Mechanical Engineering • 6th SemesterCore / Standard CurriculumChange Track

Mechanical Engineering — 6th Semester Syllabus

Mechanical Engineering

Credits Allocation Table (L-T-P Structure)

Course TitleCodeLTPCredits
Design of Machine Elements1026013003
Dynamics of Machinery1026023003
Manufacturing Technology1026033003
Automation in Manufacturing1026053003
Program Elective-I-3003
Program Elective-II-3003
Renewable Energy Systems (Open Elective-I)1026113003
Design of Machine Elements Lab102601P0021
Dynamics of Machinery Lab102602P0031.5
Manufacturing Technology Lab102603P0031.5
Automation in Manufacturing Lab102605P0021
TOTAL----26

Design of Machine Elements

102601
Theory Course • 6 Units
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Unit 1: Introduction to design (8 hrs)

  • Steps in design process
  • Design factors
  • Practical considerations in design
  • Selection of materials
  • Strength of mechanical elements
  • Impact load, shock load, fatigue loading
  • Effects of surface, size, temperature and stress concentration
  • Consideration of creep and thermal stress in design

Unit 2: Design of shafts (8 hrs)

  • Stresses in shafts
  • Design of static loads
  • Combined stresses
  • Reversed bending and steady loads
  • Design of shafts based on deflection and strength
  • Critical speed of shafts
  • Analysis and design of sliding and rolling contact bearings

Unit 3: Joints (9 hrs)

  • Riveted Joint: Stresses in riveted joint, design of riveted joints with central and eccentric loads, boiler and tank joints, structural joints
  • Bolt Joints: Stresses in bolt joint, design of bolt joints with central and eccentric loads
  • Welded Joints: Types of welded joints, stresses, design of welded joints subjected to axial, torsional and bending loads, welds subjected to fluctuating loads

Unit 4: Design of Clutches and Brakes (7 hrs)

  • Design of Clutches: Friction clutches, uniform wear and uniform pressure assumptions, centrifugal clutches
  • Brakes: Design of internal expansion elements, assumptions, design of external contraction elements, band type brakes

Unit 5: Design of transmission elements (4 hrs)

  • Spur, helical, bevel and worm gears

Unit 6: Springs (6 hrs)

  • Stresses in helical springs
  • Deflection of helical compression and tension springs
  • Springs subjected to fatigue loading
  • Concentric and helical torsion spring
  • Critical frequency of springs
  • Leaf springs, and design of automotive leaf springs

Dynamics of Machinery

102602
Theory Course • 6 Units
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Unit 1: Force analysis of mechanism (4 hrs)

  • Dynamics of plane motion of a rigid body
  • Dynamically equivalent two mass system
  • Correction torque
  • Forced in mechanism and machines

Unit 2: Turning moment diagram (6 hrs)

  • Fluctuations of crankshaft speed and energy in a direct acting engine mechanism
  • Flywheels

Unit 3: Cams (8 hrs)

  • Classification of cams and followers
  • Types of follower and retardation
  • Cam profile and generation of concentric and offset radial cam profiles by graphical method
  • Cams with specified contours tangent cam with roller follower
  • Circular arc cam with flat follower

Unit 4: Analysis of gyroscopic motion (8 hrs)

  • Principle of gyroscope
  • Gyroscopic couple and gyroscopic reaction couple
  • Gyroscopic effects on the movement of ships, aeroplanes, two wheeled and four wheeled vehicles
  • Gyro stabilizers

Unit 5: Effects of inertia of reciprocating masses on engine frame (7 hrs)

  • Unbalanced primary and secondary forces and couples
  • Balancing of primary and secondary forces
  • Partial balancing of locomotives
  • Balancing of multicylinder in line and radial engines
  • Direct and reverse cranks methods for balancing of radial engines

Unit 6: Mechanical vibrations (9 hrs)

  • Basic concepts degree of freedom
  • Types of damping and viscous damping
  • Natural free, damped free and damped forced vibrations of a single degree of freedom spring mass system
  • Reciprocating and rotating unbalance
  • Vibration isolation and transmissibility
  • Whirling of shaft
  • Elementary treatment of two degree of freedom systems torsional vibrations of single rotor and two rotor systems
  • Transverse vibration of simply supported beam energy method
  • Rayleigh's and Dankerley method

Manufacturing Technology

102603
Theory Course • 5 Units
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Unit 1: Tooling for conventional and non-conventional machining processes (7 hrs)

