares:

Stone, Blisters, Seeds, chords & Bad color.

13 Decorative purpose and surface coating:

Cutting and grinding of glass, Etching, Sand blasting, and Coatings.

14. Properties of glass:

Physical Properties, Methods of Determining Density of Glass, Electrical Properties,

Thermal Properties, Mechanical Properties, Optical Properties, Viscosity of Glass

15. Testing glass wares:

Strength test, Heat Shock test and Testing of color.

16. Environmental awareness in glass plant:

Role of the pollution control in glass industry and types of pollutants like Sulphur, carbon mono oxide, carbon di-oxide etc. Control of pollutants and necessary precautions to prevent them particularly for the workers. Cleaning of regenerators and flue line. Control devices for particulate contaminants like cyclone dust collector, Bag filters, Electrostatic precipitators ( ESP’S).

17. Layout of Modern Glass Plant:

Draw the modern glass plant layout

GENERAL OBJECTIVES.

1.0 Know about definition, General Properties of Glass, Crystal Structure & Criteria of glass forming.

2.0 To Study the different types of glasses, their Properties and applications. 3.0 Knowing the detailed Raw Materials used for manufacture of glasses. 4.0 Studying the glass batch, batch preparations and calculations related to batch preparations 5.0 Knowing the different type of furnaces used for glass melting 6.0 Know the process of melting in detail 7.0 Know about different types of feeders used in glass manufacturing processes 8.0 Know the different types of moulds used in manufacture of glass 9.0 Know and understand the manufacturing processes of bottle glass, sheet glass, and optical Glass

15

10.0 Know and understand annealing process 11.0 Know the defects of glass 12.0 Know the various decorative processes of glass 13.0 To study the various properties of glass 14.0 To study and understand various tests of glass 15.0 Know and understand the cause, control of pollutants in glass industry 16.0 To Know and draw the modern glass plant layout

SPECIFIC OBJECTIVES

1.0 Introduction:

1.1 Know the brief history, definition and general properties of glass. 1.2 Know silicate structure of glass and criteria of glass formation.

2.0 Classification of glasses:

2.1 Know the classifications as Soda lime glass, Potash lime glass, Potash lead glass, Borosilicate glass, Optical glass, Fiber glass. Each definition, properties and applications.

3.0 Raw materials: 3.1 To know and understand the various raw materials used in the manufacture of

glasses.

4.0 Composition of glasses: 4.1 To know and understand the compositions of different glasses.

5.0 Glass batch preparations:

5.1 To know and understand the storage, weighing and mixing of various raw materials. 5.2 Solve the problem related to batch preparations.

6.0 Glass melting furnaces:

6.1 Know the types of furnaces used for melting. 6.2 Study in detail the regenerative end port type and regenerative side port type

furnaces. 6.3 Know the pot and tank furnaces and their comparison.

7.0 Melting: 7.1 Know charging of batch. 7.2 Know the tank temperatures. 7.3 Understand the mechanism of melting. 7.4 Study the fining.

8.0 Feeding devices:

8.1 Know the different types of feeding devices used in manufacture of glass.

9.0 Moulds:

16

9.1 Know the different types of moulds used in the glass manufacture.

10.0 Manufacture of Glasses: 10.1 Know and understand the detailed manufacturing process of bottle glass. 10.2 Know and understand the detailed manufacturing process of sheet glass. 10.3 Know and understand the detailed manufacturing process of optical glass. 10.4 Know the lens preparation methods like cutting, grinding, polishing and shaping.

11.0 Annealing: 11.1 Know the definition, chamber furnace and lehr. 11.2 Know and understand the annealing process.

12.0 Defects of glass:

12.1 Know and study the various types of defects of glass, such as stone, blisters, Seeds, cords and bad color.

13.0 Properties of glass: 13.1 Know the physical property. Density and its measurement methods. 13.2 Know the electrical properties of glass and electrical conductivity in detail. 13.3 Know and understand the thermal properties of glass. Thermal Conductivity and

Thermal expansion. 13.4 Know and understand the mechanical properties of glass such as hardness and

Crushing strength. 13.5 Know the optical properties of glass. Refraction, Refractive index, Dispersion

And Reflection. 13.6 Know and understand about viscosity of the glass.

14.0 Decorative process and surface coatings: 14.1 Know the cutting and grinding. 14.2 Study the etching method. 14.3 Study the sand blasting method. 14.4 Understand the coatings

15.0 Testing of glass ware:

15.1 Know the strength test, heat shock test and color test of a glass

16.0 Environmental awareness in glass plant: 16.1 Know the role of the pollution control in glass industry 16.2 Understand types of pollutants like Sulphur, carbon mono oxide, carbon di-oxide

etc. 16.3 Understand control of pollutants and necessary precautions to prevent them

particularly for the workers. Cleaning of regenerators and flue line. 16.4 Know control devices for particulate contaminants like cyclone dust collector,

Bag filters, and Electrostatic precipitators.

17.0 Layout of a modern glass plant: 17.1 Draw and know the modern glass plant layout.

17

References:

1. Modern Glass practice by Samuels. 2. Fundamental Ceramics By Mc. Graw & Hill 3. Hand book of Glass Technology by R. Charan. 4. Introduction to Glass Science & Technology By. J. F. Shelhy.

WEIGHTAGE TABLE


allotted

Marks

allotted

1 I All Chapters 10

2

II

Introduction, properties,

classification,

15

45

Raw materials, glass

compositions,

20

Batch and Batch calculations 10

III Glass melting furnaces and

melting

20

45 Feeding devices and Moulds, 15

18

Model Question paper

V Semester Diploma Examination

CERAMICS BOARD

3 Manufacture of bottle, sheet

& optical glasses

10

4

IV Annealing and Defects of

glasses,

15

45 Properties of glass ,

Decorative process & Surface

coatings

15

Testing of glass ware,

Environmental awareness in

glass plant, Layout of a

modern glass plant

15

Total 145

19

GLASS TECHNOLOGY

Time: 3 HOURS Max marks: 100

INSTRUCTIONS:

1) Section 1 is compulsory

2) Answer any two full questions from each section ii, iii & iv (total six full questions)

SECTION -I

1. (a) Fill in the blanks 5x1=5

i) Alumina in glass composition is called------------. (Ans.Amphotric oxide)

ii) Glasses have -------------- distribution of bond angle. (Ans. wide or broad)

iii) Lead oxide --------------- the density of glass.(Ans. Increase)

iv) Glass is ----------- solid. (Ans. Amorphous)

v) Glass is a ------------- conductor of heat & electricity. (Ans. Bad or poor)

(b) Write short notes on structure of a glass. 5

SECTION – II

2. (a) Define glass. 2

(b) Write the general properties of glass. 8

(c ) Describe criteria of glass forming. 5

3. (a) What is de- colorize? Give example. 2

(b) Name the oxides that are used in glass. 6

(c) Explain any two oxides in detail. 8

4. (a) Define crystal. 2

(b) Describe the structure of silicate. 7

(c) Explain the mechanism of glass formation. 6

SECTION – III

5. (a) Define batch. 2

(b) Explain storage and mixing of glass raw materials. 5

20

(c) Calculate the Molecular weights of SiO2, CaCO3, KMnO4, and Na2SiO3. 8

6. (a) Define optical glass. 2

(b) Explain the manufacturing process of optical glass. 8

(c) Write the applications of optical glass. 5

7. (a) What is pot furnace? 2

(b) Draw and explain regeneration end port furnace. 8

(c) Explain any one feeding device. 5

SECTION – IV

8. (a) Define annealing. 2

(b) Explain in detail annealing of glass in lehr. 7

(c) Explain heat shock test of glass. 6

9. (a) Define thermal conductivity. 2

(b) Write the thermal properties of glass. 8

(c) Explain the lens preparation process. 5

10. (a) Define strength of glass. 2

(b) Explain in detail the defects of glass.

(c) How Cleaning of regenerators and flue line is done. 5

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


FIFTH SEMESTER

Subject: Ceramics processing technology

NO OF HRS/ WEEK: 04 Total no of Hrs: 64 Hrs

SL NO TOPICS HOURS ALLOTED

01 Ceramic processing and ceramic products 01 02 Surface chemistry 04

03 Powder processing by chemical methods.

03

21

04 Liquids and wetting agents 03

05 Deflocculates and coagulants 04

06 Flocculants, Binders And bonds 04

07 Plasticizers ,foaming and antifoaming agents, lubricants and preservatives

02

08 Particle packing characteristics 04 09 Rheological behavior of slurries and paste 05

10 Granulation 02

11 Pressing 03

12 Plastic forming processes 03 13 Casting processes 05

14 Molecular polymerization forming 03

15 Drying 03

16 Surface processing 02

17 Firing processes 05

18 Industrial Visit/ Guest Lecture 04

19 Tests and Revision 04

Total 64

CONTENTS IN DETAIL

1. Ceramic processing and ceramics products: 1.1 A brief history of ceramics technology. 1.2 Industrial ceramics processing. 1.3 Science in ceramics processing.

2. Surface chemistry: 2.1 The atomic structure of surface differs from that in the interior of the particle. 2.2 Surface energy causes a pressure difference across a curved surface. 2.3 Weak van-der Waals forces or chemical bonding causes solid surfaces to absorb

molecules from gases and liquid solutions. 2.4 The wetting and spreading of a liquid on a solid surface depends on short-range

molecular forces that can be significantly modified by a monolayer coating. 2.5 Wetting may cause compressive forces between particles and liquid migration.

22

2.6 Weak intermolecular forces can cause the adhere of molecules on a surface and the agglomeration of small particles.

3. Powder processing by chemical methods. 3.1 Powders from chemical solution techniques. 3.2 Powders from vapor phase reactions. 3.3 Powder preparation by sol gel technique/hydrothermal methods

4. Liquids and wetting agents: 4.1 Water. 4.2 Organic liquids. 4.3 Polar liquids near oxide surfaces. 4.4 Surfactants.

5. Deflocculates and coagulants:

5.1 Particle charging in liquid suspensions. 5.2 Development of an electrical double layer. 5.3 Electro kinetic properties. 5.4 Deflocculating and the stability of suspensions. 5.5 Coagulation and flocculation.

6. flocculants, binders, and bonds:

6.1 Binder compositions. 6.2 Clay binders. 6.3 Molecular binders. 6.4 Gelation. 6.5 General effect of binders. 6.6 Polymer resins. 6.7 Reaction bonds. 6.8 Hydraulic cements.

7. Plasticizers , foaming and anti foaming agents lubricants and preservatives:

7.1 Plasticizers. 7.2 Foaming and anti foaming agents. 7.3 Lubricants. 7.4 Preservatives.

8. Particle packing characteristics:

8.1 Characteristics of packing of uniform spheres. 8.2 Packing in interstices among coarser particles. 8.3 Packing of continuous size distributions. 8.4 Hindered packing.

9. Rheological behavior of slurries and pastes:

9.1 Effective stress and shear resistance in saturated systems. 9.2 Rheological properties. 9.3 Determination of viscosity. 9.4 Viscosity of liquids.

23

9.5 Viscosity of binder solutions. 9.6 Viscosity of suspensions of dispersed colloidal particles. 9.7 Viscosity of slurries of dispersed powders and powder colloid mixtures. 9.8 Rheology of coagulated systems. 9.9 Rheology of suspensions and slurries containing binders.

10. Granulation:

10.1 Direct granulation. 10.2 Spray drying.

11. Pressing:

11.1 Process variables in dry pressing. 11.2 Powder flow and dye filling. 11.3 Compaction Behavior. 11.4 Ejection and transfer. 11.5 Die wall effects. 11.6 Control compact defects. 11.7 Uniaxial, Biaxial and Isostatic compaction 11.8 Combination pressing. 11.9 Roll pressing.

12. Plastic forming processes:

12.1 Equipment and material variables in extrusion. 12.2 Extrusion mechanics. 12.3 Control of extrusion defects. 12.4 Plastic transfer pressing and jiggering.

13. casting processes:

13.1 Slip casting in a permeable mould. 13.2 Slip casting mechanics and behavior. 13.3 Nontraditional casting. 13.4 Control of cast defects. 13.5 Tape casting. 13.6 Casting of monosize, spherical colloids.

14. Molecular polymerization forming:

14.1 Sol-gel processing. 14.2 Chemical vapor deposition.

15. Drying:

15.1 Drying systems. 15.2 Mechanism in drying. 15.3 The drying process. 15.4 Drying shrinkage and defects. 15.5 Modes of drying.

16. surface processing:

24

16.1 Trimming, smoothing and grinding. 16.2 Blanking, punching and laminating.

17. Firing processes:

17.1 Firing systems. 17.2 Presintering processes. 17.3 Solid state sintering. 17.4 Sintering of glass particles. 17.5 Liquid-phase Sintering 17.6 Sintering of white ware bodies. (vitrification) 17.7 Sintering of glazes and glassy thick films. 17.8 Cooling. 17.9 Hot pressing.

GENERAL OBJECTIVES

1. Know the history of ceramic technology and understand industrial ceramic processing and science in ceramic processing.

2. Understand the surface chemistry of particles . 3. Know and study the special inorganic chemicals. 4. Understand the liquids and wetting agents. 5. Know the deflocculates and coagulants. 6. Know the flocculants, binders and bonds. 7. Know the plasticizers, foaming and antifoaming agents, lubricants and preservatives. 8. Understand the particle packing characteristics. 9. Understand the rheological behavior of slurries and pastes. 10. Know and understand the batching and mixing. 11. Understand the particle separation, concentration and washing processes. 12. Understand the granulation. 13. Understand about pressing. 14. Know the plastic forming processes. 15. Understand the casting processes. 16. Understand the molecular polymerization forming. 17. Know and understand the drying mechanism. 18. Understand shaping and surface finishing. 19. Know and understand the firing processes..

25

SPECIFIC OBJECTIVES

1. Ceramic processing and ceramics products: 1.1 Know the brief history of ceramic technology. 1.2 Know the industrial ceramic processing. 1.3 Understand science in ceramic processing.

2. Surface chemistry:

2.1 Study the differences between atomic structure surface and interior of the particle.

2.2 Understand the effect of surface energy on pressure difference across the curved surface.

2.3 Study the cause of van-der Waals force or chemical bonding on solid surface to absorb molecules from gases and liquids.

2.4 Understand the causes for wetting and spreading of liquid on solid surface. 2.5 Understand the effect of wetting on compressive force between the particles. 2.6 Study the causes for adherence of molecules on surface.

3. Powder processing by chemical methods:

3.1 Study the powder preparation from chemical solution techniques. 3.2 Study the powder preparation from vapor phase reaction. 3.3 Powders preparations by sol-gel method/ hydrothermal methods.

4. Liquids and Wetting agents:

4.1 Know the principal liquid(water) used for processing of ceramic components. 4.2 Understand the organic additives added for ceramic processing. 4.3 Know the effect of polar liquids near oxide surfaces. 4.4 Understand the types of surfactants and its effect on ceramic material.

26

5. Deflocculants and Coagulants:

5.1 Know the particle charging in liquid suspensions. 5.2 Study the deflocculation and stability of suspensions. 5.3 Understand the mechanism of coagulation and flocculation.

6. Flocculants, Binders and Bonds:

6.1 Know the various binder compositions. 6.2 Know and understand clay as a binder. 6.3 Know about molecular binders. 6.4 Study the principle of gelation. 6.5 Understand the effect of different binders. 6.6 Know various polymer resins. 6.7 Understand the definition of reaction bonds. 6.8 Know about hydraulic cements.

7. Plasticizers, Foaming and Antifoaming agents, Lubricants and Preservatives:

7.1 Know the definition and examples of plasticizers. 7.2 Know the definition and examples of foaming and antifoaming agents. 7.3 Know the definition and examples of lubricants. 7.4 Know the definition and examples of preservatives.

8. Particle packing characteristics:

8.1 Understand the characteristics of packing of uniform spheres. 8.2 Study the packing in interstices among coarser particles. 8.3 Study packing of continuous size distributions.

9. Rheological behavior of slurries and pastes:

9.1 Understand effective stress and shear resistance in a saturated system. 9.2 Know the rheological properties. 9.3 Study the determination of viscosity. 9.4 Know viscosity of liquids. 9.5 Understand viscosity binder solutions. 9.6 Study viscosity of suspensions of dispersed colloidal particles. 9.7 Know viscosity of slurries of dispersed powders and powder colloid mixtures. 9.8 Understand rheology of coagulated system. 9.9 Study rheology of suspensions and slurries containing binders.

10. Granulation : 10.1 Understand the direct granulation process. 10.2 Study the spray drying mechanism.

11. Pressing:

11.1 Understand pressing variables in dry pressing. 11.2 Study powder flow and die filling. 11.3 Know compaction behavior.

27

11.4 Understand the ejection and transfer of pressed wares. 11.5 Study the die wall effects. 11.6 Know the measures to control compact defects. 11.7 Study the compaction by Uniaxial, Biaxial and Isostatic methods. 11.8 Know about combination pressing. 11.9 Understand roll pressing

12. Plastic forming processes:

12.1 Know the equipment and material variables in extrusion. 12.2 Understand the extrusion mechanics. 12.3 Study the measures to control extrusion defects.

13. Casting processes: 13.1 Understand slip casting in e permeable mould. 13.2 Know slip casting mechanics and behavior. 13.3 Understand nontraditional casting. 13.4 Study the measures to control cast defects. 13.5 Understand the casting of mono-size, spherical colloids.

14. Molecular polymerization forming:

14.1 Understand sol-gel processing technique. 14.2 Study chemical vapor deposition.

15. Drying:

15.1 Understand drying systems. 15.2 Know the mechanisms in drying. 15.3 Study the drying process. 15.4 Understand drying shrinkage and defects.

16. Shaping and surface finishing:

16.1 Know trimming, smoothing and grinding. 16.2 Understand blanking, punching and laminating.

17. Firing processes :

17.1 Understand the firing systems. 17.2 Study presintering processes. 17.3 Know solid state sintering. 17.4 Study sintering of glass particles. 17.5 Understand the Liquid-phase Sintering. 17.6 Know sintering of white ware bodies (vitrification). 17.7 Understand the cooling process. 17.8 Study the hot pressing method.

28

References:

1. Principles of ceramics processing by James Reed 2. Fine ceramics by F.H Norton 3. Industrial ceramics by Singer and Singer 4. Hand book of advanced ceramic by S.Somiya

WEIGHTAGE TABLE


allotted

Marks allotted


2

II

Ceramic processing and ceramic products, Surface chemistry

15

45

Special inorganic chemicals, Liquids and wetting agents

15

Defloucculants and coagulants, Flocculants, Binders And bonds

15

3

III Plasticizers ,foaming and antifoaming agents, lubricants and preservatives, Particle packing characteristics

10

45

Rheological behavior of slurries and paste, Granulation

20

Pressing, Plastic forming processes

15

4

IV Casting processes 15

45

Molecular polymerization forming, Drying

12

Surface finishing, Firing processes.

18

29

V Semester Diploma Examination

CERAMICS BOARD

CERAMICS PROCESSING TECHNOLOGY

Total 145

30

Time: 3 HOURS Max marks: 100

INSTRUCTIONS:

1) Section I is compulsory.

2) Answer any two full questions from each section II, III & IV.(total six full questions)

SECTION-I

1. a) Fill in the blanks. 5x1=5

i) Barium titan ate is an example for ________ ceramics (ans: Ferro electrics)

ii) Boiling point of glycerol is __________ (ans: 2900C)

iii) Tetra sodium pyrophosphate acts as _______ in suspensions (ans: Deflocculant)

iv) Air or some other gases enclosed within a thin film of liquid is known as ____ (ans: Foam)

v) Preservatives are ________ in nature (ans: toxic)

b) Write a short note on Surfactants. 5

SECTION-II

2. a) Write the classification of ceramics based on its function with an example. 6

b) Explain Van-der Waals force of attraction. 5

c) Explain Young equation. 4

3. a) Define Antifoaming agent. Give example 4

b) Explain how wetting causes compressive force? 5

c) Explain capillary rise and depression. 6

4. a) Define coagulants. 3

b) Explain the preparation of BaTiO3 by precipitation technique. 8

c) What is sol-gel technique? 4

SECTION-III

5. a) Write the properties of ethyl alcohol. 3

b) Explain any one method of charging the particle in liquid suspension. 7

c) Write a short note on flocculation. 5

31

6. a) Write the examples for cellulose ether based binders. 2

b) Explain gelatin process. 5

c) Explain ordered packing arrangements of uniform spheres. 8

7. a) Define shear stress and shear rate. 4

b) Write shear rates of different processing operation. 5

c) Explain spray drying mechanism. 6

SECTION-IV

8. a) Write the formula to find out compact density. 3

b) Explain process variables in dry pressing. 6

c) Describe iso static compaction. 6

9. a) Write a note on tape casting. 4

b) Explain the extrusion defects with remedies. 6

c) Explain pressure casting. 5

10. a) Explain briefly microwave drying. 3

b) Explain C.V.D. 5

c) Explain solid state sintering. 7

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


Fifth Semester

Subject: Cements & Ceramics testing lab.

