AUTOMOBILE ENGINEERING DIPLOMA PROGRAM

Final Version REVISED CURRICULUM OF

AUTOMOBILE ENGINEERING DIPLOMA PROGRAM IN MULTI POINT ENTRY & CREDIT SYSTEM PART-II

For the State of Meghalaya

National Institute of Technical Teachers’ Training & Research Block – FC, Sector – III, Salt Lake City, Kolkata – 700 106

June 2015

NI T T T

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K O L K A T A

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Table of Contents

(Part-II) Topic Page No. 1. Structure of MPECS 1-7 2. Structure of Sample Path 8-13 3. Detailed Course Content

Meghalaya/Automobile/Part-II/Final/June 2015 iii

Scheme of Studies and Evaluation (MPECS) DIPLOMA IN AUTOMOBILE ENGINEERING

1. FOUNDATION COURSES FOR AUTOMOBILE ENGINEERING:

Sl. No

Code Course Study Scheme Evaluation Scheme Total Marks

Credit Pre-requisite

Contact Hour/Week Theory Practical L T P End

Exam Progressive Assessment End

Exam Progressive Assessment

Class Test

Assignment

Attendance

Sessional

Viva

1 G101 Communication Skill-I 2 0 2 70 15 10 5 0 25 0 125 3 2 G102 Communication Skill -

II G 101 2 0 2 70 15 10 5 0 25 0 125 3

3 G103 Mathematics-I 4 1 0 70 15 10 5 0 0 0 100 5 4 G103 Mathematics-II G- 103 4 1 0 70 15 10 5 0 0 0 100 5 5 G106 Physics-I 2 0 2 70 15 10 5 25 25 0 150 3 6 G107 Physics II G 106 2 0 2 70 15 10 5 25 25 0 150 3 7 G108 Chemistry-I 2 0 2 70 15 10 5 25 25 0 150 3 8 G109 Chemistry II G 108 2 0 2 70 15 10 5 25 25 0 150 3

TOTAL 20 2 12 560 120 80 40 100 150 0 1050 28

Meghalaya/Automobile/Part-II/Final/June 2015 iv

2. HARD CORE COURSES FOR AUTOMOBILE ENGINEERING:

Sl. No






Class Test

Assignment

Attendance

Sessional

Viva

1. G201 Engineering Drawing -I 1 0 4 0 0 0 0 0 50 0 50 3 2. G202 Engineering Drawing II G201 1 0 4 0 0 0 0 0 50 0 50 3 3. G203 Workshop Practice-I 0 0 4 0 0 0 0 0 25 25 50 2 4. G204 Workshop Practice II G203 0 0 4 0 0 0 0 0 25 25 50 2 5. G206A Engineering Mechanics G 106

& G 107

3 0 2 70 15 10 5 0 25 25 150 4

6. G205A Introduction to Information Technology

2 0 3 50 0 0 0 25 50 0 125 4

TOTAL 7 0 21 120 15 10 5 25 250 50 475 18

Meghalaya/Automobile/Part-II/Final/June 2015 v

3. SOFT CORE COURSES FOR AUTOMOBILE ENGINEERING: (Any TWO to be taken in addition to G301 and G302)

Sl. No





End Exam

Progressive Assessment

Class Test

Assignment

Attendance

Sessional

Viva

1. G301 Development of Life Skill-I

1 0 2 - - - - - 25 25 50 2

2. G302 Development of Life Skill-II

1 0 2 - - - - - 25 25 50 2

3. G303

Engineering Economics & Accountancy

3 0 0 70 15 10 5 - - - 100 3

4. G304 Entrepreneurship Development

3 0 0 70 15 10 5 - - - 100 3

5. G305 Principles of Management

3 0 0 70 15 10 5 - - - 100 3

6. G306 Organizational Behaviour

3 0 0 70 15 10 5 - - - 100 3

7. G307 Environmental Education

3 0 0 70 15 10 5 - - - 100 3

TOTAL 8 0 4 140 30 20 10 - 50 50 300 10

Meghalaya/Automobile/Part-II/Final/June 2015 vi

4. BASIC TECHNOLOGY COURSES FOR AUTOMOBILE ENGINEERING

Sl. No






Class Test

Assignment

Attendance

Sessional

Viva

23 AE401 Strength of Materials G206A 3 0 0 70 15 10 5 0 0 0 100 3 24 AE402 Heat Power Engineering. G106 &

G107 3 0 0 70 15 10 5 0 0 0 100 3

25 AE403 Automobile Engines I 3 0 2 70 15 10 5 0 25 25 150 4 26 AE404 Machine Drawing 0 0 6 0 0 0 0 0 50 0 50 3 27 AE405 Manufacturing

Technology – I 3 0 0 70 15 10 5 0 0 0 100 3

28 AE406 Theory of Machines 3 0 0 70 15 10 5 0 0 0 100 3 29 AE407 Workshop Practice -III G203 &

G204 0 0 6 0 0 0 0 0 50 0 50 3

30 AE408 Fluid Mechanics, oil Hydraulics & Pneumatics

G206A 3 0 2 70 15 10 5 25 25 0 150 4

31 AE409 Elements of Electrical Engineering.

G106 & G107

3 0 2 70 15 10 5 0 25 25 150 4

32 AE410 Machine Design AE 410 3 0 0 70 15 10 5 0 0 0 100 3 33 AE411 Basic Electronics 105,106

AE409 3 0 2 70 15 10 5 0 25 25 150 4

34 AE412 Automobile Drawing AE 412 1 0 4 0 0 0 0 0 50 0 50 3 TOTAL 28 0 24 630 135 90 45 25 250 75 1250 40

Meghalaya/Automobile/Part-II/Final/June 2015 vii

5. APPLIED TECHNOLOGY COURSES FOR AUTOMOBILE ENGINEERING

Sl. No






Class Test

Assignment

Attendance

Sessional

Viva

1. AE 501 Motor Vehicle Act 3 0 0 70 15 10 5 0 0 0 100 3 2. AE 502 Installation, Maintenance

& Garage Practice 3 0 0 70 15 10 5 0 0 0 100 3

3. AE503 Automobile Engines- II AE 403 3 0 2 70 15 10 5 0 25 25 150 4 4. AE504 Automobile Power

Train 3 0 2 70 15 10 5 0 25 25 150 4

5. AE 505 Automobile Electronics AE 409 3 0 2 70 15 10 5 0 25 25 150 4 6. AE506 Automobile Chassis 3 0 2 70 15 10 5 0 25 25 150 4 7. AE507 Automobile

Workshop – I 1 0 4 0 0 0 0 0 50 25 75 3

8. AE 508 Manufacturing Technology- II

3 0 0 70 15 10 5 0 0 0 100 3

9. AE509 Auto Machine Shop 1 0 4 0 0 0 0 0 50 25 75 3 10. AE 510 Automobile

Workshop – II AE 507 0 0 4 0 0 0 0 0 50 25 75 2

11. AE511 Projects and Driving Practices

2 0 6 0 0 0 0 0 150 100 250 4

12. AE512 Professional Practices-I 0 0 2 0 0 0 0 0 50 0 50 1 13. AE513 Professional Practices-II 0 0 2 0 0 0 0 0 50 0 50 1 14. AE514 Professional Practices-III 0 0 2 0 0 0 0 0 50 0 50 2 15. AE515 Professional Practices-IV 0 0 4 0 0 0 0 0 50 0 50 2 16. AE516 Professional Practices-V 0 0 4 0 0 0 0 0 50 0 50 2

TOTAL 25 0 40 420 105 70 35 0 650 275 1625 45

Meghalaya/Automobile/Part-II/Final/June 2015 viii

6. ELECTIVE COURSES FOR AUTOMOBILE ENGINEERING (Any THREE to be taken) Sl. No






Class Test

Assignment

Attendance

Sessional

Viva

1. AE601 Automotive Air Conditioning

AE 402 3 0 0 70 15 10 5 0 0 0 100 3

2. AE 602 Automotive Heavy Equipment

3 0 0 70 15 10 5 0 0 0 100 3

3. AE603 Design & Fabrication of Automobiles

AE 504, AE 506

3 0 0 70 15 10 5 0 0 0 100 3

4. AE 604 Welding Technology

AE 407 3 0 0 70 15 10 5 0 0 0 100 3

5. AE 605 Renewable Sources of Energy

AE 402 3 0 0 70 15 10 5 0 0 0 100 3

TOTAL 9 0 0 210 45 30 15 0 0 0 300 9

Meghalaya/Automobile/Part-II/Final/June 2015 ix

SAMPLE PATH- TERM - I

Sl. No


Credit Pre-

requisite Contact Hour/Week Theory Practical L T P End



Class Test

Assignment

Attendance

Sessional

Viva

1 G101 Communication Skill-I 2 0 2 70 15 10 5 0 25 0 125 3 2 G103 Mathematics-I 4 1 0 70 15 10 5 0 0 0 100 5 3 G106 Physics-I 2 0 2 70 15 10 5 25 25 0 150 3 4 G108 Chemistry-I 2 0 2 70 15 10 5 25 25 0 150 3 5 G201 Engineering Drawing -I 1 0 4 0 0 0 0 0 50 0 50 3 6 G203 Workshop Practice-I 0 0 4 0 0 0 0 0 25 25 50 2 7 G205A Introduction to

Information Technology 2 0 3 50 0 0 0 25 50 0 125 4

TOTAL 13 1 17 330 60 40 20 75 200 25 750 23

Meghalaya/Automobile/Part-II/Final/June 2015 x

SAMPLE PATH- TERM - II

Sl. No


Credit Pre-

requisite




Class Test

Assignment

Attendance

Sessional

Viva

1 G102 Communication Skill -II G 101 2 0 2 70 15 10 5 0 25 0 125 3 2 G104 Mathematics II G 103 4 1 0 70 15 10 5 0 0 0 100 5 3 G107 Physics II G 106 2 0 2 70 15 10 5 25 25 0 150 3 4 G109 Chemistry II G 108 2 0 2 70 15 10 5 25 25 0 150 3 5 G202 Engineering Drawing II G201 1 0 4 0 0 0 0 0 50 0 50 3 6 G204 Workshop Practice II G203 0 0 4 0 0 0 0 0 25 25 50 2 7 G206A Engineering Mechanics G 106

& G 107

3 0 2 70 15 10 5 0 50 0 150 4

8 G301 Development of Life Skill-I

1 0 2 0 0 0 0 0 25 25 50 2

9 AE512 Professional Practice I 0 0 2 0 0 0 0 0 50 0 50 1 TOTAL 15 1 20 350 75 50 25 50 275 50 875 26

Meghalaya/Automobile/Part-II/Final/June 2015 xi

SAMPLE PATH- TERM – III

Sl. No


Credit Pre-




Class Test

Assignment

Attendance

Sessional

Viva

1 AE401 Strength of Materials 3 0 0 70 15 10 5 0 0 0 100 3 2 AE402 Heat Power

Engineering. 3 0 0 70 15 10 5 0 0 0 100 3

3 AE403 Automobile Engines I 3 0 2 70 15 10 5 0 25 25 150 4 4 AE404 Machine Drawing 0 0 6 0 0 0 0 0 50 0 50 3 5 AE405 Manufacturing

Technology – I 3 0 0 70 15 10 5 0 0 0 100 3

6 AE406 Theory of Machines 3 0 0 70 15 10 5 0 0 0 100 3 7 AE407 Workshop Practice -

III 0 0 6 0 0 0 0 0 50 0 50 3

8 AE409 Elements of Electrical Engineering.

3 0 2 70 15 10 5 0 25 25 150 4

9 AE513 Professional Practice-II

0 0 2 0 0 0 0 0 50 0 50 1

10 G302 Development of Life Skill – II

1 0 2 0 0 0 0 0 50 0 50 2

TOTAL 19 0 20 420 90 60 30 0 250 50 900 29

Meghalaya/Automobile/Part-II/Final/June 2015 xii

SAMPLE PATH- TERM – IV

Sl. No


Credit Pre-

requisite




Class Test

Assignment

Attendance

Sessional

Viva

1 AE410 Machine Design 3 0 0 70 15 10 5 0 0 0 100 3 2 AE408 Fluid Mechanics, oil

Hydraulics & Pneumatics

3 0 2 70 15 10 5 0 25 25 150 4

3 AE412 Automobile Drawing 1 0 4 0 0 0 0 0 50 0 50 3 4 G303-

G307 Soft Core- III (Environmental Education)

3 0 0 70 15 10 5 0 0 0 100 3

5 AE503 Automobile Engine- II 3 0 2 70 15 10 5 0 25 25 150 4 6 AE411 Basic Electronics 105,106

AE409 3 0 2 70 15 10 5 0 25 25 150 4

7 AE507 Automobile Workshop – I

1 0 4 0 0 0 0 0 50 25 75 3

8 AE509 Auto Machine Shop 1 0 4 0 0 0 0 0 50 25 75 3 9 AE514 Professional Practice

III 1 0 2 0 0 0 0 0 50 0 50 2

TOTAL 19 0 20 350 75 50 25 0 275 125 900 29

Meghalaya/Automobile/Part-II/Final/June 2015 xiii

SAMPLE PATH- TERM - V

Sl. No


Credit Pre-




Class Test

Assignment

Attendance

Sessional

Viva

1 AE 501 Motor Vehicle Act 3 0 0 70 15 10 5 0 0 0 100 3 2 AE 502 Installation

Maintenance and Garage Practice

3 0 0 70 15 10 5 0 0 0 100 3

3 AE504 Automobile Power Train

3 0 2 70 15 10 5 0 25 25 150 4

4 AE 505 Automobile Electronics

3 0 2 70 15 10 5 0 25 25 150 4

5 AE506 Automobile Chassis 3 0 2 70 15 10 5 0 25 25 150 4 6 AE 508 Manufacturing

Technology- II 3 0 0 70 15 10 5 0 0 0 100 3

7 G303 –G307

Soft Core -IV (Entrepreneurship Development).

3 0 0 70 15 10 5 0 0 0 100 3

8 AE 510 Automobile Workshop – II

0 0 4 0 0 0 0 0 50 25 75 2

9 AE515 Professional Practice-IV

0 0 4 0 0 0 0 0 50 0 50 2

TOTAL 21 0 14 420 90 60 30 0 175 125 975 28

Meghalaya/Automobile/Part-II/Final/June 2015 xiv

SAMPLE PATH- TERM – VI

Sl. No


Credit Pre-




Class Test

Assignment

Attendance

Sessional

Viva

1-3 AE601- AE605

Elective I 3 0 0 70 15 10 5 0 0 0 100 3 Elective II 3 0 0 70 15 10 5 0 0 0 100 3 Elective III 3 0 0 70 15 10 5 0 0 0 100 3

4 AE511 Projects and Driving Practices

2 0 6 0 0 0 0 0 150 100 250 4

5 AE516 Professional Practice V *

0 0 4 0 0 0 0 0 50 0 50 2

TOTAL 11 0 10 210 45 30 15 0 200 100 600 15

*This includes seminar & Viva on Project.

Meghalaya/Automobile/Part-II/Final/June 2015 1

STRANGTH OF MATERIALS L 3

T 0

P 0

Curri. Ref. No.: AE 401

Total Contact hrs.: 45 Theory: 45 Practical: 0 Prerequisite: G206A Total Credit: 3

Total Marks: 100 Theory: End Term Exam: 70 P.A.: 30 Practical: End Term Exam: 0 P.A.: 0

UNIT TOPIC/SUB-TOPIC HRS. TOTAL

HRS. 1.0 INTRODUCTION :

3

1.1 Scope of the subject Use of the structures, importance of knowledge of – stress strain and deformation in a structure, permissible stresses in a materials, safety and economic. Contents and importance of the subject.

1.2 Engineering Materials : Elastic Materials, linearly elastic materials, ductile materials brittle materials, composite materials, isotropic materials, orthotropic materials (Definition), examples and application. - Identify different engineering materials in specific application.

2.0 STRESS AND STRAIN: 10 2.1 Introduction: Definition of stress; Type of stress:-tensile,

compressive and shear.

2.2 Stress strain Relation: Hook’s law, Young’s Modulus of rigidity, Poisson’s ratio, generalize Hook’s law for two dimensional stresses, relation among the elastic constant for an isotropic materials. - Distinguish among different elastic constant for a material.

2.3 Stresses, strain and deformation of axially loaded member:-Bars of varying section, taper rope, bars of composite section, rod and tube connected by boiled joint, temperature stresses and shuttering of axially loaded members - Solving Simple problems on determination of stresses and shortening of axially loaded members.


UNIT TOPIC/SUB-TOPIC HRS. TOTAL HRS.

3.0 STRESSES IN BEAM: 10 3.1 Beam: definition, types of beams – simple supported and

container beams, propped container, fixed – ended and continuous beams. - Identify deferent types of beams and loading condition. - Determine the support reactions and draw the free body diagram of determinate beams.

3.2 Sharing force and bending moment in beams; sign convention and relationship among load, sharing force and B.M.

3.3 Shear force and B,M. diagrams: contravener beam with concentrated and Uniformly distributed load, simply supported beam with uniformly distributed and verging load. - Draw the shear force and bending moment diagrams of beam with given load on it.

4.0 SIMPLE BENDING OF BEAM. 6 4.1 Centroid of an area, moment of inertia of beam cross-

section, parallel axis theorem, principal moments of inertia.

4.2 Assumptions in simple bending, neutral surface, neutral axis determination of bending stresses in beams with simple cross sections and standard sections used in industry. - Determine the moment of inertia, section modulus and moment of resistance of beam cross- section. - Determine the bending stresses in a beam under pure bending.

5.0 DEFLECTION OF BEAMS: 6 5.1 Member bending into a circular are slope, deflection and

radius of curvature.

5.2 Derivation of formula for slope and deflection, cantilever propped cantilever beam.

5.3 Mohr’s Theorem, relation between maximum bending stress and maximum deflection, beams of varying section, strain energy store due to bending, law of reciprocal deflection. - Determine the deformation produced by a bending moment. - Calculation the deflection under the load and draw bending moment diagrams.

6.0 TORSION: 5 6.1 Basic assumption for pure torsion of circular shafts (hollow

and solid, no proof)- Polar moment of inertia, torsion shearing stress, angle of twist; Tensional rigidity. - Deter the maximum shear stress and angle of position shaft transmitting given tongues.



HRS. 6.2 Applications: Hose power transmitted by a shaft moment

transmitted by a key, horse power Transmitted by a flange coupling with bolts, stiffness of closed coil helical spring (no proof). - Apply the tension formula in determination of (a) safe power transmitted by a flange coupling (b) stiffness of helical spring.

7.0 WELDED CONNECTIONS: 5 7.1 Process of welding, Advantages and disadvantages of

welding connection.

7.2 Types welds – minimum sizes of weld, effective length, minimum length, fillet welds applied to the adzes of a plate.

7.3 Angle between fusion faces, throat thickness. 7.4 Intermitted fillet welds lop joints and fillet welds in slots or

hours. - Bending about a single fillet, permissible stresses in welds. - Determine the load in the welds and greatest resistance offered by the weld in length. - To find the stresses in the welds.

REFERENCE BOOKS: 1. S. P. Timoshenko, D. H. Young; Elements of Strength of materials - Affiliated

East – West Press Private Limited. 2. R. K. Bansal; Engineering Mechanics and Strength of materials - Laxmi

Publications, New Delhi 3. Surendra Singh; Strength of Materials - Vikas Publishing House Pvt. Ltd. 4. Ferdinand L. Singer; Strength of materials - Harper & Row and John

Weatherbill. 5. William A. Nash; Theory and Problems of Strength of Materials - Shaum’s

outline of - Shaum’s Outline Series, McGraw Hill. Inc. 6. Egor P. Popov; Engineering Mechanics of Solids - Prentice Hall of India

Private Limited, New Delhi. 7. R.S. Khurmi, Strength of Materials - S. Chand & Company Ltd., New Delhi. 8. Dr. Sadhu Singh; Strength of Materials - Khanna Publishers, Delhi-110 006. 9. S. Ramamrutham; Engineering Mechanics & Strength of Materials - Dhanpat

Rai Publishing Co., Delhi – 110 006. 10. A. C. Ugural; Mechanics of Materials - McGraw Hill. Inc 11. D.R. Malhotra and H.C. Gupta; Strength of Materials - Satya Prakashan, New

Delhi – 110 005. 12. B. K. Sarkar; Strength of Materials Through Problems - Allied Publishers

Limited, New Delhi – 110 002.


