Shivaji University, Kolhapur. Examination Scheme · 2018-07-04 · Shivaji University, Kolhapur. Mechanical Engineering Scheme of Teaching & Examination T.E. (Semester-V) Sr. No

1

Shivaji University, Kolhapur.

Mechanical Engineering Scheme of Teaching & Examination

T.E. (Semester-V)

Sr. No.

Name Of Subject Teaching Scheme Examination Scheme L T P TOTAL PAPER TW OE POE TOTAL

1 Control Engineering 3 - 2 5 100 25 - - 125 2 Theory of Machines-II 3 - 2 5 100 25 25 - 150 3 Heat and Mass Transfer 3 - 2 5 100 25 - 25 150 4 Machine Design I 3 1 - 4 100 25 - - 125 5 Manufacturing Engineering 3 - 2 5 100 25 - - 125 6 CAD/CAM Laboratory - - 2 2 - 25 - 25 50 7 Professional Skill Development 1 - - 1 - 25 - - 25 8 Workshop Practice V - - 2 2 - 25 - - 25 9 Mini-Project - - 1 1 - 25 - - 25 TOTAL 16 1 13 30 500 225 25 50 800

INDEX

Sr. No. Name of The Subject Code Page No 1 Control Engineering ME301 2 2 Theory of Machines-II ME302 13 3 Heat and Mass Transfer ME303 23 4 Machine Design I ME304 32 5 Manufacturing Engineering ME305 40 6 CAD/CAM Laboratory ME306 59 7 Workshop Practice V ME308 62 8 Mini-Project ME309 64

2

Course Code ME301 Course Control Engineering Prepared by A. P. Dhawan Date 09/06/2018 Prerequisites Partial Expansion, Laplace Transform, Basics of Electrical Engineering,

Basics of Mechanical Engineering, Computer Programming Fundamentals Course Outcomes At the end of the course the students should be able to: CO301.1 Describe1 different types of Control Systems, representation of systems by

mathematical models and solve the numerical of electrical and mechanical analogy.

CO301.2 Represent2 control system in block diagram and convert non-linear differential equation into linear equation

CO301.3 Describe1 difference between steady state and transient response and solve numerical on transient response specification.

CO301.4 Describe3Stability of Control System and find Stability Criterion by various methods like Routh’s Criterion, Root Locus.

CO301.5 Describe2 Dynamic System Stability & analysis by Frequency Response Analysis with Magnitude Plots, Phase Angle Plots, Grain Margin, Polar Plots.

CO301.6 Represent3 and solve advanced control techniques using various programming techniques, State Space Analysis.

Mapping of COs with POs POs COs

a b c d E f G h i j k l

CO301.1 1 CO301.2 2 CO301.3 1 CO301.4 3 CO301.5 2 CO301.6 3 Course Contents Unit No. Description Hours

01 Introduction to Automatic Control: Generalized Control System Types, Open Loop and Closed Loop, Linear and Non-Linear, Time Variant and Time invariant Systems with examples. Advantages of 08

3

Automatic Control Systems

Mathematical Model of Control System: Mechanical Translational Systems, Rotational System, Grounded Chair Representation, Electrical Elements, Analogous Systems, Force – Voltage Analog, Force – Current Analog, Mathematical Model of Liquid Level System, Hydraulic/Pneumatic System, Thermal System, Gear Train

02 Representation of control system: Linearization of nonlinear functions, Linearization of operating curves.

06 Block Diagram Algebra, Rules for Reduction of Block Diagram.

03 Transient Response: General Form of Transfer Function, Concept of Poles and Zeros, Distinct, Repeated and Complex Zeros. Response of systems (First and Second Order) to Various Inputs (Impulse, Step, Ramp & Sinusoidal). Damping Ratio and Natural Frequency, Transient Response Specification. 06

04 Stability and Root Locus Technique: Routh’s Stability Criteria, Significance of Root Locus, Construction of Root Loci, General Procedure, Effect of Poles and Zeros on the System Stability. 07

05 Frequency Response Analysis: Frequency Response Log Magnitude Plots and Phase angle Plots, Gain Margin, Phase Margin, Evaluation of Gain ‘K’, Polar Plots (No numerical), and Stability analysis. Introduction to system Compensation: Types of Compensators, Lead, Lag, Lead-Lag Compensators. 07

06 State Space Analysis: System Representation, Direct, Parallel, Series and General Programming. 06

Reference Books: Sr. No.

Book Author(s) Publication Units

01 Control System Engineering

R Anandnatarajan,

P. Ramesh Babu

SciTech Publi. 1,2,3

02 Control Systems A. Anand Kumar Prentice Hall Publi 4,5,6

4

03 Automatic Control Engineering

F.H. Raven (5th ed.)

Tata McGraw Hill Publi

1,6,5

04 Modern Control Systems

K Ogata, 3rd Ed Prentice Hall Publi 1,2,3,4

05 Automatic Control Systems

B.C. Kuo7th Ed Willey India Ltd. / Prentice Hall Publi

1,5,4,6

06 Automatic Control Engineering

D. Roy and Choudhari

Orient Longman Publi. Calcutta

1,2,6

07 Modern Control Engineering

K. Ogata Pearson Education 1,2,6,5

Examination Scheme Examination Scheme

Theory Term Work POE Total

Max. Marks 100 25 -- 125 Contact Hours/ week

3 2 -- 5

Scheme of Marks Section Unit No. Title Approx.

Marks COs I 1 Introduction to Automatic Control,

Mathematical Model of Control System 18 CO 301.1 2 Linearization of nonlinear function,

Block Diagram Algebra 16 CO 301.2 3 Transient Response Analysis 16 CO 301.3

II 4 Stability and Root Locus Technique 18 CO 301.4 5 Frequency Response Analysis 16 CO 301.5 6 State Space Analysis 16 CO 301.6 Total 100

Course Unitization CO’s Units Internal Assessments Course end survey CO 301.1 1 CAT -I Assignments and Quiz CO 301.2 2 CO 301.3 3 CO 301.4 4 CAT II CO 301.5 5

5

CO 301.6 6 Unit wise lesson plan Unit No

01 Unit Title Introduction to Automatic Control Planned Hrs.

08

Lesson schedule Class No.

Details to be covered

01 Generalized Control System Types, Open Loop and Closed Loop, Linear and Non-Linear,

CO 301.1

02 Time Variant and Time invariant Systems with examples. Advantages of Automatic Control Systems

03 Mathematical Model of Control System: Mechanical Translational Systems, Rotational System,

04 Grounded Chair Representation, Electrical Elements, 05 Analogous Systems, Force – Voltage Analogy, Force – Current Analogy 06 Mathematical Model of Liquid Level System, 07 Hydraulic/Pneumatic System, 08 Thermal System, Gear Train Review Questions Q.01 Write classification of Control System? CO

301.1 Q.02 Write difference between open loop & closed loop control system Q.03 For the mechanical system shown in fig.

a) Construct Direct analog. b) Construct Inverse analog. Write the force equation for both the cases.

Q.04 For the mechanical system shown in fig, determine the equation which relates x-f, y-f and y-x.

Unit No

02 Unit Title Linearization & Block Diagram Planned Hrs.

06



01 Representation of control system - Introduction CO

M

K

B

F X

Y

6

02 Linearization of nonlinear functions, 301.2 03 Linearization of operating curves.

04 Linearization of operating curves. 05 Block Diagram Algebra, Rules for Reduction of Block Diagram. 06 Block Diagram Algebra, Rules for Reduction of Block Diagram. Review Questions Q.01 The equation for length of chord L=2.Rsin (θ /2) where R is the radius.

Determine the equation for the variation l in the length due to a change r in the radius and change Δ θ of the angle. For Ri=10 and θi=600,what is the approximate value of L when R=12 and θ =63o

Q.02 Explain rules to reduce block diagram Q.03 Examples on Block Diagram (any 5, covering max. reduction rules) Unit No

03 Unit Title Transient Response Analysis Planned Hrs.

06



01 Transient Response: General Form of Transfer Function, CO 303.3

02 Concept of Poles and Zeros, Distinct, Repeated and Complex Zeros. 03 Response of systems (First and Second Order) to Various Inputs (Impulse, Step,

Ramp & Sinusoidal). 04 Response of systems (First and Second Order) to Various Inputs (Impulse, Step,

Ramp & Sinusoidal). 05 Damping Ratio and Natural Frequency, Transient Response Specification. 06 Damping Ratio and Natural Frequency, Transient Response Specification. Review Questions Q.01 For the unity feedback system

shown in figure 5b, find damping ratio, natural frequency, damped natural frequency and percentage overshoot.

Q.02 A unity feedback system having forward transfer function K G(s) = ------------- is subjected to a unit step input. Determine the values of s(Ts + 1) K & T if output response curve shows 25.4 % maximum over shoot at 3 second peak time. Also find rise time and settling time.

Unit No

04 Unit Title Stability & Root Locus Techniques Planned Hrs.

07



01 Stability and Root Locus Technique: Routh’s Stability Criteria, CO 303.4

02 Routh’s Stability Criteria, 03 Routh’s Stability Criteria, 04 Significance of Root Locus, 05 Construction of Root Loci, General Procedure,

7

06 Effect of Poles and Zeros on the System Stability. 07 Effect of Poles and Zeros on the System Stability. Review Questions Q.01 Apply Routh’scriterion, determine the number of roots that lie in right half plane

of the following characteristic equation. Comment on the system stability. s4 + 5s3 + 7s2 + 5s + 6 = 0

Q.02 Sketch the root loci for the system shown in figure 5a. and show that the system is stable for all K>0

Q.03 Sketch the root locus of the unity feedback system whose open loop function is K (s2 – 2s + 2) G(S) = ---------------------- (s+2) (s+3) (s+4)

Q.04 The open loop transfer function of an aero plane with an autopilot is represented K(s+1) G(s) . H(s) = ---------------------------- Determine : s(s – 1) (s2 + 4s + 16)

i) Limiting value of K ii) Cross over frequency iii) Break away points iv) Angle of departure

Unit No

05 Unit Title Frequency Response Analysis Planned Hrs.

07

Unit Outcomes Lesson schedule Class No.


01 Frequency Response Analysis: Frequency Response Log Magnitude Plots and Phase angle Plots

CO 301.5

02 Gain Margin, Phase Margin, Evaluation of Gain ‘K’ 03 Gain Margin, Phase Margin, Evaluation of Gain ‘K’ 04 Polar Plots (No numerical), and Stability analysis 05 Introduction to system Compensation: Types of Compensators, Lead, Lag, Lead-

Lag Compensators (No numerical) 06 Introduction to system Compensation: Types of Compensators, Lead, Lag, Lead-

Lag Compensators (No numerical) 07 Introduction to system Compensation: Types of Compensators, Lead, Lag, Lead-

Lag Compensators (No numerical) Review Questions Q. 01 Explain Frequency Response Analysis and various criterion to analyze the

Frequency Response.