Contact Hrs/ Week: 6hrs. Contact Hrs/ Semester: 96hrs.

1. Draw the layout of modern cement plant. 3hrs 2. Preparation of cement blocks and studies the curing and other properties. 9hrs

32

3. Determine the cold crushing strength of cement cube. 9hrs 4. Determine the tensile strength of cement cube. 9hrs 5. Grinding of cement clinker in laboratory ball mill and mixing with gypsum. 6hrs 6. Preparation of clinker in stationary furnace by heating from argillaceous

and calcareous materials for preparing O.P cement . 6hrs 7. Find the Specific gravity of cement by Pycnometer method. 9hrs 8. Find the soundness of cement by “Le Chatelier” & “Auto clave” method. 6hrs 9. Determine the initial and final setting time of cement by “VICAT’S”needle

apparatus. 6hrs

10. Determine the initial and final setting time of plaster of Paris (P.O.P) by 6hrs “VICAT’S”needle apparatus.

11. Determine the particle size of cement by “Sieve” test & “Blains air permeability “ apparatus. 6hrs

12. Determination of bulk density of cement. 6hrs 13. Determination of PH value of cement. 6hrs 14. Determination of Percentage Volume Drying Shrinkage of Clay. 6hrs 15. Determination of PH value of Clay, Slaked lime, Cement Slurry, Tap Water etc. 3hrs


Sl. No Name of the Equipment Quantity (Nos)

1 Cold crushing strength machine 01

2 Tensile strength machine 01

3 Ball mill 01

33

4 High temperature electric furnace 01

5 Pycnometer 20

6 Le Chatelier apparatus 10

7 Auto clave apparatus 02

8 Vicats apparatus 05

9 Standard sieve set 05

10

PH – Meter Digital type.

01

11

Blains air permeability apparatus.

01


Fifth Semester

Subject: Glass Work Shop practice &Ceramics testing.

Contact Hrs/ Week: 6 hrs. Contact Hrs/ Semester: 96hrs.

1. Determination of water of plasticity in fresh body and after aging, pugged body by maintaining fixed moisture in the body. 06hrs

2. Determination of PH - value and viscosity in the casting slip. 03hrs 3. Determination of specific gravity, viscosity, dry content of slip and % residue of casting

slips. 09hrs 4. Determination of bulk density of alumina refractory, glass products, fireclay refractory,

ferrite products, porcelain insulator by different methods. 06hrs 5. Determination of porosity of stone ware, earthen ware, porcelain glazed tiles. 06hrs

34

6. Determination of absorption ratio of stone ware , earthen ware , Porcelain glazed tiles. 03hrs

7. Determination of % loss on ignition of calcite, dolomite, sand and clay. 06hrs 8. Determination of % CaO in calcite by analysis. 03hrs 9. Determination of % MgO in dolomite by analysis. 03hrs 10. Determination of % Sio2 in quartz & sand by analysis. 03hrs 11. Determination of Softening Point of Glass by “Littletons” method. 06hrs 12. Determination of Density of Glass.

06hrs

13. Sand blasting on glass plate.

03hrs

14. Decoration of glass by Etching. 06hrs

15. Defects in glass. 03hrs

16. Testing Glass ware Strength.

06hrs

17. Chemical analysis of Glass.

06hrs

18. Determination of Refractive Index of Glass.

03hrs

19. Decoration of Glass by Surface coating. 03hrs

20. Determination of i) Thermal Shock resistance. ii) Thermal Expansion of Glass.

06hrs


Sl. No Name of the Equipment Quantity (Nos)

1 Steel basins 12 inch dia 20

2 Drying oven 01

3 Electronic balance 01

4 Digital pH meter 02

35

5 Specific gravity bottles 20

6 Viscosity apparatus 05

7 Standard sieve of 400 mesh 05

8 Beakers 100 ml 10

9 Porcelain crucibles 4 inch dia 20

10 Burettes 10

11 Platinum crucibles 02

12 Fused silica crucibles 05


Fifth Semester

COMMUNICATION AND ANALYSIS SKILL DEVELOPMENT PROGRAMME

(CASP)

HOURS/WEEK: 06 TOTAL HOURS: 96

Competence to be developed (in place of objectives):

I. To present orally about any topic of the student’s interest to the rest of the class without the assistance of media or any other aid (only talk) for about 10 minutes creating interest in the listeners and sustaining the interest with a meaningful conclusion.

II. To prepare a study report on any product/service in comparison with another one that is comparable from technical specification to customer satisfaction.

36

III. To present with the aid of slides (6 to 10) about the study conducted above to the rest of the class in about 10 minutes with the use of print for information and slides for graphs, pictures, images, video and animations etc.

Note to teachers:

A teacher may guide only 6 to a maximum of ten students per year. This is to ensure active participation of each learner.

All 96 hours need NOT be contact hours by the teacher. Students may be encouraged to do activities on their own with peer group to ensure higher level of participation.

There are ten different tasks to be completed in the course of 96 hours. On completion of each task, record the result and the marks along with the initials of the learner for future reference, inspection and evaluation.

A few activities are suggested under each task. Teachers can improvise on the list and add more activities as they progress from one batch to another.

Students should not be compared with each other; instead they must be compared to the standards given against each task.

The standard suggested is minimum requirement, learners may excel. The services of those who excel may be utilised to guide other learners to reach the suggested minimum.

The tasks 8, 9 and 10 may be evaluated in the presence of the total group so that learners get the benefit of knowing the inferences made by others and even their presentation style.

Details of tasks to be completed:

Task 1 – Communication skills: - One to one personal communication. 6 hrs. 5 marks.

Practice in pairs through role play

Suggested activities:

1. Telephonic conversation of a customer and supplier. 2. Front office receptionist and a visitor. 3. Negotiation between suppliers of equipment/chemical to a technical representative of a

manufacturing unit. 4. Conversation between quality inspector from the bulk buyer to the shop floor supervisor

regarding maintenance of any quality.

Standards to be met:

Given a telephone number, a student must be able to call and gather information from the person, sustaining the conversation for about 3 min using proper etiquettes and report on the enquiry made about the product or service. [e.g., call a toll free number to ask details about a product or service]

Given a situation, a student must be able to talk to a person face to face in simulation, gather information about a product, discuss about it and also negotiate with him in the specified time (here, time can be specified by the teacher as per the need).

37

Task 2 – Communication exercise between one to many in simulation: 6 hrs. 5 marks.

Suggested Activities:

1. A very short talk highlighting the features of a branded product. 2. A creative advertisement sequence for a product being green. 3. A debate on solid waste management in ceramic goods manufacturing industry. 4. A panel discussion among students on issues related to ceramic and finished goods.


Given a brochure, one must be able to study about the product and understand it in 15 min and talk about it to his group highlighting its features and explain it in about 3 min.

A student must be able to identify a topic of interest for debate, initiate the debate and carry it on, dividing the group into two based on different perspectives(e.g., For and against the topic)

Task 3 – Listening Skills: 6 hrs. 5 marks.

Suggested Activities:

1. View an advertisement of a branded product and write down the message behind. 2. Listen to the audio in a promotional CD for about 15 minutes of any chosen product or service

.Make hints and discuss. 3. View a CD of an innovative practice in tanning or producing finished goods for a length of 15

minutes and write down the summary in a paragraph of 20 lines. 4. Listen to a lecture on environmental effects of chemical effluents from ceramic industry and

write a summary in 200 words.


Given an audio clip or a visual of an advertisement, one must be able to listen carefully and understand it enabling him to write the message behind it in the specified time (say in about 5 min.).

A student must be able to listen to a lecture or watch a CD for 15 min, noting down the key points and write a summary in 200 words in the next 15 min. Note: Hints taken and the summary must be hand written by the student and

documented for evaluation.

Task 4 – Reading skills: 6 hrs. 5 marks.


1. Read an article from a magazine on the trade of ceramic products and talk to the rest of the group in about 5 minutes.

38

2. Read an advertisement of a branded ceramic product and elaborate its qualities after collecting information from a different source like the company web site.

3. Read an article on ceramic product from the internet and discuss the merits. 4. Read a note on usage of raw materials in ceramic industry from any technical journal and

narrate in the class


Given an article from a journal or an advertisement from a magazine, one must be able to comprehend it in 15 to 20 min. Later on read it out to an audience, with proper intonation and elaborate it in the next 10 min.

Given an article from the internet, a student must be able to gather more information from the net about it, understand it and read it out for an audience and narrate it.

Task 5- Writing Skills: 12 hrs. 10 marks.


1. Write a resume and a covering letter for three different jobs

1) Wanted ceramic Engineer for an Industry. 2) Wanted Ceramic-designer who is proficient in CAD for an MNC. 3) Wanted Supervisor for Ceramic company

2. Write a synopsis for given topics related to Ceramics in 100 words.

3. Write a summary on the latest style & trends in Ceramic products.

4. Write an essay on functioning of any ceramic machinery for 150 words.


Given a job advertisement, a student must be able to write a suitable resume and a covering letter in 30 min [Advertisements can be tailor-made by the teacher deliberately to train their students- e.g., two different jobs like a marketing person and an assistant in a Research & Development section and train students to prepare two resume for these jobs highlighting different achievements of the student in co-curricular activities to suit each job]

Given a topic, a student must be able to write a synopsis or summary or an essay in about 150 words in the stipulated time.

Note: All these have to be hand written by the learner and documented for evaluation.

Task 6- Knowledge of using Internet: 6 hrs. 5 marks.


1. Create an e-mail id and mail to 6 others

39

1) Sending simple messages 2) Forwarding messages with their comments

2. Sending message with attachments

1) Adding files as attachments

2) Adding scanned attachments

3. Collecting data from net

1) Latest designs in Ceramic articles.

2) Brand list for Ceramic articles.

4. Forwarding resumes to different jobs.


Given an access to internet, one must be able to create an email ID, send mails, forward simple mails and also mails with attachments including scanned attachments and URL (web addresses for direct link). Also, they must be able to collect data from different websites using internet search engines and forward resumes to different job offering companies. Note: Printouts of the mails, replies received and also the attachments with date and

time have to be documented.

Task 7- Oral communication: 6 hrs. 5 marks.


1. Debate on current topics.

2. Group discussion on latest developments in ceramic sector.

3. Discussion on qualities required for good entrepreneur.

4. Debate on role of women in ceramic industry.


Given a topic of relevance, they must be able to form groups and discuss/debate on it. Also one must take cue and participate actively in a group discussion . Encourage students to note down the points of discussion and file the points in the portfolio for evaluation.

Task 8- Collecting market data and analysing for meaningful inferences: 18 hrs. 10 marks.

40


1. Collect data for any two ceramic products/chemicals/machines of two different producers which includes technical details, specifications, cost and customer satisfaction.

2. Use appropriate tools and collect data from authentic sources. Depending on the source decide the number of units for collecting the data.

3. Analyse the data with a view to compare these two ceramic products/chemicals/machines.

4. Interpret the analysis for meaningful conclusions.

5. Record the whole process for any other person to verify.


Given two products/equipments/service, one must collect adequate information from an authentic source for each, like the company website or the printed brochure and record the specifications.

The maintenance of quality of the product/service needs to be studied from personnel working at different levels in the company(3 -5 in number) for each product/service. A set of questions needs to be prepared for collecting data. The same questionnaire has to be used for collecting data from the personnel mentioned above.

One must compare the two products for all the parameters based on the specifications. Also, a market survey has to be done preparing a printed questionnaire of around 5 questions and collecting responses from 20 customers. Then, analyse the data, compare them and interpret the analysis for meaningful conclusions. Note: This being a comprehensive task may require few weeks to finish. The data

collected and the analysis carried out need to be documented.

Task 9 - Presentation Skills: 12 hrs. 10 marks.

1. Student should present the report of activities done in Task 8 for 10 minutes supported by few

slides (6 to 10) of pictures, graphs, images etc. The text material if any may be printed and given to

the audience. Discourage students from using text material in slides.


One must present the analysis done in task 8 using slides with pictures, graphs, images etc in 10 min. The first slide may contain text only as per need but other slides should preferably have pictures and images. Usage of graphs for comparison and analysis is preferred. Text materials have to be given as handouts to the audience.

Task-10 Pick and talk. 12 hrs. 5 marks.

1. Pick a topic from a lot and student should allowed to speak for the duration of

2 to 3 minutes without the aid of any other media.

41


One must be able to talk extempore for 2 min on any topic picked randomly from the lot, given a time of two minutes for organising his/her thoughts. The topics can be kept simple and general (current events of interest like cricket or tsunami). It must be totally an oral activity without the aid of any other media.

List of topics in Ceramic technology for learners to use in the tasks 1 to 10.

Present condition of Indian ceramic industry.

Availability of raw materials.

Cleaner technology in ceramic processing.

Non-conventional sources of energy.

Merits of CAD in ceramic products designing.

Safety in ceramic industry.

Clicking technology.

Up gradation techniques for ceramic.

Environmental pollution.

Automation in ceramic industry.

Recycling of ceramic waste.

Managing sludge produced in ceramic industry.

Eco friendly dies and chemicals.

FORMAT OF LOG SHEETS *

Sl.No. Date Task Progress of

Task

Initials of staff in charge and the

student

Evaluation

(as suggested in each

task)

Signature of Guide Signature of HOD

All documented work as described in each task need to be filed in a portfolio with task no.1 at the bottom and task 10 on top.

The log sheet may be filed on top.

42

Learners need to have only one portfolio which contains all original documents. Duplicate copies need not be maintained. This is to ensure the authenticity of data collected and the analysis conducted on the data.

SCHEME OF EVALUATION

( Total no. of students in one batch for end examination should not exceed 20)

1. Maintenance of portfolio and log book 10 2. Evaluation of prepared report on all ten tasks 65 3. End examination:

A portfolio evaluation is recommended for the end examination evaluating the record of all

ten activities of each individual learner for consistency and in case of any inconsistency the

learner may be assessed on the criteria given against each task.

Marks awarded for evaluating the portfolio - 50

Total= 125 marks.

Note to End examination evaluators:

Check the genuineness and authenticity of all recorded activities.

The learner may be asked to do one activity of the choice of the examiner which involves listening to instructions, writing a small paragraph of 50 words, reading it and talking for a few minutes.

The learner may be asked about his satisfaction of the marks awarded and in case of any mismatch the examiner may assess his performance and alter the portfolio assessment (here the benefit of doubt may be in favour of the learner i.e., an improvement may be recorded but in case the examiner feels that the marks awarded is more the same may be retained).

Do not compare the performance of one student with that of another.

Always compare the performance to the standard.

Any one task at random need be checked for each learner.

Total time taken for the evaluation of a portfolio need not exceed 15 minutes.

All documented work as described in each task need to be filed in a portfolio with task no.1 at the bottom and ten on top. The log sheet may be filed on top.

Learners need to have only one portfolio which contains all original documents. Duplicate copies need not be maintained. This is to ensure the authenticity of data collected and the analysis conducted on the data.

Recommended text book for the prescribed syllabus:

Ashan Academy (2011), Communication and Analysis skills, Orient Blackswan,

Hyderabad.

43

References:

1. Chakravarthi K. T. & Chakravarthi L. T. (2011), Soft Skills for Managers, biztantra, New Delhi.

2. Alex K., (2009), Soft Skills: S. Chand & company Ltd, New Delhi. 3. Pink M. A. & S. E. Thomas. : Communication Skills, S. Chand & company Ltd, New

Delhi. 4. Siddons S. (2008), Presentation Skills, Universities Press, Hyderabad. 5. Adler.: Communication : Goals and Approaches, Cengage Learning. 6. http://en.wikipedia.org/wiki/English_Language_Skills_Assessment 7. http://www.how-to-write-a-resume.org/resume_writing_examples.html 8. http://www.mindtools.com/page8.html 9. http://lorien.ncl.ac.uk/ming/Dept/Tips/present/present.html

In case during the implementation of CASP any teacher has a suggestion to improve

the learners competence concerning any one of the ten tasks please feel free to

mail to the following addresses: 1) [email protected] or 2) [email protected]


Fifth Semester

Subject: Ceramics processing lab-2.

Contact Hrs/ Week: 6Hrs. Contact Hrs/ Semester: 96Hrs.

1. Preparation of single piece and double piece plaster of Paris mould. 12hrs. 2. Preparation of casting slip and casting by using plaster moulds. 09hrs 3. Use the different binders in body and find out green density. 09hrs. 4. Use deflocculants in casting slip and find out the density. 09hrs 5. Study the viscosity of the slip with varying water, binder and deflocculant. 12hrs. 6. Use the surfactants(sodium stearate)for extrusion and study the extrusion behavior.9hrs

Prepare powder from sol-gel technique. 09hrs.

http://en.wikipedia.org/wiki/English_Language_Skills_Assessment

http://www.how-to-write-a-resume.org/resume_writing_examples.html

http://www.mindtools.com/page8.html

http://lorien.ncl.ac.uk/ming/Dept/Tips/present/present.html


44

7. Prepare a porous ceramics by using foaming agents (Tal oil or sodium alkyl sulphate, poly propylene glycol) 09hrs.

8. Find out the packing density using different grain size of powders. 09hrs. 9. Prepare a earthen ware tile body composition and pressing in uniaxial press. 09hrs.


SL NO

Name of the Equipment

Quantity

1

Extruding machine

01

2

Wire cut machine

01

3

Extruding die set, die tools( round pipe, square and rectangular)

03

4

Granulators machine

01

5

Fly press machine

01

6

Potter’s wheel machine operated

01

7

Metal Models

10

8

Metal sheet 2feet/4feet

10

9

Ball mill

01

10

Magnetic separator

01

11

Blunger

01


SIXTH SEMESTER

Subject: Raw materials Technology

45

No of Hrs/ Week: 04hrs. Total no. of Hrs: 64 Hrs.

Slno Topic Hrs allotted

1. Clay 10

2. Silica 10

3. Alumina 10

4. Auxiliary raw materials 02

5. Carbides 06

6. Nitrides 06

7. Borides 05

8. Silicides 05

9. Special synthetic raw materials 06

Tests and revision 04

Total 64

CONTENT IN DETAIL

1. CLAY:

0.1 Definition, formation of clays, classification – primary clays, secondary clays, china clay, kaolin, betonies, fire clay, ball clay, shale’s, loams, latte rites, refractory clay, verifiable clay, fusible clay.

0.2 Impurities in clay like silica, alumina, calcium magnesium, titanium alkalis, and carbonaceous material.

0.3 Purification of clay – mechanical and chemical methods – sorting, sifting, air separation washing, magnetic separation, froth floatation, electro osmosis.

0.4 Properties of clay – Color, slaking, shrinkage, texture, power of suspension, strength, plasticity – theories of plasticity (water of hydration theory, plate theory, colloidal theory, Molecular attraction theory, Fineness theory and interlocking theory) and measurement of plasticity.

0.5 Effect of heat on clays.

2. SILICA:

2.1 Properties, occurrence of various silica raw materials like quartz, sand stone, quartzite, ganister, flint and their uses in the manufacture of various ceramic articles.

2.2 Effect of heat on silica.

3. ALUMINA:

46

Properties, occurrence of various alumina raw materials like gibbsite, Diaspora, bauxite, corundum, fused alumina and sintered alumina. Alumina silicates like kayanite, silimanite, fused mullite, sintered mullite & andalusite their uses in the manufacture of various ceramic products.

4. AUXILARY RAW MATERIALS:

Definition, properties of various auxiliary raw materials like water, binders, lubricants,

and coloring agents.

5. CARBIDES:

Definition of carbides, preparation, properties and uses of silicon carbide(Sic), boron

carbide(B4C), tungsten carbide(WC) and calcium carbide(Ca2C).

6. NITRIDES:

Definition of nitrides, preparation, properties and uses of silicon nitride (Si3N4), boron

nitride (BN), titanium nitride(Tin) and aluminum nitride(AlN).

7. BORIDES:

Definition of borides, preparation, properties and uses of magnesium di boride (MgB2)

and titanium di boride (TiB2).

8. SILICIDES:

Definition of silicides, properties and uses of magnesium silicide(MgSi2), platinum

silicide(PtSi2) ,tungsten silicide (WSi2)and molybdenum silicide(MoSi2).