HEAT POWER ENGINEERING L 3

T 0

P 0


Total Contact hrs.: 45 Theory: 45 Practical: 0 Prerequisite: G106 & G107 Total Credit: 3


RATIONALE: Amount of useful energy produced and spent is the most important factor by which a country’s technical advancement is measured. Useful mechanical and electrical energy is produced from heat energy. It is of paramount importance to an engineer to know the basic principles by which heat energy can be converted into mechanical energy, which in turn can be converted into electrical energy.

Thermodynamics is the field of applied science which deals with the energy possessed by heated gases and vapours and the laws which govern the conversion of this energy into mechanical energy and vice versa. This is the fundamental subject for understanding the process of producing vast amount of mechanical energy from heat energy and therefore necessary to be learned by the engineering students. Understanding the working principles and features of the various machines and plants in which either such heated gas/vapours are produced or conversion of heat to mechanical energy takes place is of great importance. AIM:

To have a clear understanding of the subject “Thermodynamics” and its importance for automobile engineers. Students will know and understand the physical significance of first law and second law of thermodynamics. They will also learn about the thermodynamic properties of gases and steam which acts as the thermodynamic medium and how heat energy contained in the medium is converted to mechanical energy by passing through cyclic thermodynamic processes. Students will also learn the properties of steam, how steam is produced commercially in a boiler. Students will also have basic understanding of various heat engines like steam Engine, Steam Turbine and I.C. Engines.



HRS. 1.0 INTRODUCTION :

2

Impor Importance of conversion of heat energy into mechanical energy and electrical energy; definition of Thermodynamics; concept of heat engines.

2.0 FUNDAMENTALS OF THERMODYNAMICS :

6

2.1 Definition and understanding of terms :

Energy, work, power, law of conservation of energy, heat, units of heat, temperature, absolute temperature, pressure, absolute and gauge pressure, specific heat.

2.2 Thermodynamic system; closed, open and isolated systems; system boundary; properties of a thermodynamic system; concept of work and heat energy transfer to and from a system

• State relationship between : work and power, Centigrade and Fahrenheit scale of temperature, work and heat energy

• Distinguish between absolute pressure and gauge pressure

• Understand a thermodynamic system

• Differentiate between closed, open and isolated system

3.0 PROPERTIES OF GASES

6

3.1 Gas as the working substance in a thermodynamic system; definition of gas and perfect (or ideal) gas; laws of perfect gases—Boyle’s law, Charle’s law and Gay-Lussac law with corresponding gas equations; characteristic gas equation pv = mRT; problems.



HRS.

3.2

Specific heat of gas; specific heat at constant volume and at constant pressure; work done by gas during expansion; internal energy; relation between two specific heats (Cp – Cv = R/J; Cp/Cv = 1 + R/JCv); simple problems. • Define an ideal (or perfect) gas

• State three laws of perfect gases

• Write mathematical expression for the three gas laws

• Deduce characteristic equation of gas from the gas laws • Solve problems on gas laws

• Explain why Cp>Cv

• Prove Cp-Cv = R/J and Cp/Cv = 1 + R/JCv

• Solve problems on specific heats of gas

4.0 LAWS OF THERMODYNAMICS : 6

Thermal equilibrium; statement of Zeroth law; first law of thermodynamics; mechanical equivalent of heat; non flow energy equation (heat added = work done + rise in internal energy); second law of thermodynamics-statements; physical significance of second law. • Understand meaning of first and second law of

thermodynamics

• Justify that second law does not contradict first law

5.0 THERMODYNAMIC PROCESSES OF PERFECT

GASES :

6

5.1 Definition of thermodynamic (or non-flow) process; P-V diagram; constant volume, constant pressure, isothermal, adiabatic, polytropic and throttling processes



5.2 Representing above processes in p-v diagram; estimation

of pressure, volume, temperature, heat absorbed, work done, change of internal energy during above thermodynamic processes; simple problems

• Understand meaning of thermodynamic process

• Draw p-v diagrams for different thermodynamic processes

• Deduce formulae for work done by gas in (i) Constant pressure, (ii) isothermal expansion,

(iii) adiabatic expansion.

• Solve simple problems on thermodynamic processes

6.0 THERMODYNAMIC AIR CYCLES : 6

Definition of thermodynamic cycle; representation of a cycle in P-V diagram; work done in the cycle; reversible and irreversible cycle; working of an ideal engine; efficiency of a cycle; Carnot cycle in P-V; expressions for work done and efficiency; simple problems on air cycles.

• Explain thermodynamic cycle

• Represent a cycle in the p-v diagram and identify the work done per cycle

• Draw a Carnot cycle in P-V diagram

• Solve problems on air cycles.

7.0 INTERNAL COMBUSTION (IC) ENGINE

8

7.1 Function and use of IC engines 7.2 Classification of IC engines; working principle of 2 stroke

and 4 stroke cycles IC engines; SI engine and CI engine; Ott cycle; Diesel cycle. Solving simple problems on I.C. engine performance.



8.0 AIR COMPRESSOR 5 8.1 Types of Air Compressor 8.2 Working principle of positive displacement Air

Compressors 8.3 PV Diagram 8.4 Power absorbed in compressor 8.5 Other types of compressor • Screw Compressor • Centrifugal Compressor 8.6 Valves in reciprocating compressor 8.7 Maintenance aspects of air compressors. REFERENCE BOOKS: 1. V. P. Vasandani & D. S. Kumar: Heat Engineering - Metropolitan Book Co. (P)

Ltd. 2. R. S. Khurmi : A text book of Engineering Thermodynamics – S. Chand & Co.

Ltd. 3. B. K. Sarker : Thermal Engineering – TMH

4. P. L. Ballaney : Thermal Engineering – Khanna Publishers

5. K. C. Pal : Heat Power – Orient Longman

6. Pandya & Shah : Elements of Heat Engines – Charotar Publishing House

7. S. L. Somasundaram : Thermal Engineering – New Age International (P) Ltd.

8. S.R. Majumdar: Pneumatic Systems - Principles and Maintenance-Tata McGraw

Hill


AUTOMOBILE ENGINES – I L 3

T 0

P 2

Curri. Ref. No. : AE 403

Total Contact hrs. : 75 Theory: 45 Practical: 30 Pre requisite: Nil Credit: 4

Total Marks: 150 Theory: End Term Exam: 70 P.A.: 30 Practical: End Term Exam: 0 P.A : 50

RATIONALE: Automotive industry is one of the major industrial sectors in the country. A large number of people are employed in engine maintenance and repair. The automotive industry needs technically qualified people. Each year, improvements on the new models of automobiles make their repair or adjustment more complex and difficult but also more interesting and rewarding to the trained men. Tremendous research and development programs, public demand, and competition among car manufactures have produced automobiles with more power, comfort and economy. In these circumstances the study of automotive engines is a must for the diplomats in automobile engineering. AIM: The aim of this subject is to enable students to understand the basic construction and working principle of internal combustion engines, cooling systems of the engines, mechanical and power balance of multi-cylinder engines.


THEORY: 45 HRS.


1.0 INTRODUCTION 7 1.1 Definition of automobile 1.2 Classification of automobiles with regard to the

following:

a) Purpose : passenger, goods b) Fuel used : petrol, diesel, CNG etc. c) Number of wheels : six-wheeler, four-wheeler, three-

wheeler, two wheeler

d) Drive : six wheel, four wheel, two wheel e) Construction: single unit, articulated vehicles and

tractors.

1.3 Parts of an automobile : a) Basic structure : frame, suspension system, axles,

wheels and tyres

b) Engine c) Transmission system : clutch, gear box, propeller

shaft, rear axle, differential gear

d) Auxiliaries – electrical systems e) Controls – steering system and brakes f) Superstructure – body. 1.4 Factors in describing an automobile: types capacity,

drive, make, model.

1.5 Technical specification of an automobile: engine, power

transmission, chassis, weights, driving performances.

• Classify automobiles according to different criteria

• Write technical specification of an automobile

• List the main parts of an automobile



2.0 ENGINE 10 2.1 Construction and functions of different parts of

conventional internal combustion engine. − Cylinder block, crank case, cylinder head, oil

pan or sump, manifolds, gaskets, cylinder liners, pistons, piston rings, connecting rods, piston pins, crankshaft, main bearings, valves, valve actuating mechanisms, mufflers.

2.2 Classification of engines according to different

criteria as following : -

2.2.1 Cylinder arrangements: four cylinder in-line

engines, eight-cylinder in-line engines, V-8 engines, twelve and sixteen-cylinder engines, radial engine.

2.2.2 Valve arrangements :

L-head engine, I-head engine, F-head engine, V-8 valve arrangements

2.2.3 Cooling : air cooled and liquid cooled 2.2.4 Cycles : two stroke cycle, four stroke cycle 2.2.5 Fuel: petrol, diesel, liquefied petroleum gas.

• Describe the construction of different parts of an I.C. engine

• Explain the functions of the main parts of an I.C. engine

• Classify the engines according to different criteria.

3.0 WORKING PRINCIPLE OF I.C. ENGINE 20 3.1

Construction of an IC engine: Cylinder block, cylinder head, piston, piston ring, crank shaft, connecting rod, crank case, valve mechanism, manifold.

• Explain working principle of a 4 stroke IC engine through sketches

• Identify various components of an IC engine and state their constructional features

Compare between S.I. and C.I. engines


3.2 Processes : suction of air fuel mixture, compression of air fuel mixture, ignition of fuel remove, air mixture, power development, exhaust of used gases

3.3 Cycle of operation of 4-stroke petrol engine –

suction stroke, compression stroke, power stroke, exhaust stroke

3.4 Cycle of operation for two stroke petrol engine

- first stroke (induction and compression), second stroke (power, transference and exhaust)

3.5 Cycle of operation for four-stroke diesel engine –

suction stroke, compression stroke, injection, power stroke, exhaust stroke.

3.6 Cycle of operation for two-stroke diesel engine –

first stroke (compression and injection), second stroke (power, exhaust and induction).

3.7 Scavenging in two stroke engine

- blow down period, lead in exhaust opening, lag in closing, cross scavenging, loop scavenging

3.8 Functions of different components related to intake

and exhaust of gases in petrol engine: carburetor, induction manifold, intake port, intake valve, exhaust valve, exhaust port, exhaust manifold (exhaust pipe, muffler, tail pipe)

3.9 Functions of different components related to intake

and exhaust of gases in diesel engine: air cleaner, induction manifold, intake port, intake valve, exhaust valve, exhaust port, exhaust manifold, silencer.

3.10 Factors affecting power output of engine: piston

displacement, quantity of fuel air mixture, throttle valve, opening, engine speed, atmospheric pressure, compression ratio, opening of valves, ignition timing, type of fuel, engine friction, moisture present in the air.

• Describe the working principle of an I.C. engine

• List the main parts related to intake and exhaust system

• Describe the functions of different parts of intake and exhaust systems.

7



4.0 ENGINE COOLING SYSTEM 8 4.1 Introduction : Definition; function of cooling system;

types of cooling system : air cooling system; water cooling system

4.2 Air cooling system 4.3 Liquid cooling system 4.3.1 Thermosyphon system 4.3.2 Pump circulation system –

Radiator: tubular, grilled tube, honey comb; radiator cap; overflow tank; fan; water pump; Thermostat valve: bellows type, sleeve type, butterfly type; temperature indictor or gauge: vapour pressure type, electric type.

4.4 Antifreeze solutions - definition, characteristics,

examples.

• Describe different types of cooling system

• Explain the use of antifreeze solutions.

5.0 PRACTICAL 30 5.1 Servicing of cylinder head 5.2 Servicing of valves and valve mechanism 5.3 Servicing of piston 5.4 Study of cylinder block (construction, material, crack

detection)

5.5 Servicing of crankshaft and main bearings (cleaning,

inspection, dimensions)

5.6 Testing of following items of the cooling system :

thermostat, water pump, radiator cap, fan belt

5.7 Cleaning the cooling system.


REFERENCE BOOKS: 1. Dr. Kirpal Singh, Automobile Engineering - Vol. I and II, Standard Publishers

Distributors 2. Harbans Singh Reyat – The Automobile: S. Chand & Company Ltd. 3. William H. Crouse and Donald L. Anglin - Automotive Mechanics:

Tata McGraw Hill Publishing Company Ltd., New Delhi 4. Shyam K. Agrawal - Internal combustion Engines : New Age International (P)

Limited, Publishers 5. K. Newton, W. Steeols, T. K. Garrett - The Motor Vehicle: Butterworth

Heinemann. 6. Joseph Heitner – Automotive Mechanics: Principles & Practices, CBS

Publishers & Distributors. 7. Dr. Amitosh De “Automobile Engineering” Galgotia Publication, New Delhi.


MACHINE DRAWING L 0

T 0

P 6

Curri. Ref. No: AE404

Total Contact hrs.: 90 Theory: 0 Practical: 50 Credit: 3

Total marks: 50 Practical: End Term Exam: 0 P.A: 50

RATIONALE: For learning and practicing mechanical engineering use of mechanical drawing is most essential. With the advent of computers, knowledge of Computer-Aided Drawing making has become a must in industries. Thus knowledge and practice of mechanical engineering in the CAD environment is a must for a mechanical engineer. AIM: Students will be able to understand and produce drawings of various mechanical components and devices and should be conversant with CAD operation. UNIT TOPIC/SUB-TOPIC HRS. TOTAL

HRS. 1.0 INTRODUCTION : 9 1.1 Specification of Standard Mechanical Components

(a) Hexagonal bolts and nuts : Precision and semi precision bolts (IS : 1364 – 1967), hexagonal bolts (IS : 3640 – 1967), square bolts, screws and nuts (IS : 2585 – 1963), hexagonal socket head cap screws (IS: 2269-1967), slotted counter-slink head screws (IS : 1365 - 1968), slotted cheese head screws (IS: 1366-1968), STUDS (IS: 1862-1975), slotted and costle – nuts (IS : 2232-1967). (b) Washers – plain washers (IS : 2016-1967) (c) Keys – Taper keys and key ways (IS : 2292-1974) (d) Splines ( IS : 2327) (e) Miscellaneous pins – cylindrical pins (IS : 2393-1980) taper pins ( IS : 6688 – 1972) (f) Circlips – external and internal (g) Rivets ( IS : 2155) (h) Oil Seals – rotary shaft oil seals (IS : 5129), O-rings (i) Ball bearings Select a standard machine component from IS codes or design hand books to use in machine drawing.



1.2 Limits, Tolerances and Fits (IS: 919 Part I and II) (i) Limit system – Tolerance, limits, deviation, allowance, basic size, design size, (ii) Tolerances – Fundamental tolerances, fundamental deviation, method of placing limit dimensions. (iii) Fits – Clearance fit, transition fit, interference fit, hole basis system, shaft basis system, tolerance grades.

Calculate the values of clearance / interference, hole tolerance and shaft tolerance with given basic size for common assemblies like H7 / g6, H7/m6, H8 / u7.

1.3 Surface Roughness

(a) Introduction – actual profile, reference profile, datum profile, mean profile, peak-to-valley height, mean roughness index, surface roughness number. (b) Use of machining symbols in production drawings (c) Indication of surface roughness

Indication of special surface roughness characteristics, indication of machining allowance, indication of surface roughness, symbols on drawings, method of indicating surface roughness on a given component.

• Show how the roughness is indicated on a component for

(a) surface to be obtained by any production method (b) surface to be obtained without removal of material.

2.0 ISOMETRIC DRAWINGS OF MACHINE PARTS 9 3.0 ASSEMBLY DRAWING AND DETAILED DRAWING OF

MACHINES 12

i. I.C. Engine piston, petrol engine connecting rod. ii. Revolving, centre, square tool post

iii. Hydraulic cylinder iv. Crane hook v. Spindle assembly

Prepare the assembly drawing and the part drawings providing necessary tolerances, fits, between mating parts and surface finishes.

4.0 KEYS AND COTTERS 6 4.1 Keys and Splines

• Draw different forms of keys in position

4.2 Cotter joint, kunckle joint, Universal joint • Draw the three principal views (with local section,

if necessary) of the assembly of above joints.

5.0 SHAFT COUPLING 6 5.1 Rigid coupling, Flange Coupling, and Muff Coupling



5.2 Non-rigid or Flexible coupling: Pin-bush coupling, Universal Coupling or Hooke’s joint. Draw the three principal views of the coupling (with local Section if necessary).

6.0 BEARINGS (ANY ONE) 6 6.1 Foot step bearing, bracket 6.2 Ball bearing mounted on a shaft

Draw the principal views of foot step bearing and plummer block (with local sections if necessary)

7.0 STRUCTURAL DRAWING 15 7.1 Drawings of riveted structure with the following types of

riveted joints single riveted, double riveted (chain, Zig-gag), lap joint, butt joint. Draw two views of a riveted joint with given rivet diameter and plate thickness.

7.2 Drawing of welded structures with following types of

welds and their symbols fillet, square butt, single V butt, double V butt, single U- butt, double U-butt, single level butt, double level butt, single J-butt, double J-butt, stud, bead, sealing run, plug or slot, backing strip, spot, seam, meshed seam, stitch, meshed stitch, projection, flash, belt resistance. Draw sketches of a given fabricated by welding showing welding symbols on the assembled drawing of the component (IS: 813 – 1961).

8.0 PULLEY 6 8.1 Assembly of Fast and Loose pulley 8.2 Cone Pulley:

(a) Front view-full in section (b) Side view-half in section from the left.

• Draw the principal views of pulley (with local section if necessary).

9.0 PIPE DRAWINGS 9 9.1 Pipe joints – Cast iron flanged joint, spigot and socket

joint, hydraulic joint, expansion joint, union joint, coupler or socket

9.2 Pipe fittings and tubing 9.3 Pipe threads: straight, tapered 9.4 Pipe drawings – a) Scale layout b) diagrammatic layout 10.0 COMPUTER AIDED DRAFTING 12 Use of AutoCAD or any other drafting package to make

simple engineering drawings. The use of commands will enable the student to do the following activities


(i) Making of simple drawing (ii) Editing of existing drawing (iii) Dimensioning, drawing section lines and hatched

sections. (iv) Writing text on drawings (v) Display of drawings (vi) Making different settings of drawings related to

scale, units, co-ordinate system. REFERENCE BOOKS AND STANDARDS: 1. Thomas E. French, Charles J. Vireck, Robert J. Foster: Engineering Drawing and Graphic Technology – Mc Graw Hill Inc. 2. Gerard G. S. Volland : Modern Engineering Graphic & Design - CBS Publishers & Distributors. 3. M. Bhattacharyya and S. Pal : Fundamentals of Engineering Drawing - CBS Publishers & Distributors, Delhi. 3. Subrata Pal and Madhusudan Bhattacharyya :

Mechanical Engineering Drawing – Arnold Associates, Calcutta. 5. K. L. Narayana, P. Kannaiah, K. Venkata Reddy : Production Drawing - New Age International (P) Ltd., Publishers, New Delhi. 6. R. B. Gupta : A Text Book of Engineering Drawing

- Satya Prakashan, New Delhi. 7. R. B. Gupta : A Text Book of Machine Drawing

- Satya Prakashan, New Delhi. 8. N. D. Bhatt and V. M. Panchal : Engineering Drawing – Charotar Publishing House, Anand, Gujrat. 9. V. Lakshminarayan, M. L. Mathur and R. S. Vaishwanar : Machine Drawing – Jain Brothers. 10. N. D. Bhatt : Machine Drawing – Charotar Book Stall 11. R. K. Dhawan : A Text Book of Machine Drawing – S. Chand & Company

Ltd. 12. IS : 4897 – 1986 Bureau of Indian Standards. 13. IS : 919 (Part I & II) : 1993 Bureau of Indian Standards.

