Design of Machine Elements

Unit 1 Design of Simple Machine Elements

Factor of safety, Selection of Factor of Safety, Service factor, Design of Cotter joint, Knuckle joint, Design of hand / foot lever, lever for safety valve, bell crank lever, Design of components subjected to eccentric loading.

Unit 2 Design of Shafts, Keys and Couplings

Shaft design on the Strength basis, torsional rigidity basis and lateral rigidity basis, Design of shaft as per A.S.M.E. code. Design of square and rectangular keys, Kennedy key and splines. Design of Flange Coupling and Bushed-Pin Flexible Coupling.

Unit 3 Design of Power Screws

Terminology of Power Screw, Torque analysis and Design of power screws with square and trapezoidal threads, Collar friction torque, Self-locking screw, Efficiency of square threaded screw, Efficiency of self-locking screw, Design of screw, nuts and C-Clamp. Design of screw jack, Differential and Compound Screw and Re-circulating Ball Screw

Unit 4 Design against Fluctuating loads

Stress concentration and its factors, Reduction of stress concentration factors, fluctuating stresses, fatigue failures, endurance limit, S-N curve, Notch sensitivity, Endurance limit, Endurance strength modifying factors, Reversed stresses – Design for Finite and Infinite life, Cumulative damage in fatigue failure, Soderberg, Gerber, Goodman Lines, Modified Goodman diagrams, Fatigue design under combined stresses

Unit 5 Threaded and Welded joints

Introduction to threaded joints, Bolts of uniform strength, locking devices, eccentrically loaded bolted joint in shear, Eccentric load perpendicular and parallel to axis of bolt, Eccentric load on circular base. Introduction to welded joints, Strength of butt, parallel and transverse fillet welds, Axially loaded unsymmetrical welded joints, Eccentric load in plane of welds, Welded joints subjected to bending and torsional moments.

Unit 6 Design of Springs

Types and applications of springs, Stress and deflection equations for helical compression Springs, Springs in series and parallel, Design of helical springs, concentric helical springs, surge in spring, Design of Multi-leaf springs, Nipping of Leaf springs, Shot Peening.

References Books:
1. Spotts M.F. and Shoup T.E., Design of Machine Elements, Prentice Hall International.
2. Juvinal R.C., Fundamentals of Machine Components Design, John Wiley and Sons.
3. Black P.H. and O. Eugene Adams, Machine Design, McGraw Hill Book Co. Inc.
4. Willium C. Orthwein, Machine Components Design, West Publishing Co. and Jaico Publications House.
5. Hall A.S., Holowenko A.R. and Laughlin H.G, Theory and Problems of Machine Design, Schaum’s Outline Series.
6. C. S. Sharma and Kamlesh Purohit, Design of Machine Elements, PHI Learing Pvt. Ltd.
7. D. K. Aggarwal & P. C. Sharma, Machine Design, S.K Kataria and Sons.
8. P. C. Gope, Machine Design: Fundamentals and Applications, PHI Learing Pvt. Ltd.
9. Design Data - P.S.G. College of Technology, Coimbatore.

Manufacturing Processes

Module-I
Conventional Manufacturing Processes: Casting and moulding: Metal casting processes and equipment, Heat transfer and solidification, shrinkage, riser design, casting defects and residual stresses. 

Module-II
Introduction to bulk and sheet metal forming, plastic deformation and yield criteria; fundamentals of hot and cold working processes; load estimation for bulk forming (forging, rolling, extrusion, drawing) and sheet forming (shearing, deep drawing, bending) principles of powder metallurgy.
Metal Cutting: Single and multi-point cutting; Orthogonal cutting, various force components: Chip formation, Tool wear and tool life. Surface finish and integrity, Machinability, Cutting tool materials, cutting fluids coating; Turning, Drilling, Milling and finishing processes, Introduction to CNC machining

Module-III

Joining/ fastening processes: Physics of welding, brazing and soldering; design considerations in welding. Solid and liquid state joining processes; Adhesive bonding