9. SPECIAL SYNTHETIC RAW MATERIALS:

Spinel Ceramics, Sialons, Ceramets, Foresterites,Corderite,Industrial diamond and

Zirconia .

GENERAL OBJECTIVES

1.0 Know and understand the definition , classification Impurities, purification, properties and effects of heat on clay.

2.0 Understand the properties uses and sources of Silica.

3.0 Understand the properties uses and sources of alumina.

4.0 Understand the definition, properties, types and uses of auxiliary minerals.

5.0 Know the definition, properties, types and uses of Carbides.

47

6.0 Know the definition, properties, types and uses of Nitrides.

7.0 Know the definition, properties, types and uses of Borides.

8.0 Know the definition, properties, types and uses of Silicides.

9.0 Understand the properties and uses of special synthetic materials.

SPECIFIC OBJECTIVES

1.0 Clay:

1.1 Know the definition, formation and classification of clays.

1.2 Understand the effects of impurities in clays like silica, alumina, calcium, magnesium, titanium, alkali’s and carbonaceous materials.

1.3 Study the purification of clay by sorting, sifting, air separation, washing, and magnetic separation froth flotation and electro osmosis methods.

1.4 Know and understand the properties of clay like color, shrinkage, texture, power of suspension.

1.5 Know the definition and theories and measurement of plasticity.

1.6 Understand the effect of heat and clays.

2.0 Silica:.

2.1 Know the properties of silica.

2.2 Study the various sources of silica and their uses.

2.3 Understand the effect of heat of silica from room temperature to its melting temperature.

3.0 Alumina:

3.1 Know the properties of alumina.

3.2 Study the various alumina raw materials like gibbsite, Diaspora, Bauxite, Fused alumina, sintered alumina and corundum.

3.3 Know the alumina silicate minerals like kainite, sillimanite, fused mullite, sintered mullite and andulasite.

3.4 know the uses of alumina and aluminous silicate raw materials.

4.0 Auxiliary Raw materials:

4.1 Know the definition of water binder lubricant and coloring agents.

48

4.2 Understand the properties and uses of auxiliary raw materials.

5.0 Carbides:

5.1 Know the definition of Carbides.

5.2 Understand the preparation of SiC,B4C, Ca2C & WC.

5.3 Understand the properties and uses of SiC,B4C, Ca2C & WC.

6.0 Nitrides:

6.1 Know the definition of Nitrides.

6.2 Understand the preparation of Si3N4, BN, Tin and AlN.

6.3 Understand the properties and uses of Si3N4, BN, TiN, and AlN.

7.0 Borides:

7.1 Know the definition of Borides.

7.2 Understand the preparation of MgB2 & TiB2.

7.3 Understand the properties and uses of MgB2 & TiB2.

8.0 Silicides:

8.1 Know the definition of Silicides.

8.2 Understand the preparation of MgSi2, PtSi2, WSi2 and MoSi2.

8.3 Understand the properties and uses of MgSi2, PtSi2, WSi2 and MoSi2.

9.0 Special Synthetic raw materials:

9.1 Know the introduction and application of Spinel Ceramics, Sialons, Ceramets,

Foresterites, Corderite, Industrial diamond and Zirconia .

References:

1. Industrial ceramics by Singer and Singer 2. Clay and ceramic raw materials by W.E. Worrall

3. Raw materials for glass and ceramic by Christopher. W. Sinton

4. Ceramics and Glass materials by James .F.Shackelford

49

WEIGHTAGE TABLE

Sl. No. Section Chapter Name Marks to be

allotted Marks Allotted

1. I All Chapter 10 10

2. II

Definition ,formation and properties

of Clays. 15

45 Silica 15

Alumina 15

3. III

Types of clay and impurities in clays 15

45 Auxiliary raw materials 10

Carbides and Nitrides 20

50

4. IV

Theories of plasticity, purification

methods of clay and effect of heat on

clay

15

45

Borides and Silicides 15

Synthetic Raw materials 15

TOTAL 145

51



SIXTH SEMESTER

Subject: Raw materials Technology INSTRUCTIONS:

1. Section no. 1 is compulsory 2. Answer any 2 full questions from II, III & IV sections (total six full questions)

SECTION-1

1 fill in the blanks 5

(i) China clay belongs to _________clay groups.(ans: primary)

(ii) To improve the workability and plasticity of body __________is done.(ans: ageing

&pugging)

(iii) Trydamite and crystobalite are the forms of___________.(ans: silica)

(iv) The ph value of acidic water will be______________.(ans: 6.8)

(v) The formulae of magnesium di boride ___________.(ans:MgB2)

(b) Write a short note on Secondary clays. 5

SECTION-II

2. (a) Define clay. 2

(b) Write the sequential equations occurring during the formation of clay. 6

(c) Explain Bentonite and Fire clay. 6

3. (a) Name the polymorphic forms of silica. 2

(b) Write four important properties and uses of dolomite. 6

(c) Explain the effect of heat on silica from room temperature to its melting point. 7

4. (a) State the properties of clay. 3

(b) Explain power of suspension and shrinkage of clay. 6

(c)Explain electro osmosis plant. 6

SECTION-III

52

5. (a) What is Late rite? 3

(b) Explain Plate theory and Molecular attraction theory of plasticity. 8

(c) State the uses of zirconia. 5

6 (a) Explain the effect of silica and alkali minerals in on clay. 6

(b) Define Plasticity. 2

(c) Mention the purification methods adopted for clay and explain any two. 7

7. (a) State the properties of fused alumina. 5

(b) Write a note on bauxite and corundum. 6

(c) Differentiate between kainite and sillimanite. 4

SECTION-IV

8. (a) Explain the preparation of Sic by Carbo thermal reduction process. 4

(b) State the properties and uses of Boron carbide. 7

(c) Define Nitrides and give example. 4

9. (a) Mention the properties of cordierite. 3

(b) Explain the preparation of silicon Nitride by different methods. 6

(c) Explain the role of water and binder in ceramic wares manufacture. 6

10. (a) Write the preparation of aluminum nitride. 2

(b) State the properties and uses of boron carbide. 6

(c) List the uses of molybdenum di silicate and magnesium boride. 6

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


53

SIXTH SEMESTER SUBJECT: ADVANCED CERAMICS.

No of Hrs/ Week: 04hrs. Total no. of Hrs: 64 hrs.


1. Introduction to advanced ceramic 2

2. Electronic ceramics 5

3. Electric ceramics 5

4. Magnetic ceramics 5

5. Mechano-ceramics 5

6. Automobile ceramics 5

7. Bio-ceramics. 5

8. Ceramic powders for high tech applications 5

9. Ceramic for energy systems. 4

10. Porous ceramics for filteration 5

11. Opto electro ceramics 5

12. Tile Ceramics 3

13. Environmental awareness 6

14. Tests and Revisions 4

Total 64

CONTENTS IN DETAIL

1. Introduction of Advanced ceramics:

Definition of advanced ceramics , classification of advanced ceramics, R&D activities in India.

54

2. Electronic ceramics:

Introduction of electronic ceramics, Definition of capacitor, Types of capacitors, manufacturing method of disc capacitor, properties and applications, Definition and different types of sensors, Application of gas and humidity sensors, Definition of thermistors, varistors , Types :PTC and NTC thermistors, varistors, properties and applications.

3. Electric ceramics:

Definitions of conductors, semiconductors and insulators, comparison between conductors, semiconductors and insulators., properties and uses of high and low tension insulators, properties and uses of rutile and steatite bodies, difference between rutile and steatite bodies, Definition of piezoelectricity, Piezoelectric materials, properties and application of piezoelectric materials.

4. Magnetic ceramics:

Definition of ferrites, history ,Classification of ferrites, Definition of hard and soft ferrites, comparison between hard and soft ferrites, batch recipe calculations for hard and soft ferrites, manufacture of soft ferrite with a flow chart, manufacture of hard ferrites with a flow chart, Difference between hard isotropic and hard anisotropic ferrites, properties and application of soft and hard ferrite,

5. Mechano-ceramics:

Definition of abrasive grinding wheel, manufacturing of abrasive grinding wheels, Uses of grinding wheel, Definition of cutting tools, types of cutting tools, manufacturing of alumina based cutting tools, properties and uses of alumina based cutting tool, properties and application of TIC and WC based cutting tools, Definition and explanation of thread guides.

6. Automobile ceramics:

Definition of ceramic spark plug, manufacturing of ceramic spark plug, properties and uses of spark plug, types of sensors used in automobiles, definition and application of oxygen, NOx sensor, and knock sensors, definition of honey comb, application and properties of honey comb

7. Bio-ceramics: Definition of Bio-ceramics, Types of Bio Ceramics ,Bioinert Ceramics, Biodegradable ceramics & Bioactive ceramics with each definition, Ceramics for artificial bone and joints, definition of dental ceramics, manufacturing of dental porcelain ,properties and application. 8. Ceramic powders for high tech applications: Introduction, preparation methods and applications like: silicon nitride and sialon powders, monoclinic and partially stabilized Zirconia, high purity boron carbide powder.

9. Ceramics for energy systems: Introduction of Li-ion battery, production process and application. Introduction of fuel cells, ceramic materials for fuel cells, and types of fuel cells like monolithic and single chamber.

55

10. Porous ceramics for filtration: Introduction, classification of separation process, types of membrane, General preparation of ceramic membrane and applications.

11. Optoelectro ceramics:

Introduction, properties, preparation of optoelectroceramics, introduction of PLZT ceramics, application of optoectroceramics.

12. Tile Ceramics: Definition of glazed and vitrified tiles, raw materials, properties and manufacturing with flow chart, tests for tiles. Comparison between glazed and vitrified.

13. Environmental awareness:

The final product rejected must be recycled and used instead of throwing as a garbage which leads to pollution and Global warming.

GENERAL OBJECTIVES

1.0 Introduction of Advanced ceramics.

1.1 Know and understand the definition, classification ,R& D activities of Advanced ceramics.

2.0 Electronic ceramics.

2.1 Know the definition of electronic ceramics 2.2 Know the types of capacitor, manufacturing, properties and application of capacitor. 2.3 Know the different types of sensor and thermostats.

56

3.0Electric ceramics.

3.1 Know the definition, properties and application of conductor, semiconductor and insulator. 3.2 Understand the properties and uses of high and low tension insulators. 3.3 Know the difference between rutile and steatite bodies 3.4 Know the definition properties and application of piezoelectric materials

4.0 Magnetic ceramics.

4.1 Know the definition history and classification of ferrite 4.2 Understand the hard and soft ferrites and make the recipe. 4.3 Know the difference between isotropic and anisotropic ferrites 4.4 Properties and application of hard and soft ferrites

5.0 Mechano-ceramics.

5.1 Know the definition, manufacture, application of grinding wheel. 5.2 Know the definition, manufacture, application of cutting tools. 5.3 Know the definition, application of thread guides.

6.0 Automobile ceramics.

6.1 Know the definition, manufacturing, properties and uses of spark plug. 6.2 Understand types of sensors and application of sensors. 6.3 Know the definition, properties and application of honey comb. 7.0 Bio-ceramics. 7.1 Know the definition, types and application of bio-ceramic materials. 7.2 Know the definition, preparation properties and application of Dental ceramics. 8.0 Ceramic powders for high tech applications.

8.1Know the introduction, preparation and applications of ceramic powders for high tech applications.

9.0 Ceramic for energy systems.

9.1 Know the li-ion battery and fuel cells , its types 10.0 Porous ceramics for filtration.

10.1 Know the introduction, classification, general preparation methods and applications.

11.0 Optoelectro ceramics.

11.1 Know the introduction, properties and application of optoelctro ceramics.

12.0 Ceramic tiles.

57

12.1 Know the definition, properties, and manufacturing ceramics tiles. 12.2 Know the difference of porous and vitrified tiles. 13.0 Environmental awareness. 13.1 Know the recycling of rejected products & controlling pollution.

SPECIFIC OBJECTIVES

1. Introduction of Advanced ceramics:

1.1 Know the Definition of advanced ceramics. 1.2 Know classification of advanced ceramics. 1.3 Know R&D activities in India.

2. Electronic ceramics:

2.1 Know the Introduction of electronic ceramics. 2.2 Know Definition of capacitor. 2.3 Understand the Types of capacitors. 2.4 Know manufacturing method of disc capacitor. 2.5 Know properties and applications of capacitor. 2.6 Know different types of sensors. 2.7 Know the application of gas and humidity sensors. 2.8 Know the definition of thermistors & varistors . 2.9 Understand the Types: PTC and NTC thermistors &varistors,

58

2.10 Know properties and applications of thermistors & varistors.

3. Electric ceramics:

3.1 Know the definitions of conductors, semiconductors and insulators. 3.2 Know the comparison between conductors, semiconductors and insulators. 3.3 Understand properties and uses of high and low tension insulators. 3.4 Understand properties and uses of rutile and steatite bodies. 3.5 Know the difference between rutile and steatite bodies. 3.6 Know the definition of piezoelectricity. 3.7 Know the Piezoelectric materials. 3.8 Understand the properties and application of piezoelectric materials.

4. Magnetic ceramics:

4.1 Know the definition of ferrites. 4.2 Know the history, Classification of ferrites. 4.3 Know the definition of hard and soft ferrites. 4.4 Understand comparison between hard and soft ferrites. 4.5 Know the batch recipe calculations for hard and soft ferrites. 4.6 Know the manufacture of soft ferrite with a flow chart. 4.7 Know the manufacture of hard ferrites with a flow chart. 4.8 Understand the difference between hard isotropic and hard anisotropic ferrites. 4.9 Understand the properties and application of soft and hard ferrite.

5. Mechano-ceramics:

5.1 Know the definition of abrasive grinding wheel. 5.2 Understand the manufacturing of abrasive grinding wheels. 5.3 Know the Uses of grinding wheel. 5.4 Know the Definition of cutting tools. 5.5 Know the types of cutting tools. 5.6 Understand the manufacturing of alumina based cutting tools. 5.7 Understand the properties and uses of alumina based cutting tool. 5.8 Know the properties and application of TIC and WC based cutting tools. 5.9 Know the definition and explanation of thread guides.

6 Automobile ceramics:

6.1 Know the definition of ceramic spark plug. 6.2 Understand the manufacturing of ceramic spark plug. 6.3 Know the properties and uses of spark plug. 6.4 Know the types of sensors used in automobiles. 6.5 Know the definition and application of oxygen, NOx sensor, and knock sensors. 6.6 Know the definition of honey comb. 6.7 Understand the application and properties of honey comb. 7. Bio-ceramics:

59

7.1 Know the definition of Bio-ceramics. 7.2 Understand types of Bio Ceramics, Bio-inert Ceramics, Bio-degradable ceramics & Bio-active ceramics. 7.3 Know the Ceramics for artificial bone and joints. 7.4 Know the definition manufacturing of dental porcelain. 7.5 understand the properties and application of Dental ceramics. 8. Ceramic powders for high tech applications: 8.1 Know the Introduction of ceramic powders. 8.2 Know the preparation methods of ceramic powders like silicon nitride and SiAlON powders. 8.3 Know the preparation methods of ceramic powders like monoclinic and partially stabilized Zirconia . 8.4 Know the preparation methods of ceramic powders like high purity boron carbide powder. 9. Ceramic for energy systems: 9.1 Know the Introduction of Li-ion battery. 9.2 Know the production process Li-ion battery. 9.3 Know the application Li-ion battery. 9.4 Know the Introduction of fuel cells. 9.5 Know the ceramic materials for fuel cells. 9.6 Know the types of fuel cells like monolithic and single chamber. 10.0 Porous ceramics for filtration: 10.1 Know the Introduction Porous ceramics for filtration. 10.2 Understand the separation process’s classification. 10.3 Know the types of membranes. 10.4 Know the General preparation of ceramic membrane. 10.5 Know the applications ceramic membranes.

11.0 Optoelectro ceramics:

11.1 Know the Introduction. 11.2 Know the properties. 11.3 Understand the preparation of optoelectroceramics, 11.4 Know the introduction of PLZT ceramics. 11.5 Know the application of optoectroceramics. 12.0 Tile Ceramics : 12.1 Know the definition of glazed tiles. 12.2 Know the vitrified tiles. 12.3 Know the raw materials. 12.4 Know the properties. 12.5 Know the manufacturing with flow chart.

60

12.6 Understand the tests for tiles. 12.7 Understand the comparison between porous and vitrified. 13. Environmental awareness:

13.1 know the process of recycling the rejected products.

REFERENCES

1. High performance ceramics by B.V.S Subbarao 2. Advanced Ceramics by M.K.Murthy 3. Advanced Technical Ceramics by Shigeyuki Somiyag 4. Ceramic powders for high tech applications by BVS Subbarao 5. From technology through machinery to kilns for SACMI tiles

WEIGHTAGE TABLE

Sl.

No. Section Chapter Name

Marks to be

allotted

Marks

Allotted


2. II

Introduction to advanced ceramic Electronic ceramics

10

45 Electric ceramics 15

Magnetic ceramics 20

3. III

Mechano-ceramics 10

45

Automobile ceramics,

Bio-ceramics 15

Ceramic powder for high tech

applications 20

4. IV

Ceramics for energy systems

Porous ceramics for filteration 10

45

Optoelectroceramics 15

61

Tile Ceramics and Environmental

awareness 20

TOTAL 145

Model question paper DIPLOMA IN CERAMICS TECHNOLOGY

SIXTH SEMESTER

SUBJECT: ADVANCED CERAMICS.

INSTRUCTIONS

1. Section no. 1 is compulsory 2. Answer any 2 full questions from II, III & IV sections (total Six full questions)

Section I

1. a) Fill in the blanks. 5 i) Zircon oxide and Titanium oxide are used in -------- sensors II) Capacitor is a device for introducing -------- into circuit iii) Spark plugs usually are made from a 90-95% of ------- porcelain iv) Vitrified tiles have ------% porosity v) _______method of pressing is economical in tile fabrication (b) Write a short note on ceramic capacitors. 5

Section II

2. (a) Define Ferrites. 3 (b) Write the differences between conductors, insulators & semiconductors. 7 c) Give the detail classification of ferrites with example. 5 3. a) With a neat flow chart explain the manufacturing of soft ferrite. 9 b) Define Sensors. Explain Gas sensors. 6

62

4 a) Explain the body preparation process for antistrophic structures. 7 b) Explain the manufacture of PLZT ceramic piezo electric material. 8

Section-III 5 a) With a neat flow chart explain the manufacture of high tension insulator. 9 b) Write the properties & uses of low loss steatite bodies. 6 6. a) What are cutting tools? 2 b) With a neat flow chart explain the manufacturing of Sialon cutting tools. 8 c) Write the properties and uses of alumina cutting tools. 5 7. a) Define Tiles. 2 b) Write the classification of ceramic tiles, explain briefly. 7 c) Write the classification of bio ceramics, explain briefly. 6

Section-iv 8. a) Define optoectroceramics. 3 b) Write the preparation method of optoelectroceramics. 6 c) Write the classification of different separation process. 6 9. a) Define fuel cells. 3 b) What are the different types of fuel cells? 6 c) What are the different properties and application of dental ceramics? 6

10. a) Write the preparation of partially stabilized zirconia powder. 7

b) Define honey comb. Write the application of honeycomb. 8

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

63

ELECTIVE SUBJECTS


SIXTH SEMESTER SUBJECT: FERRITE & TECHNICAL CERAMICS.



1. Ferrites 25

2. High frequency ceramics. 10

3. Hard paste porcelain 15

4. Vitreous sanitary wares 14

Total 64

Contents details

1.0 FERRITES:

Introductions and History. Classification. Definitions of Permittivity, Permeability.

Composition of soft ferrite, Calculation of Percentage batch mix, process of batch

preparation, body preparation for wet plastic soft body extrusion. Anita core

manufacturing flow chart, control, Humidity drying process, sintering in Tunnel Kiln

and testing. composition of Hard Ferrite, Calculation of batch mix, process of batch

preparation. Definition of Isotropy and Anisotropy. Pressing of Isotropic structures,

pressing of slurry by Dorst HPA-100 for anisotropic loudspeaker magnets, sintering,

flow chart of Hard Ferrite Magnetic Values. Similarities and dissimilarities between

Soft Ferrite and Hard Ferrite then Isotropic Verses Anisotropic Permanent Magnets.

2.0 HIGH FREQUENCY CERAMICS CONDENSER:

64

The Old type condensers, the New Ceramic compositions for capacitors, batch preparation and manufacturing, properties & applications, Firing Results and discussion on sintered density verses sintering temperature graphs, XRD-patterns of the modified BaTiO3, ZrO2, PbTiO3 phases and Dielectric constant and loss factor variation.

