COURSE FILE Semester VI 2017-2018bldeacet.ac.in/PDF/CourseFile/Mech/VI Semster.pdfb.l.d.e.a’s
Transcript of COURSE FILE Semester VI 2017-2018bldeacet.ac.in/PDF/CourseFile/Mech/VI Semster.pdfb.l.d.e.a’s
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 1 of 89
B.L.D.E.A’s
Vachana Pitamaha Dr. P.G. Halakatti College of Engineering & Technology,
Bijapur – 586 103
Department of Mechanical Engineering
Semester – VI
Course Title: Finite element method (15ME61)
2017-2018
COURSE FILE
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 2 of 89
Program Educational Objectives (PEOs)
The educational objectives of the Mechanical Engineering Program are to prepare our graduates to:
1. Establish a successful career in Mechanical Engineering or related fields in Industry and
other organizations where an engineering approach to problem solving is highly valued.
2. Develop the ability among the students to synthesize the data and technical concepts for
applications to the product design.
3. Contribute significantly in a multidisciplinary work environment with high ethical standards
and with understanding of the role of engineering in economy and the environment.
4. Excel in graduate study and research, reaching advanced degrees in engineering and related
disciplines.
5. Achieve success in professional development through life-long learning.
Program outcomes (POs)
a. an ability to apply knowledge of mathematics, science, and Mechanical Engineering
b. an ability to design and conduct experiments, as well as to analyze and interpret data
c. an ability to design a mechanical system, mechanical component, or process to meet desired
needs within realistic constraints such as economic, environmental, social, political, ethical,
health and safety, manufacturability, and sustainability
d. an ability to function on multidisciplinary teams
e. an ability to identify, formulate, and solve mechanical engineering problems
f. an understanding of professional and ethical responsibility
g. an ability to communicate effectively
h. the broad education necessary to understand the impact of mechanical engineering solutions
in a global, economic, environmental, and societal context
i. a recognition of the need for, and an ability to engage in life-long learning,
j. a knowledge of contemporary issues
k. an ability to use the techniques, skills, and modern mechanical engineering tools necessary
for engineering practice.
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
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COURSE PLAN
Semester: VI Year: 2017-18
Subject: Finite Element Method Subject Code: 15ME61
Total No. of Lecture Hours: 54 I A Marks : 20
Exam Marks: 80 Exam Hours: 03
Lesson plan prepared by : Prof. S.S.Chappar
Prof. R.K.Kanakaraddi
Date:5/1/2018
COURSE CONTENT
Module I
Introduction to Finite Element Method:
General description of the finite element method. Engineering applications of finite element method.
Boundary conditions: homogeneous and nonhomogeneous for structural, heat transfer and fluid flow
problems. Potential energy method, Rayleigh Ritz method, Galerkin’s method, Displacement method of
finite element formulation. Convergence criteria, Discretisation process, Types of elements: 1D, 2D and
3D, Node numbering, Location of nodes. Strain displacement relations, Stress strain relations, Plain stress
and Plain strain conditions, temperature effects.
Interpolation models: Simplex, complex and multiplex elements, linear interpolation polynomials in
terms of global coordinates 1D, 2D, 3D Simplex Elements. 12Hours
Module II
One-Dimensional Elements-Analysis of Bars and Trusses: Linear interpolation polynomials in terms
of local coordinate’s for 1D, 2D elements. Higher order interpolation functions for 1D quadratic and
cubic elements in natural coordinates, , , Constant strain triangle, Four-Nodded Tetrahedral Element (TET
4), Eight-Nodded Hexahedral Element (HEXA 8), 2D isoparametric element, Lagrange interpolation
functions, Numerical integration: Gaussian quadrature one point, two point formulae, 2D integrals. Fore
terms: Body force, traction force and point loads,
Numerical Problems: Solution for displacement, stress and strain in 1D straight bars, stepped bars and
tapered bars using elimination approach and penalty approach, Analysis of trusses 12Hours
Module III
Beams and Shafts: Boundary conditions, Load vector, Hermite shape functions, Beam stiffness matrix
based on Euler-Bernoulli beam theory, Examples on cantilever beams, propped cantilever beams,
Numerical problems on simply supported, fixed straight and stepped beams using direct stiffness method
with concentrated and uniformly distributed load.
Torsion of Shafts: Finite element formulation of shafts, determination of stress and twists in circular
shafts. 08 Hours
Module IV
Heat Transfer: Basic equations of heat transfer: Energy balance equation, Rate equation: conduction,
convection, radiation, energy generated in solid, energy stored in solid, 1D finite element formulation
using vibrational method, Problems with temperature gradient and heat fluxes, heat transfer in composite
sections, straight fins. Fluid Flow: Flow through a porous medium, Flow through pipes of uniform and
stepped sections. 12 Hours
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DEPARTMENT OF MECHANICAL ENGINEERING
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Module V
Axi-symmetric Solid Elements: Derivation of stiffness matrix of axisymmetric bodies with triangular
elements, Numerical solution of axisymmetric triangular element(s) subjected to point loads.
Dynamic Considerations: Formulation for point mass, Consistent element mass matrix of one
dimensional bar element, truss element, lumped mass matrix of bar element, truss element. 10 Hours
Text Books:
1. Logan, D. L., A first course in the finite element method,6th Edition, Cengage
Learning, 2016.
2. Rao, S. S., Finite element method in engineering, 5th Edition, Pergaman Int. Library of
Science, 2010.
3. Chandrupatla T. R., Finite Elements in engineering, 2nd Edition, PHI, 2013.
Reference Books:
1. J.N.Reddy, “Finite Element Method”- McGraw -Hill International Edition.Bathe K. J.
Finite Elements Procedures, PHI.
2. Cook R. D., et al. “Concepts and Application of Finite Elements Analysis”- 4th Edition,
Wiley & Sons, 2003.
Prerequisites:
Elementary mathematics, Mechanics of materials.
Course Description:
The contents of the course “FEM” is designed by the members of board of studies (BOS) constituted by
VTU Belgaum.
Basically the subject deals with
Basics of finite element methods
Detailed procedure in finite element analysis
Applications of finite element method
Course outcomes:
Upon successful completion of this course you should be able to:
1. Understand the concepts behind formulation methods in FEM.
2. Identify the application and characteristics of FEA elements such as bars, beams, plane and
iso-parametric elements.
3. Develop element characteristic equation and generation of global equation.
4. Able to apply suitable boundary conditions to a global equation for bars, trusses, beams,
circular shafts, heat transfer, and fluid flow, axi symmetric and dynamic problems and solve
them displacements, stress and strains induced
Relevance of the course: The primary function of design engineer is to give size and shape to
components of machine elements. While doing so he has to check its safety by finding the stress
distribution in that element. If the geometry, material properties and loading conditions are
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
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simple the formulae of mechanics of materials can be used to analyze the stress. If these are
complicated, in the absence of exact methods he has to go for approximate methods like finite
element methods. As the computational capabilities of modern computers are very high, the use
of FEM is vital in industries. So it is essential to know the details of finite element analysis.
Application Areas:
Stress analysis
Fluid flow analysis
Heat transfer
Computational fluid dynamics
Unit wise plan
Course Title / Code: Finite Element Methods (15ME61)
Module: 1 Introduction to Finite Element Method & Interpolation models
Planned hours: 12
Learning Objectives:
At the end of the Unit, the student should be able to;
1. Explain the basics of theory of elasticity.
2. Discuss the need of FEA
3. Understand steps in FEA
4. Apply potential energy and virtual work methods to formulate.
5. Discuss the method of discretization.
6. Explain types and size of elements
7. Discuss interpolation models for different applications.
Lesson Plan:
Lesson No.
Topics covered Teaching
Method POs
attained COs
attained
Text/Reference Book/Chapter
No.
L1
General description of the finite
element method. Engineering
applications of finite element method
Chalk & Board
a,b,e,k
1 T1,T2,T3,R1
L2 Boundary conditions: homogeneous
and nonhomogeneous for structural,
Chalk &
Board
1 T1,T2,T3,R1
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heat transfer and fluid flow
problems.
L3 Galerkin’s method Chalk &
Board 1 T1,T2,T3,R1
L4 Displacement method of finite
element formulation. Chalk &
Board
1 T1,T2,T3,R1
L5 Convergence criteria, Discretisation
process, Chalk &
Board
1 T1,T2,T3,R1
L6 Types of elements: 1D, 2D and 3D, Chalk &
Board 2 T1,T2,T3,R1
L7 Node numbering, Location of nodes. Chalk &
Board 2
L8 Strain displacement relations, Stress
strain relations, Chalk &
Board
2 T1,T2,T3,R1
L9 Plain stress and Plain strain
conditions, temperature effects Chalk &
Board
2 T1,T2,T3,R1
L10 Simplex, complex and multiplex
elements, Chalk &
Board
2 T2,T3,R1
L11
Linear interpolation polynomials in
terms of global coordinates 1D, 2D,
3D Simplex Elements
Chalk &
Board
2 T2,T3,R1
L12 Simple numericals Chalk &
Board 2 T2,T3,R1
Assignment Questions COs attained
Explain the steps in FEA 1
Discuss the applications of FEA 1
Explain essential and natural boundary conditions with examples 1
Derive the expression for total potential energy for one dimensional bar subjected to
an axial force.
1
Obtain the equilibrium equation of the system shown in figure using principle of
minimum potential energy
1
K1
K2
K3
F
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DEPARTMENT OF MECHANICAL ENGINEERING
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Find the stress at x=0 and displacement at the midpoint of the rod as shown in
figure. Use Rayligh Ritz method
1
Determine the deflection at the free end of a cantilever beam of length ‘l’ carrying a
vertical load ‘p’ at its free end by Rayligh Ritz method
1
Compute the value of central deflection for the beam shown in figure, considering
trigonometric functions and Rayligh Ritz method.
1
Obtain the stress strain relations in Plane stress problem 1
Explain descretization process and different types of elements with
sketches.[element library]
2
Explain simplex, complex and multiplex elements with sketches
2
Explain node location scheme 2
L/2 L/2
P
E, I
1 unit
1 unit
2 units X
Take E=1 unit
A=1 unit
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DEPARTMENT OF MECHANICAL ENGINEERING
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Course Title / Code: Finite Element Methods (15ME61)
Module: II One-Dimensional Elements-Analysis of Bars and Trusses Planned hours: 12
Learning Objectives:
At the end of the Unit, the student should be able to;
1.Derive shape functions for different elements.
2. Determine displacement, stress, strain and reactions in different bars.
3. Determine displacement and stress in different strusses.
Lesson Plan:
Lesson. No.
Topics covered Teaching
Method POs
Attained COs
Attained
Reference
book/Chapter
no.
L13 Linear interpolation polynomials
in terms of local coordinate’s for
1D, 2D elements.
Chalk and
Board
a,b,e,k
2,3 T2,T3,R1
L14
Higher order interpolation
functions for 1D quadratic and
cubic elements in natural
coordinates
Chalk and
Board 2,3 T2,T3,1
L15 Constant strain triangle, Four-
Nodded Tetrahedral Element
(TET 4),
Chalk and
Board 2,3 T2,T3,R1
L16 Eight-Nodded Hexahedral
Element (HEXA 8), 2D
isoparametric element
Chalk and
Board 2,3 T2,T3,R1
L17 Lagrange interpolation functions Chalk and
Board 2,3 T2,T3,R1
L18 Numerical integration: Gaussian
quadrature one point, two point
formulae, 2D integrals
Chalk and
Board 2,3 T2,T3,R1
L19
Force terms: Body force, traction
force and point loads,
Chalk and
Board 4 T2,T3,R1
L20 Solution for displacement, stress
and strain in 1D straight bars Chalk and
Board 4 T2,T3,R1
L21 Problems on stepped bars bars. Chalk and
Board 4 T2,T3,R1
L22 Problems on tapered bars. Chalk and
Board 4 T2,T3,R1
L23 Problems on truss. Chalk and
Board 4 T2,T3,R1
L24 Problems on truss. Chalk and
Board 4 T2,T3,R1
Assignment Questions COs
attained
Explain linear, quadratic and cubic models 2
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DEPARTMENT OF MECHANICAL ENGINEERING
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Define shape function. What are the properties of shape function? 2,3
Derive the shape function for bar element in global coordinate system 2,3
Derive the shape function for bar element in natural coordinate system. 2,3
Derive the shape function for quadratic bar element. 2,3
Derive the shape function for quadratic bar element. 2,3
Derive the shape function for CST element 2,3
Derive the shape function for four noded tetrahedral element 2,3
Derive the shape function for eight noded hexahedral element 2,3
Find the values of following integrals using 2point and 3point Gauss quadrature
methods
a)
1
1
1
1
32 )2( dd
b) dxx
xe x
1
1
2 ])2(
13[
c) 3
1x
dx
d) d)223( 2
1
1
3
2,3
Determine deformation, strain, stress and reactions in following bars
1 2
P
A1=2400mm2
A2=600mm2
E1=70X109 N/m2
E2=200X109 N/m2
300mm 400mm
P=200KN
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DEPARTMENT OF MECHANICAL ENGINEERING
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Determine deformation, strain, stress and reactions in following bars
b)
4
Determine deformation and stress in members of following truss
4
400m
m
400m
m
400m
m 2000m
m2
2000m
m2
1500m
m2
150KN
E=200GP
a
E=200GPa
P=300KN
150 300mm 150
250mm2
400mm2
P
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
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Course Title / Code: Finite Element Methods (15ME61)
Module: III Beams, Shafts and Torsion of Shafts Planned Hours: 07
Learning Objectives:
At the end of the Unit, the student should be able to;
1.Derive Hermite shape function for beam element
2. Analyze beams with different types of loads
3. Analyze Shafts with different torque.
Lesson Plan:
Lesson. No.
Topics covered Teaching
Method POs
Attained COs
Attained
Reference
book/Chapter
no.
L25 Boundary conditions, Load
vector, Hermite shape functions Chalk and
Board
a,b,e,k
3 T1,T3
L26 Beam stiffness matrix based on
Euler-Bernoulli beam theory
Examples on cantilever beams
Chalk and
Board 3 T1,T3
L27 propped cantilever beams,
Numerical problems on simply
supported beams,
Chalk and
Board 4 T1,T3
L28
Numerical problems on fixed
straight and stepped beams using
direct stiffness method with
concentrated
Chalk and
Board 4 T1,T3
500mm
500mm
50KN
E=200GPa
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DEPARTMENT OF MECHANICAL ENGINEERING
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L29
Numerical problems on fixed
straight and stepped beams using
direct stiffness method with
uniformly distributed load
Chalk and
Board 4 T1,T3
L30 Finite element formulation of
shafts Chalk and
Board 3 T3
L31 Determination of stress and twists
in circular shafts Chalk and
Board 4 T3
L32 Numericals Chalk and
Board 4 T3
Assignment Questions COs attained
Derive Hermite Shape functions 3
A beam of length 10m, fixed at one end and supported by a roller at the other end
carries 20KN concentrated load at the centre of the span.By taking the modulus of
elasticity as 200GPa and moment of inertia as 24X10-6 m4, determine
a) Deflection under the load
b) Shear forge and bending moment on each element
4
Solve for deflections and slopes at points 2 & 3 using beam elements for the
following. Also determine the deflection at centre of the portion of the UDL
4
1m 1m
12KN/m
E=200GPa
I=4X106mm4
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
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Unit wise plan
Course Title / Code: Finite Element Methods (15ME61)
Module IV : Heat Transfer and Fluid Flow Planned Hours: 06
Learning Objectives:
At the end of the Unit, the student should be able to;
1.Derive stiffness matrix for one dimensional heat transfer using variational method.
2.Analyze one dimensional heat transfer problems
3.Analyze flow through pipes
Lesson Plan:
Lesson. No.
Topics covered Teaching
Method POs
Attained COs
Attained
Reference
book/Chapter
no.
L33 Basic equations of heat transfer:
Energy balance equation
Chalk and
Board
a,b,e,k
3 T1,T2
L34 Rate equation Chalk and
Board 3 T1,T2
L35 energy generated in solid,
energy stored in solid
Chalk and
Board 3 T1,T2
L36 1D finite element formulation
using variation method Chalk and
Board 3 T1,T2
L37
Problems with temperature
gradient and heat fluxes
approach
Chalk and
Board 4 T1,T2
L38
Problems with temperature
gradient and heat fluxes
approach
Chalk and
Board 4 T1,T2
L39
Problems with temperature
gradient and heat fluxes
approach
Chalk and
Board 4 T1,T2
L40 Problems continued.. Chalk and
Board 4 T1,T2
L41 Flow through a porous medium Chalk and
Board 3 T1,T2
L42 Flow through pipes of uniform
sections Chalk and
Board a,b,e,k
3 T1,T2
L43 Flow through pipes of stepped
sections Chalk and
Board 4 T1,T2
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
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L44 Flow through pipes of stepped
sections Chalk and
Board 4 T1,T2
Assignment Questions COs attained
Explain energy balance equation 3
Explain conduction, convection and radiation 3
Derive stiffness matrix for one dimensional heat conduction using variation approach. 3
A composite wall consists of three materials as shown in fig. The outer temperature
T0 =20oC. Convective heat transfer takes place on the inner surface of the wall with T
=800oC and h=25W/m2 oC. Determine the temperature distribution on the wall.
4
Consider a brick wall of thickness L=0.3m, K=0.7W/m0C. The inner surface is at
28oC and outer surface is exposed to cold air at -15 oC. Heat transfer coefficient on
outside surface h= 40 W/m2 oC. Determine the temperature distribution within the wall
and also the heat flux through the wall. Use two element model.
4
A metallic fin with thermal conductivity K=360W/m°C, 0.1cm thick, and 10cm long
extends from a plane wall whose temperature is 235°C. Determine the temperature
distribution and amount of heat transferred from the fin to the air at 20°C with h=9
W/m2 °C. Take the width of fin to be 1m.
4
Derive element stiffness matrix and equation for one dimensional fluid flow. 3
Determine a) The fluid head distribution along the length of the coarse gravelly
medium of length 0.762 m, b) The velocity in the upper part, c) The volumetric flow
rate in the upper part. The fluid head at the top is 0.254m and that at the bottom is
0.0254m. Let the permeability coefficient be Kxx=0.0127m/s. Assume a cross
sectional area of 0.646X10-3m2.
4
0.3m 0.15m 0.15m
K1 K2 K3
T0 =20oC.
K1=20W/moC
K2=30W/moC
K3=50W/moC
h=25W/m2 oC
T =800 oC
h
T
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DEPARTMENT OF MECHANICAL ENGINEERING
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Unit wise plan
Course Title / Code: Finite Element Methods (15ME61)
Module V
Axi-symmetric Solid Elements & Dynamic Considerations Planned Hours: 12
Learning Objectives:
At the end of the Unit, the student should be able to;
Analyze axisymmetric bodies
Analyze dynamic problems
Lesson Plan:
Lesson. No.