  • Mould and die design
  • Press tools, Cutting tools
  • Holding tools: Jigs and fixtures, principles, applications and design
  • Press tools –configuration, design of die and punch
  • Principles of forging die design

Unit 2: Metrology (7 hrs)

  • Dimensions, forms and surface measurements
  • Limits, fits and tolerances
  • Linear and angular measurements
  • Comparators
  • Gauge design
  • Interferometry

Unit 3: Metrology in tool wear and part quality (7 hrs)

  • Metrology in tool wear and part quality including surface integrity
  • Alignment and testing methods
  • Tolerance analysis in manufacturing and assembly
  • Process metrology for emerging machining processes such as microscale machining
  • Inspection and workpiece quality

Unit 4: Assembly practices (5 hrs)

  • Manufacturing and assembly
  • Process planning
  • Selective assembly
  • Material handling and devices

Unit 5: Unconventional Machining Processes (9 hrs)

  • Abrasive Jet Machining, Water Jet Machining, Abrasive Water Jet Machining
  • Ultrasonic Machining, principles and process parameters
  • Electrical Discharge Machining, principle and processes parameters, MRR, surface finish, tool wear, Dielectric, power and control circuits, wire EDM
  • Electro-chemical machining (ECM), etchant & maskant, process parameters, MRR and surface finish
  • Laser Beam Machining (LBM), Plasma Arc Machining (PAM) and Electron Beam Machining

Automation in Manufacturing

102605
Theory Course • 6 Units
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Unit 1: Introduction (5 hrs)

  • Why automation, Current trends
  • CAD, CAM, CIM
  • Rigid automation: Part handling, Machine tools

Unit 2: Flexible automation (7 hrs)

  • Flexible automation: Computer control of Machine tools and Machining centres
  • NC and NC part programming, CNC-Adaptive Control
  • Automated Material Handling, Assembly, Flexible fixturing

Unit 3: Computer Aided Design (6 hrs)

  • Fundamentals of CAD
  • Hardware in CAD
  • Computer Graphics software and Data Base
  • Geometric modelling for downstream applications and analysis methods

Unit 4: Computer Aided Manufacturing (7 hrs)

  • CNC Technology, PLC, Micro-controllers
  • CNC Adaptive control

Unit 5: Low cost automation (8 hrs)

  • Mechanical & Electromechanical systems
  • Pneumatic and Hydraulics
  • Illustrative examples and case studies

Unit 6: Introduction to Modeling and Simulation (9 hrs)

  • Product design, process route modelling
  • Optimization techniques
  • Case studies & Industrial applications

Program Electives - I

ELECTIVE
Theory Course • Course Details
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Available Elective Tracks & Options (3):

Process Planning and Cost Estimation

102606

Unit 1: Introduction of Process Planning (8 hrs)

Methods of process planning, drawing interpretation

Unit 2: Material evaluation (5 hrs)

Steps in process selection, production equipment and tooling selection

Unit 3: Process planning activities (8 hrs)

Process parameter calculation for various production processes • Selection of jigs and fixtures, selection of quality assurance methods • Documents for process planning, economics of process planning, case studies

Unit 4: Introduction to cost estimation (8 hrs)

Importance of costing and estimation, method of costing • Elements of cost estimation, types of estimates, estimating procedure • Estimation of labor cost, material cost, allocation of overhead charges, calculation of depreciation cost

Unit 5: Machining time estimation (6 hrs)

Importance of machine time calculation • Machining time for different lathe operations • Drilling and boring time calculation • Machining time calculation for Milling, Shaping, Planning and Grinding

Unit 6: Production costs (7 hrs)

Different production processes for different jobs • Estimation of forging cost, estimation of welding cost • Estimation of foundry cost, estimation of machining cost

Microprocessors in Automation

102608

Unit 1: Number Systems and digital electronics (6 hrs)

Number Systems, codes, digital electronics: Logic Gates, combinational circuits design • Flip-flops, Sequential logic circuits design: Counters, Shift registers

Unit 2: Introduction to 8085 (6 hrs)

Introduction to 8085 Functional Block Diagram • Registers, ALU, Bus systems, Timing and control signals

Unit 3: Machine cycles and memory interfacing (6 hrs)

Machine cycles, instruction cycle and timing states • Instruction timing diagrams, Memory interfacing

Unit 4: Assembly Language Programming (9 hrs)