Q. 02 Explain Gain Margin, Phase Margin and method to evaluate gain ‘K’ through graphically and analytically.

Q. 03 Explain importance of polar plots and stability analysis.

8

Q. 04 Examples on Frequency Response Analysis (any 5 examples) evaluating Gain Margin, Phase Margin, and K.

Unit No

06 Unit Title State Space Analysis Planned Hrs.

06



01 State Space Analysis: System Representation, mathematically & by programming

CO 301.6

02 State Space Analysis: System Representation, mathematically & by programming

03 Direct Programming 04 Parallel Programming 05 Series Programming 06 General Programming Review Questions Q.01 Determine the state space representation for

the feedback control system shown in figure 7b.

Q.02 The dynamics of helicopter in the hovering condition are described by the differential equation 1 y (t) = ----------------------. f (t). (D + 2) (D + 3) Determine computer diagram by i) Direct Programming ii) Parallel Programming

Q.03 Determine the transfer function G(s) for following state space model.

Q.04 A transfer function of a system is representation as C(s) s3 + 8s2 + 17s + 8 ----- = ------------------------- . Determine the computer diagram and R(s) s3 + 6s2 + 11s + 6 state space representation by using direct programming.

Q.05 Determine the state space representation and computer diagram for the feedback system shown in figure 7b.

Sr. No.

List of experiments/assignments to meet the requirements of the syllabus

9

01 Study of Control System Components – Tachometer, D.C. Servomotor, Hydraulic Servomotor, Stepper Motor, Jet – Pipe Amplifier, Pneumatic Amplifier. CO 301.2

02 Study of On-Off Controller for Flow/ Temperature. CO 301.3 03 Study of Control Modes like P, PD, PI, PID for Pressure / Temperature /

Flow. CO 301.1 04 One assignment on each unit ( 01 to 06 ) CO

301.1 to 301.6 05 Assignment based on use of Software ‘MATLAB’ on Unit 3,4,5,6. CO

301.3 to 301.6

Model Question Paper

Course Title : Control Engineering Duration 3 Hours Total

Marks 100

Instructions: All questions are compulsory. SECTION - I Marks

Q. 1 a) For thermometer shown in figure 1a, the ambient temperature is Ta and temperature of fluid is T. The rate of heat flow from surrounding medium to the fluid is Q = C1 (Ta – T). The rate of change of temperature of fluid is DT = C2.Q. Construct the block diagram representation for this system in which Ta is input and T is output. Determine the time constant τ.

6 b) Find differential

equation between x and y for the mechanical system shown in figure 1b. 6

c) Explain Force Current analog. 6 Q. 2 a) For sonic flow of air through a restriction the mass flow rate is

0.53 M = ______ AP. Where M is mass flow rate, T is inlet temperature, A is area of √T Restriction and P is inlet pressure. Determine linear approximation for the variation m when area of restriction A is held constant. 8

10

b) The block diagram and steady state operating curves for a pressure control system are shown in figure 2b. At the reference operating condition Vi = Ci = 100, Mi = 50 and Ui = 25. Determine K2 and B. Determine K1 such that V = Vi (v=0), the change in controlled variable will be 1 unit when load changes by 5 units.

8

Q. 3 a) Reduce the block diagram shown in figure 3a and obtain transfer

function. 8

b) Derive the transfer function for the armature controlled DC Servomotor and represent it with the block diagram. 8

Q. 4 a) Steady state operating curves for a unity feedback control system s shown in figure 4a. Construct the block diagram that describes the steady state operation of this system.

8

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b) Explain Linearization of operating curves with the help of example. 8

SECTION - II Q. 5 a) Sketch the root locus of the unity feedback system whose open loop

function is K (s2 – 2s + 2) G(S) = ---------------------- (s+2) (s+3) (s+4) 9

b) Find the transfer function for the system which is represented in state space representation as follows, ẋ1 = -2 x1 + x2; ẋ2 = -3 x2 + x3; ẋ3 = -3 x1 – 4 x2 – 5 x3 + u(t) and y(t) = x2 9

Q. 6 a) A unity feedback system having forward transfer function K G(s) = ------------- is subjected to a unit step input. Determine the values of s(Ts + 1) K & T if output response curve shows 25.4 % maximum over shoot at 3 second peak time. Also find rise time and settling time. 8

b) The open loop transfer function of an aero plane with an autopilot is represented K(s+1) G(s) . H(s) = ---------------------------- Determine : s(s – 1) (s2 + 4s + 16)

i) Limiting value of K ii) Cross over frequency iii) Break away points iv) Angle of departure 8

Q. 7 a) Determine value of K &α, so that unity feedback system oscillates at a frequency of 2 rad/sec. The system has open loop transfer function K (s+1) G(s) = ---------------------------.

12

S3 + α s2 + 2s + 1 b) Determine the state space representation and computer diagram for the

feedback system shown in figure 7b.

8 Q. 8 a) A transfer function of a system is representation as

C(s) s3 + 8s2 + 17s + 8 ----- = ----------------------------- . Determine the computer diagram and R(s) s3 + 6s2 + 11s + 6 state space representation by using direct programming. 8

b) The forward loop of unity feedback control system is given by K G(s) = ------------. It is desired to vary K from 8 to 13 and determine the value of s (s + 6) K above which the system exhibits oscillations behavior. 8

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Course Code ME 302 Course Theory of Machines II Prepared by Sujit S. Patil / S B Kamble Date 09/06/2018 Prerequisites This course requires the student to know about the basic concepts of

fundamental laws, force, moment and couple, resolution and composition of force, resultant, free body diagram also Basics of Displacement, Velocity,& Acceleration

Course Outcomes At the end of the course the students should be able to: CO302.1 Explain2 the basics of Gear, Gear Geometry and laws for different types of

gears. CO302.2 Solve3 numerical problems on Epicyclic Gear Train CO302.3 Identify3 the Gyroscopic couple and its effect on Aero plane, Ship, Four-

Wheeler, Two –Wheeler. CO302.4 Analyze4 force analysis of various mechanisms. CO302.5 Demonstrate2 the procedure of balancing to reduce vibrations. CO302.6 Explain2 the basics of flywheel & its types. Mapping of COs with POs POs COs

a b c d E f G h i j k l

CO302.1 2 CO302.2 2 CO302.3 2 CO302.4 1 2 CO302.5 1 CO302.6 2 Course Contents

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Unit No. Title No. of Hours

Section I

1.

Toothed Gearing: Geometry of motion, Gear geometry, Types of gear profile- involute & cycloidal, Theory of Spur, Helical & Spiral gears, Interference in involute tooth gears and methods for its prevention, Path of contact, Contact ratio ,Efficiency and center distance of spiral gears.

07

2.

A. Gear Trains: Types of Gear trains - Simple, Compound, Reverted, Epicyclic gear train, Tabular method for finding the speeds of elements in epicyclic gear train, Torques in epicyclic gear train, Differential gear box. B. Equivalent mass and Moment of Inertia applied to gear trains.

07

3..

Gyroscope: Gyroscopic couple, spinning and Precessional Motion, Gyroscopic couple and its effect on i) Aero plane ii) Ship iii) Four-Wheeler iv) Two –Wheeler.

06

4.

Static and dynamic Force analysis of Mechanisms: Velocity and acceleration of slider crank mechanism by analytical method, Inertia force and torque, D’Alembert’s principle, Dynamically equivalent system, force analysis of reciprocating engine mechanism and four bar chain mechanism.

07

5.

Balancing: Static and Dynamic balancing of rotary and reciprocating masses. Primary and Secondary forces and couples. Direct and Reverse cranks. Balancing of Single cylinder, Multi cylinder-In-line and Radial Engines for four wheeler.

07

6. Flywheel: Turning moment diagrams, Fluctuation of energy, Coefficient of fluctuation of speed, Rimmed flywheel

06

Reference Books: Sr. No. Title of Book Author Publisher/Edition Topics

1 Theory of Machines Rattan S.S Tata McGraw Hill 1, 2, 4 2 Theory of Machines & Mechanisms Shigley Tata McGraw Hill 1,2 3 Theory of Machines Khurmi R. S S. Chand Pub. All 4 Theory of Machines Dr. V.P.Singh DhanpatRai All 5 Theory of Machines Sadhu Singh Pearson EdU. Pub. All 6 Theory of Machines Sadhu Singh Khanna Publications 1st to 4th 7 Theory of Machines R.K.Bansal Laxmi Publications All

Examination Scheme Examination Theory Term Work POE Total

15

Scheme Max. Marks 100 25 25 150

Contact Hours/ week

3 2 -- 5

Scheme of Marks Unit No. Title Marks

1 Toothed Gearing 16-18 2 Gear Trains 16-18 3 Gyroscope 16-18 4 Static and dynamic Force analysis of Mechanisms 16-18 5 Balancing 16-18 6 Flywheel 16-18

Course Unitization CO’s Units Internal Assessments Course end survey

CO302.1 1 CAT-I

Assignments and Quiz

CO302.2 2

CO302.3 3 CAT-II

CO302.4 4

CO302.5 5 CAT-III

CO302.6 6

Unit wise lesson plan

Section I Unit No 1 Unit Title Toothed Gearing Planned

Hrs. 07

Lesson schedule Class No. Details to be covered 1 Geometry of motion, Gear geometry, Types of gear profile- involute &cycloidal, 2 Theory of Spur, Helical & Spiral gears. 3 Interference in involute tooth gears and methods for its prevention 4 Path of contact, Arc of contact & Contact ratio 5 Efficiency and center distance of spiral gears. 6 Numerical problems on Path of contact, Contact ratio 7 Numerical problems on Path of contact, Contact ratio & Efficiency

16

Review Questions Q1 Derive an expression for the length of the arc of contact in a pair of meshed

spur gears. CO302.1

Q2 State and prove the law of gearing. Show that involute profile satisfies the conditions for correct gearing.

Q3 Derive an expression for the centre distance of a pair of spiral gears. Q4 Define (i) normal pitch, and (ii) axial pitch relating to helical gears. Q5 Prove that for two involute gear wheels in mesh, the angular velocity ratio

does not change if the centre distance is increased within limits, but the pressure angle increaseshe pitch circle diameter of the smaller of the two spur wheels which mesh externally and have involute teeth is 100 mm. The number of teeth are 16 and 32. The pressure angle is 20° and the addendum is 0.32 of the circular pitch. Find the length of the path of contact of the pair of teeth.

Unit No 2 Unit Title Gear Train Planned

Hrs. 07

Lesson schedule Class No. Details to be covered 1 Types of Gear trains- Simple, Compound, Reverted, Epicyclic gear train 2 Tabular method for finding the speeds of elements in epicyclic gear train, 3 Solve Numerical problems on Gear train by using Tabular method 4 Solve Numerical problems on Gear train by using Tabular method 5 Differential gear box. Equivalent mass and Moment of Inertia applied to gear trains. 6 Equivalent mass and Moment of Inertia applied to gear trains. 7 Equivalent mass and Moment of Inertia applied to gear trains &Numericals. Review Questions Q1 What do you understand by ‘gear train’?