Additive manufacturing: Rapid prototyping and rapid tooling

Module-IV

Unconventional Machining Processes: Abrasive Jet Machining, Water Jet Machining Abrasive Water Jet Machining, Ultrasonic Machining principles and process parameters

Module-V

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

References:
1. Kalpakjian and Schmid, Manufacturing processes for engineering materials (5th Edition)- Pearson India, 2014.
2. Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems.
3. Manufacturing Technology by P.N. Rao., MCGRAW HILL INDIA.
4. Materials and Manufacturing by Paul Degarmo.
5. Manufacturing Processes by Kaushish, PHI.
6. Principles of Foundry Technology, Jain, MCGRAW HILL INDIA
7. Production Technology by RK Jain.
8. Degarmo, Black &Kohser, Materials and Processes in Manufacturing.

Heat Transfer

Module: 1 
Introduction to three modes of heat transfer, Derivation of heat balance equation- Steady one
dimensional solution for conduction heat transfer in Cartesian, cylindrical and spherical
geometry, concept of conduction and film resistances, critical insulation thickness, lumped
system approximation and Biot number, heat transfer through pin fins- Two dimensional
conduction solutions for both steady and unsteady heat transfer-approximate solution to
unsteady conduction heat transfer by the use of Heissler charts.

Module:2 
Heat convection, basic equations, boundary layers- Forced convection, external and internal
flows- Natural convective heat transfer- Dimensionless parameters for forced and free
convection heat transfer-Correlations for forced and free convection- Approximate solutions
to laminar boundary layer equations (momentum and energy) for both internal and external
flow- Estimating heat transfer rates in laminar and turbulent flow situations using appropriate
correlations for free and forced convection.

Module: 3 
Interaction of radiation with materials, definitions of radiative properties, Stefan Boltzmann’s
law, black and gray body radiation, Calculation of radiation heat transfer between surfaces
using radiative properties, view factors and the radiosity method.

Module: 4 

Types of heat exchangers, Analysis and design of heat exchangers using bothLMTD and ε-
NTU methods.

Module: 5 

Boiling and Condensation heat transfer, Pool boiling curve.

Module: 6
Introduction mass transfer, Similarity between heat and mass transfer

Text Books:
1. Bejan, Heat Transfer John Wiley, 1993
2. J.P.Holman, Heat Transfer, Eighth Edition, McGraw Hill, 1997.
3. F.P.Incropera, and D.P. Dewitt, Fundamentals of Heat and Mass Transfer, John Wiley, Sixth Edition, 2007.
4. MassoudKaviany, Principles of Heat Transfer, John Wiley, 2002
5. Yunus A Cengel, Heat Transfer: A Practical Approach, McGraw Hill, 2002

Dynamics of Machinery

Module: 1
Force analysis of mechanism: Dynamics of plane motion of a rigid body, dynamically equivalent two mass system, correction torque, forced in mechanism and machines.

Module: 2
Turning moment diagram: Fluctuations of crankshaft speed and energy in a direct acting engine mechanism, flywheels.

Module: 3
Cams: 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.

Module: 4
Analysis of gyroscopic motion : Principle of gyroscope, gyroscopic couple and gyroscopic reaction couple, Gyroscopic effects on the movement of ships, aeroplanes, two wheeled and four wheeled vehicles, gyrostabilizers.

Module: 5
Effects of inertia of reciprocating masses on engine frame: 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.

Text/References Books:
1. Theory of Machines / S.S Ratan/ Mc. Graw Hill Publ.
2. Mechanism and machine theory by Ashok G. Ambedkar, PHI Publications.
3. Mechanism and Machine Theory / JS Rao and RV Dukkipati / New Age.
4. Theory of Machines / Shiegly / MGH
5. Theory of Machines / Thomas Bevan / CBS Publishers
6. Theory of machines / Khurmi / S.Chand.