Topics covered Teaching
Method POs
Attained COs
Attained
Reference
book/Chapter
no.
L45 Derivation of stiffness matrix of
axisymmetric bodies with
triangular elements
Chalk and
Board
a,b,e,k
3 T1,T3
L46
Numerical solution of
axisymmetric triangular
element(s) subjected to point
loads
Chalk and
Board 4 T1,T3
L47 Numericals continued.. Chalk and
Board 4 T1,T3
L48 Numericals continued.. Chalk and
Board 4 T1,T3
L49 Numericals continued.. Chalk and
Board 4 T1,T3
L50 Formulation for point mass Chalk and
Board 3 T1,T3
L51 Consistent element mass matrix
of one dimensional bar element Chalk and
Board 3 T1,T3
L52 Consistent element mass matrix
of one dimensional truss element Chalk and
Board 3 T1,T3
L53 Lumped mass matrix of bar
element Chalk and
Board 3 T1,T3
L54 Lumped mass matrix of, truss
element. Chalk and
Board 3 T1,T3
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DEPARTMENT OF MECHANICAL ENGINEERING
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Assignment Questions COs attained
Derive stiffness matrix for axisymmetric body with triangular element 3
A long cylinder of inside diameter 80mm and outside diameter 120mm snuggly fits in
a hole over its full length. The cylinder is then subjected to an internal pressure of
2MPa. Using 2 elements on the 10mm length shown, find the displacement at the inner
radius. Take E=200GPa and µ=0.3
4
Derive the expression for element mass matrix of a solid body with distributed mass. 3
Write the properties of Eigen values and Eigen vectors. 3
Derive element mass matrix for bar element. 3
Derive element mass matrix for truss element. 3
Determine the Eigen values and eigenvector for the stepped bar shown in fig.when it is
subjected to axial vibrations.
l/2 l/2
E,2A,ρ E,A,ρ
4
For a bar element obtain lumped mass matrix 3
2 1
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DEPARTMENT OF MECHANICAL ENGINEERING
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Semester – VI
Course Title: Computer Integrated Manufacturing
(15ME62)
2017-2018
Program Educational Objectives (PEOs)
COURSE FILE
Prof. B.M.ANGADI
Module Coordinator Prof.Ramesh M.Nyamagoudar
NNuM.Nyamagoudar Course Coordinator
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 18 of 89
The educational objectives of the Mechanical Engineering Program are to prepare our graduates
to:
6. Establish a successful career in Mechanical Engineering or related fields in Industry and
other organizations where an engineering approach to problem solving is highly valued.
7. Develop the ability among the students to synthesize the data and technical concepts for
applications to the product design.
8. Contribute significantly in a multidisciplinary work environment with high ethical standards
and with understanding of the role of engineering in economy and the environment.
9. Excel in graduate study and research, reaching advanced degrees in engineering and related
disciplines.
10. Achieve success in professional development through life-long learning.
Program outcomes (POs)
l. an ability to apply knowledge of mathematics, science, and Mechanical Engineering
m. an ability to design and conduct experiments, as well as to analyze and interpret data
n. an ability to design a mechanical system, mechanical component, or process to meet desired
needs within realistic constraints such as economic, environmental, social, political, ethical,
health and safety, manufacturability, and sustainability
o. an ability to function on multidisciplinary teams
p. an ability to identify, formulate, and solve mechanical engineering problems
q. an understanding of professional and ethical responsibility
r. an ability to communicate effectively
s. the broad education necessary to understand the impact of mechanical engineering solutions
in a global, economic, environmental, and societal context
t. a recognition of the need for, and an ability to engage in life-long learning,
u. a knowledge of contemporary issues
v. an ability to use the techniques, skills, and modern mechanical engineering tools necessary
for engineering practice.
Department of: Mechanical Engineering
Program: B.E (Mechanical Engineering)
Course Title:CIM Course Code:15ME62
Theory: Practical: x
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DEPARTMENT OF MECHANICAL ENGINEERING
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Prerequisites to this course:
(Course title with course codes)
Maths Productio
n Tech
CNC Robotics
Program Outcomes
(POs) a b c d E f g h i j k l m
x x x x x x x
Mapping of Course
Outcomes with POs
2,4
1,2
,3,4
,5
,6
4
1,2
,3
2,3
,4,5
,6
4
1 t
o 8
Course category
Bas
ic
Sci
ence
s
Gen
eral
/
Hu
man
itie
s
Gen
eral
Core
Elective G-A G-B G-C G-D G-E G-F
x
Teaching Methods: PPT OHP Face to
Face
Guest
Lecture
Video
lecture
Demo
(Lab
visit)
Seminars Industrial
Visits
Units I to X I,II,III,VI,
VII
II,IV,
V,VI,
VII
VIIi 1 to 8 Vii,
Vii,IX,X
Continuous Assessment Internal assessment tests Assignment Tutorial
03 03
Contents beyond
syllabus to meet POs:
Topics POs attained
1.Videos
2. Animations
3.Industrial visit
A,b,c,h,I,k
Approved by: Module Coordinator Prof B M Angadi
Program coordinator Prof S B Koulagi
Achieving Intended Course Learning Outcomes
The following skills are directly or indirectly imparted to the students in the following
teaching and learning methods:
Sl.No. Course
Learning
Outcomes
Possible capabilities, skills,
expertise gained (codes)
Means of imparting the
curriculum
1 CO1 Kn, PS, PSS Class room lectures
2 CO2 PSS, Un Class room lectures
3 CO3 PSS, AS Class room lectures
4 CO4 PSS,PS Class room lectures
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
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5 CO5 AK, PS Lab visit
Possible capabilities, skills, expertise gained Code
Knowledge Kn
Understanding (Comprehension) Un
Problem solving skills (application skills) PSS
Practical skills (application skills) PS
Analytical skills AS
Synthesis skills SS
Written communication skills WCS
Verbal/oral communication skills VCS
Presentation skills PS
Leadership skills LS
COURSE PLAN
Semester: VI Year: 2017-18
Subject: Computer Integrated Manufacturing Subject code: 15ME62
Total Teaching Hours: 50 I A Marks:20
Exam Marks: 80 Exam Hours: 03
Lesson Plan Prepared by: Prof:Ramesh
M.Nyamagoudar Date:01/01/2018
Course Content
PART-A
Module-1.
1.Introduction to CIM and Automation: Automation in Production Systems,
automated manufacturing systems- types of automation, reasons for automating,
Computer Integrated Manufacturing, computerized elements of a CIM system,
CAD/CAM and CIM. Mathematical models and matrices: production rate,
production capacity, utilization and availability, manufacturing lead time, work-in-
process, numerical problems. 5 HOURS
2. Automated Production Lines and Assembly Systems: Fundamentals, system
configurations, applications, automated flow lines, buffer storage, control of
production line, analysis of transfer lines, analysis of flow lines without storage,
partial automation, analysis of automated flow lines with storage buffer,
fundamentals of automated assembly systems, numerical problems. 5 HOURS
10 Hours
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
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Module – 2
3. CAD and Computer Graphics Software: The design process, applications of
computers in design, software configuration, functions of graphics package,
constructing the geometry. Transformations: 2D transformations, translation,
rotation and scaling, homogeneous transformation matrix, concatenation, numerical
problems on transformations. 5HOURS.
4. Computerized Manufacture Planning and Control System: Computer Aided
Process Planning, Retrieval and Generative Systems, benefits of CAPP, Production
Planning and Control Systems, typical activities of PPC System, computer integrated
production management system, Material Requirement Planning, inputs to MRP
system, working of MRP, outputs and benefits, Capacity Planning, Computer Aided
Quality Control, Shop floor control. 5HOURS
10 Hours
Module - 3
5. Flexible Manufacturing Systems: Fundamentals of Group Technology and
Flexible Manufacturing Systems, types of FMS, FMS components, Material
handling and storage system, applications, benefits, computer control systems, FMS
planning and design issues, Automated Storage and Retrieval Systems, AS/RS and
Automatic parts identification systems and data capture. 5HOURS
6. Line Balancing: Line balancing algorithms, methods of line balancing, numerical
problems on largest candidate rule, Kilbridge and Wester method, and Ranked
Positional Weights method, Mixed Model line balancing, computerized line
balancing methods. 5 HOURS
10 Hours
Module - 4.
7. Computer Numerical Control: Introduction, components of CNC, CNC
programming, manual part programming, G Codes, M Codes, programming of
simple components in turning, drilling and milling systems, programming with
canned cycles. Cutter radius compensations. 5 HOURS
8. Robot Technology: Robot anatomy, joints and links, common robot
configurations, robot control systems, accuracy and repeatability, end effectors,
sensors in robotics. Robot programming methods: on-line and off-line methods.
Robot industrial applications: material handling, processing and assembly and
inspection. 5 HOURS
10 Hours
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
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Module – 5
9. Additive Manufacturing Systems: Basic principles of additive manufacturing,
slicing CAD models for AM, advantages and limitations of AM technologies,
Additive manufacturing processes: Photo polymerization, material jetting, binder
jetting, material extrusion, Powder bed sintering techniques, sheet lamination, direct
energy deposition techniques, applications of AM. Recent trends in manufacturing,
Hybrid manufacturing. 5 HOURS
10. Future of Automated Factory: Industry 4.0, functions, applications and
benefits. Components of Industry 4.0, Internet of Things (IOT), IOT applications in
manufacturing, Big-Data and Cloud Computing for IOT, IOT for smart
manufacturing, influence of IOT on predictive maintenance, industrial automation,
supply chain optimization, supply-chain & logistics, cyber-physical manufacturing
systems. 5 HOURS
10 Hours
Course Outcomes:
After studying this course, students will be able to:
CO1 Able to define Automation, CIM, CAD, CAM and explain the differences
between these concepts. Solve simple problems of transformations of entities on
computer screen.
CO2 Explain the basics of automated manufacturing industries through mathematical
modelsand analyze different types of automated flow lines.
CO3 Analyze the automated flow lines to reduce down time and enhance
productivity.
CO4 Explain the use of different computer applications in manufacturing, and able to
prepare part programs for simple jobs on CNC machine tools and robot
programming.
CO5 Visualize and appreciate the modern trends in Manufacturing like additive
manufacturing, Industry 4.0 and applications of Internet of Things leading to
Smart Manufacturing.
Text Books:
1. Automation, Production Systems and Computer-Integrated Manufacturing, by Mikell P
Groover, 4th Edition, 2015, Pearson Learning.
2. CAD / CAM Principles and Applications by P N Rao, 3rd Edition, 2015, Tata McGraw-Hill.
3. CAD/CAM/CIM, Dr. P. Radhakrishnan, 3rd edition, New Age International Publishers, New
Delhi.
Reference Books:
1. “CAD/CAM” by Ibrahim Zeid, Tata McGraw Hill.
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DEPARTMENT OF MECHANICAL ENGINEERING
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2. “Principles of Computer Integrated Manufacturing”, S.Kant Vajpayee, 1999, Prentice Hall of
India, New Delhi.
3. “Work Systems And The Methods, Measurement And Management of Work”, Groover M.
P.,Pearson/Prentice Hall, Upper Saddle River, NJ, 2007.
4. “Computer Automation in Manufacturing”, Boucher, T. O., Chapman & Hall, London, UK,
1996.
5. “Introduction to Robotics: Mechanics And Control”, Craig, J. J., 2nd Ed., AddisonWesley
Publishing Company, Readong, MA, 1989.
6. Internet of Things (IoT): Digitize or Die: Transform your organization. Embrace the digital
evolution. Rise above the competition, by Nicolas Windpassinger, Amazon.
7. "Internet of Things: A Hands-on Approach", by Arshdeep Bahga and Vijay Madisetti
(Universities Press)
8. Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing,
2nd Ed. (2015), Ian Gibson, David W. Rosen, Brent Stucker
9. “Understanding Additive Manufacturing”, Andreas Gebhardt, Hanser Publishers, 2011
10. Industry 4.0: The Industrial Internet of Things, Apress, 2017, by Alasdair Gilchrist
Scheme of Examination:
Assessment Marks
CAI 20
SEE 80
Total 100
INTERNAL ASSESSMENT SYALLABUS
I I.A – MODULE I AND II
II I.A - MODULE III NAD IV
III I.A - MODULE V
Course Description:
Overview of the course
The contents of the course “Computer Integrated Manufacturing (CIM)” is designed by
the members of the Boards of Studies (BoS) constituted by Visveswaraya Technological
University (VTU) Belgaum.
Basically, CIM course deals with:
Types of automation, CIM, processing in manufacturing , Production concepts
Mechanized and automated flow lines and It also deals with transfer mechanisms.
Design and analysis of Assembly lines and line balancing
Design and analysis Automated Assembly Systems
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DEPARTMENT OF MECHANICAL ENGINEERING
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Computerized Manufacturing Planning System
CNC Machining Centers
Robotics
Relevance of the course:
The main purpose of studying this subject is to have knowledge of various techniques
used for manufacturing. These techniques should be used to get higher productivity with lower
cost of manufacturing and hence automation is necessary. Automation helps to improve
equipment utilization, labor utilization and the overall productivity rate. This importance of
automation through design, manufacturing and analysis should be practically implied to transfer
lines and their efficient usage, line balancing, material handling systems, group technology,
flexible manufacturing systems, computerized planning CNC part programming, robotics etc.
Application Areas:
Manufacturing industries
Automotive industries
Ancillary industries
Assembly operations
Material Handling
This subject would be helpful in finding out the efficiency of the department and labor,
there by determining the idle times of the same so that effective action can be taken. It helps in
designing as well as selecting correct type of AFL’s for different types of work-part transport in
manufacturing industries.
Prerequisites:
This subject requires the student to know about basics of production, manufacturing, and
manufacturing systems. It also needs to have a prior knowledge of simple laws of probability for
analysis of transfer lines.
Module wise lesson plan
Course title and code: Computer Integrated Manufacturing (15ME62)
MODULE.1 : 1.Introduction to CIM and Automation
2. Automated Production Lines and Assembly
Systems:
Planned hours: 10
Learning objectives: The student will be able to
1. Explain the concept of Automation, Types of automation, CIM and the reasons why
companies install automated system.
2. Discuss the production concepts which provide mathematical models for computing
MLT, Rp, WIP, TIP etc.
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3. Explain the Fundamentals, system configurations, applications, automated flow lines,
buffer storage, control of production line, analysis of transfer lines,
4. analysis of flow lines without storage, partial automation, analysis of automated flow
lines with storage buffer, fundamentals of automated assembly systems,
Lesson Schedule:
Lecture
No. Topics Covered
Teaching
Method
PO
attained
COs
attained
Reference
Book/Chapter
No
L1 Introduction, automation
definition
Chalk and
Board
a,b,e
k
1 T1/1
L2 Types of automation Chalk and
Board 1 T1/1
L3 CIM, processing in
manufacturing
Chalk and
Board 1 T1/1
L4 Production concepts,PR Chalk and
Board 1 T1/2
L5 system configurations,
applications,
Chalk and
Board 1 T1/2
L6
automated flow lines, buffer
storage, control of production
line, analysis of transfer lines,
Chalk and
Board 1 T1/2
L7 analysis of flow lines without
storage, partial automation
Chalk and
Board 1 T1/2
L8 analysis of automated flow
lines with storage buffer,
Chalk and
Board 1 T1/2
L9 Fundamentals of automated
assembly systems
Chalk and
Board 1 T1/2
L10 numerical problems. Chalk and
Board 1 T1/2
Assignments:
Questions COs
attained
1. What is automation? explain different types. 1
2. Derive an expression for MLT. 1
3. Explain various reasons for automation. 1
4. Explain analysis of flow lines without storage, 1
5. Define Various production concepts such as WIP,PC,PU,MLT Etc 1
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DEPARTMENT OF MECHANICAL ENGINEERING
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6. Explain the buffer storage 1
7. A production unit is operated for 48 hrs/week at its full capacity. Its
production rate is 5 units /hr .During a certain week the unit produced 200
good parts and was idle for remaining time.
1
8. Determine the PC and PU. 1
9. There are 4 machines in a plant .the set up and operation time for each
machine is shown below .the batch size is 150 and the avg non operation time
is 6 hrs. Determine the MLT and the production rate for operation number 2
1
Module wise lesson plan
Course title and code: Computer Integrated Manufacturing (15ME62)
Module 2:3.CAD and Computer Graphics Software:
4.Computerized Manufacture Planning and
Control System:
Planned hours: 10
Learning objectives: The student will be able to
1. Explain Computer aided Process Planning, Retrieval and Generative Systems,
2. Write the benefits of CAPP,
3. Explain inputs of MRP
4 .what are the functions of graphics package,
4. Explain 2D transformations, translation, rotation and scaling,
Lesson Schedule:
Lecture
No. Topics Covered
Teaching
Method
PO
attained
COs
attained
Reference
Book/Chapter
No
L11
The design process,
applications of computers in
design
Chalk
and
Board
a,b,e,
k
2 T1/18
L12
software configuration
functions of graphics
package, constructing the
geometry.
Chalk
and
Board
2 T1/18
L13 Transformations: 2D
transformations
Chalk
and
Board
2 T1/18
L14
translation, rotation and
scaling, homogeneous
transformation matrix,
Chalk
and
Board
2 T1/18
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DEPARTMENT OF MECHANICAL ENGINEERING
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concatenation,
L15 numerical problems on
transformations
Chalk
and
Board
2 T1/18
L16 Computer Aided Process
Planning,
Chalk
and
Board
2 T1/18
L17
Retrieval and Generative
Systems, benefits of CAPP,
Production Planning and
Control Systems,
Chalk
and
Board
2 T1/18
L18
typical activities of PPC
System, computer integrated
production management
system, Material Requirement
Planning,
Chalk
and
Board
2 T1/18
L19
Inputs to MRP system, working
of MRP, outputs and benefits,
Capacity Planning,
Chalk
and
Board
2 T1/18
L20 Computer Aided Quality
Control, Shop floor control.