3.0 HARD PASTE PORCELAIN:

Introduction, classification, Raw Materials. Kaolin’s, ball clays, fluxes, auxiliary fluxes, flow sheet of body preparation for porcelain (I) Electro-Porcelain- Introduction, composition, structures of Electrical porcelain, diagrams and specifications of few Insulators, pin type, shackle, strain and bushing. Influence of glaze on technical characteristics of porcelain insulator's shaping methods, throwing, jollying and jiggering, Turning & Extruding. Properties and tests for porcelain Insulator's like dielectric or puncture voltage, power factor and dielectric constant, Resistivity, mechanical strength, compressive or crushing strength, Resistance to thermal change &Thermal conductivity .

4.0 Vitreous sanitary wares:

Raw materials, body preparation, shaping by slip casting i) single cast, ii) core/solid cast, iii) over cast, iv) drain cast, drying, glazing & firing of wash basin, commode & bath tub.

General objectives 1. Know the definition, history & classification of ferrite. 2. Understand the recipe batch calculations for soft & hard ferrite. 3. Know the manufacturing process of soft & hard ferrite with flow chart. 4. Know the definition of isotropy & anisotropy. 5. Understand the old & new type ceramic capacitors. 6. Know the manufacturing, properties & applications of capacitors. 7. Understand the firing results & discussion. 8. Know the introduction, classification, raw materials and body preparations of

electro porcelain. 9. Study the structure of electro porcelain. 10. Know the diagrams and specifications of pin type, shackle, strain & bushing

insulators. 11. Know the shaping methods for porcelain insulators 12. Study the tests on porcelain insulators. 13. Study the raw materials, body preparation, shaping, drying, glazing & firing

of vitreous sanitary wares.

Specific objectives

1. Ferrite:

1.1 Know and understand about introduction and history of ferrite. 1.2 Know the definition of permittivity and permeability.

65

1.3 Know the composition of soft ferrite. 1.4 Understand the calculation of percentage batch mix of soft ferrite. 1.5 Know the extrusion of isotropic structure of soft ferrite antina core. 1.6 Understand the calculation of percentage batch mix of hard ferrite. 1.7 Know the slurry pressing by HPA-100 dorst for anisotropic hard ferrite. 1.8 know the similarities & dissimilarities between soft & hard ferrite. 1.9 Study the differences between isotropic & anisotropic hard ferrite.

2. HIGH FREQUENCY CERAMICS CONDENSER

2.1 know about the old type condensers 2.2 know the new ceramic composition for capacitors 2.3 Understand the batch preparation, shaping, drying & firing of ceramic capacitors.

2.4 To understand the di-electric constant and loss factor variation. 2.5 To study the graphs of sintered density verses sintering temperature. 2.6 To study the XRD-patterns of the modified BaTiO3, ZrO2, PbTiO3 phases.

3. Hard paste porcelain:

3.1 To know about definition, introduction & classification of porcelain.

3.2 To understand the flow sheet, body preparation of electro porcelain insulator.

3.3 Know the diagrams and working of shaping machines and methods of jigger & jolly,

extrusion & turning.

3.3 know and understand about test for porcelain insulators like puncture voltage, CCS,

thermal conductivity etc.

4. Vitreous sanitary wares:

4.1 know the raw material & body preparation of vitreous sanitary wares.

4.2 Study the shaping by slip casting of ) single cast, ii) core/solid cast, iii) over cast, iv)

drain cast.

4.3 Know the drying, glazing & firing of wash basin, commode & bath tub.

References:

1. High performance ceramics by B.V.S Subbarao 2. Advanced Ceramics by M.K.Murthy 3. Advanced Technical Ceramics by Shigeyuki Somiyag

66

WEIGHTAGE TABLE

Sl.


Marks to be



2. II

Introduction to ferrites 10

45 History of ferrites 15

High frequency ceramic

condensers 20

3. III

Classification 10

45

Raw Materials & flow sheet of

body preparation 15

Composition, structure for motion

of electrical burning 20

4. IV

Refractory & flame resistant

porcelain 10

45 Abrasion Resistance ware 15

Chemical laboratory and hospital

ware composition 20

TOTAL 145

Model question paper DIPLOMA IN CERAMICS TECHNOLOGY

67

SIXTH SEMESTER

SUBJECT: FERRITE & TECHNICAL CERAMICS.

INSTRUCTIONS:

3. Section no. 1 is compulsory 4. Answer any two full questions from II, III & IV sections (total Six full questions)

Section I 2. Fill in the blanks. 5

(i) Increase in the glassy structure may affect_______________ of the products.(mech.strength)

(ii) The pre-firing temperature is ______________ for hard ferrite (Ans.11600C) (iii) Soft ferrite antina core is _________________ magnetic and its permittivity

is______________ (Ans.para magnetic & very high) (iv) The sintering temperature of electro porcelain insulator is___________ (13500C) (v) Sintering temperature of hard ferrite is _________________ (Ans.11400C)

(b) What is hard ferrite and soft ferrite explain 5 Section II 2. (a) Draw a neat sketch of H.P.A -100 dorst and label its parts ? 8 (b) Write a short note on dental porcelain furnishing one composition? 3 (c) Explain briefly about the importance of porcelain insulators glaze and its color? 4 3. (a) Explain the body preparation process for anistrophic structures? 7 (b) Explain about fired structure formation of electro-porcelain insulator? 4 (c) Write brief notes on raw materials used in manufacture of porcelain? 4 4. (a) Write brief introduction on ferrite in general? 7 (b) Define permeability and permittivity? 6 (c) State your conclusion about new ceramic composition for good quality capacitors? 2 Section III 5. (a) Write brief historical background and ferrite electronic property? 7 (b) Define the term porcelain? 3 (c) Draw a neat diagram of shackle insulator and give electrical specifications? 5 6. (a) Describe batch preparation process of hard ferrite? 7 (b) Write brief history on porcelain? 4 (c) What are fluxes and how they are useful in porcelain? 4 7. (a) Explain the operational mechanism of H.P.A -100 dorst? 5 (b) Describe the role of flame resistant porcelain with examples? 6 (c) Give the chemical recipe of hard ferrite and calculate its batch? 4

68

Section IV 8. (a) Describe with simple circuit the applications of ferrite components? 9 (b) Define chemical resistant porcelain with example? 3 (c) Describe the advantages of new ceramic composition for capacitors compared to old organic type? 3 9. (a) Explain batch preparation for Soft ferrite? 7 (b) Explain the working process of wander veeds particle size analyzer? 4 (c) Draw a neat graph related to sintered density versus sintering temperature for new ceramic capacitors? 4 10(a) Explain with a neat sketch the manufacturing of high-tension condensers ? 7 (b) State the classification of ferrite? Give examples? 6 (c) Give the classification of porcelain? 2

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


SIXTH SEMESTER

Subject: Bio & Dental Ceramics


69

Contents

Chapter no Course content No of hrs

1 Introduction of Bio ceramics 02

2 Classification of Bioceramics 04

3 Bio ceramic materials 05

4 Bio ceramics skeletal system 05

5 Science of dental materials 05

6 The parts of tooth 05

7 Dental Ceramics 05

8 Dental restorations 03

9 Dental Cements 08

10 Dental gypsum products 08

11 Dental waxes 03

12 Abrasive and polishing materials 03

13 Industrial visit and guest lecture 04

Total 64

CONTENT IN DETAILS

1. Introduction of Bio ceramics:

Definition, brief history

2. Classification of Bio ceramics:

Bio inert ceramics, Bio-degradable ceramics and Bio-active ceramics with each definition

application and properties.

3. Bio ceramic materials:

70

Types of Bio-ceramics like Alumina, Zirconia, Carbon, Calcium phosphate, Bio-glass each

properties and applications, Medial applications of bio-ceramics.

4. Bio ceramics skeletal system :

Bio-ceramics artificial bones and joints with neat sketches and brief explanations, Draw the

human body skeletal systems and mention the artificial bio-ceramic parts.

5. Science of dental materials:

Definition for dental material, stress, strain, modulus of elasticity, permanent deformation,

strength, toughness, hardness, ductility, malleability, resilience, flexibility, impact, fatigue,

creep, and applied aspects and dentistry.

6. The parts of tooth:

Definition of Tooth, sketches of tooths and labels parts, Enamel, Dentine, Cementum, Pulp each

definition and explanations. Primary and secondary teeth explain about. Chronology of teeth

like dentition, tooth, eruptions.

7. Dental Ceramics:

Definition, developments, classifications, applications, Dental porcelain raw materials,

composition, fabrication, castable glass-ceramic, CAD-CAM ceramics.

8. Dental restorations:

Definition,fabrication of ceramic restoration, ceramic-metal restoration, , ceramic jacket

crowns, technical aspects of metal-ceramic restorations, benefit and draw back metal-ceramics.

9. Dental Cements:

Definition and classifications of dental cement, Silicate cement,Zinc phosphate cement, Zinc

oxide eugenol cement, Glass ionomer cemen, zinc silico phosphate cement, Zinc

polycarboxylate cement, Calciumhydroxide cement, each cements definition, applications,

composition, properties, manipulations. Cavity liner, cavity varnish and cavity bases each

definition and application.

10. Dental gypsum products:

Classification of gypsum products like dental plaster, dental stone, improved stone each

manufacturing process, chemical reactions, properties , applications, water-powder ratios.

Difference between dental plaster and dental stone. Measurement of setting time, factors

affecting setting time. Definition of modifier, accelerators ,retarders.

11. Dental waxes:

71

Definition, classification and types of dental wax, applications. Ideal requirement of inlay wax,

difference between direct and indirect pattern wax.

12. Abrasive and polishing materials:

Definition of abrasive, types of abrasives with examples and uses. Definition of polishing ,types

of polishing, difference between abrasion and polishing.

GENERAL OBJECTIVES

1. Introduction of Bio ceramics.

.1.1 Know the Definition of Bio-ceramics

1.2 Know the brief history of Bio-ceramics

2. Classification of Bio ceramics.

2.1 know the classification of Bio-ceramics

2.2 To understand the properties of Bio-ceramics

3. Bio ceramic materials.

3.1 Know the types of Bio-ceramic materials.

3.2 Understand the medical applications of Bio-ceramic materials.

4. Bio ceramics skeletal system.

4.1 Understand the Bio-ceramic artificial bones and joints.

4.2 Know the sketches and labels of Bio-ceramic human body skeletal systems.

5. Science of dental materials.

5.1 Understand the physical properties of dental materials.

6. The parts of tooth.

6.1 understand the parts of the tooth

6.2 Know the chronology of the dentition and eruptions.

7. Dental Ceramics.

7.1 Know the definition and classification of dental ceramics

72

7.2 Know the properties and applications of dental ceramics.

7.3 know the fabrication of dental porcelain.

8. Dental restorations.

8.1 Know the dental restorations.

8.2 Understand the ceramic and ceramic-metal restoration.

9. Dental Cements.

9.1 know the definition and classification of dental cements

9.2 understand the manipulation, composition of dental cements.

9.3 Know the properties and applications of dental cements.

10. Dental gypsum products.

10.1 Know the classifications of dental gypsum products.

10.2 Know the manufacturing of gypsum products.

10.3 Understand the setting time of gypsum products.

11. Dental waxes.

11.1 Know the definition and classifications of dental waxes

11.2 Know the difference of direct and indirect pattern waxs.

12. Abrasive and polishing materials.

12.1 Know the definition and types of abrasive and polishing materials

12.2 Know the difference and application of abrasive and polishing materials.

SPECIFIC OBJECTIVES

1. Introduction of Bio ceramics:

1.1 Know the Definition of Bio-ceramics.

1.2 Understand the brief history of Bio-ceramics.

73

2. Classification of Bio ceramics:

2.1 Know the definition, properties and application of Bio inert ceramics,

2.2 Know the definition, properties and application of Bio-degradable ceramics

2.3 Know the definition, properties and application of and Bio-active ceramics.

3. Bio ceramic materials:

3.1 Know the types of Bio-ceramics

3.2 Understand the Bio-ceramic materials like Alumina, Zirconia, Carbon, Calcium phosphate,

3.3 Explain the properties and applications of Alumina, Zirconia, Carbon, Calcium phosphate,

3.4 Understand the Bio-glass properties and applications.

3.5 Know the medical applications of bio-ceramics materials.

4. Bio ceramics skeletal system:

4.1 Explanation and sketches of Bio-ceramics artificial bones and joints

4.2 Draw the human body skeletal systems and mention the artificial bio-ceramic parts.

5. Science of dental materials:

5.1 Understand the Definition for dental material.

5.2 Know the physical properties of dental materials like stress, strain, modulus of elasticity,

permanent deformation, strength, toughness, hardness, ductility, malleability, resilience,

flexibility, impact, fatigue, creep,

5.3 Know the physical property aspects in dentistry.

6. The parts of tooth:

6.1 Understand the Definition of Tooth,

6.2 Know the sketches of tooth and labels parts like Enamel, Dentine, Cementum, Pulp.

6.3 Understand the definition and explanations of Enamel, Dentine, Cementum, Pulp.

6.4 Know the difference between Primary and secondary teeth

6.5 Explain about Chronology of teeth like dentition, tooth, and eruptions.

74

7. Dental Ceramics:

7.1 Know the Definition and developments of dental ceramics.

7.2 Understand classifications and applications of dental ceramics.

7.3 Know the Dental porcelain raw materials, composition

7.4 Know the fabrication of dental porcelain.

7.5 Understand the cast able glass-ceramic

7.6 Know the CAD-CAM ceramics.

8. Dental restorations:

8.1 Know the Definition of dental restoration

8.2 Understand the fabrication of ceramic restoration,

8.3 Know the ceramic-metal restoration,

8.4Understand ceramic jacket crowns

8.5 Know the technical aspects of metal-ceramic restorations,

8.6 Understand benefit and draw back metal-ceramics.

9. Dental Cements:

9.1 Know the Definition and classifications of dental cement

9.2 Know the composition and properties and manipulation of Silicate cement,

9.3 Know the composition and properties and manipulation of Zinc phosphate cement,

9.4 Know the composition and properties and manipulation of Zinc oxide eugenol cement,

9.5 Know the composition and properties and manipulation of Glass ionomer cemen,

9.6 Know the composition and properties and manipulation of zinc silico phosphate cement,

9.7 Know the composition and properties and manipulation of Zinc polycarboxylate cement,

9.8 Know the composition and properties and manipulation of Calciumhydroxide cement,

9.9 Understand the definition and application of Cavity liner, cavity varnish and cavity bases .

10. Dental gypsum products:

10.1 Know the Classification of gypsum products

75

10.2 Know the definition, properties, application and water powder ratio of dental plaster.

10.3 Know the definition, properties, application and water powder ratio of dental stone

10.4 Know the definition, properties, application and water powder ratio of improved stone.

10.5 Know the manufacturing process, chemical reactions, of gypsum products.

10.6 Understand the Difference between dental plaster and dental stone.

10.7 Know the Measurement of setting time, factors affecting setting time.

10.8 Understand the Definition of modifier, accelerators ,retarders.

11. Dental waxes:

11.1 Understand the Definition, classification of dental wax,

11.2 Know the types of dental wax and applications.

11.3 Understand the Ideal requirement of inlay wax,

11.4 Know the difference between direct and indirect pattern wax.

12. Abrasive and polishing materials:

12.1 Know the Definition of abrasive,

12.2 Understand the types of abrasives with examples and uses.

12.3 Know Definition of polishing materials

12.4 Understand types of polishing materials

12.5 Know the difference between abrasion and polishing materials.

References:

1. Bio-medical materials--- 2001 material science-UNSW

2. Advanced technical ceramics by Shigeyuki Somiyag

3. Notes on dental materials by V.K Subba Rao

4. Dental technician by Syed Sadatullah

5. Basic dental materials by John J Manappallil

76

6. Notes on Bio-ceramic and dental material by K Mariswamy

WEIGHTAGE TABLE

Sl.


Marks to be

allotted

Marks

Allotted

1. I All chapter 10 10

2. II

Introduction of Bio ceramics,

Classification of Bio-ceramics,

20

45 Bio-ceramic materials

10

Bio-ceramic skeletal system

15

3. III

Science of dental materials 15

45 The parts of tooth 15

Dental Ceramics

Dental restorations 15

4. IV

Dental Cements 15

45 Dental gypsum products 15

Dental waxes

Abrasive and polishing 15

145

77

Model question paper


SIXTH SEMESTER

Subject: Bio and Dental ceramics INSTRUCTIONS:

1. Section no. 1 is compulsory 2. Answer any 2 full questions from II, III & IV sections (total six full questions)

Section-I

1. a. Fill in the blanks with appropriate word. 5x1=5

I. More translucent ceramic is termed as _________

II Zinc phosphate cement are good thermal ________

III) Pyrolytic carbon is commonly used an artificial ______

IV) Chemical formula of gypsum is ______

V) Alumina ceramic is a example of ________ ceramics.

b. Write a short note on CAD-CAM ceramics. 5

Section-II

2. a. Define Bio-ceramics? 3

b. Write the classifications of Bio-ceramics.? Explain Bio-active ceramics. 6

c. What are Bio-degradable and Bio-inert ceramics, explain briefly. 6

3. a. Mention important Bio-ceramic materials, explain briefly. 8

b. Explain with neat sketch of artificial bone and Joints. 7

78

4 a. Define Bio-glass. 3

b. What is pyrolytic carbon, explain briefly. 5

c. Write the medical application of Bio-ceramic materials. 7

Section-III

5. a. Define dental material. 3

b. Write the different physical properties of dental materials. 5

c. What is tooth? Draw the neat sketch and label it 7

6. a. Which is the hardest part in tooth? 2

b. What are cementum and dentin? Explain briefly. 5

c. Write the difference between the primary and secondary teeth. 8

7.a. Define dental ceramic 3

b. write the classification and application of dental ceramic. 6

c. Write the fabrication of ceramic metal restoration. 6

Section-IV

8. a. What is dental cement? 3

b. What is glass ionomer cement? Write the composition, manipulation and application?

6

c. What is silicate cement? Write the composition,manipulation and application.?6

9.a. What is dental stone? 3

b. Explain the manufacturing of dental plaster. 6

c. Write the difference dental plaster and dental stone. 6

10. a. What is dental wax? 3

b. Write the classification dental wax. Explain briefly. 6

c. Write the difference between abrasive and polishing materials. 6

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

79


SIXTH SEMESTER

Subject: Special refractories and management


Contents

Chapter no Course content No of hrs 01 Introduction to refractories 02

02 Refractories in iron and steel industry 04

03 Refractories in cement industry 05

04 Refractories in Power industry 05

05 Refractories in Glass industry 05

06 Refractories in Chemical industry 05

07 Super refractrories 05 08 Pre Cast Pre fire Refractories (PCPF) 03

09 Monolithic Refractories 08

10 High temperature insulation refractories 08

11 Applications of refractories 03

12 The future trend of refractories 03

13 Tests and revision 04 Total 64

80

CONTENTS IN DETAIL

1.0 Introduction to refractories:

Introduction & know the Use of refractories in different industries like steel, cement, glass, chemical, power etc 2.0 Refractories in iron and steel industry: Study the Different types of refractories used in Iron and steel industry with functions like Magnesite, alumina, high grog, carbon bricks, SIC, Chromites along with specification and application. 3.0 Refractories in cement industry: Know in detail about the Different types of refractories used in Cement industry with functions like direct bonded Magchrome, high alumina and castables with specification and application 4.0 Refractories in Power industry:

Understand the Different types of refractories used in Power industry with functions like high abrasive resistant bricks and liners and insulating castables with specification and application. 5.0 Refractories in Glass industry: Study the various refractories used in Glass industry with functions like Zirconia, mullite, Sillimanite for corrosion resistant with specification and application. 6.0 Refractories in Chemical industry: Know in detail about the Different types of refractories used in Chemical industry with functions like acid proof bricks and mortars with specification and application. 7.0 Super refractories: Know the importance of super refractories like Silicon carbide, spinel, mullite, zirconia, graphite etc in industry along with specification and application. 8.0 Pre Cast Pre Fired Refractories (PCPF):

Study the Importance and application with respect to the critical shaped refractories used in critical areas like tundish pads, well blocks, porous plug, furnace roof etc

9.0 Monolithic Refractories : Understand in detail about the present and future trends of Monolithic Refractories s 10.0 High temperature insulation refractories:

81

Know the Importance of high temperature insulation in the present scenario of conservation of energy and fuel – Bubble Alumina, Mullite based tabular alumina etc with specification and application. Importance of high porosity, low Bulk density, higher thermal insulation, high PCE. 11.0 Application of refractories : Study the importance of the application and the actual usage of refractories in different ways in the industry like Casting, ramming, gunning, lining, and insulation forming etc, the dependency of performance of refractories on the application process. 12.0 The future trend of refractories : Considering the depletion of naturally available raw materials –know the Usage of recycled products, Use of synthetic raw materials, use of unfired refractory products etc.

