draft curriculum & syllabus – 2008

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Curriculum and Scheme of Examination Diploma in Mechanical Engineering (COURSE No: 1020, 2020 & 3020)

K – Scheme (With effect from 2008-2009)

SYLLABUS COMMITTEE MEMBERS

Convener Mr. B.Nandagopal, Principal

Murugappa Polytechnic College, Avadi, Chennai. Members 1. Mr. V.Abraham Cheliappa Dass, HOD Central Polytechnic College, Tharamani, Chennai

2. Mr. S.K.Somasundaram, HOD Govt. Polytechnic College, Coimbatore

3. Mr. R.Manivannan, Sr.Lecturer

Alagappa Polytechnic College, Karaikudi

4. Mr.P.Sambandam, HOD Central Polytechnic College, Tharamani, Chennai

5. Mr.G.Velayudham, HOD

Tamilnadu Polytechnic College, Madurai

6. Mr. Davidson, Sr.Lecturer Govt. Polytechnic College, Nagercoil

7. Mr.Siva Manohara Verma, HOD I/c

Valivalam Desika Polytechnic College, Nagapattinam

8. Mr.K.Marimuthu, Sr.Lecturer Govt. Polytechnic College, Aranthagi

9. Mr.R.Sornakumar, HOD

Central Polytechnic College, Tharamani, Chennai

10. Mr.A.Srinivasan, HOD I/c Thiagaraja Polytechnic College, Salem

11. Mr.V.Narayanan, Technical Asst.(Mechanical)

DOTE, Chennai Industrialist Mr.A.N.Rajendran, Managing Director NUTech CNC Pvt.Ltd., Chennai Academician Dr.R.Kesavan, Prof. in Production Engg. MIT, Chennai Alumni Mr.A.Jayakumar, Vice Principal Muthiah Polytechnic College, Chidambaram.

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Diploma in Mechanical Engineering J - Scheme (with effect from 2008)

List of Equivalent Subjects of J-Scheme III SEMESTER

J - SCHEME K-SCHEME

Sl. No

Subject Code Name of Subject Subject

code Name of Subject

1. 2. 3. 4. 5.

6.

2031 2032 2033 2034 2035

2036

Mechanics of Materials Manufacturing Processes Fluid Mechanics & Fluid Power Machine Drawing Mechanics of Materials & Fluid Mechanics Lab Workshop – I (Smithy, Foundry & Welding)

12031 12032 12033 12034 12035

12036

Mechanics of Materials Manufacturing Processes Fluid Mechanics & Fluid Power Machine Drawing-CAD Mechanics of Materials & Fluid Mechanics Lab Workshop – I (Smithy, Foundry & Welding)

IV SEMESTER J - SCHEME K-SCHEME

Sl. No


Code Name of Subject

1. 2. 3. 4. 5.

6.

2041 2042 2043 2044 2045

2046

Applied Thermodynamics Machine Shop Technology Electrical & Electronics Engineering Thermodynamics Lab Electrical & Electronics Engineering Lab Workshop – II (Lathe & Metrology)

12041 12042 12043 12044 12045

12046

Applied Thermodynamics Machine Shop Technology Electrical & Electronics Engineering Thermodynamics Lab Electrical & Electronics Engineering Lab Workshop – II (Turning, Drilling and Shaping )

V SEMESTER

J - SCHEME K-SCHEME

Sl. No



1. 2. 3. 4. 5. 6.

2051 2052 2053 2054 2055 2056

Design of Machine Elements Thermal Engineering Elective Theory - I Auto CAD Lab Elective Practical - I Work Shop - III (Special Machines)

12051 12052

-- 12034 -- 12056

Design of Machine Elements Thermal Engineering Refer Table 1 Machine Drawing-CAD Refer Table 2 WorkShop-III(slotting, Planning, Milling, Grinding & CNC machine)

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TABLE 1:

Sl. No

Subjects Code Name of Subject Subjects


1. 2. 3. 4. 5.

6.

2053 2071 2072 2073 2074 2075

Elective Theory – I Foundry Technology Refrigeration & Air Conditioning Welding Technology Metrology & Machine Tool Testing Farm Equipment Technology

-- 12071 -- 12072 --

No Equivalent Refrigeration & Air Conditioning No Equivalent Metrology & Machine Tool Maintenance and Testing No Equivalent

TABLE 2:

Sl. No



1. 2. 3.

4. 5.

6.

2055 2076 2077 2078 2079 2080

Elective Practical – I Foundry Technology Practical Refrigeration & Air Conditioning Practical Welding Technology Practical Metrology & Machine Tool Testing Practical Farm Equipment Technology Practical

-- 12073 -- 12074 --

No Equivalent Refrigeration & Air Conditioning Lab No Equivalent Metrology & Machine Tool Maintenance and Testing Lab No Equivalent

VI SEMESTER J - SCHEME K-SCHEME

Sl. No



1. 2.

3. 4.

5. 6.

2061 2062

2063 2064

2065 2066

Industrial Engineering & Management CAD / CAM Elective Theory - II CAD / CAM Lab Elective Practical - II Project work, Entrepreneurship & Personal Skills

12061 12062 -- 12064 -- 12066

Industrial Engineering & Management Computer Aided Design and Manufacturing Refer Table 3 Computer Aided Design and Manufacturing Practical Refer Table 4 Project work, Entrepreneurship, Environmental & Disaster Management

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TABLE 3:

Sl. No



1. 2. 3. 4. 5. 6.

2063 2081 2082 2083 2084 2085

Elective Theory – II Automobile Technology Mechatronics Metallurgy Plastic Engineering Robotics

12081 12082 -- -- --

Automobile Technology Mechatronics No Equivalent No Equivalent No Equivalent

TABLE 4:

Sl. No



1. 2. 3. 4. 5. 6.

2065 2086 2087 2088 2089 2090

Elective Practical -II Automobile Technology Practical Mechatronics Practical Metallurgy Practical Plastic Engineering Practical Robotics Practical

12083 12084 -- -- --

Automobile Technology Lab Mechatronics Lab No Equivalent No Equivalent No Equivalent

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DIPLOMA COURSE IN MECHANICAL ENGINEERING (Implemented from 2007- 2008)

K - SCHEME

R E G U L A T I O N S

1. Description of the Course

a. Full Time (3 years)

The Course for the full Time Diploma in Engineering shall extend over a period of three academic years, consisting of 6 semesters and the First Year is common to all Engineering Branches. b. Sandwich (3½ years) The Course for the Diploma in Engineering shall extend over a period of three and half academic years, consisting of 7 semesters and the First Year is common to all Engineering Branches. The subjects of three years full time diploma course being regrouped for academic convenience. During 4th semester the students undergo industrial training for six months. Industrial training examination will be conducted after completion of 6 months of industrial training During 7th semester students undergo another spell of 6 months industrial training Industrial training examination will be conducted after completion of 6 months of industrial training c. Part Time (4 years) The course for the diploma in Engineering shall extend over a period of 4 academic years containing of eight semesters,the subjects of 3 year full time diploma courses being regrouped for academic convenience. Each Semester will have 16 weeks duration of study

The Curriculum for all the 6 Semesters of Diploma courses (Engineering & Special Diploma Courses) have been revised and revised curriculum is applicable for the candidates admitted from 2007 – 2008 academic year onwards.

The salient features of this revised curriculum under ‘K’ Scheme are:

Removal of obsolete portions Addition of topics covering of new technology, new industrial practices to cope up with the modern

trends in Engineering and Services. Inclusion of Professional Ethics Creation of consciousness about Environment Management Preparing the students to tackle emergency situations due to various disasters Adoption of Industrial Safety Practices Offering electives to suit the local needs of industries Laying more stress on Communication English Training in Soft Skills Enhancement of Computer Skills Enhanced Practical Skills to supplement the theory learnt Introduction of Continuous Internal Assessment Conduct of Periodical Tests and Assignments and uniformity in assigning sessional marks Listing of Equipment, Instruments/ manuals along with the Practical Experiments Revised Question Paper pattern to test the in-depth knowledge of students.

2. Eligibility for the Award of Diploma

No candidate shall be eligible for the Diploma unless he/she has undergone the prescribed course of study for a period of not less than 3 academic years in any institution affiliated to the State Board of Technical Education and Training, Tamilnadu, when joined in First Year and two years if joined under Lateral Entry scheme in the second year and passed the prescribed examination.

The minimum and maximum period for completion of Diploma courses are as given below Diploma Course Minimum Period Maximum Period

Full Time 3 Years 6 Years Full Time(Lateral Entry)

2 Years 5 Years

Sandwich 3½ Years 6½ Years Part Time 4 Years 7 Years

3. Subjects of study and curriculum outline

The subjects of study shall be in accordance with the syllabus prescribed from time to time, both in theory and practical. The curriculum outline for III, IV, V and VI Semester is given in Annexure -I

4. Examinations Board Examinations in all subjects of all the semesters under the scheme of examinations will be conducted at the end of each semester. The sessional marks for all the subjects will be awarded on the basis of continuous internal assessment earned during the semester concerned. For each subject 25 marks are allotted for sessional marks and 75 marks are allotted for Board Examination.

5. Continuous Internal Evaluation

For Theory Subjects: It has been decided to introduce Continuous Internal Assessment marks for a total of 25 marks, which are to be distributed as follows:

i) Attendance 5 Marks (Award of marks for attendance will be as per the range given below)

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80% - 83% 1 Mark 84% - 87% 2 Marks 88% - 91% 3 Marks 92% - 95% 4 Marks 96% - 100% 5 Marks ii) Test 10 Marks

3 Tests each of 2 / 2½ hours duration for a total of 30 / 50 marks are to be conducted out of which the best two will be taken and the marks to be reduced to 10.

TEST UNITS WHEN TO CONDUCT MARKS DURATION

Test – I Unit – I End of 4th week 30 2 Hrs

Test – II Unit – II & III End of 10th week 50 2 ½ Hrs

Test – III Unit – IV End of 14th week 30 2 Hrs

Question Paper Pattern for Periodical Test:(Test -I & Test-III) 5 Questions X 1 mark … … 05 marks

5 Questions X 3 marks … … 15 marks


----------- 30 marks ----------- Question Paper Pattern for Periodical Test:(Test -II) 5 Questions X 1 mark … … 05 marks



----------- 50 marks ----------- Model Examination covering all 5 units for 75 marks and 3 hrs. duration.

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iii) Assignment 10 Marks

For each subject three Assignments are to be given each for 20 marks and the average marks scored should be reduced for 10 marks

All Test Papers and assignment notebooks after getting the signature from the students must be kept in

the safe custody in the Department for verification and audit. It should be preserved for a Semester for Academic Audit.

For Practical Subjects The Sessional mark calculation for Practical subjects is to be done as follows:-

a) Attendance : 5 Marks -Evaluation pattern

same as Theory) b) Procedure/ observation and tabulation/

other Practical related Work : 10 Marks c) Result : 5 Marks d) Record writing : 5 Marks

----- TOTAL : 25 Marks -----

The Record for every completed exercise should be submitted in the subsequent Practical classes and marks should be awarded for 20 for each exercise as per the above allocation.

At the end of the Semester, the average marks of all the exercises should be calculated for 20 marks and the marks awarded for attendance is to be added to arrive at the sessional mark for Practical.

All the marks entries for assignment, Test and attendance should be entered in the Personal Log Book of the staff, handling the subject. This is applicable to both Theory and Practical subjects.

6. English Communication Practical The English Communication Practical with more emphasis is being introduced in IV Semester for Circuit Branches and in V Semester for other branches of Engineering. Much Stress is given on: Reading Skill Listening Skill Writing Skill Pronunciation Interview Techniques Writing Resumes

Sessional Mark 25 Marks

Board Examinations Mark Allocation

Allocation of Marks

English Communication Practical for 2 Hours ….. 45 Marks

Written Test in Professional Ethics for 1 Hour ….. 20 Marks Selection of 10 Questions (10 X 2 marks) (without choice) should be only from the Question Bank to be set by the External Examiner. Project Report Writing ….. 10 Marks

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7. Project Work

The students of all the Diploma Programmes (except Diploma in Modern Office Practice) have to do a Project Work as part of the Curriculum and in partial fulfillment for the award of Diploma by the State Board of Technical Education and Training, Tamilnadu. In order to encourage students to do worthwhile and innovative projects, every year prizes are awarded for the best three projects i.e. institution wise, region wise and state wise. The selection of Project work should be taken up in V Sem. of study. The Project may be reviewed twice during 4th and 10th week of VI semester. a) Sessional mark for Project Work & Viva Voce: Project Review I (VI Sem.) … 10 marks

Project Review II (VI Sem.) … 10 marks

Attendance 05 marks ----- Total … 25 marks ------ b) Mark Allocation for Project Work & Viva Voce in Board Examination

Viva Voce … 15 marks

Project Report … 10 marks

Demonstration … 15 marks

Applicability of the Project … 05 marks ------- Total … 45 marks ------- c)Written Test Mark (from 3 topics for 1 hour duration): i) Entrepreneurship 5 questions X 2 marks = 10 marks

ii)Environment Management 5 questions X 2 marks = 10 marks

iii)Disaster Management 5 questions X 2 marks = 10 marks -----

30 marks -----

Selection of Questions should be from Question Bank by the External Examiner, no choice need be given to the candidates.

8. Scheme of Examinations

The Scheme of examinations for subjects in the III, IV, V and VI Semesters are given in Annexure - II. 9. Criteria for Pass

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

prescribed course of study successfully in an institution approved by AICTE and affiliated to the State Board of Technical Education & Training, Tamil Nadu and pass all the subjects prescribed in the curriculum.

2. A candidate shall be declared to have passed the examination in a subject if he/she secures not less than 40% in theory/drawing subjects and 50% in practical subject out of the total prescribed maximum marks including both the sessional and the Board Examination marks put together, subject to the condition that he/she secures at least a minimum of 30 marks out of 75 marks in the Board’s Theory/Drawing and a minimum of 35 marks out of 75 marks in the Board Practical Examinations.

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10. Classification of successful candidates Classification of candidates who pass out the final examinations from April 2010 onwards (joined in first

year in 2007-2008) will be done as specified below. First Class with Distinction: A candidate will be declared to have passed in First Class with Distinction if he/she secures not less than 75% of the aggregate marks in all semesters put together, except I and II Semester and passes all the above Semesters in the first appearance itself and completes all papers including that of I & II Semester within the stipulated period of study 3/ 3½/ 4 years (Full Time/Sandwich/Part Time) without any break in study. First Class A candidate will be declared to have passed in First Class if he/she secures not less than 60% of the aggregate marks in all semesters put together except I & II Semesters and completes all papers including that of the I & II Semester within the stipulated period of study 3/ 3½ / 4 years (Full Time/Sandwich/Part Time) without any break in study. Second Class All other successful candidates will be declared to have passed in Second Class. The above mentioned classification is applicable for the Sandwich / Part-Time students who pass out Final Examination from October 2010 /April 2011 onwards (both joined in First Year in 2007-2008)

11. Duration of a period in the Class Time TableThe duration of each period of instruction 1 hour and the total period of instruction hours excluding interval and Lunch break in a day should be uniformly maintained as 7 hours corresponding to 7 periods of instruction (Theory & Practical).

* * *

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Curriculum and Scheme of Examination Diploma in Mechanical Engineering (Full Time) (Course no: 1020)

K-Scheme (With effect from 2008-2009)

Total Curriculum Hours: 35 Hours / Week Total Working Hours : 35 Hours / Week 16weeks/Semester

III Semester

Scheme of Exam Sl. No.

Subject Code

Subject Hrs per week Duration

of Exam Hours

IA BE Total Min. Marks

for Pass

1 12031 Mechanics of Materials 6 3 25 75 100 40 2 12032 Manufacturing Process 5 3 25 75 100 40

3 12033 Fluid Mechanics and Fluid Power 6 3 25 75 100 40

4 12034 Machine Drawing - CAD 8 3 25 75 100 50

5 12035 Mechanics of Materials and Fluid Mechanics Lab. 4 3 25 75 100 50

6 12036 Work shop – I ( Smithy, Foundry & Welding) 6 3 25 75 100 50

IV Semester


Subject Code

Subject Hrs per week Duration

of Exam Hours

IA BE Total Min. Marks

for Pass

1 12041 Applied Thermodynamics 6 3 25 75 100 40

2 12042 Machine shop Technology 6 3 25 75 100 40

3 12043 Electrical and Electronics Engineering 5 3 25 75 100 40

4 12044 Thermodynamics Lab 6 3 25 75 100 50

5 12045 Electrical and Electronics Engineering Lab 6

3 25 75 100 50

6 12046 Workshop II (Turning, Drilling and Shaping) 6 3 25 75 100 50

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V Semester


Subject Code

Subject Hrs per

week Duration of Exam Hours

IA BE Total Min. Marks for Pass

1 12051 Design of Machine Elements 7 3 25 75 100 40

2 12052 Thermal Engineering 6 3 25 75 100 40

Elective Theory-I

12071 1. Refrigeration and air Conditioning 3

12072 2. Metrology, Machine Tool Maintenance and Testing

6 3 25 75 100 40

4 11011 English Communication Practical 4 3 25 75 100 50

Elective Practical – I

12073 1. Refrigeration and air Conditioning Lab 5

12074 2. Metrology, Machine Tool Maintenance and Testing Lab

6 3 25 75 100 50

6 12056 Workshop – III(Slotting, Planning, Milling, Grinding & CNC machines)

6 3 25 75 100 50

VI Semester

Scheme of Exam

Total Marks Sl. No

Subject Code Subject

Hrs per

week Duration of Exam Hours IA BE Tota

l

Min. Marks

for Pass

1 12061 Industrial Engineering & Management 6 3 25 75 100 40

2 12062 Computer Aided Design and Manufacturing 6 3 25 75 100 40

Elective Theory –II

12081 1. Automobile Technology 3

12082 2. Mechatronics

5 3 25 75 100 40

4 12064 Computer Aided design and Manufacturing Practical 6 3 25 75 100 50

Elective Practical-II

12083 1. Automobile Technology Lab 5

12084 2. Mechatronics Lab

6 3 25 75 100 50

6 12066 Project work, Entrepreneurship, Environment and Disaster management

6 3 25 75 100 50

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Curriculum and Scheme of Examination Diploma in Mechanical Engineering (Sandwich) (Course no: 2020)


Total Curriculum Hours: 35 Hours / Week Total Working Hours : 35 Hours / Week 16weeks/Semester

III Semester

Scheme of Exam

Total Marks Sl. No


Hrs per

week Duration of Exam Hours IA BE Tota

l

Min. Marks

for Pass

1 12031 Mechanics of Materials 6 3 25 75 100 40 2 12032 Manufacturing Process 5 3 25 75 100 40

3 12033 Fluid Mechanics and Fluid Power

5 3 25 75 100 40

4 12041 Applied Thermodynamics 5 3 25 75 100 40 5 12034 Machine drawing - CAD 6 3 25 75 100 50

6 12035 Mechanics of Materials and Fluid Mechanics Lab. 4

3 25 75 100 50


IV Semester

Scheme of Exam

Total Marks Sl. No


Hrs per

week Duration of Exam Hours IA BE Tot

al

Min. Marks

for Pass

1 12036 Workshop I (Smithy, Foundry & Welding) * 3 25 75 100 50

2 12047 Industrial training I (Report writing & Viva Voce) - 3 # 25 75 100 50

* To be completed before/ during industrial training

# Industrial training- I Board Examination will be conducted after completion of Six months Industrial

training

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V Semester

Scheme of Exam Total Marks Sl.

No Subject

Code Subject Hrs per

week Duration of Exam Hours IA BE Total

Min. Mark

s for

Pass

1 12042 Machine shop Technology 4 3 25 75 100 40

2 12043 Electrical and Electronics Engineering 5 3 25 75 100 40

3 12052 Thermal Engineering 5 3 25 75 100 40

Elective Theory-I

12071 Refrigeration and Air Conditioning

4

12072 Metrology, Machine Tool Maintenance & Testing

5 3 25 75 100 40

5 12045 Electrical and Electronics Engineering Practical 4 3 25 75 100 50

6 12046 Workshop – II(Turning, drilling & Shaping ) 4 3 25 75 100 50


Elective Practical - I

12073 Refrigeration and Air Conditioning Lab 8

12074 Metrology, Machine Tool Maintenance & Testing Lab

4 3 25 75 100 50

VI Semester

Scheme of Exam

Total Marks Sl. No


Hrs per

week Duratio

n of Exam Hours IA BE Total

Min. Mark

s for

Pass 1 12051 Design of Machine Elements 5 3 25 75 100 40

2 12061 Industrial Engineering & Management 5 3 25 75 100 40

3 12062 Computer Aided Design and Manufacturing 5 3 25 75 100 40

Elective Theory –II

12081 Automobile Technology 4

12082 Mechatronics

4 3 25 75 100 40

5 12056 Workshop – III(Slotting, Planning, Milling, Grinding & CNC Machines)

4 3 25 75 100 50

6 12064 Computer Aided design and Manufacturing Practical 6 3 25 75 100 50

Elective Practical-II

12083 Automobile Technology Lab 7

12084 Mechatronics Lab

6 3 25 75 100 50

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VII Semester

Scheme of Exam

Total Marks Sl. No


Hrs per

week Duratio

n of Exam Hours IA BE Total

Min. Mark

s for

Pass

1 12066

Project work, Entrepreneurship, Environment and Disaster management

** 3 25 75 100 50

2 12067 Industrial training II (Report writing & Viva voce) - 3 # 25 75 100 50

** To be completed during Industrial training # Industrial training-II Board Examination will be conducted after completion of Six months Industrial training

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Curriculum and Scheme of Examination Diploma in Mechanical Engineering (Part Time) (Course no: 3020)


Total Curriculum Hours: 18 Hours / Week Total Working Hours : 18 Hours / Week 16weeks/Semester III Semester

Scheme of Exam

Total Marks Sl. No


Hrs per


Min. Marks for Pass

1 12005 Engineering Graphics 4½ 3 25 75 100 40 2 12031 Mechanics of Materials 3 3 25 75 100 40 3 12032 Manufacturing Process 3 3 25 75 100 40 4 12008 Computer Applications Lab 3 3 25 75 100 50

5 12036 Work shop – I ( Smithy, Foundry, Welding) 4½ 3 25 75 100 50

IV Semester

Scheme of Exam

Sl. No Subject Code Subject

Hrs per


Total Marks Min. Marks for Pass

IA BE Total

1 12033 Fluid mechanics and fluid power 3 3 25 75 100 40

2 12041 Applied thermodynamics 3 3 25 75 100 40

3 12034 Machine Drawing - CAD 6 3 25 75 100 50

4 12035 Mechanics of Material and fluid mechanics lab 3 3 25 75 100 50


V Semester

Scheme of Exam


Hrs per


Total Marks

Min. Mark

s for

Pass

IA BE Total

1 12042 Machine shop Technology 4½ 3 25 75 100 40

2 12043 Electrical and Electronics Engineering 4½ 3 25 75 100 40

3 12045 Electrical and Electronics Engineering Lab 4½ 3 25 75 100 50

4 12046 Workshop – II(Turning, Drilling and Shaping) 4½ 3 25 75 100 50

16

VI Semester

Scheme of Exam

Total Marks Sl. No


Hrs per


Min. Marks

for Pass

1 12051 Design of Machine elements 5 3 25 75 100 40

2 12052 Thermal Engineering 4½ 3 25 75 100 40


4 12056 Workshop III(Slotting, Planning, drilling, grinding and CNC Machines)

4½ 3 25 75 100 50

VII Semester

Scheme of Exam


Hrs per


Total Marks Min.

Marks for

Pass IA BE Tot

Elective Theory-I 12071 Refrigeration and Air Conditioning 1 12072 Metrology, Machine Tool

Maintenance & Testing

4½ 3 25 75 100 40

2 12062 Computer Aided Design & Manufacturing 4½ 3 25 75 100 40

Elective Practical – I

12073 Refrigeration and Air Conditioning Lab 3

12074 Metrology, Machine Tool Maintenance & Testing Lab

4½ 3 25 75 100 50

4 12064 Computer Aided Design & Manufacturing Practical 4½ 3 25 75 100 50

VIII Semester

Scheme of Exam

Total Marks Sl. No


Hrs per


Min. Marks for Pass

1 12061 Industrial Engineering & Management 4½ 3 25 75 100 40

Elective Theory II

12081 Automobile Technology 2

12082 Mechatronics

4½ 3 25 75 100 40

Elective Practical – II

12083 Automobile Technology Lab 3

12084 Mechatronics Lab

4½ 3 25 75 100 50

4 12066

Project work, Entrepreneurship, Environmental & Disaster Management

4½ 3 25 75 100 50

17

I Semester

Scheme of Exam

Total Marks Sl. No


Hrs per


Min. Marks

for Pass

1 11001 Communication Skills in English – I 3 3 25 75 100 40

2 11002 Mathematics 5 3 25 75 100 40

3 11003 Engineering Physics –I 3 3 25 75 100 40

4 11004 Engineering Chemistry – I 3 3 25 75 100 40

5 12009 Workshop Practice 4 3 25 75 100 50

II Semester

Scheme of Exam

Total Marks Sl. No


Hrs per


Min. Marks

for Pass

1 12001 Communication Skills in English II 3 3 25 75 100 40

2 12002 Applied mathematics 3 3 25 75 100 40

3 12003 Engineering Physics -II 3 3 25 75 100 40

4 12004 Engineering Chemistry - II 3 3 25 75 100 40

5 12006 Engineering Physics Practical 3 3 25 75 100 50

6 12007 Engineering Chemistry Practical 3 3 25 75 100 50

18

12031 MECHANICS OF MATERIALS

6 Hrs/Week 16 Weeks /Sem. Total Hrs : 96 OBJECTIVES:

• Define various mechanical properties of materials. • Calculate the deformation of materials, which are subjected to axial load and shear. • Determine the moment of Inertias of various section used in the Industry. • Estimate the stresses induced in thin and thick cylinder under internal pressure • Draw the Graphical representation of shear force and bending moment of the beam subjected to

different loads. • Construct SFD and BMD. • Calculate the power transmitted by the solid & hollow shafts. • Distinguish different types of spring and their applications. • Define types of friction. • Describe the power transmission by the belt, chain and gear drives.

SCHEME OF INSTRUCTION AND EXAMINATION

Subject Instruction Examinations

Hours/Week Hours/Semester Assessment Marks

Internal Board Exam Total

12031- Mechanics

of Materials

6

96 25 75 100

TOPICS AND ALLOCATION

Unit Topic TIME (Hrs) I. Mechanical properties of materials and Simple stresses and

strains

18

II. Geometrical properties of sections and Thin cylinders and thin spherical shells

18

III. Shear force and Bending moment diagrams and Theory of Simple bending

18

IV. Torsion and Springs 18 V. Deflection of beams, Friction, Gear drives and Belt drives

18

Revision and test 6 TOTAL 96

UNIT I MECHANICAL PROPERTIES OF MATERIALS AND SIMPLE STRESSES AND STRAINS 18 Hrs Mechanical properties of materials: Introduction - Definition of mechanical properties such as strength – elasticity, plasticity, ductility, malleability, stiffness, toughness, brittleness, hardness, wear resistance, machinability, cast ability and weld ability – Fatigue, Fatigue strength, creep – temperature creep – cyclic loading and repeated loading – endurance limit. Simple stresses and strains: Introduction – Definition – Load, stress and strain – Classification of force systems – tensile, compressive and shear force systems – Behavior of mild steel in tension upto rupture – Stress – Strain diagram – limit of proportionality – elastic limit – yield stress – breaking stress – Ultimate stress – percentage of elongation and percentage reduction in area – Hooke’s law – Definition – Young’s modulus working stress, factor of safety, load factor, shear stress and shear strain modulus of rigidity. Linear strain – Deformation due to tension and compressive force – Simple problems in tension, compression and shear force. Definition – Lateral strain – Poisson’s ratio – volumetric strain – bulk modulus – volumetric strain of rectangular and circular bars – problems connecting linear, lateral and volumetric deformation – Elastic constants and their relationship ( No derivation ) – Problems on elastic constants.

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Definition – Composite bar – Problem in composite bars subjected to tension and compression – Temperature stresses and strains – Simple problems – Definition – strain energy – proof resilience – modulus of resilience – The expression for strain energy stored in a bar due to Axial load ( no Derivation ) – Instantaneous stresses due to gradual, sudden, impact and shock loads – Problems computing instantaneous stress and deformation in gradual, sudden, impact and shock loadings. UNIT II GEOMETRICAL PROPERTIES OF SECTIONS AND THIN CYLINDERS AND THIN SPHERICAL SHELLS 18hrs Geometrical properties of sections: Introduction – definition – center of gravity and centroid-position of centroids of plane geometrical figures such as rectangle, triangle, circle and trapezium-problems to determine the centroid of angle, channel, T and I sections only (No problems on removed sections)- Definition-centroidal axis-Axis of symmetry. Moment of Inertia – Statement of parallel axis theorem and perpendicular axis theorem. (No derivation)-moment of Inertia of lamina of rectangle, circle, triangle, I and channel sections-(No derivations)-Definition-Polar moment of Inertia-radius of gyration – Problems computing moment of inertia and radius of gyration for angle, T, Channel and I sections.(No problems on removed sections). Thin Cylinders and Thin Spherical Shells: Introduction – Definition – Thin and thick cylindrical shell – Failure of thin cylindrical shell subjected to internal pressure – Derivation of Hoop and longitudinal stress causes in a thin cylindrical shell subjected to internal pressure – simple problems – change in dimensions of a thin cylindrical shell subjected to internal pressure – problems – Derivation of tensile stress induced is a thin spherical shell subjected to internal pressure – simple problems – change in diameter and volume of a thin spherical shell due to internal pressure – problems. UNIT III SHEAR FORCE AND BENDING MOMENT DIAGRAMS AND THEORY OF SIMPLE BENDING 18hrs Shear force and Bending moment diagrams: Introduction – classification of beams – Definition – shear force and Bending moment – sign conventions for shear force and bending moment – types of loadings – Relationship between load, force and bending moment at a section – shear force diagram and bending moment diagram of cantilever and simple supported beam subjected to point load and uniformly distributed load – Determination of Maximum bending moment in cantilever beam and simple supported beam when they are subjected to point load and uniformly distributed load. Theory of simple bending: Introduction – theory of simple bending – Assumptions – Neutral axis – bending stress distribution – moment of resistance – bending equation – M/I=f/y=E/R(No Derivation) – Definition – section modulus - rectangular and circular sections – strength of beam – simple problems involving flexural formula for cantilever and simple supported beam. UNIT IV TORSION AND SPRINGS 18hrs Torsion Introduction – theory of torsion – Assumptions – torsion equation – T/J=fs/R=Cθ/l(No Derivation) – strength of solid and hollow shafts – power transmitted – Definition – Polar modulus – Torsional rigidity – strength and stiffness of shafts – comparison of hollow and solid shafts in weight and strength considerations – Advantages of hollow shafts over solid shafts – Problems. Springs Introduction – Types of springs – Laminated and coiled springs – Types of coiled springs – Difference between open and closely coiled helical springs – closely coiled helical spring subjected to an axial load – problem to determine shear stress, deflection, stiffness and resilience of closed coiled helical springs. UNIT V DEFLECTION OF BEAMS, FRICTION, GEAR DRIVES AND BELT DRIVES 18hrs Deflection of beams: Introduction – Definition – slope, deflection, stiffness and flexural rigidity – Derivations of relationship between slope, Deflection and Radius of curvature – Derivation of slope and deflections of cantilever and simply supported beam by area moment method under point load and UDL– simple problems. Friction: Introduction – Definition – Force of friction – Limiting friction – Static Friction – Dynamic friction – Angle of friction – co-efficient of friction – cone of friction – Laws of static and dynamic friction. Gear drives and Belt Drives: Introduction – classification of gears – Nomenclature of a gear – Explanation and application of spur, helical and bevel gears, worm and worm wheel, rack and pinion – Velocity ratio of a gear drive – merits and demerits of gear drive – problems on simple gear train and Power transmitted by gear.