Discuss the various types of gear trains. CO302.2

Q2 Explain briefly the differences between simple, compound, and epicyclic gear trains. What are the special advantages of epicyclic gear trains?

Q3 How the velocity ratio of epicyclic gear train is obtained by tabular method? Q4 A compound epicyclic gear is shown diagrammatically in Figure. The gears

A, D and E are free to rotate on the axis P. The compound gear B and C rotate together on the axis Q at the end of arm F. All the gears have equal pitch. The number of external teeth on the gears A, B and C are 18, 45 and 21 respectively. The gears D and E are annular gears. The gear A rotates at 100 r.p.m. in the anticlockwise direction and the gear D rotates at 450 r.p.m. clockwise. Find the speed and direction of the arm and the gear E.

17

Unit No 3 Unit Title Gyroscope Planned

Hrs. 06

Lesson schedule Class No. Details to be covered 1 Gyroscopic couple, Spinning and Precessional motion, 2 Gyroscopic couple and its effect on – i) Aero plane 3 Gyroscopic couple and its effect on – ii) Ship 4 Gyroscopic couple and its effect on – iii) Four-Wheele 5 Gyroscopic couple and its effect on – iv) Two –Wheeler. 6 Numerical problems on Gyroscopic Couple Review Questions Q1 Write a short note on gyroscope.

CO302.3

Q2 What do you understand by gyroscopic couple? Derive a formula for its magnitude.

Q3 Explain the application of gyroscopic principles to aircrafts. Q4 Explain the effect of the gyroscopic couple on the reaction of the four wheels

of a vehicle negotiating a curve. Unit No 4 Unit Title Static and dynamic Force analysis of

Mechanisms Planned Hrs.

07

Lesson schedule Class No. Details to be covered 1 Velocity and acceleration of slider crank mechanism by analytical method. 2 Inertia force and torque. 3 D’Alembert’s principle. 4 Dynamically equivalent system. 5 Force analysis of reciprocating engine mechanism. 6 Force analysis of four bar chain mechanism. 7 Numerical Problems on force analysis. Review Questions Q1 The connecting rod of an IC engine is 450 mm long and has a mass of 2 kg.

The center of the mass of the rod is 300 mm from the small end and its radius of gyration about an axis through this center is 175 mm. The mass of the piston and the gudgeon pin is 2.5 kg and the stroke is 300 mm. The cylinder diameter is 115 mm. Determine the magnitude and direction of the torque

18

applied on the crankshaft when the crank is at 40 degree and the piston is moving away from the inner-dead center under an effective gas pressure of 2 N/mm2. The engine speed is 1000 rpm.

Q2 The connecting rod of a vertical reciprocating engine is 2 m long and has a weight of 300 kg. The mass center is 825 mm from big end bearing. When suspended as pendulum from the gudgeon pin axis, it makes 10 complete oscillations in 25 sec. Calculate radius of gyration of the connecting rod. The crank is 400 mm long and rotates at 200 rpm. When the crank has turned through 45 degree from the top dead center and the piston is moving downwards, analytically and graphically find the torque acting at the crankshaft.

Unit No 5 Unit Title Balancing Planned

Hrs. 07

Lesson schedule Class No. Details to be covered 1 Static and Dynamic balancing of rotary masses 2 Static and Dynamic balancing and reciprocating masses. 3 Primary and Secondary forces and couples. 4 Direct and Reverse cranks. 5 Balancing of Single cylinder, Multi cylinder-Inline and V-Engines for four wheeler. 6 Numerical problems on Balancing of Single cylinder Engine 7 Numerical problems on Multi cylinder-Inline and V-Engines for four wheeler. Review Questions Q1 Explain the difference in static and dynamic balancing

CO302.5

Q2 Four masses A, B, C, and D as shown below are to be completely Balanced A B C D

Mass (kg) 30 50 40

Radius(mm) 180 240 120 150

The planes containing masses B and C are 300 mm apart. The angle between planes containing B and C is 90 degree. B and C make angles of 210 and 120 degree respectively with D in the same sense. Find: i) The magnitude and the angular position of mass A, and ii) The positions of planes A and D.

Q3 A shaft carries four A, B, C, D of magnitude 200 kg, 300 kg, 400 kg, 200 kg respectively at radii 80 mm, 70 mm, 60 mm and 80 mm in planes measured from A at 300mm, 400 mm, and 700 mm. The angles between the cranks measured anti clockwise are A to B 45, B to C 70 and C to D 120 degree. The balancing masses are to be placed in planes X and Y. The distance between the planes A and X is 100 mm between X

19

and Y is 400 mm and between Y and D is 200 mm. If the balancing masses revolve at a radius of 100 mm find their magnitudes and angular position.

Q4 Explain the concept of direct and reverse crank method in case of balancing Unit No 6 Unit Title Flywheel Planned

Hrs. 06

Lesson schedule Class No. Details to be covered 1 Turning moment diagrams. 2 Fundamental equation of motion. 3 Fluctuation of energy. 4 Coefficient of fluctuation of speed. 5 Rimmed flywheel. 6 Numerical Problems. Review Questions Q1 The turning moment diagram for a petrol engine is drawn to the

followingscales:Turning moment, 1 mm = 5 N-m;Crank angle, 1 mm = 1º.The turning moment diagram repeatsitself at every half revolution of the engineand the areas above and below the meanturning moment line, taken in order are295, 685, 40, 340, 960, 270 mm2.Determine the mass of 300 mmdiameter flywheel rim when the coefficientof fluctuation of speed is 0.3% and theengine runs at 1800 r.p.m. Also determinethe cross-section of the rim when the widthof the rim is twice of thickness. Assumedensity of rim material as 7250 kg / m3.

CO302.6

Q2 A single cylinder double acting steam engine develops 150 kW at a mean speedof 80 r.p.m. The coefficient of fluctuation of energy is 0.1 and the fluctuation of speed is ± 2% ofmean speed. If the mean diameter of the flywheel rim is 2 metres and the hub and spokes provide 5 percent of the rotational inertia of the wheel, find the mass of the flywheel and cross-sectional areaof the rim. Assume the density of the flywheel material (which is cast iron) as 7200 kg / m3.


1 Generation of involute profile using rack cutter method.

CO302.1

2 Experiment on Torque Measurement in epicyclic Gear Train.

CO302.2

3 Experiment on Gyroscope.

CO302.3

4 Determination of M.I. using Bifilar suspension system.

CO302.4

20

5 Determination of M.I. using Trifilar Suspension system.

CO302.4

6 Experiment on Balancing of rotary masses (Static and Dynamic).

CO302.5

7 Problems on balancing of reciprocating masses. ( Minimum 3)

CO302.5

8 Determination of M.I. of connecting rod by Compound pendulum method.

CO302.4

9 Assignment on Flywheel.

CO302.6

10 Industrial Visit based on above syllabus CO302.5

Model Question Paper

Course Title : Theory of Machines-II

Duration 3 Hours Total Marks

100

Instructions: All questions are compulsory.

Q Marks

1 a Derive an expression for minimum number of teeth on pinion in order to

avoid interference for spur gear in mesh. 08

b A drive on a machine tool is to be made by two spiral gear wheels, the

spirals of which are of the same hand and has normal pitch of 12.5 mm.

The wheels are of equaldiameter and the centre distance between the axes

of the shafts is approximately 134 mm. The anglebetween the shafts is

80° and the speed ratio 1.25. Determine : 1. the spiral angle of each

wheel,2. the number of teeth on each wheel, 3. the efficiency of the drive,

if the friction angle is 6°, and4. the maximum efficiency.

10

2 In an epicyclic gear train, the internal wheels A and B and compound

wheelsC and D rotate independently about axis O. The wheels E and F

rotate on pins fixed to the arm G. Egears with A and C and F gears with

B and D. All the wheels havethe same module and the number of teeth

16

21

are : TC = 28; TD = 26;TE = TF = 18.1. Sketch the arrangement ; 2. Find

the number of teeth on A and B ; 3. If the arm G makes 100 r.p.m.

clockwise and A is fixed,find the speed of B ; and 4. If the arm G makes

100 r.p.m. clockwiseand wheel A makes 10 r.p.m. counter clockwise ;

find the speed ofwheel B.

3 a Explain effect of gyroscopic couple in case of ship for following cases.

a. Steering

b. Pitching

c. rolling

06

b A four wheel vehicle a mass 2500 kg has a wheel base 2.5 m track width

1.5 m, and height of centre of gravity 0.6 m above the ground level and

lies at 1 m from the front axle. Each wheel has an effective diameter of

0.8 m and the moment of inertia of 0.8 kgm². The drive shaft, engine

flywheel and transmission are rotating at four times the speed of road

wheels, in clockwise direction when viewed from the front, and is

equivalent to a mass of 80 kg having a radius of gyration 100 mm. if the

vehicle is tacking a right turn of 60 m radius at 60 km/hr, find the load on

each wheel.

10

4 a The following data relate to a connecting rod of a reciprocating engine:

Mass = 55 kg; Distance between bearing centres = 850 mm; Diameter of

small end bearing= 75 mm; Diameter of big end bearing = 100 mm; Time

of oscillation when the connecting rod issuspended from small end =

1.83 s; Time of oscillation when the connecting rod is suspended from

big end = 1.68 s.Determine: 1. the radius of gyration of the rod about an

axis passing through the centreofgravity and perpendicular to the plane of

oscillation; 2. the moment of inertia of the rod about thesame axis; and 3.

the dynamically equivalent system for the connecting rod, constituted of

two masses,one of which is situated at the small end centre.

08

b In a slider crank mechanism, the length of the crank and connecting rod

are150 mm and 600 mm respectively. The crank position is 60° from

inner dead centre. The crank shaft speed is 450 r.p.m. (clockwise). Using

analytical method, determine: 1. Velocity and acceleration ofthe slider,

08

22

and 2. Angular velocity and angular acceleration of the connecting rod.

or

b A connecting rod is suspended from a point 25 mm above the centre of

small end, and 650 mm above its centre of gravity, its mass being 37.5

kg. When permitted to oscillate,the time period is found to be 1.87

seconds. Find the dynamical equivalent system constituted oftwo masses,

one of which is located at the small end centre.

08

5 a A shaft carries two masses m1 and m2 distance L apart rotating with

shaft at eccentricities r1 and r2 resp. The eccentricities r1 and r2 are

parallel and in the same sense. The shaft is to be balanced by a mass M

attached to the shaft at an eccentricity R. determine the distance between

planes of rotation of I) m1 and M ii) m2 and M in terms of m1, m2, r1,

r2, and L.