Assembly Language Programming: Addressing modes, Instruction set • Simple programs in 8085; Concept of Interrupt, Need for Interrupts • Interrupt structure, Multiple Interrupt requests and their handling • Programmable interrupt controller; Interfacing peripherals: Programmable peripheral interface (8255)

Unit 5: Interfacing and data communication (8 hrs)

Interfacing Analog to Digital Converter & Digital to Analog converter • Multiplexed seven segments LED display systems, Stepper Motor Control • Data Communication: Serial Data communication (8251) • Programmable Timers (8253); 8086/8088 Microprocessor and its advanced features

Unit 6: Introduction to Digital Control (7 hrs)

Sampling theorem, Signal conversion and Processing • Z-Transform, Digital Filters, Implementation of Digital Algorithm

Power Plant Engineering

102610

Unit 1: Power plants types and classification (7 hrs)

Power plants – types and classification based on energy sources

Unit 2: Coal based thermal power plants (7 hrs)

Basic Rankine cycle and its modifications • Layout of modern coal power plant; Super critical boilers, FBC boilers • Turbines, condensers, steam and heating rates; Subsystems of thermal power plants • Fuel and ash handling; Draught system; Feed water treatment • Binary cycles and cogeneration systems

Unit 3: Gas turbine and combined cycle power plants (7 hrs)

Brayton cycle analysis and optimization • Components of gas turbine power plants • Combined cycle power plants; Integrated Gasifier based Combined Cycle (IGCC) systems

Unit 4: Nuclear power plants (7 hrs)

Basics of nuclear energy conversion • Layout and subsystems of nuclear power plants • Boiling Water Reactor (BWR); Pressurized Water Reactor (PWR); CANDU Reactor • Pressurized Heavy Water Reactor (PHWR); Fast Breeder Reactors (FBR) • Gas cooled and liquid metal cooled reactors; Safety measures for nuclear power plants

Unit 5: Renewable energy power plants (7 hrs)

Hydroelectric power plants, hydrological cycle • Rainfall & run-off measurement & plotting of various curves for estimating stream flow • Site selection, classification, comparison with other types of power plant • Typical layout and components • Principles of wind, tidal, solar photovoltaic, solar thermal, geothermal, biogas and fuel cell power systems

Unit 6: Economic and environmental issues (7 hrs)

Power tariffs; Load distribution parameters; Load curve • Capital and operating cost of different power plants • Pollution control technologies including waste disposal options for coal and nuclear plants

Program Electives - II

ELECTIVE
Theory Course • Course Details
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Available Elective Tracks & Options (2):

Mechatronics Systems

102607

Unit 1: Introduction (8 hrs)

Definition of Mechanical Systems, Philosophy and approach • Systems and Design: Mechatronics approach • Integrated Product Design, Modeling, Analysis and Simulation • Man- Machine Interface

Unit 2: Sensors and transducers (8 hrs)

Classification, Development in Transducer technology • Optoelectronics Shaft encoders, CD Sensors, Vision System, etc.

Unit 3: Drives and Actuators (6 hrs)

Hydraulic and Pneumatic drives • Electrical Actuators such as servo motor and Stepper motor • Drive Circuits, open and closed loop control • Embedded Systems: Hardware Structure, Software Design and Communication • Programmable Logic Devices, Automatic Control and Real Time Control Systems

Unit 4: Smart materials (6 hrs)

Shape Memory Alloy • Piezoelectric and Magnetostrictive Actuators: Materials, Statics and dynamic characteristics • Illustrative examples for positioning, vibration isolation, etc.

Unit 5: Micromechatronic systems (8 hrs)

Microsensors, Microactuators • Micro-fabrication techniques LIGA Process: Lithography, etching, Micro- joining etc.

Unit 6: Application examples (8 hrs)

Case studies Examples of Mechatronic Systems from Robotics Manufacturing • Machine Diagnostics, Road vehicles and Medical Technology

Composite Materials

102609

Unit 1: Introduction to composite materials (7 hrs)

Definition and applications of composite materials • Fibers-glass, carbon, ceramic and aramid fibers • Matrices-polymer, graphite, ceramic and metal matrices • Characteristics of fibers and matrices

Unit 2: Lamina assumptions and properties (7 hrs)

Lamina assumptions, macroscopic viewpoint, generalized Hookes law • Reduction of homogenous orthotropic lamina, isotropic limit case • Orthotropic stiffness matrix, commercial material properties • Rule of mixtures, transformation matrix, transformed stiffness