20

Belt drive – types-open belt drive – cross belt drive – flat belt drive – v belt drive - problems on power transmitted. (Problems not involving centrifugal tension Condition for maximum power transmission and initial tension). Revision and Test 6Hrs Text Books:

1. A. K. Upadhyay, Applied Mechanics, pyblished by Charotar Publishing House, Opp. Amul Dairy, Court Road, Anand 388 001, India 2002.

2. R. S. Khurmi, Strength of Materials, S.Chand & Co., Ram Nagar, New Delhi – 2002.

Reference Books:

1. SB Junnarkar, Dr. HJ Shara, Applied Mechanics, 16th Edn 2001, Charator publishing house, Anand 388001.

2. S. Ramamrutham, Strength of Materials, 15th Edn 2004, Dhanpat Rai Pub. Co., New Delhi.

21

12031 MECHANICS OF MATERIALS MODEL QUESTION PAPER – I

DURATION: 3 HRS. MAX. MARKS: 75

NOTE: Answer all the questions in Part – A. Each carries one mark. Answer all the questions in Part – B. Each carries three marks.

Answer all the questions in Part – C by either or choice. Each carries ten marks.

PART – A Answer all the questions 1x10=10

1. Define elasticity. 2. Define load factor. 3. Define centroid. 4. What is the relation between hoop and longitudinal stress. 5. Define neutral axis. 6. List the types of loads acting on beam. 7. How do you classify the springs. 8. Define torsional rigidity. 9. Define slope. 10. What is limiting friction.

PART – B Answer all the questions 3x5=15

11. If the ultimate shear stress for mild steel is 300 N/mm2. Find the force required to punch a 13mm diameter hole in a mild steel plate 10mm thick.

12. A channel section is of size 300 × 100mm overall. The base as well as the flanges of the channel are 10mm thick. Find the centroid about x-x axis.

13. Draw the shear force and bending moment diagram of a cantilever beam with a point load of 50KN at free end. The length of the beam is 8m.

14. State the assumptions made in theory of pure torsion. 15. Explain angle of friction.

PART – C Answer any one question from each unit. 10x5=50 16. 1. A steel tube 100mm internal diameter and 12.5mm thick is surrounded by a brass tube of the same

thickness in such a way that the axis of the two tubes coincide. The compound tube is loaded by an axial compressive load of 5KN. Determine the load carried by each tube. Assume that there is no bucking of the tube. Take Young’s modulus for steel as 200 KN/mm2 and that for brass is 100 KN/mm2. Tubes are of same length. (10)

OR 2. A bar of steel 28mm diameter and 250mm long is subjected to an axial load of 80KN. It is found that the

diameter has contracted by 1/240 mm. If the modulus of rigidity is 80 KN/mm2. Calculate i)Poissons ratio. ii)Youngs modulus and Bulk modulus. (10)

17. 1. Find Ixx and Iyy for the T section flange of 150mm and overall depth of 250mm with the thickness of

20mm for both web and flange. (10) OR

2. A Cylindrical shell 2.4m long, 600mm in diameter is made up of 15mm thick plates. Find the changes in length, diameter and volume of the cylinder when the shell is subjected to an internal pressure of 2N/mm2 , E= 200 KN/mm2 , 1/m=0.3. (10)

18. 1. A beam 8m long is simply supported at its ends. It carries an udl of 1KN/m run over the length of left half

of its span, together with concentrated loads 2, 3 and 2KN Situated at 2, 4 and 6m respectively from the left hand support. (10)

OR 2. A rectangular beam of 200mm deep and 100mm wide is simply supported over a span of 8m and carries

a central point load of 25KN. Determine the maximum stress in the beam. Also calculate the values of longitudinal fibre stress at a distance of 25mm from the top surface of the beam. (10)

22

19. 1. (a)Write the difference between open and closed coil helical springs. (4)

(b)A closed coiled helical spring made of steel wire 100mm diameter has 10 coils of 120mm mean diameter, calculate the deflection under an axial load of 100N, what is the stiffness of the spring? Take C=1.2MPa. (6)

OR 2. A solid shaft has to transmit 10KW at 210r.p.m. The maximum torque in each revolution exceeds the

mean by 30%. If the shear stress is not to exceed 80Mpa find a suitable diameter of the solid shaft, Calculate the angle of twist for a length of 2m. C=0.8x105N/mm2. (10)

20. 1. (a) State the laws of static friction. (4)

(b) A 3m cantilever beam supports a concentrated load of 10KN at the free end. E=2x105N/mm2. and I= 20x106mm4.Compute the maximum slope & deflection. (6)

OR 2. An open belt drive 100mm wide connects pulleys mounted on parallel shaft 2.5m apart. The diameter

of larger pulley is 300mm and that smaller pulley 150mm. The bigger pulley is rotating at 120r.p.m. If the permissible tension in the belt is Limited is 14N/mm width. Find the power that can be transmitted at this speed. Take coefficient of friction is 0.3. (10)

23

12031 MECHANICS OF MATERIALS MODEL QUESTION PAPER – II

DURATION : 3 HRS. MAX. MARKS:75

NOTE: Answer all the questions in Part – A. Each carries one mark. Answer all the questions in Part – B. Each carries three marks. Answer all the questions in Part – C by either or choice. Each carries ten marks. PART – A Answer all the questions 1x10=10

1. Define Creep. 2. Define resilience. 3. Define axis of symmetry. 4. Write the formula for lateral strain in thin cylinders. 5. Define section modulus. 6. Write any two differences between closed and open coil helical spring. 7. At maximum bending moment what will be the value of shear force? 8. What type of stress will be developed in the neutral layer axis when it is subjected to bending load? 9. Define deflection. 10. Define circular pitch.

PART – B Answer all the questions 3x5=15

11. Calculate the strain energy that can be stored in a steel bar 40mm in diameter and 3m long subjected to a pull of 100KN. Take E = 200 KN/mm2

12. State Hoop stress and Longitudinal stress. 13. Define Shear force and bending moment of a beam. 14. Calculate the torque transmitted by a shaft of 100mm diameter running at 250r.p.m. If the shear stress

in the shaft material is not to exceed 75MPa. 15. Explain about cone of friction.

PART – C Answer any one question from each unit. 10x5=50 16. 1. A steel specimen 150mm2 in cross section stretches by 0.05mm over a 50mm gauge length under an

axial load of 30KN. Calculate the strain energy stored in the specimen at this stage. If the load at the elastic limit for the specimen is 50KN. Calculate the elongation at elastic limit and proof resilience. (10)

OR 2. (a) Draw stress strain diagram and mark the salient points. (5) (b) A steel wire 10m long and 3m diameter is subjected to pull of 600N. Calculate (i) stress (ii) the

elongation if E=2x105N/mm2. and (ii) factor of safety if the tensile strength is 500MPa. (5) 17. 1. A long steel tube 70mm internal diameter and wall thickness 2.5mm has closed ends and is subjected to

an internal pressure of 10 N/mm2. Calculate the magnitude of hoop and longitudinal stress set up in the tube. If the efficiency of the longitudinal joint is 80%. Which stress is affected and what is its revised value. (10) OR

2. Determine the moment of inertia about centroidal coordinate axis of an I-section having equal flanges 120x20mm size and web 120x20mm thick. (10)

18. 1. A simply supported beam of effective span 6m carries three point loads of 30 KN, 25KN and 40KN at

1m, 3m and 4.5m respectively from the left support. Draw the SFD and BMD diagram. (10) OR

2. A cast iron water pipe 450mm bore and 25mm thick is supported at two points 9m apart. Find the maximum stress in the metal a) when it is running full, b) when it is empty. Specific weight of cast iron is 78KN/m3 and that of water is 10 KN/m3 . (10)

24

19. 1. a) Write the assumptions made in theory of pure torsion. (4) b) A solid circular shaft has to transmit a power of 40KW at 120r.p.m.. The permissible shear stress is

100N/mm2 , determine the diameter of the shaft if the maximum torque exceeds the mean torque by 25%. (6)

OR 2. A truck weighing 30KN and moving at 5Km/hr has to be brought to rest by a Buffer. Find how many

springs each of 18 coils will be required to store the energy of motion during compression of 200mm. The spring is made out of 25mm diameter steel rod coiled to a mean diameter of 240mm. Take N=0.84x105 N/mm2 . (10)

20. 1. A cantilever beam of length 3m is carrying a uniformly distributed load of w KN./m. Assuming

rectangular cross section with depth equal to twice the width, determine the dimensions of the beam so that the vertical deflection at free end does not exceed 8mm. Take maximum bending stress is 100 N/mm2 , and E= 2x105 N/mm2 . (10)

OR 2. A train of wheel transmit 3KW. The driving pinion has 20 teeth of 25mm pitch. Calculate the speed in

r.p.m. for the pinion, if the pressure between the teeth exerted is not to be exceed 600N. (10)

25

12032 MANUFACTURING PROCESS

5 Hrs/Week 16 Weeks /Sem. Total Hrs : 80 OBJECTIVE:

• Acquire Knowledge about types of pattern, casting, moulding. • Explain hot working and cold working processes • Describe the various casting processes • Appreciate the safety practices used in welding. • Explain powder metallurgy process • Distinguish the different heat treatment processes • Explain the lathe and its working parts. • Describe the functioning of semi automatic and automatic lathes. • Compare the various types of gauges used in metrology • Compare the various types of linear and angle measuring devices. SCHEME OF INSTRUCTION AND EXAMINATION

Subject Instruction Examination

Hour/Week Hours/Semester Assessment Marks


12032

Manufacturing

Process

5

80 25 75 100


UNIT TOPIC TIME ( Hours )

I. Foundry 15

II. Forging and Welding 15

III. Powder Metallurgy and Heat Treatment 15

IV. Lathe Work, Semi Automatic and Automatic Lathes 15

V. Metrology and Theory of Metal cutting 15

Revision Test 5

Total 80

UNIT – I FOUNDRY 15hrs PATTERNS – definition – pattern materials – factors for selecting pattern materials – single piece solid, split patterns – pattern allowances – core prints. MOULDING – definition – moulding boxes, moulding sand – ingredients – silica – clay – moisture and miscellaneous materials – properties of moulding sand – sand additives – moulding sand preparation – mixing – tempering and conditioning – types of moulding – green sand – dry sand – machine moulding – Top and bottom squeezer machines – Jolting machines – sand slinger- core – CO2 process core making – types of core – core boxes. CASTING – definition – sand casting using green sand and dry sand – gravity die casting – pressure die casting – hot and cold- chamber processes – centrifugal casting – continuous casting – chilled casting – malleable casting – melting of cast iron – cupola furnace – melting of non ferrous metals – crucible furnace melting of steel and arc furnaces – induction furnaces – instrument for measuring temperature – optical pyrometer – thermo electric pyrometer – cleaning of casting – tumbling, trimming, sand and shot blasting – defects in casting – causes and remedies – safety practices in foundry.

26

UNIT – II FORGING AND WELDING 15hrs Hot working, cold working – advantages of hot working and cold working– hot working operations – rolling – forging, smith forging, drop forging, upset forging, press forging – roll forging. Welding – arc welding definition – arc welding equipment – arc welding methods – carbon arc, metal arc, Metal Inert gas (MIG), Tungsten inert gas (TIG), Atomic hydrogen, Plasma arc, Submerged arc and Electro slag welding, Gas welding – definition Gas Welding Equipment– oxy – acetylene welding Three types of flame– resistance welding – definition – classification of resistance welding – butt – spot – seam – projection welding – welding related processes – oxy – acetylene cutting – arc cutting – hard facing bronze welding – soldering and brazing special welding processes – cast iron welding – thermit welding – solid slate welding, ultrasonic, diffusion and explosive welding – explosive cladding – modern welding, electron beam and laser beam welding – types of welded joints – merits and demerits of welded joints – inspection and testing of welded joints – destructive and non destructive types of tests – magnetic particle test – radiographic and ultrasonic test defects in welding – causes and remedies – safety practices in welding . UNIT – III POWDER METALLURGY AND HEAT TREATMENT 15 hrs Methods of manufacturing metal powders – atomization, reduction and electrolysis deposition – compacting – sintering – sizing – infiltration – mechanical properties of parts made by powder metallurgy – design rules for the power metallurgy process. Heat treatment processes – purpose – procedures – applications of various heat treatment processes – Iron – carbon equilibrium diagram – full annealing – process annealing stress relief annealing - spherodising annealing – isothermal annealing – normalizing – hardening – tempering – quenching medium – different types and their relative merits – case hardening – pack carburizing – cyaniding – nitriding – induction hardening and flame hardening. UNIT – IV LATHE WORK, SEMI AUTOMATIC AND AUTOMATIC LATHES 15hrs Theory of lathes – specifications – simple sketches – principal parts – head stock – back geared type – all geared type – tumbler gear mechanism – quick change gear box – apron mechanism – carriage cross slide – automatic, longitudinal and cross feed mechanism – tail stock and its functions – work holding device – face plate – three jaw chuck – four jaw chuck – catch plate and carrier – types of centres – machining operations done on lathe straight turning – step turning-taper turning-knurling-Thread cutting-Facing-Boring-chamfering– lathe attachments – tool post grinders – milling attachments-cutting speed-feed-depth of cut. Semi automatic lathes: Types of semi automatic lathes – capstan and turret lathes – difference between turret and capstan – tools and work holding devices – self opening die head – collapsible taps – simple tool lay out – process sheet. Automatic Lathes: Automatic lathe – classification of single spindle automatic lathe – principle of automatic lathes – automatic screw cutting machines – multi spindle automatic lathes – use of cams in automats. UNIT – V METROLOGY AND THEORY OF METAL CUTTING 15 Hrs Metrology, Micrometer – inside and outside vernier caliper-digital vernier-digital micrometer – vernier height gauge – digital type vernier micrometers – depth gauges – applications – plug and ring gauges – snap gauges – thread micrometers – gear tooth vernier – bevel protractor – slip gauges – sine bar – comparators – mechanical (dial gauges) – electrical, optical and pneumatic comparators – profile measurements – optical flat – surface finish measurements – profilometers. Cutting tool material-High carbon Steel-High Speed Steel-Stellites-Cemented carbides-ceramics-Composition and applications for the above-Single point cutting tool-nomenclature-tool life-Chip Breakers. Revision and Test 5Hrs Text Books:

1. Hajra Chowdry & Bhattacharaya, Elements of workshop Technology Volume I & II, Edn. XI, Media Promoters & Publishers Pvt. Ltd., Seewai Building `B’, 20-G, Noshir Bharucha Marg, Mumbai 400 007 – 2007.

27

2. R. S. Khurmi & J. K. Gupta, A Text book of workshop Technology, Edn. 2, S.Chand & Co., Ram Nagar, New Delhi - 2002.

Reference Books:

1. Begeman, Manufacturing process, Edn. 5, McGraw Hill, New Delhi 1981. 2. WAJ Chapman, Workshop Technology, Volume I, II, & III, Vima Books Pvt. Ltd., 4262/3,

Ansari Road, Daryaganj, New Delhi 110 002. 3. Raghuwanshi, Workshop Technology, Khanna Publishers.

Jain & Gupta, Production Technology, Edn. XII, Khanna Publishers, 2-B, North Market, NAI Sarak, New Delhi 110 006 - 2006

4. P. C. SHARMA, Production Technology, Edn. X, S.Chand & Co. Ltd., Ram Nagar, New Delhi 110 055 - 2006

5. HMT, Production Technology, Edn. 18, published by Tata McGraw Hill publishing Co. Ltd., 7 West Patel Nagar, New Delhi 110 008. – 2001.

6. Kalpakjian, Manufacturing Engineering & Technology

28

12032 MANUFATCURING PROCESS MODEL QUESTION PAPER-I

DURATION : 3 HRS. MAX. MARKS: 75

NOTE : Answer all the questions from Part-A (1 mark each) Answer all the questions from Part-B (3 marks each) Answer all the questions in Part – C by either or choice. Each carries ten marks.

PART-A Answer all the questions 1x10=10

1. What is core? 2. What are the advantages of wooden pattern? 3. What is Hot Working? 4. List out the equipment used in gas welding. 5. What is compacting in powder metallurgy process? 6. What is case hardening? 7. What are functions of a tumbler gear mechanism? 8. What are functions of a turret in a capstan lathe? 9. What is measuring instrument? 10. What for the snap gauges are used?

PART-B Answer all the questions 3x5=15

11. List out the types of pattern. Explain any 2 types of pattern. 12. What are advantages of Press forging? 13. What are advantages of powder metallurgy components?

14. Write the specification of a lathe. 15. What are properties of a cutting tool material?

PART-C Answer any one question from each unit. 10x5=50 16. 1. a) List out the pattern allowance. Explain? (5) b) Explain with a meat sketch jolt moulding machine (5) OR 2. a) Sketch a cupola and label the Principal parts (5) b) Explain the safety precautions practical in a foundry shop (5) 17. 1. a) Explain with a neat sketch the drop forging process. (5) b) Explain with a neat sketch the explosive welding (5) OR 2. a) Explain with a neat sketch the TIG welding processes. Write its application. (6) b) What are advantages of press forging processes? (4) 18. 1. What are the different methods of manufacturing powders in powder metallurgy processes? Explain.

OR (10) 2. a) What is annealing? Explain Full annealing process. (5)

b) What are the purposes for heat treatment of metals? (5)

19. 1. a) Explain with a neat sketch the all geared head stock of a lathe. (6) b) Explain with a neat sketch the self-opening die head. (4)

OR 2. a) List out the work holding devices used in a lathe. Explain with neat sketch any one work holding

devices. (5) b) Tool schedule and process chart for manufacturing of a belt in a Semi automatic lathe. (5)

20. 1. a) Explain with a neat sketch the profilometer. (5)

b) Sketch and nomenclature of a single point cutting tool. (5) OR 2. a) Explain with a neat sketch the optical comparators. Write its advantages. (6) b) Explain 18-4-1 high speed steel (4)

29

12032 MANUFATCURING PROCESS

MODEL QUESTION PAPER-II DURATION : 3 HRS. MAX. MARKS: 75

NOTE : Answer all the questions from Part-A (1 mark each) Answer all the questions from Part-B ( 3 marks each) Answer all the questions in Part – C by either or choice. Each carries ten marks.

PART – A Answer all the questions 1x10=10

1. What is pattern? 2. What is the function of a optical pyrometer? 3. List out the hand tool used in smith forging. 4. List the equipment used in Arc welding. 5. What is sintering in powder metallurgy process? 6. What are the quenching mediums used in heat treatment processes? 7. What are the functions of a lead screw? 8. What are functions of a cam in automatic lathe? 9. What is least count of a measuring instrument? 10. What are compositions of a satellite tool?

PART-B Answer all the questions 3x5=15 11. What are the properties of a good moulding sand? Explain. 12. Differentiate between hot working and cold working.

13. What are the different methods of manufacturing powders in powder metallurgy processes? Explain any one method.

14. Differentiate between capstan lathe and turret lathe. 15. Explain with a sketch the vernier caliper.

PART-C Answer any one question from each unit 10x5=50 16. 1. a) Explain with neat sketch co2 process of core making. (5) b) Explain with neat sketch the pressure die casting process. (5)

OR 2. a) What are the different casting defects? Explain its causes and remedies. (10) 17. 1. Explain with neat sketch submerged Arc welding. Write its advantages and disadvantages.(10)

OR 2. a) What are the 3 types of flame used in gas welding? Write its Application? (6) b) Explain with sketch the drop forging processes (4) 18. 1. Sketch the iron-carbon equilibrium diagram. Write its different phase transformation. (10)

OR 2. a) What are the advantages of powder metallurgy components? (5)

b) What are the design rules to consider for metallurgy components? (5) 19. 1. What are the operations done on a lathe? Explain with a neat sketch any two methods of taper turning in

a lathe. (10) OR

2. a) Explain with neat sketch the single spindle automatic lathe. (5) b)What are the different work holding devices used in semi automatic lathes? Explain anyone work

holding device. (5) 20. 1. a) How to measure the unknown angle by using the sin bar? (4) b) What are the properties of a good cutting tool material? Explain. (6)

OR a) What are the advantages of ceramic tools? (4) b) Explain with a neat sketch the pneumatic comparators. Write its advantages. (6)

30

12033 FLUID MECHANICS AND FLUID POWER

6 Hrs/Week 16 Weeks / Sem Total Hrs : 96 OBJECTIVES:

• Define the properties of Fluids. • Explain the working of pressure measuring devices • Explain continuity equation and Bernoulli’s Theorem • Assess the impact of frictional loss of head in flow through pipes • Estimate the discharge through orifices • Distinguish the working principles of pumps and turbines. • Explain the working of centrifugal pumps and reciprocating pumps. • Compare pneumatic system with hydraulic system • Draw Pneumatic circuits for industrial application. • State the properties of hydraulic Systems • Develop hydraulic circuit for machine tools applications.


Subject Instruction Examination Hours/week Hours/Semester Assessment Marks

Internal Board Exam Total 12033 – Fluid Mechanics

and Fluid Power 6

96 25 75 100

TOPIC AND ALLOCATION

UNIT TOPIC TIME

(Hrs) I Properties of Fluids and Pressure Measurements 18 II Flow of Fluids and Flow through Pipes 18 III Impact of Jets, Hydraulic Turbines, Centrifugal and Reciprocating Pumps 18 IV Pneumatic Systems 18 V Hydraulic Systems 18 Revision Test 6 Total 96

UNIT-I PROPERTIES OF FLUIDS AND PRESSURE MEASUREMENTS 18 Hrs. Introduction-Definition of fluid-Classification of Fluids-ideal and real fluids-Properties of a fluid – definition and units. Pressure-units of Pressure-Pressure head-atmospheric, gauge and absolute pressure-problems-Pascal’s law-proof-applications of Pascal’s law-Hydraulic press- Hydraulic jack Pressure measurement-Piezometer tube- Simple U-tube manometer-Differential U-tube manometer-Inverted Differential manometer-Micromanometer-Inclined tube micromanometer Mechanical Gauges-Bourdon’s Tube Pressure Gauge-Diaphragm pressure gauge-Dead weight pressure gauge UNIT-II FLOW OF FLUIDS AND FLOW THROUGH PIPES 18 Hrs. Types of fluid flow-path line and stream line-mean velocity of flow-discharge of a flowing fluid- equation of continuity of fluid flow-energies of fluid. Bernoulli’s theorem-statement, assumptions and proof-applications and limitations of Bernoulli’s theorem-problems on Bernoulli’s theorem- venturi meter-derivation for discharge-orifice meter- derivation for discharge-difference between venturi meter and orifice meter-problems on venturimeter and orifice meter - Pitot tube –theory only (no problems) Orifice-types-applications-hydraulic coefficients-determining hydraulic coefficients – problems- discharge through a small orifice discharging freely only-problems –Experimental method of finding Cv, Cc and Cd. Flow through pipes-laws of fluid friction-hydraulic gradient line-total energy line- wetted perimeter- hydraulic mean radius- loss of head due to friction-Darcy-Weisbach equation and Chezy’s formula-problems-minor losses (description only)-no problems-Power transmission through pipes- problems.

31

UNIT-III IMPACT OF JETS, HYDRAULIC TURBINES, CENTRIFUGAL AND RECIPROCATING PUMPS 18 Hrs. Impact of jet-on a stationary flat plate held normal to the jet and inclined to the direction of jet- Impact of jet on a flat plate moving in the direction of jet- Impact of jet on a series of moving plates or vanes-force exerted and work done by the jet-problems. Hydraulic turbines-classifications-Pelton wheel-components and working-speed regulation (theory only)-Francis and Kaplan turbines- components and working-draft tube-functions and types-surge tank-differences between impulse and reaction turbines. Centrifugal Pumps-classifications-construction and working of single stage centrifugal pumps-components with types- theory only-multi stage pumps-advantages-priming – manometric, mechanical, overall efficiencies-definitions only-no problems-cavitation. Reciprocating Pumps- classifications-construction and working of single acting and double acting reciprocating pumps-plunger and piston pumps-discharge of a reciprocating pump-theoretical power required- coefficient of discharge-slip-problems-negative slip-indicator diagram-separation-air vessel (functions and working) Special pumps-jet pump-Turbine pump-Submersible pump. UNIT-IV PNEUMATIC SYSTEMS 18 Hrs. Pneumatic Systems- elements-filter-regulator-lubricator unit-pressure control valves- pressure relief valves- pressure regulation valves- directional control valves-3/2 DCV- 4/2 DCV – 4/3 DCV – 5/2 DCV – flow control vales – throttle valves –shuttle valves – quick exhaust valves –ISO symbols of pneumatic components – pneumatic circuits – direct control of single acting cylinder – operation of double acting cylinder – operation of double acting cylinder with metering in control - operation of double acting cylinder with metering out control – use of shuttle valve in pneumatic circuits – use of quick exhaust valve in pneumatic circuits-automatic operation of double acting cylinder –merits and demerits of pneumatic system-applications. UNIT-V HYDRAULIC SYSTEMS 18 Hrs. Hydraulic system-elements-merits and demerits-service properties of hydraulic fluids. Hydraulic accumulator-weighted or gravity type accumulator - spring loaded type accumulator-gas filled bladder accumulator-pressure intensifier. Fluid power pumps-external and internal gear pump, vane pump, radial piston pump ISO symbols for hydraulic components –hydraulic circuit using sequencing valve-hydraulic circuit using counter balance valve- hydraulic circuit for shaping machine, table moment in surface grinding machine and milling machine. Comparisons of hydraulic and pneumatic systems. Revision and Test 6Hrs Text Books: 1. R.S.Khurmi, A Text Book of Hydraulics, Fluid Mechanics and Hydraulic Machines, Edn. 18, published by

S.Chand & Co., Ram Nagar, New Delhi. 2. R.K.Rajput, A Text Book of Hydraulics Reference Books: 1. Jagadishlal, Hydraulic Machines, 1990, published by Metropolitan Book Co. Pvt. Ltd., 1 Faiz Bazaar, New

Delhi – 6. 2. R.K.Bansal, Fluid Mechanics and Hydraulic Machines , Edn. 8, Laxmi Publications P. Ltd., 22 Golden house,

Daryaganj, New Delhi 110 002 – 2003. 3. Andrew Parr, Hydraulics and Pneumatics (A Technician’s and Engineer’s Guide) 4. FESTO manual, Fundamentals of Pneumatic control Engineering 5. Text book of Hydraulics by H. Meixner and R.Kober, Edn. 1990 published by FIESTO DIDACTIC KG, D –

7300 Esslingen, 1977, 1988.

32

12033 FLUID MECHANICS AND FLUID POWER MODEL QUESTION PAPER – I

DURATION: 3 HRS. MAX MARKS:75

NOTE : Answer all the questions from Part-A (1 mark each)

Answer all the questions from Part-B ( 3 marks each) Answer all the questions in Part – C by either or choice. Each carries ten marks.

PART-A Answer all the questions 1x10=10

1. Define Specific Gravity. 2. State the applications of Pascal’s law. 3. Define uniform flow. 4. State the applications of Bernoulli’s theorem. 5. What is meant by Impact of jet? 6. Define Slip. 7. What is the use of pressure regulators? 8. Name any two types of DCV’s. 9. What are the elements of Hydraulic system? 10. What is the purpose of Counter balance valve?


11. One litre of petrol weighs 7N. Calculate its Specific Weight & Density. 12. Compare Venturimeter with Orificemeter. 13. State the difference between Kaplan turbine & Francis turbine. 14. Explain the function of Quick Exhaust Valve. 15. List the advantages of Hydraulic system.

PART-C Answer any one question from each unit 10x5=50 16. 1. Explain the construction and working principle of Diaphragm type pressure gauge with a simple sketch.

(10) OR

2. Explain the simple U- tube Manometer with a neat sketch. (10) 17. 1. State and prove Bernoulli’s theorem. (10)

OR 2. Using chezy’s formula, determine the head lost due to friction in a pipe of 80mm diameter and length

35m. The velocity of flow is 2m/s. Take chezy’s constant C=0.62. (10)

18. 1. Explain the construction and working principle of Kaplan turbine. (10) OR

2. Explain the working principle of Double Acting Reciprocating pump with a neat sketch. (10) 19. 1. a) Sketch and explain the working of 3/2 DCV. (5) b) Sketch and explain the working of shuttle valve (5)

OR 2. Explain the operation of double acting cylinder with metering out control with a circuit diagram.

(10) 20. 1. a) State any four differences between a pneumatic system and hydraulic system. (4) b) Sketch and explain gravity type accumulator (6) OR 2. Draw and explain Hydraulic circuit for Shaping machine. (10)

33

12033 FLUID MECHANICS AND FLUID POWER MODEL QUESTION PAPER – II

DURATION : 3 HRS. MAX MARKS:75


PART –A Answer all the questions 1x10=10 1. Define Viscosity. 2. Define Pascal’s law. 3. Define Bernoulli’s theorem. 4. Define Hydraulic Co-efficient of Velocity. 5. Define Impulse Turbine. 6. What is meant by Cavitation? 7. Draw the ISO symbol for 3/2 DCV. 8. Draw the ISO symbol for Shuttle Valve. 9. Write any two service properties of Hydraulic fluids. 10. Draw the ISO symbol for Accumulator?