10

b A,B,C, and are four masses carried by rotating shaft at radii 180,240,120

and 150 mm resp. and the mass of B, C and D are 30, 50 & 40 kg

respectively. The Planes containing masses B & C are 300mm apart. The

angle between planes containing B& C is 90 degrees. B & C make angles

of 210o and 120o respectively with D in the Same Sense find

i. The magnitude and the angular position of mass A

Position of planes A & D

or

08

b The three cranks of a three cylinder locomotive are all on the same axle

and are set at 120°. The pitch of the cylinders is 1 metre and the stroke of

each piston is 0.6 m. Thereciprocating masses are 300 kg for inside

cylinder and 260 kg for each outside cylinder and theplanes of rotation of

the balance masses are 0.8 m from the inside crank.If 40% of the

reciprocating parts are to be balanced, find :1. the magnitude and the

position of the balancing masses required at a radius of 0.6 m ;and

2. the hammer blow per wheel when the axle makes 6 r.p.s.

08

6 a Derive the expression for the energy stored in the flywheel 06

b The turning moment diagram for an engine is drawn to the following

scales:1 mm = 3100 N-m ; 1 mm = 1.6ºThe areas of the loops above and 10

23

below the mean torque line taken in order are: 77, 219, 588, 522, 97,

116, 1200 and 1105 mm2.The mean speed of the engine is 300 r.p.m. and

the permissible fluctuation in speed is ± 2 per cent ofmean speed. The

stress in the material of the rim is not to exceed 4.9 MPa and density of

its materialis 7200 kg/m3. Assuming that the rim stores15/16thof the

energy that is stored by the flywheel, estimate(a) Diameter of rim; and

(b) Area of cross-section of rim.

Course Code ME 303 Course Heat and Mass Transfer Prepared by A. A Patwegar / N.S.Desai Date 11/06/2018 Prerequisites This course requires the student to know about the basic concepts of

knowledge of Heat and mass transfer, application of heat transfer to varies real life problems.

Course Outcomes At the end of the course the students should be able to: CO303.1 Understand2 the mode by which energy is transported CO303.2 Remember1 Unsteady state heat transfer and effect of heat generation. CO303.3 Understand2 the enhancement of heat transfer using Extended surfaces. CO303.4 Understand2 the fundamentals of convective heat transfer process, Evaluate

heat transfer coefficients for natural convection. CO303.5 Analyze4 the radiation heat transfer between black body surfaces, Calculate

radiation heat exchange between gray body surfaces. CO303.6 Analyze4 heat exchanger performance by using the method of log mean

24

temperature difference and Number of Unit transfer method. Mapping of COs with POs POs COs

a B c d E f G h i j k L

CO415.1 1 1 2 CO415.2 1 3 CO415.3 1 2 2 CO415.4 1 2 2 3 CO415.5 1 2 CO415.6 1 1 3 Course Contents Unit No. Title No. of

Hours

Section I

1. 1.1 Basic Concepts:

Modes of heat transfer. Basic laws of heat transfer, Introduction to combined modes of heat transfer, Thermal conductivity and its variation with temperature for various Engg. Materials (Description only). Nano fluids. Introduction to mass transfer: Modes of mass transfer, Analogybetween heat, mass and momentum transfer, Fick’s law of diffusion, various dimensionless numbers. Derivation of Generalized differential equation of Heat Conduction in Cartesian co-ordinates, its reduction to Fourier, Laplace and Poisson’s equations. Generalized Heat conduction equation in cylindrical and spherical coordinates (no derivation) 1.2 One dimensional steady state heat conduction without heat generation: Reduction of Generalized differential equation of Heat Conduction to one dimension (1D), Heat conduction through plane wall, cylinder, sphere; electrical analogy; concept of thermal resistance and conductance, composite slab, composite cylinder and composite sphere, critical radius of insulation for cylinder and sphere. Economic thickness of insulation.

7

2. Heat conduction with heat generation and unsteady state heat conduction:

2.1 One dimensional steady state heat conduction with heat generation: One dimensional steady state heat conduction with uniform heat generation for plane wall cylinder, and sphere.

6

25

2.2 One dimensional unsteady State Heat Conduction Lumped Heat capacity Analysis,Biot and Fourier number and their significance,(Numericals based on Lumped Heat capacity Analysis).Use of Hiesler and Grober Charts (No numerical based on Hiesler and Grober Charts) .

3. EXTENDED SURFACES: Boundary and Initial conditions: Temperature boundary conditions, heat flux boundary condition, convection boundary condition and radiation boundary condition. Heat transfer through extended surfaces: Types and applications of fins, Heat transfer from rectangular and pin fins. Fin effectiveness and efficiency, Error estimation in temperature measurement in thermo well.

7

4. CONVECTION 4.1 Fundamentals of convection: Mechanism of natural and forced convection. Concept of Hydrodynamic and thermal boundary layer, local and average convective coefficient for laminar and turbulent flow for flat plate and pipe 4.2 Forced Convection: Dimensional analysis, Physical significance of dimension less numbers, Reynolds analogy for laminar flow, correlations for forced convection over flat plate and closed conduits. 4.3 Natural or Free Convection: Dimensional analysis, Physical significance of dimensionless numbers, correlations for natural convection over vertical plate cylinder sphere and flow patterns.

7

5. RADIATION: Nature of thermal radiation, absorbitivity, reflectivity, transmissivity, emissive power and emmissivity,spectural and total concept, blackbody, gray body, and white body Kirchoff’s law, Wein’s law and Planck’s law, and deduction of Stefan Boltzmann law. Lambert cosine rule, Intensity of radiation. Energy exchange by radiation between two black surfaces with non-absorbing medium in between and in absence of reradiating surfaces. Shape factor and its characteristics .Energy exchange by radiation between two gray surfaces without absorbing medium , concept of radiosity and irradiation. Radiation network method, network for two surfaces which see each other and nothing else, radiation shields.

6

6. HEAT EXCHANGERS AND PHASE CHANGE PHENOMENON 6.1 Heat Exchangers: Classification and types ofHeat exchangers, Fouling factor, and Overall heat transfer coefficient, Heat Exchanger Analysis using LMTD and NTU methods for parallel and counter flow, Design consideration of Heat exchangers and introduction to design standards like TEMA.

7

26

6.2 Boiling and Condensation (Descriptive treatment only): Types of boiling, pool boiling and Forced convection boiling, Nusselt’s theory of condensation for vertical plate, condensation correlations for practical applications, Film wise and drop wise condensation, promoters.

Reference Books: Sr. No. Title of Book Author Publisher/Edition Topics

1 Heat Transfer J.P. Holman McGrawHill 1,2,3,4,5,6

2 Heat Transfer- A Practical approach

Yunus. A .Cengel McGrawHill 1,2,3,4

3 A Text Book on Heat Transfer

Dr. S. P.Sukhatme

Orient Longman Publication 1,2,5,6

4 Heat and Mass Transfer R.K.Rajput S. Chand & Company Ltd 1,2,3,4,6



Max. Marks 100 25 25 150 Contact Hours/ week

3 2 -- 5

Scheme of Marks Unit No. Title Marks

1 Modes of Heat Transfer, Conduction 16

2 Heat Conduction with heat generation and unsteady State Heat Conduction

16

3 Extended Surfaces 18

4 Convection 16

5 Radiation 16

6 Heat Exchangers, Boiling and condensation 18

27

Course Unitization

Unit No.

Title Course Outcomes

No. of Questions in CAT-I CAT-II CAT-III

1 Modes of Heat Transfer and mass transfer

CO303.1

Q1, Q2,

& Q3

Solve any

two

questions

Steady state Conduction without heat generation

CO303.1

2 Steady state Conduction with heat generation

CO303.2

Lumped heat analyasis

CO303.2

3 Heat transfer through fins

CO303.3 Q1, Q2, & Q3

Solve any two

questions

4 Natural Convection

CO303.4

Forced Convection

CO303.4

5 Radiation CO303.5

Q1, Q2,

& Q3

Solve

any two

questions

6 Heat Exchangers CO303.6 Boiling and condensation

CO303.6


Unit No

1. Unit Title Basic Concepts: Planned Hrs.

7

Lesson schedule

Class No.


1 Modes of heat transfer. Basic laws of heat transfer, Introduction to combined modes of heat transfer, Thermal conductivity and its variation with temperature for various Engg. Materials (Description only). Nano fluids

28

2 Introduction to mass transfer: Modes of mass transfer, Analogybetween heat, mass and momentum transfer, Fick’s law of diffusion, various dimensionless numbers.

3 Derivation of Generalized differential equation of Heat Conduction in Cartesian co-ordinates, its reduction to Fourier, Laplace and Poisson’s equations. Generalized Heat conduction equation in cylindrical and spherical coordinates

4 Reduction of Generalized differential equation of Heat Conduction to one dimension (1D), Heat conduction through plane wall,

5 Reduction of Generalized differential equation of Heat Conduction to one dimension (1D), Heat conduction through cylinder, sphere;

6 electrical analogy; concept of thermal resistance and conductance, composite slab, composite cylinder and composite sphere

7 Critical radius of insulation for cylinder and sphere. Economic thickness of insulation.

Review Questions

Q1 Derive an one dimensional heat transfer equation without heat generation for cylinder

CO303.1

Q2 Effect of temperature on thermal conductivity CO303.1

Unit No

2 Unit Title Heat conduction with heat generation and unsteady state heat conduction:

Planned Hrs.

6

Lesson schedule

Class No.


1 One dimensional steady state heat conduction with uniform heat generation for plane wall

2 One dimensional steady state heat conduction with uniform heat generation for cylinder, and sphere.

3 Numerical on above topic.

29

4 Lumped Heat capacity Analysis,Biot and Fourier number and their significance


6 Use of Hiesler and Grober Charts

Review Questions

Q1 Explain Lumped heat analysis CO303.2

Q2 Explain Hiesler and Grober Charts CO303.2

Unit No

3. Unit Title EXTENDED SURFACES

Planned Hrs.

7

Lesson schedule

Class No.


1 Types and applications of fins,

2 Temperature boundary conditions, heat flux boundary condition

3 Convection boundary condition and radiation boundary condition.

4 , Heat transfer from rectangular and pin fins

5 Fin effectiveness and efficiency

6 , Error estimation in temperature measurement in thermo well.


Review Questions

Q1 Explain different types of fins CO303.3

Q2 Find the efficiency of long fin. Derivation) CO303.3

Unit No

4 Unit Title CONVECTION

Planned Hrs.

7

30

Lesson schedule

Class No.


1 Mechanism of natural and forced convection. Concept of Hydrodynamic and thermal boundary layer, local and average convective coefficient for laminar and turbulent flow for flat plate and pipe

2 Dimensional analysis

3 Physical significance of dimensionless numbers,

4 Correlations for Forced convection over vertical plate cylinder sphere and flow patterns.


6 Physical significance of dimensionless numbers ( Natural Convection)

7 Correlations for natural convection over vertical plate cylinder sphere and flow patterns.

Review Questions

Q1 Explain dimensionless numbers used in natural convection CO303.4

Q2 Correlations for forced convection over flat plate CO303.4

Unit No

5. Unit Title RADIATION Planned Hrs.

6

Lesson schedule

Class No.