Chalk
and
Board
2 T1/18
Assignments:
Questions COs
attained
1. What is design process and write the applications of computers in design 2
2. What are the functions of graphics package 2
3. Explain constructing the geometry. 2
4. Explain 2D transformations, translation, rotation and scaling 2
5. Explain Process Planning, Retrieval and Generative Systems, benefits of CAPP 2
6. What is Production Planning and Control Systems, 2
7. Explain MRP 2
8. Explain inputs of MRP 2
9. Explain Capacity planning 2
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DEPARTMENT OF MECHANICAL ENGINEERING
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Module wise lesson plan
Course title and code: Computer Integrated Manufacturing (15ME62)
Module 3: 5.Flexible Manufacturing Systems:
6. Line Balancing:
Planned hours: 10
Learning objectives: The student will be able to
1. Demonstrate the assembly operations.
2. Construct precedence diagrams
3. Balance the line using different methods.
4. What is FMS?
5. What are the types of FMS?
Lesson Schedule:
Lecture
No. Topics Covered
Teaching
Method
PO
attained
COs
attained
Reference
Book/Chapter
No
L21
Fundamentals of Group
Technology and Flexible
Manufacturing Systems
Chalk
and
Board
b,e,k
k
3 T1/18
L22
types of FMS, FMS
components, Material
handling and storage system
Chalk
and
Board
3 T1/18
L23
Applications, benefits,
computer control systems,
FMS planning and design
issues,
Chalk
and
Board
3 T1/18
L24 Automated Storage and
Retrieval Systems,
Chalk
and
Board
3 T1/18
L25
AS/RS and Automatic parts
identification systems and
data capture
Chalk
and
Board
3 T1/18
L26 Line balancing algorithms,
methods of line balancing,
Chalk
and
Board
3 T1/18
L27 Numerical problems on
largest candidate rule
Chalk
and
Board
3 T1/18
L28 , Kilbridge and Wester
method, and Ranked
Chalk
and 3 T1/18
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DEPARTMENT OF MECHANICAL ENGINEERING
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Positional Weights method Board
L29 Mixed Model line balancing
Chalk
and
Board
3 T1/18
L30 computerized line balancing
methods
Chalk
and
Board
3 T1/18
Assignments:
Questions COs
attained
1. What is line balancing what is its necessity. 3
2. Explain the terminology of line balancing. 3
3. Explain briefly various methods of line balancing. 3
4. Draw the precedence diagram and by using largest candidate rule, kilbridge
and westers, ranked positional weight method balance the line and calculate
the balance delay.
3
5. What is FMS? 3
6. What are the types of FMS?
Module wise lesson plan
Course title and code: Computer Integrated Manufacturing (15ME62)
Module 4: 7. Computer Numerical Control:
8. Robot Technology
Planned hours: 10
Learning objectives: The student will be able to
1. Discuss the concepts of manufacturing with CNC machining centers.
2. Develop part programs for milling and turning operations.
3. Analyze the Robot configurations
4. Discuss the Robot motions
5. Develop Robot programming
Lesson Schedule:
Lecture
No. Topics Covered
Teaching
Method
PO
attained
COs
attained
Reference
Book/Chapter
No
L31 Introduction, components of
CNC
Chalk
and
a,b,k 4 T1/17
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DEPARTMENT OF MECHANICAL ENGINEERING
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Board
L32
CNC programming, manual
part programming, G Codes,
M Codes
Chalk
and
Board
4 T1/17
L33
programming of simple
components in turning,
drilling and milling systems
Chalk
and
Board
4 T1/17
L34 programming with canned
cycles
Chalk
and
Board
4 T1/17
L35 Cutter radius compensations.
Chalk
and
Board
4 T1/17
L36 Robot anatomy, joints and
links
Chalk
and
Board
4 T1/17
L37 common robot configurations,
robot control systems
Chalk
and
Board
4 T1/17
L38
accuracy and repeatability,
end effectors, sensors in
robotics
Chalk
and
Board
4 T1/17
L39 Robot programming methods:
on-line and off-line methods
Chalk
and
Board
4 T1/17
L40
Robot industrial applications:
material handling, processing
and assembly and inspection.
Chalk
and
Board
4 T1/17
Assignments:
Questions COs
attained
1. What is a CNC and what are elements of CNC? 4
2. What is CNC Machining center? 4
3. Explain fundamental steps involved in part programming? 4
4. Write Programs for milling and turning? 4
5.What is meant by Robot Configuration? 4
6.Explain different robot motions? 4
7.Explain about end effectors of robots? 4
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DEPARTMENT OF MECHANICAL ENGINEERING
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8.Explain about Robot sensors and applications of robots? 4
Module wise lesson plan
Course title and code: Computer Integrated Manufacturing (10ME61)
Module 5:: 9.Additive Manufacturing Systems:
10. Future of Automated Factory:
Planned hours: 08
Learning objectives: The student will be able to
1. Explain the concepts of Additive manufacturing systems
2. Discuss the future of automated factory
Lesson Schedule:
Lecture
No. Topics Covered
Teaching
Method
PO
attained
COs
attained
Reference
Book/Chapter
No
L41
Basic principles of
additive
manufacturing, slicing
CAD models for AM,
Chalk and
Board
a,e,k
5 T1/19
L42
advantages and
limitations of AM
technologies, Additive
manufacturing
processes:
Chalk and
Board 5 T1/19
L43
Photo polymerization,
material jetting, binder
jetting, material
extrusion
Chalk and
Board 5 T1/19
L44
Powder bed sintering
techniques, sheet
lamination, direct
energy deposition
techniques,
applications of AM
Chalk and
Board 5 T1/19
L45
Recent trends in
manufacturing, Hybrid
manufacturing
Chalk and
Board 5 T1/19
L46 Industry 4.0, functions Chalk and
Board 5 T1/10
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DEPARTMENT OF MECHANICAL ENGINEERING
Page 32 of 89
L47
applications and
benefits. Components
of Industry 4.0,
Internet of Things
(IOT),
Chalk and
Board 5 T1/10
L48
IOT applications in
manufacturing, Big-
Data and Cloud
Computing for IOT,
IOT for smart
manufacturing,
Chalk and
Board 5 T1/10
L49
influence of IOT on
predictive
maintenance, industrial
automation, supply
chain optimization,
supply-chain &
logistics,
Chalk and
Board 5 T1/10
L50
cyber-physical
manufacturing
systems.
Chalk and
Board 5 T1/10
Assignments:
Questions COs attained
1. Explain the Basic principles of additive manufacturing 5
2. Write the advantages and limitations of AM technologies 5
3. Explain Recent trends in manufacturing and Hybrid manufacturing 5
4. Explain internet of things 5
5. Explain supply-chain & logistics 5
6. Explain cyber-physical manufacturing systems. 5
… End of Computer Integrated Manufacturing Lesson Plan …
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 33 of 89
Semester – VI
Course Title: Heat Transfer (15ME63)
2017 - 2018
Department of Mechanical Engineering
COURSE FILE
Dr. R. G. Tikotkar
Module Coordinator
Prof. R. S. ELLUR
Course Coordinator
Prof. S. B. Koulagi
Program Coordinator
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 34 of 89
Program: BE Mechanical
Course Title: HEAT TRANSFER Course Code:15ME63
Theory: Practical:
Prerequisites to this course:
(Course title with course
codes)
Program Outcomes
(POs) a b c d e f g h i j k l m
-- --
Mapping of Course
Outcomes with Pos
1,2
,3,4
,5
1,2
,34
,5
1,2
,3,4
,5
1,2
,3,4
,5
1,2
,3,4
,5
Course category
Bas
ic
Sci
ence
s
Gen
eral
/
Hum
anit
ies
Gen
eral
Core
Elective G-A G-B G-C G-D G-E G-F
Teaching Methods: PPT OHP Face to
face
Guest
Lecture
Video
lecture
Demo
(Lab visit)
Seminars Industrial
visits
Module I,II,III,IV,V,
Continuous Assessment Internal assessment tests Assignment Tutorial
3 3
Contents beyond
syllabus to meet POs:
Topics POs attained
1.
2.
3.
Approved by: Module Coordinator Dr. R.G.Tikotkar
Program coordinator Prof. S.B.Koulagi
Program Educational Objectives (PEOs)
The educational objectives of the Mechanical Engineering Program are to prepare our graduates to:
11. Establish a successful career in Mechanical Engineering or related fields in Industry and
other organizations where an engineering approach to problem solving is highly valued.
12. Develop the ability among the students to synthesize the data and technical concepts for
applications to the product design.
13. Contribute significantly in a multidisciplinary work environment with high ethical standards
and with understanding of the role of engineering in economy and the environment.
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DEPARTMENT OF MECHANICAL ENGINEERING
Page 35 of 89
14. Excel in graduate study and research, reaching advanced degrees in engineering and related
disciplines.
15. Achieve success in professional development through life-long learning.
Program Outcomes (POs)
w. an ability to apply knowledge of mathematics, science, and mechanical engineering
x. an ability to design and conduct experiments, as well as to analyze and interpret data
y. an ability to design a mechanical system, mechanical component, or process to meet desired
needs within realistic constraints such as economic, environmental, social, political, ethical,
health and safety, manufacturability, and sustainability
z. an ability to function on multidisciplinary teams
aa. an ability to identify, formulate, and solve mechanical engineering problems
bb. an understanding of professional and ethical responsibility
cc. an ability to communicate effectively
dd. the broad education necessary to understand the impact of mechanical engineering solutions
in a global, economic, environmental, and societal context
ee. a recognition of the need for, and an ability to engage in life-long learning,
ff. a knowledge of contemporary issues
gg. an ability to use the techniques, skills, and modern mechanical engineering tools necessary
for engineering practice.
hh. competence to adopt technical knowledge and managerial skill in planning projects and
deployment of resources
Course Plan
Semester: VI Year: 2017 - 18
Course Title Heat Transfer Course Code 15ME63
Total Teaching Hours 54 Teaching hours/week 3 + 2
Internal Assessment Marks 20 Semester Examination Marks 80
Course Plan prepared by Dr. R. G. Tikotkar, Prof. R. S. Ellur & Prof. M. D. Kulkarni
Course Content
Module - I
Introductory concepts and definitions: Modes of heat transfer: Basic laws governing
conduction, convection, and radiation heat transfer; Thermal conductivity; convective heat
transfer coefficient; radiation heat transfer combined heat transfer mechanism, Types of
boundary conditions. General Heat Conduction Equation: Derivation of the equation in (i)
Cartesian, (ii) Polar and (iii) Spherical Co-ordinate Systems.
Steady-state one-dimensional heat conduction problems in Cartesian System: Steady-
8 Hours
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DEPARTMENT OF MECHANICAL ENGINEERING
Page 36 of 89
state one dimensional heat conduction problems (i) with and without heat generation and (ii)
with and without varying thermal conductivity - in Cartesian system with various possible
boundary conditions, Thermal Resistances in Series and in Parallel.
Module -II
Critical Thickness of Insulation: Concept, Derivation, Extended Surfaces or Fins:
Classification, Straight Rectangular and Circular Fins, Temperature Distribution and Heat
Transfer Calculations, Fin Efficiency and Effectiveness, Applications.
Transient [Unsteady-state] heat conduction: Definition, Different cases - Negligible
internal thermal resistance, negligible surface resistance, comparable internal thermal and
surface resistance, Lumped body, Infinite Body and Semi-infinite Body, Numerical
Problems, Heisler and Grober charts.
9 Hours
Module - III
Numerical Analysis of Heat Conduction: Introduction, one-dimensional steady
conduction, one dimensional unsteady conduction, two-dimensional steady and unsteady
conduction, the difference equation, boundary conditions, solution methods, cylindrical
coordinates and irregular boundaries.
Thermal Radiation: Fundamental principles - Gray, White, Opaque, Transparent and Black
bodies, Spectral emissive power, Wien’s, Rayleigh-Jeans’ and Planck’s laws, Hemispherical
Emissive Power, Stefan-Boltzmann law for the total emissive power of a black body,
Emissivity and Kirchhoff’s Laws, View factor, Net radiation exchange in a two-body
enclosure, Typical examples for these enclosures, Radiation Shield.
9 Hours
Module - IV
Forced Convection: Boundary Layer Theory, Velocity and Thermal Boundary Layers,
Prandtl number, Governing Equations – Continuity, Navier-Stokes and Energy equations,
Boundary layer assumptions, Integral and Analytical solutions to above equations, Turbulent
flow, Various empirical solutions, Forced convection flow over cylinders and spheres,
Internal flows –laminar and turbulent flow solutions, Forced Convection Cooling of
Electronic Devices.
Free convection: Laminar and Turbulent flows, Vertical Plates, Vertical Tubes and
Horizontal Tubes, Empirical solutions.
8 Hours
Module - V
Heat Exchangers: Definition, Classification, applications, LMTD method, Effectiveness –
NTU method, Analytical Methods, Fouling Factors, Chart Solution Procedures for solving
Heat Exchanger problems: Correction Factor Charts and Effectiveness-NTU Charts, compact
heat exchangers. Heat Transfer with Phase Change:
Introduction to boiling, pool boiling, Bubble Growth Mechanisms, Nucleate Pool Boiling,
Critical Heat Flux in Nucleate Pool Boiling, Pool Film Boiling, Critical Heat Flux, Heat
Transfer beyond the Critical Point, filmwise and dropwise Condensation, heat pipes,
entrainment, wicking and boiling limitations.
9 Hours
TEXT BOOKS:
T1 Principals Of Heat Transfer, Frank Kreith, Raj M. Manglik, Mark S. Bohn, Seventh Edition,
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 37 of 89
Cengage learning, 2011.
T2 Heat transfer, a practical approach, Fifth edition, Yunus A. Cengel Tata Mc Graw Hill.
REFERNCE BOOKS:
R1 Heat And Mass Transfer, Kurt C, Rolle, second edition, Cengage learning.
R2 Heat Transfer, M. Necati Ozisik, A Basic Approach, McGraw Hill, New York, 2005.
R3 Fundamentals of Heat and Mass Transfer, Incropera, F. P. and De Witt, D. P., 5th Edition, John
Wiley and Sons, New York, 2006.
R4 Heat Transfer, Holman, J. P., 9th Edition, Tata McGraw Hill, New York, 2008.
Scheme of Examination:
Two questions to be set from each module. Students have to answer five full questions, choosing at least
one full question from each module.
Assessment Marks
Internal Assessment tests 20
VTU Semester examination 80
Total 100
COURSE DESCRIPTION:
1. Overview of the course
Heat transfer is the flow of thermal energy driven by thermal non-equilibrium, commonly
measured as a heat flux, i.e. the heat flow per unit time at a control surface. This course focuses on the
problems and complexities of heat and mass transfer and emphasizes on analysis using correlations. The
course assumes basic understanding of thermodynamics and fluid mechanics and exposure to differential
equations and methods of solution.
The contents of the course “Heat and Mass Transfer” is designed by the members of the Board of
Studies (BoS) constituted by Visvesvaraya Technological University (VTU) Belgaum.
Basically, Heat and Mass Transfer course deals with:
Conduction Heat Transfer
Variable thermal conductivity
Transient Conduction Boundary layers
Convection (Free & Forced)
Heat Exchangers
Boiling & Condensation
Radiation heat transfer 2. Relevance of the Course:
Heat transfer theory is used to compute heating/cooling rate in heat transfer problems, or to
compute temperature fields and heat fluxes, or to compute required dimensions or properties for heat
insulation or conduction. Heat and mass transfer occur in coupled form in most production processes and
chemical-engineering applications of a physical, chemical, biological or medical nature. Very often they
are associated with heating and cooling, boiling, condensation and combustion processes and also with
fluids and their flow fields.
3. Application areas:
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 38 of 89
Heat-transfer problems arise in many industrial and environmental processes, particularly in
energy utilization, thermal processing, chemical processing and thermal control.
4. Prerequisite:
This subject requires the knowledge of fundamentals of Thermodynamics and Fluid Mechanics.
5. Course Outcomes:
At the end of the course, the student should be able to
1. Understand the basic modes of heat transfer
2. Compute temperature distribution in steady-state and unsteady-state heat conduction.
3. Understand and interpret heat transfer through extended surfaces.
4. Explain the principles of radiation heat transfer and understand the numerical formula for heat
conduction problems.
5. Interpret and compute forced and free convective heat transfer.
6. Design heat exchangers using LMTD and NTU methods.
7. Explain the phenomenon of boiling and condensation on different surfaces.
Module wise lesson plan
Course title and code: Heat Transfer (15ME63)
Module 1 Planned hours: 08
Learning objectives: At the end of this chapter student will understand
1. Discuss heat transfer and compare three modes of heat transfer
2. Explain the desirable thermal properties for a given class of thermal applications
3. Derive 3-D heat conduction equation and use it for solution of heat transfer problems.
4. Discuss Boundary conditions (BC) of first, second and third kinds.
5. Formulate problems connected to heat conduction associated to different Boundary conditions
6. Determine temperature distribution, interface temperatures and heat flow rate across slab.
Lesson Plan:
Lecture
No. Topics covered
Teaching
Method
PO’s
Attained
CO’s
Attained
Reference
Book/
Chapter No.
L1
Introductory concepts and definitions: Modes of
heat transfer: Basic laws governing conduction,
convection, and radiation heat transfer; Thermal
conductivity; convective heat transfer
coefficient; radiation heat transfer combined heat
transfer mechanism,
Chalk and
Board
a,b,c,e,i
1, 2 R1/1
T2/1
L2 Types of boundary conditions. General Heat
Conduction Equation: Derivation of the equation
in Cartesian coordinate system.
Chalk and
Board 1, 2
T2/1
R1/2
L3 Derivation of the equation in Polar and Spherical
coordinate systems.
Chalk and
Board 1, 2
R1/2
T2/2
L4 Steady-state one-dimensional heat conduction
problems in Cartesian System with heat
generation.
Chalk and
Board 1, 2
R1/2
T2/3
T1 Tutorial 1 Chalk and
Board 1, 2
R1/2
T2/3
L5 Steady-state one-dimensional heat conduction
problems in Cartesian System without heat
Chalk and
Board 1, 2
R1/2
T2/3
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 39 of 89
generation.
L6 Steady-state one-dimensional heat conduction
problems in Cartesian System with varying
thermal conductivity.
Chalk and
Board 1, 2
R1/2
T2/3
L7 Steady-state one-dimensional heat conduction
problems in Cartesian System without varying
thermal conductivity.
Chalk and
Board 1, 2
R1/ 1&2
T2/1,2&3
L8 Thermal Resistances in Series and in Parallel. Chalk and
Board 1, 2
R1/ 1&2
T2/1,2&3
T2 Tutorial 2 Chalk and
Board 1, 2
R1/ 1&2
T2/1,2&3
Assignment questions:
1. Define and explain the different modes of heat transfer. 1
2. Define thermal conductivity, convection and radiation heat transfer coefficient. 1
3. Identify modes of heat transfer: Room lighting using tube-lights, water heating using
electric heater. 1
4. What are the different types of boundary conditions? Explain with neat sketches. 1, 2
5. Derive an expression for the temperature distribution and the rate of heat transfer for a plane. 1, 2
6. Derive an expression for the rate of heat transfer for composite plane. 1, 2
7. A temperature difference of 500˚C is applied across a fireclay brick 10cm thick with thermal
conductivity 1.0 W/m˚C. Determine the heat transfer rate per square meter area. 1, 2
8. A temperature difference of 100˚C is applied across a cork board 5cm thick with thermal
conductivity 0.04 W/m˚C. Determine the heat transfer rate across 3-m2 area per hour. 1, 2
9. Obtain expression for 3-D heat conduction equation in Cartesian, Polar and Spherical coordinate
systems. 1, 2
10. Water at a mean temperature of 20˚C flows over a flat plate at 80˚C. If the heat transfer coefficient
is 200 W/m2 ˚C, determine heat transfer per square meter of the plate over 5h. 1, 2
11. A thin metal plate 0.1m by 0.1m is placed in a large evacuated container whose walls are kept at
300K. The bottom surface of the plate is insulated, and the top surface is maintained at 500K as a
result of electric heating. If the emissivity of the plate is 0.8, what is the rate of heat exchange
between the plate and the walls of the container take =5.67X10-8W/m2 K4.