11. A gauge records a pressure of 25KN /m2 . Calculate the corresponding absolute pressure in KN /m2.

The local atmospheric pressure is 760mm of Mercury. 12. Compare Venturimeter with Orificemeter. 13. Sketch & explain the Draft tube. 14. Sketch & explain the lubricator used in Pneumatic system. 15. Write the function of Accumulator used in Hydraulic system?

PART-C Answer any one question from each unit 10x5=50

16. 1. a) State the properties of fluid. (4) b) Prove the Pascal's law. (6)

OR 2. Sketch & explain the Bourdon tube pressure gauge. (10)

17. 1. Describe with a neat sketch the experimental method of determining the Co-efficient of Contraction.

(10) OR

2. A Venturimeter 0.15m x 0.075m is discharging water. Find the discharge through the venturimeter, if the Mercury gauge shows a deflection of 175mm and Co-efficient of the meter is 0.95. (10)

18. 1. Explain the construction and working of Pelton wheel. (10)

OR 2. In a single acting reciprocating pump, the diameter of cylinder is 152mm and the stroke is 304mm. The

water is raised to a height of 18m at a pump speed of 40 rpm. Calculate the theoretical power required and the discharge in litres/second. If the actual discharge is 0.2122m3/mt. Determine the Co-efficient of discharge and percentage slip. (10)

19. 1. a) Explain 4/3 DCV used in pneumatic system. (5) b) Explain working of quick exhaust valve. (5)

OR 2. Explain the operation of double acting cylinder with metering in control with a circuit diagram.

20. 1. Sketch and explain Gear pump.

OR 2. Draw and explain hydraulic circuit for table movement in surface grinding machine. (10)

34

12034 MACHINE DRAWING - CAD

8 Hrs/Week 16 Weeks /Sem Total Hrs : 128 OBJECTIVES:

• Appreciate the need of sectional view and types of sections. • Draw sectional views using different types of sections. • Explain the use of threaded fasteners and the types of threads. • Compare hole basis system with shaft basis system. • Select different types of fits and tolerance for various types of mating parts. • Practice on AutoCAD commands in making 2D drawings. • Draw assembled drawings of different types of joints and couplings using AutoCAD • Draw assembled drawings of various types of machine elements using AutoCAD.

SCHEME OF INSTRUCTION AND EXAMINATIONS

Instruction Examination Assessment Marks

Subject Theory / Week

Theory / Semester

Practical / Week

Practical / Semester

Total Hours Internal Board

Exam Total

12034 Machine Drawing - CAD

2 32 6 96 128 25 75 100

TOPIC AND ALLOCATION

Unit Topic Time (Hrs) I. Section views 6 II. Limits, fits and tolerances 10 III. Keys and surface finish 8 IV. Screw Threads and fasteners 8 V. CAD Drawings 90

Revision and Test 6 Total 128 Hrs

UNIT I SECTION VIEWS: 6hrs Introductions – need for sectioning – Hatching – Inclination of hatching lines – Spacing between hatching lines – Hatching of larger areas – Hatching of adjacent parts – sketch and explanation of full section, Half sections – types, Partial or local sections, Revolved or super unposed sections, Removed sections and offset sections. UNIT II LIMITS, FITS AND TOLERANCES: 10hrs Introduction – Definition of various terms used in limits – Hole basis system – Shaft basis system – Types of fits – Selection of fits and applications – types of tolerances – form and position – Indication of tolerances and fits on the drawing. UNIT III – KEYS AND SURFACE FINISH: 8hrs Introduction – Types of keys – taper keys – Parallel or feather keys – wood druff keys – Empirical relation between diameter of the shaft and width & thickness of key for the above types of keys. Definition – Nominal surface – roughness – waviness – lay – productions methods and surface quality – symbol for lay – Indication of surface roughness for various machining operations. UNIT IV SCREW THREADS AND THREADED FASTENERS 8hrs Introduction – Nomenclature of screw threads – Basic profiles and forms of screw threads – Left hand and right hand threads – Internal and external threads – Drawing of Vee and square threads – Application of threads – Bolts and Nuts – Drawing of Hexagonal bolt and Nut – Drawing of square head bolts – Riveted head – Types.

35

UNIT V CAD DRAWINGS

1. Auto cad Theory and Practice 30Hrs 2. Sleeve and cotter joint 3Hrs 3. . Socket and spigot cotter joint 3Hrs 4. Gib and cotter joint 3Hrs 5. Knuckle joint 3Hrs 6. Flange coupling – protected type 6Hrs 7. Universal coupling 6Hrs 8. Bushed bearing 6Hrs 9. Plummer block 6Hrs 10. Swivel bearing 6Hrs 11. Simple eccentric 6Hrs 12. Machine vice 6Hrs 13. Screw Jack 6Hrs Total 90 Hrs

Auto CAD Theory and Practice : Introduction – open-save-save as-exit-Limits, Units-Line command-Abs coordinate System-Relative Polar-Different toolbars in screen-explanation Draw commands-Circle-Arc-Ellipse-Rectangle-Spline-pline-Donut Editing Commands-Array-mirror-break-copy-rotate-chamfer-fillet-move-offset-scale-trim-extend-strecth-plineedit-pedit-xplode. Display commands-Zoom-pan-oops-regen-viewres. Layer – Properties-create Layer-laytrans-matchprop Text Command-text-mtext-textedit-mtedit Dimensioning commands- DimLinear, Dimaligned, Dimradius, Dimdia, Dimangular, Dimbaseline, Dimcontinuous, Dimstyle, Dimedit Make BLOCK, Insert block, Divide, Measure, Bhatch Attdef, attedit Pagesetup, Plot preview, plot Revision and Test 6hrs Text Books:

1. N. D. Bhatt, Machine Drawing, Edn. 37, Charotar Publishing House, Opp. Amul Dairy, Court Road, Anand 388 001, India – 2002.

2. K. R. Goplakrishnan, Engineering Drawing, Dhanalakshmi Publishers, M97-B, 30th Cross Street, 7th Avenue, Besant Nagar, Chennai 600 090.

3. R.C.Parkinson, Engineering Drawing published by English University Press, London – 1986.

Reference Book: A. C. Parkinsan, A First year Engineering Drawing. First Rep 1982, A.H. Wheeler & Company (P) Ltd.,

15, L. B. Shastri Marg, Allaghabed – 211 001.

36

12034 MACHINE DRAWING - CAD

MODEL QUESTION PAPER DURATION : 3 HRS. MAX MARKS:75

NOTE : Answer all the questions from Part-A (1 mark each) Answer all the questions from Part-B ( 3 marks each) Answer all the questions in PART- C.

PART –A Answer all the questions 1x10=10 1. When half-sectional view is used? 2. How is a cutting plane represented in the Orthographic view for obtaining a full section. 3. What is meant by the term Fit? 4. Write down the application for transition fit H7/n6. 5. Where a wood druff key is used? 6. Indicate roughness grade symbol for N10. 7. What type of thread is used for transmitting high power? 8. Where are multi start thread is used? 9. What command is used to constrain the line drawn horizontal and vertical direction only? 10. When do you choose the command PLINE?


11. Explain removed section with suitable sketch. 12. When a shaft based system is preferred to hole based system? 13. What are the roughness value that can be normally obtained by i) Fine turning ii) Machine reaming iii) Milling iv) Grinding v) Chrome Plating. 14. Draw the neat proportionate conventional sketch for a M20 nut 15. i) How to begin a new drawing? ii) What are the options available to draw a circle?

PART-C (20+30) 16. Assemble and draw the orthographic views (Front view and side view/Top view) for the given parts drawing

a) Manual drafting (on the given drawing sheet) (20) b) Using CAD software and print-out (30)

******

37

12035 MECHANICS OF MATERIALS AND FLUID MECHANICS LAB

4 Hrs/Week 16 Weeks / Sem Total Hrs : 64 OBJECTIVES:

• Determine stress strain relations for steel and cast iron. • Determine hardness of materials. • Perform torsion, bending, impact and shear tests. • Determine coefficient of discharge of venture meter and orifice meter. • Determine the friction in pipes. • Verify Bernoulli’s theorem. • Conduct performance test on centrifugal and reciprocating pump. • Conduct performance test on impulse and reaction turbine. • Design and make fluid power circuits.

Scheme of Instructions and Examinations


Subject Hours/week Hours/

Semester Internal Board Exam Total 12035 – Mechanics of

Materials and Fluid Mechanics lab

4 64 25 75 100

I MECHANICS OF MATERIALS LAB: (2Hrs/Week)

1. Test on Ductile Materials: Finding Young’s Modulus of Elasticity, yield points, percentage elongation and percentage reduction in area, stress strain diagram plotting, tests on mild steel and cast iron. (Equipment : UTM )

2. Hardness Test: Determination of Rockwell’s Hardness Number for various materials like mild steel, high carbon steel, brass, copper and aluminium. (Equipment : Rockwell’s Hardness Testing Machine)

3. Torsion test: Torsion test on mild steel – relation between torque and angle of twist-determination of shear modulus-determination of elastic constants for mild steel. (Equipment : Torsion testing machine)

4. Bending and deflection tests: Determination of Young’s Modulus for steel by deflection test. (Equipment : Deflection testing arrangement )

5. Impact test: Finding the resistance of materials to impact loads by Izod test or Charpy test. (Equipment: Impact testing machine)

6. Tests on springs of circular section: Determination of modulus of rigidity, strain energy, shear stress by load deflection method-Comparison and tension test (Closed coil spring only) (Equipment: Tension testing arrangements)

7. Shear test: Shear test on M.S. bar (Equipment: Shear testing machine)

38

II FLUID MECHANICS LAB: (2 Hrs/Week)

1. Verifying the Bernoulli’s Theorem (Equipment: The Bernoulli’s Apparatus)

2. Determination of Coefficient of discharge of a Venturimeter (or) Orifice meter. (Equipment: A Centrifugal pump having the discharge line with Venturimeter or Orifice meter arrangement)

3. Determination of the Friction Factor in a Pipe (Equipment: An arrangement to find friction factor)

4. Performance test on a reciprocating pump and draw the characteristic curves. (Equipment: A reciprocating pump with an arrangement for collecting data to find out the efficiency and plot the characteristic curves)

5. Performance test on a centrifugal pump and draw the characteristic curves. (Equipment: A centrifugal pump with an arrangement for collecting data to find out the efficiency and plot the characteristic curves)

6. Performance test on an impulse turbine (Equipment: An impulse turbine with an arrangement for collecting data to find out the efficiency)

7. Performance test on a reaction turbine (Equipment: A reaction turbine with an arrangement for collecting data to find out the efficiency)

8. Determination of Coefficient of discharge of a small orifice (or) an external mouthpiece by constant head method. (Equipment: An open tank fitted with a small orifice (or) an external mouthpiece and a collecting tank with piezometer)

9. Determination of Coefficient of discharge of a small orifice (or) an external mouthpiece by variable head method. (Equipment: An open tank fitted with a small orifice (or) an external mouthpiece and a collecting tank with piezometer)

10. Making a suitable Pneumatic (or) Hydraulic circuit connection with DCVS, flow control valve and check valve to show the reciprocating motion of a double acting cylinder with metering-in control circuit. (Equipment: Either Pneumatic trainer kit with air compressor (or) Hydraulic trainer kit with hydraulic power pack)

11. Making a suitable Pneumatic (or) Hydraulic circuit connection with DCVS, flow control valve and check valve to show the reciprocating motion of a double acting cylinder with metering-out control circuit. (Equipment: Either Pneumatic trainer kit with air compressor (or) Hydraulic trainer kit with hydraulic power pack) SCHEME OF EXAMINATION: Mechanics of Materials Lab(any one exercise) : 35 marks(1½ Hrs) Fluid Mechanics Lab(any one exercise) : 35 marks(1½ Hrs) Viva - voce : 05 marks Total : 75 marks

39

12036 WORKSHOP – I (SMITHY, FOUNDRY & WELDING)

6 Hrs/Weeks 16 Weeks / Sem Total Hrs : 96 OBJECTIVES:

• Identify the tools used in foundry. • Identify the tools and equipments used in welding. • Prepare sand moulds for different patterns. • Perform welding operation to make different types of joints. • Identify the different welding defects. • Appreciate the safety practices used in Smithy and welding. • Make components in smithy.


Examinations Subject Instruction Assessment Marks

Hours/Week Hours/Semester Internal Board Exam Total 12036 Workshop – I ( Smithy, Foundry &

Welding ) 6 96 25 75 100

1.0 Smithy

Syllabus:

1. Introduction to safety in smithy shop 2. Introduction of hand tools and equipments 3. Operations in smithy 4. Identify the defects in smith forged components

Exercises: 1. Round rod to hexagonal rod 2. Round rod to square rod 3. Round rod to square headed bolt 4. Round rod to ‘S’ Shape 5. Round rod to flat with 25mm

Material: Dia 12mm X 100mm Length.

2.0 Foundry Syllabus

1. Introduction of tools and equipments 2. Types of patterns 3. Types of sand 4. Preparation of sand moulds 5. Furnaces- crucible furnace and tilting furnace 6. Melting if non ferrous metal 7. Core sands, preparation of cores

Exercises: Preparation of sand mould: 1. Solid pattern

a. Stepped Pulley b. Bearing top c. Gear Wheel d. T-pipe

2. Split pattern a. Bent Pipe b. Dumbles

3. Loose Piece Pattern- Dowtail 4. Cylindrical core making 5. Melting and casting– (Not for Examination, only for class exercises)

40

3.0 Welding Syllabus 1. Introduction of safety in welding shop 2. Introduction to hand tools and equipments 3. Are and gas welding equipments 4. Types of joints Exercises:

1. Arc welding

• Lap joint ( Material: 25mm x 3mm Ms Flat ) • Butt joint ( Material: 25mm x 6mm Ms Flat ) • T-joint ( Material: 25mm x 3mm Ms Flat ) • Corner joint ( Material: 25mm x 3mm Ms Flat )

2. Gas Welding

• Lap joint ( Material: 25mm x 3mm Ms Flat ) • Butt Joint ( Material: 25mm x 6mm Ms Flat )

3. Gas cutting: Profile cutting. 4. Spot welding-Lap joint(18/20swg) 5. Demonstration of Soldering and brazing

SCHEME OF EXAMINATION: Foundry : 45 marks (2 hours) Smithy / Welding (by lot) : 25 marks (1 hour) Viva-voce : 05 marks Total : 75 marks

41

12041 APPLIED THERMODYNAMICS

6 Hrs/Week 16 Weeks /Sem.

Total Hours : 96 OBJECTIVES:

• Explain the basics of systems and laws of thermodynamics, and thermodynamic processes. • Explain different Air cycles. • Apply steady flow energy equation for nozzles and condensers. • Explain the types and functions of I.C. Engines. • Explain the fuels and calorific value of fuels. • Explain the performance tests on I.C. Engines. • Compare the modes of heat transfer and evaluate the heat transfer by various modes. • Familiarize parts, function and types of Air compressors and determine their efficiency. • Describe the working of Gas turbines.


Subject Instruction Examinations Hours/Week Hours/Semester Assessment Marks

Internal Board Exam Total 12041- Applied

Thermodynamics 6

96 25 75 100


Unit Topic TIME (Hrs) I. Thermodynamics and Expansion of gases 18 II. Steady flow energy equation and Air cycles 18 III. Internal combustion engines 18 IV. Fuels and Performance of IC Engines 18 V. Air Compressors and Gas Turbines 18


UNIT I: THERMODYNAMICS AND EXPANSION OF GASES 18hrs Introduction - definitions and units of mass, weight, volume, density, specific weight gravity - pressure - units - atmospheric, gauge, vacuum and absolute pressure - temperature - Celsius and absolute temperature - S.T.P and N.T.P conditions - heat - specific heat capacity at constant volume and at constant pressure - work - power - energy - types - thermodynamic system - types -properties and state of system - intensive and extensive properties - thermodynamic process - cycle - point and path function - law of conservation of energy - equilibrium - thermodynamic - zeroth , first and second law of thermodynamics- problems Perfect gases - law of perfect gases - Boyle's, Charles', Joule's, Regnault's and Avagadro's law -characteristic gas equation - relation between specific heats and gas constant - universal gas constant - problems -enthalpy -change in enthalpy - entropy - change in entropy - general equation for change in entropy. Expansion of gases - thermodynamic processes - constant volume, constant pressure, isothermal (hyperbolic), isentropic (reversible adiabatic), polytropic, free expansion and throtting processes - p-V and T-s diagrams, work done, change in internal energy, heat transfer, change in enthalpy, change in entropy for various processes - problems.

UNIT II: STEADY FLOW ENERGY EQUATION AND AIR CYCLES 18hrs Steady flow system - control volume - steady flow energy equation - applications- steam boiler - condenser -nozzles - steam and gas turbines -reciprocating and rotary compressors - non flow energy equation - problems. Air cycles - air standard efficiency - reversible and irreversible processes - thermodynamic reversibility - conditions of reversibility assumptions in deriving air standard efficiency -Carnot cycle- Otto cycle - Joule cycle -Diesel cycle -comparison of Otto cycle and Diesel cycle- ideal and actual p-V diagram of Diesel cycles - comparison - problems - dual combustion cycle (description only).

42

UNIT III: INTERNAL COMBUSTION ENGINES 18hrs Introduction - classifications -four stroke cycle petrol and diesel engines - merits and demerits - two stroke cycle petrol and diesel engines - comparison- constructional details of I.C.engine -components of engines - cylinder block, crankcase, cylinder head, liners, oil pan, piston, piston rings, connecting rod, crank shaft, cam shaft, valve and valve train - material and manufacturing methods - valve timing diagram for four stroke petrol and diesel engines - port timing for four stroke petrol and diesel engines Layout of fuel supply system in petrol engines - A.C. mechanical fuel pump- simple carburetor - Solex carburetor - layout of fuel supply system in diesel engine - single acting fuel feed pump - CAV fuel injection pump -fuel injectors -types of nozzles - fuel filters. Ignition systems - compression and spark ignition - coil, magneto and electronic ignition systems - governing of I.C.engines - quantity and quality governing -cooling systems - air-cooling - water cooling -merits and demerits. Lubrication - purpose - properties of lubricant - types of lubrication system - oil pump and oil filters -scavenging - super charging- effects and applications - turbo charger. UNIT IV: FUELS & PERFORMANCE OF I.C ENGINES 18hrs Fuels - classifications - merits and demerits - requirements of a good fuel - combustion of fuels - stoichiometric air required for complete combustion of fuels- excess air- products of combustion - problems -calorific value - Bomb and Junker’s calorimeter - problems - Orsat apparatus for flue gas analysis - air pollution - effects and control of pollution Performance of I.C engines - Testing - thermodynamic and commercial tests - indicated power - brake power - friction power- efficiencies of I.C engines- indicated thermal, brake thermal, mechanical and relative efficiencies - Morse test- procedure - problems -heat balance sheet - problems. UNIT V: AIR COMPRESSORS AND GAS TURBINES 18hrs Air compressor - uses of compressed air - classifications of compressor - working principle of a compressor - single stage reciprocating compressor - compression processes - power required to drive the compressor - problems -clearance volume and its effects - volumetric efficiency - power required to drive the compressor with clearance volume -problems- multi stage air compressor - merits and demerits - intercooler - perfect inter cooling - work input on multi stage compressor - condition for minimum work input in multi stage compressor with perfect inter cooling - ratio of cylinder diameter for minimum work input - problem - rotary compressors - Roots, vane blowers - centrifugal and axial flow air compressors. Gas turbines- classifications - advantages and disadvantages of gas turbines - constant pressure gas turbine - gas turbine with regenerator - inter cooler - reheater - effects - closed cycle gas turbines - merits and demerits of open and closed cycle gas turbine - turbojet engines- merits and demerits - turbo propeller engines- merits and demerits -ramjet- comparison of air - craft and industrial gas turbines.

Revision and Test 6Hrs

Text Books:

1. R.S.Khurmi and J.K..Gupta, Thermal Engineering, Edn. 18,, published by S.Chand & Co. 2. P.K.Nag, Applied Thermodynamics, Edn. 2, Tata McGraw Hill Publishing Co. Ltd., 7, West Patel

Nagar, New Delhi 110 008.

Reference Books:

1. P.L Ballaney, Thermal engineering, Edn. 24, Khanna Publishers, 2B, North Market, Naisarak, New Delhi 110 006 - 2005.

2. B.K Sarkar, Thermal engineering, Edn. 3, 1998, published by Dhanpat Rai & Sons, 1982, Naisarak, New Delhi 110 006

3. Domkundwar and C.P kothandaraman, Applied Thermodynamics, Edn. 2 – 1996 published by Khanna Publishers.

43

12041 APPLIED THERMODYNAMICS MODEL QUESTION PAPER-I



PART –A Answer all the questions 1x10=10 1. Define temperature 2. Define intensive property 3. Write the SFEE for a) Steam Boiler b) Steam condenser 4. Write the expression for air standard efficiency of Diesel cycle. 5. Name the four strokes of a petrol engine 6. What is the main function of a carburetor? 7. State the difference between indicated power and brake power. 8. What for an orat apparatus is used? 9. What is an air compressor? 10. What is a gas turbine?

PART- B Answer all the questions 3x5=15

11. Derive an expression for work done during Isothermal process. 12. Calculate the air standard efficiency of an Diesel cycle having compression ratio 18 and expansion ratio

10. 13. List out the important properties of a lubricant. 14. Explain what is higher calorific value and lower calorific value of a fuel. 15. State the effects of a clearance volume in a air compressor.

PART-C Answer any one question from each unit 10x5=50 16. 1. 0.25KG of air at a pressure of 140kn/m2 occupies 0.15m3 and from this conditions it is compressed to

1.4MN/m 2 according to the law pv1.25 = C. Determine (i) Change in Internal energy (ii) Work transfer (iii) Heat transfer iv) Change in Entropy. Assume Cp=1.005kj/jg.k and Cv=0.718kj/kg.k. OR (10)

2. Explain open and closed system with atleast two examples each. (10) 17. 1. (a) State and explain steady flow energy Equation. (4)

(b) In a steady flow of air through a nozzle, the enthalpy decreases by 40kj between two sections. Assuming that there are no other energy changes than the kinetic energy, determine the increase in velocity at section 2 if the velocity at section 1 is 100m/s. (6)

OR 2. (a) In an otto cycle the compression ratio is changed from 4.5 to 8.5. Determine the increase in A.S.E

of the cycle. (4) (b) Find the A.S.E of a Diesel cycle engine if the cut off is 6% of the stroke and the clearance is 1/13th

of the stroke take γ = 1.4. (6) 18. 1. Explain the neat sketch the working of inline fuel injection pump used in Diesel Engine. (10)

OR 2. Explain the neat sketch the construction and working of water pump cooling system. (10) 19. 1. With a sketch explain the construction, working and calculation method for finding out calorific value of

a solid fuel using Bomb Calorimeter. (10) OR

2. Explain a) Procedure for Morse Test on a petrol Engine. b) Procedure of heat balance test on a diesel engine. (10) 20. 1. Explain with sketches the construction and operation of a) Roots for blower b) Centrifugal compressor.

(10) OR

2. Find the percentage saving in work by compressing air in two stages from one bar to seven bars instead of in one stage. Assume compression index as 1.35 in both cases and complete intercooling in two-stage compression. (10)

44

12041 APPLIED THERMODYNAMICS MODEL QUESTION PAPER-II

DURATION : 3 HRS. MAX MARKS:75 NOTE : Answer all the questions from Part-A (1 mark each)


PART –A Answer all the questions 1x10=10 1. Explain the term absolute zero of temperature. 2. State the First law of thermodynamics. 3. What is meant by control volume. 4. Define Air standard efficiency. 5. What is meant by valve timing diagram? 6. State the different types of cooling systems used in I.C. Engines. 7. Write expression for theoretical minimum air required for complete combustion of 1kg of a fuel. 8. Define Mechanical efficiency. 9. Name the various types of compression process used in air compression. 10. What is an open cycle gas turbine? PART-B Answer all the questions 1x10=10 11.A cylinder contains 3kg of oxygen at 5-bar pressure and temperature of 27ºc. Determine the volume of

the cylinder. 12.State the conditions for reversibility. 13.Define carburetion and state the requirements of a carburetor. 14.What are the requirements of a good fuel? 15.Explain with a p-v diagram, the various types of compression. PART-C Answer any one question from each unit 10x5=50 16. 1. 1Kg of air at 11 bar and 80ºc is expanded to 10 times the original volume by i) Isothermal process

ii) Isentropic process. Determine the work done in each of cases. Also plot these two on a common p-v diagram R=287J/Kg.k and γ=1.4. (10)

OR 2. Derive an expression for work done during a polytropic process. (10) 17. 1. a) State the assumptions made in deriving air standard efficiency. (4) b) Derive an expression for A.S.E of an otto cycle. (6)

OR 2. What will be the loss of thermal efficiency of a diesel engine with a compression ratio of 14, if the fuel cut

–off is delayed from 5% to 9% of the stroke. (10) 18. 1. Explain with neat sketches the construction and operation of a two stroke cycle petrol engine. (10)

OR 2. Explain with sketches the working of A.C Mechanical fuel pump. (10)

19. 1. The following data were obtained during a trial on an oil engine. Brake power=73.5kw. Fuel consumed=1kg 16.5kg/hour calorific value of fuel=45200Kj/kg. Mechanical efficiency = 82%. Find i) Brake Thermal efficiency ii) indicated Thermal efficiency iii) Indicated power. (10)

OR 2. A fuel contains 92% carbon, 4% hydrogen, 2% sulphur, oxygen 1.5%, Ash 0.5%. It is supplied with 50%

excess of air. Find i) Minimum mass of air required for complete combustion of 1kg of fuel ii) Gravimetric composition of the products of combustion. (10)

20. 1. a) Explain the working of a multistage air compression with intercooling. (4) b) Derive an expression for workdone by a two stage reciprocating air compressor with complete inter

cooling. (6) OR

2. Explain with a neat sketch the working of a ramjet. State its applications and advantages.(10)

45

12042 MACHINE SHOP TECHNOLOGY


• Explain the working of machine tools planer, shaper and slotter. • Compare various work holding devices • Explain the working of machine tools drilling machine and milling machine. • Distinguish various types of milling cutter. • Classify the different types of grinders and grinding wheels. • Explain the broaching operation and boring operation and their applications. • Explain the milling procedure for spur, helical and bevel gears. • Explain the various types of gear generating processes • Compare the various types of jigs and fixtures. • Explain the different types of press working operations. • Appreciate the use of non-conventional machining processes.



Internal Board Exam Total 12042- Machine

Shop Technology 6

96 25 75 100


Unit Topic TIME (Hrs) I. Planer, Shaper and Slotter 18 II. Drilling Machines and Milling Machines 18 III. Grinding, Broaching, Boring and Jig Boring 18 IV. Gear manufacturing Practice – Forming and

Generating 18

V. Jigs & Fixtures, Press working & Non-Conventional Machining process.

18


UNIT-I: PLANER, SHAPER AND SLOTTER 18 Hrs Planer: Types of planers-description of double housing planer-specifications-principles of operation-drives-quick return mechanism-feed mechanism- work holding devices and special fixtures-types of tools-various operation. Shaper: Types of shapes-specifications-standard-plain-universal-principles of operations-drives-quick return mechanism-crank and slotted link-feed mechanism-work holding devices-Special fixture-various operations. Slotter: Types of slotters-specifications-method of operation-Whitworth quick return mechanism-feed mechanism-work holding devices-types of tools. UNIT -II: DRILLING MACHINES AND MILLING MACHINES 18 Hrs Drilling machines: Drills-flat drills-twist drills-nomenclature-types of drilling machines-bench type-floor type-radial type-gang drill-multispindle type-principle of operation in drilling-speeds and feeds for various materials-drilling holes-methods of holding drill bit-drill chucks-socket and sleeve-drilling-operation-reaming-counter sinking-counter boring-spot facing-tapping-deep hole drilling. Milling machines: Types-column and knee type-plain-universal milling machine-vertical milling machine-specification of milling machines-principles of operation-work and tool holding devices-arbor-stub arbor-spring collet-adapter-milling cutters-cylindrical milling cutter-slitting cutter-side milling cutter-angle milling cutter-T-slot milling cutter-woodruff milling cutter-fly cutter-nomenclature of cylindrical milling cutter-milling process-conventional milling-climb milling-milling operations-straddle milling-gang milling-vertical milling attachment.

46

UNIT-III: GRINDING, BROACHING, BORING AND JIG BORING 18 Hrs Grinding machines: Types and classification-specifications-rough grinding – pedestal grinders- portable grinders- belt grinders-precision grinding-cylindrical grinder-center, centerless type – surface grinder-planetory grinders-principles of operations-grinding wheels-abrasives-natural and artificial diamond wheels-types of bonds-grit, grade and structure of wheels-wheels shapes and sizes-standard marking systems of grinding wheels-selection of grinding wheel-mounting of grinding wheels-Dressing and Truing of wheels-Balancing of grinding wheels. Broaching: Types of broaching machine-horizontal vertical and continuous broaching-principles of operation-types of broaches-classification-broach tool nomenclature-broaching operations-simple examples. Boring and Jig boring: Boring machines-horizontal and vertical types-fine boring machines-boring tools-jig boring machine-measuring system-hole location procedure-deep hole boring. UNIT-IV: GEAR MANUFACTURING PRACTICE – FORMING AND GENERATING 18 Hrs Gear manufacturing practice-Forming and Generating processes: Gear forming process in milling-dividing head-principles of operation-indexing-linear indexing-simple-differential and angular indexing-problems-gear milling, cutter selection-module-pressure angle-milling procedure for spur, helical and bevel gears-problems. Generating process-gear shaper-gear hobbing-principle of operation only-gear finishing processes-burnishing-shaving-grinding and lapping-gear materials-cast iron, steel, alloy steels, brass, bronze, aluminium, nylon.

UNIT-V: JIGS & FIXTURES, PRESS WORKING & NON-CONVENTIONAL MACHINING PROCESS 18 Hrs Jigs and Fixtures: Definitions and concept of Jig and fixture-Advantages of jigs and fixtures-elements of jigs and fixtures-locating devices-'V' locators-fixed stop locators-adjustable stop locators-clamping devices-strap clamp, screw clamp-cam action clamp-types of jigs-box drill jig-indexing drill jig-types of fixtures-keyway milling fixture-string milling fixture. Press working: Types of presses-mechanical and hydraulic presses-press tools and accessories-press working operations-bending operations-angle bending-channel bending -curling-Drawing-shearing operations - blanking, piercing trimming-notching-lancing-shaving-parting off. Non-Conventional Machining process: Construction and working of Ultrasonic machining-chemical machining-electro chemical grinding-electrical discharge machining-plasma arc machining-LASER machining-Advantages – Disadvantages-Applications-of the above processes.