GENERAL OBJECTIVES

1.0 Introduction to refractories:

1.1 Know in detail about the uses of refractories in modern world

1.2 Know the types of refractories

1.3 Understand the types of refractories used in various fields

2.0 Refractories in iron and steel industry: 2.1 Know the types of refractories used in iron and steel plants. 2.2 Study in detail the types of refractories used in iron and steel industries. 2.3 Study in detail about the refractories like Magnesite ,Alumina, High grog,

Carbon bricks etc 2.4 Know the specifications with applications of types of refractories used in iron

and steel industry. 3.0 Refractories used in Cement industry:

3.1 Understand the types of refractories used in Cement industry. 3.2 Study in detail the types of refractories used in cement industry 3.3 Study in detail about the refractories like Direct bonded, Magchrome, high

alumina and Castables. 3.4 Know the specifications with applications of types of refractories used in

Cement industry. 4.0 Refractories in Power industry:

4.1 Understand the types of refractories used in power industry. 4.2 Study in detail the types of refractories used in power industry.

82

4.3 Know the specifications with applications of types of refractories used in power industry.

5.0 Refractories in Glass industry:

5.1 Study the types of refractories used in glass industry. 5.2 Study in detail the types of refractories used in glass industry like Zirconia,

mullite etc . 5.3 Know the specifications with applications of types of refractories used in glass

industry. 6.0 Refractories in chemical industry:

6.1 Study the types of refractories used in Chemical industry. 6.2 Study in detail the types of refractories used in Chemical industry like acid proof

bricks and mortars etc. 6.3 Know the specifications with applications of types of refractories used in

Chemical industry. 7.0 Super refractories :

7.1 Know the importance of super refractories . 7.2 Study in detail the types of super refractories like Silicon carbide , spinnel

,mullite, zirconia, graphite etc. 7.3 Understand the specification with applications of super refractories.

8.0 Pre cast Pre fired Refractories (PCPF) :

8.1 Know the importance and role of pre cast pre fired refractories. 8.2 Know the applications of Pre cast Pre fired Refractories.

9.0 Monolithic refractories:

9.1 Know the present and future trends of Monolithic refractories 10.0 High temperature insulation refractories:

10.1 Know the importance of high temperature insulation refractories, with their applications and properties.

11.0 Applications of refractories :

11.1 Know the role of refractories in present scenario. 11.2 Know the ways the refractories used in industries in modern world.

12.0 The future trend of refractories:

12.1 Know the process of using the rejected materials in compositions. 12.2 Understand the importance of synthetic materials

SPECIFIC OBJECTIVES

1.0 Introduction to refractories : 1.1 Know the origin of refractories . 1.2 Understand the role of refractories in modern world . 1.3 Know the types of refractories used indifferent industries.

83

2.0 Refractories in iron and steel industries :

2.1 Know the types of refractories used in iron and steel plants. 2.2 Study the role of refractories in iron and steel industries. 2.3 Study in detail the specifications of refractories used in iron and steel plants with

applications. 3.0 Refectories in Cement industry:

3.1 Know the types of refractories used in Cement industry. 3.2 Study the role of refractories in Cement industries. 3.3 Study in detail the specifications of refractories used in cement industry with

applications. 4.0 Refractories in power industry:

4.1 Know the types of refractories used in Power industry. 4.2 Study the role of refractories in power industries. 4.3 Study in detail the specifications of refractories used in power industry with

applications. 5.0 Refractories in glass industry:

5.1 Know the types of refractories used in glass industry. 5.2 Study the role of refractories in glass industries. 5.3 Study in detail the specifications of refractories used in glass industry with

applications. 6.0 Refractories in chemical industry:

6.1 Know the types of refractories used in Chemical industry. 6.2 Study the role of refractories in chemical industries. 6.3 Study in detail the specifications of refractories used in Chemical industry with

applications. 7.0 Super refractories :

7.1 Know the definition of super refractory. 7.2 Know the types of super refractories like silicon carbide, spinnel, mullite and

zirconia etc. 7.3 Know the specifications of super refractories. 7.4 Study in detail the applications of super refractories. 7.5 Understand the role of refractories in modern world.

8.0 Pre cast pre fired refractories (PCPF): 8.1 Know the importance of Pre cast pre fired refractories. 8.2 Know the applications of PCPF .

9.0 Monolithic refractories:

9.1 Study in detail about the present and future trends of Monolithic refractories . 10.0 High temperature insulation refractories:

10.1 Know the role of High temperature insulation refractories in the present world.

84

10.2 Study the specification and application of High temperature insulation refractories.

10.3 Study in detail the importance of High porosity, low bulk density, high thermal insulation etc.

11.0 Applications of refractories:

11.1 Know the role of refractory in the present scenario. 11.2 Study in detail about Casting, Ramming, Gunning, lining etc.

12.0 The future trend of refractories :

12.1 Study the process of recycling the rejected products. 12.2 Know the importance of use of Synthetic raw materials. 12.3 Study the process of using unfired refractory products.

References :

1.0 Fundamentals of refractory technology by James P Rennet, Jeffery D Smith.

2.0 Hand book of refractories by Charles A Schast.

3.0 Hand book of industrial refractories by Stephen Caniqlia.

4.0 Hand book of advanced refractories by High pierson.

5.0 Refractories production and properties by J.H Chestes.

6.0 Electric refractory materials by Yukinobu Kumashiro.


SIXTH SEMESTER

Subject: Special refractories & Management INSTRUCTIONS:

1. Section no. 1 is compulsory 2. Answer any two full questions from II, III & IV sections (total six full questions)

Section-I

85


I). Chromite is a example for_________ refractory

II). ______ property of zirconia makes it suitable for glass industry (ans: corrosion

resistant )

III) ._______ refractory conserves energy and fuel (ans: high temperature insulation)

IV). The Refractoriness of spinnel is________ (ans: high)

V).__________is an example for refractory used in cement industry (ans:

magchrome)

b. Write the short notes on Functions of acid proof bricks 5

Section-II

2. a. What is PCPF? 2

b. Name the industries where refractories are essential. Why? 7

c. Explain briefly any six properties of refractories. 6

3. a. Explain the importance of magnesite and alumina refractory in iron and steel industry. 7

b. Write the specification and applications of Magchrome refractories? 8

4. a. Give five examples of super refractories 3

b. Write the functions of Zirconia and mullite in Glass industry 6

c. Explain briefly specification and applications of mortars. 6

Section-III

5. a. Define mortars. 2

b. Draw three shapes of refractories used in critical areas. 9

c. Explain monolithic. 4

6. a. How insulation refractories help in conservation of energy and fuel? 6

b. List the applications of bubble alumina and mullite based tabular alumina. 6

c. What is ramming? 3

7 . a. Explain dependency of performance of refractories on application process. 7

b. Explain the synthetic raw materials used in refractories 8

86

Section-IV

8 a. Give the comparison between uses unfired and fired refractories. 5

b. Explain how high abrasive resistant brick helps in power industry ? 5

c. What are the properties of direct bonded magchrome refractories? 5

9. a Explain different types of refractories used in tank furnace. 9

B. Write a note on spinnel refractories. 6

10. a. Draw a neat sketch of blast furnace &Label its parts. 7

b. Which refractory is used in burning zone of kiln? Why? 4

c. Explain the process how the rejected bricks are recycled 4

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


Sixth Semester

Subject: Vitrified & glazed Tile Ceramics


Contents

Sl no Chapters Alloted hours

I Introduction of tiles 3

2 Glazed tiles 4

3 Vitrified tiles 4

4 unit operations in tile ceramics

5

87

5 Grinding

3

6 Preparation of slip

3

7 Engobe

3

8 Spray drying process 5

9 Pressing

4

10 Drying 5

11 Kiln systems 4

12 Fuels for tiles industry 3

13 Glaze line 3

14 Testing of tiles 5

15 Defects in tile 4

16 Environmental awareness in tile industry 3

17 Industrial visit and guest lecture 3

Total 64

CONTENTS IN DETAIL

1. Introduction of tiles: History of tile, introduction of tiles like roofing tile, mosaic tile, paving tile, ceramic tile raw material properties and application of each, advances in tile technology. 2. Glazed tiles: Definition of Glazed tiles, raw materials, composition, Properties. Types of glazed tiles Manufacturing process and flow chart of glazed tiles. 3. Vitrified tiles; Definition of Vitrified tile, raw materials, composition, Properties. Types of vitrified ceramic tiles Manufacturing process and flow chart of vitrified tiles. 4. unit operations in tile ceramics: a) Crushing, Grinding b) Blunging c) Spray drying d) Pressing

88

e) Drying f) Firing g) Sorting h) Flow charts of single firing and double fired ceramic tiles. 5. Grinding: Definition of grinding . Types of grinding . Explain the wet grinding theory. 6. Preparation of slip: Introduction of slip, flocculants, deflocculates, properties of slip. 7 .Engobe: Definition of engobe, raw materials, composition and application. 8. Spray drying process: Introduction of spray driers. Functions of the spray driers. Nozzle spray drier operation with neat sketch. 9. Pressing: Principle of pressing. Pressing system and Types of presses, pressing defects. 10. Drying: The drying of ceramic tiles. Industrial driers, briefly explain on intermittent and continuous driers. Comparison between tunnel drier with horizontal and vertical driers. 11. Kiln system: Introduction of kiln , types of kilns and various applications. Explanation on tunnel and roller kiln. Comparison between roller kiln and tunnel kiln. 12. Fuels for tiles Industry: Introduction of fuels. Classifications of fuels. Fuel used in tile industry. 13. Glaze line: Glazes and glazing: General principles of glazing process. Control of glazing lines. 14. Testing:

89

Moisture content, particle size analysis , viscosity of slip,Strength like green and fired, water absorption test, porosity test, density test, shrinkage, thickness test, glossiness, MOR test,warpage test. 15. Defects: Defects in tiles, pinholes,crazing,crawling, fishscaling,blisters,etc. 16.Environmental awareness in tile industry: Introduction of environmental in tiles industry, different dust collecting systems like bag

collectors, ESPetc.

GENERAL OBJECTIVES

1.0 Introduction of Tiles:

1.1 Understand in detail the history ,Introduction for ceramic tiles example roofing tiles,

mosaic tiles, paving tiles.

1.2 Study the raw materials ,properties and application of the above said tiles.

1.3 Know the advances in tile technology

2.0 Glazed tiles:

2.1 Know the definition, raw materials, composition& properties of glazed tiles

3.0 Vitrified tiles:

3.1 understand definition, raw materials, composition and properties of vitrified tiles

3.2 Know types and manufacturing process , flow chart of vitrified tiles

4.0 Unit operations in tile ceramics:

4.1 Understand crushing process, grinding, mixing and blunging, spray drying of tiles

4.2 Know pressing, drying , firing, and sorting of tiles

4.3 Study the flowcharts of single firing and double firing of tiles

90

5.0 Grinding:

5.1 Understand the definition of grinding and types of grinding in tiles.

5.2 explain the wet grinding theory.

6.0 Preparation of slip:

6.1 Understand introduction for preparation of slip, flocculates,deflocculants and

properties of slips

7.0 Engobe:

7.1 Know the definition of engobe, raw materials, and composition and application

methods.

8.0 Spray drying process:

8.1 Understand the introduction to spray drying, functions of spray dying and nozzle

spray drying operation with neat sketch.

9.0 Pressing:

9.1 Know about the principle of pressing, pressing system and types of pressers and

defects in pressing.

10.0 Drying:

10.1 Know about drying of tiles, industrial dryers, and types of dryers comparison

between intermittent, continous tunnel dryers with horizontal and vertical dryers.

11.0 Kiln system:

11.1 Know about the introduction to kiln, types of kiln and various applications

11.2 describe Tunnel and roller kiln comparison between them.

12.0 Fuels for tiles industry:

12.1 Know introduction to fuels, classification, types of fuels used in tile industry

13.0 Glaze lines:

13.1 understand the glazes, general properties of glazing process with controlling of

glaze lines or pattern design.

91

14.0 Testing:

14.1 Know about moisture content, particle size, viscosity, hardness. Absorption,

porosity, density, shrinkage, thickness, glassiness and modulus of rupture test and warpage

test.

15.0 Defects:

15.1 Explain defects in tiles like, pinholes, crazing, crawling, fish scaling ,blisters, color

defects if any etc.

16.0 Environmental awareness in tile industry:

16.1 understand the pollutions and precautions to save environment in the interest

of public

16.2 The possible precautionary measure are dust collecting systems like bag

collectors , recycling of the rejected tiles instead of throwing which destroy the fertility of the

soil and the forests will be destroyed which leads to global warming and total damage to the

nature.

SPECIFIC OBJECTIVES

1.0 Introduction to tiles:

1.1 Know the history and introduction of tiles.

1.2 Understand the selection of raw materials, properties and applications of each raw

material for tiles.

1.3 Know advances and latest technology emerged in tile industry.

2.0 Glazed tiles:

2.1 Study the definition of glazed tiles, raw materials used.

2.2 Understand the composition, properties and types of glazed tiles.

3.0 Vitrified tiles:

3.1 Understand the definition of vitrified tiles and raw materials used.

3.2 Know about compositions, properties of vitrified tiles.

3.3 List the types of vitrified tiles with specific qualities.

3.4 Understand the manufacturing process with flow charts with reference to different

types of vitrified tiles.

92

4.0 Unit operation in tile ceramics:

4.1 Understand the crushing and grinding of raw materials of tiles.

4.2 Know how to blunge and mix different raw material powders .

4.3 Learn about Spray drying method .

4.4 Understand Typical tile pressing with difficulties .

4.5 Study the drying methods by using waste flue gases from the kiln.

4.6 Understand the complete loading, zones, temperatures and cooling cycles in firing.

4.7 Understand sorting and grading the finished products with rejections etc.

4.8 Know the flow charts of single and double firing of firing in tiles.

5.0 Grinding:

5.1 Understand importance of grinding with general definition.

5.2 List the types of grinding machines and effects in grinding processes.

5.3 Study in detail the wet grinding theory with reference to ball mills.

6.0 Preparation of slips:

6.1 Understand average casting slip in an average industry and a good casting slip, Best

casting slip.

6.2 Know about effect of flocculants and deflocculates in the preparation of casting slip .

6.3 Understand the Measuring of the viscosity, density, Specific gravity of a average

casting slip, good casting slip and best casting slip.

7.0 Engobe:

7.1 Understand the definition of engobe with requirement of an engobe in different

bodies to hide the surface defects like Uneven, holes and color after firing.

7.2 Understand the raw materials used in preparation of engobe and matching with the

body and glaze as a intermediate or foundation coating.

7.3 Understand the composition of engobe with examples and its preparation then

application methods.

8.0 Spray drying process:

8.1 Understand the introduction to spray dryers and their importance in tile industry.

93

8.2 Explain about spray drying unit and its functions for production of granules.

8.3 Know more about Nozzle spray dryer with its operational methods and a sketch.

9.0 Pressing:

9.1 Know about Specific principle in pressing of tiles .

9.2 Understand dyes used in tile pressing with dyes and their lubrication methods to

release the pressed tiles.

9.3 Understand Defects and difficulties and precautions to overcome them.

10.0 Drying:

10.1 Know more about intermittent and continuo’s dryers .

10.2 Understand the continuo’s tunnel dryers and horizontal, vertical dryers

commonly used In tile s drying process.

11.0 Kiln system :

11.1 Know more about kilns used in tile firing with difficulties in different zones.

11.2 List the types of kilns used like tunnel and roller kiln with comparison and

advantages, disadvantages.

12.0 Fuels for tile industry:

12.1 Understand precautions In storing the fuels , cost and use of fuel efficiently for

effective fuel consumptions.

12.2 Know more about types of fuels available, awareness about storing safely and

using them efficiently for tile industry.

13.0 Glaze line:

13.1 Explain in glaze, over glaze, under glaze decoration methods how to apply in tile

glazing and decoration.

13.2 Know about importance of screen printing and accuracy in printing correct and

perfect designs on tiles.

14.0 Testing:

14.1 Know percentage M.C, Particle size and their importance in the final product.

14.2 Explain the tests viscosity of slip Specific gravity, density and porosity.

14.3 Know about thickness test , glossiness test and M.O.R test and warpage test

94

15.0 Defects:

15.1 Study the defects in tiles like pin holes, crazing, crawling, fish scaling, blisters etc

15.2 Understand the precautionary measures for defects.

16.0 Environmental awareness in tile industry:

16.1 Study the types of pollutants produced from tile industry.

16.2 Study the precautionary measure in regulating of the pollutants causing

pollution.

16.3 Study in detail about the various dust collectors like Bag collectors and ESP.

References:

1 From technology through Machinery to kilns for SACMI Tiles, Part A& B 2 Industrial ceramics --- Singer and Singer 3 Notes on Manufacture of ceramic Tiles -- K. Mariswamy.

95

WEIGHTAGE TABLE

Sl.


Marks to be


1. I All chapters 10 10

2. II

Introduction, History, definition,

Composition, types and

manufacturing process of tiles.

15

45

Vitrified tiles, definition, unit

operation, raw materials,

composition, and manufacturing.

15

Crushing, Grinding, Mixing, Spray

drying , pressing, drying , firing,

and sorting

15

3. III

Raw material grinding, slip

preparation, engobe 15

45 Spray drying, Pressing, Drying,

Firing 15

Glazing, Firing and defects 15

4. IV

Environmental awareness, types

of presses. 15

45 Types of dryers 15

Types of grinding 15

TOTAL 145


96


SIXTH SEMESTER

Subject: Vitrified & glazed Tile Ceramics INSTRUCTIONS:


Section-I


I. Glazed tiles are ______________ in nature (ans: opaque)

II _____________ is used to convert slurry in to powder (ans: Spray dryer)

III) Engobe is an intermediate coating between ____________and __________

(ans: body and glaze)

IV) The porosity of vitrified tiles is _____________ (ans: Zero)

V).To increase the fluidity of slip _____________ is added (ans: deflocculant)

b. Write a short note on Engobe. 5

Section-II

2. a. Define glazed tiles. 2

b. Give the brief history of tiles. 5

c. Explain the manufacturing of tiles with a neat flow chart. 8

3. a. State the properties of vitrified tiles. 5

b. What are deflocculates? Give examples. 4

c. Enumerate the differences between glazed tiles and vitrified tiles . 6

4 a Define wet grinding. 2

b. State the theory of wet grinding. 7

c. Draw a neat sketch of spray drier and explain its working. 8

97

Section-III

5. a. Define fuels. 3

b. List the fuels used in tile industry. 4

c. Draw a net sketch of roller hearth kiln and explain its working. 7

6. a. Define drying. 2

B...Give the comparison between tunnel drier and vertical drier. 5

c. Explain the defects occurring during pressing with remedies. 8

7. a. Define glaze. 2

b. Explain the general principles of glazing 4

c. What are the causes and remedies for crazing crawling and pinhole defects? 9

Section-IV

8 a. Name the tests conducted for slip. 2

b. State the properties of slip. 5

c. Explain any two glaze application methods adopted in tile industry. 8

9. a What are the pollutants from the tile industry. 4

b. Explain how dust is collected in bag collectors. 6

c. Draw a neat flow chart for double fired Ceramic tiles. 5

10. a. Explain how thickness and war page of tile is tested. 8

b. Write the composition for engobe. 3

c. What are intermittent dryers give example. 4

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


SIXTH SEMESTER

Subject: Composite & Chemical Ceramics


Contents

98


01 Introduction and history 05

02 Methods of fabrication 06

03 Properties of composite ceramics 06

04 Ceramics matrix composites (C.M.C) 06

05 Silicon carbide matrix composites 06

06 Alumina and alumina silica (mullite) matrix composites 08

07 Carbon-carbon composites 08

08 Fiber reinforced glass/glass-ceramics matrix composites 06

09 Environmental awareness in ceramics composites 05

10 Industrial visit/guest lectures 04

11 Tests and revision 04

Total 64

CONTENTS IN DETAIL

1.0 Introduction and history:

Composites , types of composites,matrix,filler,reinforcement,definition,phases-continous

phase, dispersed phase , fibers, long fibers ,short fibers , whiskers , filament, monofilament.