PCC-ME 302 Fluid Machinery

Module: 1
Introduction – Classification of fluid machinery. (Lectures: 2)
Module: 2
Dynamic action of fluid jet – Impact of fluid jet on fixed and moving flat places, impact of jet on
fixed and moving curved vanes, flow over radial vanes, jet propulsions. (Lectures: 4)
Module: 3
Euler’s fundamental equation, degree of reaction. (Lectures:2)
Module: 4
Hydraulic turbines, introduction, classification, impulse turbine, construction details, velocity
triangles, power and efficiency calculations, reaction turbines; constructional details, working
principle, velocity triangles, power and efficiency calculations, draft tube, cavitation, governing.
(Lectures: 10)
Module: 5
Principle of similarity in fluid machinery; unit and specific quantities, testing models and
selection of hydraulic turbines. (Lectures: 3)
Module: 6
Positive displacement pumps: Reciprocating pump; working principle, classification, slip,
indicator diagram, effect of friction and acceleration, theory of air vessel, performance

characteristics gas gear oil pump and screw pump.
(Lectures: 4)
Module: 7
Rotodynamic pumps: Introduction, classification, centrifugal pump; main components, working
principle velocity triangle, effect of shape of blade specific speed, heats, power and efficiency,
calculations minimum steering speed, multi stage pumps, performance characteristic,
comparison with reciprocating pump.
(Lectures: 7)
Course Outcomes:
Upon completion of this course, students will be able understand the deformation behavior of
solids under different types of loading and obtain mathematical solutions for simple geometries.
Text Books:
1. G. T. Mase, R. E. Smelser and G. E. Mase, Continuum Mechanics for Engineers, Third
Edition, CRC Press,2004.
2. Y. C. Fung, Foundations of Solid Mechanics, Prentice Hall International, 1965.
3. Lawrence. E. Malvern, Introduction to Mechanics of a Continuous Medium, Prentice Hall
international, 1969.
4. Hydrantic Machine by Jagdish Lal
5. Hydraulics & Hydraulic Machines by Vasandari
6. Hydrantic Machine by RD Purohit

Mechatronics

Unit 1: Introduction to Mechatronics, Sensors & Actuators
Introduction to Mechatronics and its Applications Measurement Characteristics (Static/Dynamic),
Sensors: Types of sensors; Motion Sensors – Encoder (Absolute & incremental), Lidar, Eddy Current, Proximity (Optical, Inductive, Capacitive), MEMS Accelerometer;
Temperature sensor –Pyrometer, Infrared Thermometer; Force / Pressure Sensors – Strain gauges, Piezoelectric sensor; Flow sensors – Electromagnetic, Ultrasonic, Hot-wire anemometer; Color sensor – RGB type; Biosensors – Enzyme, ECG, EMG
Actuators: Servo motor; Hydraulic and Pneumatic (must be restricted to classification and working of one type of linear and rotary actuator); linear electrical actuators Selection of Sensor & Actuator.

Unit 2: Data Acquisition and Signal Communication
Signal Communication: Serial, Parallel; Synchronous, Asynchronous Introduction to DAQ, Types, Components of a Data Acquisition System (Sensor, Signal conditioning, processing, controlling and storage/display/action)
Data Acquisition: Signal collection, Signal conditioning – Isolation& Filtering, Amplification, Sampling, Aliasing, Sample and hold circuit, Quantization, Analog-to-digital converters (4 bit Successive Approximation type ADC), Digital-to-Analog converters (4 bit R2R type DAC), Data storage Applications: DAQ in Household ,Digital Pressure Gauge, Digital Flow measurement, DVB Digital Video Broadcast, AM/FM.

Unit 3: Control systems & transfer function based modelling
Introduction to control systems, need, Types- Open and Closed loop, Concept of Transfer Function, Block Diagram & Reduction principles and problems; Applications (Household, Automotive, Industrial shop floor).
Transfer Function based modeling of Mechanical, Thermal and Fluid system; Concept of Poles & Zeros; Pole zero plot, Stability Analysis using Routh Hurwitz Criterion (Numerical Approach).