Revision and Test 6Hrs Text Books: 1. Hajra Choudry & Battacharya, Elements of Workshop Technology-Vol. I & II, Edn. 11, published by Media

Promoters and Publishers Pvt. Ltd., Seervai Buildings `B’, 20-G, Noshir Bharucha Marg, Mumbai 400 007 - 2007

2. Jain & Gupta, Production Technology, Khanna Publishers, 2-B, North Market, Naisarak, new Delhi – 110 006 – 2006.

Refenence Books: 1. HMT, Production Technology, Edn. 18, published by Tata McGraw Hill Publishing Co. Ltd., 7, West Patel

Nagar, New Delhi 110 008. 2. Myro N Begman, Manufacturing process, Edn. 5, Tata McGraw Hill Publishing Co. Ltd., 7, West Patel Nagar,

New Delhi 110 008. 3. WAJ. Chapman, Workshop Tech Vol I,II, III, published by Viva Books Pvt. Ltd., 4262/3, Ansari Road,

Daryaganj, New Delhi 110 002. 4. NITTTR, Production processes published by . 5, Tata McGraw Hill Publishing Co. Ltd., 7, West Patel Nagar,

New Delhi 110 008.

47

12042 MACHINE SHOP TECHNOLOGY MODEL QUESTION PAPER – I



PART –A Answer all the questions 1x10=10

1. What are different drive mechanism used to drive the table of a planer? 2. What are types of slotting machines used in the Industry? 3. Define the depth of a drilling operations. 4. Differentiate between plain milling machine and universal milling machine. 5. What is grit in a grinding wheel manufacturing? 6. What are types of boring machine? 7. What is pressure angle of a gear? 8. What are the different types of Indexing? 9. Define fixture. 10. What is plasma?


11. Explain with a neat sketch machining of angular surface in a Shaper. 12. What are the specifications of a milling machine? 13. Explain with a neat sketch the mounting of a grinding wheel. 14. Write the step by step procedure for manufacturing of spur gear in a milling machine. 15. Differentiate between the blanking tool and piercing tool.

PART-C Answer any one question from each unit 10x5=50 16. 1. a) Explain with a neat sketch the slotted link quick return mechanism of a shaper. (5) b) What are the different operation performed on a slotter? Explain with a neat sketch any one such

operation. (5) OR

2. a) Explain with a neat sketch the automatic feed mechanism of a planer. (6) b) What are specifications of a shaper? (4) 17. 1. a) Nomenclature of a twist drill. (5) b) Explain with a neat sketch the ‘T’ – slot milling operation. (5)

OR 2. a) List out the drilling operations. Explain with a neat sketch any two such operations. (6) b) Explain with a neat sketch the arbor of a milling machine. (4) 18. 1. a) BIS marking of a grinding wheel – explain? (6) b) Explain with a neat sketch the Jig boring machine. (4)

OR 2. a) Sketch the horizontal boring machine and label the parts. (5) b) Explain with a neat sketch the planetary grinding operations. (5)

19. 1. a) Explain with a neat sketch the differential Indexing method. (4) b) Explain with a neat sketch the gear hobbing Process. Write its advantages. (6)

OR 2. a) What are different methods of gear finishing processes? Explain any two Process? (6)

b) What are the merits and demerits of nylon as gear material? (4) 20. 1. a) Explain with a neat sketch the box drill jig. (4) b) Write short notes on: (i) Bending

(ii) Lancing (iii) Shaving (6)

OR 2. Explain with a neat sketch the electrical discharge machining processes. What are merits and demerits

of this processes. (10)

48

12042 MACHINE SHOP TECHNOLOGY MODEL QUESTION PAPER-II




1. What is the function of a clapper box in a shaper? 2. What is quick return mechanism of slotter? 3. What are the different types of drilling machine? 4. What are the different tool holding devices used in a milling machine? 5. List out the boring tools. 6. What are the different types of broaching machine? 7. What is the amount of crank movement for manufacturing 20 Teeth gear on a milling machine. 8. What are the advantages of aluminum as a gear material? 9. Define Jig. 10. What is Press tool?

PART – B Answer all the questions 5X3=15

11. What are the specifications of a Planer? 12. Differentiate between the gang milling and struddle milling operations. 13. What are the different feeds used in centreless? 14. List out the gear finishing processes. Explain any one gear finishing processes. 15. What are the advantages of Electrical discharge machining?

PART – C Answer any one question from each unit 5X10=50 16. 1. a) Sketch a double housing planer and label the principal parts of a planer. (5) b) Explain with a neat sketch the whit worth quick return mechanism of a slotter. (5)

OR 2. a) Explain with a neat sketch the automatic feed mechanism of a shaper. (5) b) List out the work holding devices used in a planer. Explain with a neat sketch any one such device.

(5) 17. 1. List out the drilling operations. Explain with a neat sketch any four operations. (10)

OR 2. a) Nomenclature of a cylindrical milling cutter. (5) b) Explain with a neat sketch the milling processes. (5) 18. 1. a) Explain with a neat sketch the cylindrical grinding machine. (5) b) Nomenclature of a pull broach (5)

OR 2. a) What are the criteria while selecting a grinding wheel? (5) b) List out the different methods of locating a hole in jig boring machine. Explain any one method? (5) 19. 1. a) Explain with a neat sketch the gear shaper. Write its demerits. (6) b) Explain with a neat sketch the simple indexing method (4)

OR 2. a) Write the step by step procedure for manufacturing of bevel gear in a milling machine. (5) b) What are the different materials used for manufacturing of gears? Write its advantages. (5) 20. 1. a) What is locating elements? Explain with neat sketch any two locators. (5) b) Explain with a neat sketch the ultrasonic machining process. (5)

OR 2. Explain with a neat sketch the different drive mechanism used in a presses. (10)

49

12043 ELECTRICAL AND ELECTRONICS ENGINEERING

5 Hrs/Week 16 Weeks /Sem. Total Hrs : 80

OBJECTIVES:

• Define Voltage, Current, Resistance, Power and energy. • State Ohm's law, Kirchoff's law and Faraday's laws of electromagnetic induction. • Explain the fundamentals of alternating current. • Describe the construction and working of DC machines. • Describe the construction and working of transformer and alternator. • Explain the working of various types of AC motors. • Describe the construction and working of stepper motor. • Appreciate the use of safety practices in electrical safety. • State the characteristics of semiconductor diode. • Explain the construction and working of PNP and NPN transistor. • Explain the principle and working of thyristors. • State the features and benefits of PLC. • Compare PLC circuits and hardware circuits. • Design ladder logic for operating motors.



Subject Hours / Week Hours / Semester

Internal Board Exam

Total

12043 Electrical and Electronics Engineering

5

80

25

75

100


UNIT TOPIC TIME (Hrs)

I DC and AC Circuits and Batteries 15 II DC Generator, DC Motor, Transformer and Alternator 15 III AC Motors and Electrical Safety 15 IV Basic Electronics and logic gates 15 V Programmable Logic Controller 15 Revision and Test 5 TOTAL 80

UNIT I – DC AND AC CIRCUITS AND BATTERIES 15 HRS. Definitions – Electric current, voltage and resistance – Ohm’s Law and Kirchoff’s Laws – Resistance in series, parallel and series parallel – Simple problems – Electromagnetism (Definitions only), Magnetic flux, Flux density, Magnetic field Intensity, MMF, permeability, reluctance, Faraday’s laws of electro magnetic Induction. Fundamentals of AC voltage and current – Peak, average, RMS value of sine wave, Frequency, time period, amplitude, power, power factor (Definition only) Ac circuits RLC in series star, Delta Connections - relationship between phase and line voltages, current in star and Delta connections. Batteries – classification of cells – construction of ni – iron and cadmium cell concept of recharging cells – lead acid cell – construction - indication of full charged cells defects, and remedies, applications. UNIT II – DC GENERATOR, DC MOTOR, TRANSFORMER AND ALTERNATOR 15 HRS. DC Generator Construction – Principles of operation, types and applications. DC Motor construction – Principles of operation, types and applications. Necessity for starter – three point, four point starter. Transformer – principle of operation and construction EMF equation – losses in a transformer – efficiency – autotransformer – three phase transformer – applications. Alternator construction – principle of operation – types and applications.

50

UNIT III – AC MOTORS AND ELECTRICAL SAFETY 15 HRS. AC motors: Principle of operation of single phase capacitor start induction motor – applications – three phase induction motors – squirrel cage and slip ring IM (construction and working principle only) – applications – speed control of three phase induction motor – necessity of starter – DOL and star delta starter. Special motor: PMDC, Stepper motor – construction, working principle and application. Electrical Safety – importance of earthing – electric shock – first aid for electric shock – precautions against shock – cause of accidents and their preventive measures – energy conservation. UNIT IV – BASIC ELECTRONICS AND LOGIC GATES 15 HRS. Semiconductor materials – N type and P type – PN Junction – forward and reverse bias, characteristics of PN functions diode – Half wave rectifier, full wave rectifier, bridge rectifier, zener diode and avalanche break down, characteristics of zener diode – application of zener diode. Transistor – construction of NPN and PNP types – basic bias requirements (common emitter configuration only) Thyristors – principle and working of SCR – characteristics – applications. Introduction of integrated circuits – classification and packages only – applications. Logic Gates – positive and negative logic, definition, symbol, truth table, Boolean expression for OR, AND, NOT, NOR, NAND, EXOR and EXNOR gates. UNIT V – PROGRAMMABLE LOGIC CONTROLLER 15 HRS. PLC definition – features and benefits of PLC – Systems and its elements – input and output elements – PLC memory system – PLC circuit verses hard wired circuits – sensors – types of sensors – limit switch, reed switch, photo electric sensor, inductive proximity sensor – types of contacts normally open (NO) contact, normally closed (NC) contract – ladder logic symbol – AND logic OR logic , truth table – steps involved in application circuits using a PLC – PLC scan input Programme scan and output scan – design ladder diagram for operation of motor using AND and OR logic. Design ladder logic diagram for ON delay control of a motor and OFF delay control of a motor.

Revision and Test 5 Hrs Text Books: 1. B.L. Theraja, Fundamentals of Electrical and Electronics Engineering, S.Chand & Co. 2. T. Thiyagarajan, Fundamentals of Electrical and Electronics Engineering, Scitech Publicatiuons (India)

Pvt.ltd.

Reference Books: 1. Mikell P. Groover, Automation, Production System and Computer Integrated Manufacturing, Edn. 2

published by Pearson Education (Singapore) Pte. Ltd., Indian Branch, 2842 F.I.E., Patparganj, Delhi 110 002, India.

2. KB Raina & S.K.Battachariya, Electrical Design Estimating and Costing, Edn. 6, Tata McGraw Hill Publishing Co., 7, West Patel Nagar, New Delhi 110 008.

3. Gary Dummy, Introduction to Programmable logic controls, Thomson Debnar learning second edition second reprint 2003.

4. B.L.Theraja & A.K. Theraja, Electrical Technology Vol. I & II, Edn. 23, published by S.Chand & Co. Ltd., Ram Nagar, New Delhi 110 055.

12043 ELECTRICAL AND ELECTRONICS ENGINEERING MODEL QUESTION PAPER – I




1. Define Electrical power? Write its unit. 2. Define flux density? 3. Write any two applications of transformer.

4. What is the necessity of starter? 5. What are the types of three phase induction motors? 6. How will you avoid Electrical shock. Any two precautionary measure? 7. Mention any two types of P type Semi conducting material. 8. Draw the symbols for the following logic gates. 1.AND 2.EXOR 9. Write any two benefits of PLC. 10. Draw the ladder diagram for obtaining the OR logic.

PART –B Answer all the questions 3x5=15

11. When two resistors are connected in series the effective resistance is 10 ohms and when they are connected in parallel the effective resistance is 2 ohms. Find the value of two resistors.

12. Write the principle of operation of DC motor. 13. Write the types of single phase induction motors and write any two application for each. 14. Draw the basic circuit of half wave rectifier using diode and write its principle of operation. 15. Develop the ladder diagram for on delay timer and write its truth table.

PART –C Answer any one question from each unit 10x5=50

16. 1. a) Find the effective resistance for the following circuit and power developed (6) 5Ω 3Ω 2Ω 50V b) What are the applications of lead acid cell (4)

OR 2. a) State and explain Kirchoff’s law. (4)

b) Find the current flowing through 5 ohms resistor using Kirchoff’s laws. (6) 2Ω 10Ω

5Ω 15V 20V 17. 1. Explain the constructional features of Altenator with suitable diagram (10) OR 2. Explain the principle of operation of single phase transformer. What are its losses and derive the emf equation of single phase transformer. (10)

18. 1. a) Draw three point starter for DC machine. (6) b) Write the working principle of stepper motor. (4)

OR 2. a) Write the working principle of three phase Squirrel cage induction motor. (6) b) Write any four applications of single phase induction motors (4)

51

52

19. 1. Draw the basic diagram for common emitter configuration with proper biasing and explain. (10)

OR 2. Write the principle and working of SCR along with its characteristic (10)

20. 1. a) Compare PLC circuit with hard wired circuit (6)

b) Develop a ladder diagram for starting a three phase induction motor using DOL starter using PLC. (4)

OR 2. a) Design a ladder diagram for off delay control of a motor using PLC (6) b) What are the different types of sensors used in automation industry using PLC (4)

12043 ELECTRICAL AND ELECTRONICS ENGINEERING

MODEL QUESTION PAPER – II




1. Define mmf. 2. What is the relationship between line voltage and phase voltage and line current and phase current in star and delta connected system. 3. Explain the principle of operation of DC generator. 4. Mention any two application of DC motor. 5. Write the types of single phase induction motors. 6. What is the first aid you will give when a person is affected by shock? 7. Classify Integrated circuits. 8. Draw the symbols for the following 1. Semiconductor diode 2. Zener diode 9. Define PLC. 10. Draw the ladder diagram to obtain AND logic using PLC.


11. What are the indications of fully charged cell? 12. Explain the principle of operation of single phase transformer. 13. What is the importance of earthing? Write any three types. 14. Draw the circuit of full wave bridge and its operation with suitable waveforms. 15. Design and develop the ladder diagram for ON delay timer using PLC.


16. 1. a) Define faraday’s laws of Electro magnetic induction (4) b) Determine the value of R if the voltage across it is 25 volts (6)

20Ω 100V 50Ω R

2. a) Draw the constructional features of lead acid battery. (4)

b) Find the value of current flowing through 3Ω for the following circuit. (6) 5Ω 2Ω

53

3Ω 10V 20V 17. 1. Explain the constructional features of DC machine with suitable diagram. (10) OR 2. Draw the circuit of four point starter and write in detail about its operation. (10)

18 1. Write in detail how will you control the speed of three phase induction motor. (10) OR

2. Write the principle of operation of single phase capacitor srart induction motor with suitable sketch. (10)

54

19 1. a) Explain avalanche break down and zener break down (4) b) Draw the characteristics and applications of zener diode also write how it can be used as a

stabilizer (6) OR

2. a) Explain what is mean by positive and negative logic (4) b) Draw the symbol and truth table for the following logic gates

1. NOT 2. OR 3. AND 4. NAND 5. EXOR 6. EXNOR (6)

20 1. a) What is input and output scan regarding PLC operation (4) b) Develop the ladder diagram for OFF delay timer control of motor using PLC. (6) OR

2. a)Design and develop ladder logic for semi automatic starter for starting of three phase induction motor using PLC (6)

b) What are the different types of contactors used in automation industry using PLC (4)

55

12044 THERMODYANAMICS LABORATORY


• Determine the flash point, power point and viscosity of oil. • Identify the parts of petrol engine and their functions. • Identify the parts of diesel engine and their functions. • Draw the Valve timing diagram of petrol Engine. • Draw the port timing diagram of two stroke petrol engine. • Conduct performance test on petrol engines. • Conduct performance test on diesel engines. • Identify the parts of a high pressure boiler and their applications. • Prepare heat balance sheet for an I.C. Engine.



Internal Board Exam Total 12044-

Thermodynamics Laboratory

6

96 25 75 100

Study Exercise: (Not for Examination) 1. Study of petrol engine & diesel engine and its components. 2. Study of high-pressure boiler (with model). 3. Study of boiler mountings. 4. Study of boiler accessories. List of experiments PART A 1. Determining flash and fire points of the given oil using open cup apparatus. 2. Determining flash and fire points of the given oil using close cup apparatus. 3. Determining the absolute viscosity of the given lubricating oil using Redwood viscometer. 4. Determining the absolute viscosity of the given lubricating oil using Saybolt viscometer. 5. Valve timing diagram of four-stroke cycle petrol engine. 6. Valve timing diagram of four-stroke cycle diesel engine. 7. Port timing diagram of two-stroke cycle petrol engine. PART B 1. Load test (Performance Test) on petrol engine. 2. Load test (Performance Test) on diesel engine. 3. Morse test on multicylinder petrol engine. 4. Heat balance sheet on I.C engine. 5. Emission test for petrol / diesel engine. 6. Volumetric efficiency of air compressor. SCHEME OF EXAMINATION:

One question from PART A : 25 marks (1 hour) One question from PART B : 45 marks (2 hours) Viva voce : 05 marks Total : 75 marks

56

12045 ELECTRICAL AND ELECTRONICS ENGINEERING LABORATORY 6 Hours / Week 16 Weeks/Sem.

Total Hours : 96 Hrs. SCHEME OF INSTRUCTION AND EXAMINATION

Subjects Instructions Examinations Hours/Week Hours/Semesters Internal Board Exam Total 12045- Electrical and

Electronics Engineering Laboratory

6 96 25 75 100

OBJECTIVES: • Verify Ohm's law. • Estimate power and power factor in single phase circuit. • Determine the efficiency of single phase transformer. • Find the efficiency of DC shunt motor and induction motors. • Determine the VI characteristics of PN diode and SCR. • Construction and testing of half wave and full wave rectifier. • Use bridge rectifiers to convert AC into DC. • Verify the different logic gates AND, OR, NOT, NOR, NAND, EXOR, EXNOR. LIST OF EXPERIMENTS : ELECTRICAL: 1. Verification of Ohm’s Law. 2. Measurement of power and power factor in single phase circuit. 3. Open circuit and short circuit test on a single phase transformer to find the losses and efficiency. 4. Starting a three-phase induction motor by DOL starter and noting the no load current and speed. 5. Load test on DC shunt motor to find the efficiency. 6. Load test on a three-phase induction motor at various loads to find the efficiency. 7. Starting a three phase induction motor by Star / Delta starter and noting the no load current and speed. 8. Load Test Single-Phase transformer. ELECTRONICS: 9. VI Characteristics of a PN Junction diode. 10. VI Characteristics of a SCR. 11. Construct a Half wave Rectifier without filter and measure AC input and DC output voltage. 12. Construct a Full wave rectifier without filter and measure AC input and DC output voltage. 13. Construct a bridge Rectifier with filter and measure AC input and DC output voltage. 14. Verification of truth table for AND, OR, NOT, NOR, NAND, EXOR and EXNOR gates. SCHEME OF EXAMINATION: Electrical Experiment : 35 marks (1½ Hrs) Electronics Experiment : 35 marks (1½ Hrs) Viva-Voce : 05 marks

Total : 75

57

12046 WORK SHOP-II (Turning, Drilling, Shaping)


• Identify the parts of a center lathe, drilling machine & shaping machine and their functions. • Use tools and instruments for turning, drilling and shaping. • Identify the work holding devices • Hold the work in proper work holding devices. • Set the tools for various operations. • Operate the lathe, drilling machine & shaping machine • Machine a component using lathe, drilling machine & shaping machine. • Follow safety practices while machining.


Instruction Examinations Subject Hours/Week Hours/Semester Assessment Marks

Internal Board Exam Total 12046- Workshop –II (Turning, Drilling &

Shaping)

6

96

25

75

100

LATHE, DRILLING & SHAPING MACHINES

Syllabus:

1. Introduction of safety in operating machines. 2. Introduction to lathe, drilling machine & shaping machine and its parts. 3. Introduction to work holding devices and tool holding devices. 4. Types of tools used in lathe work, drilling & shaping. 5. Types of measuring instruments and their uses. 6. Setting of work and tools. 7. Operation of lathe, drilling & shaping. 8. Practice on a lathe, drilling and shaping machine

Note: The dimensions may be modified according to the materials specified. Enclosure: Sketches of Lathe, drilling & shaping Exercises. Scheme Of Examination: Lathe exercise : 45 marks (2 hours)

Shaping / Drilling by lot : 25 marks (1 hour) Viva-Voce : 05 marks

Total : 75 marks

LATHE

58

DRILLING

59

SHAPING

61

63

12051 DESIGN OF MACHINE ELEMENTS

7 Hrs/Week 16 Weeks / Sem. Total Hrs : 112 OBJECTIVES:

• Select Engineering materials for specific applications. • Explain the design consideration of machine parts. • Design shafts, keys and couplings for power transmission. • Compare the different types of couplings. • Design belts and pulleys for power transmission. • Differentiate the various types of bearings and their applications. • Design gears for power transmission. • Design hand lever, foot lever and crank lever



Subject Hours/week Hours/Semester

Internal Board Exam Total 12051 – Design of Machine Elements

7 112 25 75 100


UNIT TOPIC TIME ( Hours ) I. Selection of Materials, Procedure for design, Design of Shaft 21 II. Design of bolt, Pins, Keys

Design of cotter joint and couplings 21

III. Design of Belts 21 IV. Design of Bearings 21 V. Design of Levers

Design of Gears 21

Revision and Test 7 Total 112

UNIT – I SELECTION OF MATERIALS, PROCEDURE FOR DESIGN, DESIGN OF SHAFT 21 Hrs Factors affecting selection of materials – Ferrous metals – Cast Iron, wrought Iron, Steel, alloy steel-BIS Specification of Engineering material- Non – ferrous metals – copper, alloys of copper, Aluminium – alloys of aluminium, Tin, Zinc- Procedure for designing machine elements – Types of failures. Design of Shafts: Forces on the shaft due to belt and gear drives – Maximum bending moment – Maximum Torque – Determination of shaft size based on combined bending and twisting moments – Problems. UNIT – II DESIGN OF BOLT, PINS, KEYS DESIGN OF COTTER JOINT AND COUPLINGS 21 Hrs. Design of bolts, Pins and keys: Bolt – Stud – Nut – Design of bolted joints – Design of cylinder cover studs – Taper pins – Type of keys – sunk keys – Feather keys –spline shafts – Design of sunk key – Effect of Key ways -Problems. Design of Cotter Joint and Couplings: Design of – Sleeve and cotter joint – socket and spigot joint – rigid flange couplings – Problems. UNIT – III DESIGN OF BELTS 21 Hrs. Design of Flat belts: Type of belts – materials for belts – Designation of belts – Belt drives – Slip –power transmitted by belt – centrifugal tension-condition for maximum power transmission-initial tension (No derivation) Problem - Design procedure for flat belts – Design of flat belt based on Manufacturer’s data – Problem. Design of V-belts: V-belt drives – power transmitted (Problem)– power Design of V-belt drives – Selection of V-belt by using Manufacturer’s data – Problems.

64

UNIT – IV DESIGN OF BEARINGS 21 Hrs. Design of Bearing: Types of bearing – Ball bearing – Radial and thrust ball bearing – Single row – Double row – Self aligning bearings – Roller bearings – Cylindrical, Spherical, Needle and taper – Standard dimensions and designation of bearings – Materials used for ball and roller bearings – Lubrication of bearings – Journal bearing – Heat generated – Heat dissipated – Design procedure for journal bearings – Problems (Design questions based on approved data book only) UNIT – V DESIGN OF LEVERS DESIGN OF GEARS 21 Hrs. Design of Levers: Type of levers – Application – Design of hand lever – Foot lever – Cranked lever – Problems. Design of Gears: Type of Gears – Gear materials – Spur gear terminology – Gear design by Lewis and Buckingham Equation – Design procedure for spur gear based on Lewis and Buckingham equation – Problems (Based on approved data book only) - Speed reducer. Revision and Test 7Hrs. Text Book 1. Pandya & Shah, Machine Design, Edn. 1995, Charotar Publishing House. 2. S.E.Sundararaja Moorthy & N. Shanmugam, Machine Design, Revised End. June 2003, Narayana

Publications, No.1, M.I.G. Block, Second Avenue, Indira Nagar, Chennai 600 020 – 2004. 3. Design Data Book, by PSG College of Technology, Revised Edn. 1978 published by Kalaikathir Achagam,

Kalakathir Buildings, 670 Avinasi Road, Coimbatore 641 037 – 2004. 4. Design Data Book, Bala Chitra Publishers, Revised Edn. 2003, published by Balachitra Publication,

Coimbatore – 2. Reference 1. R. S. Khurmi & J. K. Gupta, A text book of machine design, Edn. 18, Eurosia Publishing House Pvt. Ltd., Ram Nagar, New Delhi 110 055 – 2006.

65

12051 DESIGN OF MACHINE ELEMENTS MODEL QUESTION PAPER - I

DURATION : 3 HRS. MAX MARKS:75 NOTE: Answer all the questions by either or choice.

Each question carries 15 marks. Approved Data book, P.S.G Data book may be permitted. 1. a) What are the effects of alloying elements on steel? (5)

b) A mild steel rod supports a tensile load of 50KNand the stress in the rod is limited to 100N/mm2. Determine the size of the rod when the cross section is i) circular ii) square and iii) rectangular with width = 3 x t. OR (10)

A shaft is supported on bearings A and B 800 mm between centres. A 20° straight tooth spur gear with 600 mm pitch diameter is located 200mm to the right of left hand bearing A and a 700 mm diameter pulley is mounted 250 mm towards the left of bearing B. The gear is driven by a pinion with a downward tangential force while the pulley drives the horizontal belt having 180°angle of wrap. The pulley also serves as a flywheel and weighs 2000N. The maximum belt tension is 3:1. Determine the maximum bending moment and the necessary shaft diameter if the allowable shear stress of the material is 40N/mm2. (15)

2. A steam engine cylinder has an effective diameter of 350mm and the maximum Steam pressure acting on

the cylinder cover is 1.25N/mm2, Calculate the number and the size of studs required to fix the cylinder cover. Assuming the permissible Stress in the studs as 33MPa. (15)

OR Design a sleeve and cotter joint to withstand a tensile load of 70KN. All parts of the joint are made of the

same material and the permissible stresses are as in tension 56 N/mm2 , in compression 135 N/mm2 and in shear is 62 N/mm2 (15)

3. a) List the types of belts and the material used for it. (5) b) Design a belt drive to transmit 22.5KW at 740r.p.m. to an aluminium rolling machine. The speed ratio is

3. The distance between the pulleys is 3m. Diameter of the rolling machine pulley is 1.2m. OR (10)

a) Design a V-belt drive and calculate the actual belt tensions and average stress from the following data: diameter of driven pulley is 500mm, diameter of driving pulley is 150mm, centre distance between pulleys is 925mm, speed of the driven pulley is 300r.p.m., speed of the driving pulley is 1000r.p.m. power transmitted is 7.5KW. (15)

4 a) With a neat sketch explain rolling contact bearing. (5) b) A full journal bearing has the following specifications: Journal diameter is 60 mm, bearing length is

75mm, radial load on the bearing is 25KN, radial clearance is 0.06mm, speed of the rotation is 1450r.p.m. Determine the mean viscosity of the lubricating oil ,if the minimum film thickness under the operating condition is 0.0125mm. (10)

OR a) Explain the significance of the bearing characteristics number (5) b) Design a journal bearing for a centrifugal pump from the following data: Load on the journal is 20KN,

Speed of the journal is 900p.m., Type of the Oil used is SAE 10 for which the absolute viscosity at 55°C is 17Cp, Ambient Temperature of the oil is 15.5°C, Maximum bearing pressure for the pump is 1.5N/mm2, Heat dissipation co-efficient is 1232J/s/m2/°C. Calculate also mass of lubricating oil required for artificial cooling , if rise of temperature of oil is limited to 10oC.

(10) 5. a) A gear drive is required to transmit a maximum power of 25KW. The velocity ratio is 1:2 and r.p.m. of

the pinion is 200. The approximate centre distance between the shafts may be taken as 600mm. The teeth has 20° stub involute profiles. The material used for the gear is C.I. Find the module, face width and number of teeth on each gear. Check your design for dynamic and wear loads. (15)

OR a) A foot lever is 1m from the centre of the shaft to the point of application of the load of 750N. The

allowable tensile stress is 75N/mm2 and the allowable shear stress is 70N/mm2. Determine 1) diameter of shaft 2) dimensions of boss 3) diameter of shaft at the centre of the bearing 4) dimensions of key 5) dimensions of rectangular arm of the foot lever from the centre of the Shaft, assuming the width of the arm is 3 times the thickness. (15)

66

12051 DESIGN OF MACHINE ELEMENTS MODEL QUESTION PAPER - II

DURATION : 3 HRS. MAX MARKS:75 NOTE: Answer all the questions by either or choice.