1 Nature of thermal radiation, absorbitivity, reflectivity, transmissivity, emissive power and emissivity

2 spectural and total concept, blackbody, gray body, and white body Kirchoff’s law, Wein’s law and Planck’s law, and deduction of Stefan Boltzmann law

3 . Lambert cosine rule, Intensity of radiation. Energy exchange by radiation between

31

two black surfaces with non-absorbing medium in between and in absence of reradiating surfaces

4 Shape factor and its characteristics

5 Energy exchange by radiation between two gray surfaces without absorbing medium , concept of radiosity and irradiation.

6 Radiation network method, network for two surfaces which see each other and nothing else, radiation shields.

Review Questions

Q1 Explain Wein’s law. CO303.5

Q2 Derive an qeation for heat transfer between infinite plates CO303.5

Unit No

6 Unit Title HEAT EXCHANGERS AND PHASE CHANGE PHENOMENON

Planned Hrs.

7

Lesson schedule

Class No.


1 Classification and types ofHeat exchangers,

2 Fouling factor, and Overall heat transfer coefficient

3 Heat Exchanger Analysis using LMTD and NTU methods for parallel and counter flow,

4 Design consideration of Heat exchangers and introduction to design standards like TEMA.

5 Numerical on above topic

6 Types of boiling, pool boiling and Forced convection boiling, Nusselt’s theory of condensation for vertical plate

7 condensation correlations for practical applications, Film wise and drop wise condensation, promoters.

32

Review Questions

Q1 Explain the design consideration in heat exchanger CO303.6

Q2 Explain the pool boiling CO303.6

Assignments: List of experiments/assignments to meet the requirements of the syllabus

Assignment No. 1 Assignment Title

computer program in C language CO303.1,CO303.5,CO303.4

Batch I To Determine thermal conductivity of insulating powder

Batch II To Determine Stefan Boltzmann Constant.

Batch III To Determine thermal conductivity of Composite wall

Batch IV To Determine Heat Transfer Coefficient for forced convection

Assignment No. 2

Assignment Title

computer program in C language CO303.6,CO303.4

Batch I To Determine Heat Transfer Coefficient for parallel flow heat exchanger.

Batch II To Determine Heat Transfer Coefficient for Counter flows heat exchanger.

Batch III To Determine Heat Transfer Coefficient for natural convection.

Batch IV To Determine thermal conductivity of Metals at different temperatures

List of additional assignments /experiments Assignment No. 1

Assignment Title

Nano Fluids CO303.1

Batch I Types of Nanofluids

Batch II Preparation of Nanofluids

Batch III Heat transfer enhancement using Nanofluids

Batch IV Applications of Nanofluid

33

List of open ended experiments/assignments Assignment No. 1

Assignment Title

CO303.3

Batch I Determine Heat transfer Coefficient for rectangular Notched fins

Batch II Determine Heat transfer Coefficient for semi circular Notched fins

Batch III Determine Heat transfer Coefficient for triangular Notched fins

Batch IV Determine Heat transfer Coefficient for trapozoidal Notched fins

Model Question Paper Course Title : Heat and Mass Transfer Duration- 3 hours

Max. Marks

Instructions:1) All questions are compulsory

2) Draw neat sketches whenever necessary 3)Assume suitable data if necessary and state them clearly 4)Use of Calculator is allowed

1 Solve any two questions Marks a Define thermal conductivity and explain how it varies with temperature 8 b What is critical radius of insulation ?Derive expression for critical radius for

a spherical system 8

c Two parallel infinite gray surfaces are maintained at temperature 127°C and 227 °C respectively If temperature of hot surface is increased to 327 °C By what factor is the net radiation exchange per unit area increased ?Assume emissivity’s of colder and hotter surface to be0.9and 0.7respectively

8

2 Solve any two questions a Derive heat transfer per unit area equation for insulated tip fin 8 b Explain fin efficieny and effectiveness 8 c Explain Lumped heat capacity system with biot and fourier numbers 8

3 Solve any two questions a Derive expression for temperature distribution and heat transfer rate of a Fin

with insulated tip 8

b A steam at 300°C is passing through a steel tube A thermometer pocket of steel(K=45W/m°K) of inside diameter of 14mm and 1mm thick is used to measure the temperature .Calculate the length of thermometer pocket needed to measure the temperature within 1.8% possible error The diameter of steel tube is 95mm The heat transfer coefficient is 93 W/m2°K and tube wall temperature is 100°C

10

c Explain different types of fins. 4 Solve any two questions Marks

a Explain the analysis the problem of forced convention with the help of 8

34

dimension analysis b Explain the hydrodynamic and thermal boundary layer 8 c A two stroke motor cycle petrol engine cylinder consists of 15 annular fins

If outside and inside diameters of each fin are 200mm & 100mm respectively The average fin surface temperature is 475°C & they are exposed to air at 25°C Calculate heat transfer rate when motor cycle is at rest The thermo physical properties of air at 250°C are k=0.0427 W/m°KPr=0.677 v=40.61*10-6m2/s use following correlation Nu=0.54(Gr.Pr)0.25

8

5 Solve any two questions a State Planks law and derive Stefan Boltzmann law from planks law 8 b .Explain absorbitivity, reflectivity, transmissivity. 8 c Two parallel infinite gray surfaces are maintained at temperature 127°C and

227 °C respectively If temperature of hot surface is increased to 327 °C By what factor is the net radiation exchange per unit area increased ?Assume emissivity’s of colder and hotter surface to be0.9and 0.7respectively

8

6 Solve any two questions

a Distinguish between i) Sub cooled and saturated boiling ii) Pool Boiling and forced convection boiling

8

B Effectiveness –NTU method of heat exchanger Design 8

b A Heat Exchanger is required to cool 55000kg/Hr of alcohol from 66°C to 40°C using 40,000kg/hr of water entering at 5 °C Calculate:

I)Exit Temperature of water

ii)Heat Transfer Rate

iii) Surface area required for parallel and Counter flow type of heat exchanger

Take Cp(alcohol)=3760 J/kg °K,Cp(Water)=4180 J/kg °K,U=580W/m2°K

10

CourseCode ME304 Course Machine Design-I Prepared by L.B. Mulla & S. B. Kamble Date 11/06/2018 Prerequisites Fundamental equations: Tensile stress, Bending Stress, Shearing stress

Elastic theories of failure, types of loads

35

Course Outcomes At the end of the course the students should be able to: CO304.1 Explain1 general design procedure of designing a machine element, factor of

safety- its selection & selection of various engineering materials CO304.2 Design5 and draw of machine elements against static loading, knuckle joint,

Turn buckle, Levers

CO304.3 Design5 welded & bolted joints subjected to transverse and eccentric loads. Bolted joint.

CO304.4 Design5 solid & hollow shafts, transmission & line shafts, splined shafts, Keys and Couplings

CO304.5 Explain1 various types of springs and their applications, and design Helical, Compression & Tension springs subjected to static loading. Stresses induced in helical springs

CO304.6 Explain1 forms of threads, and design power screw & nuts CO304.7 Selection3 of flat belt, V belt and rope drives as permanufacturer’s catalogue.

Mapping of COs with POs

POs COs

a b c d E F G H i j k l

CO304.1 2 CO304.2 1 CO304.3 1 CO304.4 3 CO304.5 2 CO304.6 2 CO304.7 1

Course Contents


SECTION I 1. Fundamentals of Machine Design:

Concept of Machine design, Types of loads, Factor of safety- its selection & significance, Review of theories of elastic failure & their applications, Basic procedure of design of machine elements, Review & selection of various engineering material properties & I.S. coding for ferrous materials, Factors governing selection of Engineering materials.

05

2. Design of Joints and Machine Elements: Design of machine elements under static loading- Knuckle joint, Turn buckle and bell crank Lever. Design of bolted joints subjected to following

09

36

conditions- 1) Joints in shear 2) joints subjected to load perpendicular to the axis of bolt. Design of welded joints- 1)Strength of transverse and parallel fillet welds 2) Eccentric load in the plane of weld 3) Welded joint subjected to bending moment.

3. Design of Shaft, Keys, and Couplings: Design of solid & hollow shafts, splined shafts, ASME code for shaft design, Types and Design of Keys, Types of Couplings, Design of Muff, Rigid Coupling, flexible bushed pin type flanged coupling.

06

SECTION II 4 Design of Springs:

Types of springs and their applications, Styles of end, Design of Helical Compression Spring subjected to static loading.

05

5 Design of Power Screw: Forms of threads, Terminology of threads, Torque requirement (lifting and lowering load) Self-locking and overhauling properties, Efficiency of square threaded, Self-locking screw, Trapezoidal and Acme thread, collar friction torque, Design of power screw & nuts, Introduction to recirculating ball Screw.

09

6 Design of Pulley and Selection of Belts: Design of Pulley- flat and V belt pulley, Selection of flat belt, V belt as per the standard manufacturer’s catalogue, Introduction to timing belts.

06

Reference Books:

Sr. No. Title of Book Author Publisher/Edition Units 1 Design of Machine Elements V.B.Bhandari Tata McGraw

Hill 1to 6

2 Machine Design R.K. Jain Khanna 1to 6

3 Machine Design Pandya Shah, Charotar 1to 6

4 Design of Machine Element J.F. Shigley Tata McGraw Hill

1to 6

5 Design of Machine Elements P. Kannaiah Scitech Publication

1to 6

6 PSG Design data Book 1to 6



Max. Marks 100 25 25 150 Contact Hours/ week

3 2 -- 5

37

Scheme of Marks

Section Unit No. Title Marks I 1 Concept of Machine Design 16

2 Design of Joints and Machine Elements 28 3 Design of Shaft, Keys, and Couplings 18

II 4 Design of Springs 16 5 Design of power screw 28 6 Design of flywheel and pulleys 18

Course Unitization

Section

Unit Course Outcomes No. of Questions in No. Title CAT-I CAT-II

I

1,2 Concept of Machine Design, Design against static loading

CO304.1, CO304.2

Q1, Q2

3 Design of Shafts, keys & couplings

CO304.3 Q3

II

4,5 Design of springs, power screw

CO304.5,CO304.6 Q1, Q2

6 Selection of belts & rope drives

CO304.7 Q3

Unit wise Lesson Plan

Section I Unit No 1 Unit Title Concept of Machine Design Planned

Hrs. 05



1 Types of loads, Factor of safety, Theories of elastic failure & their applications, 2 General design procedure for a machine element 3 Selection of various engineering materials properties 4 I.S. coding of various materials, 5 Factors governing selection of Engineering materials.