Unit 4: Time and Frequency Domain Analysis
Time Domain Analysis – Unit step Response analysis via Transient response specifications (Percentage overshoot, Rise time, Delay time, Steady state error etc.)
Frequency Domain Analysis – Frequency Domain Parameters - Natural Frequency, Damping Frequency and Damping Factor; Mapping of Pole Zero plot with damping factor, natural frequency and unit step response ; Introduction to Bode Plot, Gain Margin, Phase Margin.

Unit 5: Controllers 
Introduction to controllers, Need for Control, Proportional (P), Integral (I) and Derivative (D) control actions; PI, PD and PID control systems in parallel form; (Numerical approach), Feed forward anticipatory control
Manual tuning of PID control, Ziegler–Nichols method
Applications: Electro–Hydraulic/Pneumatic Control, Automotive Control.

Unit 6: Programmable Logic Controller (PLC) 
Introduction to PLC; Architecture of PLC; Selection of PLC; Ladder Logic programming for different types of logic gates; Latching; Timers, Counters; PLC control of Hydraulics / Pneumatics / Mechatronics systems involving timing and counting operations.

Computer Aided Engineering

Unit 1 Elemental Properties 
Introduction to Computer Aided Engineering (CAE), Use of CAE in Product development, Discretization methods – Finite Element Method (FEM), Finite Difference Method (FDM) and Finite Volume Method (FVM), CAE Tools- Pre-processor, Solver and Post-Processor. Element Shapes – 1D, 2D and 3D elements, Nodal Unknowns and field variables, Coordinate Systems, Shape Functions- linear, quadratic and cubic, Convergence Requirements of Shape Functions, Derivation of Polynomial Shape Functions using coordinate systems for Bar, Beam, Triangular, and rectangular elements.

Unit 2 Meshing Techniques 
Discretization of a Structure, 1D, 2D and 3D element Meshing, Element selection criteria, Refining Mesh, Effect of mesh density in critical region, Use of Symmetry. Element Quality Criterion:-Jacobian, Aspect ratio, Warpage, Minimum and Maximum angles, Average element size, Minimum Length, skewness, Tetra Collapse etc., Higher Order Element vs Mesh Refinement, Geometry Associate Mesh, Mesh quality, Bolted and welded joints representation, Mesh independent test.
 

Unit 3 1D Finite Element Analysis 
Consistent Unit System, Introduction to approaches used in Finite Element Analysis ( FEA) such as direct approach and energy approach Bar and Truss Element - Element stiffness matrix, Assembling stiffness Equation, Load vector, stress and reaction forces calculations. Temperature effect on Bar Element- Calculation due to uniform temperature change, Stress and reaction forces calculations.
 

Unit 4 2D Finite Element Analysis 
Plane Stress-Strain, axi-symmetric problems in 2D elasticity. Constant Strain Triangle (CST) - Element Stiffness matrix, Assembling stiffness equation, Load vector,
Stress and reaction forces calculations. Post Processing Techniques – Check and validate accuracy of results, Average and Un-average stresses, and special tricks for Post Processing. Interpretation of results and design modifications, CAE reports.
 

Unit 5 Non-Linear and Dynamic Analysis.
Non-Linear Analysis: Introduction to Nonlinear Problems, Comparison of Linear and Nonlinear analysis, Types of Nonlinearities, Stress-strain measures for Nonlinear analysis, Analysis of Geometric, Material Nonlinearity, Solution Techniques for Nonlinear analysis, Newton Raphson Method, Essential steps in Nonlinear analysis. Dynamic Analysis: Introduction to Dynamic Analysis, Comparison of Static and Dynamic analysis,Time domain and frequency domain, Types of loading, Simple Harmonic motion, Free vibration, Boundary conditions of free vibration, Solution.
 