Each question carries 15 marks. Approved Data book, P.S.G Data book may be permitted. 1. a) State the purpose of alloying (5) b) A pull of 100KN is transmitted from one shaft to another shaft through a pin by a knuckle joint. If the

maximum permissible tensile stress in the shaft is 100 N/mm2 and the permissible shear stress in the pin is 80 N/mm2. Find the diameter of the shaft and of the pin. (10)

OR a) A pair of wheels of a railway wagon carries a load of 50KN on each axle box, acting at a distance of

100mm outside the wheel base. The gauge of the rails is 1.4m. Find the diameter of the axle between the wheels, if the permissible stress is 100N/mm2. (10)

b) How the free cutting steel is designated? (5) 2. a) Design a sleeve and cotter joint to withstand a tensile load of 60KN. All parts of the joint are made of

the same material and the permissible stresses are as in tension 60 N/mm2 , in compression 125 N/mm2 and in shear is 70 N/mm2 . (15)

OR a) Design a protected type cast iron flange coupling for a steel shaft transmitting 15KW at 200 rpm and

having an allowable shear stress of 40 MPa. The working stress in the bolt should not exceed 30MPa. Assume that the same material is used for shaft and key and that the crushing stress is twice the value of its shear stress. The maximum torque is 25% greater than the full load torque. The shear stress is for cast iron is 14MPa. (15)

3. a) Compare V-belt with flat belt. (5) b) A power of 60KW at 750 rpm is to be transmitted from an electric motor to a Compressor shaft at

300rpm by V-belt. The approximate larger pulley diameter Is 1500mm. The approximate centre distance is 1650mm, cross sectional area is 350 mm2 , and density is 1000kg/m3 , having an allowable tensile stress of 2 MPa is available for use. Overload factor is 1.5, ∝ = 34°, µ = 0.28. Design the belt drive. OR (10)

a) A leather belt drive transmits 15KW power. The centre distance between the pulleys is twice the diameter of the big pulley. The speed of big and small pulleys are 480r.p.m. and 1440r.p.m. respectively. The belt should operate at a velocity of 20m/s approximately and the stresses in the belt should not exceed 2.25 N/mm2 , the density of the leather is 0.95gm/cc and the co-efficient of friction is 0.35. The thickness if the belt is 5mm. Find 1) the diameters of the Pulleys 2) the length and width of belt and 3) the belt tension. (15)

4. a) A full journal bearing 100 mm diameter takes a radial load of 5000 N. The bearing is 100 mm long and the speed of the shaft is 400 rpm. The permissible minimum film thickness is 0.025mm and diametral clearance is 0.152 mm. find viscosity of a suitable oil b) co-efficient of friction c) heat generated d) amount of oil pumped through bearing e) amount of end leakage and f) temperature rise of the oil flow through the bearing. (15)

OR a) List out the properties of lubricants and the purpose of lubrication. (5) b) A journal bearing 300mm long 150mm diameter carries a radial load of 9KN at 1200 r.p.m.. The

power lost in friction is 6KW. Viscosity of oil at room temperature is 0.018Pa-s. Find the diametral clearance. (10)

5. a) A reciprocating compressor is to be connected to an electric motor with the help of spur gears. The distance between the shafts is to be 500mm. The speed of the electric motor is 900r.p.m. and speed of the compressor shaft is desired to be 200r.p.m. The torque to be transmitted is 500N-m. Taking starting torque as 25% more than the normal torque. Determine 1) Module and face width of the gears Using 20° stub teeth. 2) Number of teeth and pitch circle diameter of each gear. Assume suitable values of velocity factor and lewis factor. (15)

OR a) A cranked lever has the following dimensions. Length if the handle is 300mm, length of the lever arm

is 400mm, overhang of the journal is 100mm. The lever is operated by a single person exerting a Maximum force of 400N at a distance 1/3rd the length of the handle from its free Hand. The permissible bending stress for the lever is 50 N/mm2 and shear stress For the shaft material is 40 N/mm2 . Find 1) Diameter of the handle 2) Cross-Section of the lever arm. 3) Diameter of the journal. (15)

67

12052 THERMAL ENGINEERING 6 Hrs/Week 16 Weeks /Sem. Total Hrs : 96 OBJECTIVES:

• Define various types of steam. • Explain the of boiler • Compare various types of boilers. • Familiarize boiler mountings and accessories. • Describe various circuits used in the steam power plant. • Explain working of a nuclear power plant. • Compare conventional energy sources with non conventional sources of energy • Appreciate the application of refrigeration and airconditioning • Define the various parameters used in psychometry • Compare the different types of refrigeration & airconditioning system.



Internal Board Exam Total 12052- Thermal

Engineering

6

96 25 75 100 TOPICS AND ALLOCATION

Unit Topic TIME (Hrs) I. Steam and Expansions of Steam 18 II. Steam Boilers and performance of boilers 18 III. Thermal power plant 18 IV. Energy Engineering and management 18 V. Refrigeration and Air Conditioning 18 Revision and test 6 TOTAL 96

UNIT - I: STEAM AND EXPANSIONS OF STEAM: 18hrs Introduction-formation of steam-t-h diagram-t-v-diagram-t-s-diagram-phase diagram-critical conditions-enthalpy of water-enthalpy of evaporation-conditions of steam-wet, dry and superheated steam-advantages of superheated steam-dryness fraction-enthalpy of wet, dry and superheated steam-specific volume of water and steam-density of steam-external work of evaporation-internal latent heat-internal energy of steam-entrophy of water and steam-steam tables-Mollier chart-problems. Expansion processes of steam-constant volume, constant pressure, constant temperature, hyperbolic, isentropic, polytropic and throttling processes-problems. Steam calorimeters-bucket, combined separating and throttling calorimeters-problems. UNIT - II: STEAM BOILERS AND PERFORMANCE OF BOILERS: 18hrs Classification of boilers-high pressure boilers-Lamount and BHEL high pressure boilers-advantages of high pressure boilers, boiler mountings-function, construction and working-boiler accessories-function, construction and working-comparison of mountings and accessories-feed water treatment-methods-starting boiler from cold condition- safety precautions in boiler operation-Indian boiler act. Performance of boilers-actual, equivalent and factor of evaporation-boiler efficiency-Factors influencing boiler efficiency-boiler power-problems-efficiency of economiser and super heater-problems-boiler trail-heat losses in a boiler-heat balance sheet-problems. UNIT - III: THERMAL POWER PLANT: 18hrs Layout of thermal power plant -fuel and ash circuit -water and steam circuit - air and flue gas circuit - cooling water circuit -merits and demerits of thermal power plant - air pollution by thermal power plants -pollutant and effects of pollution-pollution control-cyclone separator-wet scrubber-electrostatic precipitator-control of No2 and SO2. Steam turbine-steam power cycle-Carnot, Rankine and modified Rankine cycles-classification of steam turbine-necessity of compounding-Industrial turbines.

68

Steam condenses - elements of condensing plant-classification of condensers-jet condenser types-surface condensers-types-merits and demerits of surface condensers-sources of air in condenser vacuum-vacuum efficiency-condenser efficiency-mass of cooling water required-mass of air presen-number of tubes-problems.

UNIT - IV: ENERGY ENGINEERING AND MANAGEMENT: 18hrs Nuclear fuels-requirements-fissile and fertile fuels-Nuclear fission and fusion-chain reaction-radio activity-layout of nuclear power plant-merits and demerits-Nuclear reactors-classification-components of nuclear reactor-reactor core-moderators-control rods-coolant-reflectors-biological shield-pressurised water reactor-boiling water reactor-Candu type reactor-fast breeder reactor-effect of nuclear radiation-disposal of nuclear wastes-comparison of nuclear power plants with thermal power plants. Conventional sources of energy-layout of hydel and diesel power plants-merits and demerits. Non-conventional sources of energy- solar-wind-tidal-geothermal and gobar gas plant

UNIT - V: REFRIGERATION AND AIR CONDITIONING: 18hrs Refrigeration-refrigerators and heat pumps-types and applications of refrigeration-vapour compression refrigeration system-vapour absorption system-comparison-refrigerating effect-capacity of refrigerating unit-C.O.P-actual C.O.P-power required-mass of ice produced-problems-C.O.P of reversed Carnot cycle-Bell-Coleman cycle- problems-refrigerants-desirable properties-classification of refrigerants. Air conditioning-psychometric properties-dry air-moist air-water vapour-saturated air-dry bulb temperature-wet bulb depression-dew point depression-dew point temperature-humidity-spcific and relative humidity-psychometric chart-psychometric processes-sensible heating and cooling-humidification-dehumidification-simple problems using psychometric chart-air conditioning-classification and applications of air conditioning system-room air conditioning -central air conditioning-comparison-differences between comfort and industrial air conditioning-factors to be considered in air conditioning-loads encountered in air conditioning systems.


Text Books: 1. P.L.Ballaney, Thermal Engineering, Edn. 24, Khanna Publishers, 2B, North Market, Naisarak, New Delhi

110 006. 2. R.S.Khurmi and J.K.Gupta, Thermal Engineering, Edn. 18, published by S. Chand & Co., Ram Nagar, New

Delhi 110 055. Reference Books: 1. R.K.Rajput, Thermal Engineering 2. B.K.Sarkar, Thermal Engineering, Edn. 3, 1998, published by Dhanpat Rai & Sons, 1982, Naisarak, New

Delhi 110 006. 3. S.Domkundwar, A.V.Domkundwar S.C.Arora, Power plant Engineering 4. Nagpal, Power plant Engineering, Edn. 8, published by by 24, Khanna Publishers, 2B, North Market,

Naisarak, New Delhi 110 006. 5. P.C.Sharma, Power plant Engineering 6. G.D.Rai, Non Conventional Energy sources, Edn.4, Published by 24, Khanna Publishers, 2B, North Market,

Naisarak, New Delhi 110 006. 7. P.L.Ballaney, Refrigeration and Air condition, Edn. 4, published by by 24, Khanna Publishers, 2B, North

Market, Naisarak, New Delhi 110 006. 8. Manohar Prasad, Refrigeration and Air-condition, 1993, Edn. Published by H.S.Popali for Wiley Eastern

Ltd., 4835/24 Ansari Road, Daryaganj, New Delhi 110 053.

69

12052 THERMAL ENGINEERING MODEL QUESTION PAPER – I




1. What is wet steam? 2. Write expression for enthalpy of super heated steam. 3. State the function of fusible plug in a boiler. 4. Define Boiler efficiency. 5. State the major pollutants from power plants. 6. What is a steam condenser? 7. Give examples of fissile fuels. 8. What is Radioactivity? 9. Define C.O.P of Refrigeration unit. 10. What is Humidity?

PART –B Answer all the questions 3x5=15 11. State the advantages of super heated steam. 12. State the main clauses of Indian Boiler Act. 13. List out factors to be considered while selecting a site for Thermal power plant. 14. Explain chain reaction with a sketch. 15. Explain any one of the Psychometric processes


16. 1. Determine the enthalpy, external work of evaporation and entropy of 2kg of wet steam having dryness

fraction 0.9 at a pressure of 10bar. (10) OR

2. Describe the working of separating and throttling calorimeter with a sketch. (10) 17. 1. A Boiler generates 750 kg of steam per hour at 11 bar absolute and 40º c super heat and turns 100kg

cal per hour. If the calorific value of coal is 29,300 kj/kg feed water temperature 45ºC. Cps=2.09kj/kg.k. Calculate a) factor of evaporation. B) equivalent evaporation C) Boiler Efficiency.

(10) OR

2. Explain with sketches the working of the following mountings in a boiler. a) Lever Safety valve. b) Pressure gauge. (10)

18. 1. Explain the following with sketches in a Thermal power plant.

a) Fuel and Ash circuit b) Water and steam circuit. (10)

OR 2. Explain with sketches the construction and working of

a) Any one Jet condenser b) Any one Surface Condenser (10)

19. 1. Describe the working of candu type reactor with a sketch. (10)

OR 2. Explain the working of a Bio-gas plant with a sketch. (10) 20. 1. Explain with a line diagram the vapour compression method of refrigeration. (10)

OR 2. Describe the working of window type air-conditioning system with a sketch. (10)

70

12052 THERMAL ENGINEERING MODEL QUESTION PAPER – II



PART –A Answer all the questions 1x10=10 1. Define dryness fraction of steam.

2. What do you understand by internal energy of steam 3. What is a Fire Tube Boiler? 4. Name any four Boiler Mountings. 5. Name the Four important circuits of a steam power plant. 6. State the principle of working of an impulse turbine. 7. State the main elements of a nuclear power plant 8. Name any two reactors currently used in our country. 9. Define the term ‘Refrigerationr’. 10. What is meant by air-conditioning? PART –B Answer all the questions 3x5=15

11. Determine the condition of steam at a pressure of 20 bar and 2520 kJ/kg heat is required to generate this steam from water at 0ºc. 12.Define the following terms a) Actual evaporation b) Equivalent Evaporation

c) factor of Evaporation. 13. Explain with a sketch the principle of working of a reaction turbine. 14. Draw a neat sketch of a nuclear reactor. Name the various components. 15. Mention any five applications of refrigeration. PART –C Answer any one question from each unit 10x5=50

16. 1. Steam at a pressure of 4 bar absolute and 0.75 dry is heated at constant volume to a pressure of 5 bar

(abs). Find the final condition of steam and heat absorbed by one kg of steam. (10) OR

2. a) Explain the various stages in the formation of steam. (4) b) Find the specific volume of the steam when its pressure is 7 bar and the condition of steam is (i) wet having dryness fraction of 0.9 and (ii) Superheated to a temperature of 250°c.

(6) 17. 1. Describe with a neat sketch the working of Lamont boiler (10)

OR 2. The following results were obtained in a boiler trial feed water per hour=750kg at 25ºc. Steam produced

– 0.95 dry at 8 bar, coal used per hour – 100kg. Calorific value of coal is 27300 kJ/kg. Ash and unburnt coal collected from beneath fire bars – 8kg/hour of calorific value 2800 Kj/Kg. Mass of flue gas per kg of coal burnt – 17kg. Flue gas temperature-325ºc, air temperature – 15ºc. Specific heat of the flue gases-1.03kJ/kg.k. Calculate (i) Boiler Efficiency (ii) Prepare a heat balance sheet. (10)

18. 1. Explain the working of following with suitable sketches

a. Back Pressure turbine b. Exhaust Turbine c. Bleeder Turbine (10)

OR 2. During a trial on a condenser the following readings were taken. Barometer reading – 766mm of

mercury. Actual vaccum recorded by gauge – 716mm of mercury. Mean temperature of condenser – 34ºc temperature of hot well – 29ºc. Inlet temperature of cooling water-15ºc. outlet temperature of cooling water-24ºc. Determine (i) corrected vaccum (ii) vacuum Efficiency (iii) Condenser Efficiency. (10)

19. 1. Describe with a neat sketch the construction and operation of Fast breeder reactor.

OR 2. a) Discuss the merits and demerits of a nuclear power plant. (5) b) Explain any one method of using solar energy for power generation. (5)

71

20. 1. Find the least KW required by a perfect reversed heat engine that will make 450kg of ice per hour at-3ºc from water at 20.5ºc. Take latent heat of ice as 340 kJ/kg and specific heat as 2 kJ/kg. (10)

OR 2. a) Explain the following terms (i) humidity (ii) Specific humidity and (iii) Relative Humidity b) Explain the various loads encountered in an air conditioning system. (10)

72

12071 REFRIGERATION AND AIR CONDITIONING 6 Hrs/Week 16 Weeks /Sem. Total Hrs : 96 OBJECTIVES:

• Explain the working of open and closed air system of refrigeration. • Describe the working and construction of compressors used for air conditioning. • Explain vapour compression refrigeration system. • Explain vapour absorption refrigeration system. • Compare the properties and applications of various refrigerants. • Define the parameters used in psychrometry. • Use Psychrometry chart • Describe the equipment used for air conditioning. • Estimate the cooling load for the given requirement. • Explain the industrial application of refrigeration.



Internal Board Exam Total 12071- Refrigeration and Air conditioning

6


UNIT TOPIC TIME ( Hrs ) I. Refrigeration system and Refrigeration equipments 18 II. Vapour compression refrigeration system and Vapour absorption

refrigeration system 18

III. Refrigeration flow controls, refrigerants and lubricants and Applications of refrigeration

18

IV. Psychrometry and comfort air conditioning 18 V. Air conditioning systems and Cooling load calculations 18

VI. Revision Test 6 TOTAL 96

UNIT I REFRIGERATION SYSTEM AND REFRIGERATION EQUIPMENTS 18 Hrs Refrigeration system: Thermodynamic state of a pure substance, modes of heat transfer –laws of heat transfer - mechanisms of production of cold - unit of refrigeration –types of refrigeration –reversed Carnot cycle - C.O.P of heat engine-heat pump- refrigerating machine – principle of working of open and closed air system of refrigeration – advantages and disadvantages – and its application of air cycle-problems Refrigeration Equipments: Compressor – principle of working and constructional details of reciprocating and rotary compressors, hermetically and semi hermetically sealed compressors- condensers-principle of working and constructional details of air cooled and water cooled condensers, evaporative condensers- advantages and disadvantages - natural and forced draught cooling towers. Evaporators- natural circulation and forced circulation type – principle of working constructional details. UNIT II VAPOUR COMPRESSION REFRIGERATION SYSTEM AND VAPOUR ABSORPTION REFRIGERATION SYSTEM 18 Hrs. Vapour Compression Refrigeration System: Principle of working of vapour compression system – analysis of vapour compression cycle using T-s diagram and p-H diagram- refrigerating effect- compression work - C.O.P - effect of superheating and under cooling - problems – effect of - evaporative pressure - condenser pressure - liquid –vapour refrigeration heat exchangers - advantages and disadvantages of superheating and under cooling –use of flash chamber and accumulator. Vapour Absorption Refrigeration System: Simple absorption system – Electrolux system -NH3 and lithium Bromide system – solar absorption refrigeration system- absorption system comparison with mechanical refrigeration system.

73

UNIT III REFRIGERATION FLOW CONTROLS, REFRIGERANTS AND LUBRICANTS AND APPLICATIONS OF REFRIGERATION 18 Hrs. Refrigerant flow controls, refrigerants and lubricants: Capillary tube-automatic expansion valve-thermostatic expansion valve-solenoid valve-evaporator pressure regulator –suction pressure regulator-selection of a refrigerant-properties and applications of following refrigerants SO2 , CH4 , F11, F12 ,F22, and NH3 –CFCs refrigerants- equivalent of CFCs refrigerants (R-123a,R-143a,R-69S)- lubricants used in refrigeration and their applications. Applications of refrigeration: Slow freezing –quick freezing- cold storage-frozen storage-freeze drying –dairy refrigeration –ice cream cabinets-ice making – water cooler, milk cooler, bottle cooler-frost free refrigeration. UNIT IV PSYCHROMETRY AND COMFORT AIR CONDITIONING 18 Hrs. Definitions of dry air, moist air, water vapour, Avagadro’s law, Dalton’s law of partial pressure - dry and wet bulb temperature - dew point - humidity - specific and absolute - relative humidity - degree of saturation - enthalpy of moist air- adiabatic saturation of air by evaporation of water- psychometric chart and its uses – psychometric processes – sensible heating and cooling - humidifying and heating - dehumidifying and cooling - adiabatic cooling with humidification - total heating or cooling processes -sensible heat factor - by pass factor with simple problems – governing optimum effective temperature – comfort chart-design consideration. UNIT V AIR CONDITIONING SYSTEMS AND COOLING LOAD CALCULATIONS 18 Hrs. Air Conditioning Systems: Equipment for air conditioning and insulation factors – air purification – temperature control – humidity control – dry and wet filters- centrifugal dust collector – air washer humidifier – dehumidifier - fans and blowers – grills and registers – summer and winter air conditioning, window type air conditioner – central plant system – properties of ideal insulator, types of insulating materials –air distribution and duct systems – tools and installation, servicing and maintenance of R & AC systems. Cooling load calculations: Different heat sources – conduction heat load – radiation load of sun – occupants load – equipment load - infiltration air load – miscellaneous heat sources –fresh air load - simple problems. Revision and Test 6 Hrs Text books :

1. P.L . Ballaney, Refrigeration and air conditioning, Khanna Publishers, 2B, North Market, Naisarak, New Delhi 110 006.

2. V.K. Jain, Refrigeration and air conditioning Reference Books:

1. Domkundwar, A course in refrigeration and air conditioning 2. Dossat , Principles of refrigeration 3. Audels, Home refrigeration and air conditioning, 1996 Edn., published by Theo. Audel & Co.

publisher, 49, West 23rd Street, New York. - 1998 4. C.P Arora, Refrigeration and air conditioning

74

12071 REFRIGERATION AND AIRCONDITIONING MODEL QUESTION PAPER – I



PART –A Answer all the questions 1x10=10 1. Define COP of a refrigeration system. 2. State Carnot theorem. 3. The gauge reading of a refrigerant cylinder is 150 PSIG. What is the absolute pressure. 3. State any two disadvantages of superheating. 4. What is the function of accumulator in a VCR system. 5. Give some two desirable properties of refrigerant. 6. State any two application of refrigeration system. 7. State the Daltons law of partial pressure. 8. Define the term dew point temperature. 9. What is meant by air washer. 10.What are the various heat loads in an air conditioning system.

PART –B Answer all the questions 3x5=15 11. Explain in short the operation of a reciprocating compressor. 12. With the neat sketch explain the working of solar absorption refrigertion system. 13. What are the factors to be considered for the selection of a refrigerant. 14. Define the terms dry bulb temp., wet bulb temp., dew point temp., specific humidity and absolute humidity. 15. With the neat sketch explain the working of centrifugal dust collector.

PART –C Answer any one question from each unit 10x5=50 16. 1. (a) Define conduction convection and radition modes of heat Transfer. (3)

(b) A refrigeration system works between the temp limits of 37 degree celsius and -13 degree celsius. Find the amount of ice that will be produced per Kwh at 260k from water available at 27 degree celsius. Take cp of ice and water as cpi=2.09kj/kg-k and cpw=4.197kj/kg-k and hs=335kj/kg. (7)

(OR) 2. (a) With the neat sketch explain the working of different types of condensers. (5) (b) Explain the working of any one type of cooling towers. (5) 17. 1. Explain with the neat sketch the working of vapour compression refrigertion system. (10)

(OR) 2. With the neat sketch explain the working of vapour absorption refrigeration system (10)

18. 1. (a) Give the various application of refrigeration system. (5) (b) List out the affects caused by using various refrigerants to the environment. (5)

(OR) 2. (a) Explain the working of slow freezing and quick freezing refrigeration system. (5) (b) List out some of the absoluble properties of refrigerants. (5) 19. 1. The values obtained from a sling psychrometer are tlb=30 degree celsius and twb=20 degree

celsius. The barometric reading is 740mm of Hg. Calculate (i) dew point temp and relative humidity. (ii) degree of saturation (iii) specific humidity (iv)specific volume (v) specific enthalpy. (OR) (10)

2. (a) Define the term psychrometer an psychrometry . (4) (b) Draw the neat layout of the psychrometric chart and indicate the various processers available on

it. (6) 20. 1. Explain the working of window type air conditioning with the sketch. (10)

(OR) 2. With the neat sketch explain the working of a centralized air conditioning system. (10)

75

5. What are the lubricants used in the refrigeration system.

(b) Explain the working of centrifugal dust collector with the sketch. (5)

12071 REFRIGERATION AND AIRCONDITIONING MODEL QUESTION PAPER – II



PART –A Answer all the questions 1x10=10 1. Define a ton of refrigeration. 2. Define COP of a refrigeration system. 3. Draw the T-s and P-h diagram of a vapour compression refrigeration system. 4. Give two advantages of VCR system over VAR system.

6. What is the use of capillary tube in a refrigeration system? 7. State the Daltons law of partial pressure. 8. Define sensible heat and latent heat. 9. What are the materials used as insulators in air conditioning system. 10. What are the various heat loads in an air conditioning system.


11. Explain the working of evaporative condensers with neat sketch. 12. Give some five differences between the VCR system and VAR system. 13. What are the factors to be considered for the selection of refrigerant? 14. What is meant by psling psychrometer. Explain the process of cooling and dehumidification and heating

and humidification with the use of psychometric chart. 15. Explain the material used and working of dry and wet filters.

PART –C Answer any one question from each unit 10x5=50 16. 1. (a) Define conduction, convection and radiation modes of heat transfer. (4) (b) A 15 ton refrigeration system working on the simple air refrigeration cycle takes 0.6kg/sec

of air from the main compressor. From the given values obtained the cop and the power needed and the amount of flud to be evaporated per hour if the enthalpy charge is 260kJ/kg. PI=1.05 bar P2=5.25 bar P cabin=1.02bar T1=288k 10mp=0.8, cooling turbine efficiency=o.76. air 1cares the cabin at 30 degree celsius, heat exchanger effectiveness=0.75. (6)

(OR) 2. (a) Explain the working of any one type of cooling tower. (5) (b) With the neat sketch explain the working of different types of condensors. (5) 17. 1. Explain the working of vapour compression refrigeration system with the neat sketch. (10)

(OR) 2. Explain with sketch the working of Electrolux refrigeration system. (10) 18. 1. (a) Give the various application of refrigeration system. (5) (b) List out the effects caused by the using various refrigerants to the environment (5)

(OR) 2. (a) List out some of the desirable properties of refrigerants. (5) (b) Explain the working of slow freezing and quick freezing refrigeration system. (5) 19. 1. The values obtained from a sling psychrometer are tdb=30 degree celsius and tub=20 degree

celsius. The barometric readings is 740 mm of Hg. Calculate (i) dew point temp and relative humidity (ii)degree of saturation (iii) specific humidity (iv) specific volume (v)specific enthalpy. (10)

(OR) 2. Explain the various psychrometric process in detail with the psychrometric chart. (10) 20. 1. (a) State the working of air blowers with the neat sketch. (5)

(OR) 2. Explain the working of centralised air conditioning system with the neat sketch. (10)

76

•

12072 : METROLOGY, MACHINE TOOL MAINTENANCE AND TESTING

6 Hrs/Week 16 Weeks/Sem Total Hrs : 96 OBJECTIVES:

• State the objectives of metrology and define various terms • Explain the working principles of mechanical, electrical and optical measuring instruments. • Describe the construction and operating procedures and applications of linear, angular and taper

measuring instruments. • Compare various methods of measuring external thread • Explain the different methods of measuring internal thread nomenclature. • Explain the various methods of measuring gear tooth thickness and tooth profile. • Represent the surface finish as per BIS code. • Compare the various methods of measuring surface inspection. • State the importance, types and uses of comparators. • Describe the construction, procedure of usage of major mechanical comparators. • Describe the construction procedure of usage of major electrical/electronic comparators. • Describe the construction procedure of usage of major pneumatic and optical comparators • Explain the working and applications of CMM • Explain the various machine tool tests generally carried out.

Explain the maintenance procedure of standard machine elements.



Internal Board Exam Total 12072- Metrology,

Machine Tool Maintenance and testing

6

96 25 75 100


UNIT TOPIC TIME (Hrs) I Standards of Measurements & Principles of Measuring Instruments 18 II Linear, Angular & Taper Measurements 18 III Measurement of Threads and Gears 18 IV Measurement of Surface Finish & Comparators 18 V Machine tool testing and maintenance 18 Revision, Test 6 Total 96

UNIT-I STANDARDS OF MEASUREMENTS & PRINCIPLES OF MEASURING

Sources of errors – Classification of measuring instruments – Selection of instruments – Principles of measuring instruments: Mechanical, Optical, Electrical and Pneumatic measuring principles.

Taper Measurements: Gauges for tapers – Measurement of taper shafts – measurement of taper holes.

INSTRUMENTS 18 hrs

Introduction to metrology – Objectives of Metrology – Precision and Accuracy – Standards of Measurements: Line standard, End Standard, Wavelength Standard – Classification of Standards – Characteristics of line and end standards.

UNIT-II LINEAR, ANGULAR AND TAPER MEASUREMENTS 18 hrs Linear Measurements: Vernier calipers – Vernier height gauges – Vernier depth gauges - Micrometers – Bore gauges – Slip gauges. Angular Measurements: Bevel Protractors and its types – Sine bar, Sine table and Sine centre – Angle gauges – Microptic Autocollimator and Angle Dekkor - Clinometer.

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UNIT-III MEASUREMENT OF THREADS AND GEARS 18 hrs

2. 3.

Threads: External screw thread measurements: Measurement of Major dia, Minor dia, Effective dia and Pitch – Internal screw thread measurements: Measurement of Major dia, Minor dia, Effective dia and Pitch – Screw thread gauges. Gears: Gear tooth terminology – Sources of errors in manufacturing of gears – Measurement of tooth thickness: Gear tooth vernier, Constant chord method, Addendum comparator method and Base tangent method – Measurement of tooth profile: Tool maker’s microscope or projector, Involute tester – Measurement of pitch – Measurement of run out – Lead and Backlash checking .- Measurement of concentricity – Alignment of gears – Composite errors: Master gear, Parkinson’s gear tester. UNIT-IV MEASUREMENT OF SURFACE FINISH & COMPARATORS 18 hrs Measurement of Surface Finish : Representation of surface finish as per BIS – Methods of measuring surface finish: Comparison method and Direct instrument measurements – Surface inspection by comparison methods: Touch inspection, Visual inspection, Scratch inspection, Microscopic inspection, Comparison with standard specimen, Surface photographs – Direct instrument measurement: Intersectional method, Interference method and Stylus method . Features of comparators – Uses of comparators – Types of comparators – Mechanical comparators: Dial indicator, Reed type and Sigma comparators – Optical comparators: Optical lever, Simple optical comparator, Cooke and Zeiss optimeter – Electrical/Electronic comparators: Electrical comparator, Electro-mechanical comparator, Electro-limit gauges, Electronic comparator and Electronic measuring equipment – Pneumatic comparators: Solex pneumatic comparator, Air gauging important characteristics. UNIT-V MACHINE TOOL TESTING AND MAINTENANCE 18 hrs Machine Tool Testing: Introduction – Machine Tool tests – Instruments required for alignment tests – Alignment test on lathe – Alignment tests on drilling machine – Alignment tests on milling machine – Acceptance test for surface grinders. Bearing inner race loose on shaft – Housing bore loose on shaft – Bearing running dry – Mis-alignment – Damaged one or more balls/rollers – Radial play – Assembly of bearing unit. Key – Shaft/housing key-way – Disassembly of keyed joints – Assembly of keyed joints. Lead Screw Repair: Thread wears up to 0.3 mm – Thread wear exceeding 0.3mm – Repairs of lead nut – Elimination of play. Spindle Shank & Journal Seats: Repair standards, Repair methods for bush bearing seats, Repair methods for ball/roller bearing seats. Taper Bore: Repair standard, Repair methods – Threads: Repair standards, Repair methods – Keyways: Repair methods. Revision and Test 6 Hrs Text Books:

1. M.Mahajan, Engineering Metrology, 2005, Dhanpatrai & Co,.New Delhi. 2. Garg.H.P, Industrial Maintenance, Reprint 2002, S.Chand & Co. Ltd., New Delhi

Reference Books:

1. R.K.Jain, Engineering Metrology, 2002, Khanna Publisher, New Delhi. ASTME, Hand Book of Industrial Metrology, 1990, Prentice Hall of India, New Delhi. R.K.Rajput, Engineering Metrology & Instrumentation, 4th Edition 2004, S.K.Kataria & Sons, New Delhi.

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1. Explain the term ‘Accuracy’ 2. What are the objectives of engineering metrology?

5. Define Pitch

12. State the principles of optical measuring instruments.

b) Explain measurement of Tapper Shaft. (5)

OR

20. 1. Explain the procedure of ‘alignment tests’ to be done on a milling machine. (10)

2. Explain the procedure of ‘alignment tests’ to be done on a lathe. (10)

12072 METROLOGY, MACHINE TOOL MAINTENANCE AND TESTING MODEL QUESTION PAPER – I

NOTE : Answer all the questions from Part-A (1 mark each) Answer all the questions from Part-B ( 3 marks each) Answer all the questions in Part – C by either or choice. Each carries ten marks. PART –A Answer all the questions 1x10=10

3. Define Least Count of vernier Caliper 4. What precautions should be taken while using slip gauges?

6. Define Backlash 7. What is a Comparator? 8. What is microscopic inspection?

9. What is meant by alignment tests on m/c tools 10. What is meant by radial play?

PART –B Answer all the questions 3x5=15 11. Distinguish between Line standard & End standard.