Review Questions

Q1 Explain general design procedure for a machine element CO304.1

Q2 Define factor of safety & explain factor affecting selection of f.o.s. Q3 Explain factors governing, selection of engineering materials for designing

a machine element

38

Unit No 2 Unit Title Design of Joints and Machine Elements: Planned Hrs.

09



1 Design procedure of Knuckle joint 2 Design of knuckle joints 3 Design procedure for turn buckle with neat sketch 4 Types of levers with examples, design of levers 5 Design of welded joints subjected to transverse and eccentric loads 6 Design of bolted joints subjected eccentric loads 7 Bolted joints subjected to load perpendicular to the axis of bolt 8 Design of welded joints – transverse and parallel fillet welds 9 Bolted joints subjected to eccentric load on circular base

Review Questions

Q1 Explain in detail design procedure of Knuckle joint. CO304.2

Q2 Explain types of levers with examples Q3 Design a Knuckle Joint to transmit 150 KN load. The design stresses may

be taken as 75 MPa in tension 60 MPa in shear & 150 MPa in compression Q4 Explain design procedure for Turn Buckle with neat sketch Q5 Explain eccentric load acting in the plane of bolts

Q6 Explain eccentric load acting in the plane of bolts

Q7 A bracket carrying a load of 15 KN is to be welded as shown in fig. Find the size of weld, if permissible shear stress for the weld is 80N/mm2. Assume static condition.

Q8 Write the advantages of welded joint over bolted joint

Unit No 3 Unit Title Design of shaft, keys & couplings Planned

Hrs. 06



1 Design of solid shafts 2 Transmission & line shafts, splined shafts 3 Types of Couplings, Design Procedure of Muff 4 Rigid flange coupling, Flexible bushed pin type flanged coupling 5 Design of keys & splines. 6 Design of hollow shafts

Review Questions

Q1 A shaft made of mild steel is required to transmit 100 KW at 300 rpm. The supported length of the shaft is 3 metres. It carries two pulleys each weighing 1500 N supported at a distance of 1 metre from the ends respectively. Assuming the safe value of stress as 60 MPa, determine the

39

diameter of the shaft. CO304.3

Q2 Explain design procedure of rigid flange coupling Q3 A steel spindle transmits 4 kW at 800 rpm. The angular deflection should

not exceed 0.25° per metre of the spindle. If the modulus of rigidity for the material of the spindle is 84 GPa, find the diameter of the spindle and the shear stress induced in the spindle.

Q4 Explain different types of keys with neat sketches Section II Unit No 4 Unit Title Design of Springs Planned

Hrs. 05



1 Various types of springs and their applications 2 Design of Helical compression spring 3 Design of Helical compression spring, different end styles 4 Design of Helical tension spring 5 Stresses induced in helical springs

Review Questions

Q1 A compression coil spring made of an alloy steel is having the following specifications: Mean diameter of coil = 50 mm ; Wire diameter = 5 mm ; Number of active coils = 20. If this spring is subjected to an axial load of 500 N ; calculate the maximum shear stress (neglect the curvature effect) to which the spring material is subjected.

CO304.4

Q2 A helical spring is made from a wire of 6 mm diameter and has outside diameter of 75 mm. If the permissible shear stress is 350 MPa and modulus of rigidity 84 kN/mm2, find the axial load which the spring can carry and the deflection per active turn.

Unit No 5 Unit Title Design of Power screws Planned

Hrs. 09



1 Forms of threads, terminology 2 Design of power screw & nuts, to explain self locking and overhauling properties 3 Efficiency of square thread, self locking screw 4 Trapezoidal and Acme thread 5 Collar friction torque 6 Design of power screw & nuts 7 Design of power screw & nuts 8 self locking and overhauling properties 9 Introduction to recirculating ball screw

Review Questions Q1 Explain different forms of threads with relative advantages &disadvantages

40

Q2 A square threaded screw exerts a load of 30 KN, with outer diameter of threads as 75mm and pitch of 6mm. the height of nut is 150mm. Find i) force req. at the end of rim of 300mm diameter wheel with coefficient of friction 0.12 ii) max. Compressive stress in screw, bearing pressure on threads &shear stress in the threads. ii) Efficiency of the screw.

CO304.5

Unit No 6 Unit Title Design of pulley and selection of belts Planned

Hrs. 06



1 Fundamental equation of motion, Coefficient of Fluctuation of Energy 2 Design of pulley 3 Flat & V belt pulley 4 Selection of flat belt and V belt as per the standard manufacturer catalogue 5 Selection of flat belt and V belt as per the standard manufacturer catalogue 6 Introduction to timing belts

Review Questions

Q1 Explain Coefficient of Fluctuation of Energy of flywheel CO304.6 Q2 Explain step by step procedure to select flat belt from as per the standard

manufacturer’s catalogue

Q3 Explain step by step procedure to select V belt and rope drives from as per the standard manufacturer’s catalogue

Laboratory plan:


1 General design procedure and Selection of materials for various engineering applications showing their IS codes, composition and properties

CO304.1

2 Problems on knuckle joint and levers (Different problems for each batch)

CO304.2

3 One problem each on bolted and welded joints subjected to eccentric loading (Different problems for each batch)

CO304.3

4 Problems on design of helical compression springs subjected to static load (Different problems for each batch)

CO304.4

5 Selection of belts as per manufacturer catalogue CO304.5 6

Design, Drawing of the following. (Any Two) 1. Knuckle joint or turn buckle. 2. Rigid or flexible flange coupling. 3. Application of power screw.

CO304.6

CO304.7

A detail report of design procedure calculation and sketches should be submitted along with A 2 size drawing Sheet containing details & assembly. All the assignments should be solved by using standard design procedure

41

using design data book such as PSG design Data book Model Question Paper

Course Title : Machine Design-I Duration 3 hrs

Max. Marks 100

Instructions:

Solve any three questions from each section. Assume any data if necessary and state it clearly

Section-I Marks 1 A Define factor of safety. What is its significance in the machine design? 06

B Suggest suitable material for following and give reasons for your selection.1. Flange for coupling 2. Cylinder block of ICE 3. Pistons 4 Connecting rod

06

C Explain step by step general design procedure 06

2 A Explain design procedure for turn buckle 06

B Design a Knuckle Joint to transmit 150 KN load. The design stresses may be taken as 75 MPa in tension 60 MPa in shear & 150 MPa in compression.

10

3 A Explain eccentric load acting perpendicular to the axis of bolts

06

B A 50mm diameter solid shaft is welded to a flat plate as shown in fig. if the size of the weld is 15mm, find the maximum normal and shear stress in the weld.

6

4 10 A Explain the procedure to design muff coupling with neat sketch B Design a rigid type flange coupling to connect two shafts. The input shaft

transmits 37.5 kW power at 180 rpm to the output shaft through the coupling. The shaft material is 40C8 having Syt=380N/mm2. The keys and bolts are made of 30C8 having Syt= 400N/mm2. It is assumed that compressive strength is 150% of tensile strength. The factor of safety for keys & bolts is 2.5. The flanges are made of gray C.I. having Sut=200N/mm2 with factor of safety as 6.

5 A Derive expression for torque required to raise load by power screws 6 B A triple start threaded screw is used to raise a load of 50 KN. The screw

has a nominal dia. of 50mm & pitch of 8mm, height of nut is 40mm and coeff of friction between nut and screw is 0.12. there is no collar friction. Find the max shear stress induced in the screw & nut threads. Also find the bearing pressure between screw & nut.

10

6 A Explain various styles of compression helical springs with sketches 6 B Design a compression helical spring to carry a load of 500 N with a

deflection of 25 mm. The spring index may be taken as 8. Assume the following values for the spring material: Permissible shear stress = 350

10

42

MPa, Modulus of rigidity = 84 kN/mm2 Wahl’s factor = K = 4C-1/4C-4 +0.615/C where C = spring index.

7 A Explain coefficient of fluctuation of energy 8

B Derive expression for maximum efficiency of square threaded screw. 10 8 A Explain step by step procedure to select flat belt from as per the standard

manufacturer’s catalogue 6

B It is required to select V belt drive to connect 20 kw, 1440 rpm motor to a compressor running at 480 rpm for 15 hrs per day. Space available for centredistance is approx. 1.2m. determine the specifications of belt.

10

Course Code ME 305 Course Manufacturing Engineering Prepared by P. B. Gavali/ Y.N. Dhulugade Date 11/06/2018 Prerequisites Basic knowledge of machines, metal cutting, properties of tools.

Course Outcomes At the end of the course the students should be able to: CO305.1 Describe2 effect of cutting parameters on tool properties and problems based

on metal cutting. CO305.2 Identify1 parameters of single and multipoint cutting tools and problems on

tool life (Taylor’s Tool life Equation) CO305.3 Understand2 Single spindle automat, tool layout, cam design and solve

numerical CO305.4 Design2 of jigs and fixtures and understand concept of locating, clamping. CO305.5 Select1 and design dies for press working operations & understand press

working terminology CO305.6 Understand1 and apply CNC technology.


POs COs

a b c d e f g h i j k l

CO305.1 2 1 CO305.2 2 2 CO305.3 1 1 CO305.4 3 CO305.5 2 1 CO305.6 2

43

Course Contents


1.

Theory Of Metal Cutting Wedge action, Concept of speed, Feed and depth of cut, orthogonal and oblique cutting. Mechanics of metal cutting-Chip formation, Types of chips, cutting ratio, shear plane and shear angle, velocity relationships, force measurement by tool dynamometers, cutting tool materials and their properties, Advanced cutting tools. Machinability of Metals- Factors affecting, improvement and machinability index.

07

2.

Tool life and Tool geometry A. Tool life - Types of wear, relationship with cutting parameters, Taylor’s equation, and improvement measures. Surface finish- Factors affecting, effect of cutting parameters, improvements. Heat generation in machining, its effect on cutting force, tool life and surface finish, types and selection criteria of cutting fluids. B. Tool geometry-Parts, angles and types of single point cutting tools, tool geometry of single point cutting tool, tool geometry of multipoint cutting tools.-drills, milling cutters, reamers.

07

3. Form Tools and Automat Types (Flat, circular, Dovetail) Correction of form tools with and without rake angles, tool layout of single spindle, automat, process sheet, cam profile, tool layout, calculation of production rate.

06

4.

Drilling Jigs and Milling Fixtures Applications, basic elements, principles and types of locating, clamping and indexing elements, auxiliary elements like tenon, setting block etc. Type of Drilling jigs and Milling fixtures-Design consideration of Jigs and fixtures with respect to different operations. Introduction to modular fixtures.

08

5.

Press Tools Dies, punches, types of presses, clearances, types of dies, strip layout, calculation of press capacity, centre of pressure, Design consideration for die elements(Theoretical treatment only).