Ceramics matrix composites (introduction) , matrix materials, reinforce materials carbides,

oxides, nitrides, glass fibers.

99

2.0 Methods of fabrication:

Fibers, particulates, powder fillers C.V.D, P.V.D.

3.0 Properties of composite ceramics:

High mechanical strength, thermal shock resistance, high toughness, thermal stability,

density, corrosion resistance.

4.0 Ceramics matrix composites:

It is a material consisting of ceramics matrix combined with a ceramic (oxides, carbides)

dispersed phase.

Ceramic matrix composites are designed to improve toughness of conventional ceramics,

the main dis advantage of which is brittle ness.

Ceramics matrix composites are reinforced by either continous (long) fibers or dis continous

(short) fibers.

Short-fiber (discontinuous) composites are produced by conventional ceramics processes

from an oxide (alumina) or non oxide (silicon carbide) Ceramics matrix re in forced by whiskers

of silicon carbide (Sic) titanium boride (TiB2), aluminum nitride (AlN), zirconium oxide (ZrO2) and

other ceramic fibers . Most of CMC are reinforced by silicon carbide fibers due to their high

strength and stiffness (modulus of elasticity)

Whiskers in corporate in a short –fiber ceramics matrix composites improve its toughness

resisting to cracks propagation. However a character of failure of short fiber reinforced

materials is catastrophic

Long fiber (continous) composites are re in forced either by long mono filament of long multi

filament fibers

The best strengthening effect is provided by dispersed phase in form of continous mono

filament fibers, which are fabricated by chemical vapour deposition (CVD) of silicon carbide on

a substract made of tungsten (W) or carbon(C) fibers.

Mono filament fibers produce stronger interfacial bonding with the matrix material improving

its toughness

Failure of long-fiber ceramics matrix composite is not catastrophic.

5.0 Silicon carbide matrix composites:

These are fabricated by chemical vapor infiltration or liquid phase in filtration methods of a

matrix material in to a free form prepared from silicon carbide fibers

100

Silicon carbide matrix composites are used for manufacturing combustion liners of gas

turbine engines, hot gas re circulating fans, Heat exchangers, Rocket Propulsion

components, filters for hot liquids, gas-fired burner parts, Furnace pipe hangers , immersion

burner tubes .

6.0 Alumina and alumina -silica ( mullite) matrix composites :

These are produced by sol-gel method, direct metal oxidation, or chemical bonding.

Alumina and alumina silica (mullite ) matrix composites are used for manufacturing heat

exchangers , filters ,for hot liquid , thermo-photo voltaic burners, burner stabilizers ,

combustion liners of gas turbine engines .

7.0 Carbon-carbon composites :

These are fabricated by chemical vapour in filtration or liquid phase infiltration methods of

a matrix material in to a perform prepared from carbon fibers.

Carbon-carbon composites are used for manufacturing high performance breaking systems,

refractory components, hot pressed dyes, heating elements, turbojet engine components.

Carbon-carbon composites properties and testing of composite material, areas of

applications.

Typical properties of long fiber ceramics matrix composites

High mechanical strength even at high temperatures

High thermal shock resistance

High stiffness

High toughness

High thermal stability

Low density

High corrosion resistance even at high temperatures.

Matrix material for long fiber (continous fiber) composite may be silicon carbide, ceramics,

alumina(alumni-silica) ceramics or carbon.

8.0 Fiber reinforced glass/glass-ceramics matrix composites:

-introduction

101

Types of fiber suitable for re In for cements in different glass /glass-ceramics matrix

composites

Methods for manufacturing different fiber reinforced glass/glass-ceramics matrix

composites

Properties of glass/glass-ceramics matrix composites

Micro-structural observation

Application areas

Future trends

GENERAL OBJECTIVES

1.0 introduction and history:

Understand Composites , types of composites,matrix,filler,reinforcement,definition,phases-

continous phase, dispersed phase , fibers, long fibers ,short fibers , whiskers , filament,

monofilament.

Study in detail about Ceramics matrix composites (introduction) , matrix materials, reinforce

materials carbides, oxides, nitrides, glass fibers.

2.0 Methods of fabrication:

Know the methods of fabricating Fibers, particulates, powder fillers C.V.D, P.V.D.

3.0 Properties of composite ceramics:

Study in detail about High mechanical strength, thermal shock resistance, high toughness,

thermal stability, density, corrosion resistance.

4.0 Ceramics matrix composite (CMC):

4.1 Understand the definition of ceramics matrix

4.2 Know why ceramic composite ceramics are designed

4.3 Know how short and long fibers are prepared


Understand the formation of silicon carbide matrix, their uses in detail

6.0 Alumina and alumina –silica (mullite) matrix composites :

Understand the formation of Alumina and alumina –silica (mullite) matrix, their uses in

detail

102

7.0 Carbon-carbon composites:

Understand the formation of Carbon-carbon matrix, their uses in detail

9.0 Fiber reinforced glass/glass –ceramic matrix composites:

Study in detail about introduction, types of fibers, manufacturing of fibers, properties of

glass/glass-ceramic fibers / micro structure

SPECIFIC OBJECTIVES

1.0 Introduction and history:

1.1 Know in detail about composites.

1.2 Understand the types of composites.

1.3 Know the definitions of matrix, reinforcement, dispersed phases, fibers ,long

fibers ,short fibers and whiskers etc.

1.4 Introduction to ceramic matrix composites, matrix materials, reinforcement

materials carbides, oxides and nitrides.

2.0 Methods of fabrication :

2.1 Know in detail about Fibers, particulates, powder fillers.

2.2 Understand the term CVD, PVD.

3.0 Properties of ceramic composites:

3.1 Know the properties of Ceramic composites.

4.0 Ceramics matrix composites (CMC):

4.1 Know the definition of Ceramics matrix composites.

4.2 Understand the term fabricating.

4.3 Understand long and short fibers and the comparison between them.

4.4 Understand the term whiskers.

4.5 Understand how the strengthening effect is produced.

4.6 Introduction to Monofilament fibers.


5.1 Know the process of fabricating Silicon carbide matrix composites.

103

5.2 Study in detail the application of Silicon carbide matrix composites.

6.0 Alumina and alumina –silica (mullite) matrix composites:

6.1 Know the process of fabricating Alumina and alumina –silica (mullite) matrix

composites.

6.2 Study in detail the applications of Alumina and alumina –silica (mullite) matrix

composites.

7.0 Carbon-carbon composites:

7.1 Know the process of fabricating Carbon-carbon composites.

7.2 Study in detail the applications of Carbon-carbon composites.

8.0 Fiber reinforced glass/glass –ceramic matrix composites:

8.1 Know in detail about Fiber reinforced glass/glass –ceramic matrix composites.

8.2 Understand their properties.

8.3 Study the micro-structural observations.

8.4 Know the applications of Fiber reinforced glass/glass –ceramic matrix

composites.

8.5 Study the future trends of glass –ceramic matrix composites.

9.0 Environmental awareness in composite ceramics.

9.1 Know the different types of pollutants from ceramic composites.

9.2 Study the process of regulating them.

References:

1.0 Ceramics matrix composites by I.M Low ,Curtin university Austrailia

2.0 Fibrous monolithic ceramics by Y.H Koh

3.0 Fibre reinforced Glass/glass-ceramic matrix by R.B Banerjee &N.R Bose, Calcutta, India

4.0 Particulate composites by R.T Todd, University of Oxford

5.0 Functionally graded ceramics , University of Curtin

104

WEIGHTAGE TABLE

Sl.


Marks to be



2. II

Introduction and history 15

45 Methods of fabrication 15

Properties of composite ceramics 15

3. III

Ceramics matrix composites

(C.M.C) 20

45 Silicon carbide matrix composites 12

Alumina and alumina silica

(mullite) matrix composites 13

4. IV

Carbon-carbon composites 10

45

Fiber reinforced glass/glass-

ceramics matrix composites 20


ceramics composites 15

TOTAL 145



SIXTH SEMESTER

Subject: Composite &Chemical Ceramics INSTRUCTIONS:


105

Section-I


I. The chemical formulae of mullite is______________ (Al203.3Sio2)

II Zro2 is used for __________________ceramics (structural)

III) Main disadvantage of ceramic composite is ____________ (brittleness)

IV) The abbreviation of CVD is________________

V).The formulae of aluminum nitride is____________ (AlN)

b. Write the short note on P.V.D. 5

Section-II

2. a. Define composites and list few composite materials. 6

b. Write a brief introduction about glass fibers. 5

c. State the general properties of composites. 4

3. a. Define whiskers. 2

b. Mention the advantages and disadvantages of ceramics composite. 8

c. Name the fabrication methods for composites and explain any one. 5

4 a What are carbon -carbon composites? Explain . 5

b. Explain fabrication of carbon-carbon composites. 6

c. State the properties of C-C composites. 4

Section-III

5. a. Mention the uses of C-C composites. 5

b. Name the tests conducted on composites and explain any one. 5

c. List the typical properties of Long-fiber ceramics matrix composites. 5

6. a. Explain the fabrication of silicon carbide matrix composite. 8

b. Write the properties of Sic Matrix composites. 4

106

c. Write the applications of Sic matrix composites. 3

7. a. What are monofilaments explain. 2

b. Explain the direct metal oxidation or chemical bonding methods of fabrication for

composites. 8

c. Mention the properties of mullite matrix. 5

Section-IV

8 a. Explain the processing of Mullite matrix by sol-gel method. 9

b. List the uses of alumina and mullite matrix composites. 6

9.a What are long and short fibers ? Explain. 3

b. Write the properties and uses of ZrO2. 8

c. Explain the toughness properties of composites. 4

10. a. What are glass ceramic matrix composites? Explain. 2

b. Explain the manufacturing glass ceramic matrix composite. 7

c. State the applications and properties of glass ceramic matrix? 6

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


SIXTH SEMESTER

Subject: Graphite & Carbon Ceramics


Contents


01 History & Introduction to carbon ceramics. 04

107

02 Graphite electrodes, Crucibles, Blocks, Carbon fibers & carbon

moulds for glass industry

04

03 Natural diamonds & Artificial diamonds. 04

04 Plant Operations in Carbon ceramics. 05

05 Grinding & Mixing 03

06 Preparation of batch & Binders 05

07 Pre firing of Carbon and Graphite batch composition. 05

08 Extrusion Process. 03

09 Drying and End cutting. 05

10 Kiln System. 05

11 Fuels for graphite industry. 05

12 Inspection & defects. 04

13 Environmental awareness in graphite industry. 03

Tests and revision 04

Total 64

CONTENTS IN DETAIL

1.0 History & Introduction to carbon ceramics:

graphite electrodes, blocks, Crucibles, carbon fibers, artificial diamonds etc. raw materials,

properties, and applications of each, advance in carbon ceramics.

2.0 Graphite electrodes, crucibles, blocks, carbon fiber & carbon moulds for glass industry:

Definition of each, raw material composition, manufacturing process an flow charts of

above products.

3.0 Natural diamonds & Artificial diamonds:

Occurrence of natural diamonds, properties ,structure, geological Properties

Definition of artificial diamonds, raw materials, composition and manufacturing process,

types of artificial diamonds, flow charts of artificial diamonds.

4.0 Plant Operations in Carbon ceramics:

108

a) Crushing and grinding

b) Mixing

c) Melting

d) Shaping

e) Sorting

5.0 Grinding & Mixing:

Definition of grinding, types of grinding, Principles of dry mixing, types of mixers like sigma

mixers, Box mixers, uniaxial horizontal mixers, vertical mixers.

6.0 Preparation of batch & binders:

Introduction to binders like P.V.A, Sarbid oil, Castor oil, Batch mixing ,

7.0 Pre firing of Carbon and Graphite batch composition:

Importance of prefiring, Structure formations of graphite, flow charts.

8.0 Extrusion Process:

Principles of extrusion, Dies used in extrusion, Lubricators, Defects in extrusion.

9.0 Drying and End cutting:

Drying of extruded graphite electrodes by natural drying and in controlled humidity driers,

Importance of Humidity dryers, maintaining correct length by cutting ends of electrodes by

using accurate cutting machines.

10.0 Kiln System:

Introduction to kilns used in graphite industry, types of atmospheres maintained, Zone

formations, temperature rate of rise and cooling cycles. Importance of atmosphere

maintained in the kiln during sintering.

11.0 Fuels for graphite industry:

Introduction to fuels, inert gases used for maintaining atmospheric conditions, classification

of fuels.

12.0 Inspection & defects:

109

Testing of sintered products, defects in sintered products, rejecting the defect products and

packing the good products, dispatching.

13.0 Environmental awareness in graphite industry:

Graphite and carbon powders are very dangerous when the workers breathing it directly

attacks the respiratory system and causes lung cancer then it spread total cancer problems

in the employees. And also it spreads all around the industry and causes problems to the

public living around the industry.

Precautionary measures: the employees are instructed very strictly to wear shoes,

breathing masks and hand gloves during working with the carbon and graphite

manufacturing. It is better to locate the industry away from the public colonies, towns and

cities at least in 5km distance to safe guard the public health.

The rejections from the carbon ceramics industries instead of throwing as a garbage which

is not a bio degradable material cause’s damage to the environment.

Precautions- The sintered rejected graphite products must be recycled and used in the

batches which saves the nature and also gives profit to the industry.

GENERAL OBJECTIVES

1.0 Understand the History & Introduction of carbon ceramics like graphite electrodes, blocks,

Crucibles, carbon fibers, artificial diamonds etc.and raw materials used in their preparation,

their properties, and applications.

2.0 Study the process of preparing Graphite electrodes, crucibles, blocks, carbon fiber & carbon

moulds

Their raw material composition, manufacturing process and flow charts of them.

3.0 Know the occurrence of natural diamond, its properties, and geological properties.

Know definition of artificial diamonds, their raw materials, composition and manufacturing

process and their types of flow charts of artificial diamonds.

4.0 Study in detail the processes of Crushing, grinding, Mixing, Melting, Shaping& Sorting.

5.0 Study the definition of grinding, types of grinding, Principles of dry mixing, types of mixers

like sigma mixers, Box mixers, uniaxial horizontal mixers, vertical mixers.

6.0 Understand the uses of binders like P.V.A, Sorbidol, Castor oil, Batch mixing and their role.

7.0 Know the Importance of prefiring, Structure formations of graphite during pre firing, flow

charts.

110

8.0 Study the Principles of extrusion, Dies used in extrusion, Lubricators and Defects in

extrusion.

9.0 Understand the process of drying of extruded graphite electrodes in controlled humidity

driers, Importance of Humidity dryers, maintaining correct length by cutting ends of

electrodes by using accurate cutting machines.

10.0 Know the types of kilns used in graphite industry, types of atmospheres maintained,

Zone formations, temperature rate of rise and cooling cycles. Importance of atmosphere

maintained in the kiln during sintering.

11.0 Study in detail the types of fuels used in graphite industry, inert gases used for

maintaining atmospheric conditions, classification of fuels.

12.0 Know the process o f testing of sintered products, defects in sintered products, rejecting

the defect products and packing the good products and dispatching.

13.0 Know the pollutants caused by graphite and carbon industry, causes, regulating.

SPECIFIC OBJECTIVES

1.0 History & Introduction to carbon ceramics:

1.1 Understand the history of carbon ceramics.

1.2 Know the types of carbon ceramic products.

1.3 Know the raw materials used in manufacturing in graphite electrodes, other

products.

1.4 Know the applications of carbon ceramic products.

2.0 Graphite electrodes, Crucibles, Blocks, Carbon fibers & carbon moulds used for glass

industry:

2.1 Know the raw materials used in manufacturing of graphite electrodes, crucibles,

blocks and fibers

2.2 Know the manufacturing process of the above products.

2.3 Study in detail the flow charts of the manufacturing of above said products.

3.0 Natural diamonds & Artificial diamonds:

3.1 Understand the definition of artificial diamond.

3.2 Know the raw materials used in manufacturing of artificial diamond.

3.3 Study in detail the compositions of artificial diamond.

111

3.4 Understand the Manufacturing process of artificial diamonds.

3.5 Study the types of artificial diamonds

3.6 Study the occurrence of natural diamond

3.7 Understand in detail the geological characteristics of natural diamonds.

4.0 Plant Operations in Carbon ceramics:

4.1 Know the processes involved in preparation of carbon ceramics.

4.2 Understand the process of grinding and mixing

4.3 Study in detail the processes of melting, shaping and sorting

5.0 Grinding & Mixing:

5.1 understand the definition of grinding

5.2 Know the types of grinding

5.3 Understand the principles of grinding.

5.4 Study in detail the types of mixers like Sigma mixers, box mixers , uniaxial horizontal

mixers and vertical mixers.

6.0 Preparation of batch & Binders:

6.1 Understand the role of binders in carbon ceramics

6.2 Study in detail about the binders like P.V.A, Sarbid oil, Castor oil.

6.3 Know the process of batch mixing in detail.

7.0 Pre firing of Carbon and Graphite batch composition:

7.1 Understand the importance of pre firing.

7.2 Know the structure formation of graphite.

7.3 Study the flow charts of prefiring of carbon and graphite products.

8.0 Extrusion process:

8.1 Study in detail the principles of extrusion.

8.2 Know the types of dyes used for extruding carbon ceramics.

8.3 Know the importance of lubricators in extrusion process.

112

8.4 Understand the defects that can be formed during extrusion process.

9.0 Drying and End cutting:

9.1 Know the process of drying carbon ceramics.

9.2 Study in detail about humidity dryers.

9.3 Understand the importance of humidity dryers.

9.4 Understand the process of end cutting.

10.0 Kiln System:

10.1 Know the types of kilns used in graphite and carbon ceramics industries.

10.2 Study about the atmospheres maintained in kiln during firing carbon ceramics.

10.3 Study in detail about the cooling cycles.

10.4 Know the importance of maintaining of atmosphere during firing.

11.0 Fuels for graphite industry:

11.1 Know the types of fuels used in carbon ceramics industries.

11.2 Study in detail about the types of inert gases used for maintaining atmospheric

conditions

11.3 Understand the classification of fuel and their importance.

12.0 Inspection & defects:

12.1 Know how to test the sintered products.

12.2 Study in detail about the defects that can be formed in carbon ceramics.

12.3 Know the process of rejecting the defect product.

12.4 Understand the processes of packing and dispatch.

113

13.0 Environmental awareness in graphite industry:

13.1 Know the types of pollutants caused by graphite and carbon industries.

13.2 Study the role of graphite and carbon in polluting the environment.

13.3 Know the effects on workers working in the industrial environment.

13.4 Know the precautionary measures to be taken to protect environment.

13.5 Know the recycling of rejected wares.

13.6 Understand the harm caused by rejected ware to the open environment.

References:

1.0 Graphite and carbon nanotube reinforced materials by University of Stamford

2.0 Physical properties of ceramics & carbon nanoscale structures. (Collection)

3.0 Advanced ceramics by Mc Grew

WEIGHTAGE TABLE

Sl.


Marks to be



2. II

History and introduction to

carbon ceramics, Graphite

electrodes, crucibles, blocks,

carbon fibers , carbon moulds

15 45

114

Natural & artificial diamonds,

plant operation in carbon

ceramics

15

Grinding and mixing 15

3. III

Preparation of batch and binders 15

45

Prefiring of carbon and graphite

batch compositions, Extrusion

process

15

Drying and end cutting 15

4. IV

Kiln system, fuels for graphite

industry 15

45 Inspection and defects 15


graphite industry 15

TOTAL 145


SIXTH SEMESTER

Subject: Graphite & Carbon Ceramics INSTRUCTIONS:


Section-I


I. The crystallographic structure of diamond is_________ (ans : Isometric)

115

II the Chemical formulae of carbon is ____________ (ans: “C”)

III) The abbreviation P.V.A stands for ____________ (ans: polyvinyl alcohol)

IV) The melting temperature of carbon is _______________ (ans: 36000c )

V).The chemical formulae of coal is____________________ (ans: “C”)

b. Write a short note on sigma mixers. 5

Section-II

2. a. Define carbon fiber. 2

b Write a brief history of carbon ceramics. 5

c. With a neat flow chart explain the manufacturing of graphite electrodes. 8

3. a. Define artificial diamonds & name its types. 5

b. Mention the properties and uses of carbon crucibles. 6

c. Draw a neat flow chart for manufacturing artificial diamonds. 4

4 a Define mixers 2

b. Explain the principles of dry mixing . 7

c. Explain uniaxial and horizontal mixers. 6

Section-III

5. a. What are binders? Give examples . 4

b. Why prefiring of carbon is necessary? Explain. 5

c. Explain the structure of graphite formation. 6

6. a. Define extrusion. 3

b. State the importance of lubricators in extrusion process. 5

c. Explain the causes and remedies for defects occurring during extrusion. 5

7. a. Write the composition for making artificial diamonds. 4

b. Explain the process of drying the graphite electrodes in humidity driers . 6

116

c. What are end cutting machines? How are they used? 5

Section-IV

8 a. Define fuels . 2

B.What is reducing atmosphere? How it is maintained in kiln during firing? 7

c. Classify the fuels with examples. 6

9. a Name the types of kilns used In graphite industry . 3

b. Mention the tests conducted for sintered graphite products and explain any two. 6

c. Explain the defects in graphite products with remedies. 6

10. a. Define pollutants? List some of them produced in graphite industry. 5

b. Explain the precautionary measures to safe guard workers working in graphite industry .