Unit 3: Manufacturing of composite materials (7 hrs)

Bag moulding, compression, pultrusion, filament welding • Other manufacturing processes

Unit 4: Laminated anisotropic plates (7 hrs)

Basic assumptions of laminated anisotropic plates • Symmetric laminates, angle ply plates, cross ply laminates • Laminate structural moduli, evaluation of lamina properties • Determination of lamina stresses, maximum stress and strain criterias • Von Mises yield criterion for isotropic materials

Unit 5: Failure criteria and thermal analysis (7 hrs)

Generalized Hill's criterion for anisotropic materials • Tsai-Hill's criterion for composites • Prediction of laminate failure • Thermal analysis of composite laminates

Unit 6: Analysis of laminated plates (7 hrs)

Analysis of laminated plates-equilibrium equations of motion • Energy formulation, static bending analysis, buckling analysis • Free vibrations, natural frequencies

Renewable Energy Systems (Open Elective-I)

102611
Theory Course • 6 Units
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Unit 1: Principles of Renewable Energy (8 hrs)

  • Introduction, Energy and sustainable development
  • Fundamentals, Scientific Principles of renewable energy
  • Technical implications, Social implications, Problems

Unit 2: Solar radiation and applications (8 hrs)

  • Solar radiation: Introduction, Extra-terrestrial solar radiation
  • Components of radiation, Geometry of collector and the solar beam
  • Effects of the Earth's atmosphere, Measurements of solar radiation
  • Estimation of solar radiation, Solar water heating: Introduction
  • Calculation of heat balance: general remarks
  • Uncovered solar water heaters, Improved solar water heaters
  • Evacuated collectors, Buildings and other solar thermal applications
  • Air heaters, Crop driers, Space cooling, Water desalination, Solar ponds
  • Solar concentrators, Solar thermal electric power systems

Unit 3: Photovoltaic generation (6 hrs)

  • Introduction, The silicon p-n Junction
  • Photon absorption at the Junction, solar radiation absorption
  • Maximizing cell efficiency, Solar cell construction, Applications

Unit 4: Hydro-power (6 hrs)

  • Introduction, Principles
  • Assessing the resource for small installations
  • An impulse turbine, Reaction turbines, Hydroelectric systems
  • The hydraulic ram pump

Unit 5: Power from the wind (8 hrs)

  • Introduction, Turbine types and terms
  • Linear momentum and basic theory, Dynamics matching
  • Blade element theory, Characteristics of the wind
  • Power extraction by a turbine, Electricity generations, Mechanical power

Unit 6: Biomass and Biofuels (8 hrs)

  • Introduction, Biofuel classification
  • Biomass production for energy farming
  • Direct combustion for heat, Pyrolysis (destructive distillation)
  • Further thermochemical processes, Alcoholic fermentation
  • Anaerobic digestion for biogas, Wastes and residues
  • Vegetable oils and biodiesel

Design of Machine Elements Lab

102601P
Laboratory Subject • 1 Units
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Topics Part 1

  • To study the design procedure of Knuckle & Cotter joint.
  • Design of shafts subjected to torsion, bending moment and combined bending and torsion.
  • Design of flat and square key
  • Design and drawing of riveted joints
  • Design and drawing of screw jack
  • Journal Bearing Test Rig.

Prescribed Experiments

  1. To study the design procedure of Knuckle & Cotter joint.
  2. Design of shafts subjected to torsion, bending moment and combined bending and torsion.
  3. Design of flat and square key
  4. Design and drawing of riveted joints
  5. Design and drawing of screw jack
  6. Journal Bearing Test Rig.

Dynamics of Machinery Lab

102602P
Laboratory Subject • 1 Units
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Topics Part 1

  • To study various types of Links, Pairs, Chain and Mechanism
  • To study inversion of Four Bar Mechanism
  • To study velocity diagram for Slider Crank Mechanism.
  • To study various kinds of belts drives.
  • To study and find coefficient of friction between belt and pulley.
  • To study various types of Cam and Follower arrangement.
  • To plot follower displacement Vs cam rotation graph for various cam follower arrangement.
  • To study Different types of Gears.
  • To study Different types of Gear Trains.
  • To Perform Experiment on Watt, Porter, Proell and Hartnell Governors and prepare Performance Characteristic Curves also analyze Stability & Sensitivity
  • To study gyroscopic effects through models.
  • To determine gyroscopic couple on Motorized Gyroscope.
  • To perform the experiment of Balancing of rotating parts and find the unbalanced couple and forces.
  • To study Dynamically Equivalent System.
  • Determine the moment of inertial of connecting rod by compound pendulum method and trifler suspension pendulum.
  • To study the various types of dynamometers.
  • To find out critical speed experimentally and to compare the Whirling Speed of a shaft with theoretical values.