14. IS : 1364 – 1967 Bureau of Indian Standards 15. IS : 3640 - 167 Bureau of Indian Standards 16. IS : 2585 – 1963 Bureau of Indian Standards 17. IS : 2269 – 1967 Bureau of Indian Standards 18. IS : 1365 – 1968 Bureau of Indian Standards 19. IS : 1366 – 1968 Bureau of Indian Standards 20. IS : 1862 – 1975 Bureau of Indian Standards 21. IS : 2232 – 1967 Bureau of Indian Standards 22. IS : 2016 – 1967 Bureau of Indian Standards 23. IS : 2292 – 1974 Bureau of Indian Standards 24. IS : 2327 - 1993 Bureau of Indian Standards 25. IS : 2393 – 1980 Bureau of Indian Standards 26. IS : 6688 – 1972 Bureau of Indian Standards 27. IS : 2155 - 1982 Bureau of Indian Standards 28. IS : 5129 - 1987 Bureau of Indian Standards 29. IS: 919 (Part I and II) Bureau of Indian Standards 30. IS : 813 – 1961 Bureau of Indian Standards.


MANUFACTURING TECHNOLOGY – I L 3

T 0

P 0

Curri Ref. No. : AE 405

Total Contact hrs.: 45 Theory: 45 Practical: 0 Prerequisite: Nil Total Credit: 3


RATIONALE: Manufacturing is the backbone of any industrial nation. The level of manufacturing activity is directly related to the economic health of a country. Generally, the higher the level of manufacturing activity in a country, the higher is the standard of living of it’s people. Manufacturing is generally a complex activity, involving people who have a broad range of knowledge and skills of wide variety of machinery, equipment, and tooling with various levels of automation, including computers, robots, and material handling equipment. Work of a practicing engineer of any discipline is directly or indirectly connected with manufacturing of goods or services. Therefore, this subject is of vital importance in the curriculum of mechanical and automobile engineering. AIM: To develop basic concepts and understand working principles of different fabrication processes, welding, forging, casting and heat treatment of steel.



1.0 GENERAL INTRODUCTION 2 Examples of manufactured products, selection of manufacturing

processes, selection of materials.

2.0 INTRODUCTION TO FABRICATION PROCESSES 3 2.1 Mechanical joining: bolts, screws and rivets 2.2 Adhesive bonding: epoxy resins

2.3 Welding, brazing and soldering

• Identify the factors that affects the choosing of a particular method of fabrication.

3.0 BRAZING, BRAZE WELDING AND SOLDERING 5 3.1 Brazing: definition, fluxes used in brazing, properties of

filler metal.

3.2 Braze welding: definition, necessity, design of joint 3.3 Soldering: definition, joint design, types of fluxes, filler

metals • State the difference between brazing and welding

• Identify the filler materials used in brazing

• Explain silver brazing

• Define braze welding

• Compare brazing and braze welding

• State the typical applications of soldering

• Differentiate between brazing and soldering.

4.0 WELDING 8 4.1 Overview of welding processes 4.2 Types of gas welding, oxy-acetylene welding, principle of

operation, process, and equipment



4.3 Principle of arc welding, types of arc welding, brief

discussion on manual metal arc welding, carbon arc welding, tungsten inert gas welding, submerged arc welding.

• State the operational sequence of oxy-acetylene processes

• State different types of applications of oxy-acetylene welding

• Distinguish between arc and gas welding processes from the point of view of heat concentration, temperature, operation and running cost

• Explain reasons for choosing TIG for welding aluminium.

5.0 METAL FORMING PROCESSES

Fundamentals of metal forming processes, nature of plastic deformation, hot working and cold working.

12

5.1 Hot working processes: rolling principle, rolling stand

arrangement, roll passes, breakdown passes, roll pass sequences.

Forging: forging operation, smith forging, drop forging, press

forging, machine forging, forging design, drop forging die design.

5.2 Cold working processes: squeezing processes, bending,

shearing operations, drawing and sheet metal forming processes, press working and classification of different types of presses and their uses

• Distinguish between cold rolling and hot rolling in terms of process and product

• Explain the principle of rolling with a sketch

• Distinguish between open and closed die forging processes

• List the advantages of forging of metals

• Explain the operations that are normally employed in forging

• List a few products made by press working.



6.0 CASTING

Introduction, specific use of cast products in automobile engineering

6

6.1 Melting of metal and types of furnaces 6.2 Casting processes: sand casting, pressure die casting, centrifugal

casting

6.3 Fettling and cleaning of casting 6.4 Defects in casting and their remedies; non-destructive testing:

visual, sound, ultra sound, X-ray, magnetization, and liquid penetration.

6.5 Safety precautions required in casting.

• State specific use of casting • State the different procedural steps in casting • Identify the defects in casting

7.0 HEAT TREATMENT OF STEEL 9

7.1 Introduction, definition, importance of heat treatment process related to manufacturing, examples of heat treated parts

7.2 Different heat treatment processes of carbon steel, methods

and specific use; description of the processes with the help of phase diagram: annealing, normalising, hardening and tempering

7.3 Case hardening process: application and principle of carburising, nitriding and cyaniding processes • Define heat treatment of steel • Explain the importance of heat treatment processes in

manufacturing • Define annealing, normalizing, hardening and tempering. • Describe annealing, normalizing, hardening and tempering

processes and their specific applications • Define carburising, nitriding and cyaniding • Describe carburising, nitriding, and cyaniding processes

and their specific uses.


REFERENCE BOOKS: 1. R. K. Jain : Manufacturing Technology – Khanna Publishers 2. L. Doyle: Manufacturing Process and Materials for Engineers – Prentice Hall,

New Jersy 3. E. P. Degarmo : Materials and Process in Manufacturing - Prentice Hall of

India 4. B. H. Amstead, Phillipe. F. Ostwald & Myron L. Begeman : Manufacturing Process – John Wiley & Sons 5. J. S. Campbell: Principles of Manufacturing Materials and Processes

- Tata McGraw Hill Publishing Company 6. George E. Dieter: Mechanical Metallurgy – McGraw Hill International Book

Company 7. Donal S. Clark and Wilbur R. Varney: Physical Metallurgy for Engineers

- Affiliated East – West Press Private Limited 8. B. S. Raghuwanshi: A Course in Workshop Technology Vol. I and II

- Dhanpat Rai & Sons 9. John A. Schey: Introduction to Manufacturing Process: McGraw Hill Book Company 10. P. N. Rao: Manufacturing Technology: Foundry, Forming and Welding

- Tata Mc. Graw - Hill Publishing Company Limited 11. Serope Kalpakjian : Manufacturing Engineering and Technology - Addison Wesley Publishing Company.


THEORY OF MACHINES L 3

T 0

P 0


Total Contact hrs.: 45 Theory: 45 Theory Class duration: 45 classes of 1 hr. or 60 classes of 45minutes Pre requisite: Nil Credit: 3

Total Marks: 100 Theory: End Term Exam: 70 P.A.: 30

RATIONALE: Mechanical Engineering is primarily related with design, manufacture & use of various types of machines, which receives input energy in some available form and converts it to do a particular kind of useful work at the output. Each machine consists of a large number of static parts and connected moving parts or subassemblies called mechanisms. There exist a large number of different kinds of mechanisms. Each of these mechanisms can generate a particular type of output motion with some other kind of input motion. Theory of Machines is basically study of such different types of mechanisms. Any machine utilizes one or many such mechanisms to obtain desired kind of motions in different parts of that machine. It is, therefore, necessary to study and understand functions of different types of mechanisms for design manufacture and use of various machines. AIM: To study and understand different types of mechanisms with respect to their functions, functional relationship between different components, relationship between the input and output motions and their design features.



1.0 MECHANISM:

Definition of machine, mechanism and kinematics; types of motions; link; kinematic pair; kinematic chain; inversion; four-bar linkage; slider crank mechanism; crank and slotted lever quick return mechanism.

6

2.0 BELT, ROPE AND CHAIN DRIVE

9

2.1 Flat belt & pulley drive; velocity ratio; effect of belt thickness and slip on velocity ratio; length of belt for open or crossed belt condition; power transmission by belt drive; belt material and safe strength; belt creep and tensioning; idler pulley; belts connecting non parallel shafts; applications.

2.2 V-belts and pulleys – advantages and disadvantages; specification of a V-belt; applications.

2.3 Use of wire ropes; construction of wire ropes. 2.4 Chain & sprocket drive; advantage and specific uses

of chain drives; constructional features of roller chain and sprocket; simplex and duplex chain & sprocket; applications.

3.0 GEAR DRIVE 12 Classifications of gears with respect to relative

disposition of their axes (spur, helical, herringbone, rack & pinion, bevel, worm & wheel); leading terms and definitions pertaining to a gear tooth; velocity ratio and center distance for simple or compound gear trains; epicyclic gear train; concept of gear box; selection of a gear box from manufacturers’ catalogue; applications.

4.0 FLYWHEEL AND GOVERNOR 4 4.1 Fluctuation of turning moment and energy of a prime-

mover; function of a flywheel; calculation of size of a flywheel; simple problems; hoop stress in a rotating flywheel.

4.2 Functions of a governor; Watts, Porter and Hartnell

governors – description and functions


• Explain the function of a flywheel • Deduce the expression for moment of Inertia of a

fly wheel in terms of maximum fluctuation of energy and speed

• Deduce the expression of hoof stress in a rotating flywheel

• Solve simple problems on flywheel • Understand functions of a governor.

5.0 BALANCING

Effect of imbalance in a rotary shaft; static balancing and dynamic balancing; balancing of one or several revolving masses in a shaft.

• Explain effects of imbalance in a rotating body • Differentiate between static and dynamic balancing • Understand method of balancing several masses

revolving in different planes • Solve simple problems of balancing.

3

6.0 CAMS

Types of cams and cam followers; time displacement diagram for follower motion; drawing a rotating cam profile from a given displacement diagram for knife edge, flat and roller type follower; applications.

• Understand function of a cam and cam follower • List different types of cams and cam followers • Identify working of cams in different machines • Design a plate cam to displace a roller cam-follower as

per a given time-displacement diagram for the follower motion. Effect cam profile correction for the roller follower.

5

7.0 BRAKES, CLUTCHES AND DYNAMOMETER 6 7.1 Functions of brakes; types – block or shoe, band;

calculation of braking torque; simple problems; brake shoe materials; applications.

7.2 Function of clutches; types – friction (plate, conical),

toothed; estimation of friction torque (formula only no derivation); applications.

7.3 Function of dynamometers; absorption dynamometers:

pony brake & rope brake type.


REFERENCE BOOKS: 1. Thomas Bevan: the Theory of Machines – CBS Publishers & Distributors

2. A. Shariff and N. A. Shariff : Theory of Machines – Dhanpat Rai & Sons

3. Jagdish Lal : Theory of Machines and Mechanism

4. P. L. Ballany : Theory of Machines – Khanna Publishers.

5. J. S. Rao, R. V. Dukkipati, Mechanism and Machine Theory

6. Dr. R. K. Bansal, A Text Book of Theory of Machines (S. I. Units)

7. J. S. Brar and R. K. Bansal, A Text Book of Theory of Machines Firewall

Media.


WORKSHOP PRACTICE III L 0

T 0

P 6


Total Contact hrs. : 90 Practical : 90 Pre requisite: G203 & G204 Credit: 3

Total Marks: 50 Practical : P.A : 50

RATIONALE: The wealth of a community is measured by the variety and quality of the articles it possesses for its use and consumption. All the materials we posses are made from substances, which in the first place are won from the earth, or from nature. Our property depends upon our ability to convert these raw materials into useful articles for consumption, and to distribute these articles equitably amongst the various members of our community. The productivity of engineering workshops is an important factor, since a large proportion of our industries are of an engineering nature. Our ability, therefore, to maintain a high standard of skill in our engineering workshops is an important factor. AIM: To use and describe the tools, materials and working principles of various processes for pattern making shop, foundry shop, electric shop and fitting shop.


UNIT TOPIC / SUB-TOPIC HRS. TOTAL HRS.

1.0 WELDING SHOP 30 1.1 Shop Talk 1.1.1 Introduction to welding processes 1.1.2 Gas welding processes 1.1.2.1 Oxy-acetylene welding 1.1.2.2 Metal Inert Gas welding (MIG). Relative advantages over other

processes stating specific applications.

1.1.3 Arc welding processes 1.1.3.1 Types of arc welding processes 1.1.3.2 arc welding principle 1.1.3.3 Setting of various parameters for

welding

1.1.3.4 Arc welding equipment Electrode holder, welding Helmet, Safety goggles, welder’s chipping hammer, Earthing clamps, Hand gloves Approus and sleeves, wire brush.

1.2 Welding shop practice 1.2.1 Leftward and Right ward welding 1.2.2 Buts-joints practice on M.S. sheet at

horizontal Position by gas welding.

1.2.3 Arc welding practice on M.S. flat bar, 4-6 mmthick both left and right ward for hand balancing.

1.2.4 Making a double Vee-Butt joint on M.S. flat of 6 mm thick with minimum 2 runs on each side by Arc welding.

1.2.5 Making Tee Fillet – joint on flat position using M.S. flat of 4 mm. thick by arc welding.

1.2.6 Making small grill or window frame etc. by Arc welding.

2.0 ELECTRIC SHOP 15 2.1 Functions and importance of electric shop in

automobile engineering, safety precautions observed in the electric shop

2.2 Common conductors and insulators used in electric engineering practice, various types of electrical fittings

2.3 Practice on the followings: 2.3.1 Marking of a bare conductor joint and

soldering of the same.

2.3.2 Wiring with single core P.V.C. cable



HRS. 2.3.3 Wiring of twin core cable through main

switch, plug points etc.

3.0 ADVANCED FITTING SHOP 15 3.1 Description and use of vernier caliper, slip gauges,

sine bar, centre gauge, dial test indicator, micrometer and special purpose files.

3.2 Practice on the following:

3.2.1 Selection and determination of slip gauges for

different types of measurement

3.2.2 Determination of taper using sine bar and step gauges

3.2.3 Determination of internal dovetail angle using rollers and slip gauges.

3.2.4 Measurement of effective diameter and minor diameter of a screw thread.

3.2.5 Calculation of internal and external diameter using rollers and slip gauges.

REFERENCE BOOKS: 1. Fitter – Trade Theory (1st year and 2nd year), Central Instructional Media

Institute, Madras, Govt. of India. 2. Jay Webster: Auto Mechanics – Glencoe Publishing Company 3. Mechanic Motor Vehicle – Trade theory (1st year), Central Instructional Media

Institute, Madras, Govt. of India. 4. Arthur R. Judge : Modern Electrical Equipment for Automobiles

- Chapman and Hall Ltd., London 5. A. Smelov, I. Udalov et. al. : Maintenance of Automotive Electrical

Equipment – MIR Publishers.


FLUID MECHANICS, OIL HYDRAULICS AND PNEUMATICS

L 3

T 0

P 2

Curri Ref. No: AE 408

Total Contact hrs.:75 Theory: 45 Practical: 30 Pre requisite: G206A Credit: 4

Total Marks: 150 Theory: End Term Exam: 70 P.A.: 30 Practical: End Term Exam: 25 P.A: 25

RATIONALE: Though in majority of cases we use solids as engineering materials, use or application of fluids (i.e. liquids and gases) in engineering field is also numerous and of great importance. A number of materials (elements and compounds) are available in fluid forms only, viz. air, water petroleum products, steam, mercury etc. Many metals are extracted from ores by pyrometallurgical process in liquid form only. Water is a liquid and is involved in all spheres of human activity, ranging from daily needs to irrigation, generation of power, water transportation, cooling agent in chemical & metallurgical processes and innumerable other applications. Heat Engines utilise fluid medium for conversion of heat energy to useful mechanical energy or for generation of electrical energy in power plants. It is, therefore, necessary to study the physical properties and characteristics of fluids as a distinct group of materials which have very important use and application in a wide range of fields of engineering. Actual use of or action by different liquids can be realised by a group of machines called fluid machines. It is essential for an engineer to be conversant with such machines. AIM: To understand the properties and characteristics of fluids (mainly liquid) particularly in relation to handling and using fluids in engineering fields, like: physical properties of a liquid, pressure exerted by a liquid, property of buoyancy, energy of flowing fluid, characteristics of fluid flow in a pipe or open channel and measurement of flow of liquid. To have a working knowledge about the principle of working and uses of different fluid machines including oil hydraulic system and pneumatic system.



1.0 FLUID AND PROPERTIES OF FLUID

4

Definition and classification of fluid; definition of fluid mechanics and hydraulics; specific weight; density; compressibility; viscosity; surface tension.

2.0 PRESSURE AND ITS MESUREMENT

7

2.1 Intensity of pressure; pressure head; Pascal’s Law; hydraulic press; atmospheric pressure; barometer; absolute pressure and gauge pressure; pressure measuring devices; manometer; pressure gauges - Bourdon tube and diaphragm type.

2.2 Total Pressure on plane and curved surface one face of which is

submerged in liquid; centre of pressure.

3.0 FLOW OF FLUID 7 Types of fluid flow : steady and unsteady, uniform and non-

uniform, laminar and turbulant; rate of flow and their units; continuity equation of flow; potential energy of a flowing liquid; total head; Bernoulli’s theorem (statement and proof)

4.0 FLOW THROUGH PIPES 7 4.1 Definition of pipe flow, wetted perimeter, hydraulic

mean depth, hydraulic gradient; loss of head due to friction; syphons

4.2 Loss of head in pipes due to sudden enlargement, sudden

contraction, obstruction on flow path, change of direction and pipe fittings.

5.0 OIL HYDRAULICS 10

5.1

Definition of oil hydraulic system; advantages and disadvantages of oil hydraulic system; various components and uses of an oil hydraulic system: pump, storage tank, filter, flow and pressure control valve, direction control valve, hydraulic cylinder, accumulator, pipes & fittings; symbol used for these components

5.2 Principle of operation of rotary positive displacement

pumps: gear pump, vane pump variable delivery piston pumps; pressure range of hydraulic systems



5.3 Constructional features of a hydraulic cylinder 5.4 Hydraulic circuit drawing for a few typical applications

like holding a job, hydraulic press etc.

6.0 PNEUMATICS 10 6.1 Properties of air, perfect gas laws, fluid conditioners. 6.2 Definition of pneumatic systems, advantages and

disadvantages of pneumatic systems, various components used in pneumatic system, compressor – reciprocating and rotary, various control valves, pneumatic cylinders.

6.3 Symbols of pneumatic components. 6.4 Pneumatic circuits with typical example of multi cylinder

circuits.

7.0 LABORATORY 30 7.1 To determine specific gravity of different liquids (like

kerosine, mobile oil, aqueous solution of HCL, water) by use of an hydrometer.

7.2 Measurement of Buoyancy 7.2.1 Prove Archimedes’ Principle by using a balance 7.2.2 Determine volume of an odd shaped object. 7.3 Measurement of Pressure and Velocity 7.3.1 Show that pressure head of a liquid increases

linearly with depth using (i) piezometric tube, (ii) double column manometer and (iii) differential manometer

7.3.2 Calibrate a pressure gauge by using different

columns of water contained in a flexible PE tube.

7.3.3 To determine the velocity distribution in a

pipeline and calculate average velocity using a pitot tube.

7.4 To operate a hydraulic circuit trainer kit on different circuits.



HRS. 7.5 To operate a pneumatic circuit trainer kit on different

pneumatic circuits.

REFERENCE BOOKS: 1. Jagadish Lal: Hydraulics and Fluid Mechanics 2. A. K. Jain: Fluid Mechanics – Khanna Publishers 3. R. S. Khurmi: Hydraulics, Fluid Mechanics and Fluid Machines 4. Gupta and Gupta: Fluid Mechanics and its Applications

- New Age International (P) Ltd. 5. S. K. Likhi: Hydraulics Laboratory Manual

- New Age International (P) Ltd. 6. Jagadish Lal: Hydraulic Machines – Metropolitan Book 7. TTTI, Madras: Hydraulics and Hydraulic Machinery - Tata McGraw Hill. 8. S. R. Majumdar: Oil Hydraulics – Tata McGraw Hill.

9. Anthony Esposito ‘Fluid Power with Applications’ Pneumatic Hall

International. Inc. 10. S. R. Majumdar ‘Pneumatic System: Principles and Maintenance’, Tata

McGraw Hill.