5

c. State the effects of pollutants from graphite industry to the public and environment. 5

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


Sixth Semester

Subject: Raw materials testing lab.

Contact Hrs/ Week: 6 hrs. Contact Hrs/ Semester: 96hrs.

Details of contents

10.0 To make a study of influence of non-plastic material on Plasticity of clays. 12hrs 1.1 By varying the Particle size. 1.2 By varying the percentage of materials addition.

2.0 To study the drying and firing shrinkage behavior of plastic clays by the addition of non-plastic

materials. 12hrs

3.0 To study the influence of Particle size on the strength of the body mass. 09hrs

4.0 To study the role of pH value, on the viscosity of the slip by varying the pH value and study its flow characteristics. 09hrs

117

5.0 To study the L.O.I in the materials such as Mg Co3, CaCo3, Feldspar at 1000ºC and 1200º C.

09hrs

6.0 To study the green strength, green density of the plugged mass with respect to fitter press mass.

09hrs

7.0 To study impact of fluxes in body composition by 12hrs

7.1 Varying the flux content keeping others constant.

7.2 Studying the Porosity and bulk density of the mass. 7.3 7.1 & 7.2 at different temperatures 1000º C, 1100º C, 1150º C and 1200ºC.

8. 0Make a study in Refractory. Verifiable and fusible clays with respect to its classifications. 12hrs

9.0 Study the effect of heat on clay . 06hrs

10.0 study the measurement of plasticity by extrusion. 06hrs

Equipment list for a batch of 20 students

Sl no Name of the equipment Quantity (nos)

01 Drying oven 02

02 Electronic balance 01

03 Electro therm furnace 01

04 Digital pH meter 01

05 Pug mill 01

06 Frit furnace 01

07 Beakers 500 ml 20

08 Basins 10

118

09 Plastic buckets 10 ltrs 10

Diploma Course in Ceramics Technology Sixth Semester

Subject: Product testing lab

Contact Hrs/ Week: 6hrs. Contact Hrs/ Semester: 96hrs.

DETAILS OF CONTENTS

1. Determination of bulk density of fired and un fired sample 6hrs.

2. Determination of porosity and water absorption of fired samples 6 hrs.

3. Determination of soundness of given product 9hrs

4. Determination of compressive strength and tensile strength of given product 9hrs

5. Determination of hardness of fired product 9hrs

6. Determination of modulus of rupture of fired samples of fired product 9 hrs

7. Determination of thermal shock resistance of fired insulator &any product 9hrs

8. Determination of crazing resistance of fired glazed tiles 9hrs

9. Determination of thermal conductivity of fired refractory blocks 9hrs

10. Determination of Phases by optical microscope of fired stoneware, earthenware, porcelain

insulator and glass products 9hrs

11. Determination of thermal expansion of fired products 6hrs

119

Equipment list for a batch of 20 students

Sl no Name of the equipment Quantity (nos)

01 Water bath 02

02 CCS machine 01

03 M.O.R Machine 01

04 Tensile Strength Machine 01

05 Muffle furnace 01

06 Optical microscope 01

120


Sixth Semester

Subject: PROJECT WORK No of Hrs/ Week: 06hrs. Total no. of Hrs: 96 Hrs.

As student has to be trained in manufacture of any one ceramics product, by involving

themselves practically such that they come across with all aspects both commercially; technically and

interact with teacher and manufactures in solving all problems to produce the selected product

Students involvement will be to the manufacture of the product, student shall be trained to prepare a

project report and a project model which should impress the prospective finance institutions such as

commercial banks/Industrial banks, KSFC etc..

Deputing the student to the industry & manufacturing the product shall be considered for a

short span without hampering other classes.

The project work should cover the following topics

01. Refractories.

02. Glass.

03. Cement.

04. Bio and Dental ceramics.

05. Vitrified and glazed tiles.

06. White wares and heavy clay wares.

07. Fabrication of ceramic equipments.

08. Advanced ceramics.

121

Note:

1Any one of the project areas mentioned above to be identified and select by each batch of

the students. ( Each batch 2 to 6 students).

3. A student has to be trained in manufacture of any one ceramic product by involving

themselves practically such that they come across with all aspects both commercially,

technically and interact with lecture and manufacturer in solving all the problems to

produce the selected project.

4. Study project work carries in various ceramic research institute and related ceramic

industries.

5. Deputing the students to the industry, up to 15-30 days. Manufacturing the product shall be

considered for a short span without hampering the other classes.

6. She/he should prepare the project report along with the project report model and submit to

the project guide.

7. A performance report from the project guide to be obtained for evaluation purpose.

FIFTH & SIXTH SEMESTER (Final end examination will be in Sixth Semester) SUBJECT: PROJECT WORK AND INDUSTRIAL VISIT

Contact Hrs/Week: 3 Hrs. Contact Hrs: 48 Hrs + 48 Hrs

As far as possible students should be given application oriented project problems with a view to:

1. Develop an understanding regarding the size and scale of operations and nature of field work in which students are going to play their role after completing the course of study in Mechanical Engineering.

2. Develop an understanding of subject based knowledge given in the classroom in the context of its application at work places.

3. Provide first hand experience to develop confidence amongst the students to enable them to use and apply acquired technical knowledge and skills to solve practical problems of the world of work.

4. Develop special skills and abilities like interpersonal skills, communication skills, attitudes and values.

5. Practical exposure to an industrial activity

For the fulfillment of above competencies, polytechnics may establish close linkage with

8-10 relevant organizations for providing such an experience. It is necessary that each organization is

visited well in advance by respective teachers and activities to be performed by students are well

defined. The chosen activities should be such which are of curricular interest to students and of

professional value to industrial/field organizations.

122

Each Project batch must have Minimum of 5 students.

Effort should be made to identify actual field problems to be given as project work to the

students. Project selected should not be too complex which is beyond the comprehension level of the

students. The placement of the students for such a practical cum project work should match with the

competency profile and interest of students.

Students may be assessed both by industry and polytechnic faculty.

The suggested performance criteria are given below:

a) Punctuality and regularity (Log book - mandatory and to be produced during IA verification)

b) Initiative in learning/Demonstration and fabrication of model

c) Level/proficiency of practical skills acquired

d) Originality

e) Scope for patentability

f) Sense of responsibility

g) Self expression/Communication skills

h) Interpersonal skills.

g) Report writing skills

h) Viva voce

Some of suggested projects are given below: These are only guidelines, teacher may take any project

related to Mechanical and allied area depending upon the availability of projects. Preference should be

given to practical oriented projects.

1) Industrial Visit

123

Students are required to undergo an industrial visit for period of at least 3(Three) working days, either in

V/VI semester. After completion of their visit the reports should be prepared. Each Student should write

the report independently in view of his own observation in industry. All days for the visit should be

accounted for clearly giving attendance particulars. The concern accompanying staff is to check student

presence and access progress periodically

1.1 Industrial report

Students are required to submit a comprehensive report on factory visit with details of the organization

where the training was undergone. The comprehensive report should focus on study of plant/ product

/process/ along with intensive in-depth study on anyone of the topics such as processes, methods,

tooling, plant layout and equipment, highlighting aspects of quality, productivity of the system. Any

data, drawings etc should be incorporated with the consent of the Organization. The comprehensive

report should be submitted for the end exam for evaluation.

The Project Report should consist of following items.

1. Introduction 2. Review of Literature 3. Study Area 4. Methodology/Design/fabrication/Tests 5. Result and Discussion 6. Conclusion and scope for future study 7. References.

_________________________________________________________

GUIDELINES FOR THE PREPARATION OF PROJECT REPORTS

1. Project reports should be typed neatly in Times New Roman letters with font size 14 for titles and 12

for text on both sides of the paper with 1.5 line spacing on a A4 size paper (210 x 297 mm). The

margins should be: Left - 1.5", Right - 1", Top and Bottom - 0.75".

2. The total number of reports (Soft bound) to be prepared are

One copy to the department /library

One copy to the concerned guide(s)

One copy to the candidate.

3. Before taking the final printout, the approval of the concerned guide(s) is mandatory and suggested

corrections, if any, must be incorporated.

4. Every copy of the report must contain

124

Inner title page (White)

Outer title page with a plastic cover

Candidate declaration and Certificate in the format enclosed both from the institution and the

organization where the project is carried out.

An abstract (synopsis) not exceeding 100 words, indicating salient features of the work.

5. The organization of the report should be as follows

1. Inner title page

2. Abstract or Synopsis

3. Acknowledgments

4. Table of Contents

5. List of table & figures (optional)

Usually numbered in

roman

Chapters (to be numbered in Arabic) containing Introduction-, which usually specifies the scope

of work and its importance and relation to previous work and the present developments, Main body of

the report divided appropriately into chapters, sections and subsections.

The chapters, sections and subsections may be numbered in the decimal form for e.g. Chapter 2,

sections as 2.1, 2.2 etc., and subsections as 2.2.3, 2.5.1 etc.

The chapter must be left or right justified (font size 16). Followed by the title of chapter

centered (font size 18), section/subsection numbers along with their headings must be left justified

with section number and its heading in font size 16 and subsection and its heading in font size 14. The

body or the text of the report should have font size 12.

The figures and tables must be numbered chapter wise

The last chapter should contain the summary of the work carried, contributions if any, their

utility along with the scope for further work.

Reference or Bibliography: The references should be numbered serially in the order of their

occurrence in the text and their numbers should be indicated within square brackets for e.g. [3]. The

section on references should list them in serial order in the following format.

1. For textbooks – Dr.Paramar S, Welding process and technology, Khanna publishers, New

Delhi, 2 Edition, 2003.

2. For papers – Y.Javadi and I.sattari, Welding distortion in pipes, Journal of pressure vessels

and piping, Vol 85, Aug 2008, pp 337-343

Only SI units are to be used in the report. Important equations must be numbered in decimal form for

e.g.

V = IZ .......... (3.2)

All equation numbers should be right justified.

Separator sheets, used if any, between chapters, should be of thin paper

PROJECT EVALUATION:

1. Relevance of the subject in the present context 10 mark

2. Literature Review 10 mark

125

3. Fabrication of the model/Data collection/repair and

Overhauling work 40 mark

4. Results & Discussion 10 mark

5. Industrial visit report 10 mark

6. Presentation 20 mark

TOTAL 100 mark

SESIONAL MARKS EVALUATION:

1. First review (During the end of V th semester) 25 mark

2. Second review (During the end of VI th semester) 25 mark

TOTAL:50 mark

I A Marks:

Scheme of Evaluation

1 Log record 05

2 Synopsis 10

3 Presentation 10

Total 25

NOTE: 1.Sesional marks to be awarded at the end of EACH SEMESTER ONLY

2.The candidate declaration and certificate sample copy are enclosed here for incorporation in final project

report

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

CANDIDATE’S DECLARATION

126

I, ------------------------------------------ a student of Diploma in ------------------------------ Department

bearing Reg No---------------------------------------of ---------------------------------------------- hereby declare

that I own full responsibility for the information, results and conclusions provided in this project work

titled “----------------------------------------------------------------------------------- “submitted to State Board of

Technical Examinations, Government of Karnataka for the award of Diploma in -------------------------

----------.

To the best of my knowledge, this project work has not been submitted in part or full elsewhere in any

other institution/organization for the award of any certificate/diploma/degree. I have completely taken

care in acknowledging the contribution of others in this academic work. I further declare that in case of

any violation of intellectual property rights and particulars declared, found at any stage, I, as the candidate

will be solely responsible for the same.

Date:

Place: Signature of candidate

Name: --------------------

Reg No-------------------

DEPARTMENT OF TECHNICAL EDUCATION

NAME OF THE INSTITUTION

Address with pin code

127

Department of ……………………………………………………..

CERTIFICATE Certified that this project report entitled --------------------------------------------------------------------

----------------------------------------------------------------------------------------”which is being submitted by Mr./Ms.

………………………….……………….., Reg. No…..……………, a bonafide student of …………………………………….in

partial fulfillment for the award of Diploma in -----------------Engineering during the year ……………………...

is record of students own work carried out under my/our guidance. It is certified that all

corrections/suggestions indicated for internal Assessment have been incorporated in the Report and

one copy of it being deposited in the polytechnic library.

The project report has been approved as it satisfies the academic requirements in respect of Project

work prescribed for the said diploma.

It is further understood that by this certificate the undersigned do not endorse or approve any statement

made, opinion expressed or conclusion drawn there in but approve the project only for the purpose for

which it is submitted.

Guide(s)

Name and signature

Examiners

1

2

Head of Department

Dept. of --------------------

ROADMAP FOR PROJECT GUIDES

128

1. The project work is proposed to be carried out during the V and VI semesters so that

learners prepare during the V semester, do some field work based on the preparation

during the mid semester vacation and report the analysis and inferences during the VI

semester.

2. The learners would reach a level of maturity by the time they reach V semester and so a

meaningful project lasting for a year can be executed by them.

3. To execute the project with involvement needs constant guidance and monitoring of the

progress of the learners by the guide.

4. This does not mean teacher has to advice learners.

5. Be confident about the ability of the learner and “intellectually provoke” them with

challenging questions. These questions should prompt the learners to search information

and update themselves (to be carried out during the first two weeks).

6. Do not feed information to learners. Instead crate a „cognitive dissonance‟ (a challenging

question or situation that the learner is not able to find an immediate answer but feels the

need to search for information to find a solution).

7. Defer judgement on learners and give them identified sources if required like a journal

article, book or a web site.

8. Even if the learners report their inability to solve do NOT give or prescribe a solution.

9. Be patient and give time for the learner to construct his knowledge.

10. Give corrective feedback to the learner by challenging his solutions so that his logic is

questioned and it develops further.

11. This leads to the first activity viz., literature survey and conceiving a project.

12. During this phase meet the project team in a group and create a healthy competition

among the learners to search different sources and synthesise their findings in the group.

13. Aim for bringing out a workable innovative project conceived within the first eight weeks

as given in the schedule attached.

14. During these two phases and the third phase the teacher should assess the strengths and

weakness of the members of the group and allocate differential work to team members on

the remaining tasks to be carried out during the next thirty weeks.

15. This is to ensure active participation of all the members of the team.

16. By the end of the twelfth week finalise the project and a schedule of further activities for

each member indicating the time frame in which his activities are to be executed may be

made ready. A soft copy of this schedule may be collected from each learner by the

guide to follow up.

129

17. This schedule prepared by each learner need to be documented for checking further

progress of the project.

18. The next few phases of the project may require active guidance of the guide especially

regarding the sources of collecting data, if a sample data is to be collected the number of

units has to be decided, collating the data/fabricating, tryout/analysis and finally coming

out with meaningful conclusions or models or application.

19. Data like models, designs, technical specifications, source code, protocols and original

records need be collected from one authentic source as there will not be any variation.

The teacher may guide the learners to authentic source.

20. Data having limited variability like product/service quality, processes and standards,

procedures need to be collected from a sample as there is a variation. The number of

units from whom (source) the data is to be collected is called sample. The sample needs

to be representative of the expected variation. The decision on the size of the sample and

the number of units need guidance from the teacher. For example, data regarding the

quality of a product/service need be collected from 3 to 5 personnel at different levels of

a service provider or dealers of a product. The numbers given are suggestive but a guide

based on his experience has to make valid suggestions.

21. Data having a wide range of variation like customer satisfaction where the customers are

members of the public need a larger number of units to accommodate the diversity. A

tool like questionnaire with predetermined questions need to be prepared, tried out on a

small sample and finalise the questions. Data may be collected from at least 30 units.

This number is suggested to apply statistical analysis for meaningful conclusions.

Guides may decide on the sample size depending on the accessibility of data.

22. The intention of the above three points viz., 19, 20 and 21 is to ensure objectivity in data

collection i.e., to reduce the subjectivity of the human mind.

23. All the above activities need to be completed before three to four weeks before the end of

V semester (refer the spread sheet related to scheduling).

24. The learners may be instructed to collect data objectively with identified sample during

the next 4 to six weeks which includes the mid semester holidays. This would enable the

learners to visit the field and collect data without the constraint of reporting to institution

and attending classes on a regular basis.

25. The collected data need to be organised and entered to spread sheets or similar formats

for analysis. Qualitative data may be converted to quantitative using a rating scale or

similar data organisation procedures.

26. The result of most analysis on spreadsheet could be obtained in tables or graphs as per the

requirement.

27. Activities mentioned in points 24, 25 and 26 may be carried out by learners during 4 to 8

weeks after commencement of VI semester.

130

28. Interpretation of the analysed tables and graphs to arrive at meaningful inference. The

guide at this stage may defer his ideas on interpretation allowing the learners to do this.

In case the learners err in the process they may be given corrective feedback.

29. A report of the whole process of doing the project may be written, word processed and

submitted in triplicate.

30. Guides may contact industries and try to solve their problems so that the learners get a

field experience and they get ready for the industry.

31. Innovations and innovative practices may be encouraged among the learners to be

pursued as a project. Developing prototypes, (in simulation or real) trying out feasibility

of new ideas, changing existing systems by adding modules, combining, assembling new

modules and developing new systems may be given higher priority over routine bookish

projects.

32. The schedule of events proposed is for an investigative project as a model. Guides may

alter the prescribed schedule to suit the kind of innovative projects sited in point No.31

above.

33. Industry personnel may be involved in conceiving, executing and evaluating projects.

This gives credibility to the institute and acceptance of learners for absorption into the

company.

GUIDELINES TO LEARNERS TO CARRY OUT A TWO SEMESTER PROJECT

1. Carry out the project work through the V and VI semesters. Preparation must be done

during the V semester and based on this, field work should be done during the mid

semester vacation and reporting of analysis and inferences should be done in the VI

semester.

2. You have the ability and the level of maturity needed to conceive an innovative and

meaningful project accomplishing which gives you recognition by the industry and

empowers you with the power of knowledge.

3. Understand your strength and weakness and make an effort to find the strength and

weakness of other peers in the team.

4. Complement each other‟s strength rather than compete with peers within the team. This

will enable you to complete a comprehensive and innovative project relevant to the

industrial needs rather than doing a routine copy of what others have done.

5. Seek guidance from the teacher and update him/her about the progress.

131

6. Be confident about your ability and that of other members of your group. Take extra

efforts to collect information, share with your peers and synthesise your knowledge.

7. Question everything including the ideas of your teacher. Accept the ideas and

instructions which are internally consistent (logical).

8. Involve actively in group activities and contribute towards the tasks.

9. Do not depend too much on the teacher as a source of information, search on your own

and build your knowledge structure. Search for authentic sources like journal articles,

books and authentic sites rather than blogs and tweets.

10. Though brief, record your thoughts and activities including searches immediately.

11. Prepare a schedule for your work on a spread sheet and encourage your peers to do the

same.

12. Show your schedule and that of others to the teacher and get his feedback.

13. Keep reviewing the schedule every fortnight and take corrective steps if needed. For

doing this keep the general guideline schedule given in the curriculum as a backdrop.

14. Tools used for data collection like instruments, testing machines, questions to be asked

and software may be tried out and standardised by the twelfth week of the project. Seek

the teacher‟s help who is experienced in doing this.

15. Collect data dispassionately or objectively (without applying your personal prejudice).

Complete this task before the VI semester begins.

16. While entering data into the spread sheet ask your peer member to verify. This will

ensure accuracy of data entry.

17. Use appropriate mathematics/statistics for calculations. Seek help from external sources

(other than your teacher) if required.

18. The results of your analysis need to be graphically represented and documented. You

may also add photographs and video clips to increase the validity.

19. This task needs to be completed within 8 weeks after commencement of VI semester.

20. Interpret the data (after analysis) and arrive at meaningful inferences on your own in

discussion with your peers. Get it ratified by your teacher. Suggestions from the teacher

may be discussed among your peers and incorporated if they are internally consistent.