Unit 6 Applications of Computer Aided Engineering 
Computational Fluid Dynamics (CFD): Introduction, Three dimensions of Fluid Dynamics, Equilibrium Equation for a fluid, Conservation form of Fluid flow equation, Integral form of the Conservation Laws. Injection moulding of Plastics: Simplification of Mould Geometry for FEA, Material Model for Mould FEA, Boundary Conditions for Mould FEA, Loading of Mould in FEA, Results Analysis. Simulation for Manufacturing Processes like Casting and Sheet Metal Applications: Introduction and workflow of Casting Simulation Software and Sheet Metal Applications. Durability Analysis: Durability, Reliability and Fatigue, FEA bases fatigue analysis viz: Stress-Life approach (S-N method) and Strain-Life approach (E-N method). Crash Analysis: Introduction, Explicit time integration schemes, implicit integration schemes. Noise Vibration and Harshness (NVH) Analysis: NVH Concepts, Terminology, FEA for structural Dynamics, FEA for Acoustics.

 Design of Transmission Systems

Unit 1 Spur and Helical Gears 
Introduction to gears: Material selection for gears, Modes of gear tooth failure, Gear Lubrication Methods. Spur Gears: Number of teeth and face width, Force analysis, Beam strength (Lewis) equation, Velocity factor, Service factor, Load concentration factor, Effective load on gear, Wear strength (Buckingham’s) equation, Estimation of module based on beam and wear strength, Estimation of dynamic tooth load by velocity factor and Buckingham’s equation. AGMA (American Gear Manufacturing Association) approach of Gear design Helical Gears: Force analysis of Helical Gear, Beam Strength of Helical Gear, Wear strength and estimation of effective load based on Velocity factor (Barth factor) and Buckingham’s equation. 
 

Unit 2 Bevel and Worm Gear 
Bevel Gears: Types of Bevel gears, Terminology, Virtual number of teeth, and force analysis of Straight Bevel Gear. Design of Straight Bevel Gear based on Beam Strength, Wear strength and estimation of effective load based on Velocity factor (Barth factor) and Buckingham’s equation. Worm Gears: Worm and worm gear terminology and proportions of worm and worm gears, Force analysis of worm gear drives, Friction in Worm gears, efficiency of worm gears, Worm and worm gear material, Strength and wear ratings of worm gears (Bending stress factor, speed factor, surface stress factor, zone factor) IS 1443-1974, Thermal consideration in worm gear drive.

 

Unit 3 Sliding and Rolling Contact Bearing 
Sliding contact bearing (Theoretical treatment only): Introduction to sliding contact bearing, classification, Reynolds’s equation (2D), Petroff’s equations, Sommerfeld number, Parameters of bearing design. Rolling Contact Bearings: Types of rolling contact Bearings and its selection, Static and dynamic load carrying capacities, Stribeck’s Equation, Equivalent bearing load, Load-life relationship, Selection of bearing life, Selection of rolling contact bearings from manufacturer's catalogue, Design for cyclic loads, Types of failure in rolling contact bearings - causes and remedies. 
 

Unit 4 Design of Clutches and Brakes 

Clutches: Introduction, Types of clutches, Material, Positive clutches, friction clutches, single plate, multiple plate, Cone clutch, and centrifugal clutches, Application of friction clutches automotive and industrial machinery sector. (Only Theoretical Treatment) Brakes: Introduction, Types of brakes, Material, Design of band brake, external and internal shoe breaks internal expanding shoe brakes, design of disc brakes. Application of brakes in automotive and industrial machinery sector. (Only Theoretical Treatment)
 

Unit 5 Design of M/C Tool Gear Box 

Introduction to Machine Tool Gearboxes, classification, basic considerations in design of drives and its Applications, Determination of variable speed range, Graphical representation of speed and structure diagram, Ray diagram, selection of optimum ray diagram, Kinematic /Gearing Diagram, Deviation diagram, Difference between numbers of teeth of successive gears in a change gear box. 
 

Unit 6 Transmission system in Hybrid Electric Vehicle 
Introduction, Types of Hybrid Electric Vehicles: Basic Classification, Basic Modes of Operation, Other Derivatives, Degree of Hybridization. Power Split Devices (PSD): Simple and EM compound PSD, HEV Component Characteristics: The IC Engine, Electric Machines, Battery, HEV Performance Analysis: Series HEV, Parallel HEV, HEV Component Sizing: General Considerations, Sizing for Performance, Optimum Sizing, Power Management: Control Potential, Control.