Prescribed Experiments

  1. To study various types of Links, Pairs, Chain and Mechanism
  2. To study inversion of Four Bar Mechanism
  3. To study velocity diagram for Slider Crank Mechanism.
  4. To study various kinds of belts drives.
  5. To study and find coefficient of friction between belt and pulley.
  6. To study various types of Cam and Follower arrangement.
  7. To plot follower displacement Vs cam rotation graph for various cam follower arrangement.
  8. To study Different types of Gears.
  9. To study Different types of Gear Trains.
  10. To Perform Experiment on Watt, Porter, Proell and Hartnell Governors and prepare Performance Characteristic Curves also analyze Stability & Sensitivity
  11. To study gyroscopic effects through models.
  12. To determine gyroscopic couple on Motorized Gyroscope.
  13. To perform the experiment of Balancing of rotating parts and find the unbalanced couple and forces.
  14. To study Dynamically Equivalent System.
  15. Determine the moment of inertial of connecting rod by compound pendulum method and trifler suspension pendulum.
  16. To study the various types of dynamometers.
  17. To find out critical speed experimentally and to compare the Whirling Speed of a shaft with theoretical values.

Manufacturing Technology Lab

102603P
Laboratory Subject • 2 Units
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Topics Part 1

  • Measurement of angle using Sine Center / Sine bar / bevel protractor
  • Measurement of alignment using Autocollimator / Roller set
  • Measurement of cutting tool forces using: a. Lathe tool Dynamometerb. Drill tool Dynamometer
  • a. Lathe tool Dynamometer
  • b. Drill tool Dynamometer
  • Measurement of Screw Threads Parameters using Two wire or Three-wire method
  • Measurements of Surface roughness, Using Tally Surf/Mechanical Comparator
  • Measurement of gear tooth profile using gear tooth Vernier/Gear tooth micrometer
  • Calibration of Micrometer using slip gauges
  • Measurement using Optical Flats

Topics Part 2

  • a. Lathe tool Dynamometer
  • b. Drill tool Dynamometer

Prescribed Experiments

  1. Measurement of angle using Sine Center / Sine bar / bevel protractor
  2. Measurement of alignment using Autocollimator / Roller set
  3. Measurement of cutting tool forces using: a. Lathe tool Dynamometerb. Drill tool Dynamometer
  4. a. Lathe tool Dynamometer
  5. b. Drill tool Dynamometer
  6. Measurement of Screw Threads Parameters using Two wire or Three-wire method
  7. Measurements of Surface roughness, Using Tally Surf/Mechanical Comparator
  8. Measurement of gear tooth profile using gear tooth Vernier/Gear tooth micrometer
  9. Calibration of Micrometer using slip gauges
  10. Measurement using Optical Flats

Automation in Manufacturing Lab

102605P
Laboratory Subject • 1 Units
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Topics Part 1

  • Case study on automated system of any industry.
  • Practice programming on manual part program.
  • Practice Programming on APT.
  • Demonstration on robot.
  • Performance on robot.
  • Demonstration on CNC lathe.
  • Performance on CNC lathe.
  • Performance and simulation with CNC lathe software.
  • Demonstration on CNC milling.
  • Performance on CNC milling.
  • Performance and simulation with CNC milling software.
  • Case study on Computer aided process planning.
  • Case study on part coding and group technology.
  • Case study on Computer aided quality control.
  • Case study on flexible manufacturing system.

Prescribed Experiments

  1. Case study on automated system of any industry.
  2. Practice programming on manual part program.
  3. Practice Programming on APT.
  4. Demonstration on robot.
  5. Performance on robot.
  6. Demonstration on CNC lathe.
  7. Performance on CNC lathe.
  8. Performance and simulation with CNC lathe software.
  9. Demonstration on CNC milling.
  10. Performance on CNC milling.
  11. Performance and simulation with CNC milling software.
  12. Case study on Computer aided process planning.
  13. Case study on part coding and group technology.
  14. Case study on Computer aided quality control.
  15. Case study on flexible manufacturing system.