06

6. CNC Technology and Tooling CNC Technology and CNC tooling: Introduction, Construction and working of CNC, DNC and machining center. CNC axes & drives. Automatic Tool Changer (ATC) and Automatic pallet changer (APC) New trends in Tool Materials, Turning tool geometry, Tool inserts (coated and uncoated), Modular tooling system for Turning. Milling tooling systems, Tools presetting, Work holding.

06

44

Reference Books:

Sr. No. Title of Book Author Publisher Topics 1. Text Book of

Production Engg. P.C. Sharma S. Chand

Publication, 8th Edition

1,2,4,5.

2. Production Technology

S.Karunakaran Tata McGraw-Hill Publishing Ltd.,1st

Edition 1980

1,2

3. Tool Design- – Donaldson THM Publication,1st Edition 1976

1,2,4

4. Machine tool Engg.- - G.R. Nagapal Khanna Publication,6th

Edition

2

5. Thoery of Metal Cutting-

Sen Bhattacharya

New central book agency pvt. Ltd.1st

Edition 1984

1,3

6. Production Engg. Design (Tool Design)-

S. Chandar & K. Surendra

Satya Prakashan-Delhi,2nd Edition

1994

1,2,4

7. Metal cutting and Machine Tools

Thirupati Reddy

Scitech Publication 1,2,6

8. Production Technology

Thirupati Reddy

Scitech Publication 1,2,5,6

Examination Scheme

Examination Scheme

Theory Practical(Term Work)

POE Total

Max. Marks 100 25 125 Contact Hours/ week

03 02 -- 05

Scheme of Marks

Unit No. Title Marks 1 Theory Of Metal Cutting 18 2 Tool life and Tool geometry 18 3 Form tools and Automat 18 4 Drilling Jigs and Milling Fixtures 26

45

5 Press tools 16 6 CNC Technology and Tooling 16

Course Unitization

CO’s Units Internal Assessments Course end survey CO305.1 1 CAT-I

Assignments and Quiz

CO305.2 2 CO305.3 3 CO305.4 4 CAT-II CO305.5 5 CO305.6 6


Unit No 1 Unit Title Theory Of Metal Cutting Planne

d Hrs. 07



1 Wedge action, Concept of speed, CO305.1

2 Feed and depth of cut, orthogonal and oblique cutting. 3 Mechanics of metal cutting-Chip formation, Types of chips 4 Cutting ratio, shear plane and shear angle, velocity relationships. 5 Tool dynamometers 6 Force measurement by cutting tool materials and their properties,

Advanced cutting tools. 7 Machinability of Metals- Factors affecting, improvement and

machinability index. Review Questions Q1 Explain orthogonal and oblique cutting with neat sketch.

CO305.1

Q2 Explain Chip formation mechanics. Q3 Explain different types of dynamometers. Q4 Explain machinability & factors affecting on machinability. Q5 Explain types of chips with neat sketches. Q6 Explain types of wear. Unit No 2 Unit Title Tool life and Tool geometry Planne

d Hrs. 07



46

1 Tool life - Types of wear, relationship with cutting parameters. CO305.2

2 Surface finish- Factors affecting, effect of cutting parameters, improvements.

3 Heat generation in machining, its effect on cutting force, 4 Surface finish, types and selection criteria of cutting fluids 5 Study tool geometry of single and multipoint cutting tools. 6 Solve problems based on metal cutting. 7 Taylor’s equation, improvement measures. Review Questions Q1 Explain tool geometry of single point cutting tool.

CO305.2

Q2 Explain Tool geometry of multipoint cutting tools.-drills, milling cutters, reamers.

Q3 Explain surface finish and explain factors affecting on it. Q4 Explain heat generation in machining process. Q5 Explain types of wear with neat sketch. Q6 During an orthogonal turning operation of C-40 steel following data was

obtained: Width of cut = 2.5 mm Cutting force = 1200 N Feed force = 500 N Cutting speed = 120 rpm Rake angle = 80

Feed = 0.30 mm/rev. Chip thickness = 0.55 mm Calculate: Chip thickness ratio, Shear angle, Forces acting along and perpendicular to shear plane, Shear strain and Friction angle, Forces acting along chip tool interface.

Q7 Following equation for tool life is given for a turning operation,

=

28.38T.ଵଷf .d.ଷ

A 60 minute tool life was obtained while cutting at V=30m/min. f=0.3mm/rev and d=2.5mm

Determine the change in tool life if the cutting speed, feed and depth of cut are increased by 20% individually and also taken together.

Unit No 3 Unit Title Form tools and Automat Planne

d Hrs. 06


Details to be covered CO305.3

1 Formtools and Automat –Types (Flat, circular, Dovetail) 2 Correction of formtools with and without rake angles,

47

3 tool layout of single spindle, automat 4 process sheet 5 process sheet, camprofile, tool layout 6 Calculation of production rate per hour. Review Questions Q1 What are different types of form tools?

CO305.3

Q2 The component shown in fig. is to be processed on single spindle automat. Study the component and prepare:- 1. Detailed process sheet 2. Tool Layout 3. Cam profile for drilling operation

Q3 The component shown in fig. is to be processed on single spindle automat.

Study the component and prepare:- 1. Detailed process sheet 2. Tool Layout 3. Cam profile for drilling operation 4. Production Rate per hour

Q4 The component shown in fig. is to be processed on single spindle automat.

Study the component and prepare:- 1. Detailed process sheet 2. Tool Layout 3. Cam profile for drilling operation

48

Unit No 4 Unit Title Jigs and Fixtures Planne

d Hrs. 08



1 Applications ,basic elements, , 2 principles and types of locating 3 clamping and indexing elements 4 Auxiliary elements like tenon, setting lock 5 Type of Jigs and Fixtures 6 Type of Jigs and Fixtures 7 Design consideration of Jigs and fixtures with respect to different

operations. 8 Design consideration of Jigs and fixtures with respect to different

operations. Review Questions Q1 Explain principle of location.

Q2 Explain types of jigs and fixtures. Q3 Explain types of locating, clamping and indexing elements. Q4 Design and draw a jig for producing M-16 hole at the component shown in

the figure.

49

CO305.4

Q5 Design and draw a neat dimensional sketch in three views with one sectional view of a suitable drilling jig for Ø 12 holes, 4 no.s in a flange shown in Fig. Show clearly the location, clamping and jig bushes. This is a last operation. All dimensions are in mm.

Q6 Design and draw dimensional drawing in three views with one sectional view of a milling fixture, for milling the surface marked as (√) in the fig.

50

show clearly location, clamping and setting of the cutter.

Unit No 5 Unit Title Press tools Planne

d Hrs. 06



1 Press Tool-Dies, punches. CO305.5

2 types of presses 3 clearances, types of dies 4 strip layout 5 Calculation of press capacity, center of pressure 6 Design consideration for die elements Review Questions Q1 Explain types of presses.

CO305.5

Q2 Differentiate between blanking and punching. Q3 Explain different terms used in press working. Q4 A hole of 60 mm diameter is to be produced in 2.5 mm thick steel plate.

The ultimate shear strength of the plate material is 450 N/mm2. If the punching force is to be reduced to the half of the force using a punch without shear, estimate the amount of shear on a punch. Take the percentage penetration as 40%.

Q5 Explain with neat sketches dies. Unit No 6 Unit Title CNC Technology and Tooling Planne 06

51

d Hrs. Lesson schedule Class No.


1 CNC Technology and CNC tooling: Introduction, Construction and working of CNC.

2 CNC axes & drives 3 Automatic Tool Changer (ATC) and Automatic pallet changer (APC) 4 New trends in Tool Materials, Turning tool geometry, Tool inserts (coated and

uncoated) 5 Modular tooling system for Turning 6 Milling tooling systems, Tools presetting, Work holding. Review Questions Q1 Explain construction and working of CNC machine

CO305.6

Q2 Explain automatic tool changer. Q3 Explain tool material for CNC machine.

Model Question Paper Course Title : TE Mechanical SEM- V

Manufacturing Engineering

Duration 3 hrs Max.

Marks 100

Instructions: All questions are compulsory. Assume any data if necessary and state it clearly

Figures to right indicates full marks to the questions.

Q.1 Solve Any two questions

a) Explain the different types of chips formation with neat labeled diagrams. 8

b) What is machinability? Explain various factors affecting machinability. 8

c) Follow information observations were made during orthogonal machining on steel Cutting speed =20 m/min

8

52

Undeformed chip thickness = 0.10 min Deformed chip thickness = 0.25 mm Rake angle = 8 degrees Clearance angle = 6 degrees Width of cut = 3.2 min Cutting force in cutting velocity direction = 800 N Normal to the cutting velocity = 500 N Find shear angle, shear strain, work done in shear.

Q.2 Solve Any two questions

a)

Define tool life. Discuss various factors affecting tool life. 8

b) Draw tool geometry of milling cutter and explain nomenclature in detail. 8

c) Following equation for tool life is given for a turning operation,

=28.38

T.ଵଷf .d.ଷ A 60 minute tool life was obtained while cutting at V=30m/min. f=0.3mm/rev and d=2.5mm Determine the change in tool life if the cutting speed, feed and depth of cut are increased by 20% individually and also taken together.

8

Q.3

The component shown in fig. is to be processed on single spindle automat. Study the component and prepare:-

18

a) Detailed process sheet b) Tool Layout c) Cam profile for drilling operation

Q.4

Solve any one

26

a) Design and draw a neat dimensional sketch in three views with one sectional view, for drilling two holes ɸ12 through as shown in figure and showing clearly details of clamping and location of workpiece. Assume this as final operation.

53

b) Design and draw a neat dimensional sketch of milling fixture in three views with one sectional view for milling faces to size 50 ± 0.05as shown in the figure.

Q.5

Solve any two

a) With neat sketch write down different types of dies. 6

b) Find the total pressure, dimensions of tool to produce a washer 5cm outside diameter with a 2.4 cm hole, from material 4mm thick, having a

6

54

Assignments


Assignment No. 1 Study of Broaching machine CO305.1 Assignment No. 2 Study and Demonstration of Grinding machine.

CO305.1

Assignment No. 3 Study of Slotting machine CO305.2 Assignment No. 4

Assignment Title

Tool layout, process sheet and cam design for single spindle automat

CO305.3

Batch I The component is shown in figure is to be processed on single spindle automat. Study the component and prepare: i) Detailed process sheet.ii) Tool layout. iii) Cam profiles for all radial and axial operations. iv) Production rate per hour.

shear strength of 360 N/mm2 .

c) Discuss design considerations for die element 6

Q6

Write short notes on any three

12 a) Work holding devices in CNC b) Automatic tool changers. c) Automatic pallet changer d) Tool materials and tool geometry signature of CNC

55

Batch II The component is shown in figure is to be processed on single spindle automat. Study the component and prepare:i) Detailed process sheet.ii) Tool layout. iii) Cam profiles for all radial and axial operations. iv) Production rate per hour.