ELEMENTS OF ELECTRICAL ENGINEERING

L 3

T 0

P 2

Curri. Ref. No: AE409

Total Contact hrs.:75 Theory: 45 Practical: 30 Pre requisite: G106 & G107 Credit: 4

Total marks: 150 Theory: End Term Exam: 70 P.A.: 30 Practical: End Term Exam: 0 P.A: 50


HRS. 1.0 CURRENT ELECTRICITY 4 1.1 Definition of e.m.f. and p.d. electric current and

resistance Ohm’s Law, resistivity and calculation of resistance

1.2 Kirchoff’s Law and ample network problems. 1.3 Power and Energy

Definition and units of electrical power and energy heating effect of electric current; relation between electrical mechanical and heat units, problems

2.0 A.C. FUNDAMENTALS 4 2.1 Definition – cycle-time period, frequency

amplitude, generation of A.C. voltage and current and their interpretation

2.2 Phase, phase difference, R.M.S and average value with definitions and mathematical equation, form factor and ripple factor

2.3 Vector representation of alternating quantities concept of active apparent power and p.f.

3.0 A.C.CIRCUITS 4 3.1 A. C. circuits with pure resistance pure inductance

and pure capacitance voltage current relationship and phase diagram power and p.f. Series and parallel circuits including simple problems (Using vector Diagram), computation of power and p.f. in simple R.L.C. circuits

4.0 THREE PHASE CIRUCIT 4 4.1 Interconnection of three phase, voltage and current

in delta and Star connection 3-phase power



5.0 MEASURING INSTRUMENTS 4 Principle and constuction of simple moving iron and

moving coil ammeter and voltmeter

5.1 Principle and construction of dynamometer type wattmeter

5.2 Measurement of three phase power by two wattmeter method

6.0 STORAGE CELLS 4 6.1 Lead acid accumulations its construction and uses 6.2 Maintenance free battery

Charging and discharging of cells, characteristics and a lead acid battery, maintenance of lead acid battery, problems

7.0 D.C. MACHINES 7 7.1 D.C. Generator: description, working principle, type

e.m.f equation OCC and load characteristics.

7.2 D.C. motor : description, working principle, types, back e.m.f. starting and speed control of C.C. motor

8.0 A.C. MACHINES 8 8.1 Transformer: construction, types, principles, e.m.f.

equation, transformer on no load, transformer on load. Single phase and 3 phase transformers, connection of transformers (star-star, star delta, delta-star). Principles and uses of auto transformer, losses and efficiency of transformer.

8.2 A.C. motors : Induction motor, construction, working principles, concept of rotatingmagnetic field, slip, torque equation, starting torque and maximum torque, efficiency, starting of induction motor, different types of starter

8.3 Synchorous Machine : as alternator and motor, working principle, frequency e.m.f equation, distribution factor and breadth factor (asalternators working principle and starting when used as synchronous motor)

8.4 Choice of motors for different industries and for traction purpose (comparative Study of A.C. and D.C. machines)

9.0 INDUSTRIAL HEATING 2 Induction and dielectric heating, different standard

formulae regarding selection of voltage and frequency of power supply for both induction and dielectric heating, description and application


10.0 GENERATION AND TRANSMISSION 4 10.1 Lay out of thermal generating station and hydro-

electric generation station

10.2 A.C. and D.C. transmission and distribution system LIST OF EXPERIMENTS: 30 1. Verification of Kirohhoff’s Law 2. Verification of Thevnin’s Theorem 3. Measurement of voltages across resistor, inductor and capacitor in series RLC

circuit, to draw phase diagram and determination of power factor of the circuit 4. Measurement of 3 phase power by 2 watt meter method 5. Study of construction of three-phase transformer and to find its turns ratio. 6. Study of constructions of a slip ring induction motor and its method of starting REFERENCE BOOKS: 1. H.Cotton Applied Electricity 2. H. Pradip Utilisation of Electric Power 3. S.K. Bhattacharya & K.B. Raina Transmission, Distribution and Utilisation of

Electric Power Electrical Installation TMH 4. Mothershed Electronic Devices & Currents PHI 5. H. Kalsi Electronic Instrumentation TMH 6. C. L. Wadhwa Basic Electrical Engineering


MACHINE DESIGN

L 3

T 0

P 0

Curri. Ref. No. AE410

Total Contact hrs : 45 Theory: 45 Tutorial: 0 Practical: Pre-requisite: AE 410 Credit: 3

Total Marks: 100 Theory: End Term Exam: 70 P. A: 30 Practical: End Term Exam: 0 P. A: 0


HRS. 1.0 INTRODUCTION TO MACHINE DESIGN: 3 1.1 Introduction to Indian standards, I.S. codes related to

preferred numbers (I.S.1076) and standard sizes.

1.2 Limits and fits and tolerances:-Basic hole system, Basic System, Reading of Tables from I.S.919,2709;Use in Engineering Drawing, selection of standard limits and fits Indian standard, Surface roughness.

1.3 Types of load, Ideas of stress concentration, factor of safety - Collect information on preferred numbers, material properties from relevant codes and hand books. - Use limit, Fits and tolerances in machine design.

2.0 RIVETED AND WELDED JOINTS: 8 2.1 Essential quantities of rivet, strength of rivet. Types

of rivet heads and joints .Failures of riveted joint, strength of joint. Efficiency of rivet joint.

2.2 Design of Boiler joints: - Design of longitudinal Butt joint for boiler. - Design of circumferential Lap joint for a boiler. - Types of Welded joints (Lap and Butt joint) - Basic symbols; Strength of butt joints. Stresses for welded joints-stresses for concentration factor for welded joints.

3.0 SCREW THREADS AND JOINTS: 4 3.1 Design of screwed, stresses due to external forces,

design of bolts for cylinder cover.

3.2 Design of nut, bolted joints under eccentric loading. - To design and draw screwed joints given loading on the joints.



4.0 SHAFTS AND SHAFT COUPLING: 7 4.1 Design of shafts on the basis of strength and rigidity

(say solid and hollow shaft).

4.2 Design of axle. 4.3 Design of shaft subjected to:-

(a) Fluctuation loads. (b) Axial load in addition to combine. (c) Torsion and bending load.

4.4 Design of shafts and shafts coupling for specified duty. Design shafts and shafts coupling for given loading condition.

5.0 BEARINGS: 5 5.1 Simple loaded shafts on bearings, calculations (shaft

diameter and bearing loads.

5.2 Types of bearings, bearing materials, bearing lubrication (I.S.10260, I.S.11473)

5.3 Design and drawing of journal bearing (simple type).

5.4 Rolling contact bearing-types, standard dimensions and designation of bearings, selection of rolling element bearing from catalogues hand books.

5.5 Design of shaft mounted on anti-friction bearings. - To design journal bearing for given load. - Select rolling bearing for given loading.

6.0 DRIVES AND GEARS: 4 6.1 Pulleys- Design of hub rims, arm, key and key way. 6.2 Flats Belt drive: Belt speed, coefficient of friction

between belt and pulley. Standard belt thickness and widths, velocity ratio of a belt drive. Power transmitted by belt.

6.3 Spur gear: Calculation of number of teeth’s, gear ratio, forces acting between gear wheels, selection of gear dimensions. - Design gear drive for given power and speed. - Design pulley for given power, speed and angle of contact.

7.0 FLY WHEEL: 5 7.1 Coefficient of fluctuation of speed and energy. 7.2 Maximum fluctuation of energy-energy stored in

flywheel.

7.3 Stresses in a flywheel Rim and arm. 7.4 Design of flywheel arms, shafts, Hub and key. 7.5 Construction of flywheel.


8.0 CLUTCHES: 4 8.1 Types of clutches, considerations in designing a

friction clutch.

8.2 Design of a Disc or Plate clutch. 8.3 Design of a cone clutch and centrifugal clutch. 9.0 BRAKE: 4 9.1 Types of brake-pivoted block or shoe brake. 9.2 Double block or shoe brake. 9.3 Calculation of their torques.

REFERENCE BOOKS: 1. P. C. Sharma and D. K. Aggarwal: Machine Design – S. K. Kataria &Sons,

Delhi. 2. R. L. Khurmi and J. K. Gupta: Machine Design – Eurasia Publishing House

Ltd. 3. R. B. Gupta: Machine Design – Satya Prakashan, New Delhi. 4. J. E. Shigley and Charles R. Mischke: Mechanical Engineering Design –

McGraw-Hill Book Company. 5. N. C. Pandya and C. S. Shah : Elements of Machine Design – Charotar

Publishing House, Anand. 6. Allen S. Hall, Alfred R. Holowenko and Herman G. Laughlin : Schaum’s

Outline of theory and Problems of Machine Design – McGraw – Hill Book Company.

7. M. F. Spotts : Design of Machine Elements – Prentice Hall of India Limited. 8. Aaron D. Deutschman, Walter J. Michels and Charles E. Wilson: Machine

Design : Theory and Practice – Macmillan Publishing Co. Inc 9. IS : 1076 (Part 1 and 2) : 1985 Bureau of Indian Standards. 10. IS : 919 (Part 1 and 2) : 1993 Bureau of Indian Standards. 11. IS : 10206 (Part 1,2,3) : 1982 Bureau of Indian Standards. 12. IS : 14473: 1997 Bureau of Indian Standards.


BASIC ELECTRONICS L 3

T 0

P 2

Curri. Ref. No. AE 411

Total Contact hrs : 75 Theory: 45 Tutorial: 0 Practical: 30 Pre-requisite:G106&G107 Credit: 4

Total Marks: 150 Theory: End Term Exam: 70 P. A: 30 Practical: End Term Exam: 0 P. A: 50

RATIONALE The application of Electronic circuits and devices are widespread in all sphere of Engineering. Even knowledge of this subject is essential in Mechanical or Civil Engineering related disciplines. This subject covers the basic electrical principles both in d.c. and a.c. circuits, fundamental principles of Magnetic circuits, basic knowledge of semiconductor physics, working principles of diode, transistors, field effect transistors, and feedback amplifiers. DETAIL COURSE CONTENT THEORY:

UNIT TOPIC/SUB-TOPIC Lecture Hrs.

1.0 SEMICONDUCTOR 5

1.1 Explain structure of solid. 1.2 Explain energy band theory & energy level diagram of solids. 1.3 Define & explain intrinsic and extrinsic semiconductor. 1.4 Define acceptor and donor type impurities.

2.0 DIODES AND CIRCUITS. 8

2.1 Discuss construction and working principle of p-n junction diode. 2.2 Explain Biasing of p-n junction diode. 2.3 Derive efficiency of half-wave rectifier and full-wave rectifiers. 2.4 Define ripple factor. 2.5 Describe construction, working and I-V characteristics of Zener diode. 2.6 Explain Special Purpose Diodes: Tunnel Diode, Varactor Diode,

Schottky Diode, Pin Diode, Light Emitting Diode, Photo Diodes. 3.0 TRANSISTOR AND CIRCUITS 4

3.1 Discuss construction and working principle of p-n-p and n-p-n transistor.

3.2 Explain different types of transistor configurations (CB, CE and CC).


3.3 Explain input & output characteristics of transistors in different configurations.

3.4 Define α and β and derive relation between α and β of transistors. 3.5 Explain Transistor as a switch and as an amplifier. 3.6 Explain the different transistor biasing circuits. 3.7 Draw the load line and determine the Q- point.

4.0 FIELD EFFECT TRANSISTOR 4

4.1 State concept of FET. 4.2 Differentiate between JFET & BJT. 4.3 Classify FET. 4.4 Explain construction, working principle & characteristics of JFET. 4.5 Explain JFET as an amplifier. 4.6 Establish JFET parameters & relation between them. 4.7 Explain construction &working principle of MOSFET.

5.0 FEEDBACK AMPLIFIER & OSCILLATOR. 3

5.1 Define feedback amplifier. 5.2 Explain principle of negative feedback with the help of block diagram. 5.3 Define gain of an amplifier with feedback. 5.4 Explain principle of working, characteristics & use of emitter follower. 5.5 State and explain fundamental principle of working of oscillators. 5.6 Explain Barkhausen criteria. 5.7 Differentiate between amplifier and oscillators. 5.8 Explain construction, working principle of Hartley and Collpits

oscillators.

6.0 INTEGRATED CIRCUITS AND OPERATIONAL AMPLIFIERS 5 6.1 Explain Integrated Circuits (ICs). 6.2 Classify Integrated Circuits. 6.3 Explain Characteristics of Operational Amplifiers 6.4 Describe Application of Operational Amplifiers in summing Amplifier,

Differential Amplifier, Voltage follower, Integrator and Differentiator. 7.0 REGULATED POWER SUPPLY 5 7.1 Voltage Regulator 7.2 Types of Voltage Regulator 7.3 Zender Diode Shunt Regulator 7.4 Linear voltage regulator ICs

7.5 Working principle of Switched Mode Power Supply 7.6 Working principle of UPS

8.0 ELECTRONICS INSTRUMENT 4

8.1 Explain Importance of general purpose test Instruments 8.2 Explain Working principle and applications of Analog Multimeter. 8.3 Explain Working principle and applications of CRO 8.4 Explain Working principle and applications of Function Generator


Class Test 2 PRACTICAL: Suggested list of experiments: 1. Study Diode Characteristics. 2. Study Transistor Characteristics. 3. Construct half wave, full wave bridge rectifier circuits and study the output

waveforms and the input and output voltage levels (peak and RMS). 4. Study Zener diode characteristics 5. Construct single stage transistor amplifier and measure Zin, Zout and gain. Plot

its frequency response curve and find its band width. 6. Construct emitter follower and plot its frequency response curve and find its

bandwidth. 7. Study of FET. 8. Study of oscillators. 9. Study of Operational Amplifiers as summing Amplifiers, Different Amplifiers,

Voltage Follower, Integrator & Differential. SUGGESTED LEARNING RESOURCES Reference Books: 1. V.K.Meheta, Principle of Electronics 2. D. Chottopadhyay and Rakshit, Electronics Fundamentals and Applications 3. G.K.Mithal, Electronics Devices 4. Robert Boyelstad, Electronics Devices & Circuit theory 5. S. K. Mandal, Basic Electronics, TMH. 6. R. S. Sedha, Electronic Circuits 7. Copper and Helfrick, Pendice Hall of India, Modern Electronics Instrumentation

and Measuring Techniques.


AUTOMOBILE DRAWING L 1

T 0

P 4

Curri. Ref. No: AE 412

Total Contact Hrs.: 75 Theory: 15 Practical: 60 Pre requisite: AE404 Credit: 3

Total Marks: 50 Theory: End Term Exam: 0 P.A.: 0 Practical: End Term Exam: 0 P.A: 50

RATIONALE: The importance of drawings in the communication of technical information is demonstrated by their use in numerous manuals and leaflets issued by car and component manufacturers. The automobile engineering students should use this medium to a greater extent in their own work. This subject is very useful to the students because through this students develop ability to interpret engineering drawings and produce intelligible free hand sketches. AIM: The aim of the subject is to develop skills in the students to interpret automobile drawings through assembly and detailed drawings of automobile components of major sub-assemblies like engine, transmission, suspension, braking system etc.



1.0 ASSEMBLY AND DETAILED DRAWINGS OF ENGINE COMPONENTS (ANY TWO)

15

1.1 Piston 1.2 Connecting rod 1.3 Crank shafts 1.4 Valves and valve gear. 2.0 ASSEMBLY AND DETAILED DRAWINGS OF

TRANSMISSION LINE (ANY TWO) 15

2.1 Transmission gear box 2.2 Universal joints 2.3 Clutches 2.4 Propeller shaft 2.5 Rear axle • Draw the principal and sectional views of major

components of transmission line.

3.0 ASSEMBLY AND DETAILED STEERING AND

SUSPENSION (ANY ONE) 9

3.1 Steering arm 3.2 Track rod end 3.3 Front suspension 3.4 Spring 4.0 ASSEMBLY & DETAILED DRAWING OF

MECHANICAL & HYDRAULIC BRAKING (ANY TWO) 9

4.1 Brake linkage 4.2 Wheel units 4.3 Master cylinder 4.4 Wheel cylinder 4.5 Disc Brake 5.0 PULLEY 9 5.1 Assembly of Fast and Loose pulley 5.2 Cone Pulley : (a) Front view-full in section

(b) Side view-half in section from the left

• Draw the principal views of pulley (with local section if necessary).

6.0 COMPUTER AIDED DRAFTING

Use of AutoCAD or any other drafting package to make simple engineering drawings. The use of commands will enable the student to do the following activities.

18

i) Making of simple drawing ii) Editing of existing drawing iii) Dimensioning, drawing section lines and hatched

sections.

iv) Writing text on drawings v) Display of drawings


vi) Making different settings of drawings related to scale, units, co-ordinate system.

REFERENCE BOOKS AND STANDARDS: 1. Thomas E. French, Charles J. Vireck, Robert J. Foster: Engineering Drawing and Graphic Technology – Mc Graw Hill Inc. 2. Gerard G. S. Volland : Modern Engineering Graphic & Design - CBS Publishers & Distributors. 3. M. Bhattacharyya and S. Pal : Fundamentals of Engineering Drawing - CBS Publishers & Distributors, Delhi. 4. Subrata Pal and Madhusudan Bhattacharyya :

Mechanical Engineering Drawing – Arnold Associates, Calcutta. 5. K. L. Narayana, P. Kannaiah, K. Venkata Reddy : Production Drawing - New Age International (P) Ltd., Publishers, New Delhi – 110 002. 6. R. B. Gupta : A Text Book of Engineering Drawing

– Satya Prakashan, New Delhi – 110 005. 8. R. B. Gupta : A Text Book of Machine Drawing

– Satya Prakashan, New Delhi – 110 005. 9. N. D. Bhatt and V. M. Panchal : Engineering Drawing – Charotar Publishing House, Anand, Gujrat. 10. K. Venugopal : Engineering Drawing and Graphics + Auto CAD – New Age

International Publishers 11. K. L. Narayana, P. Kannaiah and K. Venkata Reddy: Machine Drawing - New Age International Publishers 12. V. Lakshminarayan, M. L. Mathur and R. S. Vaishwanar : Machine Drawing – Jain Brothers. 13. N. D. Bhatt: Machine Drawing – Charotar Book Stall 14. R. K. Dhawan: A Text Book of Machine Drawing - S. Chand & Company Ltd. 15. IS: 4897 – 1986 Bureau of Indian Standards. 16. IS: 919 (Part I & II): 1993 Bureau of Indian Standards. 17. IS : 1364 – 1967 Bureau of Indian Standards 18. IS : 3640 - 167 Bureau of Indian Standards 19. IS : 2585 – 1963 Bureau of Indian Standards 20. IS : 2269 – 1967 Bureau of Indian Standards 21. IS : 1365 – 1968 Bureau of Indian Standards 22. IS : 1366 – 1968 Bureau of Indian Standards 23. IS : 1862 – 1975 Bureau of Indian Standards 24. IS : 2232 – 1967 Bureau of Indian Standards 25. IS : 2016 – 1967 Bureau of Indian Standards 26. IS : 2292 – 1974 Bureau of Indian Standards 27. IS : 2327 - 1993 Bureau of Indian Standards 28. IS : 2393 – 1980 Bureau of Indian Standards 29. IS : 6688 – 1972 Bureau of Indian Standards 30. IS : 2155 - 1982 Bureau of Indian Standards 31. IS : 5129 - 1987 Bureau of Indian Standards 32. IS: 919 (Part I and II) Bureau of Indian Standards 32. IS: 813 – 1961 Bureau of Indian Standards.


MOTOR VEHICLES ACT

L 3

T 0

P 0


Total Contact hrs. : 45 Theory : 45 Practical : Nil Pre requisite: Credit: 3

Total Marks: 100 Theory : End Term Exam : 70 P.A. : 30 Practical : End Term Exam : 0 P.A : 0

RATIONALE: The Motor Vehicles Act is a central legislation through which the road transport is regulated in the country. In recent amendments of the act the environmental issue is considered to encourage vehicles operating on eco-friendly fuels. People dealing with automobiles have to deal with licensing, registration, insurance, offences, penalties etc. as user, dealer, owner or driver of automobiles. The automobile engineering diploma holders may go for entrepreneurship like running an automobile garage, taking dealership of automobile or they may go for doing jobs in automobile organizations. The knowledge of motor vehicles act help the students to deal with procedural parts of their job efficiently. AIM: The aim of the subject is to enable the students with basic rules that govern many managerial activities related to automobile. The subject covers the essential rules and concepts related to licensing registration, insurance, offences, penalties etc.