1, 2
12. A small hot surface at a temperature of 430 K with an emissivity of 0.8 dissipates heat by radiation
into the surrounding at a temperature of 400 K. If this radiation is characterized by radiation heat
transfer coefficient hr calculate its value.
1, 2
13. An industrial furnace made of fire clay brick (L1=0.25m, k1=1.0 W/moC) and is insulated using
insulation of k= 0.05 W/moC. Determine thickness of the layer to limit the heat loss to 1000W/m2
when the inside surface of the wall is maintained at 1030 oC and the outside surface at 30 oC A wall
is constructed of 10cm thick layer of brick (k=0.69 W/moC),1.5 cm thick fibre insulating board
(k=0.0.048 W/moC),followed by a 5cm layer of glass wool (k=0.038 W/moC) and 1.5cm thick
insulating board k=0.048 W/moC. Heat transfer coefficient on both sides is 12W/m2 Determine
overall heat transfer coefficient U.
1, 2
Module wise lesson plan
Course title and code: Heat Transfer (10ME63)
Module -2 Planned hours: 09
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 40 of 89
Learning objectives: At the end of this chapter student will understand 1. Discuss the importance of critical thickness of insulation & the importance thermal contact
resistance concept.
2. Discuss the heat transfer in extended surfaces of uniform cross-section without heat generation
for long fin, short fin and tip insulated.
3. Discuss the fin efficiency and effectiveness.
4. Explain the transient heat conduction in solids with negligible internal temperature gradient
(Lumped system analysis).
5. Discuss the use of Transient temperature charts (Heisler’s charts) for transient conduction in slab,
long cylinder and in sphere
Lesson Schedule:
Lecture
No. Topics covered
Teaching
Method
PO’s
Attained
CO’s
Attained
Reference
Book/
Chapter No.
L9 Critical Thickness of Insulation, Concept,
Derivation,
Chalk and
Board
a,b,c,e,i
3 R1/3
R4/2
L10 Extended Surfaces or Fins: Classification.
Straight Rectangular and Circular Fins,
Chalk and
Board 3
R1/3
R4/2
T3 Tutorial 3 Chalk and
Board 3
R1/3
R4/2
L11 Temperature Distribution and Heat
Transfer Calculations,
Chalk and
Board 3
R1/3
R4/2
L12 Fin Efficiency and Effectiveness,
Applications.
Chalk and
Board 3
R1/3
R4/2
T4 Tutorial 4 Chalk and
Board 3
R1/3
R4/2
L13 Transient [Unsteady-state] heat
conduction: Definition, Different cases -
Negligible internal thermal resistance
Chalk and
Board 3
R1/3
R4/2
L14 Negligible surface resistance, comparable
internal thermal and surface resistance,
Chalk and
Board 3
R1/3
R4/2
L15 Lumped body, Infinite Body and Semi-
infinite Body
Chalk and
Board 3
R1/3
R4/2
L16 Numerical Problems Chalk and
Board 3
R1/3
R4/2
L17 Heisler and Grober charts. Chalk and
Board 3
R1/3
R4/2
T5 Tutorial 5 Chalk and
Board 3
R1/3
R4/2
Assignment questions:
1. Define the terms Critical thickness of insulation, Fin efficiency, Contact and thermal
resistances. 3
2. Classify the fins 3
3. Copper plate fins of rectangular cross section having thickness 1mm, height 10mm and 3
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 41 of 89
thermal conductivity 380 W/moC are attached to a plane wall maintained at 230 oC. Fins
dissipate heat by convection into the ambient air at 30 oC with a heat transfer coefficient of
40 W/m2 oC. Fins are spaced at 8mm (ie125 fins/m). Assume negligible heat loss from the fin
tip to determine fin efficiency, Area weighted fin efficiency. Net rate of heat transfer per m2 of
the wall surface, heat transfer rate without fins.
4. What do you mean by Lumped System Analysis? Obtain an expression for temperature distribution for
this system in terms of Biot and Fourier numbers. 3
5. Define Biot and Fourier number. Explain their significance. 3
6. A solid copper sphere of 10cm diameter [ρ=8954kg/m3 Cp=383J/kg C, k=386 W/moC] initially at a
uniform temperature of 250oC is suddenly immersed in a well stirred fluid which is maintained at a
uniform temperature of 50 oC.The heat transfer coefficient of the fluid and sphere is 200 W/m2 oC.
check if the lumped system analysis is suitable and hence determine the temperature of the block
t=5,10,15 min after the immersion (Ans=120, 74.5 &53 oC).
3
7. Using the lumped analysis determine the time required for the solid steel[ρ=7833kg/m3 Cp=0.46 kJ/kg
C, k=54 W/moC sphere of 5cm diameter to cool from 600 oC to 200 oC if it is exposed to air stream at
50 oC having a heat transfer coefficient of 100 W/m2 oC (Ans= 6min 34 S).
3
8. A 12mm diameter mild steel sphere (K=42.5W/mK) is placed in an air stream at 27˚C and the
corresponding heat transfer coefficient is 114 W/m2˚C. Calculate time taken to cool sphere from 540 ˚C
to 95˚C and Instantaneous heat transfer rate two minutes after commencement of cooling. For mild
steel:Density=7850 kg/m3 Sp. heat=475J/kgk Thermal diffusivity=0.043m2/hr.
3
9. A 0.10m thick brick wall (α=0.5X10-6 m2/s, k=0.69W/m˚C and ρ=2300kg/m3) is initially at Ti=230˚C.
The wall is suddenly exposed to an environment at T∞=30˚C with a heat transfer coefficient h=60
W/m2˚C. By using the transient temperature charts, Determine the centre temperature at 0.5, 2 and 4h
after exposure to the cooler ambient, surface temperature at 0.5 and 2h, and Energy removed from the
plate per square meter during 0.5h.
3
10. Consider a slab of thickness 10cm, a cylinder of diameter 10 cm and a sphere of 10 cm diameter each
made of steel (α=1.6X10-5 m2/s, k=61W/m˚C )and initially at uniform temperature of 300 ˚C. Suddenly
they are all immersed into a well stirred bath at 50˚C.The heat transfer coefficient between the fluid and
surface is1000 W/m2 oC. Calculate the time required for the centers of the solids to cool to 80˚C.
3
Module wise lesson plan
Course title and code: Heat Transfer (10ME63)
Module 3 Planned hours: 09
Learning objectives: At the end of this chapter student will understand.
1. Learn how to formulate and solve steady and unsteady state1D and 2D heat conduction problems.
2. Explain the conceptual features of radiation heat transfer and its applications.
3. Discuss terms involved in Radiation process & quantify the process of Radiation.
4. Discuss laws of shape factor and determining radiation heat exchanges between different
geometries of surfaces and enclosures. 5. Formulate radiation heat transfer for practical application.
Lesson Schedule:
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 42 of 89
Lecture
No. Topics covered
Teaching
Method
PO’s
Attained
CO’s
Attained
Reference
Book/
Chapter No.
L18
Numerical Analysis of Heat Conduction:
Introduction, one-dimensional steady
conduction
Chalk and
Board
a,b,c,e,i
4 R4/3
L19 One dimensional unsteady conduction Chalk and
Board 4 R4/3
L20 Two-dimensional steady and unsteady
conduction,
Chalk and
Board 4 R4/3
L21 The difference equation, boundary
conditions
Chalk and
Board 4 R4/3
L22 Solution methods, cylindrical coordinates
and irregular boundaries.
Chalk and
Board 4 R4/3
T6 Tutorial 6 Chalk and
Board 4 R4/3
L23
Thermal Radiation: Fundamental principles
- Gray, White, Opaque, Transparent and
Black bodies, Spectral emissive power,
Chalk and
Board 4
R1/4
T2/4
L24
Wien’s, Rayleigh-Jeans’ and Planck’s
laws, Hemispherical Emissive Power,
Stefan-Boltzmann law for the total
emissive power of a black body
Chalk and
Board 4
R1/4
T2/4
L25
Emissivity and Kirchhoff’s Laws, View
factor, Net radiation exchange in a two-
body enclosure,
Chalk and
Board 4
R1/4
T2/4
L26 Typical examples for these enclosures,
Radiation Shield
Chalk and
Board 4
R1/4
T2/4
T7 Tutorial 7 Chalk and
Board 4
R1/4
T2/4
Assignment:
1. When numerical solution adopted for a problem? What are its advantages and limitations? 4
2. Explain the method of handling an irregular boundary while writing finite difference equations. 4
3. One face of a slab of thickness 1 cm (k = 20 W/m°C), is maintained at 40°C and the other surface is
subjected to a convection heat transfer with a fluid at 100°C with a heat transfer coefficient of 4000
W/m2°C. There is uniform internal heat generation in the slab at a rate of 8 x 107 W/m3.
a) Dividing the slab into 5 equally spaced sub-regions, find the temperatures at the different nodes.
Assume one dimensional, steady state conduction.
b) If the left surface is insulated, what is the temperature on that surface in steady state?
4
4. Explain the following laws as applied to radiation: i) Stefan Boltzman law ii) Plank’s Distribution law
iii) Wein’s Displacement law iv) Kirchoff’s law. 4
5. Determine the radiative energy emitted between 2-10μm wavelengths by a 1x1m grey surface at 600 K
which has an emissivity of 0.8. 4
6. A tungsten filament is heated to 2300K.What fraction of the total energy is emitted in the wave length
range of 0.4 to 0.8 μm? 4
7. A black body at 1111K is emitting into air. Calculate the wavelength at which black body 4
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 43 of 89
emissive power is maximum and energy emitted over wave length limits 1-10 μm and 10-20
μm.
8. A small surface of area 8 cm2 is subjected to radiation of constant intensity I=105 W/m2.Sr over a solid
angle subtended by 30,20 . Calculate energy emitted by surface. 4
9. Determine average emmissivity of filament at 3000K for entire wavelengths using given data
212101 5.01.05.005.0 toformtofor 4
10. Calculate the heat dissipated by radiation through a 0.2-m2 opening of a furnace at 1100K into
an ambient at 300K. Assume both the furnace and the ambient to be black bodies. 4
Module wise lesson plan
Course title and code: Heat Transfer (10ME63)
Module 4 Planned hours: 08
Learning objectives: At the end of this chapter student will understand
1. Discuss the applications of dimensional analysis for forced convection.
2. Discuss the physical significance of Reynolds, Prandtl, Nusselt and Stanton numbers.
3. Discuss the use the various correlations for hydro dynamically and thermally developed flows inside a duct.
4. Discuss the various correlations for flow over a flat plate, over a cylinder and sphere.
5. Explain the velocity and thermal boundary layers & its importance in convection heat transfer.
6. Discuss the expressions for heat transfer coefficient, lift and drag coefficients.
7. Derive expressions for friction factor and pressure drop for laminar flow through tubes.
8. Explain the free or natural convection, Application of dimensional analysis for free convection- physical
significance of Grashoff number.
9. Discuss the use of correlations of free convection in vertical, horizontal and inclined flat plates, vertical and
horizontal cylinders and spheres
Lesson Schedule:
Lecture
No. Topics covered
Teaching
Method
PO’s
Attained
CO’s
Attained
Reference
Book/
Chapter No.
L27
Forced Convection: Boundary Layer
Theory, Velocity and Thermal Boundary
Layers, Prandtl number,
Chalk and
Board
a,b,c,e,i
5 R4/6
T2/6
L28 Governing Equations – Continuity, Navier-
Stokes
Chalk and
Board 5
R4/6
T2/9
L29
Energy equations, Boundary layer
assumptions, Integral and Analytical
solutions to above equations
Chalk and
Board 5
R4/6
T2/9
L30 Turbulent flow, Various empirical
solutions,
Chalk and
Board 5
R4/6
T2/9
T8 Tutorial 8 Chalk and
Board 5
R4/6
T2/9
L31
Forced convection flow over cylinders and
spheres, Internal flows –laminar and
turbulent flow solutions
Chalk and
Board 5
R4/9
T2/9
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 44 of 89
L32 Forced Convection Cooling of Electronic
Devices.
Chalk and
Board 5
R4/9
T2/9
L33 Free convection: Laminar and Turbulent
flows, Vertical Plates, Vertical Tubes
Chalk and
Board 5 R4/7
L34 Horizontal Tubes, Empirical solutions. Chalk and
Board 5 R4/7
T9 Tutorial 9 Chalk and
Board 5
R4/6
T2/9
Assignment questions:
1. Explain the thermal boundary layer. Distinguish between developing and developed hydrodynamic
flow through pipes. 5
2. Determine the thickness of thermal boundary layer, local drag coefficient and local shear stress at a
distance of 0.5 m from the leading edge of a flat plate for the boundary layer flow of air at 77 oC and a
velocity of 2m/s.
5
3. Atmospheric air at 27oC flows with a free stream velocity of 10 m/s along a flat plate 4m long.
Compute the drag coefficient at 2 and 4m from the leading edge. Assume an all turbulent boundary
layer, determine the drag force exerted per 1m width of plate.
5
4. Air at 0.6 atm and -15 oC flows with a free stream velocity of 120m/s over the wing of an airplane. The
wing is 2m long in the direction of flow and can be regarded as a flat plate. Determine the local drag
coefficient and the shear stress at the trailing edge of the wing. What is the drag force per meter width
of the wing?
5
5. Determine the thickness of the thermal boundary layer and the local heat transfer coefficient at a
distance of 1m from the leading edge of a flat plate for the flow of air at 77oC and velocity 4m/s at
pressures of 0.5, 1.0 and 2 atmosphere.
5
6. Explain Hydrodynamic and thermal boundary layer with reference to flow over flow heated plate. 5
7. Explain the following Dimensionless number and their physical significance:
(i) Reynolds number, (ii) Prandtl number, (iii) Nusselt number 5
8. Write short notes on (any two): (i) Biot number and Fourier and their significance.
(ii) Hydrodynamic and Thermal boundary layer 5
9. Air at 30oC is flowing over 2 cm long plate maintained at 70oC at m/s. Determine heat transfer from the
plate. 5
10. A highly viscous fluid flows through a 5 cm I.D. pipe at rate 50 kg/hr. Fluid passes through 1 m long
heated section where a constant flux of 1000 Wm2 is supplied. Calculate the final temperature of liquid
if initial temperature is 40oC. Obtain the maximum wall temperature. Assume properties of liquid as, P
= 1500 kg/m3, Cp = 1.675 kJ/kg K, ks = 0.865 W/mK.
5
11. Water at 20oC is to be heated by passing it through the tube. Surface of tube is maintained at 90oC. The
diameter of tube is 4 cm while its length is 9 m. Find the mass flow rate so that exit temperature of
water will be 60oC. The properties of water are p = 995 kg/m3, Cp = 4.175 kJ/ kg K, K = 0.64 W/mK. ,
V = 0.62 x 10-6 m2/s, B = 4.25 x 10-3K-1
Use the correlation Nu = 0.023* (Re)0.8. (Pr)0.3
5
12. In a certain process, castor oil at 30oC flows past a flat plate. The velocity of oil is 0.08 m/sec.The
length of the plate is 5 m. The plant is heated uniformly and maintained at 90oC. Calculate the
following: (i) Hydrodynamic and thermal boundary layer thickness at the trailing edge of plate. (ii)
Total drag force per unit width on one side of the plate. Use the following correlation: Nu = 0.332
(Rel)1/2 . (Pr)1/3 Take properties as,
P = 956.8 kg/m3, k = 0.213 W/ moK, a = 7.2 x 10-8 m2 /s, v = 0.65 x 10-4 m2 /s.
5
13. In a certain process, castor oil at 30oC flows past a flat plate. The velocity of oil is 0.08 m/sec. he
length of the plate is 5 m. The plate is heated uniformly and maintained at 90oC. Calculate the 5
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 45 of 89
following:
(a) Hydrodynamic and Thermal Boundary layer thickness at the trailing edge of plate.
(b) Total drag force per unit width on one side of the plate Use following
correlation:- Nu = 0.332 (Rel)1/2 (Pr)1/3
Take properties as, p=956.8kg/m3, k =0.2132 W/moK, a =7.2 X 10-8m2/s, v = 0.65 X 10-4 m2/s.
Module wise lesson plan
Course title and code: Heat Transfer (10ME63)
Module 5 Planned hours: 09
Learning objectives: At the end of this chapter student will understand
1. Discuss the classification of heat exchangers based on flow and mode of heat Exchanger and the
different terms associated with heat exchanger.
2. Explain the LMTD equations for parallel and counter flow type heat exchangers.
3. Discuss the fouling and fouling factor in an exchanger.
4. Explain the, NTU, effectiveness of heat exchangers with specified operating conditions
5. Discuss the terms associated with condensation and boiling and use co-relations for film wise
condensation on plane surfaces, horizontal tubes and tube-banks.
6. Discuss the different boiling processes and use co-relations for solve physical problems.
7. Explain the utility of condensation and Boiling in problems of heat transfer.
8. Discuss the mass transfer and Fick’s law of diffusion.
Lesson Schedule:
Lecture
No. Topics covered
Teaching
Method
PO’s
Attained
CO’s
Attained
Reference
Book/
Chapter No.
L35 Heat Exchangers: Definition, Classification,
applications,
Chalk and
Board
a,b,c,e,i,
6 R4/10
L36 LMTD method Chalk and
Board 6 R4/10
L37 Effectiveness – NTU method, Chalk and
Board 6 R4/10
L38
Analytical Methods, Fouling Factors, Chart
Solution Procedures for solving Heat
Exchanger problems: Correction Factor Charts
Chalk and
Board 6 R4/10
L39 Effectiveness-NTU Charts, compact heat
exchangers.