Batch III The component is shown in figure is to be processed on single spindle automat. Study the component and prepare:i) Detailed process sheet.ii) Tool layout. iii) Cam profiles for all radial and axial operations. iv) Production rate per hour.

Batch IV The component is shown in figure is to be processed on single spindle automat. Study the component and prepare:i) Detailed process sheet. ii) Tool layout. iii) Cam profiles for all radial and axial operations. iv) Production rate per hour.

Assignment No. 5

56

Assignment Title

Design and Drawing of Jig CO305.4

Batch I Design and draw a neat dimensional sketch in three views with one sectional view of a suitable drilling jig for Ø 12 holes, 4 no.s in a flange shown in Fig. Show clearly the location, clamping and jig bushes. This is a last operation. All dimensions are in mm.

Batch II Design an indexing jig for drilling four holes of ¢10 mm in the component

shown in figure below.Draw drilling jig in three views with one sectional view showing clearly the location, clamping and jig bushes. This is a last operation. All dimensions are in mm.

57

Batch III Design and draw a neat dimensional sketch in three views with one sectional view of a suitable drilling jig for M14 two holes, shown in Fig. Show clearly the location, clamping and jig bushes. This is a last operation. All dimensions are in mm.

Batch IV Design and draw a neat dimensional sketch in two views with one sectional

view of a suitable drilling jig for M20 two holes, shown in Fig. Show clearly the location, clamping and jig bushes. This is a last operation. All dimensions are in mm.

58

Assignment No. 6

Assignment Title Design and Drawing of Fixture CO305.4

Batch I Design and draw a neat dimensional sketch in threes with one sectional view of a milling fixture for milling 22 mm x20mm-externally as shown-in Fig. Show clearly the details of location and clamping of workpiece and cutter setting arrangement.

Batch II Design and draw neat dimensional drawing in three views with one

sectional view of milling fixture cutting two slots of 16mm by 15 mm deep at right angles on a component as in figure below. Assume this as a last operation. All dimensions are in mm.

59

Batch III Design and draw a neat dimensional sketch in threes with one sectional view of a milling fixture for milling as shown-in Fig. Show clearly the details of location and clamping of workpiece and cutter setting arrangement.

Batch IV Design and draw a neat dimensional sketch in threes with one sectional view

of a milling fixture for milling as shown-in Fig. Show clearly the details of location and clamping of workpiece and cutter setting arrangement.

60

Assignment No. 7 Study and Demonstration of tools used in CNC machining. CO305.6

Assignment No. 8 Assignment Title Industrial Visit Report CO305.4

Batch I Batch II Batch III Batch IV

An industrial visit will be arranged to study jig & fixtures, sheet metal. Students are expected to write a report that includes: 1. The facility name and address, 2. Dates and times on campus, 3. Objectives of your visit followed each with observations reached about whether or not the objective was met, 4. Include details about inspections, work and safety practices and the variety of other sub-sections unique to industry that allow you to accurately describe every objective's resolution.

TERM WORK

1) Study of Broaching machine (Theoretical treatment only) 2) Study and Demonstration of Grinding machine. 3) Study of Slotting machine (Theoretical treatment only) 4) Design and drawing of any one Drilling jig. 5) Design and drawing of any one Milling fixture.

61

6) Tool layout, process sheet and cam design for single spindle automat. 7) Study and Demonstration of tools used in CNC machining. 8) Industrial visit to study jig & fixtures, sheet metal.

PRACTICAL PLAN

Planned Week Title

01 Discussion of CO’s and PO’s 02 Study of Broaching machine (Theoretical treatment only) 03 Study and Demonstration of Grinding machine. 04 Study of Slotting machine (Theoretical treatment only) 05 Design and drawing of any one Drilling Jig 06 Design and drawing of any one Milling fixture 07 Tool layout, process sheet and cam design for single spindle automat. 08 Study and Demonstration of tools used in CNC machining. 09 Industrial visit to study jig & fixtures, sheet metal.

62

Course Code ME 306 Course CAD CAM Lab Prepared by P. M. Sagare Date 19/05/2016. Prerequisites Fundamentals of Engineering Drawing, Machine Drawing, Dimensioning

and Machining Symbols, 2D-3D, Lathe & Milling Machining Operations, AutoCAD Software 2D, 3D.

Course Outcomes At the end of the course the students should be able to : CO306.1 Create5 sketching, 2D & 3D modeling with various features,

Dimensioning & Constraining of the model. CO306.2 Create5 surface modeling. CO306.3 Create5 Assembly Modeling and Production Drawing of solid models. CO306.4 Apply5 geometric dimensioning and tolerances for surface and solid

modeling. CO306.5 Create5 Part Programming for Fanuc Controller using G & M Codes for

various machining operations. CO306.6 Create5 data exchange formats for various machining operations and

machines. Mapping of COs with POs POs COs


CO306.1 3 3 3 CO306.2 3 3 3 CO306.3 3 2 3 3 CO306.4 3 3 3 CO306.5 3 1 3 3 CO306.6 3 3 3 Course Contents Unit No. Title No. of Hours

Section I 1. Unit I: Introduction to CAD/CAM, GUI, Solid Modeling

Introduction – Introduction to CAD/CAM in PLC, modeling, simulation, analysis and optimization. Introduction to Graphical User Interface (GUI), Parametric solid modeling – fundamentals, apply/modify constraints and dimensions; transform the parametric 2-D sketch into a 3D solid, feature operations.

06

2. Unit II: Surface Modeling Introduction, various commands in surface modeling. 04

3. Unit III: Assembly Modeling and Production Drawing Assembly modeling – Defining relationship between various parts of machine, creation of constraints, generation of exploded view.

06

63

Production drawing – Generation of 2-D sketches from parts and assembly 3-D model, appropriate dimensioning and tolerancing

4. Unit IV: Geometric Dimensioning and Tolerance Introduction to ASME Y14.5 – 2009, straightness, perpendicularity, flatness, angularity, roundness, concentricity, cylindricity, runout, profile, true position, parallelism, orientation.

02

5. Unit V: Part Programming Introduction to manual part programming, use of G and M codes to generate parts on turning centers, VMC’s, HMC’s etc.

04

6. Unit VI: Computer Aided Manufacturing Introduction to data exchange formats, integration of CAD/CAM software to generate tool path using suitable software, CADEM-doNC, SeeNC, CutVIEW, MillVIEW, MasterCAM, Esprit or equivalent.

04

Reference Books:

Sr. No. Title of Book Author Publisher/Edition Units 1. CAD/CAM- Principals

and applications P.N. Rao McGraw Hill

2. CAD/CAM/CAE N.K. Chougule SciTech Publication 3. Machine Drawing N. D. Bhatt and

V.M. Panchal Charoter Publications

4. ASME Y14.5 – 2009 5 Mastering CAD CAM Ibrahim Zeid McGraw-Hill 6 Help manuals and

tutorials of referred software

7 Machine Drawing N. Siddheshwar, P. Kannaiah, V V S Sastry

Tata McGraw Hill Publications

8 CAM/CAM – Theory and Practice

Ibrahim Zeid, R. Sivasubramaniam

McGraw Hill

9 CAD/CAM – Principals and applications

P.N. Rao McGraw Hill

10 CAD/CAM – Concepts and applications

Chennakesava R. Alavala

PHI

Examination Scheme Examination Scheme Theory Term Work POE Total Max. Marks -- 25 25 50 Contact Hours/ week -- 02 -- 02 Scheme of Marks Unit No. Title Marks

64

1 Introduction to CAD/CAM, GUI, Solid Modeling 5 2 Surface Modeling 5 3 Assembly Modeling and Production Drawing 5 4 Geometric Dimensioning and Tolerance 2 5 Part Programming 3 6 Computer Aided Manufacturing 5

Total 25 Course Unitization CO’s Units Internal Assessments Course end survey CO415.1 1 2D Drafting with Dimensions and

Constraints, 3D Modeling, Assembly Modeling with part detail drawing sheet and assembly drawing with various views and dimensions. CNC Programing for HMC & VMC. Machining Operation on CNC Machine.

Assignments Models, Assembly Models, Part Programming Model, Code Generation, Machining on CNC Machine

CO415.2 2

CO415.3 3

CO415.4 4

CO415.5 5

CO415.6 6

Unit wise lesson plan List of experiments/assignments to meet the requirements of the syllabus

1 Solid Modeling with drafting - 2 Exercises 2 Surface Modeling like mouse, badminton racket, monitor, hair dryer etc. –

2 Exercises 3 Assembly with minimum 5 components like crane hook, tail stock, screw jack,

universal coupling etc. 4 Part programming for CNC turning center – 2 parts 5 Part programming for Vertical Machining Center – 2 parts 6 Tool path generation by using suitable CAM software – 2 parts Important Notes:

1. Submission of all above assignments should be in Hard as well as electronic format (preferably in single CD/DVD for all batches/students) and should be reviewed by external examiner at the time of Practical Examination

2. Practical examination for this subject shall consist of creation of part models and

assembly of a machine with minimum five components and tool path generation using G and M Codes.

65

Course code ME 308 Course Workshop Practice-V Prepared by Mr. Y B Kumbhar Date 09/06/2018 Prerequisites Basic knowledge of manufacturing processes

Course Outcomes At the end of the course the students should be able to: CO308.1 Understand2 and perform the various machining operations. CO308.2 Implement3 principles of metrology CO308.3 Design4 the sequence of various processes required to manufacture the

components.


POs COs


CO309.1 2 CO309.2 3 CO309.3 1

Course Contents

Unit No.

Title No. of Hours

1. To prepare process sheets with working drawings of all components. To manufacture the components as per the drawing requiring following operations

i. Turning, ii. Boring iii. Drilling A visit report based on the industrial visit to study the following machining processes

i. Broaching, ii. Slotting, iii. Grinding

Reference Books:

Sr. No. Title of Book Author Publisher/ Edition Unit

66

1. A Course in Workshop Technology, Vol – I

B. S. Raghuvanshi Dhanapat Rai and Sons

2. Elements of Workshop Technology, Vol – I

Hajara Chaudhari Media Promoters

3. Workshop Technology, Vol – I

Gupta and Kaushik New Heights

4. Workshop Technology, Vol – I

Chapman The English Language Book

Society

5. Workshop Technology, Vol.-I

H.S. Bawa TMH Publications, New Delhi

67

Course code ME 309 Course Mini Project I Prepared by Y B. Kumbhar Date 09/06/2018 Prerequisites Basic knowledge of mechanical engineering

Course Outcomes At the end of the course the students should be able to: CO309.1 Work3 in a group on specific assignment. CO309.2 Think1 creatively to come out with feasible solution for engineering real life

problem.


POs COs


CO309.1 1 CO309.2 3

Documents

Shivaji University, Kolhapur. Examination Scheme · 2018-07-04 · Shivaji University, Kolhapur. Mechanical Engineering Scheme of Teaching & Examination T.E. (Semester-V) Sr. No