1.0 Definitions and salient features of Motor Vehicles Act. 5 2.0 Licensing of drivers of motor vehicles and licensing of

conductors of stage carriages. 5

3.0 Registration of motor vehicles. 5 4.0 Control of transport vehicles. 5 5.0 Special provisions relating to State Transport

Undertakings. 5

6.0 Control of traffic. 5 7.0 Insurance of motor vehicles. 5 8.0 Offences, Penalties and Procedure. 5 9.0 Schedules: Traffic signs, schedule for compensation. 5 10.0 Transport fee estimation method? REFERENCE BOOK: 1. Motor Vehicles Act, 1988 Ed. T. N. Shukla, Kamala Law House, Kolkata – 700 001.


INSTALLATION, MAINTENANCE AND GARAGE PRACTICE L 3

T 0

P 0


Total Contact hrs. : 45 Theory : 45 Tutorial:0 Pre requisite: Credit: 3


RATIONALE: The automotive industry may be divided into three general areas. Production or manufacturing transforms raw materials such as steel, iron, plastic, glass and vinyl into a finished automobile. Selling it is the job of the second major area. The last major part of the automobile industry is service which includes maintenance and repair. The automotive service workers work mainly in service station, automobile dealership, independent garage or with parts suppliers. The diploma students should have the knowledge of maintenance and garage practice to face the future work environment. AIM: The students will be exposed to different aspects of garage and service stations like the function, layout and equipment used in those places. They will also have the knowledge of management of sales and service.



1.0 INTRODUCTION 3 1.1 Tools and Equipments for installation and maintenance

work.

1.2 Types of maintenance and its objectives. 2.0 GENERAL INSTALLATION PROCEDURE OF ENGINE

OR MACHINE : 2.1 Location, layout and positioning of machine 2.2 Foundation: dynamic and static loads, ground condition,

vibration consideration, foundation bolts, excavation, template, concrete mixing, pouring, levelling and alignment.

2.3 Grouting, fitting of parts and fittings, final levelling and test runs.

5

3.0 ELEMENTS OF MAINTENANCE MANAGEMENT: 3 Preventive maintenance, procedure for preventive

maintenance, running maintenance, daily and periodic maintenance, breakdown maintenance.

4.0 EQUIPMENT FOR SERVICE STATION:

Function of garage, factors for locating garage, layout . Different types of lifts and hoists, jacks, towing equipment, washing machines, hydraulic ram, air compressor, blower, water pump, lubricating equipment: grease gun and nipples, hand and compressed air operated lubrication equipment, lubrication charts, servicing procedures.

6

5.0 EQUIPMENT FOR REPAIRING SHOPS

5.1 Garage tools and equipment

Different types of garage tools, cutters, pullers, stud extractors, torque wrench, piston ring sqeezer, cleaner, valve lifter.

5.2 Reconditioning equipment :

Degreasing plant, tools for de-carbonizing, cylinder reboring and homing machine, valve refacer, line boring of crank shaft main bearings, connecting rod aligner, crankshaft grinding machine, brake drum lathe, brake shoe rivetting tools, rivet gun (pneumatic type, hand operated type), valve spring tester, injector test bench, injection pump and calibration machine.

6



6.0 ENGINE TUNING:

Meaning and procedure of tuning.

2

7.0 BODY REPAIRING AND RECONDITIONING : Surface preparation for painting, procedure for upholstery works

5

8.0 GARAGE WORK PROCEDURE AND RECORDS : Inspection , test report, estimation and quotation for repairing work, work order, job control system, repair bill.

5

9.0 GARAGE STORES : Procurement, receipt and issue in stores, store records, inventory control, inspection, prevention of spoilage in stores, storage of inflammables.

5

10.0 SALES AND DISTRIBUTION OF MOTOR VEHICLES : Salesmanship, publicity, display, dealership and agency system, sales and purchase procedure, documents for new and second hand vehicles, after sales service, customer record and following.

5

11.0

INSPECTION & REPAIR OF AUTO MOBILE AS WHOLE FOR EVERY 5000 km OF RUN.

Enquiry from driver, detect the problem, take action accordingly.

REFERENCE BOOKS: 1. Jay Webster: Auto Mechanics – Glencoe Publishing Company. 2. Jain and Asthana : Automobile Engineering – Tata McGraw Hill Publishing

Company.


AUTOMOBILE ENGINES – II

L 3

T 0

P 2


Total Contact hrs. : 75 Theory: 45 Practical: 30 Pre requisite: AE 403 Credit: 4


RATIONALE: Automotive industry is one of the major industrial sector in the country. A large number of people are employed in engine maintenance and repair. The automotive industry needs technically qualified people. Each year, improvements on the new models of automobiles make their repair or adjustment more complex and difficult but also more interesting and rewarding to the trained men. Tremendous research and development programs, public demand, and competition among car manufactures have produced automobiles with more power, comfort and economy. In these circumstances the study of automotive engines is a must for the diplomats in automobile engineering. AIM: Students will develop basic knowledge about the fuels, fuel system, lubricating system, pollution control, engine performance and testing of engines and also develop skills to handle such systems.


THEORY: 45 HRS.


1.0 FUELS AND COMBUSTION 7 1.1 Desirable properties of engine fuels: Knock rating, volatility, calorific value, gum content,

sulphur content, aromatic content.

1.2 Composition, advantages and disadvantages of different

fuels.

(a) Gasoline : Combusion of gasoline; characteristics of

gasoline : volatility, chemicals and gums in fuels, octane rating; gasoline additives : tetraethyl lead, metal deactivators, phosphorous compounds, anti-icers, antioxidant inhibitors

(b) Diesel fuel – grades : 1-D, 2-D and 4-D; volatility,

cetane number, specific gravity and viscosity, sulfur content; carbon and ash, water and sediment

(c) Liquified petroleum gas (d) Alcohol (e) Compressed natural gas (CNG) (f) Benzole. 1.3 Combustion 1.3.1 Combustion chambers : hemispherical type, inverted

bath tub type, flat head type, side valve type

1.3.2 Detonation : Definition; theories of detonation;

factors influencing detonation : factors, factors concerning fuel, mixture strength

1.3.3 Fuel rating : highest useful compression, octane

number

1.3.4

1.3.5 Pre-ignition, diesel knock, cetane number; Chemistry of combustion: chemical composition of fuel, stoichiometric equation for complete combustion of fuel, reactants and products of combustion.



2.0 FUEL SYSTEMS 18 2.1 Purpose of fuel system; types of fuel system : carbureted

fuel system, fuel injection system

2.2 Construction and operation of the following components of

carbureted fuel system: fuel tank, fuel filters and screens, fuel gauges, fuel pumps, electric fuel pumps, air cleaners.

2.3 Carburetors : 2.3.1 Functions of carburetors : atomization, vaporization,

mixing of petrol and air

2.3.2 Main parts of carburetor and principle of working of

carburetors: float chamber, mixing chamber.

2.3.3 Types of carburetors with regard to following : a) Draft : down-draft carburetor, up-draft

carburetor, side-draft carburetor, semi down draft carburetor

b) Working construction: constant choke

carburetors, constant vacuum carburetor.

c) Number of units: single barrel carburetor,

multiple barrel carburetor.

2.3.4 Functions of circuits and controls in the carburetor a) Circuits : float circuit, idle circuit, low speed

circuit, high speed circuit, pump circuit, choke circuit

b) Controls: throttle, choke, throttle cracker,

unloader or dechoker.

2.3.5 Working principles of different carburetors : solex

carburetor, zenith carburetor, SU carburetor

2.4 Supercharging: Function and construction of different types

of superchargers: Roots type, centrifugal type, vane type.



2.5 Diesel Fuel Injection System 2.5.1 Functions of fuel injection system 2.5.2 Parts of fuel injection system

- fuel tank, fuel filter, fuel feed or transfer pump, fuel injection pump, injector, timing device, governor

2.5.3 Types of fuel injection: air injection, mechanical or

solid injection, CR injection, Common Rail Diesel Injection System (CDRI System).

2.5.4 Governors – Functions; Types : centrifugal and

pneumatic

2.5.5 Timing device. 2.6 Petrol Injection System : 2.6.1 Function; advantages of petrol injection system 2.6.2 Types of petrol injection system a) Single point injection : method of operation b) Multi-point fuel injection (MPFI) : method of

operation

2.6.3 Double Turn Spark Engine (DSTI): Construction and working DSTI.

3.0 ENGINE LUBRICATION SYSTEM 7 3.1 Function of lubricating system; functions of lubricating oil; 3.2 Properties of lubricating oil :

Viscosity ratings, viscosity index; oil additives: pour point depressants, oxidation inhibitors, corrosion and rust inhibitors, foaming resistance, detergents, extreme pressure resistance.

3.3 Types of lubrication system: petroil system, splash system;

semi-pressure system; pressure system; wet sump system, dry sump system.



3.4 Parts of lubrication system in four stroke engine : oil

sump or tank; oil pump : gear type, rotor type, plunger type; oil relief valve; oil filter : by pass filter, full-flow filter; oil dip- stick; oil pressure indicating light; oil pressure gauge : pressure expansion type, electric type

3.5 Crankcase ventilation

• Describe properties of lubricants used in engine

• Describe functions and construction of different parts of lubrication system.

4.0 EMISSION CONTROL 5 4.1 Pollutants from IC Engine: hydrocarbons (HC),

Carbon monoxide (CO), Oxides of nitrogen (NOX), particulates, sulfur oxides

4.2

Emission controls of automotive systems : positive crankcase ventilation (PCV), evaporative emission control system, heated air system, exhaust gas re-circulation (EGR), air injection system, catalytic converters

4.3 Bharat stage standard norms of emission. 5.0 PERFORMANCE AND TESTING OF ENGINES 8 5.1 Different ways of measuring performance of engine

: bore and stroke, piston displacement, compression ratio, volumetric efficiency, engine power output, brake horse power (BHP) using dynamometer (electric dynamometer, water brake) , indicated horse power (IHP), friction horse power (FHP), relation among BHP, IHP, and FHP, torque, engine efficiency : mechanical efficiency, thermal efficiency; overall efficiency : energy loss in cooling water and oil, loss in exhaust gas, loss in engine friction, energy used for propelling car, (rolling resistance, air resistance, acceleration power). Heat balance engine only. Engine heat balance analysis (Preparation of heat balance chart)



5.2

Engine Testing – measurement of indicated power by : Morse test, William’s line method; Measurement of frictional power by motoring test; measurement of brake power by absorption dynamometer; measurement of fuel consumption by volumetric type flow meter, gravimetric measurement; air flow rate measurement by air box method and viscous air flow airmeter; measurement of engine speed by mechanical tachometers, stroboscopes, pulse counter.

6.0 Multicylinder Engines and Engine Balancing 6.1 Power balance, crank arrangement; fixing order and power flow in various engines, one cylinder, two cylinder engine, four cylinder engine, six cylinder engine, eight cylinder engine, twelve cylinder engine.

6.2 Mechanical balance and torsional vibration: unbalanced certifagal forces and couples set up by the rotating parts, unbalanced forces and couples set up by inertia effects of rotating parts, primary and secondary inertia forces primary balance, secondary balance.

7.0

PRACTICALS

30

7.1 Study of diesel fuel injection system (testing of

injector)

7.2 Study of petrol fuel injection system 7.3 Study of different lubricating systems (using chart of

lubricating system, drawing lubricating system)

7.4 Servicing of oil pump 7.5 Servicing of catalytic converters 7.6 Determination of BHP, thermal efficiency of single

and multi-cylinder engine

7.7 Preparation of heat balance sheet of a multi-cylinder petrol engine.

7.8 Pollution measurement using pollution measurement instrument (gas analyzer).


REFERENCE BOOKS :

1. Dr. Kirpal Singh, Automobile Engineering : Vol. I and II, Standard Publishers Distributors

2. Harbans Singh Reyat – The Automobile : S. Chand & Company Ltd. 3. William H. Crouse and Donald L. Anglin - Automotive Mechanics : Tata

McGraw Hill Publishing Company Ltd., New Delhi 4. Shyam K. Agrawal - Internal combustion Engines : New Age International (P)

Limited, Publishers 5. K. Newton, W. Steeols, T. K. Garrett-The Motor Vehicle : Butterworth

Heinemann. 6. Joseph Heitner – Automotive Mechanics : Principles & Practices, CBS Publishers & Distributors. 7. Dr. Amitosh De “Automobile Engineering” Galgolia Publication Ltd, New Delhi.


AUTOMOBILE POWER TRAIN L 3

T 0

P 2


Total Contact hrs.: 75 Theory: 45 Practical: 30 Pre requisite: Credit: 4


RATIONALE: The modern automobile is made up of many systems which in turn are made up of a number of subsystems, components and innumerable parts. The systems can be grouped under four major headings viz. The Engine, The Power Train, The Chasis and the Electrics & Electronics.

The power developed by the engine of the automobile is delivered to the wheels through the Power Train. Function of the power train is not only to transmit the torque developed by the engine, but also to suitably multiply it with suitable change of rotational speeds to allow the vehicle to accelerate during starting, and also allows reverse motion of the vehicle, and differential wheel speeds during turning.

The various systems constituting the power train are of vital importance for proper movement of an automobile, and hence to be studied by every automobile engineer. AIM: After studying this subject, a fresh diploma engineer in Automobile Engineering should be able to explain the construction and operations, diagnose the problems and rectify them, and do necessary preventive maintenance of manually operated clutch with clutch linkages, manual transmission system, automatic transmission system, drive line assembly, differential gear box and rear axle assembly of an automobile.


THEORY: 45 Hours UNIT TOPIC/SUB-TOPIC HRS. TOTAL

HRS. 1.0 INTRODUCTION

Various systems of an automobile power train 1

2.0 CLUTCHES 9 2.1 Function and requirement of clutch; types of

automotive clutches: single disc and multi disc dry friction clutch, wet (oil) friction clutch, semi centrifugal clutch

2.2 Clutch construction; mechanical linkage for clutch

operation

2.3 Clutch problems; clutch adjustment; clutch service

• Explain operation of manually operated clutch during engagement and disengagement

• Identify different components of an automotive clutch

• Describe construction of automotive clutches • Sketch and explain how clutch linkage operates • List different types of problems in a clutch • Explain how to assemble a clutch.

3.0 MANUAL TRANSMISSION SYSTEM 10 3.1 Requirement of multi-speed transmission (gear

box); components of a gear box; sliding mesh; synchronizer; gear shifting mechanism: Floor shift, steering column shift

3.2 Four speed gear box: Construction and power flow

in different gears; overdrive; gear ratios

3.3 Transmission problems and remedies; gear oil 4.0 AUTOMATIC TRANSMISSION SYSTEM 10 4.1 Definition and advantages 4.2 Working principle and construction of a torque

converter; planetary gear box- principle of operation; planetary holding units : clutches, bands, overrunning clutch; hydraulic control system

4.3 Common defects and remedies in automatic

transmission



5.0 DRIVE SHAFT ASSEMBLY 5 5.1 Drive (or propeller) shaft requirements; types :

torque tube, Hotchkiss; universal joint; slip joint

5.2 Troubleshooting and preventive maintenance

6.0 REAR AXLE ASSEMBLY 7

6.1 Turning of an automobile; function of a differential; construction details of a differential

6.2 Types of rear axle: full floating, three quarter floating, semi floating; axle shafts, bearings and housing.

6.3 Rear axle trouble shooting, service and preventive maintenance.

7.0 POWER TRANSMISSION SYSTEM OF MOTOR

CYCLE AND SCOOTER 3

8.0 PRACTICAL 30 8.1 Removal and opening of a clutch assembly, inspect

the components for wear, refit the assembly

8.2 Drive a car to identify any of the following

problems of the clutch :

(i) chatter (ii) slipping (iii) drag (iv) pedal pulsation (v) pedal stiffness (vi) noise

8.3 Check lubricant level, drain and refill lubricant in a

gear box

8.4 Disassemble a gearbox and determine gear ratios in

various gears

8.5 Disassemble and refit an universal joint 8.6 Study the working of a differential. N.B.: Each student group should conduct at least five of the above or similar

practical work. Each group should not exceed more than10 students. Care should be taken to ensure that each student of the groups are actually participating in the practical work.


REFERENCE BOOKS:

1. Dr. Kirpal Singh, Automobile Engineering : Vol. I and II, Standard Publishers Distributors

2. Harbans Singh Reyat – The Automobile : S. Chand & Company Ltd. 3. William H. Crouse and Donald L. Anglin - Automotive Mechanics : Tata

McGraw Hill Publishing Company Ltd., New Delhi 4. Shyam K. Agrawal - Internal combustion Engines : New Age International (P)

Limited, Publishers 5. K. Newton, W. Steeols, T. K. Garrett-The Motor Vehicle : Butterworth

Heinemann. 6. Joseph Heitner – Automotive Mechanics : Principles & Practices, CBS Publishers

& Distributors. 7. V. A. W. Hiller & Peter Coombes, Hiller’s Fund of Motor Vehicle Tech. (Book-I) 8. Dr. Amitosh De “Automobile Engineering” Galgolia Publication, New Delhi.


AUTOMOBILE ELECTRONICS L 3

T 0

P 2


Total Contact hrs. : 75 Theory : 45 Practical : 30 Pre requisite: AE 409 Credit: 4

Total Marks: 150 Theory : End Term Exam : 70 P.A. : 30 Practical : End Term Exam. : 0 P.A. : 50

RATIONALE: Due to stringent exhaust emission regulations introduced during the early 1970’s all mechanical automobiles faced an uncertain future. Engine designers were forced to adopt electronic engine control systems as a solution to their problems and so crucial early links between the automobile and electronics industries were soon formed. Subsequently, developments in microelectronics and particularly the availability of powerful low-cost microprocessors, resulted in the development of a whole host of automotive electronic systems. Most of these may be described as mechatronic systems, meaning that they integrate mechanical, electronic and microcomputer technologies. These changes, together with increasing environmental and social pressures, have led to a revolution in the concept of the automobile, and have placed great demands on those technicians involved in maintaining cars. Thus this subject is inevitable in the diploma programme. AIM: This subject will enable the students to understand the operation of contemporary automobile electronic systems. The topics are used to explore specific aspects of electrical electronics such as engine management and pollution control, vehicle sub-systems such as battery, starting system, ignition system, lighting system etc.



1.0 INTRODUCTION 4 1.1 Vehicle sub-systems: Battery and charging system,

Engine starting system, Lighting system, Engine management system, Chassis control systems, Body electrical system, In-car entertainment.

1.2 Vehicle electrical distribution system:

Cable types, harness routing, cable colour coding, correctors, phasing, thermal circuit protection.

1.3 Multiplex wiring systems. 2.0 DIGITAL CIRCUITS 4 2.1 a) Logic gates and its truth table

b) Combinational logic c) Sequential circuits d) Counters and Registers

2.2 Function of an arithmetic logic unit and memories 2.3 a) Applications of Microprocessor

b) DAC and ADC circuits

3.0 BATTERIES 7 3.1 Introduction – functions of automotive battery; types

of batteries; lead acid, alkaline battery, zinc air battery

3.2 Lead acid battery – construction : grids, plates, case, electrolyte; chemical actions in battery; connecting cells, battery ratings, resume capacity; ampere hour capacity, (20 minute rate), cold-cranking rate, watts; battery efficiency; ways of battery charging : constant current charging, constant voltage or potential charging, quick charging; trickle charging, overcharging and its effects

3.3 Battery maintenance and service – checking battery state of charge: specific gravity test, open volt test, high discharge test, cadmium test, battery troubles: self discharge, sulphation, internal short circuiting, deterioration of plates, cracking of container, corrosion of battery terminals and clamps, loss of water, cell gravity variation, discolouring of electrolyte; steps for battery maintenance: checking the battery visually, checking electrolyte level in cells in batteries with vest caps, adding distilled water in case of lower level, cleaning off corrosion around battery terminals and from top of batteries with top terminals, checking battery condition by testing of charge, charging battery if it is low.