21. The project report may be word processed (videos, photographs attached in soft copy)

and submitted in triplicate two weeks before the end of VI semester.

22. Involve passionately in the team work, make constructive contributions and come out

with an industry friendly project which will equip you in your professional development.

132

PROPOSED EQUIPMENTS LIST 2011-2012

Sl no Name of the equipment Quantity(nos) 01 C.C.S Machine 01 02 Tensile strength machine 01

03 Ball mill 01 04 High temperature electric furnace 01

05 Pyconometer(Sp.gr bottle) 20

06 Le- chatlier apparatus 10

133

07 Auto clave apparatus 02 08 Vicat apparatus 10 09 Standard sieve set 05

10 Digital pH meter 01 11 Blains air permeability apparatus 01

12 Extruding machine 01 13 Wire cut machine 01

14 Extruding die set, die tools(Round pipe ,square &rectangle) 01 15 Granulator machine 01

16 Fly press 01 17 Potter’s wheel machine operated 01 18 Metal model 10

19 Metal sheet 2ftx4ft 10 20 Magnetic separator 01

21 Blunger 01 22 Steel basin 12 inch diameter 20

23 Drying oven 01 24 Electronic balance 01

25 Viscosity apparatus 05 26 Standard sieve of 400 mesh 05 27 Beakers (100ml) 10

28 Porcelain crucibles 4inch diameter 20 29 Burettes 10

30 Platinum crucibles 02 31 Fused silica crucibles 05

32 Pug mill 01 33 Frit furnace 01

34 Beakers(500ml) 10 35 Plastic buckets (10 ltrs) 10 36 Water bath 02

37 M.O.R machine 01 38 Muffle furnace 01

39 Optical microscope 01

TASKS RESOURCE NEEDED

I

FORT

NIGH

T

II

FORT

NIGH

T

III

FORT

NIGH

T

IV

FORT

NIGH

T

V

FORT

NIGH

T

VI

FORT

NIGH

T

VII

FORT

NIGH

T

VIII

FORT

NIGH

T

VACA

TION

IX

FORT

NIGH

T

X

FORT

NIGH

T

XI

FORT

NIGH

T

XII

FORT

NIGH

T

XIII

FORT

NIGH

T

XIV

FORT

NIGH

T

XV

FORT

NIGH

T

XVI

FORT

NIGH

T

Literature survey for project

Internet / library /

industry / Research

Centres

Finalisation of the Area in which

the project has to be done (

Example : Design / Manufacturing

/ Thermal Engineering )Internet / library /

industry

Finding out Facility to do the

project

Laboratory /

Industry/ Project

Sites

Collecting Data / Doing

experiments / writing of code

Laboratory /

Industry/ Project

Sites

Analysis of Data Using relevent

software

Results and Fine tuning the

experiment using the Data

Analysis

Laboratory /

Industry/ Project

Sites

Report writing

Submission of Project Report and

Viva voce

PROJECT WORK - SCHEDULING

GOVT. OF KARNATAKA

DEPARTMENT OF TECHNICAL EDUCATION

Subject Title : Basic Management Skills &

Indian constitution

Q P Code :

Hours Per Week : 04

Hours Per Semester : 64

BASIC MANAGEMENT SKILLS & INDIAN CONSTITUTION

TOPIC ANALYSIS

SL.No Major Topics Hours

Allotted

Weightage of

Marks

SECTION-I

1 Management Skills 09 15

2 Operations Management 12 35

SECTION-II

3 Total Preventive Maintenance 04 10

4 Total Quality Management 06 20 5 Safety and Environmental issues 06 20

SECTTION-III

6 Indian Constitution 08 20 7 Parliamentary System and procedures 05 10 8 Empowerment of Women 08 15 9 Environmental Awareness and Industry

Innovations

03 -

Tests 03 -

Total 64 145

CONTENTS

1. MANAGEMENT SKILLS

1.1 INTERPERSONAL SKILLS.

1.11 Know Thyself/ self –Discovery.

1.12 Know others and understand the perspective of others.

1.13 Intergroup communications.

1.14 Art Of Communications

1.2 TEAM BUILDING and TEAMWORK SKILLS.

1.21 Aspects of team building.

1.22 Team v/s Group.

1.23 Inter group collaboration.

2. OPERATIONS MANAGEMENT

2.1 Production & Productivity

2.1.1 Stages involved in Product Design

2.1.2 Factors considered while designing a Product

2.1.3 Types of Production

2.1.4 Factors to improve Productivity

2.2 Production, Planning & Control

2.3 Make or Buy Decision

2.3.1 Criteria considered for make or buy decision

2.3.2 Analysis for make or buy decision

2.4 Purchasing

2.4.1 Methods of Purchasing Material or Component

2.4.2 Steps involved in purchasing of material or component

2.5 Stores Management

2.5.1 Methods of Storing

2.5.2 Tools required for Stores Management

2.5.3 Codification System

2.6 Logistics Management

2.6.1 Different means of Transportation

2.6.2 Routing & Delays, Tracing, Packaging & Material Handling,

Damage Claims, Demurrage Charges and Insurance Buying

2.7 Inventory & Inventory Control

2.7.1 Functions of Inventory Control

2.7.2 Inventory Control Techniques

2.7.3 Inventory Management Software

2.8 Introduction to MRP and ERP

3.TOTAL PREVENTIVE MAINTENANCE

3.1 Maintenance and concept of TPM

3.2 Economics involved in preventive maintenance

3.3 Techniques of TPM

3.4 Benefits of TPM

3.5 Planned Maintenance and Predictive Maintenance

4. TOTAL QUALITY MANAGEMENT

4.1 Quality and Inspection

4.1.1 Factors affecting Quality

4.1.2 Relation between Quality & Cost

4.1.3 Quality Control

4.2 Concept of TQM

4.2.1 Tools and Techniques of TQM

4.3 Quality Management System

4.3.1 I.S.O 9000:2000 Quality Standards

4.3.2 Procedures and Documentation of ISO 9000 certification

5. SAFETY AND ENVIRONMENTAL ISSUES

5.1 Accident and Safety

5.2 Accident Prevention, Accident Reporting and Crisis Management

5.3 Safety provisions under Indian Factories Act

5.4 Safety Management System-OSHAS 18001

5.5 Environmental issues addressed by organization

6. INDIAN CONSTITUTION

6.1 Indian Constitution-Formation of Constituent Assembly-Framing of the

Constitution-Drafting Committee-Contributions of Dr. B R Ambedkar,

Chairman of Drafting Committee and the members in drafting a

constitution for India.

6.2 Preamble-objectives-Directive principles

6.3 Features of Constitution

6.4 Fundamental Rights

6.5 Fundamental duties

6.6 Amendments for Indian Constitution

6.7 Human Rights

7. PARLIAMENTARY SYSTEMS AND PROCEDURES.

7.1 Government-Meaning-organs-functions.

7.2 Parliament-meaning-Two houses-Lok Sabha-Composition-election-

Presiding officer-term-RajyaSabha- Composition-election-Presiding

officer-term

7.3 Powers of parliament

7.4 Executive Role - President-Vice President-Prime Minister-Council of

Ministers

7.5 Indian Judiciary system-Supreme Court-High Court-subordinate courts

7.6 Constitutional bodies-Election Commission-Public Service Commission-

Finance Commission

7.7 Structure of State government- State Legislature-Governor-Chief

Minister-Council of Ministers

7.8 Local self government-meaning-Three tier system-Village panchayath-

taluk panchayath-Zilla panchayath

7.9 Local bodies-Municipalities and Corporations

8.0 EMPOWERMENT OF WOMEN.

8.1 Concept, Definition and need for Women's Empowerment

8.2 Strategies, approaches, process, levels, principles and indicators for

women’s empowerment.

8.3 Gender statistics in India – Glaring inequalities

8.4 Women and Development:

8.4.1 Goals and Objectives of National Policy for Women's

Empowerment

8.4.2 Advancement of Women through Five-Year Plans

8.4.3 Special Programs for Women's Development.

8.5 Constitutional Provisions towards Women's Rights and Special

Legislations for Women.

8.6 Case Studies.

SPECIFIC INSTRUCTIONAL OBJECTIVES

1. MANAGEMENT SKILLS

1.1 INTERPERSONAL SKILLS.

1.11.1 Importance of knowing yourself-Process of knowing yourself.

1.11.2 SWOT analysis-Benefits of SWOT analysis

1.11.3 SWOT analysis grid and questions to complete the grid.

1.12.1 Importance of knowing others-Process of knowing others.

1.13.1 Resolving Win/Lose Situations into win/win through inter group

communications.

1.14.1 Defining communication- Special features of communication.

1.14.2 Communication process- Channels of communication.

1.14.3 Formal and informal communication network.

1.14.4 Barriers to communication- Tips of effective communication.

1.14.5 Tips of powerful presentation- Art of public speaking- Importance of

public speaking- Benefits of public speaking- Public speaking tips.

1.2 TEAM WORK AND TEAMWORK

1.21.1 Meaning and aspects of team building- Skills needed for teamwork-

A model of team building.

1.22.1 Team v/s Group- Characteristics of a effective team- Role of a team

leader- Role of a team members- A successful team of nine persons.

1.23.1 Inter group collaboration- Advantages of inter group collaboration.

1.23.2 Difficulties faced in inter-group collaboration.

1.23.3 Factors shaping inter group collaboration.

2. OPERATIONS MANAGEMENT

2.1 Define Production & Productivity

2.1.1 Explain various stages involved in product design

2.1.2 List factors considered while designing a product

2.1.3 Explain Job, Batch & Mass production with their advantages and

disadvantages

2.1.4 List factors to improve/increase productivity

2.2 State the functions of PPC- planning, routing, scheduling, dispatching and

inspection

2.3 State the importance of make or buy decision

2.3.1 List the criteria considered for make or buy decision

2.3.2 Briefly explain methods of analysis for make or buy decision-

Simple cost analysis, Break even analysis & Economic analysis

2.4 Define purchasing

2.4.1 Explain briefly different methods of purchasing the material or

component.

2.4.2 Explain the steps involved in purchasing of Material or Component

2.5 Explain Stores Management

2.5.1 Explain different methods of storing

2.5.2 Explain briefly Bin Card, Material Issue Requisition, Material

Returned Note and Store Ledger

2.5.3 Explain advantages and systems of Codification

2.6 Explain Logistics Management

2.6.1 Explain different means of transportation

2.6.2 Explain Routing & Delays, Tracing, Packaging & Material

Handling, Damage Claims, Demurrage Charges and Insurance

Buying

2.7 Define Inventory and Inventory Control

2.7.1 List important functions of Inventory Control

2.7.2 Explain briefly Inventory Control Techniques – ABC, VED, SDE,

MNG Analysis

2.7.3 List few Inventory Management Softwares

2.8 Describe about MRP & ERP. List the software’s used

3. TOTAL PREVENTIVE MAINTENANCE

3.1 Explain Maintenance and explain the concept of TPM

3.2 Explain the economics involved in preventive maintenance

3.3 Describe the techniques of TPM

3.4 List the benefits of TPM

3.5 Explain planned maintenance and predictive maintenance

4. TOTAL QUALITY MANAGEMENT

4.1 Define Quality, Inspection & explain its importance

4.1.1 List factors affecting quality

4.1.2 Explain the relation between cost & quality

4.1.3 Define and Explain quality control

4.2 Explain concept of TQM

4.2.1 Explain briefly tools & techniques of TQM – Flow charts, Control

charts, Histograms, Pareto charts, Check sheets, Scatter diagram,

Cause and effect diagram, 5-S, Poka-yoke, Kaizen, Re-engineering

and Six-sigma

4.3 Define QMS

4.3.1 Explain briefly I.S.O 9000:2000 Quality Standards – ISO 9000, ISO

9001 & ISO 9004

4.3.2 Explain procedures and documentation involved in ISO 9000 series

certification

5. SAFETY AND ENVIRONMENTAL ISSUES

5.1 Define accident and safety

5.2 Explain accident prevention, accident reporting and crisis management

5.3 List the safety provisions under Indian Factories Act

5.4 Explain Safety Management System-OSHAS 18001

5.5 Give a brief summary of ISO 14000 series and IS16949 & IS16959

certifications

6. INDIAN COSTITUTION

6.1 Introduction to Indian Constitution

6.2 Discuss the Formation of Constituent Assembly

6.3 Discuss the Contributions of Dr. B R Ambedkar as a Chairman of Drafting

Committee and the members in drafting a constitution for India.

6.4 Discuss Preamble and its main objectives

6.5 State the Directive principles

6.6 Discuss the Features of Constitution

6.7 Mention the number of parts, articles, schedules and discuss the article -1

6.8 Discuss Fundamental Rights

6.9 Discuss Fundamental duties

6.10 Explain the Amendment and its procedure

6.11 Discuss Human Rights and its significance

7. PARLIAMENTARY SYSTEM

7.1 Discuss the Parliamentary system of Government.

7.2 Discuss the about:

7.2.1 Loka Sabha: Composition, election, Presiding officer and term

7.2.2 RajyaSabha: Composition, election, Presiding officer and term

7.3 Powers of parliament

7.3.1How law is made, three readings

7.3.2Diffrence between Bill and act

7.3.3Administrative control- Explain importance of questioning- concept

of Question hour- concept of zero hour

7.3.4 Briefly explain about Confidence motion and Censure motion

7.4 Explain the meaning of the budget

7.5 President-Vice President-Prime Minister-Council of Ministers their

appointments and functions

7.6 Discuss the formation and functions of supreme court-High court-

Subordinate court.

7.7 Discuss the importance of Constitutional bodies-Election Commission-

Public Service Commission-Finance Commission

7.8 Discuss the about state legislature:

7.8.1 Legislative assembly: Composition, election, Presiding officer and

term

7.8.2 Legislative council: Composition, election, Presiding officer and

term

7.9 Governor-Chief Minister-Council of Ministers their appointments and

functions

7.10 Local self government-meaning-Three tier system

7.11 Discuss the formation and functions of Village panchayath-taluk

panchayath-Zilla panchayath and urban local bodies such as

Municipalities and Corporations

8. Empowerment of Women

8.1 Explain the Concept and Definition of Women's Empowerment.

8.2 Discuss the different strategies, approaches, process, levels, principles and

indicators for women's empowerment.

8.3 Discuss the Gender statistics in India – Glaring inequalities.

8.4 Explain Women and Development

8.4.1 List the Goals and Objectives of National Policy-2001 for

Women's Empowerment.

8.4.2 Discuss the emphasis given on the Advancement of Women

through Five-Year Plans.

8.4.3 List the Various Special Programs for Women's

Development from government.

8.5 State Constitutional Provisions towards Women's Rights -Fundamental

Rights Article 14, 15, 15(3), 16-Directive of State Policy Article 39,42-

Fundamental Duties 51(A)(e) and Reservation of seats Article 243(D)(3),

Article 243(T)(3) - explain the following Special Legislation for Women-

Dowry Prohibition Act 1961, Domestic Violence Act 2005,Sexual

Harassment at Workplace Bill 2006, Equal Remuneration Act 1976,Hindu

succession Act,1956, Prenatal diagnostic techniques (regulation and

prevention of misuse) act,1994.

8.6 Case Studies.

Text Book : “Glimpses of our Constitution”-Ashan Academy, Published by:

Orient Blackswan Pvt. Ltd.

Reference Books:

1. Soft Skills- by Dr. K. Alex, S Chand & Company Ltd.

1 Total Quality Management- Prof. Dr. H D Ramachandra

2 Industrial Organization and Engineering Economics- T.R.Banga

& S C Sharma

2 Total Quality Management- S Raja Ram, M Shivashankar.

3 Industrial management and organizational behavior- K.K.Ahuja

4 Industrial management and engineering economics- O.P.khanna

5 Production and operations management-Dr .K.Aswathappa and

Dr.Sreedhar Bhatt- Himalaya publishers

6 Introduction to the Constitution of India- Dr. Durga Das Basu

7 The constitution of India - P.M.Bhakshi- Universal law

publishers

8 Our constitution-National Book Trust of India

9 Our Parliament-National Book Trust of India

10 Our Judiciary-National Book Trust of India

11 Empowerment of rural women in India-Hemalatha H.M and

Rameshwari Varma,Hema Prakashana.

12 The right to development-centre for development and human

rights-Sage Publications.

13 Industrial Engg. &Mgmt Science By- T R Banga & SC Sharma.


FIFTH SEMESTER

BASIC MANAGEMENT SKILLS & INDIAN CONSTITUTION

Time: 3Hrs Max marks: 100

Part-I is compulsory and Answer any two full questions from Part-II, Part-III, and

Part-IV

PART- I

1. A) Fill in the blanks with appropriate words:- 5X1=5

I) The Constitution of India came into effect on ______________.

ii) The term of the chairperson of Rajyasabha is_________ years

iii) ______________ is an unforeseen event

iv) The ISO ______________ is related with Environmental management systems

v) Increased ________ leads to the benefits for both employer and employee

B) State the qualities of a good leader 5

PART-II

2 a) Explain SWOT analysis-Mention benefits of SWOT analysis 5

b) Explain special features of communication. 5

c) Explain Formal and informal communication network. 5

3 a) Explain the motivating factors 5

b) State the qualities of a good leader 5

c) Explain the process of team building 5

4 a) State the characteristics of entrepreneur 5

b) Lists the steps involved for setting up small scale/Medium scale industries

c) Define outsourcing and mention its features 5

PART-III

5 a) State the functions of Production planning and Production control 5

b) Define inventory and inventory control 5

c) State the importance of material management 5

6 a) Explain the total productive maintenance . 5

b) List the various types of preventive measures to avoid an accident 5

c) List the factors affecting quality 5

7 a) Explain the concept of Total quality management 5

b) List the various types SQC tools 5

c) State the importance of material management 5

PART-IV

8 a) What is a constitution? 5

b) Why Dr. B R Ambedkar is known as architect of Indian Constitution? 5

c) What is sovereignty? 5

9 a) Why is there a need to Economic, social and political justice in India? 5

b) Explain three tier panchayath system 5

c) Mention the salient features of Indian constitution. 5

10 a) what are the approaches to empowerment of women? 5

b) List the goals and objectives of national policy for women's empowerment.5

c) Write a note on dowry prohibition act. 5

Question Bank on Indian Constitution

1. What is a government?

2. What is a constitution?

3. Why constitution is called the rule of the State?

4. Write the importance of the constitution.

5. To draft a constitution to India was the most challenging task. Why?

6. What are the contributions of Dr. B R Ambedkar in drafting a constitution for

India?

7. What is the importance of republic day?

8. What is the importance of preamble?

9. Why is preamble said to be the soul of the constitution?

10. What is sovereignty?

11. What is the objective of Socialism?

12. The principle of Secularism is suitable to India. How?

13. Why is India called republic?

14. Why is there a need to Economic, social and political justice in India?

15. Mention the aspects which strengthen the bond of fraternity in India?

16. In the present context unity and integrity are most essential in India. Why?

17. Though Directive principles are not enforceable by law they are important in the

constitution. How?

18. Mention the salient features of Indian constitution.

19. How is written constitution, advantageous than unwritten constitution?

20. Indian constitution is one of the lengthiest constitution. Mention the factors to

substantiate the statement.

21. State the notable features borrowed from the following constitutions: a) U. S. A.

b) England c) Ireland d) Canada.

22. Why is Indian constitution termed as flexible constitution?

23. What is universal Adult Franchise?

24. Write the advantages of single citizenship.

25. Why is Indian judiciary said to be an independent judiciary?

25. What is the importance of Fundamental rights?

27. How can it be said that Fundamental rights are not absolute?

28. Mention the Fundamental rights.

29. Give reasons as to why certain sections of the society are provided concessions

and privileges in spite of right to equality.

30. How does cultural and educational right protect the interests of the minorities?

31. Mention the right introduced in 2010 under right to equality what is the

importance of it?

32. Name the right that bans child labour and provides protection to women against

exploitation.

33. The right to Constitutional remedies is said to be the heart and soul of our

constitution. Why is it said so?

34. Rights and Duties are like the two sides of the same coin - Substantiate the

statement.

35. Mention a few fundamental duties that you have to follow as a citizen of this

country.

36. When and in which the fundamental duties part of the constitution was

incorporated?

37. Name the body that has powers to amend the provisions of the constitution in

India.

38. What is the procedure followed in parliament to amend the provisions of

Fundamental rights and Directive principles?

39. Write the procedures to be followed to amend the constitutional provisions.

diploma in ceramic technology second semester subject: … · 2020-05-21 · 5.0 structural geology...

Documents