Chalk and
Board 6 R4/10
T10 Tutorial 10 Chalk and
Board 6 R4/10
L40
Heat Transfer with Phase Change:
Introduction to boiling, pool boiling, Bubble
Growth Mechanisms
Chalk and
Board 7 R4/9
L41 Nucleate Pool Boiling, Critical Heat Flux in
Nucleate Pool Boiling, Pool Film Boiling,
Chalk and
Board 7 R4/9
L42 Critical Heat Flux, Heat Transfer beyond the
Critical Point
Chalk and
Board 7 R4/9
L43
filmwise and dropwise Condensation, heat
pipes, entrainment, wicking and boiling
limitations
Chalk and
Board 7 R4/9
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 46 of 89
T11 Tutorial 11 Chalk and
Board 7 R4/9
Assignment questions:
1. Give the classification of heat exchangers based on flow and mode of heat exchanger. 6
2. Derive an expression for LMTD for a Parallel and Counter flow heat exchanger. 6
3. Derive an expression for Effectiveness for a Parallel and Counter flow heat exchanger. 6
4. A copper pipe (K=350 w/mk) of 17.5mm inner diameter and 20mm outside diameter conveys water and
oil flows through the annular passage between this pipe and a steel pipe. On the water side, the film co-
efficient is 4600 w/m2k and the fouling factor is 0.00034m2k/w. The corresponding values for the oil side
are 1200w/m2k and 0.00086 m2k/w. Calculate the overall heat transfer coefficient between the water and
oil, based on outside surface area of inner pipe.
6
5. A shell and tube heat exchanger is to cool oil(Cp=2000J/kgk) flowing at 6kg/s from 65 ˚C to 35˚C by
using water of 10kg/s flow rate with inlet temperature 20˚C.Average heat transfer coefficient
Um=600w/m2k. Calculate heat transfer area for a parallel flow and counter flow arrangement.
6
6. Steam condenses at 60˚C on shell side of a steam condenser while cooling water flows inside tubes at
3kg/s.The inlet and outlet temperatures of water are 20˚C and 50˚C respectively. The overall heat
transfer coefficient Um=2000w/m2k. Calculate the surface area required.
6
7. Derive an expression for average heat transfer coefficient using Film Condensation theory on a vertical
surface. 7
8. List the assumptions made in the derivation of the Film Condensation theory. 7
9. Differentiate between drop-wise and film-wise condensation process. 7
10. Explain with a neat sketch the various regimes of the Pool-Boiling curve. Write the appropriate
equations for each regime. 7
11. Air free Saturated stream at Tv=90˚C (P=70.14Kpa) condenses on the outer surface of a 1.5 m long,
2.5cm OD vertical tube maintained at a uniform temperature of Tw=70˚C. Assuming film condensation,
calculate the average condensation heat transfer coefficient hm over the entire length of the tube,
condensate film thickness and condensate Reynolds number at the bottom of the tube, and the total rate
of condensation at the tube surface.
7
12. Saturated air-free stream at Tv=50˚C (P=12.35Kpa) condenses on the outer surface of a 1m
long, 2.5cm OD vertical tube maintained at a uniform temperature of Tw=30˚C. Assuming film
condensation, calculate the average condensation heat transfer coefficient hm over the entire
length of the tube and the total rate of condensation at the surface of the tube.
7
… End of Heat Transfer Lesson Plan …
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 47 of 89
Semester – VI
Course Title: Design of Machine Elements-II (15ME64)
CBCS
2017-2018
Program Educational Objectives (PEOs)
The educational objectives of the Mechanical Engineering Program are to prepare our graduates to:
COURSE FILE
Prof. S.S.CHAPPAR
Module Coordinator
Prof. S.R.BIRADAR & Prof .R.N .JEERAGAL
Course Coordinator
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 48 of 89
16. Establish a successful career in Mechanical Engineering or related fields in Industry and
other organizations where an engineering approach to problem solving is highly valued.
17. Develop the ability among the students to synthesize the data and technical concepts for
applications to the product design.
18. Contribute significantly in a multidisciplinary work environment with high ethical standards
and with understanding of the role of engineering in economy and the environment.
19. Excel in graduate study and research, reaching advanced degrees in engineering and related
disciplines.
20. Achieve success in professional development through life-long learning.
Program outcomes (POs)
ii. an ability to apply knowledge of mathematics, science, and Mechanical Engineering
jj. an ability to design and conduct experiments, as well as to analyze and interpret data
kk. an ability to design a mechanical system, mechanical component, or process to meet desired
needs within realistic constraints such as economic, environmental, social, political, ethical,
health and safety, manufacturability, and sustainability
ll. an ability to function on multidisciplinary teams
mm. an ability to identify, formulate, and solve mechanical engineering problems
nn. an understanding of professional and ethical responsibility
oo. an ability to communicate effectively
pp. the broad education necessary to understand the impact of mechanical engineering solutions
in a global, economic, environmental, and societal context
qq. a recognition of the need for, and an ability to engage in life-long learning,
rr. a knowledge of contemporary issues
ss. an ability to use the techniques, skills, and modern mechanical engineering tools necessary
for engineering practice.
Department of: MECHANICAL ENGINEERING
Program: B.E.MECHANICAL ENGINEERING (REGULAR)
Course Title: Design of machine Elements-II Course Code:15ME64
Theory: Practical:
Prerequisites to this course:
(Course title with course
codes)
Mechanics of
materials
(15ME34)
Material
science &
Metallurgy
(15ME32)
Kinematics
of machine
(15ME42)
Dynamics of
machine
(15ME52)
Design of
machine
elements –I
(15ME54)
Program Outcomes
(POs) a b c d e f g h i j k
X X X X X X X
√
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 49 of 89
Mapping of Course
Outcomes with POs
1,2
,3,4
,5,6
,7,8
1,2
,3,4
,5,6
,7,8
1,2
,3,4
,5,6
,7,8
1,2
,3,4
,5,6
,7,8
1,2
,3,4
,5,6
,7,8
1,2
,3,4
,5,6
,7,8
1,2
,3,4
,5,6
,7,8
Course category
Bas
ic
Sci
ence
s
Gen
eral
/
Hu
man
itie
s
Gen
eral
Core
Elective G-D G-T G-P G-M
X X
Teaching Methods: PPT OHP
Face to
face
Guest
Lecture
Video
lecture
Demo
(Lab visit) Seminars
Industrial
visits
Module 1 to 5
Continuous Assessment Internal assessment tests Assignment Tutorial
03 03
Contents beyond syllabus
to meet POs:
Topics POs attained
Approved by: Module Coordinator Prof. S.S.CHAPPAR
Program coordinator Prof. S.B.KOULAGI
Achieving Intended Course Learning Outcomes
The following skills are directly or indirectly imparted to the students in the following
teaching and learning methods:
Sl.No. Course
Learning
Outcomes
Possible capabilities, skills,
expertise gained (codes)
Means of imparting the curriculum
1 CO1 Kn, Un, PSS,AS Class room lectures, Assignments,
Tutorials
2 CO2 Kn, Un, PSS,AS Class room lectures, Assignments,
Tutorials
3 CO3 Kn, Un, PSS,AS Class room lectures, Assignments,
Tutorials
4 CO4 Kn, Un, PSS,AS Class room lectures, Assignments,
Tutorials
5 CO5 Kn, Un, PSS,AS Class room lectures, Assignments,
Tutorials
6 CO6 Kn, Un, PSS,AS Class room lectures, Assignments,
Tutorials
7 CO7 Kn,PS Class room lectures, Assignments,
PPT
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DEPARTMENT OF MECHANICAL ENGINEERING
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8 CO8 Kn,Un, PSS,AS,LS Class room lectures, Assignments,
Tutorials
Course Plan
Semester: VI Year: 2017-18
Course Title Design Of Machine
Elements-II
Course Code 15ME64
Total Teaching Hours 50 Teaching hours/week 05
Internal Assessment Marks 20 Semester Examination Marks 80
Course Plan prepared by Prof S R Biradar
Prof R N Jeeragal
Date
Course Content
PART-A
Module-1
Curved Beams: Stresses in curved beams of standard cross sections used in crane
hook, punching presses & clamps, closed rings and links.
Cylinders & Cylinder Heads: Review of Lame’s equations; compound cylinders,
stresses due to different types of fit on cylinders; cylinder heads and flats.
8
Hours
Module-2
Belts: Materials of construction of flat and V belts, power rating of belts, concept of
slip and creep, initial tension, effect of centrifugal tension, maximum power condition.
Selection of flat and V belts- length & cross section from manufacturers’ catalogues.
Construction and application of timing belts.
Wire ropes: Construction of wire ropes, stresses in wire ropes, and selection of wire
ropes. (Only theoretical treatment)
Chain drive: Types of power transmission chains, modes of failure for chain, and
lubrication of chains. (Only theoretical treatment)
Springs: Types of springs, spring materials, stresses in helical coil springs of circular
and non-circular cross sections. Tension and compression springs, concentric springs;
springs under fluctuating loads.
Leaf Springs: Stresses in leaf springs, equalized stresses, and nipping of leaf springs.
Introduction to torsion and Belleville springs.
10
Hours
Module-3
Possible capabilities, skills, expertise gained Code
Knowledge Kn
Understanding (Comprehension) Un
Problem solving skills (application skills) PSS
Practical skills (application skills) PS
Analytical skills AS
Synthesis skills SS
Written communication skills WCS
Verbal/oral communication skills VCS
Presentation skills PS
Leadership skills LS
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DEPARTMENT OF MECHANICAL ENGINEERING
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Gear drives: Classification of gears, materials for gears, standard systems of gear
tooth, gear tooth failure modes and lubrication of gears.
Spur Gears: Definitions, stresses in gear tooth: Lewis equation and form factor, design
for strength, dynamic load and wear.
Helical Gears: Definitions, transverse and normal module, formative number of teeth,
design based on strength, dynamic load and wear.
Bevel Gears: Definitions, formative number of teeth, design based on strength,
dynamic load and wear.
12
Hours
Module-4
Worm Gears: Definitions, types of worm and worm gears, and materials for worm and
worm wheel. Design based on strength, dynamic, wear loads and efficiency of worm
gear drives.
Design of Clutches: Types of clutches and their applications, single plate and multi-
plate clutches. (Numerical examples only on single and multi-plate clutches)
Design of Brakes: Types of Brakes, Block and Band brakes, self locking of brakes, and
heat generation in brakes.
10
Hours
Module-5
Lubrication and Bearings: Lubricants and their properties, bearing materials and
properties; mechanisms of lubrication, hydrodynamic lubrication, pressure development
in oil film, bearing modulus, coefficient of friction, minimum oil film thickness, heat
generated, and heat dissipated. Numerical examples on hydrodynamic journal and thrust
bearing design.
Anti friction bearings: Types of rolling contact bearings and their applications, static
and dynamic load carrying capacities, equivalent bearing load, load life relationship;
selection of deep grove ball bearings from the manufacturers’ catalogue; selection of
bearings subjected to cyclic loads and speeds; probability of survival.
10
Hours
DESIGN DATA HAND BOOK
Design Data Hand Book – K. Mahadevan and Balaveera Reddy,CBS Publication
TEXT BOOKS:
[1] Richard G. Budynas, and J. Keith Nisbett,“Shigley's Mechanical Engineering Design”,
McGraw-Hill Education, 10thEdition, 2015.
[2] Juvinall R.C, and Marshek K.M, “Fundamentals of Machine Component Design”, John
Wiley & Sons, Third Edition, Wiley student edition, 2007.
[3] V. B. Bhandari, “Design of Machine Elements”,4th Ed., Tata Mcgraw Hill, 2016.
REFERENCES:
[1] Robert L. Norton “Machine Design- an integrated approach”, Pearson Education, 2ndedition.
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 52 of 89
[2] Spotts M.F., Shoup T.E “Design and Machine Elements”, Pearson Education, 8th edition,
2006.
[3] Orthwein W, “Machine Component Design”, Jaico Publishing Co, 2003.
[4] Hall, Holowenko, Laughlin (Schaum’s Outline Series), “Machine design” adapted by
S.K.Somani, Tata McGraw Hill Publishing Company Ltd., Special Indian Edition, 2008.
[5] G. M. Maithra and L.V.Prasad, “Hand book of Mechanical Design”, Tata McGraw Hill, 2nd
edition,2004.
Scheme of Examination:
Two questions to be set from each module. Students have to answer five full questions, choosing
one full question from each module.
Assessment Marks
Internal Assessment tests 20
VTU Semester examination 80
Total 100
Assignment: Course work includes a Design project. Design project should enable the students
to design a mechanical system (like single stage reduction gearbox with spur gears, single stage
worm reduction gear box, V-belt and pulley drive system, machine tool spindle with bearing
mounting, C-clamp, screw jack, single plate clutch,etc.) A group of students (maximum number
in a group should be 4) should submit assembly drawing and part drawings, completely
dimensioned, indicating the necessary manufacturing tolerances, surface finish symbols and
geometric tolerances wherever necessary. Design project must be completed using appropriate
solid modeling software. Computer generated drawings must be submitted. Design calculations
must be hand written and should be included in the report.
Design project should be given due credit (5 marks) in internal assessment.
COURSE DESCRIPTION:
1. Overview of the course
The contents of the course “DESIGN OF MACHINE ELEMENTS-II (DME-II)” is designed
by the members of the Board of Studies (BoS) constituted by Visveswaraya Technological
University (VTU) Belgaum.
Basically, DME-II course deals with:
Design of curved beams ,Cylinders and cylinder heads
Design of gears, belt drives, wire ropes chain drive.
Design of springs, clutches and Brakes.
Design of bearings
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DEPARTMENT OF MECHANICAL ENGINEERING
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2. Relevance of the Course:
Technical considerations of mechanical component design are largely centered on two
main areas of concern: Stress-strain-strength relationships involving the bulk of a solid member
and Surface phenomenon including friction, lubrication, wear and environmental deterioration.
This course provides the students the ability to identify, formulate, and solve engineering
problems using modern engineering tools. The course also helps in designing a system, system
component, or process to meet desired needs within realistic constraints such as economic,
environmental, social, ethical, health and safety, manufacturability, and sustainability. This course
is a prerequisite to subjects like Elements of mechanical engineering, material science ,mechanics
of materials, Kinematics of machine, Dynamic of machinery, Machine design-I,
Hence, this course is a necessity and has much relevance to Mechanical Engineering Program
3. Application areas:
The basic principles of the course, DME-II is applied in mechanical engineering design theory to
identify and quantify machine elements in the design of commonly used mechanical systems. It
is applicable in various problems associated with machine component, efficiency of the system
etc
4. Prerequisite: This subject requires the knowledge of Engineering mathematics, Elements of
mechanical engineering, mechanics of materials, Kinematics of machine, Dynamic of machinery,
machine design-I, material science .
Course outcomes: Student will be able to
CO1 Apply engineering design tools to product design.
CO2 Design mechanical systems involving springs, belts and pulleys.
CO3 Design different types of gears and simple gear boxes for different applications.
CO4 Design brakes and clutches.
CO5 Design hydrodynamic bearings for different applications.
CO6 Select Anti friction bearings for different applications using the manufacturers,
catalogue.
CO7 Develop proficiency to generate production drawings using CAD software.
CO8 Become good design engineers through learning the art of working in a team with
morality and ethics.
Module wise lesson plan
Course title and code: DESIGN OF MACHINE ELEMENTS-II (15ME64)
Module1:CURVED BEAMS, CYLINDERS & CYLINDER HEADS Planned hours: 08
Learning objectives: Student will be able to
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
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1. Analyze the stresses in curved beams of standard cross sections used in different applications.
2. Distinguish between the straight and curved beams.
3 .Evaluate stress distribution in compound cylinder and cylinder heads.
4. Evaluate stress induced due to different fits.
5. Design the cylinders as per the applications.
Lesson Schedule:
Lecture
No
Topics Covered Teaching
Method
Po’s
Attained
Co’s
Attained
Reference
Book/Chapter
No
L1
CURVED BEAMS:
Introduction,
comparison between
straight and curved
beam and applications.
Chalk & Board a,b,c,e, h ,i,k 1,7,8 T1,T2
R1,R3,R4
L2
Stresses in curved
beams of standard cross
sections used in crane
hook and problems on
it .
Chalk & Board a,b,c,e,h ,i,k 1,7,8 T1,T2
R1,R3,R4
L3
Stresses in punching
presses and problems
on it.
Chalk & Board a,b,c,e, h ,i,k 1,7,8 T1,T2
R1,R3,R4
L4
Stresses in clamps ,
closed rings and links
and problems on it
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R1,R3,R4
L5
CYLINDERS &
CYLINDER HEADS:
Review of Lame’s
Equations, compound
cylinders
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R1,R3,R4
L6
Stresses due to
different types of fits
on cylinders
and problems on it
Chalk & Board
a,b,c,e, h ,i,k 1,7,8 T1,T2
R1,R3,R4
L7 Stresses due to cylinder
heads and its problems.
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R1,R3,R4
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DEPARTMENT OF MECHANICAL ENGINEERING
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L8 Stresses due to flats and
its problems.
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Assignment Questions
Question.
Number
Assignment questions COs
attained
1 What are the assumptions made in finding stress distribution for a curved
member and Differentiate straight and curved beam.
1,7,8
2 Derive an expression for stress distribution due to bending moment in curved
beam.
1,7,8
3 Derive Lame’s equation for compound cylinders. 1,7,8
4 A crane hook has a section of trapezoidal. The area at critical section is
115*((75+25)/2) mm2. The hook carries a load of 10Kn and inner radius of
curvature is 60mm. calculate the max tensile, compressive and shear stress
1,7,8
5 A cast steel cylinder of 300mm internal dia is to contain liquid at a pressure
of 12.5Mpa. it is closed at both ends by unstayed flat cover plates rigidly
bolted to the shell flange. Determine the thickness of the cover plates if the
stress is 75 MPa.
1,7,8
6 Design a shrink fit joint to join two cylinders of dia 150mm*200mm and
200mm*250mm. maximum tangential stress in the components due to shrink
fitting is to be limited to 40MPa. Also determine the axial force necessary to
disengage the joint if the length of the joint is 200mm and the max power can
be transmitted at rated speed of 1000rpm. The cylinder material has modulus
of elasticity 210 GPa and Poisson’s ratio 0.3
1,7,8
7 Determine the value of thickness t in the T-cross section of a curved beam
shown in fig. such,that the normal stress due to bending at the extreme
inner & outer fibers is numerically equal.
100 40
Centre line of curvature
100
t
150
1,7,8
8 A curved beam with a circular central line has trapezoidal cross section and it
is subjected to pure bending in its plane of symmetry. The face 100 mm is the
1,7,8
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DEPARTMENT OF MECHANICAL ENGINEERING
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concave side of the beam and is 100 mm from the center of curvature and the
load line. If the depth of the trapezoidal is 100 mm, find the proper value of
the other parallel face to the concave side to make extreme fibre stress in
tension and compression numerically equal
9 A high pressure cylinder consist of an inner cylinder of ID and OD of
200mm and 300mm respectively. It is jacketed by an outer cylinder of OD
400mm. the difference between the OD of inner cylinder and inner dia of
jacket before assembly is 0.25mm. E=0.2 GPa. Calculate the shrinkage
pressure and stresses induced in the cylinder due to shrinkage pressure. In
service the cylinder is further subjected to an internal pressure of 200 Mpa.