13. What is sine bar? Give its uses 14. Write short note on Angle dekkor. 15. Describe any one method of measuring effective diameter of internal threads.


16. 1. a) Describe the following types of errors and state how they can be taken care of. (i)Environmental error (ii) Parallax error (6) b)Define Precision and Accuracy (4)

OR 2. Name the various methods of measurements and explain any three of them with suitable examples. (10)

17. 1. State the principle of Vernier instrument explain briefly the construction and use of vernier caliper with a neat sketch. (10)

OR 2. a) Explain a sine bar used for angular measurements. (5)

18. 1. Describe the following methods of measuring the effective diameter of the screw threads: (i) Thread micrometer method ii) One wire method (10)

2. Describe the Parkinson’s gear tester and state its limitations. (10) 19. 1. a) With the help of a neat sketch describe the principle of working of a mechanical Comparators.

(6) b) Explain simple optical comparator. (4)

OR 2. What are roughness comparison specimens? How they assess surface specimen? What are their

limitations? (10)

OR

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OR

12072 METROLOGY, MACHINE TOOL MAINTENANCE AND TESTING MODEL QUESTION PAPER – II




1. Explain the term ‘Precision’ 2. What are precision linear measuring instruments? 3. What is the Least Count of Vernier Caliper and Micrometer? 4. Define linear measurement 5. Give formula for (i) Base pitch (ii) Dimetral pitch 6. Define Run out. 7. Give reasons Mechanical comparators are less accurate as compared to optical comparators. 8. Which instrument is used for measuring surface finish deep bores? 9. What are the applications of autocollimeter? 10.What is the effect of keyway cut on a shaft?


11. Name the various types of errors in gears. 12. What are the advantages & disadvantages of electrical comparator. 13. Explain the term

(i) Ra value (ii) Rz value

14. What are the geometrical checks to be done on a m/c tool? 15. What is meant by alignment tests on m/c tools? Why they are necessary? Explain.

PART –C Answer any one question from each unit 10x5=50 16. 1. a) What are the objectives of metrology. (4)

b) Explain principles of mechanical measuring instruments. (6) OR

2. Explain the measuring of external angle of a component using any one type of precision measuring device with suitable sketch. (10)

17. 1. State the principle of a micrometer. Sketch a outside micrometer and name its various parts.

OR 2. Explain construction and user Vernier bevel protractor and optical bevel protractor. (10)

18. 1. With the help of a neat sketch explain the construction, working and applications of toolmakers microscope. (10)

OR 2. a) What are the sources of errors in manufacturing of gears? (5) b) Explain measurement of concentricity. (5)

19. 1. Name the various methods of inspecting the surface finish by comparison. State their advantages

and limitations. (10)

2. Describe the construction and working of a optical projector. (10)

20. 1. Explain the procedure of ‘alignment tests’ to be done on a drilling machine. (10) OR

2. Distinguish between alignment test and performance test of a machine tool. Discuss with neat sketches, how you would test any three of the following for a lathe.

(i) Spindle centre run-out (ii) Spindle taper bore run out (iii) chunk run out (iv) Cross slide alignment (10)

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11011 ENGLISH COMMUNICATION PRACTICAL

• To equip the learners with effective speaking and listening skills in English


(Common to all Branches)

Curriculum Outline

The course on English Communication Practical will enable the learners develop their Communication skills in English, especially at a time when the Info-Tech Explosion on one side and the search for Communicational Exploration on the other have been taking the contemporary world by leaps and bounds. Keeping in view the career requirements of the students at Diploma level, the course on English Communication Practical has been designed in such a way that it will enable the learners acquire the much needed proficiency in the art of Communication and this will go a long way in shaping and fine tuning the future career of the students. OBJECTIVES:

• To make them realize the communication potential of English language • To infuse in their minds the much-needed and all the more important ‘CONFIDENCE’ • To facilitate them to acquire a fairly acceptable skill in pronunciation • To train them to use language effectively to face interviews, group discussions and public speaking • To enable them to prepare their resume, curriculum vitae etc., • To promote ethical values and inculcate organizational behaviour…

For achieving the objectives identified above, the following skills are to be developed to enhance the communicative potential of the students.

The Skills are:

1. Listening 2. Reading and Pronunciation 3. Speaking and Presentation 4. Writing

INSTRUCTION EXAMINATION Assessment Marks

SUBJECT

Hours/Week Hours/ Semester Internal Board

Examination Total Duration

11011 English Communication

Practical 4 64 25 75 100 3 Hrs.


UNIT INSTRUCTION TIME (Hrs)

I Listening 12 II Reading 12 III Speaking 14 IV Writing 8 V Professional Ethics & Organizational Behaviour 8 VI Project Report Writing (Outline) 2 Revision and Tests 8 TOTAL 64

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DETAILED SYLLABUS

NOTE: The exercises given to the students must be recorded in the Record Notebook.

UNIT I LISTENING Listening to pre-recorded short episodes, conversations, passages, stories, (hard copy of the material and cassettes) news bulletin, speeches by famous personalities – Listening for general and specific information etc.,

UNIT II READING

Reading aloud – by students individually - reading rhymes – proverbs – passages on various topics of interest – Newspaper reading – Reading humorous passages – Anecdotes – Stories – tricky sounds (conditioners) – Reading manuals – Reading individual sentences with articulation, pronunciation, Tones, Punctuation, pauses etc…- Reading the titles of popular books, movies and poems. NOTE: All the exercises given in Reading skills should be written in the Record Notebook. UNIT III SPEAKING

i. Self-introduction – introducing one self, one’s family – one’s friends and relatives, one’s language – one’s country etc…

ii. Welcome Address, Vote of thanks iii. Extempore speeches. iv. Short speech on simple topics on simpler themes for about one minute. v. Role play – Group Discussion – Debate – Seminars – Machine Descriptions (depending upon branches) –

Compering – Interviewing others by Asking Questions – Interview Techniques – Conversational Practice – Telephonic Conversation – Telephonic Interviews – How to establish conversation / dialogues – Entry Attempts/Admissions.

NOTE: Items taught in the Speaking skill should be written in the Record Notebook. UNIT IV WRITING i. Writing Resume, preparing Curriculum Vitae. ii. Converting newspaper headlines into sentences. iii. Formation of Sentences – Using the table of Sentence-making and producing multiple sentences. iv. Framing Questions for the responses given v. Tips for better performance in interviews. vi. Describing Objects vii. Describing Situations.

NOTE: All the above topics must be taught to the students providing sufficient models and

exercises and everything must be recorded in the Record Notebook.

UNIT V PROFESSIONAL ETHICS & ORGANIZATIONAL BEHAVIOUR: Different kinds of Ethics – Ethics in different fields – Engineering Ethics – Senses of Engineering Ethics – Moral Values – Integrity & Loyalty – Work Ethics – Respect for others and authority – Empathy – Caring and Sharing – Honesty – Courage and Commitment – Valuing Time – Co-operation & Teamwork – Safety and Risk – Right Action – Professional ideals and virtues – Individual’s Ambition – Conflict Resolution – Self-Confidence – Customs and Manners – General Behaviour – Etiquettes to be followed – Professional Responsibility – Accountability – Leadership Qualities – Effective Communication skills. UNIT VI PROJECT REPORT WRITING (Outline): Significant features of Project Report Writing – Organization – Presentation – Use of Impersonal Passives – Acknowledgements.

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REFERENCES

UNIT I LISTENING: Cassette with books:

1) Spoken English for you – Level I & Level II by Radha Krishna Pillai – Emerald Publishers. 2) Activity Sheets to be prepared. 3) BBC – Lingophone with Hard copy. 4) World Great Speeches – Book – Balaji’s – Famous Speeches.

UNIT II READING:

1) Short story Books (Indian Writing – Panchathanthra) 2) Reading Illustrated Books (Gokulam – Wisdom – Chandamama – Amarchitrakatha) must be

subscribed.

UNIT III SPEAKING: Books / materials related to speaking skill. UNIT IV WRITING:

1) Internet Browsing and collecting information for C.V. 2) Book materials / Cassettes for writing skill.

3) Guided composition in English Language Teaching – Alexander L.G. Longman, 1971. 4) The Language Laboratory and Language Learning – Dahim Longman, London, 1967.

PROFESSIONAL ETHICS REFERENCE BOOKS

1. Mike Martin and Roland Schinzinger, “Ethics in Engineering”, McGraw Hill, New York 1996. 2. Charles D. Fleddermann, “Engineering Ethics”, Pearson Education / Prentice Hall, New Jersey, 2004. 3. Charles E. Harris, Michael S. Protchard and Michael J Rabins, “Engineering Ethics” – Concepts and

Cases”, Wordsworth Thompson Learning, United States, 2000. 4. Edmund G Seebauer and Robert L Barry, “Fundamentals of Ethics for scientists and Engineers”,

Oxford University Press, Oxford, 2001. 5. G.E. Moore, “Elements of Ethics”, Temple University Press, Philadelphia, 1991. 6. J.D. Mabbott, Hutchinson, “An Introduction to Ethics” Hutchinson University Library, London, 1969. 7. May Mothersill, “Ethics”, The MacMillan, New York, 1965. 8. Raymond Bradley and Stephen Duguid, “Environmental Ethics”, Vol I & II, Simon Fraser University,

Canada 1989. 9. Kevin W. Bowyer, “Ethics and Computing – Living Responsibility in a computerized World”, IEEE

Computer Society Press, California, 1996.

1. An echo-free room.

4. Headphone units – 30 Nos. with one control unit with a facility

10. Jayashree Suresh and B.S. Raghavan, “Professional Ethics”, S.Chand & Company Ltd., New Delhi, 2005

11. James V. McGlynn, Jules J. Toner, “Modern Ethical Theories”, The Bruce Publishing Company, Milwaukee, 1962.

ENGLISH COMMUNICATION PRACTICAL

(Common to all branches)

LABORATORY REQUIREMENT

2. Public Address System 3. A pair of collar microphones with amplifiers and speakers

to play and record in cassettes. 5. Colour Television (minimum size – 61”) 6. DVD/VCD Player with Home Theatre speakers 7. Clip Chart, white board. 8. Necessary furniture and comfortable chairs

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(Common to all branches)

GUIDELINES

The students should also be exposed to 44 sounds in English language and their symbols with examples. However questions need not be asked in this in the end examinations.

Teachers are requested to refer the reference books given in the syllabus and help the students to find out the answers for all the 50 questions.

ENGLISH COMMUNICATION PRACTICAL

UNIT I LISTENING

a. The students must have been trained on a minimum of 10 Passages / stories / speeches / episodes / news bulletin (about 200-250 words each) and all other topics given in the syllabus during their course of study.

In the examination a passage shall be played back for about 5 minutes from a pre-recorded cassette followed by 5 questions. Students may be allowed to take notes while listening and they shall answer the questions in writing and assessment shall be made depending upon their performance.

b. The students must have been trained on a minimum of 10 dialogues during their course of study. In the examination a dialogue (face-to-face conversation) running for about 5minutes shall be played back from a pre-recorded cassette (either Video or Audio) followed by 5 questions. The students may be allowed to take notes while listening and they shall answer the questions in writing. Assessment shall be made depending upon the performance of the students.

UNIT II READING

The Students should have been trained to read out / articulate at least 200 different types of sentences. They should also be trained to pronounce 200 words (monosyllabic, by-syllabic, tri-syllabic and polysyllabic words) and all other topics given in the syllabus. The words and sentences are to be chosen in such a way that the tongue is articulating the sounds in the manner peculiar to the English Language. The students should also be trained to read aloud newspaper headings, proverbs, rhymes, poems, (use of) minimal pairs and other items identified in the syllabus.

UNIT III SPEAKING

The students should have been trained on a minimum of 10 topics / role-play / group discussion / debate / seminar and other topics given in the syllabus. The students must also be trained to introduce themselves and others. Each student must speak at least 10 sentences. The students must be given guidelines for making their presentation / speech effective.

UNIT IV WRITING

The students should be thoroughly trained in all the items identified in the syllabus under writing. UNIT V PROFESSIONAL ETHICS & ORGANIZATIONAL BEHAVIOUR

Around 50 questions dealing with PROFESSIONAL ETHICS & ORGANIZATIONAL BEHAVIOUR are given in the syllabus. In the examination the students will be given 15 questions (selected out of 50 questions) and they have to write short answers to any 10 questions. This carries 20 marks.

UNIT VI PROJECT REPORT WRITING (Outline)

Elaborate guidelines must be given to the students as to how to write a Project Report. They must be exposed to the salient features in writing the Project Report. The students will be expected to submit outline of a Project Report relevant to their branches of study in a separate folder and this will be assessed at the time of End Examination and marks will be awarded accordingly.

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1) End examination will be conducted for duration of 3 Hrs. covering all the six units identified in the

syllabus.

2) 5 marks will be awarded for attendance.

Annexure: A statement of allocation of marks.

Time and Marks Allocation for each unit:

MARKS ALLOTTED

ENGLISH COMMUNICATION PRACTICAL (Common to all branches)

SCHEME OF EXAMINATION

END EXAMINATION (75 Marks)

2) The examination should be conducted in such a manner that there must be enough evidence regarding the performance of the students and the distribution of marks for the academic audit.

INTERNAL ASSESSMENT (25 Marks)

1) Students will maintain a 150-page Record Notebook for all the activities done in the English Communication Lab., for which 20 marks will be allotted.

GROUP UNIT TIME

PROFESSIONAL ETHICS & ORGANIZATIONAL BEHAVIOUR (UNIT V)

30 Minutes 20

WRITING (UNIT IV ) 30 minutes 10 GROUP A

(Written Test)

LISTENING (UNIT I ) 30 minutes 10

READING (UNIT II) 45 minutes 10 GROUP B

(Oral Test) SPEAKING (UNIT III) 45 minutes 15

GROUP C (Report Submission) PROJECT REPORT WRITING (UNIT VI) 10

GROUP A 1. PROFESSIONAL ETHICS & ORGANIZATIONAL BEHAVIOUR (20 Marks)

The students will be asked to write brief answers, for any 10 questions out of 15 questions. The examiners will select the questions from the question bank given in the syllabus. Each question carries 2 marks. It will be a written practical.

Annexure: A question bank of 50 questions.

The students will be assessed on –

A pre-recorded cassette on short episodes / passages / stories / news bulletin / speeches by famous personalities (not exceeding 5 min.) will be played back only once. The Students are required to listen to this play-back with utmost attention.

2. WRITING ( 5 + 5 = 10 Marks )

Out of 7 items identified in the syllabus under Writing skills, the students are required to answer for any two items out of four (i.e. 2 out of 4 questions). Each item carries 5 marks. There must be different questions for different batches.

3. LISTENING ( 5 + 5 = 10 Marks )

a) Auditory Comprehension ( 5 marks )

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Time for this exercise for the response of the students will be approximately 10 minutes.

NOTE: Reading and Speaking:

After that, a sheet of paper containing 5 questions on the topic (that was played back to the students) with adequate space under each question (for the students to write the answers) will be supplied. The students are expected to write the answers in the space provided for each question.

b) Audio Visual Comprehension ( 5 marks )

A face - to - face conversation (not exceeding 5 minutes) will be played through a video or audio system (only once). The students are required to listen to this conversation with full attention. After that, a sheet of paper containing 5 questions on this exercise shall be given with adequate space under each question for the students to write the answer. Fill in the blanks type of questions may also be given to assess the Listening skills of the students. Time to be taken by the students for this exercise will be approximately 10 minutes. The selection of topics such as short episodes/passages/stories/news bulletins /speeches / dialogues etc… is left to the discretion of the internal and external examiners.

GROUP B 1. READING ( 5 + 5 = 10 Marks )

a) Each student will have to read aloud a passage of about 200 words. ( 5 Marks ) b) The Students will also be required to read individual sentences, rhymes, poems, newspaper headings,

proverbs (use of) minimal pairs etc… ( 5 Marks )

NOTE: While reading, the students will be assessed based on their performance in pronunciation, articulation, intonation, punctuation, pauses etc…

The examiner needs to have as many passages / exercises as required, proportionate to the number of batches. The passage / exercises will be the same one to all the students of a particular batch. But it should not be repeated for other batches, there should be different passages / exercises for different batches.

2. SPEAKING ( 15 Marks )

a) Introducing one self / Introducing others and all the other topics given in the syllabus 5 Marks. b) Short speech on simple topics on simpler themes for about 2 minutes – 5 Marks. c) Assessing the performance of the students on any of the topics given in the syllabus in sub division V

under Speaking skills. – 5 Marks. NOTE: The topics identified in the syllabus for Presentation (Speaking skills) need to be written

individually one by one by the examiners in separate papers or in separate cards.

The students will be allowed to choose a topic through lot system. They are expected to speak on the topic chosen by them for at least 2 minutes.

The selection of the topics is left to the discretion of the examiner.

For assessing the performance of the students in Reading and Speaking skills in the End Examination, each batch of students may be divided into two groups (if there are 30 students in a batch, they may be divided into 15 + 15) and both groups may be assessed simultaneously, one group by the external examiner (for Reading skills) and another by the internal examiner (for Speaking skills) and then vice versa. This process will enable the examiners to complete the practical on time i.e., in 3 Hrs. duration.

GROUP C PROJECT REPORT WRITING ( 10 Marks )

The students will be expected to submit an outline of a Project Report relevant to their branches of study in a separate folder and this will be assessed at the time of End Examination and marks will be awarded accordingly.

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QUESTION BANK

1) What do we understand by ethics? 2) What are the universally accepted ethical principles?

9) What is professional ethics?

11) What are the responsibilities of engineers?

21) What are the various aspects of empathy? 22) What are the salient features of commitment? 23) What is team-work?

25) What is meant by accountability?

30) What are the main qualities of work ethics?

34) What is honesty? 35) What is courage?

PROFESSIONAL ETHICS & ORGANIZATIONAL BEHAVIOUR

3) What is meant by engineering ethics? 4) What is the need for engineering ethics? 5) Define work ethics. 6) What is integrity? 7) ‘Commitment’ – what does it mean? 8) What do you mean by empathy?

10) What is the similarity between ethics and morals?

12) What are the rights of the engineers? 13) What are codes of conduct? 14) Explain briefly the importance of ethics in engineering profession. 15) How can an engineer orient himself towards his ethical responsibilities? 16) What are the priorities of an engineer in a situation wherein which conflicting values are involved? 17) How can an engineer implement ethics of his profession in a multi-cultural/multi-national environment? 18) What are the professional obligations of an engineer? 19) What should be the ethics that an engineer should adhere to in both pre and post employment

scenarios? 20) What is the ethical way of handling retrenchment?

24) What do you mean by profession and professionalism?

26) What is environmental ethics? 27) What is computer ethics? 28) Define the term ‘morals’. 29) What do you mean by ‘values’?

31) What is altruism? 32) What is sharing? 33) What is caring?

36) What is meant by valuing time? 37) What is co-operation? 38) What are the objectives of co-operation? 39) What is meant by commitment? 40) In what way the effective communication skills shape the careers of an engineer? 41) What is self-confidence? 42) What is morality and etiquette? 43) What are the different models of engineering ethics? 44) What are the most fundamental moral principles? 45) What are the moral responsibilities of an employee towards his employer? 46) What are the moral responsibilities of an employer towards his employees? 47) What are the moral responsibilities of an organization towards community? 48) What are the advantages of team-work? 49) What is loyalty? 50) What do you mean by professional rights?

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Example Questions for Writing Skill

Staff Member may prepare similar type of questions for Class works & Examinations

WRITING

1. Your friend has asked for your advice for buying a birthday present. Write a letter to him/her suggesting

which points he\she one should keep in mind like interest, age, need etc. while buying a birthday present. You are Shanty /Shanta of 1048 D, Gulabi Bagh, Delhi.

2. Children like to spend their pocket money on their favourite food items like chips, kurkures, hot dog, pizza

and cold drinks. But they don’t know that these things cause harm to their health. Write a paragraph describing the harmful effects of fast and junk food. Mention the health and other related problems caused by it in about 50 words.

3. You have to take part in a debate on the theme ‘Examinations affect Teaching and Learning in schools’

Write down your arguments in favour or against the motion in about 125 to 150 words

4. Recently you attended a fair of Eco clubs at Bal Bhawan where the students from different schools displayed eco friendly materials and ways to protect our earth through different models and charts. Write a report in about the fair in about 50-60 words.

5. Your cousin is a brilliant student but he is not keeping good health because he avoids homemade food and

is very fond of eating outside. Write a letter telling him/her about the harmful effects of junk food and advising him/her how to maintain good health in not more than 100 words. You are Arpil/Arpita of C-8 Lawrence Road, Delhi.

6. Write a letter to the Principal of your school requesting him/her to introduce inter house activities like quiz

programmes, debates, recitation, essay-writing, painting and sports explaining how it may be beneficial for all-round development of their personality. You are Vineet/Vineeta, the head boy/girl of New Modern School, Amritsar.

7. You don’t approve of the ways of people as they waste a lot of water in different activities. Even the taps in

schools are not closed properly, thereby, wasting the valuable water due to negligence and carelessness. You wish to spread awareness among students about it. Write down your views appealing students of your school to conserve water and to save it for future in an article for school magazine in about 50-60 words.

8. You recently visited the ‘World Book Fair’ organized near your Locality and found it quite an enriching

experience. Write a report in about 50-60 words so as to encourage other students to visit it.

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ENGLISH COMMUNICATION PRACTICAL (Common to all branches)

12) What is loyalty?

15) What is altruism?

( 2 x 5 = 10)

GROUP B

1) Introduce yourself

GROUP C

10

The students will be expected to submit an outline of a Project Report relevant to their

branches of study in a separate folder and this will be assessed at the time of End Examination.

MODEL QUESTION PAPER

TIME : 3 Hrs Max.Marks : 100GROUP A

Answer any ten of the following:- (10 x 2 = 20)I 1) What is teamwork? 2) ‘Commitment’ – What does it mean? 3) What is code of conduct? 4) How can an engineer orient himself towards his ethical responsibilities? 5) What are the professional obligations of an engineer? 6) What is the ethical way of handling retrenchment? 7) What are the rights of the engineers? 8) What is environmental ethics? 9) What is sharing? 10) What are the objectives of co-operation? 11) What is morality and etiquette? 13) What are the moral responsibilities of an employee towards his employer? 14) What do you mean by professional rights? II ( 2 x 5 = 10) 1) Imagine you are applying for a job. Write a resume for the same. 2) Religious extremism, matter of concern : PM III

1) A short story to be played back (audio cassette). 2) A face to face communication to be played back (visual/audio)

I ( 2 x 5 = 10) 1) Read the following passage aloud - A passage with tricky sounds to be given. 2) Read the following aloud - A conversational passage to be given. II ( 3 x 5 = 15) 2) Short speech - A religious fair 3) Any one of the topics given in the syllabus in sub-division v under speaking skills

Project Report – writing

ENGLISH COMMUNICATION PRACTICAL Allocation & Statement of Marks

Duration : 3 Hrs. Max. Marks : 100

Communication Lab.

GROUP A GROUP B GROUP C Internal

Assessment

PE & OB Writing Listening Reading Project Report Speaking Writing Record Attendance

Total Sl. No. Reg.No. Name of the Candidate

(20) (10) (10) (20) (5) (10) (15) (10) (100)

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12073 REFIGERATION AND AIR CONDITIONING LABORATORY


• Identify the various tools used in R & AC. • Demonstrate the construction and working of window air conditioner • Demonstrate the construction and working of split type air conditioner. • Set parameters for comfortable operation of an air conditioner. • Determine the COP of an air conditioner. • Determine the capacity of a window air conditioner. • Describe the wiring of refrigerator and coolers. • Perform servicing on air conditioning system.




Refrigeration and Air conditioning

Laboratory

6

96 25 75 100

1. BASIC REFRIGERATION WORKSHOP OPERATION:

(a) Copper tubing -To study the various sizes of copper tubing. -To study the various tools used for operations. -To become familiar with various operations on copper tubing –Flaring, swaging.

(b) Soldering methods used in R& A.C

2. TO STUDY THE CONSTRUCTION FEATURES OF THE FOLLOWING :

(a) Domestic refrigerators (b) Water coolers (c) Window Air Conditioner (d) Split type air conditioner

3. PROPER METHODS OF SETTING AND ADJUSTING OF

(a) Thermostats (b) Low pressure and high pressure cut-outs (c) Thermostatic expansion valve (d) Automatic expansion valve

4. TEST PROCEDURES

1. To determine the refrigerating effect, C.O.P and the compressor capacity of a open type system with a. Thermostatic expansion valve b. Capillary tube

c. Automatic expansion valve 2. To determine the C.O.P of sealed system by using electrical measurements 3. To determine the capacity of a window air conditioner. 4. To determine the efficiency of a cooling tower. 5. Wiring of refrigerator, water cooler, desert cooler, room air conditioner - packaged air conditioner,

panel board etc. (a) SERVICE PROCEDURES

i. To change refrigerant into service cylinder from storage cylinder. ii. To evaluate the entire system iii. To Pump down the system iv. To Purge air from the system v. To locate the leaks in a system. vi. To charge the system vii. To check the oil level in the compressor. viii. Tracing the common faults in R& A.C units and their remedies.

88

SCHEME OF EXAMINATION: One Question from Test Procedure : 50 marks One Question from Service Procedure : 10 marks One Question from Setting and adjusting methods : 10 marks viva - voce : 05 marks Total : 75 marks

89

12074 METROLOGY, MACHINE TOOL MAINTENANCE & TESTING LABORATORY

• Dismantling and Assembly of various machine tools


• After Completing this practical, the students will have practical Knowledge in • Linear Measurement • Angular Measurement • Flow Measurement

• Dismantling and assembly of various motors


Subject Instruction Examinations

Hours/Week Hours/Semester Assessment Marks


12074 metrology, machine tool

maintenance & testing laboratory

6

96 25 75 100

5. Determination of inside diameter of the bore of a bush cylindrical component to an accuracy of 0.01mm using inside micrometer.

METROLOGY Syllabus: 1. Introduction to linear measurement 2. Introduction to angular measurement 3. Introduction to surface measurements 4. Linear Measuring Inurnments – Vernier Caliper, Micrometer, Inside Micrometer, Vernier Height

gauge, Depth Gauge and Slip Gauge. 5. Angular Measuring Instruments – Universal Bevel Protractor, Sine Bar. 6. comparator- Mechanical comparators and Pneumatic comparators. Exercises: I. Linear Measurements: 1. Determination of the thickness of ground MS flat to an accuracy of 0.02mm using vernier caliper. 2. Determination of the diameter and length of a turned cylindrical (turned in lable exercise) to an

accuracy of 0.02mm using vernier caliper. 3. Determination of the inside diameter of a bush component to an accuracy off 0.02 using vernier

caliper. 4. Determination of diameter of a cylindrical component to an accuracy 0f 0.01mm using micrometer

and check the result with digital micrometer

6. Determine the heights of gauge blocks or parallel bars to accuracy of 0.02mm using vernier height gauge and check the result with digital vernier height gauge.

7. Determine the depth of a blind bore component to an accuracy of 0.02mm using vernier depth gauge.

8. Determine the thickness of ground MS plates using slip gauges I. Angular Measurements:

9. Determination of angle of v-blocks, dovetails in mechanical components using universal bevel

protractor. 10. Determination of angle of machined surfaces of components using sine bar with slip gauges. 11. Measurement of V-Thread dimensions. 12. Measurement of spur gear tooth dimensions.

90

III. MACHINE TOOL MAINTENANCE & TESTING

1. Dismantling and assembly of tailstock of lathe 2. Dismantling and assembly of three jaw chuck 3. Dismantling and assembly of four jaw chuck 4. Dismantling and assembly of Bench vice 5. Dismantling and assembly of D C Motor 6. Dismantling and assembly of A.C. Induction Motor 7. Dismantling and assembly of Hydraulic cylinders

8. Dismantling and assembly of Directional control value 9. Testing of lathe 10. Testing of Horizontal milling machine 11. Testing of Shaping machine 12. Testing of Tool and Cutter grinder 13. Testing of Pillar type drilling machine 14. Testing of Radial Drilling machine 15. Testing of Planning machine

SCHEME OF EXAMINATION:

Linear measurement/ Angular measurement (any one by lot) : 20 marks Machine Tool maintenance and testing : 50 marks Viva-voce : 05 marks Total : 75 marks

91

12056 WORK SHOP – III (Slotting, Planning, Milling, Grinding & CNC Machines)


• Identify a planning machine and its parts. • Identify a slotting machine and its parts. • Identify a milling machine and its parts. • Identify a cylindrical grinder, surface grinder and tool and cutter grinder. • Identify the tools and instruments. • Handle the different types of work holding devices • Set the tools in planning and slotting. • Machine a component using different machine tools. • Calculate the indexing for a work • Operate turret and capstan lathe for machining. • Write CNC part program • Operate CNC Lathe and CNC milling machine.


Subjects Instructions Examinations Hours/Week Hours/Semesters Internal Board Exam Total 12056-

WORKSHOP – III (Slotting, Planning, Milling, Grinding & CNC Machines)

6 96 25 75 100

Syllabus:

1. Introduction to planning machine and its parts. 2. Introduction to slotting machine and its parts. 3. Introduction to milling machine and its parts. 4. Introduction to grinding machine and its parts. 5. Introduction to turret and capstan lathe. 6. Introduction to work holding devices. 7. Types of tools used in planning and slotting machines.

a) Programs using CAM software. b) Step turning operation using G00, G01, & G90 CYCLE. c) Taper turning operation using G00, G01, & G94 CYCLE.

15. List of Experiments that can be done XLMILL Machine

8. Types of cutter used in milling machine. 9. Types of grinding wheels used in grinding machines. 10. Types of tools used in turret and capstan lathes. 11. Setting of work, tools and cutters in planning, slotting, milling and grinding machines. 12. Operation performed in planning, slotting, milling and grinding machines. 13. Operation of planning, slotting, milling, grinding, capstan and turret machines. 14.List of Experiments that can be done XLTURN Machine

a) Programs using CAM software. b) Sub Programming Concepts. c) Contour/Profile Milling Machine using G00,G01,G02 & G03 CODES.