4.0 CHARGING SYSTEM 5 4.1 Introduction: purpose of charging system, function of

alternator, principles of alternator

4.2 Parts of alternator: the stator, the rotor, rectifier pack;

alternator regulator

4.3 Alternator regulation: 5.0 IGNITION SYSTEM 5 5.1 Introduction - purpose of ignition system; types of

ignition system: Contact breaker point, ignition system, electronic ignition system.

5.2 Construct and function of different parts of contact

point ignition system- battery, ignition switch, ignition coil, the ignition distributor, vacuum advance mechanism spark plugs and wires and cables connecting them.

5.3 Servicing of contact breaker point, ignition system :

causes of ignition failure, quick checks of ignition system.

5.4 Electric ignition system: battery, ignition coil,

electronic control unit, ignition distributor, spark plugs.

5.5 Magneto ignition system – construction, operation. 6.0 LIGHTING SYSTEM 5

6.1 Construction and function of the main components of

lighting system : various lamps or lights, switches, fuses and circuit breakers, junction box

6.2 Different types of lights : head lights, side or parking

lights, tail or stop lights, dash lights, cab and body lights



6.3 Parts of a lamp : bulles, reflectors, lens

6.4 Switches : main light switch, dipper switch, stop light

switch

6.5 Fuses and circuit breaker

• Describe the purpose and operation of the each component of lighting system.

7.0 MISCELLANEOUS SYSTEMS 5 7.1 Horn Circuit – function; main parts of horn circuit :

electric horn, horn relay, switch

7.2 Traifficater circuit - 7.3 Wiper motor circuit 7.4 Speedometer circuit 8.0 SOME ADVANCED FEATURES OF MODERN

AUTOMOBILES 5

8.1 Ignition system 8.2 Computer controlled petrol fuelling systems 8.3 Engine management systems (EMS) 8.4 Anti-lock braking system (ABS) 8.5 Traction control 8.6 Stability Control

8.7 Air conditioning

9.0 PRACTICAL 30

9.1 Battery servicing and testing 9.2 Inspection of ignition circuit 9.3 Overhauling of distributor 9.4 Overhauling of alternator 9.5 Overhauling of starter motor 9.6 Servicing of starting system 9.7 Servicing of charging system


REFERENCE BOOKS :

1. Dr. Kripal Singh, Automobile Engineering – Vol. I and II, Standard Publishers 2. Distributors, Delhi-6.

3. Harbans Singh Reyat, The Automobile - S. Chand & Company Ltd.

4. Joseph Heitner, Automotive Mechanics - CBS Publishers & Distributors

5. William H. Crouse, Donald L. Anglin – Automotive Mechanics - Tata

McGraw Hill Publishing Company Ltd.

6. P. L. Kohli, Automotive Electrical Equipment - Tata McGraw Hill Publishing Company Ltd. 7. Eric Chowaniety, Automobile Electronics, Butterworth - Heinemann Ltd. 8. Dr. Amitosh De “Automobile Engineering” Galgotia Publication Ltd, New

Delhi.


AUTOMOBILE CHASSIS L 3

T 0

P 2


Total Contact hrs.: 75 Theory: 45 Practical: 30 Pre requisite: Credit: 4


RATIONALE: The modern automobile is made up of many systems, components and innumerable parts. Study of all these components and parts are possible by studying the various systems and understanding the role of the components and parts which make such systems. However, the systems can again be grouped under four headings viz. The Engine, The Power Train, The Chassis and The Electrics & Electronics. The parts of an automobile under the body are referred to as Chassis. Apart from the engine and power train, several other systems are mounted on the Chassis which include the Frame work itself, suspension system through which wheels are connected to the frame, the steering arrangement by which the wheels are moved, the brake system to stop the moving car etc. The various systems making up the chassis of an automobile are vital for operation of an automobile and hence forms an important subject for the study of automobile engineering. AIM: After studying this subject, a fresh diploma holder in automobile engineering should be able to understand and explain the constructional details and operations, diagnose the problems and prescribe the remedies, and undertake necessary preventive maintenance of frame work, suspension system, steering and wheel mechanism, brake system and tyres of an automobile.


THEORY: 45 Hours


1.0 FRAME WORK

Function of frame; layout of frame: ladder frame, X-member frame, unitized body; constructional details of frame and frame members.

3

2.0 SUSPENSION SYSTEM 12 2.1 Functions of suspension system; different types of

suspension system: rigid axle front wheel system, independent front wheel suspension system, Mcpherson strut suspension system, rigid rear suspension, independent rear suspension system; engine mounting.

2.2 Different Components: springs, shock absorber, torsion bar, ball joints, stabiliser.

2.3 Troubleshooting; preventive maintenance 3.0 STEERING AND WHEELS 12 3.1 Function of steering; requirements of steering

system; different steering gears: rack and pinion, re-circulating ball; power steering; variable ratio steering.

3.2 Steering linkage; steering column 3.3 Wheel rim design; wheel alignment factors: Camber,

caster, steering axis inclination, toe-in, turning radius.

3.4 Troubleshooting: tyre wear, wander or pull, brake

pull, hard steering; preventive maintenance; wheel alignment.

4.0 BRAKE SYSTEM 12 4.1 Concept of oil hydraulics; transmission of pressure

in a oil circuit.

4.2 Necessity and requirements of brakes; Drum brakes; disc brakes; hydraulic brake system; master cylinder and wheel cylinder; brake fluid; brake shoes and lining.


4.3 Power brake system; parking brakes; stop light

switch

4.4 Troubleshooting; adjustment of brakes, master

cylinder servicing; bleeding of brakes.

5.0 TYRES 6 5.1 Types of tyres: solid, pneumatic with and without

tube; construction and design: bias ply, radial ply, belted bias ply; tyre size and ratings; re-treading of tyres.

5.2 Troubleshooting: excessive wear, sway, pull, noise,

vibration; preventive maintenance: inflation, tyre rotation, servicing; tyre and wheel runout; wheel balancing, tyre repair.

PRACTICAL: 30 Hours 6.0 PRACTICAL 30 6.1 Replace a shock absorber from an automobile 6.2 Determine the stiffness of a compression coil spring 6.3 Find out the wheel alignment factors of a car :

camber, caster, steering axis inclination and toe-in using suitable gauges

6.4 Open steering gear and make detailed sketch of same

and label components

6.5 Take out the tyre and tube from rim and refit it on

the rim, inflate it and fit it on the car

6.6 Open a master cylinder, replace all rubber parts and

refit it

6.7 Remove a drum brake assembly from the car 6.8 Check a tyre and wheel assembly for static

balancing.

N. B. : Each student group should conduct at least five of the above or similar practical work. Each group should not consist of more than 10 students. Care should be taken that each student of the groups is participating in the practical work.


REFERENCE BOOKS : 1. Automotive Chasis & Body : W. H. Course – McGraw Hill 2. Auto Mechanics : J. Webster – Glenco Publishing Co. 3. Automobile Engineering : G. B. S. Naraug 4. Automobile Engineering, Vol. I & Vol. II : Kirpal Singh. 5. V. A. W. Hiller & Peter Coombes, Hiller’s Fund of Motor Vehicle Tech.

(Book-I)

6. Dr. Amitosh De “Automobile Engineering” Galgotia Publication Ltd, New Delhi.


AUTOMOBILE WORKSHOP – I L 1

T 0

P 4


Total Contact hrs. : 75 Theory : 15 Practical : 60 Pre requisite: Credit : 3

Total Marks : 75 Theory : 0 End Term Exam : 0 P.A. : 0 Practical : End Term Exam. :0 P.A. : 75

RATIONALE: Today millions of automobiles, trucks and buses operate on the streets and highways. There are huge number of off-the-road vehicles such as tractors, power mowers, motor cycles. Huge number of mechanics work to keep all this equipment going. Most automotive troubles can be avoided by periodic inspection and adjustment of these parts of a vehicle which experience has shown are most apt to fail. Even with reasonable periodic care however, some trouble must be expected. Automotive maintenance and trouble shooting has a threefold purpose : to demonstrate how to forestall most troubles, to show how to locate quickly and accurately the source of trouble which has already developed and to describe how to restore the vehicle to satisfactory operation once it is known what is wrong with it. This practical subject is essential for diploma student because it provides the scope for hands-on-experience in maintenance and trouble shooting of automobiles. AIM: The subject develops the skills in maintenance and trouble shooting of automobiles engines.



1.0 ENGINES SERVICING (PETROL ENGINE) 15 1.1 Dismantling of a multi-cylinder petrol engine

1.2 Cleaning the parts

1.3 Inspection of parts for their condition

1.4 Checking the cylinder bores for ovality, piston diameter

1.5 Removal of piston rings

1.6 Cleaning of piston ring groove

1.7 Fitting piston in the cylinder

1.8 Servicing and cleaning of air cleaner

1.9 Reassembling the engine.

2.0 ENGINE SERVICING (DIESEL ENGINE) 15 2.1 Dismantling a multi cylinder diesel engine

2.2 Cleaning the parts

2.3 Inspection of parts for their condition

2.4 Checking the cylinder bores for ovality

2.5 Checking of valves for regrinding.

3.0 DECARBONIZING OF ENGINES 6 3.1 Removing carbon deposits from engine combustion

chamber, piston crown, valve parts

4.0 INSPECTION OF CRANKSHAFT 8 4.1 Replacement of bearing and setting of journal bearings,

crank-pin bearings and crank shaft bearings, measuring bearing clearances by gauges.

5.0 VALVE SERVICING 8 5.1 Replacement of valves, valve seat facing(new valve),

valve seat re-facing (old valve), replacement of valve guide



5.2 Checking and replacement of defective valve springs 5.3 Facing of tapet and rocker arm 5.4 Adjusting valve tapets 5.5 Valve clearance adjustment 5.6 Valve timing adjustment. 6.0 SERVICING OF COOLING SYSTEM 6 6.1 Servicing of water pump 6.2 Adjustment of fan belt tension 6.3 Radiator repairing and servicing. 7.0 SERVICING OF LUBRICATION SYSTEM 6 7.1 Servicing of oil-pump filter 7.2 Cleaning of oil gallery and changing of engine oil and oil

filter.

8.0 SERVICING OF FUEL SUPPLY SYSTEMS 3 8.1 Servicing of fuel supply system including cleaning of

petrol /diesel tank

8.2 Servicing of petrol/diesel fuel pump and testing of fuel

pump pressure and vacuum.

9.0 SERVICING OF CARBURETOR 3 9.1 Disassembling a carburetor of a good running petrol

engine

9.2 Cleaning the parts (cleaning agents carbon, tetrachloride

or lacquer thinner)

9.3 Visual inspection and replacement of defective parts



9.4 Replacing the packings with new at every dismantle and

assembly of carburetor

9.5 Identifying the various circuits starting, idling, high speed

accelerating, pump circuits.

9.6 Assembling the carburetor and refitting on the engine 9.7 Tuning-up the engine by tuning equipment. 10.0 SERVICING OF FUEL INJECTION SYSTEM 5 10.1 Study of fuel injection pump on a live diesel engine

(single cylinder and multi-cylinder)

10.2 Bleeding of fuel injection system of the engine along with

advance and retard (ignition)

10.3 Calibration and phasing of fuel injection pump (using

calibration and phasing machine)

10.4 Dismantling an injector of an engine 10.5 Cleaning and inspection of various parts 10.6 Replacement of defective parts 10.7 Refitting and testing of injector by a nozzle tester

attached with a compressor.

11.0 SERVICING OF IGNITION SYSTEM 4 11.1 Engine tuning including spark plug cleaning and gap

adjustment (using spark plug cleaner and tester along with air compressor)

11.2 Idling speed and high speed adjustment 11.3 Testing of ignition coil and condenser by coil condenser

tester

11.4 Testing of spark plug on running engine.



12.0 SERVICING OF DISTRIBUTOR 2 12.1 Testing of rotor and spark advance mechanism 12.2 Contact breaker point cleaning, setting and gap

adjustment (cleaning agent carbon tetrachloride and lacquer thinner)

12.3 Visual inspection of wires of faulty insulation or poor

connection

12.4 Setting ignition timing. 13.0 SERVICING OF STORAGE BATTERY 2 13.1 Inspection of battery using hydrometers and cell testers 13.2 Charging of battery 13.3 Prevention of leakage in batteries 14.0 SERVICING OF CHARGING SYSTEM 2 14.1 Servicing of generator and cleaning of commutator and

tuning

14.2 Rewinding field and armature, replacing brushes, brush

holders and springs

14.3 Adjustment of regulator and cutout and checking of

ammeter connections.

15.0 SERVICING OF STARTING SYSTEM 3 15.1 Servicing starter motor and replacement of brushes 15.2 Repair of Bendix or any other drive. 16.0 EMISSION CONTROL 2 16.1 Pollution testing with the aid of exhaust gas analyser

(petrol/diesel).

NOTE: At least 10 no. of servicing should be conducted per semester where a batch of five students will work for each servicing.


REFERENCE BOOKS : 1. Dr. Kirpal Singh – Automobile Engineering Vol. I and II, Standard Publishers

Distributors.

2. William H. Crouse and Donald L. Anglin – Automotive Mechanics : Tata McGraw Hill Publishing Company Ltd., New Delhi

3. Central Instructional Media Institute – Mechanic Motor Vehicle 1st year

4. Trade Practical – New Age International (P) Limited Publishers

5. Ernest Verk and Edward D. Spicer – Automotive : Maintenance and Trouble Shooting, D.B. Taraporevala Sons & Co. Private Ltd., Bombay - 1

6. Ernest Verk and Walter Billiet – Automotive Engines : Maintenance and Repair, D. B. Taraporevala Sons & Co. Private Ltd., Bombay - 1

7. Joseph Heitner – Automotive Mechanics : Principles & practices, CBS Publishers & Distributors

8. S. Srinivasan – Automotive Mechanics, Tata McGraw - Hill Publishing Company Limited, New Delhi.

9. Dr. Amitosh De “Automobile Engineering” Galgotia Publication Ltd, New Delhi.


MANUFACTURING TECHNOLOGY – II L 3

T 0

P 0

Curri Ref. No. : AE 508

Total Contact hrs.:45 Theory: 45 Practical: 0 Pre requisite: Credit:3


RATIONALE: Manufacturing is the backbone of any industrial nation. The level of manufacturing activity is directly related to the economic health of a country. Generally, the higher the level of manufacturing activity in a country, the higher is the standard of living of it’s people. Manufacturing is generally a complex activity, involving people who have a broad range of knowledge and skills of a wide variety of machinery, equipment, and tooling with various levels of automation, including computers, robots, and material handling equipment.

Work of a practicing engineer of any discipline is directly or indirectly connected with manufacturing of goods or services. Therefore, this subject is of vital importance in the curriculum of mechanical and automobile engineering. AIM: To develop concepts of operations and use of all basic types of machine tools normally used in manufacturing industry, and also to have an idea of numerical control machines, non-conventional machining and industrial automation.



1.0 INTRODUCTION TO MANUFACTURING PROCESS

DiffereDifferent types of manufacturing processes, functions of manufacturing process, factors influencing selection of manufacturing process • State the factors for selection of a particular manufacturing

process

2

2.0 DEFINITION OF MACHINE TOOLS, BASIC MACHINE TOOLS AND THEIR OPERATIONS Lathe, drilling machine, shaper, planer, slotter, broaching machine, milling machine, boring machine, grinding machine, gear hobbing machine; metal cutting process. • List out various operations that can be done in each

individual machine tool • Identify the cutting motions and feed motions for each of

above operations • Define a machine tool • Explain metal cutting process

5

3.0 LATHE 6

3.1 Types of lathe, parts of centre lathe, centre lathe specification, speed changing mechanism, all geared heaad stock, feed drive, apron mechanism, operations, classification, specifications

3.2 Accessories & attachments : centres, carriage, chucks, face

plate, angle plate, mandrel, steady rest, follower rest, taper turning attachment

3.3 Lathe operations: straight turning, taper turning, thread

cutting, calculation of change gears, facing, chamfering etc. • Write detailed specification of a centre lathe • Identify various parts and attachments of a lathe and

explain their functions • Determine various operations and corresponding tools

by which different machined objects may be made in a lathe.

4.0 DRILLING MACHINE 4 4.1 Various types of drilling machine, specification of a

drilling machine.

4.2 Tool holding devices: sleeve, socket, drill chuck etc.


4.3 Drilling machine operations: drilling, boring, reaming, counter boring, counter sinking, spot facing • Explain feed motion mechanism of a drilling

machine • Compare functions of a pillar drill and a radial drill • Sketch drilling jigs for specific jobs • List various operations that can be performed in a

drilling machine.

5.0 SPHAPING MACHINE 5 5.1 Driving mechanism: crank and slotted mechanism,

quick return mechanism, stroke length adjustment, feed mechanism

5.2 Shaping operations: Machining horizontal, vertical,

angular surface, cutting slots and keyways • List various operations which can be performed in

shaper • Draw and analyze quick return mechanism of a

shaper • Explain through sketch how feed motion is given

in a shaper.

6.0 MILLING MACHINE 4 6.1 Classifications, specifications of a milling machine,

constructional features and parts of a horizontal and vertical milling machine

6.2 Different milling cutters (slab, side and face, angular,

form relieved, end mill, face mill) and their uses; gang milling operation. • List various milling operations • Classify different types of milling machine • Sketch an universal milling machine and label

various parts • Explain uses of different milling tools.

7.0 NUMERICAL CONTROL (NC) MACHINES : 5 7.1 Introduction to numerical control machine: NC, CNC

and DNC.

7.2 Principles of numerical control; operation of NC

System; point to point, continuous path / contour system.

7.3 Constructional details of a CNC machine: axis

identification, slide ways, spindle mounting, drive units, position transducers.


7.4 Input media (punched cards, magnetic tapes, punched tape), decimal binary coding; card, magnetic tape, punched card reader; operation procedure: planning, part programming, tape/card preparation, verification, production. • Understand the basic concept of a NC machine • Define the term numerical control • Differentiate between NC, CNC and DNC • Explain through sketch the operation of NC system

for machining a profile • Explain the function of position transducer.

8.0 NON-CONVENTIONAL MACHINING Basic processes, applications, advantages and disadvantages and economics of the following process: Chemical Machining, Electrochemical Machining, Electro Discharge Machining (EDM), Laser Beam Machining, Electron Beam Machining, Water Jet Machining, Abrasive Jet Machining.

6

9.0 INDUSTRIAL AUTOMATION : 8 Basic concepts about the following 9.1 Industrial computerization and automation 9.2 Flexible manufacturing systems 9.3 CAD / CAM / CIM 9.4 Robotics

• Sate the reasons for industrial automation • Define a robot • Understand concept of flexible manufacturing

system • Understand concept of CAD/CAM/CIM.

REFERENCE BOOKS : 1. S. K. Basu and D. K. Pal : Design of Machine Tools. 2. Oxford & IBH Publishing Co. Pvt. Ltd. 3. S. K. Hajra Choudhury, S. K. Bose, A. K. Hazra Choudhury : 4. Elements of Workshop Technology Vol. : II 5. Media Promoters & Publishers Pvt. Ltd. 6. W. A. J. Chapman : Workshop Technology, Part 1 & 2 – ELBS. 7. H. Gerling : All about Machine Tools – New Age International (P) Ltd. 8. Sen and Bhattacharyya : Principles of Machine Tools 9. New Central Book Agency 10. Groover : Automation, Production Systems and Computer – 11. Integrated Manufacturing, Prentice Hall of India.


Auto Machine Shop L 1

T 0

P 4


Total Contact hrs.: 75 Theory: 15 Practical : 60 Pre requisite: Credit: 3

Total Marks: 75 Theory: 0 End Term Exam: 0 P.A.: 0 Practical: End Term Exam: 0 P.A : 75

RATIONALE : Modern automobile is a complex combination of systems, each designed for maximum efficiency and for compatible relationship with others. Each system must be maintained in first class operating condition, or it may affect the operation of the other related systems. Therefore, a good auto machine shop must have tools and equipment to undertake all types of fault finding and servicing jobs. The tools and equipment which are must in the auto machine shop are discussed in this subject. An Automobile engineer must have thorough knowledge and practice of all tools and equipment in an auto machine shop. AIM : To identify and use various tools and equipment used for maintenance and trouble shooting of automobiles.