Plot the resultant stress distribution.
1,7,8
10 A cast iron cylinder of internal dia 200mm and thickness 50mm is subjected
to a pressure of 5 Mpa. Calculate the tangential and radial stresses at the
inner , middle and outer surface
1,7,8
11 A closed ring is made of 40mm dia rod bend to a mean radius of 85mm. if the
pull along the diameter is 10,000N, determine the stress induced in the
section of the ring along which it is divided into two parts by the direction of
pull.
1,7,8
12 Determine the max stress induced in a ring of 50 mm dia rod subjected to a
compressive load of 20 KN. The mean dia of the ring is 100 mm.
1,7,8
13 A chain link made of 40mm diameter rod is semi circular at each end, the
mean diameter of which is 80mm. the straight sides of the links length are
also equal to 80mm. if the link carries load of 90kN, estimate the tensile and
compressive stresses in the link along the section of load line. Also find the
stresses at a section 90o away from the load line.
1,7,8
Module wise lesson plan
Course title and code: DESIGN OF MACHINE ELEMENTS-II (15ME64)
Module 2: BELTS, ROPES AND CHAINS and SPRINGS Planned hours:10
Learning objectives: Student will be able to
1. Design flexible transmission systems (Belt, wire ropes and Chain drive).
2. Compute an expression for the ratio of tension in flat and V belt drive.
3.Design the different types of belts and compute the velocity, centrifugal stress, capacity,
dimension of belt ,correct centre distance and initial tension in the belt
4. Design the rope drive and compute rising & lowering the load and efficiency of the rope drive.
5. Design the chain drive and compute pitch of chain, no of teeth on the sprockets, pitch
diameter, no of strands in a chain, length of chain and correct centre distance.
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
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6. Design the different types of springs for various applications.
Lesson Schedule:
Lecture
No
Topics Covered Teaching Method Po’s
Attained
Co’s
Attained
Reference
Book/Chapter
No
L9
Belts. Introduction,
Materials of
construction of flat ,V
belts and Power rating
of belts.
Chalk & Board a,b,c,e, h ,i,k 2 T1,T2
R1,R3,R4
L10
Concept of slip and
creep, initial tension,
effect of centrifugal
tension, maximum
power condition, and
problems
Chalk & Board a,b,c,e, h ,i,k 2 T1,T2
R1,R3,R4
L11
Selection of flat and V
belts- length & cross
section from
manufacturers’
catalogues.
construction and
application of timing
belts.
Chalk & Board a,b,c,e, h ,i,k 2 T1,T2
R1,R3,R4
L12
Wire ropes:
construction of wire
ropes, stresses in wire
ropes, and selection of
wire ropes
Chalk & Board a,b,c,e, h ,i,k 2 T1,T2
R1,R3,R4
L13 Problems on wire ropes Chalk & Board a,b,c,e, h ,i,k 2 T1,T2
R1,R3,R4
L14
Chain drive: Types of
power transmission
chains, modes of failure
for chain, and
lubrication of chains.
Chalk & Board a,b,c,e, h ,i,k 2 T1,T2
R1,R3,R4
L15 Problems on chain
drive
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R1,R3,R4
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DEPARTMENT OF MECHANICAL ENGINEERING
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L16
Springs: Types of
springs, spring
materials, stresses in
helical coil springs of
circular and non-
circular cross sections
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R1,R3,R4
L17
Tension and
compression springs,
concentric springs;
springs under
fluctuating loads and
problems on it.
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R1,R3,R4
L18
Leaf Springs: Stresses
in leaf springs,
equalized stresses, and
nipping of leaf springs.
Introduction to torsion
and Belleville springs
and problems on it.
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R1,R3,R4
Assignment Questions
Question.
Number
Assignment questions COs
attained
1 What are the advantages of V belt drive over flat belt drive?
2
2 Give the advantages and disadvantages of V- belt drives 2
3 Derive an expression for the following, a)Ratio of belt tensions b) length of
belt C) Power transmitted by belt drive.
2
4 Design a V-belt for transmitting 75kW with the following specifications:
Speed of driver pulley = 1440 rpm, Speed of driven pulley = 400 rpm, Center
distance = 2500mm Service condition = 16 hrs/day.
2
5 Design a chain drive to actuate a compressor from a 14.5 kW electric motor
at 970 rpm, the compressor rpm being 330. Minimum center distance should
be 550 mm. The chain tension may be adjusted by shifting the motor on rails.
The compressor is to work 16 hours / day.
2
6 An 8 X 19 (9/9/1) steel wire rope is used to lift a load 15kN from a depth of
1000m. The maximum speed of rope is 2.5m/s and the acceleration is
1.5m/sec2 when starting under no slack conditions. Determine the size of the
rope required
2
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DEPARTMENT OF MECHANICAL ENGINEERING
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7 Select a wire rope for an elevation in a building where the total lift is 40m.
The rope velocity is 100m/min and fall speed is to be reached in 2 meter. The
lifting sheaves are to be of the traction type. The elevation car weighs 10 kN
and passengers weigh 20 kN. Assume a factor of safety=10
2
8 Select a suitable chain drive to transmit 30kW from an electric motor to a line
shaft. Motor shaft diameter is 60mm, motor rpm = 1200, line shaft rpm = 250
and center distance is adjustable from 600 mm. Service is 10 hrs per day and
6 days per week. Good lubrication is expected. The sprocket on motor shaft
has 21 teeth
2
9 Design a roller chain to transmit power from a 20 kW motor to a
reciprocating pump. The pump is to operate continuously 24 hours per day.
The speed of the motor is 600 rpm and that of the pump is 200 rpm. Find: a.
Number of teeth on each sprocket; b. Pitch and width of the chain
2
10 A laminated semi elliptical leaf spring under a central load of 10KN is to
have an effective length of 1m and is to deflect not more than 50mm. the
spring has 8 leaves, two of which are full length, and have been prestressed
so that all leaves have the same stress after the full load has been applied. All
the leaves have the same width and thickness. The max stress in the leaves is
not to exeed 35 Kg/mm2. Determine
i) the width and thickness of leaves ii) central bolt load
iii) Initial gap between the full length and graduated leaves before assembly.
2
11 Two helical springs are nested and are in a concentric manner, with ane
inside other. Both the springs have the same free length and carry a total load
of 5500 N. the details are as bellow
Outer inner
No. active turns 8 12
Wire dia 16mm 12mm
Mean coil dia 128mm 84mm
Determine the max load carried by each spring, total deflection of spring
and max stresses in each spring.
2
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 60 of 89
Module wise lesson plan
Course title and code: DESIGN OF MACHINE ELEMENTS-II (15ME64)
Module 3: GEAR DRIVES, SPUR GEARS, HELICAL GEARS AND
BEVEL GEARS
Planned
hours: 12
Learning objectives: Student will be able to
1. Design of transmission system with different type of gears.
2. Select suitable materials for gears.
3. Explain Terminology of gear and law of gearing.
4. Compute Beam strength of spur gear teeth or Lewis equation.
5. Design of Spur gear, Helical gear and Bevel gear based on the strength, dynamic load and wear.
Lesson Schedule:
Lecture
No
Topics Covered Teaching
Method
Po’s
Attained
Co’s
Attained
Reference
Book/Chapter
No
L19
Gear drives:
Classification of gears,
material for gears,
standard systems of
gear tooth.
Chalk & Board a,b,c,e, h ,i,k 3,7 T1,T2
R1,R3,R4
L20
Gear tooth failure
modes and lubrication
of gears.
Chalk & Board a,b,c,e, h ,i,k 3,7 T1,T2
R1,R3,R4
L21
SPUR GEARS:
Definitions, stresses in
gear tooth
Chalk & Board a,b,c,e, h ,i,k 3,7 T1,T2
R1,R3,R4
L22 Lewis equation and
form factor
Chalk & Board a,b,c,e, h ,i,k 3,7 T1,T2
R1,R3,R4
L23 Design based on
strength
Chalk & Board a,b,c,e, h ,i,k 3,7 T1,T2
R1,R3,R4
L24 Design for dynamic
and wear load.
Chalk & Board a,b,c,e, h ,i,k 3,7 T1,T2
R1,R3,R4
L25
Helical Gears:
Definitions, transverse
and normal module
,Formative number of
Chalk & Board a,b,c,e, h ,i,k 3,7 T1,T2
R1,R3,R4
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 61 of 89
teeth
L26 Design based on
strength
Chalk & Board a,b,c,e, h ,i,k 3,7 T1,T2
R1,R3,R4
L27 Design for dynamic
and wear load.
Chalk & Board a,b,c,e, h ,i,k 3,7 T1,T2
R1,R3,R4
L28
Bevel Gear:
Definitions, Formative
number of teeth.
Chalk & Board a,b,c,e, h ,i,k 3,7 T1,T2
R1,R3,R4
L29 Design based on
strength
Chalk & Board a,b,c,e, h ,i,k 3,7 T1,T2
R1,R3,R4
L30 Design for dynamic
and wear load.
Chalk & Board a,b,c,e, h ,i,k 3,7 T1,T2
R1,R3,R4
Assignment Questions
Question.
Number
Assignment questions COs
attained
1 Derive an expression for beam strength of spur gear. 3,7
2 Explain Lewis form factor. 3,7
3 Define formative no. of teeth as applied to helical gear and explain its
importance.
3,7
4 What is interference in gears? Explain the methods to avoid interference. 3,7
5 List the advantages of helical gear. 3,7
6 Define the following: a) Pitch angle b) Face angle c) Root angle d) Back
cone distance, and e) Crown height for bevel gears
3,7
7 Design a pair of spur gears to transmit 20kw power operating 8 to 10 hrs/day
sustaining medium shock, from a shaft rotating at 1000rpm to a parallel shaft
which is to rotate at 310rpm. Assume the number of teeth on pinion to be 31
and 200 full depth involute tooth profile. The material for pinion is C40 steel
untreated stress is 206MPa and gear is cast steel 0.2% C whose stress is
137Mpa. Check the design for dynamic load if load factor is 522N/mm and
also for wear load take K=0.279 MPa. Suggest the suitable hardness.
3,7
8 Design a pair of helical gears to transmit power of 15KW at 3200rpm with
speed reduction 4:1 pinion is made of cast steel 0.4% C untreated. Gear
made of high grade CI helix angle is limited to 260 and not less than 20 teeth
are to be used on either gear. Check the gears for dynamic and wear
considerations.
3,7
9 Design a pair of spur gear to transmit power of 20KW from a shaft rotating at
1000rpm to a parallel shaft which rotate at 310 rpm. Assume no. of teeth on
pinion 31 and 200 full depth tooth form
3,7
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 62 of 89
10 A pair of bevel gears connects two shafts at right angles and transmits 9 kW.
Determine the required module and gear diameters for the following
specifications: -
PARTICULARS PINION GEAR
Number of teeth 21 60
Material Steel Grey Cast Iron
BHN 200 160
Allowable Static
Stress
85 MPa 55 MPa
Speed 1200
rpm
420 rpm
Tooth profile 14.50
composite
14.50
composite
Check the gears for dynamic and wear loads.
3,7
Module wise lesson plan
Course title and code: DESIGN OF MACHINE ELEMENTS-I (15ME64)
Module 4: WORM GEARS AND DESIGN OF CLUTCHES AND BRAKES Planned hours: 10
Learning objectives: Student will be able to
1. Explain Terminology of worm gear and self locking in worm gearing.
2. Design of worm gear for strength, dynamic load, wear load.
3. Design of clutches and their applications.
4. Design of Brakes and their applications.
5. Determine the heat generation in the brakes.
Lesson Schedule:
Lecture
No
Topics Covered Teaching
Method
Po’s
Attained
Co’s
Attained
Reference
Book/Chapter
No
L31
Worm Gears:
Definitions, types of
worm and worm gears,
materials for worm and
worm wheel.
Chalk & Board a,b,c,e, h ,i,k 3 T1,T2
R1,R3,R4
L32 Design based on Chalk & Board a,b,c,e, h ,i,k 3 T1,T2
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 63 of 89
strength R1,R3,R4
L33
Design based on
dynamic and wear
loads.
Chalk & Board a,b,c,e, h ,i,k 3 T1,T2
R1,R3,R4
L34 Efficiency of worm
gear drives.
Chalk & Board a,b,c,e, h ,i,k 3 T1,T2
R1,R3,R4
L35
CLUTCHES: Types
of clutches and their
applications,Design of
Single plate Clutches
Chalk & Board a,b,c,e, h ,i,k 4 T1,T2
R1,R3,R4
L36 Design of multi plate
Clutches
Chalk & Board a,b,c,e,h ,i,k 4 T1,T2
R1,R3,R4
L37
Design of Brakes:
types of brakes, Block
brake and
Chalk & Board a,b,c,e,h ,i,k 4 T1,T2
R1,R3,R4
L38 Design of Band brakes. Chalk & Board a,b,c,e,h ,i,k 4 T1,T2
R1,R3,R4
L39 Self locking of brakes Chalk & Board a,b,c,e,h ,i,k 4 T1,T2
R1,R3,R4
L40 Heat generation in
Brakes
Chalk & Board a,b,c,e,h ,i,k 4 T1,T2
R1,R3,R4
Assignment Questions:
Question.
Number
Assignment questions COs
attained
1 A worm gear type is required to transmit 15kW at 500 rpm of the worm. The
velocity ratio is 25:1. The center distance should be around 500 mm. Design
the worm gear train. The material of the gear is phosphor bronze and that of
the worm is hardened steel. Determine also the efficiency of the drive
3
2 Design a 200 Involute worm and gear to transmit 10kW with worm rotating at
1440 rpm and to obtain a speed reduction of 12:1. The distance between the
shafts may be about 240 mm. Axial pitch of threads may be around 25 mm.
Take service factor=2. Gear is made of chilled phosphor bronze having
allowable stress of 100MPa. Check the design for heat dissipation, not
allowing temperature rise by more than 400C above environmental
temperature. Assume =0.025 and heat dissipating capacity k=0.35 kcal/hr
3
3 Compute torque transmitted by Disc clutch or plate clutch. 4
4 A multi-disc clutch has three discs on the driving shaft and two on the driven
shaft. The outside diameter of the disc is 240mm. Inside diameter is 120mm.-
4
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 64 of 89
Assuming uniform wear and coefficient of friction is 0.3. Determine the
maximum axial intensity of pressure between the discs for transmitting 25kW
at 1600 rpm
5 A band brake acts on 3/4th of the circumference of a drum of 450mm
diameter, which is keyed, to the shaft; the band brake provides a braking
torque of 225Nm. One end of the band is attached to a fulcrum pin of the
lever and the other end to a pin 100mm from the fulcrum. If the operating
force is applied at 500mm from the fulcrum and the coefficient of friction is
0.25, find the operating force acting downwards when the drum rotates in
the counter clockwise direction. Also find the width of the band if its
thickness is 1.5mm and working stress is 70N/mm2.
4
6 A differential band brake has an operating lever 225mm long. The ends of
the brake band are attached so that their operating arms are 38mm and
150mm long. The brake drum dia is 600mm, the arc of contact is 3000, the
brake band is 3mm thick, and 100mm wide, coefficient of friction between
the band and drum is 0.22. a) Find the least force required at the end of the
operating lever to subject this band to a stress of 56N/mm2. b) What is the
torque applied to the brake drum shaft? c) Is brake self-locking. [Ref. Fig.
No.1]
4
7 An internal expending brake has an inner surface of rim of diameter 500mm.
The distance between the fulcrums 100mm. The distance between the
fulcrums and the point of application of efforts is 400mm. The brake linings
sustain an angle of 120o at the centre. The material of the lining has the co-
efficient of friction of 0.3, and an allowable bearing pressure of 0.5 MPa.
Determine, a) The effort required to stop the rotation of the brake drum b)
The width of the rake lining. The brake transmits a power of 30kW at a rated
speed of 1500r/min.
4
8 A simple band brake is used to stop rotation of the brake drum mounted on a
shaft transmitting 40 kW at a speed of 1500 rpm. Select a suitable material
4
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 65 of 89
and design brake lever, band and fulcrum pin. =2250. Drum diameter,
D=50mm, length of lever = 1100mm. Distance between the two ends of a
band where they are fixed on the lever=300mm. Force is acting in
downwards direction at extreme end of lever
Module wise lesson plan
Course title and code: DESIGN OF MACHINE ELEMENTS-II (15ME64)
Module 5: LUBRICATION AND BEARINGS and ANTI
FRICTION BEARINGS
Planned hours: 10
Learning objectives: Student will be able to
1. Define lubrication & types of lubricants.
2. Define bearing and its classification of bearings.
3. Compute Petroff’s equation for coefficient of friction for hydrodynamic bearing.
4. Select the bearings subjected to cyclic loads and speeds.
5. Design a journal bearing, thrust bearing and anti frictions bearings.
Lesson Schedule:
Lecture
No
Topics Covered Teaching Method Po’s
Attained
Co’s
Attained
Reference
Book/Chapter
No
L41
Lubrication and
Bearings: Lubricants and
their properties, bearing
materials and their
properties.
Chalk & Board a,b,c,e,h ,i,k 5 T1,T2
R1,R3,R4
L42
Mechanisms of
Lubrication,
hydrodynamic
lubrication, pressure
development in oil film.
Chalk & Board a,b,c,e,h ,i,k 5 T1,T2
R1,R3,R4
L43 Bearing modulus,
coefficient of friction
Chalk & Board a,b,c,e,h ,i,k 5 T1,T2
R1,R3,R4
L44
minimum oil film
thickness, Heat
Generated, Heat
dissipated.
Chalk & Board a,b,c,e,h ,i,k 5 T1,T2
R1,R3,R4
L45 Examples on
hydrodynamic journal
Chalk & Board a,b,c,e,h ,i,k 5 T1,T2
R1,R3,R4
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 66 of 89
and thrust bearing design
L46
Ant friction bearings:
Types of rolling contact
bearing and their
applications.
Chalk & Board a,b,c,e,h ,i,k 6 T1,T2
R1,R3,R4
L47 Static and dynamic load
carrying capacities.
Chalk & Board a,b,c,e,h ,i,k 6 T1,T2
R1,R3,R4
L48 Equivalent bearing load
and load life relationship.
Chalk & Board a,b,c,e,h ,i,k 6 T1,T2
R1,R3,R4
L49
Selection of deep groove
ball bearing from
manufactures catalogue.
Chalk & Board a,b,c,e,h ,i,k 6 T1,T2
R1,R3,R4
L50
Selection of bearings
subjected to cyclic load
and speed, probability of
survival.