92

CNC LATHE WITH BUILT IN CONTROLLER AND MONITOR CNC MILL /MACHINING CENTRE WITH ATC IN BUILT CONTROLLER & MONITOR

Specification of CNC Lathe

SCHEME OF EXAMINATION:

Total : 75 marks

Machine Specification Turning Length in chuck:80-120mm Turning Diameter ↓32 mm Distance between center: 200-250mm

Travel X axis Travel: 70mm -90mm Z axis Travel :150mm- 200mm Positioning Accuracy: 0.010mm Repeatability: 0.005mm Input Resolution: 0.001mm Distance between Centre- 210mm Rapid Traverse: 1.2m/min Spindle Speed: 150- 3000rpm Spindle Power: 0.750- 1.2kw Spindle nose taper: MT3 Chuck size: 100mm 6/8 Station Programmable Indexing Tool Post or Linear Tooling Bed Type: Slant bed 45 1.Control Specifications: Built in Industrial type control with 8 inches colour monitor Closed loop control with Servo Motors(100w) Spindle Motor with encoder Operator Panel with following on off. Switch Spindle forward,reverse,switches MPG, Feed & Speed override potentiometers. Built in PLC with Parameter for functions. 2. Program features: Essential: G&M codes as per Fanuc Oi Turning Milling Control Parametric Programming

X&Z

CNC Turning/ Mi l l ing (by lot) : 30 marks Slot t ing and Planning/Mi l l ing and Gr inding (by lot) : 40 marks Viva-Voce : 05 marks

Note: Dimensions of the component may be changed depending upon the availability of standard

dimensioned material without omitting any operations.

Enclosure : Sketches for Exercises

93

DRILLING HOLES IN RADIAL DRILLING MACHINE.MAKING INTERNAL KEYWAY AND MACHINING AN EXTERNAL PROFILE.

SLOTTING:

96

GRINDING A FLAT SURFACE IN SURFACE GRINDER

MATERIAL: 75X75X12mm

A - TOP RAKE ANGLEB - LIP ANGLEC - FRONT CLEARANCE ANGLED - SIDE RAKE ANGLEE - END CLEARANCE ANGLEF - SIDE CUTTING EDGE ANGLEG - END CUTTING EDGE ANGLEH - NOSE ANGLE

1&6 - FACE2 - SHANK3 - SIDE FLANK4 - END FLANK5 - BASE6 - END CUTTING EDGE7 - NOSE8 - SIDE CUTTING EDGE9 - NOSE RADIUS

97

12061 INDUSTRIAL ENGINEERING AND MANAGEMENT 6 Hrs/Week 16 Weeks/Sem. Total Hrs : 96 OBJECTIVES:

• Explain the different types of layout and compare them. • Appreciate the safety aspects and its impacts on an organization.

• Explain the selection and training of staff. • Analyse Inventory control system and the tools used in stock control. • Familiarize different types of companies and their financial aspects.


• Compare different productivity improvement technique. • Explain different work measurement techniques. • Estimate standard time for a job. • Explain production planning and control and its functions. • Study the role of PPC as a tool for cost control. • Prepare process control charts. • Explain the principles of management and function of management. • Compare different organizational structure.

Subject Instruction Examinations Hours/week Hours/Semester Assessment Marks

Internal Board Exam Total 12061 Industrial

Engineering And

Management

6

75

96 25 100


UNIT TOPIC TIME ( Hours ) I. Plant Engineering and Plant safety 18 II. Work study, Method study and Work measurement 18 III. Production planning and quality control 18 IV. Principles of Management and Personnel

Management 18

V. Financial Management and Material Management 18 Revision Test 6 TOTAL 96

UNIT – I : PLANT ENGINEERING AND PLANT SAFETY 18hrs Plant Engineering : Plant – Selection of site of industry – Plant layout – Principles of good layout – types – process, product and fixed position – techniques to improve layout – Principles of material handling equipment – Plant maintenance – importance – Break down maintenance, preventive maintenance and scheduled maintenance. Plant Safety: Importance – accident – cost and causes of accident – accident proneness – Planning for accident prevention – Safety laws and regulations – Indian factories act 1948 and provision – Industrial disputes – settlement of industrial disputes. UNIT – II : WORK STUDY, METHOD STUDY AND WORK MEASUREMENT 18hrs Work Study: Productivity – Standard of living – method of improving productivity – Objectives – Importance of good working conditions. Method Study: Definition – Objectives – Selection of a job for method study – Basic procedure for conduct of method study – Tools used – Operation process chart, Flow process chart, two handed process chart, Man machine chart, String diagram and flow diagram.

100

Work Measurement: Definition – Basic procedure in making a time study – Employees rating factor – Application of time allowances – Rest, Personal, Process, Special and Policy allowances – Calculation of standard time – Problems – Basic concept of production study – Techniques of work measurement.

UNIT – III : PRODUCTION PLANNING AND QUALITY CONTROL 18hrs Production Planning and Control: Introduction – Major functions of production planning and control – Pre planning – Methods of fore casting – Routing and scheduling – Dispatching and controlling – Critical path method (CPM) No problems. Production – types – Characteristics – Economic Batch Quantity (EBQ) – Principles of product and process planning – make or buy decision – problems. Quality Control: Definition – Objectives – Types of inspection – First piece, Floor and centralized inspection – Advantages and disadvantages. Quality control – Statistical quality control – Types of measurements – Method of variables – Method of attributes – Uses of X, R, p and c charts – Operating Characteristics curve (O.C curve) – Sampling inspection – Single and double sampling plan. UNIT – IV : PRINCIPLES OF MANAGEMENT AND PERSONNEL MANAGEMENT 18hrs Principles of Management: Definition of management – Administration – Organization – F. W. Taylor’s and Henry Fayol’s Principles of Management – Functions of Manager – Types of organization – Line, Staff, Taylor’s Pure functional types – Line and staff and committee type – Directing – Leadership – Styles of Leadership – Qualities of a good leader – Motivation – Positive and negative motivation – Just in time – Total Quality Management(TQM) – Quality circle – Zero defect concept – Management Information Systems – Ethics – Professional ethics. Personnel Management: Responsibility of human resource management – Selection procedure – Training of workers – Apprentice training – On the job training and vestibule school training – Job evaluation and merit rating – objectives and importance – wages and salary administration – Components of wages – Wage fixation – Type of wage payment – Halsey’s 50% plan, Rowan’s plan and Emerson’s efficiency plan – Problems.

UNIT – V : FINANCIAL MANAGEMENT AND MATERIAL MANAGEMENT 18hrs Financial Management: Fixed and working capital – Resources of capital – Shares preference and equity shares – debentures – Type of debentures – Public deposits, Factory costing – Direct cost – Indirect cost – Factory overhead – Selling price of a product – Profit – Problems. Depreciation – Causes – Methods – Straight line, Sinking fund and percentage on diminishing value method – Problems. Material Management: Objectives of good stock control system – ABC analysis of inventory – Procurement and consumption cycle – Economic order quality problems – Supply chain management – Introduction – Purchasing procedure – Store keeping – Bin card. Revision and Test 6Hrs Text Book: 1. O. P. Khanna, Industrial Engineering and Management, Revised Edition – 2004, Dhanpat Rai Publications

(P) Ltd., 67/4 Madras House, Daryaganj, New Delhi 110 002. 2.T. R. Banga & S. C. Sharma, Engineering Economics and Management, Edn. 2 - 2001, published by McGraw Hill, New Delhi.

Reference Books:

1.Heinz Weihrich,Harold Koontz, Management, A global perspective, 10th edition ,McGraw Hill international edition 1994. 2. Joseph L.Massie, Essentials of Management, 4th Edition, Prentice-Hall of India, New Delhi 2004.

101

12061 INDUSTRIAL ENGINEERING AND MANAGEMENT

MODEL QUESTION PAPER – I DURATION : 3 HRS. MAX MARKS:75



1. State the various methods of plant maintenance? 2. What is industrial dispute?

3. Define Work Measurement. 4. State the allowances as applied to stop watch study?

5. Explain the term ‘Routing’. 6. State the different techniques of forecasting? 7. Define ‘Management’ 8. What is merit rating? 9. What is the advantage of equity share over debentures? 10. What is the purpose of finding EOQ?


11.Explain briefly Breakdown maintenance. 12.Briefly explain any three methods of improving productivity. 13.Differentiate inspection & quality control. 14.State and briefly explain the various components of Wages. 15.What are the resources of fixed capital. Briefly explain.


16. 1. What are the different types of plant layout? Explain any two with neat sketches. (10) OR

2. State the important Provisions of Factories Act, 1948 governing safety & health of workers. (10) 17. 1. With a neat sketch, explain Man type flow process chart. (10)

OR 2. Write short notes on the following:-

(i) Ratio delay study (5) (ii) Analytical estimation (5)

18. 1. What is forecasting? Explain the different techniques of forecasting. (10) OR

2. Write short notes on (i) Double sampling plan (5)

20. 1. Explain by means of a block diagram how the selling price of a product is arrived at. (10)

(ii) OC curve for a simple plan (5)

19. 1.A worker completes a job in 6 hrs. The allowed standard time for the job is 8 hrs. His Wage rate is Rs.5 per hour. Calculate the total earnings of the worker under the following system of payment

(i) Halsey’s 50% plan (5) (ii) Rowan’s plan (5)

OR 2. State the principles of management as enumerated by Henry Fayol. Explain any eight of them

(10)

OR 2. Explain how total cost of inventory can be efficiently controlled by “ABC Analysis” technique. (10)

102

12061 INDUSTRIAL ENGINEERING AND MANAGEMENT


14. Write down any three functions of human resource management

(ii) Mediation and Arbitration (6)

OR 2. (i) Explain Single Sampling plan (5)

20. 1. Write short notes on

2. Explain the procurement and consumption cycle of stock control system. (10)

MODEL QUESTION PAPER – II



1. What is collective bargaining? 2. Give any two techniques to improve plant layout

3. Define Method study. 4. Define the term ‘Productivity’?

5. State the different types of production. 6. What is sampling inspection? 7. State any two qualities of a good Leadership. 8. Define ‘Quality Circle’. 9. Give two examples for inventory carrying cost. 10. What is working capital?


11. What is accident proneness? 12. Write down any three objectives of method study

13. State any three advantages of sampling inspection

15. Explain the various resources of fixed capital PART –C Answer any one question from each unit 10x5=50 16. 1. Explain the various factors that are considered for the selection of a site for plant. (10)

OR 2. Write short notes on the following:-

(i) Collective bargaining (4)

17. 1. What is operation process chart? Explain with an example. State guidelines for preparing the chart? OR (10)

2. Write short notes on (i) Production study (5) (ii) Synthesis from standard data (5)

18. 1. What is production planning & control? Explain the main function. (10)

(ii) Compare PPC with nervous system of human body (5)

19. 1. Discuss the recruitment and selection procedure done by human resource management. OR (10)

2. Explain the functional organization advanced by Taylor using an Organisation chart. State its merits and demerits. (10)

(i) Receiving and issuing of material (6) (ii) Bin cards (4) OR

103

12062 COMPUTER AIDED DESIGN AND MANUFACTURING 6 Hrs/Week 16 Weeks /Sem. Total Hrs : 96 OBJECTIVES:

• Define CAD and list stages and benefits of CAD • Explain CAD hardware and software • Appreciate the uses of computer networking • Define CAM and list its functions • Explain CAPP, its structure and types • Describe MRP and MRP-II, JIT • Describe concept of rapid proto typing • Differentiate between sequential engineering and concurrent engineering • Compare NC, CNC and DNC • Explain turning centers and machining centers and CNC EDM machines • Describe coordinate measuring machines • Explain spindle drives and slide ways • Explain ATC • Explain different feedback devices. • Prepare NC part programs using G code and M code • Describe conversational programming and APT programming • Explain the concept of group technology, FMS and CIM • Describe MICLASS and OPITZ systems • Describe AGV and robots.



Internal Board Exam Total 12062- Computer Aided Design and

Manufacturing

6


Unit Topic TIME (Hrs) I Computer Aided Design and Geometric Modeling 18 II Computer Aided Manufacturing 18 III CNC Machines 18 IV CNC Components and Part Programming 18 V GT-FMS-CIM-AGV and Robotics 18 Revision and Test 6 Total 96

UNIT – I COMPUTER AIDED DESIGN AND GEOMETRIC MODELING 18 Hrs Introduction – CAD definition – Shigley’s design process – CAD activities – benefits of CAD – CAD hardware : Input / Output devices – CRT – raster scan & direct view storage tube – LCD, plasma panel, mouse, digitizer, image scanner, drum plotter, flat bed plotter, laser printer – secondary storage devices : hard disks, floppy disks, CD, DVD, flash memory. Types of CAD system: PC based CAD system – workstation based CAD system – graphics workstation – configuration and typical specification – CAD software packages – AutoCAM – computer networking: purposes – topology – types – OSI networking standards – protocols (description only). Geometric modeling techniques: wire frame, surface, solid modeling – graphics standards: Need, GKS – IGES – DXF. Introduction to finite element methods – procedure of finite element analysis (brief description only). UNIT II – COMPUTER AIDED MANUFACTURING 18 Hrs CAM definition – functions of CAM – benefits of CAM – integrated CAD/CAM organization – process planning – master data – structure of a typical CAPP – types of CAPP : variant type, generative type – advantages of CAPP - aggregate production planning – Master Production Schedule (MPS) – capacity planning – Materials Requirement Planning (MRP) – introduction to enterprises resources planning –Manufacturing Resources

104

Planning (MRP-II) – just in time manufacturing philosophy – cost involved in design changes – concept of Design for Excellence (DFX) – guide lines of Design for Manufacture / Assembly (DFM/A).

NC part programming – manual programming – tape format : sequence number, preparatory functions and G codes, miscellaneous functions and M codes – CNC program procedure – coordinate system – types of motion control: point-to-point, paraxial and contouring - NC dimensioning – reference points – machine zero, work zero, tool zero and tool offsets.

UNIT- V GT-FMS-CIM-AGV AND ROBOTICS 18 Hrs

1.

2.

3.

Product Development Cycle – sequential engineering – concurrent engineering – rapid proto typing: concept and applications – 3D printing. UNIT-III CNC MACHINES 18 Hrs Numerical control – definition – components of NC systems – development of NC – DNC – CNC and adaptive control systems – working principle of a CNC system – distinguishing features of CNC machines - advantage of CNC machines – difference between NC and CNC – types of turning centre: horizontal, vertical – types of machining centers: horizontal spindle, vertical spindle, universal machines – machine axis conventions – design considerations of NC machine tools. CNC EDM machine – Coordinate measuring machines: construction, working principles and specifications – maintenance of CNC machines. UNIT-IV CNC COMPONENTS AND PART PROGRAMMING 18 Hrs Drives: spindle drive – hydraulic systems – direct-current motors – stepping motors – servo motors – AC drive spindles - slide ways – linear motion bearings – recirculation ball screw – ATC – tool magazine - feedback devices: encoders – linear and rotary transducers – in-process probing.

Part Program – tool information – speed – feed data – interpolation – macro – subroutines – canned cycles – mirror images – thread cutting – sample programs for lathe and milling – generating CNC codes from CAD models – post processing – conversational programming – APT programming.

Group Technology(GT) – concept of part family – parts classification and coding – coding structure – MICLASS – OPITZ – benefits of GT. FMS & CIM – introduction to FMS – types of manufacturing - FMS components – FMS layouts – types of FMS : flexible manufacturing cell – flexible turning cell – flexible transfer line – flexible machine systems – benefits of FMS - concept of CIM – historical background –- CIM hardware – CIM software – CIM wheel - introduction to intelligent manufacturing system – virtual machining. Integrated material handling – AGV: working principle and benefits – Automatic Storage and Retrieval Systems (ASRS). ROBOT – definition – robot anatomy and classifications – robot configurations – industrial applications: characteristics, material transfer, machine loading, welding, spray coating, assembly and inspection Revision and Test 6Hrs Text Books:

CAD/CAM/CIM, R.Radhakrishnan, S.Subramanian, V.Raju, 2nd, 2003, New Age International Pvt. Ltd. 2. CAD/CAM, Mikell P.Groover, Emory Zimmers Jr. Indian Reprint Oct 1993, Prantice Hall of India Pvt., Ltd. 3. S.K.Sinha, NC Programming, I Edition, 2001, Galgotia Publications Pvt. Ltd. Reference Books 1. Dr.P.N.Rao, CAD/CAM Principles and Applications, 2002, Tata Mc Graw Hill Publishing Company Ltd.

Ibrahim Zeid, Mastering CAD/CAM, Special Indian Edition 2007, Tata McGraw-Hill Publishing Company Ltd., New Delhi. Mikell P. Groover, Automation, Production Systems, and Computer-Integrated Manufacturing, 2nd Edition, Reprint 2002, Pearson Education Asia.

4. Yoram Koren, Computer control of manufacturing systems, International Edition 1983, McGraw Hill Book Co

105

12062 COMPUTER AIDED DESIGN AND MANUFACTURING

MODEL QUESTION PAPER – I




1. Expand ADSL. 2. What is a bus? 3. What is the documented form of processing sequence for producing parts called? 4. What is machine loading? 5. What is the expansion of btr? 6. What are macros? 7. How does rotary encoder works? 8. What is the g code for tool nose radius compensation left? 9. Name the device used to regulate work cell components. 10. Write the general form of an apt geometry statement.


11. Define cad. What are the essentials of CAD? 12. Write short notes on intelligent manufacturing system. 13. Explain how cnc machines are integrated with CIM environment. 14. What are the data required for manual part programming? 15. State the benefits and applications of FMS.

PART-C Answer any one question from each unit 10x5=50 16 1. (a)What are the various types of modelling techniques? (5) (b) Explain in detail surface modelling technique? (5)

OR 2. Explain any three output devices with simple sketches (10) 17. 1. What is MRP? explain how it works? (10)

OR 2. Explain in detail the operation of typical CAPP system (10) 18. 1. (a) What is CMM? (4) (b) Explain the working of CMM with neat sketch. (6)

OR 2. (a) Explain in detail how cnc drilling machine works. (5) (b) What are the benefits of adaptive control? (5) 19. 1. (a) Describe any five g codes with meaning (6) (b) Explain fixed zero,floating zero (4)

OR 2. (a) What are the requirements of spindle drives? (5) (b) Explain tool magazine and its requirements (5) 20. 1. (a) Explain the term group technology. (5) (b) What are the benefits of group technology? (5)

OR 2. (a) What are the components of agv? (4) (b) Explain vehicle guidance and routing system in AGV (6)

106

12062 COMPUTER AIDED DESIGN AND MANUFACTURING MODEL QUESTION PAPER – II


NOTE : Answer all the questions from Part-A (1 mark each)

2. Define locator in GKS. 3. Name any one approach used in CAPP. 4. What is the other name for inference engine? 5. What is arcnet? 6. What is the main objective of adaptive control?

11. What is Lan? What are the types of Lan? 12. Write short notes on capacity planning.



1. What is the tiny granular powder applied to drum in laser printer called?

7. What is called as home position? 8. N050 M06 T0616. What does this tell us? 9. Define robot. 10. What is a key machine?


13. Explain any one type of cnc grinding. 14. Explain about conversational programming. 15. Describe common robot configurations.

PART-C Answer any one question from each unit 10x5=50 16. 1. (a) Differentiate between b-rep and c-rep. (5) (b) Write short notes on interactive computer graphics (5)

OR 2. Discuss solid modelling with an example.state its merits and demerits (10) 17. 1. (a) Explain rapid prototyping (5) (b) What are the objectives of MPS? (5)

OR 2. (a) What is artificial intelligence? (4) (b) With a line diagram explain the major components of AI system. (6) 18. 1. (a) Briefly explain the maintenance of CNC machines (5) (b) State the various features of turning centres. (5)

OR 2. (a) Compare NC systems with CNC systems. (5) (b) List out the various mechanical structure of CMM (5) 19. 1. What is mirroring in CNC program?. Explain with an example. (10)

OR 2. Explain the terms macros, subroutines and canned cycles used in CNC part programming.(10) 20. 1. What are the three elements of product design? Explain each of them in detail. (10)

OR 2. Discuss in detail material handling and storage system in FMS. (10)

107

12081 AUTOMOBILE TECHNOLOGY


• Explain about the constructional details of an IC engine including cooling and lubrication system. • Describe fuel feed systems with all devices involved in it (Both for petrol and diesel engines). • Explain the construction and functional features of the power transmission systems and various parts

involved in it . • Explain the functions of different types of steering and brake systems. • Familiarize electrical and electronic equipments used in automobile. • Describe the different types of chassis and their functions. • Appreciate the techniques for automobile pollution control.



Internal Board Exam Total 12081- Automobile

Technology 5

80 25 75 100


Unit Topic TIME (Hrs) I. Automotive Engines 15 II. Fuel and Fuel Feed Systems 15 III. Transmission and Power Trains 15 IV. Automotive Chassis 15 V. Automobile Electrical Equipment and Pollution Control 15


UNIT I AUTOMOTIVE ENGINES 15hrs

Basic engine components-functions, types, materials and construction of-cylinder block-cylinder head-gaskets-crankcase-oil pan-cylinder liners-comparison of liners-piston-expansion control in pistons-piston rings-types of compression and oil control rings-piston pin- connecting rod-methods of connecting piston and connecting rod-crankshaft-fly wheel-cam shaft-methods of cam shaft drive arrangements-valve and valve arrangements-L-I-F-T. Stages of combustion-delay period-variables affecting delay period-combustion chamber-methods of generating air swirl in diesel combustion chamber-types of combustion chamber-merits and demerits. Cooling systems-purpose-methods-air, water and other coolants-pump assisted cooling systems-fan-sensors-radiator types-pressure cap-expansion systems-merits-vented and pressurised-expansion tank-troubles in cooling system-loss of coolant, overheating and overcooling-causes. Lubrication systems-purpose-types of lubricants-properties-additives-service rating of oil-types of lubricating system-types of filters-methods of cylinder and piston lubrication-high pressure systems-oil pumps-troubles in lubrication system-oil leakage, low oil pressure and excessive oil consumption-causes.

UNIT II FUEL AND FUEL FEED SYSTEMS 15hrs

Requirement of an ideal petrol-octane number-detonation-properties of a good diesel fuel-cetane number-diesel knock-methods of controlling diesel knock-fuel additives-alternate fuels for petrol and diesel engines-benzol, methanol, ethanol, natural gas, LPG, vegetable oils and bio-gas. Layout of fuel feed system of petrol engine-types of fuel feed system-A.C. mechanical fuel pump-S.U. electrical fuel pump-fuel filter-air cleaners-types-carburetion-classification of carburetors-simple carburetor-carburetor circuits-solex carburetor-construction and operation-DTSI, VTI, CCVTI, PGMFI-petrol injection-MPFI system-necessity-merits and demerits. Layout of diesel fuel feed system-single acting fuel feed pump-injection pumps-construction and working of distributed type pump, CRDI-fuel injectors-purpose-types-single and multiple-pintle and pintaux-governors-necessity-types of governors-mechanical and pneumatic-fuel filters-primary and secondary filters-location and importance.

108

UNIT III TRANSMISSION AND POWER TRAINS 15hrs General arrangement of power transmission system-arrangement of front engine drive-rear engine rear drive-four wheel drive-applications-clutch-function-components-types-single plate, multiplate wet and dry clutches and diaphragm clutch-fluid coupling-clutch troubles and their causes. Gear box-purpose-various resistance to motion-types of gear boxes-sliding mesh, constant mesh and synchromesh-floor shift and steering column gear change-mechanical and hydraulic control system-variator-gear box troubles and their causes. Drive line-propeller shaft-universal joint-cross type only-slip joint-final drive-function-types of gear arrangement-straight and spiral bevel, hypoid, worm and worm wheel-merits, demerits and application-Hotch kiss drive-torque tube drive-radius rod. Differential-purpose-construction and operation- self locking and non slip differential troubles and their causes-forces in rear axles-rear axles-semi floating, three quarter floating and full floating axle-axle housing-types.

UNIT IV AUTOMOTIVE CHASSIS 15hrs

Front axle-types-stub axle-elliot and reverse elliot-lemoine and lemoine inverted-steering system-Ackermann principle of steering-wheel alignment-factors-camber, caster, king pin inclination, Toe in and Toe out on turns-steering linkages-steering gears-cam and double roller, recirculating ball type, rack and pinion-steering troubles and causes- power steering-necessity-types-layout of any one type. Suspension system-functions-types of springs-leaf, coil and Torsion bar-front suspension systems-independent front suspension-merits and demerits-types-rear end suspension-air suspension (brief description only)-shock absorber-purpose-telescopic type-construction and working. Brake system-functions- classification of brakes-drum brakes-leading shoe and trailing shoe-self energizing action-hydraulic brake-brake bleeding-brake shoe adjustment mechanism-air assisted hydraulic brakes-air brake-layout, functions of each components and application only-disc brakes-construction and working-comparism of disc and drum type-brake troubles and their causes-antilock brake system. Wheels-disc wheels, wire wheel, spilt wheel and light alloy cast or forged wheels-brief description and applications-tyres-functions-construction of tyres-cross and radial ply tyres, tubeless tyres-comparison-properties of tyres-tyre wear and tyre service. UNIT V AUTOMOBILE ELECTRICAL EQUIPMENT AND POLLUTION CONTROL 15hrs

Battery-lead acid battery-nickel alkaline battery-construction-battery rating-charging-testing-starting system-circuit construction and operation of starter motor-starting motor drives-over running clutch and Bendix drive-construction and operation-solenoid switch-charging system-circuit-alternator construction and operation-regulators-Dynamo. Ignition system-types-battery coil ignition system-circuit-high-tension magneto-principle of operation of flywheel magneto-electronic ignition-ignition system troubles and remedies. Lighting system- circuit-head light-aiming adjustment-sealed beam head lights-fluorescent lamp-traffic indicator-directional signal circuits-horn circuits-wind screen wiper. Pollution-pollution control techniques for petrol and diesel engine emissions-controlling crankcase emission (PCV)-controlled evaporative emission (VRS, VSS, VRR, ECS and EES)-treatment of exhaust gas (catalytic converter, EGR). Introduction to automotive electronics, radio-interference-suppressors-audio systems. Revision and Test 5 Hrs

Text Books:

1. Kirpal Singh, “Automotive Engineering”, Vol.I and II, Standard Publishers, 1705-B, Naisarak, Post Box 1066, New Delhi 110 006 – 2005.

2. Banga and Singh, “Automobile Engineering”, Khanna Publishers, New Delhi, 1998. 3. Narang. G.B.S., “Automobile Engineering”, Khanna Publishers, New Delhi, 1998. 4. Automobile Transmission and Power systems- William.H.Grouse. 5. Automobile Electrical Equipments- William.H.Grouse.

Refernce Books: 1. Dolan.J.A.,”Motor vehicle technology and practical work”, ELBS, 1978. 2. Dr.Giri.N.K,”Automobile Mechanics”, Khanna Publishers, New Delhi, 1998. 3. Automotive Mechanics, Edn. 6, McGraw Hill Co., New York.

109

12081 AUTOMOBILE TECHNOLOGY

MODEL QUESTION PAPER - I


17. 1. a) Explain the methods of connecting piston and connecting rod (5)




1. State any one function of piston rings 2. Name the two types of commonly used thermostats. 3. What is the function and choke value in carburetor. 4. Why is governess necessary in diesel engines? 5. What is the main advantage of the four wheel drive vehicle? 6. What is the purpose of differential? 7. Define cawber. 8. Name important components of a drum brake 9. Enumerate main components of lead-acid battery.

10. Name the areas of automobile emitting pollutants. PART-B Answer all the questions 3x5=15

11. What are the factors influence the ignition delay periods C.I. Engines 12. Draw the neat sketch of A.C. mechanical pump 13. Draw the neat sketch of full floating axles 14. Explain clearly the requirements of automobiles brakes 15. Discuss in detail the requirements of an ignition system of an internal combustion engine.

16. 1. a) Explain detonation with its causes and control. (5) b) Draw and explain the acceleration and starter circuit in solex carburetor (5)

OR 2. Explain with neat sketch the pump assisted cooling system. (10)

b)Draw the distributor fuel injection pump with neat sketch. (5) OR

2. Name the different types of nozzle and state its function. (10) 18 1. Explain the necessity of a differential of an automobile. Discuss in detail the construction and operation

of the differential with sketch. (10) OR

2. With a simple sketch explain the construction and working of multi-plate clutch. (10) 19. 1. Discuss in detail the rack and pission type manual steering gear type by means of a simple sketch and

discuss its advantages (10) OR

2. Draw the schematic diagram showing the layout of complete air pressure system of brakes and explain the working of brake valve with the help of a neat diagram. (10)

20. 1. Explain the construction and operation of a transistor assisted ignition system. (10)

OR 2. Show with a help of neat sketch the construction and working of lead-acid battery. (10)

110

12081 AUTOMOBILE TECHNOLOGY MODEL QUESTION PAPER - II




1. State types of cylinder liners. 2. What is the purpose of cooling system. 3. What is biogas? 4. Mention types of injection nozzles. 5. What is the function of clutch? 6. List out any two types of universal joint. 7. What is dead Axle? 8. What is King pin inclination? 9. What are the two mostly used type of batteries? 10. What is mean by pollution?


11. Explain function of oil rings. 12. What is ethanol? 13. Draw a sketch of propeller shaft. 14. Explain Caster angle. 15. Explain working of solenoid switch.

PART-C Answer any one question from each unit 10x5=50 16. 1. a) Explain working of Tubular type radiator. (6)

b) Explain dry sub lubrication (4) OR

2. Explain various stages of combustion in diesel engine (10)

17. 1. With neat diagram explain working of mechanical governor (10)

b) With diagram explain A.C fuel pump (6) 18. 1. a)Draw a layout of front engine front drive (5) b)Explain with sketch working of fluid coupling (5)

OR

2. With a neat diagram explain working of differential unit. (10)

OR

2. a) What are the functions of carburetor? (4)

19. 1. Explain with sketch type of front axle (10)

OR 2. Explain with sketch working of Recirculating ball type steering gear box. (10) 20. 1. a)Explain starting circuit with solenoids (5) b)Explain major parts of a lead acid battery (5)

OR 2. Explain with diagram transistor assistant ignition system. (10)

111

12082 MECHATRONICS

5 Hrs/Week 16 Weeks/Sem Total Hrs : 80 OBJECTIVES:

• Define Mechatronics and state its role in industries. • Compare the different types of sensors/transducers • Describe the basic actuation systems and their importance. • Describe various basic Mechanical and Electrical actuation systems. • Explain the various basic pneumatic and hydraulic actuation systems. • Construct the basic mechanical system building blocks. • Construct a basic electrical system building blocks. • Construct a basic fluid system building blocks. • Explain the basic system models used in engineering • Explain the structure of PLC and its functions. • Write PLC program for simple applications. • Differentiate traditional versus mechatronics design.