1.0 STUDY AND USE OF THE FOLLOWING TOOLS

AND EQUIPMENT

Screw drivers, spanners, wrenches, pliers, hammers, chisels, files, hacksaw, drilling machine, bench vice, grinder, chain pulley block, hydraulic jack and axle stands, tools and equipment for tyres, lubrication equipment, battery testing and charging equipment, hydraulic test or service ramp, tyre remover, brake testing & equipment. High pressure washing equipment, engine analyzer, hydraulic press, piston ring compressor, ring remover, piston groove cleaner, cylinder reboring machine, cylinder honing, valve refacing machine, fuel injector tester, air compressor and pressure gauge. Piston rung squeezer.

24

2.0 MEASURING INSTRUMENTS 12 a) Study and use of the following measuring instruments. i) Micrometer, dial gauge, vernier caliper, feeler

gauge, vernier height gauge, engine compression gauge.

b) Measurement of the following items and parameters i) Measurement of crank pins, main journal of the

crank shaft, cam shaft

ii) Checking alignment of connecting rod iii) Measurement of the cylinder bore by inside

micrometer

iv) Determine the ovality and taper by using dial gauge v) Correct selections of pistons, piston ring groove

cleaning & fitting piston rings

vi) Measurement of valve lift for various angles of

crank rotation by using dial gauge

vii) Measurement of tappet clearance by using feeler

gauge and setting of tappet clearance.

3.0 MACHINING OF ENGINE VALVE 18 i) Refacing valve by valve refacing machine ii) Valve seat cutting (by manual and electric cutters) iii) Valve lapping and testing of leakage



4.0 OPERATIONS AND INSPECTIONS 24 i) Crank shaft grinding ii) Piston ring groove cleaning, iii) Cylinder reboring and honing iv) Brake drum turning (by work visit to different

organisation)

v) Turning of propeller shaft, dismantling universal

joints, cleaning, reconditioning & refitting

vi) Inspection of rear axle, differential for proper

lubrication

vii Different types of metal bush turning, reaming &

setting

viii Operation of CNC Lathe and Milling Machine

5.0 INSPECTION OF BRAKE SYSTEMS 12 5.1 Brake shoe rivetting 5.2 Adjustment and bleeding of hydraulic brakes 5.3 Adjustment of brake and clutch paddle free play 6.0 LAYOUT OF MODERN AUTO MACHINE SHOP REFERENCE BOOKS: 1. International Labour Office, Geneva : Maintenance and Repair of Motor

Vehicles. 2. Ernest Venk and Edward D. Spicer : Automotive Maintenance and Trouble

shooting – D. B. Taraporevala Sons & Co. Private Limited 3. K. Singh : Automobile Engineering, Vol. I – Standard Publishers Distributors 4. Frederick E. Bricker : Audels Automobile Guide – D. B. Taraporevala Sons &

Co. Private Ltd.


AUTOMOBILE WORKSHOP – II L 0

T 0

P 4


Total Contact hrs. : 60 Theory : 0 Practical: 60 Pre requisite: AE507 Credit: 2

Total Marks: 75 Theory : 0 End Term Exam : 0 P.A. : 0 Practical : End Term Exam. : 0 P.A. : 75

RATIONALE: Today millions of automobiles, trucks and buses operate on the streets and highways. There are huge number of off-the-road vehicles such as tractors, power mowers, motor cycles. Huge number of mechanics work to keep all this equipment going. Most automotive troubles can be avoided by periodic inspection and adjustment of these parts of a vehicle which experience has shown are most apt to fail. Even with reasonable periodic care however, some trouble must be expected. Automotive maintenance and trouble shooting has a threefold purpose: to demonstrate how to forestall most troubles, to show how to locate quickly and accurately the source of trouble which has already developed and to describe how to restore the vehicle to satisfactory operation once it is known what is wrong with it. This practical subject is essential for diploma student because it provides the scope for hands-on-experience in maintenance and trouble shooting of automobiles. AIM: The subject provides the practice on trouble shooting of engines, servicing and maintenance of control and suspension system, servicing and maintenance of transmission system to develop skills in handling automobiles.



1.0 SERVICING OF A SERVICEABLE DIESEL ENGINE

18

1.1 Doing required trouble shooting for proper starting of engine

1.2 Starting the engine.

2.0 SERVICING OF CLUTCHES 12 2.1 Removal of worn out parts 2.2 Adjustment of clutch, pedal free play and release

lever adjustment

2.3 Inspection of pressure plate and clutch disc of

automobile and two wheelers, checking their workability, machining of pressure plate and flywheel surfaces, pressure adjustment and clutch adjustment

2.4 Servicing different kinds of clutches. 3.0 SERVICING OF GEAR BOX 6 3.1 Servicing different types of gear boxes, assembling

and adjustment, selector mechanism etc.

3.2 Dismantling of a synchromesh gearbox, adjustment

of synchronizer unit.

4.0 SERVICING OF PROPELLER SHAFT AND REAR

AXLE 6

4.1 Servicing propeller shaft, universal joints and sliding

joints and inspection of splines.

4.2 Servicing / over handling of differential 4.3 Servicing / over handling of axles. 5.0 SERVICING OF SUSPENSION SYSTEM 6 5.1 Servicing of leaf springs, independent suspension,

coil spring, torsion bar, telescopic shock absorber.

6.0 SERVICING OF FRONT AXLE AND STEERING 6 6.1 Servicing of steering mechanism & wheel alignment 6.2 Servicing of front axle assembly 6.3 Checking and adjustment of camber, caster, toe-in

and toe-out, king pin inclination.


7.0 SERVICING OF WHEELS AND TYRES 6 7.1 Servicing of defective tyres and tubes 7.2 Tyre retreading using cold and hot patch 7.3 Wheel balancing (static and dynamic) 7.4 Straightening of wheel rims. 7.5 Wheel alignment 8.0 SERVICING OF BRAKES 6 8.1 Replacing brake shoe, testing brake shoe return

spring, brake pedal adjustments, servicing hydraulic brake system (brake bleeding).

8.2 Practice in brake shoe riveting and deriveting,

aligning the shoes and adjustment of brakes.

9.0 SERVICING OF HORN, WINDSHIELD WIPER

MACHINE. 3

10.0 SERVICING OF LIGHTING SYSTEM: -

Servicing head lights, rear lights parking lights, indictors, license light.

3

REFERENCE BOOKS: 1. Dr. Kirpal Singh – Automobile Engineering Vol. I and II, Standard Publishers

Distributors. 2. William H. Crouse and Donald L. Anglin – Automotive Mechanics: Tata

McGraw Hill Publishing Company Ltd., New Delhi 3. Central Instructional Media Institute – Mechanic Motor Vehicle 1st year Trade Practical – New Age International (P) Limited Publishers 4. Ernest Verk and Edward D. Spicer – Automotive: Maintenance and Trouble

Shooting, D.B. Taraporevala Sons & Co. Private Ltd., Bombay - 1 5. Ernest Verk and Walter Billiet – Automotive Engines: Maintenance and

Repair, D. B. Taraporevala Sons & Co. Private Ltd., Bombay - 1 6. Joseph Heitner – Automotive Mechanics: Principles & practices, CBS

Publishers & Distributors 7. S. Srinivasan – Automotive Mechanics, Tata McGraw - Hill Publishing

Company Limited, New Delhi.


PROJECTS AND DRIVING PRACTICE L 2

T 0

P 6


Total Contact hrs. : 120 Theory : 30 Practical: 90 Pre requisite: Credit: 4

Total Marks: 250 Theory : End Term Exam : 0 P.A. : 0 Practical : End Term Exam. : 0 P.A. : 250

RATIONALE: The project work on automobile will give the students an opportunity to develop skills undertaking repair, maintenance and overhauling works. Execution of the project in a small group develops skills in organizing a work, interacting with peers to do a work in a group and collecting data from different sources like library, industry, market etc. This develops confidence to take up responsibilities in future work environment. AIM: The aim of the project work is to enable the students to study plan and implement the repairing, maintenance and over-hauling of different automobile systems. UNIT TOPIC/SUB-TOPIC HRS. TOTAL

HRS.

1.0 PROJECT JOB (ANY ONE) 40

1.1 Prototype development of automobile component or system steering system, brake system etc.

1.2 Undertaking repair, maintenance and overhauling of automobile system

1.3 Re-conditioning of vehicles.

2.0 PREPARATION OF PROJECT REPORT FOR MANUFACTURE OF ANY ONE OF THE FOLLOWING AUTOMOBILE PARTS

10

2.1 Silencer unit

2.2 Air Cleaner

2.3 Piston type compressor for air brake system

2.4 Gears for auto transmission

2.5 Clutch disc 2.6 Brake servo cylinder 2.7 Radiator.



3.0 DRIVING PRACTICE 40 i) Identification of vehicle parts and components ii) Preliminary knowledge about power generation and

transmission

iii) Practicing and pressing of clutch, brake and accelerator

pedal

iv) Practicing steering control v) Practicing gear shifting vi) Driving of vehicle in an open field vii) Driving of vehicle in an open field by placing several

obstacles on particular route

viii) Driving of vehicle in reverse direction ix) Forward and backward driving of vehicle on a slope x) Driving of vehicle on public road xi) Driving of vehicle at night on ring road xii) Driving of vehicle on highway. Note: I. Students should visit state garage, central works or other industries before

taking over the project. II. A group of 4-5 students should be given an independent project assignment. III. The project work should relate to actual industrial /field problems and be

executed in the industrial /field setting. IV. Driving license may be acquired by student during course tenure period,


PROFESSINAL PRACTICES – I

L 0

T 0

P 2



Total marks: 50 Practical: P.A : 50

RATIONAL To develop general confidence, ability to communicate and attitude, in addition to basic technological concepts through Industrial visits, expert lectures, seminars on technical topics and group discussion.

AIM The Student will be able to: • Acquire information from different sources. • Prepare notes for given topic. • Present given topic in a seminar. • Interact with peers to share thoughts. • Prepare a report on industrial visit, expert lecture.

Activities

Industrial Visits: Structured industrial visits be arranged and report of the same should be submitted by the individual student, to form part of the term work. Visits to any two of the following: • Nearby Petrol Pump.(fuel, oil, product specifications) • Automobile Service Station (Observation of Components / aggregates) • Engineering Workshop(Layout, Machines) • Dairy Plant / Water Treatment Plant Lectures by Professional / Industrial Expert / Student Seminars based on information search to be organized from any THREE of the following areas: • Pollution control. • Non-destructive testing. • Acoustics. • Illumination / Lighting system. • Fire Fighting / Safety Precautions and First aids. • Computer Networking and Security. • Topics related to Social Awareness such as - Traffic Control System, Career

opportunities, Communication in Industry, Yoga Meditation, Aids awareness and health awareness.


Group Discussion: The students should discuss in a group of six to eight students and write a brief report on the same as a part of term work. Two topics for group discussions may be selected by the faculty members. Some of the suggested topics are - a) Sports b) Current news items c) Discipline and House Keeping d) Current topics related to mechanical engineering field. Student Activities: The students in a group of 3 to 4 will perform any one of the following activities (others similar activities may be considered Activity : a) Collect and study IS code for Engineering Drawing.. b) Collecting information from Market: Nomenclatures and specifications of

engineering materials. c) Specifications of Lubricants. d) Draw orthographic projections of a given simple machine element using and CAD

software


PROFESSINAL PRACTICES – II

L 0

T 0

P 2





AIM Student will be able to: • Acquire information from different sources. • Prepare notes for given topic. • Present given topic in a seminar. • Interact with peers to share thoughts. • Prepare a report on industrial visit, expert lecture Contents

Activities Industrial Visits

Structured industrial visits be arranged and report of the same should be submitted by the individual student, to form a part of the term work. TWO industrial visits may be arranged in the following areas / industries:

a. Manufacturing organizations for observing various manufacturing processes including heat treatment

b. Material testing laboratories in industries or reputed organizations c. Auto workshop / Garage d. Plastic material processing unit e. ST workshop / City transport workshop

Lectures by Professional / Industrial Expert be organized from ANY THREE of the following areas:

a. Use of a plastics in automobiles. b. Nonferrous Metals and alloys for engineering applications c. Surface Treatment Processes like electroplating, powder coating etc. d. Selection of electric motors. e. Computer aided drafting. f. Industrial hygiene. g. Composite Materials. h. Heat treatment processes. i. Ceramics j. Safety Engineering and Waste elimination

Individual Assignments: Any two from the list suggested


a) Process sequence of any two machine components. b) Write material specifications for any two composite jobs. c) Collection of samples of different plastic material or cutting tools with properties,

specifications and applications. d) Preparing models using development of surfaces. e) Assignments on bending moment, sheer forces, deflection of beams and torsion

chapters of strength of material. f) Select different materials with specifications for at least 10 different machine

components and list the important material properties desirable. g) Select 5 different carbon steels and alloy steels used in mechanical engineering

applications and specify heat treatment processes employed for improving the properties. Also give brief description of the heat treatment processes.

h) List the various properties and applications of following materials - a. Ceramics b. fiber reinforcement plastics c. thermo plastic plastics d. thermo setting plastics e. rubbers.

OR Conduct ANY ONE of the following activities through active participation of students and write report

a. Rally for energy conservation / tree plantation. b. Survey for local social problems such as mal nutrition, unemployment,

cleanliness, illiteracy etc. c. Conduct aptitude , general knowledge test , IQ test d. Arrange any one training in the following areas :

i) Yoga. ii) Use of firefighting equipment and First aid

Maintenance of Domestic appliances.

Modular courses (Optional): A course module should be designed in the following areas for max. 12 hrs. Batch size - min. 15 students. Course may be organized internally or with the help of external organizations. a) Forging Technology. b) CAD-CAM related software. c) Welding techniques. d) Personality development. e) Entrepreneurship development. 3-D Design using software Computer screen, coordinate system and planes, definition of HP,VP, reference planes How to create them in 2nd/3rd environment. Selection of drawing site & scale. Commands of creation of Line, coordinate points, Axis, Poly lines, square, rectangle, polygon, sp line, circles, ellipse, text, move, copy, offset, Mirror, Rotate, Trison, Extend, Break, Chamfer, Fillet,Curves, Constraints fit tangency, perpendicularity, dimensioning Line convention, material conventions and lettering. The Student should draw - different orthographic Views (including sections), Auxiliary views according to first/ Third angle method of projection. (Minimum two sheets, each containing two problems) after learning the contents as above.


PROFESSINAL PRACTICES – III

L 0

T 0

P 2





AIM Student will be able to: • Acquire information from different sources • Prepare notes for given topic • Present given topic in a seminar • Interact with peers to share thoughts • Prepare a report on industrial visit, expert lecture Contents

Activities Industrial Visits Structured industrial visits be arranged and report of the same shall be submitted by the individual student, to form a part of the term work. The industrial visits may be arranged in the following areas / industries: Sugar Factory / Dairy / Chemical Industry / Thermal Power Plant. a. Machine shop having CNC machines. b. ST workshop / Auto service station c. City water supply pumping station d. Manufacturing unit to observe finishing and super finishing processes.

Lectures by Professional / Industrial Expert lectures to be organized from any two of the following areas: Interview Techniques. Modern Boilers - Provisions in IBR Applications of Sensors and Transducers Alternate fuels - CNG / LPG , Biodiesel, Ethanol, hydrogen Piping technology Information Search: Information search can be done through manufacturer's catalogue, websites, magazines, books etc. and submit a report any one topic.


Following topics are suggested: a. Engine lubricants & additives b. Automotive gaskets and sealants c. Engine coolants and additives d. Two and Four wheeler carburetor. e. Power steering f. Filters g. Different drives/Transmission systems in two wheelers. h. Types of bearings - applications and suppliers i. Heat Exchangers j. Maintenance procedure for solar equipment. Tools holder on general purpose machines and drilling machines. Seminar: Seminar topic shall be related to the subjects of fourth semester. Each student shall submit a report of at least 10 pages and deliver a seminar (Presentation time - 10 minutes) Mini Project / Activities: (any one) a) Prepare one model out of card board paper / acrylic / wood / thermocol / metal

such as : i) Elliptical Trammel ii) Pantograph iii) Coupling iv) Cams and Followers v) Geneva mechanism

b) Dismantling of assembly (e.g. jig / fixtures, tool post, valves etc.) Take measurement and prepare drawings / sketches of different parts.

c) Make a small decorative water fountain unit. d) Toy making with simple operating mechanisms.


PROFESSINAL PRACTICES – IV

L 0

T 0

P 4




RATIONAL

To develop general confidence, ability to communicate and attitude, in addition to basic technological concepts through Industrial visits, expert lectures, seminars on technical topics and group discussion.

AIM Student will be able to: • Acquire information from different sources. • Prepare notes for given topic. • Present given topic in a seminar. • Interact with peers to share thoughts. • Prepare a report on industrial visit, expert lecture Contents

Activities Industrial Visits Structured industrial visits be arranged and report of the same shall be submitted by the individual student, to form a part of the term work.(2 visits) Following are the suggested types of Industries/ Fields – a. Automobile manufacturing / auto component manufacturing units to observe the

working of SPM b. Refrigeration and air conditioning manufacturing / servicing units / industries /

workshops c. Automobile service stations for four wheelers d. Co-ordinate measuring machine to observe its construction working specifications

and applications. e. Auto Engine Testing unit to gather details regarding the testing

procedures/parameters etc. f. Wheel Balancing unit for light and / or heavy motor vehicles. g. Food processing unit. h. Textile industry machinery manufacturing / servicing units. i. Hydro electric and Thermal power plants. j. Automotive Research Association of India, Pune, Central institute of Road

Transport, Pune, Vehicle Research and Development establishment , Ahmednagar.

k. Engine testing, exhaust gas analysis and vehicle testing l. PWD workshop. m. Safety museum at Central Labour Institute, Sion, Mumbai


The Guest Lecture/s From field/industry experts, professionals to be arranged (2 Hrs duration), minimum 4 nos. from the following or alike topics. The brief report to be submitted on the guest lecture by each student as a part of Term work a) Electronic fuel injection systems b) Exhaust gas analysis. c) Vehicle testing. d) Transducer application in automobiles. e) Environmental pollution & control. f) Vehicle aerodynamics & design. g) Earth moving machines. h) Automobile pollution, norms of pollution control. i) Biotechnology j) Nanotechnology k) Rapid prototyping l) Programmable logic controllers m) TQM n) MPFI o) Hybrid motor vehicles p) Packaging technology q) Appropriate technology r) Six sigma systems s) LPG / CNG conversion kit.

Group Discussion: The students should discuss in group of six to eight students and write a brief report on the same, as a part of term work. The topic of group discussions may be selected by the faculty members. Some of the suggested topics are (any one) – a. CNG versus LPG as a fuel. b. Petrol versus Diesel as a fuel for cars. c. Trends in automobile market. d. Load shading and remedial measures. e. Rain water harvesting. f. Trends in refrigeration Technology. g. Disaster management. h. Safety in day to day life. i. Energy Saving in Institute. j. Nano technology.