Chalk & Board a,b,c,e,h ,i,k 6 T1,T2
R1,R3,R4
Assignment Questions:
Question.
Number
Assignment questions COs
attained
1 Design a journal bearing to support a load of 10000N at 800 rpm using a harden
steel journal and bronze backed babbit bearing. The bearing is relieved for 200 from
the journal to the load line. Assuming oil temperature of 850C. Determine also i)
heat generated ii) work of friction. Assume SAE 40 oil used
5
2 Design a journal bearing for a centrifugal pump running at 1440 rpm.
Diameter of the journal is 100mm and the load on the bearing is 20 kN. The
value of p
ZN is equal to the value given in the table given in Data handbook
for centrifugal pump
5
3 A Journal bearing is to be designed for the main bearing of a four-stroke oil engine
to sustain a load of 50 KN for shaft diameter of 50 mm. The engine runs at the sped
of 1500rpm. Determine 1) The length and diameter of the bearing II) The viscosity
of oil to be used as lubricant and hence suggest a suitable oil. III) The co-efficient of
friction of the bearing IV) the heat generated.
5
4 Explain the significance of the bearing characteristic number in the design of sliding
contact bearings
5
5 A turbine shaft 6mm in diameter rotates at a speed of 10000 rpm. The load on each
bearing is estimated at 2kN and the length of the bearing is 80mm. Taking radial
clearance as 0.05mm and SAE-20 oil for lubrication determine the coefficient of
friction, power loss, minimum film thickness and the oil flow rate. The temperature
of the bearing is not to exceed 500 C.
5
6 What is the importance of bearing characteristic number in design of bearing? 5
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 67 of 89
7 Design a bearing and journal to support a load of 4800 N at 650 rpm using a
hardened steel journal and bronze backed Babbitt bearing. The bearing is lubricated
by oil rings. Take oil temperature as 800C and room.
5
8 A machine shaft supported n two identical taper roller bearings A& B is shown in
fig. it is subjected to redial force of 30KN and thrust force of 10KN. The thrust is
taken by bearing A alone. The shaft rotates at 300 rpm. The machine is
intermittently use and the expected life L10th of the bearings is 4000 h. the minimum
acceptable diameter of the shaft, were the bearings are mounted, is 60 mm. select
the suitable taper roller bearings for the shaft.
6
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 68 of 89
B.L.D.E.A’s
Vachana Pitamaha Dr. P.G. Halakatti College of Engineering & Technology,
BIJAPUR – 586 103
Department of Mechanical Engineering
Semester – VI
Course Title: Metal Forming (15ME653)
Course plan Year: 2017-18
COURSE FILE
Course Coordinator Prof. L.N.Karadi
Prof. S.M.Vijapur
Program coordinator
Prof. S B Koulagi
Module Coordinator
Dr. G.V.Patil
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 69 of 89
Department of: Mechanical Engineering
Program: Mechanical Engineering
Course Title: Metal Forming
Course Code:
Theory: Practical:
Prerequisites to this course:
(Course title with course
codes)
Engineering
Mechanics
14CIV13/23
Mathematics
14MAT11/21
Material
science and
Metallurgy
10ME32/42
Mechanics-of
Materials
10ME34
Program Outcomes
(POs) a b c d e f g h i j
k
Mapping of Course
Outcomes with Pos
Understand the
concept of different
metal forming
process.
Approach metal
forming processes
both analytically and
numerically
Design metal forming
processes
Develop approaches
and solutions to
analyze metal
forming processes
and the associated
problems and flaws
Bas
ic
Sci
ence
s
Gen
eral
/
Hu
man
itie
s
Gen
eral
Core
Elective Group A
(Design
Engineering)
Group B
(Thermal
Engineering
)
Group C
(Production
Engineering)
Group D ( Management
Engineering)
Teaching Methods: PPT OHP Face to
face
Guest
Lecture
Video
lecture
Demo
(Lab visit)
Seminars Industrial
visits
Module I-V II - V
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 70 of 89
Continuous
Assessment
Internal assessment tests Assignment Tutorial
03 03
Contents beyond
syllabus to meet POs:
Topics POs attained
Approved by: Module Coordinator DR.G.V.Patil
Program coordinator Prof.S.B.Koulagi
Program Educational Objectives (PEOs)
The educational objectives of the Mechanical Engineering Program are to prepare our graduates to:
1. Establish a successful career in Mechanical Engineering or related fields in Industry and other
organizations where an engineering approach to problem solving is highly valued.
2. Develop the ability among the students to synthesize the data and technical concepts for
applications to the product design.
3. Contribute significantly in a multidisciplinary work environment with high ethical standards and
with understanding of the role of engineering in economy and the environment.
4. Excel in graduate study and research, reaching advanced degrees in engineering and related
disciplines.
5. Achieve success in professional development through life-long learning.
Program outcomes (POs)
tt. an ability to apply knowledge of mathematics, science, and Mechanical Engineering
uu. an ability to design and conduct experiments, as well as to analyze and interpret data
vv. an ability to design a mechanical system, mechanical component, or process to meet desired
needs within realistic constraints such as economic, environmental, social, political, ethical,
health and safety, manufacturability, and sustainability
ww. an ability to function on multidisciplinary teams
xx. an ability to identify, formulate, and solve mechanical engineering problems
yy. an understanding of professional and ethical responsibility
zz. an ability to communicate effectively
aaa. the broad education necessary to understand the impact of mechanical engineering
solutions in a global, economic, environmental, and societal context
bbb. a recognition of the need for, and an ability to engage in life-long learning,
ccc. a knowledge of contemporary issues
ddd. an ability to use the techniques, skills, and modern mechanical engineering tools
necessary for engineering practice.
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 71 of 89
Subject Title: Metal Forming Subject Code: 15ME653
Total No. of Lecture Hrs: 50 Max. I. A. Marks: 20
Max. Marks: 80 Duration of Exams: 3Hrs
Prepared by: Prof. L.N.Karadi & V.V.Nagathan Date:
Course Content
MODULE -1
Introduction to Metal Forming: Classification of metal forming processes, advantages
and limitations, stress-strain relations in elastic and plastic deformation. Concepts of true
stress, true strain, triaxial & biaxial stresses. Determination of flow stress, principal
stresses, yield criteria and their significance, Tresca & Von-Mises yield criteria, concepts
of plane stress & plane strain. Deformation mechanisms, Hot and Cold working processes
and its effect on mechanical properties.
10
Hrs.
MODULE -2
Effects of Parameters: Metallurgical aspects of metal forming slip, twinning mechanics
of plastic deformation, Effects of Temperature, strain rate, friction and lubrication,
hydrostatic pressure in metalworking, Deformation zone geometry, workability of
materials, Residual stresses in wrought products.
Forging: Classification of forging processes. Forging machines equipment. Expressions
for forging pressures & load in open die forging and closed die forging by slab analysis,
concepts of friction hill and factors affecting it. Die-design parameters. Material flow lines
in forging, forging defects, residual stresses in forging. Simple problems.
10Hrs.
MODULE -3
Rolling: Classification of rolling processes. Types of rolling mills, expression for rolling
load. Roll separating force. Frictional losses in bearing, power required in rolling, effects
of front & back tensions, friction, friction hill. Maximum possible reduction. Defects in
rolled products. Rolling variables. Simple problems. Drawing: Drawing equipment &
dies, expression for drawing load by slab analysis, power requirement. Redundant work
and its estimation, optimal cone angle & dead zone formation, drawing variables, Tube
drawing, classification of tube drawing. Simple problems.
10Hrs.
MODULE -4
Extrusion: Types of extrusion processes, extrusion equipment & dies, deformation,
lubrication & defects in extrusion. Extrusion dies extrusion of seamless tubes. Extrusion
variables. Simple problems.
Sheet Metal Forming: Forming methods dies & punches, progressive die, compound die,
combination die. Rubber forming. Open back inclinable press (OBI press), piercing,
blanking, bending, deep drawing, LDR in drawing, Forming limit criterion, defects of
drawn products, stretch forming. Roll bending & contouring. Simple problems.
10 Hrs
MODULE -5
High Energy Rate Forming: Methods & Powder Metallurgy: High Energy Rate Forming
Methods: Principles, advantages and applications, explosive forming, electro hydraulic
forming, Electromagnetic forming.
10 Hrs
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 72 of 89
Powder Metallurgy: Basic steps in Powder metallurgy brief description of methods of
production of metal powders, conditioning and blending powders, compaction and
sintering application of powder metallurgy components, advantages and limitations.
TEXT BOOKS:
1. Mechanical metallurgy (SI Units), G.E.Dieter, McGraw hill Pub-2001
2. Production Technology (Manufacturing process, technology and Automation), R.K Jain,
Khanna Publishers-2004.
3. Manufacturing Science, Amithab Gosh & A.K.Malik, East-West press 2001.
4. Production Technology Vol-II by O. P. Khanna & Lal, Dhanpat Rai Publications-2012.
5. A Course in Workshop Technology Vol: 1, Manufacturing Process, B.S Raghuwanshi,
Published by Dhanpat Rai & Co (P) Ltd.-2014.
REFERENCE BOOKS:
1. Materials & Process in Manufacturing – E.Paul, Degramo, J.T.Black, Ranold, A.K.Prentice-hall of
India 2002
2. Elements of Workshop Technology Vol:1, S.K.Hajra Choudhury, Media Promoters & Publishers
Pvt Ltd.-2008.
3. Fundamentals of Manufacturing Processes by Lal G K , Narosa
4. Textbook of Production Engineering by P. C. Sharma, S Chand & Company Ltd.
5. Manufacturing Process – III by Dr K. Radhakrishna
Prerequisites:
This subject requires the basic knowledge of Mechanics, Mathematics, Material science and
Metallurgy and Mechanics of materials.
Overview of the course:
The course content is designed to provide the knowledge and skills required to become an
efficient engineer by equipping students with a manufacturing perspective. It involves basic
understanding of various metal forming processes like forging, extrusion, rolling, wire drawing, deep
drawing, sheet metal operations, etc. The course also deals with modern forming methods like exclusive
forming, electro hydraulic forming and electromagnetic forming. Powder metallurgy principles are also
dealt in detail as a part of MP-III.
Course Outcomes(CO’s): After completing this course the student will be able to
1. Outline classification of metal working processes and analyze Mechanics of metal forming
process.
2. Identify the effects of various parameters and Residual stresses in metal working. Discuss the
classification of forging processes, and analyze the expression for forging pressures and load in
open as well as closed die forging.
3. Explain types of rolling mills, power required in rolling, and Discussing the drawing equipments
and dies, and analyze the expression for drawing stress.
4. Explain the extrusion processes, equipments and dies, outline the extrusion of seamless tube and
extrusion variables. Identify the forming methods and explain the same.
5. Explain the various high energy rate forming methods and describe briefly the methods of
production of metallic powder in powder metallurgy.
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 73 of 89
Relevance of the course:
Mechanical Engineers are involved in every aspect right from designing a component to
manufacturing them. They are supposed to have thorough knowledge of the manufacturing processes by
which mechanical components are produced with high quality and economy. The student should learn the
different types of metal forming processes as some of the parts like sheet metals of different thickness,
wires of different sizes; different metal mixture components etc are manufactured by these processes.
Metal forming also shares major part in today’s manufacturing scenario along with metal removal, metal
joining and Metal casting processes.
Application areas:
For most countries manufacturing is the most significant activity for nation’s wealth creation and
overall prosperity. For example the sheet metal produced by metal forming processes is used to build the
body of the vehicles. Graduates from our program may find positions as manufacturing engineer in many
production fields in different countries.
Chapter wise plan
Course code and Title: 15ME653 Metal Forming
MODULE -1 - Introduction to Metal Forming Planned
Hours: 10
Learning Objectives: At the end of the chapter student should be able to
1. Explain the classification of metal working processes in detail.
2. Explain the distinguishing features and characteristics of wrought products.
3. Explain the unique advantages and limitations of metal working processes.
4. Explain the significance of true stress and true strain in the plastic flow of metals and deformation
processing.
5. Explain Biaxial and Triaxial state of stresses. Calculate the principal stresses and strains.
6. Explains Von – Mises and Tresca yield criteria and determine the flow stress.
7. Explain the plane stress and plane strain concepts and apply the same in predicting the
deformation loads / pressures.
8. Explain the hot working, cold working and warm working – their relative merits and demerits.
Lesson Schedule:
Lecture
No.
Portion to be covered per lecture (class) Teaching
method
Pos
attained
Cos
attained
Reference
book/
chapter No
L1 Classification of metal working processes,
Characteristics of wrought products
Chalk &
Board
a,e,i,k
1 T1/15
R5/1
L2 Advantages and limitations of metal working
processes
Chalk &
Board 1
T1/15
R5/1
L3 Concepts of true stress, true strain, tri-axial
& biaxial stresses
Chalk &
Board 1, 2
T1/15
R5/2
L4 Determination of flow stress. Principal
stresses, Tresca & Von- mises yield criteria
Chalk &
Board 1,2
T1/15
R5/2
L5 Concepts of plane stress & plane strain. Chalk & 1,2 T1/15
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 74 of 89
Brief description of methods of metal
deformation analysis.
Board R5/2
L6 Hot and Cold working processes and its
effect on mechanical properties.
Chalk &
Board 1
T1/15
R5/1
L7 Problems Chalk &
Board 1,2
T1/15
R5/2
L8 Problems Chalk &
Board 1,2
T1/15
R5/2
L9 Problems Chalk &
Board 1,2
T1/15
R5/2
L10 Problems Chalk &
Board 1,2
T1/15
R5/2
Assignment questions COs attained
1. Discuss briefly the classification of metal working
processes. 1
2. Distinguish clearly between Hot working and Cold
working. 1
3. Enumerate and explain briefly the unique characteristics of
wrought products. 1
4. Explain the advantages and limitations of metal working
processes. 1
5. Define true stress and true strain and establish the
relationships between engineering stress and strains. 1,2
6. A mild steel specimen of rectangular c/s having a length of
100 mm is extended to 120 mm. neglecting the elastic
deformation and taking the material as isotropic;
determine true strains along the length, width and
thickness.
1,2
7. At a certain point in a piece of elastic material, there are
normal stresses of 40 N/mm2 (Tensile) and 30 N/mm2
(Compression) on two planes at right angles to one another
along with this shear stress of 20 N/mm2 on the same
planes. If the loading on the material is increased so that
stress reach values of K. find the maximum value of K if
the maximum direct stress in the material not to exceed
100 N/mm2 and maximum shear stress not to exceed 70
N/mm2
1,2
Course code and Title: 15ME653 Metal Forming
MODULE -2 - Effects of Parameters & Forging Planned
Hours: 10
Learning Objectives: At the end of the chapter student should be able to
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 75 of 89
1. Explain the effects of strain rate, effects of friction and the importance of lubrication in
metalworking.
2. Explain the importance of deformation zone geometry on the yield pressure, how the hydrostatic
pressure can be utilized in enhancing the workability of brittle materials.
3. Analyse the complex technological concept of workability – concerns, factors and workability
limits. The residual stresses that are generated by non – uniform plastic deformation – their
effects and remedies.
Lesson Schedule:
Lecture
No.
Portion to be covered
per lecture (class)
Teaching
method
Pos attained Cos attained Reference
book/
chapter No
L10 Effects of temperature &
strain rate
Chalk &
Board
a,e,i,k.
1 T1/15
R5/1
L11 Ef fec t of friction and
lubrication
Chalk &
Board 1
T1/15
R5/1
L12 Hydrostatic pressure in
metalworking
Chalk &
Board 1
T1/15
R5/2
L13
Deformation zone
geometry, workability of
materials, Residual
stresses in wrought
products.
Chalk &
Board
1 T1/15
R5/1
L14
Classification of forging
processes and forging
machines
Chalk &
Board/ Video
1 T1/16
R5/3
L15
Expressions for forging
pressures & load in open
die forging and closed die
forging by slab analysis
Chalk &
Board 2,3
T1/16
R3/3
L 16
Concepts of friction hill
and factors affecting it,
Die-design parameters
Chalk &
Board 2,3 T1/16
R3/3
L 17
Material flow lines in
forging. Forging defects,
Residual stresses in
forging
Chalk &
Board 1
T1/16
R3/3
L 18 Numericals Chalk &
Board 2, 3
T1/16
R3/3
L 19 Numericals Chalk &
Board 2, 3
T1/16
R3/3
L 20 Numericals Chalk &
Board 2, 3
T1/16
R3/3
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 76 of 89
Assignment questions COs attained
1. Explain briefly i) friction and lubrication ii)
hydrostatic pressure iii) deformation zone geometry
iv) workability v) residual stresses in wrought
products.
1
2. What is friction hill? Explain briefly the factors
affecting it? 1
3. What are the typical defects observed in forging?
Explain the reasons briefly. 1
4. Write briefly on residual stresses in forging. 1
5. A block of lead 25 mm x 25 mm 150 mm is pressed
between flat dies to a size 6.25 mm x 100 mm x 150
mm. If the uniaxial flow stress is 0 = 6.9 MPa and
= 0.25. Determine the pressure distribution over the
150 mm dimension and the total forging load.
2, 3
6. A circular disc of lead of radius 150 mm and thickness
50 mm is forged to half of its original thickness by
open die forging. Determine the maximum forging
force if the coefficient of friction between the job and
die is 0.25. The average shear yield stress of lead is 4
N/mm2
2, 3
Course code and Title: 15ME653 Metal Forming
Module 3. Rolling & Drawing Planned
Hours: 10
Learning Objectives: At the end of the chapter student should be able to
1. Explain the classification of rolling process. Types of Rolling mills, Hot and Cold Rolling and
Rolling of Bars and Shapes.
2. Explain the forces and geometrical relationship in rolling and derive the expression for rolling
load.
3. Explain Roll separating force, role of friction and limiting conditions and frictional losses in
bearings etc.,
4. Explain the effect of front and back tension, friction, roll diameter and other rolling variables.
5. Explain the importance of friction – friction hill, maximum possible reduction and the defects in
rolled products.
Lesson Schedule:
Lecture
No.
Portion to be covered per
lecture (class)
Teaching
method
Pos attained Cos attained Reference
book/
chapter No
L21
Classification of rolling
processes, Types of rolling
mills, expression for
Chalk &
Board/
Video
a,e,i,k. 1 T1/17
R3/4
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 77 of 89
Rolling load
L22
Roll separating force.
Frictional losses in
bearing etc, power
required in rolling
Chalk &
Board 1,2,3
T1/17
R3/4
L23
Effects of front & back
tensions, frictions, friction
hill. Maximum possible
reduction
Chalk &
Board 1,2,3
T1/17
R3/4
L24
Defects in rolled
products. Rolling
variables,
Chalk &
Board 1 T1/17
R3/4
L25 simple problems Chalk &
Board 2, 3
T1/17
R3/4
L 26 simple problems Chalk &
Board 2, 3
T1/17
R3/4
L 27
Drawing equipment & dies.