Apply Mechatronics design to real life case studies. • SCHEME OF INSTRUCTION AND EXAMINATION



Mechatronics 5

80 25 75 100


UNIT TOPIC TIME (Hrs) I Introduction, Sensors & Transducers 15 II Actuation Systems (Mechanical, Electrical, Pneumatic & Hydraulic) 15 III Basic System Models, input/output Systems 15 IV Programmable Logic Controller (PLC) 15 V Design Examples & Advanced Applications in Mechatronics 15 Revision, Test 5 Total 80

UNIT-I INTRODUCTION, SENSORS & TRANSDUCERS 15 Hrs Introduction – Systems – Measurement Systems – Control Systems – Microprocessor Based Controllers Examples – Mechatronics approach. Measurement System terminology – Displacement, Position & Proximity Sensors – Velocity and Motion Sensors – Force Sensors – Fluid Pressure Sensors – Flow Sensors – Liquid Level Sensors – Temperature Sensors – Light Sensors – Selection of Sensors. UNIT-II ACTUATION SYSTEMS (MECHANICAL, ELECTRICAL, PNEUMATIC &

HYDRAULIC) 15 Hrs Mechanical Actuation Systems – Types of motion – Freedom and constraints – Loading – Gear Trains – Pawl & Ratchet – Belt & Chain drive – Bearing – Selection – Ball & Roller bearings – Mechanical aspects of motor selection. Electrical Actuation Systems – Switches & Relays – Solenoids – D.C Motors – A.C.Motors – Stepper Motors – Specification and control of stepper motors – Servomotors: D.C Servomotor and A.C Servomotor. Pneumatic & Hydraulic Systems – Power supplies – DCV – PCV – Cylinders – Rotary actuators. UNIT-III BASIC SYSTEM MODELS, INPUT/OUTPUT SYSTEMS 15 Hrs Mathematical Model – Introduction to mathematical model - Mechanical System building blocks – Electrical System building blocks – Fluid System building blocks – Thermal System building blocks. System Model – Engg. Systems – Rotational-Translational Systems – Electro-Mechanical System – Hydro-Mechanical System.

112

Interfacing - Input/Output ports - Interface requirements: Buffers, Handshaking, Polling and interrupts, Serial interfacing - Introduction to PIA - Serial communications interface - Example of interfacing of a seven-segment display with a decoder. UNIT-IV PROGRAMMABLE LOGIC CONTROLLER (PLC) 15 Hrs Definition – Basic block diagram and structure of PLC – Input/Output processing – PLC Programming: Ladder diagram, its logic functions, latching and sequencing – PLC mnemonics – Timers, internal relays and counters – Shift registers – Master and jump controls – Data handling – Analog input/output – Selection of PLC. UNIT-V DESIGN EXAMPLES & ADVANCED APPLICATIONS IN MECHATRONICS 15 Hrs Design process stages - Traditional Vs Mechatronics designs - Possible design solutions: Timed switch, Wind-screen wiper motion, Bath room scale - Case studies of mechatronics systems: A pick-and-place robot, Car park barrier, Car engine management system, Automatic Camera and Automatic Washing Machine only. Sensors for condition monitoring systems of production systems - Examples of monitoring methods: Vibration monitoring, Temperature monitoring, Wear behavior monitoring - Mechatronics control in automated manufacturing: Monitoring of manufacturing processes, On-line quality monitoring, Model-based systems, Hardware-in-the-loop simulation, Supervisory control in manufacturing inspection, Integration of hetrogeneous systems.

1. 2.

1. 2. 3. 4.


Text Books:

W.Bolton, Mechatronics, 2nd Edition 2001, Pearson Education, New Delhi. R.K.Rajput, A Text Book of Mechatronics, 1st Edition 2007, S.Chand & Co. Ltd., New Delhi.

Reference Books:

HMT, Mechatronics, 1st Edition 1998, Tata McGraw Hill, New Delhi. Devdas Shetty & Kolk, Mechatronics System Design, 1st Reprint, 2001, PWS Publishing Co., Boston. James H.Harter, Electromechanics, 1st Edition 2003, Prentice-Hall of India, New Delhi. M.D.Singh & J.G.Joshi, Mechatronics, 1st Edition 2006, Prentice-Hall of India, New Delhi.

113

12082 MECHATRONICS MODEL QUESTION PAPER-I




1) Define Mechatronics 2) Define Sensor 3) What are all the Mechanical elements? 4) Define Actuators. 5) Define System Model. 6) What is the purpose of dashpot in mathematical model? 7) What is the function of Latch? 8) What are the features of PLC? 9) What is meant by ROBOT? 10) Define Embedded System.


11) Draw the diagram of potentiometer sensor. 12) What is the Basic Principle of DC Motor? 13) Write the difference between parallel and serial Interface. 14) Draw the ladder diagram for counter. 15) What are the features of supervisory control system?


16) 1. a) What are the parameters to be considered while selecting sensor. (4) b) With a neat diagram explain the working principle of displacement transducer. (6)

OR 2. Explain closed loop controlled system with example. (10)

17) 1. Explain the working principle of stepper motor with specification. (10)

OR 2. a) Explain the various types of Belt with neat diagram. (5) b) Explain the factors to be considered for motor selection. (5) 18) 1. Describe mathematical model for Thermal System. (10)

OR 2. a) Briefly explain three state buffer (5) b) What is the function of peripheral interface adaptor? (5) 19) 1. Draw the ladder diagram for code converter. (10)

OR 2. a) Design ladder diagram for timing circuit that switch ON output for 2 second then OFF for 10

seconds. (5) b) Cylinder A and B will activate together and cylinder C will activate after 5 seconds delay. Draw a

ladder for the above sequence of operation. (5) 20) 1. Explain car engine management system with neat diagram. (10)

2. a) Explain car park barrier with neat diagram. (5) OR

b) What are the factors to be considered for vibrating monitoring? (5)

114

12082 MECHATRONICS MODEL QUESTION PAPER-II




1) Define Control System 2) Define accuracy 3) Define Mechanism. 4) Define Drive. 5) What is the purpose of mathematical model? 6) What is the mathematical model for spring. 7) Define PLC. 8) Define Ladder Diagram. 9) Mention the sensor that can be used for production system. 10) Mention the technique used in Automatic washing machine.


11) Explain briefly about diapharam type fluid pressure sensor. 12) Brielfy explain gear train. 13) Draw rack and pinion diagram of rotational translation system. 14) Draw ladder diagram for 4bit shift operation. 15) What is the difference between CAM operated time switch and PLC operated Time switch.


16) 1. Explain Engine management system with neat diagram. (10) OR

2. a) Draw the diagram of metal wire and metal foil type strain gauge. (4) b) Explain bellows and diaphragm type pressure sensor with neat diagram (6)

17) 1. a) Draw the neat diagram of relay . (5)

b) Briefly explain solenoid (5) OR

2. Explain the working principle of directional control valves. (10) 18) 1. Explain interfacing a seven Segment display with a decoder with a neat diagram. (10)

OR 2. a) Draw the mathematical model of a wheel of a car moving along a road. (5) b) Briefly explain serial communication (5) 19) 1. Draw Internal Architecture of PLC and explain each block. (10)

OR 2. a) Design a circuit that can be used to start a motor and then after a delay of 100 seconds start pump when the motor is switched off there should delay of 10 seconds before the pump is switched off. (5) b) Briefly explain jump instruction (5) 20) 1. Explain a pick and place Robot with any one application. (10)

OR 2.a) Design a Digital thermometer system which will display temperature between 0º c and 99ºc. You

might like to consider a solution based on the use of the microprocessor with Ram and ROM chips. (6)

b) Briefly explain steps involved in design process. (4)

115

12064 COMPUTER AIDED DESIGN AND MANUFACTURING PRACTICAL


• Practice on CAD commands for 3D drawings. • Draw 3D CAD drawings using solid modeling. • Practice on Solid rendering. • Differentiate incremental System with absolute system • Prepare a part program, edit and execute in CNC lathe. • Prepare a part program, edit and execute in CNC milling machine. • Produce parts in CNC lathe and milling machine.



Internal Board Exam Total 12064- Computer Aided design and

manufacturing Practical

6

96 25 75 100

PART-1 CAD Practical ( 50 Hours ) 3D CAD Drawing – Solid Modeling & Lisp Programming (10 Hours)

ix)

1. Predefined 3D objects – converting 2D plan into a 3D model – 3Dmesh – 3Dface - 3Dpoly - creating surfaces – Rulsurf – Revsurf – Tabsurf – Edgesurf – isolines -3DView – viewports – Vpoint – hide – dview – modelspace - paper space.

2. 3D solid primitives - creating region – pedit – extrude – revolve - combining object – union – subtract –

intersect – Align – Fillet – chamfer - Advanced 3D editing techniques – align - 3D array –Mirror 3D - Rotate3D.

3. Working with UCS – 3D coordinate system – DDUCS – Plan – UCS icon 4. Solid Rendering – material attaching and detaching – shade with color – slice and sectioning – script – 3D

orbit – calculating mass properties 5. Developing LISP program – constructing a list – input/output functions – control structures - arithmetic

operations – trigonometric functions – special functions. 3D solid modeling and LISP programming practice (40 Hours)

i) Geneva Mechanism ii) Cast Iron Block iii) Bearing Block iv) Bushed Bearing v) Gib and Cotter joint vi) Screw Jack vii) Universal Coupling viii) Simple LISP programs for drawing the following: rectangle, circle, concentric rectangles, concentric

circles, changing the colors and line types LISP program for drawing the spur gear given the gear parameters (may be done as a simple project; not for exam. Reference may be made to the book: Mastering CAD/CAM by Ibrahim Zeid, Special Indian Ed. 2007., pp91)

116

Part-2 CAM Practical (38 Hours) Introductions (8 Hours)

1. Study of CNC lathe, milling 2. Study of international standards G-Codes, M-Codes 3. Program writing – Turning simulator – Milling simulator, IS practice – commands – menus

Exercise practice (30 Hours)

Solid modeling (creating model and writing mass properties)

CNC Lathe 1. Develop a part program for step turning and simulate 2. Develop a part program for taper turning and simulate 3. Develop a part program for circular interpolation and simulate 4. Develop a part program for multiple turning operation and simulate 5. Develop a part program for thread cutting, grooving and simulate 6. Develop a part program for internal drills, boring and simulate CNC Milling 1. Develop a part program for grooving and simulate 2. Develop a part program for drilling (canned cycle) and simulate 3. Develop a part program for mirroring with subroutines and simulate 4. Develop a part program for rectangular and circular pocketing and simulate

Model exam / Revision (8 Hours) Facilities for imparting training: 1. Personal computer (Pentium processor) 2. MS Windows OS (Version 2000 or above) 3. AutoCAD software (release 2000 or above) 4. CNC Lathe and Milling simulation softwares 5. Laser jet printer for getting hard copies of student work

SCHEME OF EXAMINATION : 40 marks

CNC Program writing and execution : 30 marks Viva Voce : 05 marks

Total : 75 marks

117

Geneva Mechanism

Cast iron Block

118

Bearing Block

Bushed Bearing

119

Gib and Cotter Joint

Screw Jack

120

Universal Coupling

121

CAM Practicals – Lathe

122

CAM Practical - Milling

123

120 MOBIL LAB

16 Weeks /Sem. Total Hrs : 96

ed in Automobile.

• Dismantle and assemble fuel injection pump. ion and differential system.

• Overhauling of starter motor and dynamo. • shoot the Electric tomobile.

SC TRUCTIO AND EXAMINA N

83 AUTO E ORATORY

6 Hrs/Week OBJECTIVES:

• Identify the various tools and their applications us• Dismantle and assemble parts of petrol engine. • Dismantle and assemble parts of diesel Engine. • Service oil pump and water pump. • Service AC fuel pump • Service carburetor.

• Dismantle and assemble of power transmiss

Trouble al circuit in au

HEME OF INS N TIO



Automobile Laboratory 6 96 25 75 10

0

P 123

and measuring cylinder bore using cylinder bore dial gauge and suggesting the next

5. Removing decarbonising, inspecting and replacing connecting rods and adjusting the bearings. 6 , removing valves, lapping and adjusting valve clearance. 7 p and water pump. 89112.

1. Removing and replacing of pressure plate and clutch plate, fingers adjustment. 2 box and finding out the gear ratios. 3 ing gearbox. Finding the gear ratio. 4 pecting and assembling of final drive and differential units.

5 with respect to (i) Horn relay circuit (ii) Wiper circuit. Explain with diagram. utomobile electrical system with respect to (i) Battery coil ignition system (ii) Magneto ignition

onstant Ampere/Voltage method.

10. with respect to starting and charging systems. SCH OneOneViva Total : 75 marks

ART A

. Identification and application of mechanic’s tools.

. Dismantling and assembling of four stroke petrol engine and identification of parts. Dismantling & assembling of four stroke Diesel engine and identification of parts. .

4. Cleaning, inspectingover size.

. Removing camshaft, replacing timing gearsl pum. Removing, servicing and replacing oi

. Removing, servicing and replacing of A.C. fuel pump / S.U. electric fuel pump.

. Removing, servicing SOLEX carburetor/ MPFI. 1. Dismantling and assembling of inline F.I.P/CRDI

Dismantling and assembling of injectors.

ART B P

. Dismantling, inspecting and assembling of gearr. Dismantling, assembling and adjusting of stee

antling, ins. Dismantling and assembling dismAdjusting of backlash Trace the automobile electrical system . neat circuit

. Trace the a6system.

7. Dismantling and overhauling of a starter motor.8. Dismantling and overhauling of a dynamo/alternator. 9. est a battery with specific gravity test and charge the battery with cT

Trace the automobile electrical system

EME OF EXAMINATION:

question from PART A : 30 marks question from PART B : 40 marks - voce : 05 marks

124

12084 MECHATRONICS LABORATORY 6 Hrs/Week 16 Weeks /Sem.

TIVES:

• Identify pneumatic operated single acting cylinder and double acting cylinder.

Analyse the speed control of double acting cylinder. • Analyse t ion of hydraulic oper and motor. • Analyse the speed control of hydra ated cting cylinde• ulic al c . • A gic control cuit used i LC. • Analys of Timer, Latch ounter us PLC.

STRUCTION AND EXAMINATION

Total Hrs : 96 OBJEC

• Analyse operation of quick exhaust valve. •

he operat ated cylinder ulic oper double a r.

Analyse the operation of hydranalyse the operation of lo

e the operation

direction ontrol valvecir, C

ned in

P

SCHEME OF IN



Mechatronics Laboratory 6 96 25 75 100

A) PNEUMATICS LAB

- directional control valves (DCV) 2. Direct operation of a single acting cylinder

ion of a double acting cylinder. 4. O er controlle m two different positions using shuttle valve. 5. O ylinde ith qu exha

out circuit.

Y

2. Direct operation of double acting cylinder. motor.

4. Speed control of double acting cylinder - using metering-in and metering-out control. 5. Speed control of hydraulic motor - using metering-in and metering-out control.

al control valve.

) PL

3. Operation of a motor using AND logic control. trol.

er control of a motor. a motor.

• Hydraulic trainer kit with hydraulic power pack

SCHEME OF EXAMINATION: Pneumatic circuit / Hydraulic circuit (by lot) : 40 marks

r(PLC) : 30 marks : 05 marks

Total : 75 marks

1. Study of pneumatic system - elements - pressure control valves

3. Direct operatperations of single acting cylind d froperation of a double acting c r w ick ust valve.

6. Speed control of double acting cylinder using metering in and metering

B) H DRAULICS LAB 1. Study of hydraulic system and its elements.

3. Direct operation of hydraulic

6. Operation of a double acting cylinder using solenoid operated direction

C C LAB

1. Study of PLC system and its elements. 2. Direct operation of a motor using latch circuit.

4. Operation of a motor using OR logic con5. On-delay tim6. Off-delay timer control of

RESOURSES • Pneumatic trainer kit with air compressor.

• Programmable logic controller with electro - pneumatic training kit.

Programmable Logic ControlleViva - Voce

125

12066 PROJECT WORK, ENTREPRENEURSHIP, ENVIRONMENT & DISASTER MANAGEMENT

6 Hrs/Week 16 Weeks /Se SCHEME OF INSTRUCTION AND EXAMINATION

m. Total Hrs : 96

Subject Instruction Examinations Hours/ Week

Hours/ Semester

Assessment Marks 12066 -

Internal Board Exam Total Project work, Entrepreneurship,

25 75 100 Environment & Disaster

Management 6

96

Pro

he ave to do a Project Wo he State Board of

tate

isedonin the V

a)

P T

b) P

The allocation of Mark:

Viva Voce … 15 marks Project Report … 10 marks Demonstration … 15 marks Applicability of the Project … 05 marks ------------ Total … 45 marks ------------ Written Test in 3 topics for 1 hour: a) Entrepreneurship 5 questions X 2 marks = 10 marks b) Environment Management 5 questions X 2 marks = 10 marks c) Disaster Management 5 questions X 2 marks = 10 marks ------------ 30 marks ------------ Selection of Questions from Question Bank by the External Examiner, no choice need be given to the

candidates.

2. ENTREPRENEURSHIP 10 Marks Qualities of an entrepreneur Expectations of entrepreneurship Importance of SSI Assistances offered to SSI Feasibility study Services of finance for SSI

ject Work T students of all the Diploma Programmes (except Diploma in Modern Office Practice) h

rk as part of the Curriculum and in partial fulfillment for the award of Diploma by tTechnical Education and Training, Tamilnadu. In order to encourage students to do worthwhile and innovativeprojects, every year prizes are awarded for the best three projects i.e. institution wise, region wise and sw . The selection of Project work should be taken up in V Sem. of study. The First Project review should be

e in 14th week of study in V Semester. The Second Project Review should be done in the 8th week of study I Semester.

Internal Assessment mark for Project Work & Viva Voce:

roject Review I (VI SEM ) … 10 marks Project Review II (VI SEM) … 10 marks Attendance 05 marks

----------- otal …. …. … 25 marks ----------- roject Work & Viva Voce Board Examination

126

. ENVIRONMENTRAL MANAGEMENT: 10 Marks

(a) Introduction – Environmental Ethics – Assessment of Socio Economic Impact – Environmental Audit – Industries

(b) Solid waste management – Characteristics of Industrial wastes – Methods of Collection, transfer and

disposal of solid wastes – Converting waste to energy – Hazardous waste management Treatment

( cteristics of Industrial effluents – Treatment and disposal methods –

ts on human health.

( pollution control

I 10 Marks

( duction – Disasters due to natural calamities such as Earthquake, Rain, Flood, Hurricane, , accidents, strikes etc – Loss of property and

r disasters – Risk Identification – H azard Zones –

mum distances from Sea – Orientation of

( se, Recovery – Arrangements to be made in the

– Transportation of affected people – Hospital facilities – Fire fighting

rs / Other organizations in Recovery and Rebuilding works – Financial commitments –

3

Mitigation of adverse impact on Environment – Importance of Pollution Control – Types of and Industrial Pollution.

technologies.

c) Waste water management – CharaPollution of water sources and effec

d) Air pollution management – Sources and effects – Dispersion of air pollutants – Air

methods – Air quality management.

(e) Noise pollution management – Effects of noise on people – Noise control methods. 4. D SASTER MANAGEMENT:

a) IntroCyclones etc – Man made Disasters – Crisis due to fireslife.

(b) Disaster Mitigation measures – Causes for majoSelection of sites for Industries and residential buildings – MiniBuildings – Stability of Structures – Fire escapes in buildings - Cyclone shelters – Warning systems.

c) Disaster Management – Preparedness, Responindustries / factories and buildings – Mobilization of Emergency Services - Search and Rescue operations – First Aids arrangements – Communication systems – Restoration of Power supply – Getting assistance of neighbouCompensations to be paid – Insurances – Rehabilitation.

127

LIST OF QUESTIONS

4. the different organizations you know, which deals with pollution control?

5. List out the different types of pollutions caused by a Chemical / Textile / Leather / Automobile / Cement

7. anagement.

9. ted in an industry could be reduced.

11. s?

13. it’.

15. ndfill and state the minimum desirable depth of daily

16. g waste into energy.

disposing the solid wastes fails to do the work continuously for number of days?

20. ers / pollutants anticipated in the effluents from oil refinery industry / thermal power plants / textile industries / woolen mills / dye industries / electroplating industries / cement plants / leather industries (any two may be asked)

ater of varying characteristics

22. ion” and “Floatation” processes in the waste water

iven to the waste water.

25. method used to remove them from the effluent.

28. dge and the treatment steps needed prior to ultimate disposal.

29. List any five Industries, which act as the major sources for Hazardous Air Pollutants.

31. perature and sunlight on the severity of air pollution effects on materials.

32. Differentiate between acute and chronic health effects from Air pollution.

34. 35. ollution control devices for a few pollutants and sources.

ontrolled.

41. dangerous than steady state noise.

43. ce the noise.

ses to reduce the problem?

1. ENVIRONMENTRAL MANAGEMENT: 1. What is the responsibility of an Engineer-in-charge of an Industry with respect to Public Health? 2. Define Environmental Ethic. 3. How Industries play their role in polluting the environment?

What is the necessity of pollution control? What are all

factory. 6. What is meant by Hazardous waste?

Define Industrial waste m8. Differentiate between garbage, rubbish, refuse and trash based on their composition and source.

Explain briefly how the quantity of solid waste genera10. What are the objectives of treatments of solid wastes before disposal?

What are the different methods of disposal of solid waste12. Explain how the principle of recycling could be applied in the process of waste minimization.

Define the term ‘Environmental Waste Aud14. List and discuss the factors pertinent to the selection of landfill site.

Explain the purpose of daily cover in a sanitary lacover. Describe any two methods of convertin

17. What actions, a local body such as a municipality could take when the agency appointed for collecting and

18. Write a note on Characteristics of hazardous waste. 19. What is the difference between municipal and industrial effluent?

List few of the undesirable paramet

21. Explain briefly the process of Equalization and Neutralization of waste wdischarged from an Industry. Explain briefly the Physical treatments “Sedimentattreatment.

23. Explain briefly when and how chemical / biological treatments are g24. List the four common advanced waste water treatment processes and the pollutants they remove.

Describe refractory organics and the26. Explain biological nitrification and de-nitrification. 27. Describe the basic approaches to land treatment of Industrial Effluent.

Describe the locations for the ultimate disposal of slu

30. List out the names of any three hazardous air pollutants and their effects on human health. Explain the influence of moisture, tem

33. Define the term Acid rain and explain how it occurs. Discuss briefly the causes for global warming and its consequences Suggest suitable Air p

36. Explain how evaporative emissions and exhaust emissions are commonly c37. What are the harmful elements present in the automobile smokes? How their presence could be

controlled? 38. What is the Advantage of Ozone layer in the atmosphere? State few reasons for its destruction. 39. Explain the mechanism by which hearing damage occurs. 40. List any five effects of noise other than hearing damage.

Explain why impulsive noise is more 42. Explain briefly the Source – Path – Receiver concept of Noise control.

Where silencers or mufflers are used? Explain how they redu44. Describe two techniques to protect the receiver from hearing loss when design / redress for noise control

fail. 45. What are the problems faced by the people residing along the side of a railway track and near to an

Airport? What provisions could be made in their hou

128

2. DISASTER MANAGEMENT:

What is meant by Disaster Management? Wh1. at are the different stages of Disaster management?

3. Risk identification and Assessment Surveys while planning a project.

ster due to flood / cyclone / earthquake? (Any one may be asked)

pproached for help during a natural disaster.

. Specify the role played by an Engineer in the process of Disaster management.

. What is the cause for Earthquakes? How they are measured? Which parts of India are more vulnerable for frequent earthquakes?

. What was the cause for the Tsunami 2004 which inflicted heavy loss to life and property along the coast of Tamilnadu ? Specify its epicenter and magnitude.

0. Specify the Earthquake Hazard Zones in which the following towns of Tamilnadu lie: (a) Chennai (b) Nagapattinum (c) Coimbatore (d) Madurai (e) Salem.

1. Which parts of India are experiencing frequent natural calamities such as (a) heavy rain fall (b) huge losses due to floods (c) severe cyclones

2. Define basic wind speed. What will be the peak wind speed in (a) Very high damage risk zone – A, (b) High damage risk zone, (c) Low damage risk zone.

13. Specify the minimum distance from the Sea shore and minimum height above the mean sea level, desirable for the location of buildings.

4. Explain how the topography of the site plays a role in the disasters caused by floods and cyclones. 15. Explain how the shape and orientation of buildings could reduce the damages due to cyclones.

6. What is a cyclone shelter? When and where it is provided? What are its requirements? 7. What Precautionary measures have to be taken by the authorities before opening a dam for discharging

the excess water into a canal/river? 8. What are the causes for fire accidents? Specify the remedial measures to be taken in buildings to avoid

fire accidents. 19. What is a fire escape in multistoried buildings? What are its requirements? 0. How the imamates of a multistory building are to be evacuted in the event of a fire/Chemical spill/Toxic Air

Situation/ Terrorist attack, (any one may be asked). 1. Describe different fire fighting arrangements to be provided in an Industry. 2. Explain the necessity of disaster warning systems in Industries. 3. Explain how rescue operations have to be carried out in the case of collapse of buildings due to

earthquake / blast / Cyclone / flood. 24. What are the necessary steps to be taken to avoid dangerous epidemics after a flood disaster? 25. What relief works that have to be carried out to save the lives of workers when the factory area is suddenly

affected by a dangerous gas leak / sudden flooding? 6. What are the difficulties faced by an Industry when there is a sudden power failure? How such a situation

could be managed? 7. What are the difficulties faced by the Management when there is a group clash between the workers? How

such a situation could be managed? 8. What will be the problems faced by the management of an Industry when a worker dies because of the

failure of a mechanical device due to poor maintenance? How to manage such a situation? 29. What precautionary measures have to be taken to avoid accidents to labourers in the Industry in a

workshop / during handling of dangerous Chemicals / during construction of buildings / during the building maintenance works.

30. Explain the necessity of medical care facilities in an Industry / Project site. 31. Explain the necessity of proper training to the employees of Industries dealing with hazardous products, to

act during disasters. 2. What type of disaster is expected in coal mines, cotton mills, Oil refineries, ship yards and gas plants? 3. What is meant by Emergency Plan Rehearsal? What are the advantages of such Rehearsals? 4. What action you will take when your employees could not reach the factory site because of continuous

strike by Public Transport workers? 35. What immediate actions you will initiate when the quarters of your factory workers are suddenly flooded

due to the breach in a nearly lake / dam, during heavy rain? 6. What steps you will take to avoid a break down when the workers union of your Industry have given a

strike notice? 7. List out few possible crisis in an organization caused by its workers? What could be the part of the middle

level officials in managing such crisis? 8. What types of warning systems are available to alert the people in the case of predicted disasters, such as

floods, cyclone etc.

2. Differentiate Natural Disasters and Man made Disasters with examples. Describe the necessity of

4. What is Disasters recovery and what does it mean to an Industry? 5. What are the factors to be considered while planning the rebuilding works after a major disa

6. List out the public emergency services available in the state, which could be a

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39. Explain the necessity of Team work in the crisis management in an Industry / Local body. 40. What factors are t in the case of severe

accidents causing disability / death to them? oblems the management has to face if safely measures taken by them are

2. Describe the importance of insurance to men and machinery of an Industry dealing with dangerous jobs. tions have to be taken while storing explosives in a match/ fire crackers factory?

4. What are the arrangements required for emergency rescue works in the case of Atomic Power Plants?

o be considered while fixing compensation to the workers

41. Explain the legal / financial prfound to be in-adequate.

443. What precau445. Why residential quarters are not constructed nearer to Atomic Power Plants?

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SANDWICH DIPLOMA COURSE - INDUSTRIAL TRAINING

12047 INDUSTRIAL TRAINING -I

II

on

a well rounded technician acclimated with dustrial environment while being a student in the institution.

he Sandwich Diploma Course study is pursued by students, in 7 semesters of 3½ years duration, the subjects b g ademic convenience.

onths (December through May ). They also o course work in the institution for one day in a week, While in the 7th semester they undergo another spell of 6

he Apprenticeship (Amendment) Act 1973 is followed in regulating the Industrial training procedure for andwich Course.

12067 INDUSTRIAL TRAINING - 1. Introducti The main objective of the sandwich Diploma Course is to mould in Tof 3 years - Full Time Diploma Course eing re rouped for ac While in the 4th semester students under Industrial Training for 6 mdmonths (June through November ) industrial training. TS

I SEM II SEM III SEM IV SEM V SEM VI SEM VII SEM

irst Spell - IV Semester (December - May) econd Spell - VII Semester (June - November)

. Attendance Certification

Every month students have to get their attendance certified by industrial supervisor in the prescribed form supplied to them. Students have also to put their signature on the form and submit it to the institution supervisor. Regularity in attendance and submission of report will be duly considered while awarding the sessional mark. 3. Training Reports The students have to prepare two types of reports: • Weekly report in the form of diary to be submitted to the concerned staff incharge of the institution. This will

be reviewed while awarding sessional marks. • Comprehensive report at the end of each spell which will be used for Board Examination. 3.1 Industrial Training Diary Students are required to maintain the record of day - to- day work done. Such record is called Industrial training Diary. Students have to write this reports regularly. All days for the week should be accounted for clearly giving attendance particulars (Presence, Absence, Leave, Holidays etc). The concern Industrial supervisor is to check periodically these progress reports. 3.2 Comprehensive Training Report In addition to the diary, students are required to submit a comprehensive report on training with details of the organisation where the training was undergone after attestation by the supervisors. The comprehensive report should be incorporating study of plant/ product /process/ construction along with intensive in-depth study on any one of the topics such as precesses, methods, tooling, construction and equipment, highlighting aspects of quality, productivity and system. The comprehensive report should be completed in the last week of Industrial training. Any data, drawings etc should be incorporated with the consent of the Organisation.

Institutional study

Industrial Training

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4. Scheme of Evaluation 4.1 Sessional Marks First review (during 3P

rdP month) : 10 marks

Second review (during 5P

thP month) : 10 marks

Attendance : 05 marks (Awarded same as in Theory) Total : 25 marks 4.2 Board Examination Presentation about Industrial Training : 20 marks Comprehensive Training Report : 30 marks Viva-voce : 25 marks Total : 75 marks

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draft curriculum & syllabus – 2008

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