Expression for drawing
loads by slab analysis,
Power requirement
Chalk &
Board 1,2, 3,4
T1/19
R3/6
L 28
Redundant work and its
estimation, optimal cone
angle & dead zone
formation
Chalk &
Board 2,3
T1/19
R3/6
L 29
Drawing variables, Tube
drawing, C lassification of
T ube d rawing
Chalk &
Board 1 T1/19
R3/6
L 30
Simple Numericals Chalk &
Board 2,3
T1/19
R3/6
Assignment questions COs attained
1 Discuss briefly the classification of rolling processes
and rolling mills. 1
. 2. Write a brief note on i) defects in rolled products
ii) friction mill in rolling. 1
3 Establish the relation for maximum draft in rolling
(h) max = 2 R. 1, 2
4 Determine the maximum possible reduction for cold
rolling a 300 mm thick slab when = 0.08 and the roll
diameter is 600 mm. What is the maximum reduction
on the same mill for hot rolling where = 0.5?
2, 3
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 78 of 89
5 With a neat sketch explain the features of a drawing
die 1
6 Write briefly on i) Redundant work in drawing ii)
optimal cone angle 1, 2
7 With usual notations establish the following
relationship in case of plane strain strip drawing
through a tapered die. 2, 3
8 What is the maximum reduction possible per pass in
drawing aluminium rod through a die of semi die
angle 240, coefficient of friction µ = 0.01 2, 3
Course code and Title: 15ME653 Metal Forming
Module 4. Extrusion & Sheet Metal Forming Planned
Hours: 10
Lecture
No.
Portion to be covered
per lecture (class)
Teaching
method
Pos attained Cos attained Reference
book/
chapter No
L31
Types of extrusion
processes, Extrusion
equipment & dies,
deformation
Chalk &
Board
a,e,i,k.
1 T1/18
R3/5
L32 Lubrication & defects in
extrusion
Chalk &
Board 1
T1/18
R3/5
L33 Extrusion dies & Extrusion
of seamless tubes.
Chalk &
Board/ Video
1 T1/18
R3/5
L34 Extrusion variables Chalk &
Board 1
T1/18
R3/5
L35 Simple Numerical Chalk &
Board 2, 3
T1/18
R3/5
L 36
Forming methods, dies &
punches, Rubber forming
open back inclinable press
(OBI press)
Chalk &
Board/ Video
1
T1/20
R3/7
L 37
Piercing & blanking,
bending, deep drawing,
LDR in drawing
Chalk &
Board/ Video
1
T1/20
R3/7
L 38
Forming limit criterion,
defects drawn products
stretch forming
Chalk &
Board 1
T1/20
R3/7
L 39 Roll bending & contouring,
Simple Numerical
Chalk &
Board 1,2,3
T1/20
R3/7
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 79 of 89
L 40 Simple Numerical
Chalk &
Board 2,3
T1/20
R3/7
Assignment questions COs attained
1. With neat sketches explain the different types of extrusion
processes. 1
2. Write briefly on the following
i) Defect in extrusion
ii) Extrusion of tubes
iii) Production of seam less pipes and tubing.
1
3. With a neat sketch explain extrusion die. 1
4.Explain briefly the classification of sheet metal parts 1
5.Explain briefly the following
i) Shearing and blanking
ii) Bending
iii) Rubber forming
iv) Stretch forming
v) Notching & Nicking
1
6.With a neat sketch, explain the construction and working of
a progressive die. 1
7.Distinguish clearly between a progressive die and a
compound die 1
8.Discuss briefly on the presses used in high production
volume sheet metal forming 1
Course code and Title: 15ME653 Metal Forming
Module 5. High Energy Rate Forming & Powder Metallurgy Planned
Hours: 10
Lecture
No.
Portion to be covered per
lecture (class)
Teachi
ng
method
Pos attained Cos attained Reference
book/
chapter No
L41
Principles advantages and
applications of Explosive
forming
Chalk &
Board/
Video
a,e,i,k.
1 R3/7
L42
Principles advantages and
applications of Electro
hydraulic forming
Chalk &
Board/
Video
1 R3/7
L43
Principles advantages and
applications of Electromagnetic
forming,
Chalk &
Board/
Video
1 R3/7
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 80 of 89
L44 Basic steps in Powder metallurgy Chalk &
Board 1
T5/21
R3/8
L45 Brief description of methods of
production of metal powders,
Chalk &
Board 1
T5/21
R3/8
L 46 Conditioning and blending of
powders.
Chalk &
Board 1
T5/21
R3/8
L 47
Compaction methods Chalk &
Board/
Video
1 T5/21
R3/8
L 48 Sintering methods Chalk &
Board 1
T5/21
R3/8
L 49 Application of powder
metallurgy components.
Chalk &
Board 1
T5/21
R3/8
L 50 Advantages & Limitations Chalk &
Board 1
T5/21
R3/8
Assignment questions COs attained
1. What is HERF? Explain the principles and advantages
of HERF. 1
2. Describe briefly the principle, process characteristics and applications
of explosive forming process. 1
3. Describe briefly the principle, process characteristics and applications
of electro – hydraulic forming process. 1
4. Describe briefly the principle, process characteristics and applications
of electro – magnetic forming process. 1
5. Discuss the basic steps in powder metallurgy. 1
6. Enumerate and explain any two of the methods of production of metal
powders. 1
B.L.D.E.A’s
Vachana Pitamaha Dr. P.G. Halakatti College of Engineering & Technology,
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 81 of 89
BIJAPUR – 586 103
DEPARTMENT OF MECHANICAL ENGINEERING
Semester – VI
Course Title: Total Quality Management (15ME662)
2017-2018
COURSE FILE
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 82 of 89
Program Educational Objectives (PEOs)
The educational objectives of the Mechanical Engineering Program are to prepare our graduates to:
21. Establish a successful career in Mechanical Engineering or related fields in Industry and
other organizations where an engineering approach to problem solving is highly valued.
22. Develop the ability among the students to synthesize the data and technical concepts for
applications to the product design.
23. Contribute significantly in a multidisciplinary work environment with high ethical standards
and with understanding of the role of engineering in economy and the environment.
24. Excel in graduate study and research, reaching advanced degrees in engineering and related
disciplines.
25. Achieve success in professional development through life-long learning.
Program outcomes (POs)
eee. an ability to apply knowledge of mathematics, science, and Mechanical Engineering
fff. an ability to design and conduct experiments, as well as to analyze and interpret data
ggg. an ability to design a mechanical system, mechanical component, or process to meet
desired needs within realistic constraints such as economic, environmental, social, political,
ethical, health and safety, manufacturability, and sustainability
hhh. an ability to function on multidisciplinary teams
iii. an ability to identify, formulate, and solve mechanical engineering problems
jjj. an understanding of professional and ethical responsibility
kkk. an ability to communicate effectively
lll. the broad education necessary to understand the impact of mechanical engineering solutions
in a global, economic, environmental, and societal context
mmm. a recognition of the need for, and an ability to engage in life-long learning,
nnn. a knowledge of contemporary issues
ooo. an ability to use the techniques, skills, and modern mechanical engineering tools
necessary for engineering practice.
COURSE PLAN
Semester: VII Year: 2014-15
Subject: Total Quality Management Subject Code: 15ME662
Total No. of Lecture Hours: 40 I A Marks : 20
Exam Marks: 100 Exam Hours: 03
Lesson plan prepared by : Prof. B.M.Angadi
Date:04/01/2018
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 83 of 89
COURSE LEARNING OBJECTIVES:
This course enables students to
1. Understand various approaches to TQM
2. Understand the characteristics of quality leader and his role.
3. Develop feedback and suggestion systems for quality management.
4. Enhance the knowledge in Tools and Techniques of quality management
COURSE CONTENT
Module – 1 . 08 Hours
Principles and Practice: Definition, basic approach, gurus of TQM, TQM Framework,
Awareness, defining quality, historical review, obstacles, benefits of TQM.
Quality Management Systems: Introduction, benefits of ISO registration, ISO 9000 series
of standards, ISO 9001 requirements
Module – 2 08Hours
Leadership: Definition, characteristics of quality leaders, leadership concept, characteristics
of effective people, ethics, the Deming philosophy, role of TQM leaders, implementation,
core values, concepts and framework, strategic planning communication, decision making,
Module – 3
Customer Satisfaction and Customer Involvement:
Customer Satisfaction: customer and customer perception of quality, feedback, using customer
complaints, service quality, translating needs into requirements, customer retention, case studies.
Employee Involvement – Motivation, employee surveys, empowerment, teams, suggestion
system, recognition and reward, gain sharing, performance appraisal, unions and employee
involvement, case studies.
Module – 4 08 Hours
Continuous Process Improvement: process, the Juran trilogy, improvement strategies, types
of problems, the PDSA Cycle, problem-solving methods, Kaizen, reengineering, six sigma,
case studies.
Statistical Process Control : Pareto diagram, process flow diagram, cause and effect
diagram, check sheets, histograms, statistical fundamentals, Control charts, state of control,
out of control process, control charts for variables, control charts for attributes, scatter
diagrams, case studies
Module – 5 08 Hours
Tools and Techniques: Benching marking, information technology, quality management
systems, environmental management system, and quality function deployment, quality by
design, failure mode and effect analysis, product liability, total productive maintenance.
TEXT BOOKS:
1. Total Quality Management: Dale H. Besterfield, Publisher -Pearson Education India,
ISBN: 8129702606, Edition 03.
2. Total Quality Management for Engineers: M. Zairi, ISBN:1855730243, Publisher: Wood
head Publishing
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 84 of 89
REFERENCE BOOKS:
1. Managing for Quality and Performance Excellence by James R.Evans and Williuam M
Lindsay, 9th edition, Publisher Cengage Learning.
2 A New American TQM, four revolutions in management, Shoji Shiba, Alan Graham, David
Walden, Productivity press, Oregon, 1990
3. Organizational Excellence through TQM, H. Lal, New age Publications, 2008
Reference Books:
1. Engineering Optimization Methods and Applications, A Ravindran, K, M.Ragsdell,
Willey India Private Limited,2nd Edition,2006.
2. : Introduction to Operations Research- Concepts and Cases, F.S. Hillier. G.J.
Lieberman, 9th Edition, Tata McGraw Hill. 2010.
Scheme of Examination:
Two question to be set from each module. Students have to answer five full questions,
choosing at least one full question from each module
Prerequisites:
The students should have knowledge of Production Management, Industrial Organizational
Management and Operation Management.
Overview of the Course:
The course content is designed to provide the knowledge and skills required to become an efficient
Engineer by equipping students with a holistic approach towards Quality of Product and Managing the
Quality of Product involving;
1) Knowing what is meant by Quality in terms of Quality of a product
2) Understanding the importance of Quality and its maintenance
3) Study about the different methods to manage the Total Quality
4) Innovate and implement the methodologies to Improving the Quality of a product
The entire course structure is composed of understanding the meaning of Quality, Total quality,
importance of Quality, Quality control and continuous quality improvement.
The course deals with;
1) Basic know-how of Quality/Total quality/Quality control and its importance/historical review/basic
approach.
2) Contributions of TQM Gurus in terms of Evolution of TQM.
3) Quality cost and Economics of Quality cost.
4) Pro-active and Re-active improvements are different tools and techniques used in TQM
5) Kaizen, Re-engineering, Six-Sigma, Benchmarking, 5S, 3M, Poka yoke.
6) Importance and usages of QFD and FMEA.
7) Quality Management systems like ISO-9000 and ISO-14000.
8) Different ways of measuring the acceptance quality level.
COURSE OUTCOMES:
Student will be able to
1. Explain the various approaches of TQM
2. Infer the customer perception of quality
3. Analyze customer needs and perceptions to design feedback systems.
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 85 of 89
4. Apply statistical tools for continuous improvement of systems
5. Apply the tools and technique for effective implementation of TQM.
Relevance of the Course:
Manufacturing is the prime area for Mechanical Engineers. Manufacturing process is not only oriented to
manufacturing a product but more important is of “a quality product”. No doubt the mechanical engineers
should concentrate on the manufacturing process in the shop floor but also take care of quality of process
which should bring out a quality production.
Students should learn about Quality, Quality Control, Total Quality and improving the quality
continuously. For this mechanical engineers should learn, the different tools developed and followed by
the Japanese industries, which have succeeded in achieving the best quality products. Contributions of
great Quality Gurus have to be understood and implementing the same can also be put-forth. In all,
quality control engineers should try to reduce the wastage in the production and improve the efficiency of
the total production.
In this regard, mechanical engineers are involved in understanding “the need of the customer“ and then
struggle to fulfill his requirements in terms of his expectations and much more. Manufacturing involves i)
procuring raw material ii) conversion of raw material into finished goods. Here supplier and vendor are
also considered as the partners of the business. Otherwise achieving the goal of “customer satisfaction”
becomes very difficult. It begins with the knowledge provided by Gurus of Quality: Shewart, Juran,
Deming, Feigenbaum, Crosby, Ishikawa and Taguchi, who developed principles and practices along with
tools and techniques. These techniques are popularly used in the product or service realization activity.
The feedback from the customer helps to continually improve the product, service or organization system
as a whole.
Application Areas:
In the present era of globalization and liberalization, the competition in the market has increased neck
to neck. Any industry or any product to survive in the market, it should be of good quality and at lower
price. Complete satisfaction of the customer is main objective of Quality management.
Real time applications of TQM are:
1) Manufacturing Sector
2) Service sector
3) Inventory management
4) Supply Chain Management
5) Logistics Management
6) Technology Management
7) Process Management
8) Knowledge Management
9) Database Management
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 86 of 89
Module wise plan
Course Title / Code: Total Quality Management
Module - 1 Planned Hours: 08
Lesson Plan:
Lesson.
No. Topics covered
Teaching
Method
POs
Attained
COs
Attained
L1 Definition, basic approach, Chalk and
Board
f, g, i, j, k
1
L2
gurus of TQM, TQM
Framework,
awareness, defining quality,
PPT 1
L3 historical review, obstacles,
benefits of TQM.
Chalk and
Board 1
L4 Quality Management
Systems: Introduction,
benefits of ISO registration
Chalk and
Board 1
L5 ISO 9000 series
of standards
Chalk and
Board 1
L6 ISO 9001 requirements. Chalk and
Board 1
L7
ISO 9001 requirements. PPT 1
L8 ISO 9001 requirements.
PPT 1
S.No Assignment Questions COs attained
01 Explain historical review of TQM 1
02 Discuss contributions of gurus of TQM 1
03 List out ISO 9001 requirements. 1
Course Title / Code: Total Quality Management
Module - 2 Planned Hours: 08
Lesson Plan:
Lesson.
No. Topics covered
Teaching
Method
POs
Attained
COs
Attained
L9 Definition, characteristics of
quality leaders
Chalk and
Board f, g, i, j, k 2
L10 leadership concept, PPT 2
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 87 of 89
characteristics
of effective people,
L11 ethics, the Deming
philosophy
Chalk and
Board 2
L12 role of TQM leaders Chalk and
Board 2
L13 implementation,
core values,
Chalk and
Board 2
L14 concepts and framework Chalk and
Board 2
L15 strategic planning
communication, PPT 2
L16 decision making PPT 2
S.No Assignment Questions COs attained
01 List and explain characteristics of quality leaders 2
02 Explain Deming philosophy 2
03 Explain concepts and framework of total quality management 2
Course Title / Code: Total Quality Management
Module - 3 Planned Hours: 08
Lesson Plan:
Lesson.
No. Topics covered
Teaching
Method
POs
Attained
COs
Attained
L17 Customer Satisfaction: Chalk and
Board
f, g, i, j, k
3
L18 customer and customer
perception of quality PPT 3
L19 feedback, using customer
complaints,
Chalk and
Board
L20
service quality, translating
needs into requirements,
customer retention, case
studies
Chalk and
Board 3
L21
Employee Involvement –
Motivation, employee
surveys, empowerment
Chalk and
Board 3
L22
teams, suggestion
system, recognition and
reward,
Chalk and
Board 3
L23 gain sharing, performance
appraisal PPT 3
L24 unions and employee
Involvement, case studies. PPT 3
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 88 of 89
S.No Assignment Questions COs attained
01 Explain customer’s perception of quality with examples. 3
02 Briefly explain the different types of teams. 3
Course Title / Code: Total Quality Management
Module - 4 Planned Hours: 08
Lesson Plan:
Lesson.
No. Topics covered
Teaching
Method
POs
Attained
COs
Attained
L25 Continuous Process
Improvement: process
Chalk and
Board
f, g, i, j, k
4
L26
the Juran trilogy,
improvement strategies, types
of problems,
PPT 4
L27 PDSA Cycle, problem-
solving methods
Chalk and
Board 4
L28
Kaizen, reengineering, six
sigma,
case studies.
Chalk and
Board 4
L29 Pareto diagram, process flow
diagram,
Chalk and
Board 4
L30 cause and effect
diagram, check sheets,
Chalk and
Board 4
L31
histograms, statistical
fundamentals, Control charts,
state of control,
out of control process,
PPT 4
L32
control charts for variables,
control charts for attributes,
scatter
diagrams, case studies
PPT 4
S.No Assignment Questions COs attained
01 Explain Jurans triology 4
02 Explain PDSA cycle. 4
03 Explain Kaizen, six sigma and Reengineering. 4
Course Title / Code: Total Quality Management
Module - 5 Planned Hours: 08
Lesson Plan:
Lesson.
No. Topics covered
Teaching
Method
POs
Attained
COs
Attained
L33 Benching marking,
information technology,
Chalk and
Board f, g, i, j, k 5
L34 quality management PPT 5
B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03
DEPARTMENT OF MECHANICAL ENGINEERING
Page 89 of 89
systems, environmental
management system,
L35 quality function deployment Chalk and
Board 5
L36 quality by
design,
Chalk and
Board 5
L37 failure mode and effect
analysis
Chalk and
Board 5
L38 product liability, Chalk and
Board 5
L39 Total productive
maintenance. PPT 5
L40 Total productive
maintenance. PPT 5
S.No Assignment Questions COs attained
01 Explain tools and techniques used in TQM 5
Syllabus for the internal Assessment Tests (Tentative):
Test Units/Modules COs attained
Internal Assessment Test-I Module 1, 2. 1, 2
Internal Assessment Test-II Module 3, 4. 3,4
Internal Assessment Test-III Module 5. 5
Test pattern: Three questions will be given and students have to answer any two full questions.
Each question carries 12.5 marks.
Evaluation Scheme:
Assessment Marks
Internal Assessment tests 15
Assignments/Quiz/seminar 05
VTU Semester examination 80
Total 100