Seminar: (any 2 topics) Seminar topic should be related to the subjects of fifth semester / topics from guest lectures. Students shall submit a report of at least 10 pages and deliver a seminar (Presentation time - 10 minutes for a group of 2 students)


Mini Projects: (in a group of 4-5 students) 1. Design / drawing of simple jigs, fixtures 2. Thermocouple based temperature controller. 3. Pump on / off timer 4. Models of jigs / fixtures 5. Layout design of SSI units / factory / workshop of the institute

Models of material handling route systems OR

Modular Course on any one of the suggested or alike relevant topic be undertaken by a group of students (Min 10): a) LPG/CNG conversion of vehicles b) Advance features in CAD - CAM c) basics of PLC programming d) die design e) JIT techniques f) Nontraditional manufacturing methods g) jigs and fixture design h) 3D Modeling I) finite element method j) Mechatronics k) Advanced computer programming l) maintenance of home appliances m) value stream mapping n) Piping technology

Student Activities - Students in a group of 3 to 4 shall perform ANY TWO of the following activities (Other similar activities may be considered) and write a report as a part of term work. Activities:- 1. Collection of data regarding loan facilities or other facilities available through

different organizations / banks to budding entrepreneurs 2. Survey and interviews of successful entrepreneurs in nearby areas 3. Survey of opportunities available in thrust areas identified by Government or DIC. 4. Measuring Screw thread parameters on floating carriage dial micrometre and

select the optimum diameter of wire. 5. Survey of data regarding different types of pumps with specifications from

manufacturers catalogue, local markets, end users (any other engineering products may be considered for survey)

6. Survey of farm implements used by farmers

Text Books:

Name of Authors

Titles of the Book Name of the Publisher

Mark Ratner and Daniel Ratner

Nanotechnology Pearson Educatuion, New Delhi

YoramKorem Computer Control of Manufactring System

Mcgraw Hill Publication

Sunil Chopra, Peter Meindl

Supply Chain Management Pearson Educatuion, New Delhi


PROFESSINAL PRACTICES – V

L 0

T 0

P 4




Aim:- To develop general confidence, ability to communicate and attitude, in addition to basic technological concepts through Industrial visits, expert lectures, seminars on technical topics and group discussion. Objective:- Student will be able to: • Acquire information from different sources. • Prepare notes for given topic. • Present given topic in a seminar. • Interact with peers to share thoughts. • Prepare a report on industrial visit, expert lecture. Pre-Requisite:- Nil Activities Industrial Visits Structured industrial visits be arranged and report of the same should be submitted by the individual student, to form a part of the term work. Two industrial visits may be arranged in the following areas / industries to observe - Material Handling System, quality control charts / production record / layout flow systems / Facilities / Hydraulic & pneumatic systems / Working of Boilers and steam engineering applications. a. Auto / Electronic equipment manufacturing industry. b. Cement / Sugar / Chemical / Textile / Steel rolling mills / extrusion industries. c. Material handling in mines or ports. d. Earth Moving Equipment Maintenance Shop.

Lectures by Professional / Industrial Expert be organized from any of the following areas (four lectures of two hour duration) student shall submit the report on each lecture: a) Battery and its charging system b) Electronic ignition system c) Micro-processor based instrumentation in Automobiles d) Earth moving machines. e) Tractors f) Excavators. g) Fork lift truck. h) Road- roller. i) Automated Guided Vehicles (AGV) j) Career opportunities in Service stations, Marketing, Surveyor, Insurance, R&D, call centers, CAD, NDT, Railways, Defense, Aeronautics, Marine, Software development, Information Technology k) Continuing education / Open university Programs, l) Air compressor technology 2) Tribological Aspects in automobiles / machine tools


Group Discussion: (Two topics) The students shall discuss in group of six to eight students and write a brief report on the same as a part of term work. The topic for group discussions may be selected by the faculty members. Some of the suggested topics are a. Solar Vehicles / Electric Vehicles. b. Auto Vehicles - Comparison. c. Two stroke versus four stroke engines d. Recycling of plastics and other waste material e. Attributes of product design f. Creativity and innovativeness g. Energy conservation in institutes h. Value engineering i. Revolution in communication technology j. Pneumatic tools and equipment’s.

Student Activities:

The students in a group of 3 to 4 will perform ANY THREE of the following activities (other similar activities to be considered), and write a report as a part of term work.

Activity: a. Collecting internal communication forms. b. Collecting Failure data for automobile / machines / equipments. c. Study of Hydraulic system for any one application like - dumpers, Earth moving

equipment, Auto service station. d. Survey of oils used for hydraulic circuits - specifications, properties, costs,

manufacturers names etc. e. Study any one type of CNC machining center and prepare report on tooling and

tool holding devices f. Using finite element method analyse stresses in a cantilever beam. Write all the

steps involved with brief description. g. For a given job write a sequence of operations performed by automated

manufacturing system. Draw a block diagram of control system to perform above operations

h. Survey of types of bearings involving information about construction working principles, mounting, lubrication, materials, advantages, limitations and cost.

i. Prepare a trouble shooting chart for any refrigeration system and suggest remedial measures to avoid failures

j. For a drilling or milling operations on a simple machine component, draw a jig or fixtures showing various features like locating clamping, fool proofing etc.

k. Compare non-traditional methods on the basis of working principles, accuracy, MRR, Applications and limitations

a) EBM b) PAM C) AJM d) WJM l. For a given job involving 3 to 4 operations suggest to prepare a report

Seminar:- Seminar on any advanced technical topic to be presented by individual student in a batch of 20 students. A separate topic be selected by an individual student.


AUTOMOBILE AIR CONDITIONING L 3

T 0

P 0


Total Contact hrs.: 45 Theory: 45 Pre requisite: AE 402 Credit: 3


RATIONALE: Air Conditioning (both heating and cooling) of car interior may just be a means of comfort for certain geographical places but for many other locations having extreme climatic conditions, air conditioning becomes an essential feature. In modern cars, air conditioning system has become an integral part of the car. It is therefore, important that the automobile engineers should become acquainted with the theory and practice of air heating and cooling system in general and with car air conditioners in particular. AIM: After studying this subject, a diploma automobile engineer should have a good understanding about the diverse field of application of Air conditioning, and sufficient knowledge about the process involved and equipment used for an air conditioning plant and have clear idea of car air conditioning system. UNIT TOPIC/SUB-TOPIC HRS. TOTAL

HRS.

1.0 INTRODUCTION 4

1.1 Definition of “Refrigeration” and “Air conditioning” and their relationship.

1.2 Major uses of Air-conditioning: buildings, industrial air control, ventilation, room air conditioning, vehicles.

1.3 Major uses of Refrigeration: cold storage, food preservation, chemical & food processing, special applications.

2.0 THERMAL PRINCIPLES 3

2.1 Definition and concept of: enthalpy, heat transfer by conduction, convection and radiation, heat exchangers, evaporation.

3.0 VAPOUR COMPRESSION SYSTEM 12

3.1 Concept of vapour compression system; flow diagram and pressure-enthalpy diagram; co-efficient of performance (COP).


3.2 Classification and nomenclature of refrigerants;

properties of common refrigerant R12

3.3 Use, working principal and constructional features of: compressor, condenser, evaporator, expansion valve.

4.0 COMFORT CONDITIONS 6

Factors governing human comfort; comfort standard related to temperature, humidity, air velocity and ventilation (air change).

5.0 GENERAL AIR CONDITIONING SYSTEM 10

5.1 Concept of an air conditioning system; single zone system; outdoor air control; Multiple zone system.

5.2 Air distribution system; centrifugal blower and their characteristics.

5.3 Constructional details and working of a room air conditioner; desert cooler.

5.4 Air conditioning controls; function of various control components like : two way and three way valves, dampers, pressure regulators, thermostats, humidistats.

6.0 CAR AIR CONDITIONER 10

6.1 Heating system components: air inlet assembly with blower, heater assembly, heater control assembly; Airflow scheme through a car heater assembly.

6.2 Components of a car air conditioner: compressor, condenser, receiver/dryer, evaporator, expansion valve.

6.3 Air conditioner controls: manual control, automatic temperature control; airflow scheme in a manual control; airflow scheme in automatic temperature control system.

6.4 Air Conditioning of commercial vehicle. REFERENCE BOOKS: 1. C. P. Arora : Refrigeration and Air Conditioning - TMH 2. P. L. Ballaney : Refrigeration and Air Conditioning

– New Age International (P) Ltd. 3. Auto Mechanics – Theory & Science : dekryger, Kovacik, Bono

– South Western Publishing Co.


AUTOMOTIVE HEAVY EQUIPMENT

L 3

T 0

P 0


Total Contact hrs.: 45 Theory: 45

Pre requisite: Credit: 3

Total Marks: 100 Theory: End Term Exam: 70 I.A.: 30

RATIONALE: The modern agricultural and construction industries depend almost entirely on automotive heavy equipment. Three groups of men who are closely connected with these equipment – executives and supervisors who select the machines and direct them in their work, operators who run them, and mechanics who maintain and repair them. The diploma students in automobile engineering are mainly connected with the last group. This subject provides a general idea about the heavy equipment so that they can take up specialized jobs in the area of automotive heavy equipment.

AIM: The aim of the subject is to enable the students to understand the design and operating principles of automotive heavy equipment as well as methods of working on them. UNIT TOPIC/SUB-TOPIC HRS. TOTAL

HRS. 1.0 TRACTORS 8 1.1 Principal parts of a tractor : Power plant, chassis, clutch,

gear box, differential, final drive, wheels, steering mechanism, hydraulic transmission.

1.2 Classification of tractors according to following criteria

i) power – gas engine, diesel engine ii) running gear – three wheel, four wheel iii) duty – light, medium, heavy, super heavy iv) traction – wheel, crawler v) application of load – pulling, pushing vi) position of engine – rear mounted, front

mounted.

1.3 Construction and functions of different components of tractors

1.3.1 Tractor engines 1.3.2 Tractor clutches – engine clutch, power take off

clutch, steering brake clutch

1.3.3 Tractor transmissions 1.3.4 Tractor final drive with respect to : a) Velocity reduction : single reduction,

double reduction

b) Kind of gearing : bevel, spur, worm and worm wheel.


1.3.5 Tractor running gear : a) Axles : front, rear b) Wheels c) Tires d) Brakes

1.3.6 Tractor front axle steering gear:

- single front wheel, double front wheel

1.3.7 Tractor rear axle steering gear

1.3.8 Tractor instruments: controls ammeter, starting motor button, ignition and light switch, fuse cap, temperature gauge, oil pressure gauge, tachometer, charging regulator switch, light switch left

1.3.9 Mechanical controls: clutch pedal, gearshift lever, power take off lever, brake pedals.

1.3.10 Tractor hydraulic control

1.3.11 Hitches

1.3.12 Implements - harrow, harrow plough, rotary plough, weeder mulcher

1.3.13 Track frame and tracks – track wheels, shoes, rollers, idlers, fastenings differential steering

2.0 DUMP TRUCKS 5

2.1 Definition, classification and uses

2.2 Construction and functions of main components

2.2.1 Frame

2.2.2 Springs and Axles

2.2.3 Brakes

2.2.4 Power train: Engine, clutch, transmission box, drive shaft, differential, hubs and wheels, final drives

2.2.5 Tires

2.2.6 Body: box, tailgate, hoist

2.2.7 Steering gear, brakes.

2.3 Special features – Tandem drive, all wheel drive, live front axle, compensating drive, positive drive,

3.0 BULLDOZERS 5

3.1 Constructional features and functions of following parts : blade, push arms, pitch arms, hydraulic rams, tilting blade, control valve


3.2 Different operational techniques : mechanical tilt, power

tilt

3.3 Main features of following types of bulldozers a) Cable bulldozer b) Angle bulldozer.

4.0 LOADERS 4

4.1 Description and uses of tractor loader

4.2 Constructional features and functions of tractor loader

4.3 Types of loaders – belt loader, tractor loader, basic shovel, crawler mounted and truck mounted shovel, slide shovel, dipper shovel, revolving shovel.

5.0 CRANES 5

5.1 Functions and uses of cranes

5.2 Types of cranes : wheel mounted, truck mounted

5.3 Constructional features of cranes.

6.0 SCRAPER : Constructional features, working operations, and applications of scrapers.

2

7.0 LIFT TRUCK 5

7.1 Description, function and uses

7.2 Constructional features of engine operated and battery operated fork lift truck

8.0 TANKER / TRAILER / CARRIER 4

Constructional features, functions and uses.

9.0 ROLLERS FOR COMPACTION 4

Constructional features, functions and uses.

10.0 GRADERS 3

Constructional features, functions and uses. REFERENCE BOOKS: 1. K. Abrosimov, A. Bromberg and F. Katayev : Road Making Machinery, Mir Publishers, Moscow. 2. Frank D. Graham : Audels Truck and Trator Guide – D.B. Taraporevala Sons & Co. Private Ltd., Bombay. 3. Herbert L. Nichols Jr. : Heavy Equipment Repair, North Castle Books,

Greenwich Connecticut, USA. 4. Dr. Amitosh De “Latest Development of Heavy Earth Moving Machineries”

Galgotia Publication, New Delhi.


DESIGN AND FABRICATION OF AUTOMOBILES L 3

T 0

P 0


Total Contact hrs.: 45 Theory: 45 Pre requisite: AE 504, AE 506 Credit: 3


RATIONALE : Modern day automobile is far from the concept of being barely a moving contrievance consisting of a platform with seats attached, and driven by an IC engine. Today automobile is a mass produced, multi faceted mode of conveyance and mobile equipment. In the western world, it is considered to be the major mode of conveyance of the people which demands speed, comfort, style and extreme safety together. Level of production of cars and other automobiles in many of these western countries determines their economy. In recent times, a host of modern cars have entered Indian market, and this phenomena is only going to continue in future. With the advent of these modern cars in India, it is essential that the automobile engineers are kept abreast with the latest trends in design and fabrication technologies of automobiles. AIM : On completion of this subject, a fresh diploma engineer shall have an idea about the latest concepts in automobile design, the various components of auto body components and their manufacturing, an overall idea about the process of assembly of automobiles in manufacturing plants. They should also be aware of various safety systems used and some of the testing done on automobiles. UNIT TOPIC/SUB-TOPIC HRS. TOTAL

HRS. 1.0 MODERN DESIGN CONCEPTS 3

Fuel economy; weight reduction keeping satisfactory rigidity; safety of car and passengers; effective utilisation of space; pollution control; electric car.

2.0 AUTOMOBILE BODY 10 2.1 Classification of automobiles : wheelbase size, body

styles

2.2 Body construction : body on frame, unitised body;

doors; window regulating mechanism; roof; bonnet; luggage boot; grills; door lock; two wheeler body constructional features.

2.3 Seats and seat adjustment mechanisms; upholstery

work; dash board; interior panels and fittings; wind shield; windshield wipers.


3.0 FABRICATION AND ASSEMBLY 12 3.1 Body materials : steel, aluminium, plastics and fibre

glass; cold rolled steel for automotive body; pressed components; deep drawing process

3.2 Assembly line; overhead chain conveyor system; automatic welding; fitting of systems and components in the assembly line.

3.3 Body painting; spray painting; painting booth;

automotive paints.

4.0 SAFETY SYSTEMS 10 4.1 Importance of safety in automobiles; safety devices:

dual braking system, lights and indicators, windshield wiper with sprays, defroster, anti-theft switches, air bag.

4.2 Occupant protection: collapsible steering column, seat belt, air bag, safety glass, beams in doors/side panels, energy absorbers in bumpers.

5.0 TESTING OF AUTOMOBILES 5 Purpose of testing; laboratory tests : engine, mechanical

properties of materials; meter testing and calibration; field testing : acceleration, speed, fuel consumption, braking efficiency, noise, vibration, handling, body roll at various speed and corner radii; road tests : safety, comfort, ease of maintenance; old vehicle testing for road worthiness.

6.0 ELECTRIC VEHICLE (EV) 5 6.1 Definition; advantage and disadvantages; pure

electric vehicles; hybrid electric vehicles (HEV)

6.2 Constructional features of EV : battery, controller,

motor

6.3 Comparison of EV and IC Engine vehicle on

performance, fuel cost, pollution, application, price.

6.4 Solar cell; solar battery operated vehicle. REFERENCE BOOKS: 1. Auto Mechanics – Theory and Service : Dekryger, Kovacik, Bono – South Western Publishing Co. 2. The Car Engine & Structure : R. H. Bacon – Macmillan 3. The Automobile : H. S. Reyat 4. Automobile Engineering : R. B. Gupta 5. Auto Mechanics: J. Webster – Glenco Publishing Co.


WELDING TECHNOLOGY

L 3

T 0

P 0


Total Contact hrs.: 45 Theory: 45 Practical : 0 Pre requisite: AE 407 Credit: 3


RATIONALE: Welding Technology is essential virtually in every sphere of manufacturing like bridges, ships, equipment, building construction, boilers, pressure vessels, pipe lines, automobiles, aircraft, launch vehicles and nuclear power plants. In India, Welding Technology needs constant upgrading, particularly in the field of industrial and power generation boilers, high voltage generation equipment and transformers and in nuclear and aerospace industry. With the wide-spread application of welding, specialised knowledge of the same has become essential for an engineer. AIM: To develop basic concepts of Welding Technology and to explain working principles of gas welding, arc welding and some other modern welding method. UNIT TOPIC/SUB-TOPIC HRS. TOTAL

HRS. 1.0 INTRODUCTION 5 1.1 Welding as a fabrication process, classification of welding

processes, advantages & disadvantages of welding, welding as compared to rivetting and bolting; practical applications of welding. • State factors influencing selection of welding process

for a particular type of job.

1.2 Welding symbols used in engineering drawing 1.3 Welding science: effect of heating and cooling of weld

metal and base metal, weldability and affecting parameters, grain size, fluxes; stress and distortion in welding. • Define weldability • Identify and explain the parameters that affects the

weldability.

2.0 GAS WELDING 10

2.1 Definition, oxy-acetylene welding, principle of operation, types of welding flame, gas welding technique, base metal preparation, limitation and advantages, specific applications. • State the operational sequence of gas welding processes • State different types of applications of gas welding.


2.2 Gas welding equipment Oxygen and acetylene cylinders, single stage and two-stage oxygen and acetylene pressure regulators, oxygen and acetylene gas hoses and hose connections. • Identify different parts of a gas welding equipment

2.3 Welding torches, classification of torches, assembling and

dismantling oxy-acelytene torch, welding flames, welding nozzles or tips. • State how a welding torch flame is controlled. • Select the proper type of welding torch for a particular

type of operation.

2.4 Types of filler metals, fluxes, selection of filler metals 2.5 Preparation of parts for welding

Joint preparation, requirement of a good joint preparation, setting up the joint, joints used in welding. • Classify different types of welded joints • Explain the need for joint preparation for welding

3.0 ARC WELDING 10

3.1 Industrial use of arc welding: fabrication, maintenance and repair, construction machinery, machine tools, piping, structural steel construction; advantages and limitations. • List some of the use of arc welding • State the advantages of welding when used as a means

of fabrication. • State the advantages of arc welding processes over gas

welding process.

3.2 Principle of arc welding operation, types of arc welding,

arc welding machines, motor generator, types of D. C. welding machines, volt - ampere meters, welding circuit connection, small tools, shop equipment, arc electrodes. • Define metal arc welding • Classify & explain the different types of arc welding

processes. • List the standard sizes of electrodes available.

4.0 TUNGSTEN INERT GAS (TIG) AND METAL INERT

GAS (MIG) WELDING. 10

4.1 TIG: definition, principle of operation, equipment, base

metals, Joint design, advantages, disadvantages and application • State the procedural steps of TIG welding • Identify the specific applications of TIG welding


4.2 MIG: definition, principle of operation, self adjusted and self controlled arcs, equipment, metals welded, joint design, advantages and disadvantages and applications. • State the procedural sequence of MIG welding • Identify the specific applications of MIG welding.

5.0 SOME MODERN WELDING METHODS 7

5.1 Electron Beam Welding : Introduction, Definition, principle of operation, welding equipment, process variables, safety in electron beam welding, advantages, disadvantages and applications of electron beam welding. • State the operational sequence of electron beam welding • Identify the specific use of electron beam welding

5.2 Laser Beam Welding : definition and concept, principle and theory and operation, forms of lasers, Joint design, advantages, disadvantages, applications and safety of laser beam welding. • State the operational sequence of laser beam welding • Identify the specific use of laser beam welding.

5.3 Welding automation : introduction, concept of welding automation, classification of welding automation, machine welding, automatic welding. • Explain the use and need for welding automation • Classify different types of welding automation.

6.0 TESTING AND INSPECTION OF WELDS 3

6.1 Testing and inspection prior to welding, during welding, and post welding

6.2 Destructive testing: tensile strength, shearing strength, bend test, hardness test, and density test.

6.3 Non destructive test: visual test, ultrasonic inspection, and

radiography

REFERENCE BOOKS: 1. Marfels ; Gas-Welding and arc-Wiley Eastern 2. D. Smith : Welding Skills and Technology – McGraw Hill, New York 3. O. P. Khanna : Welding Technology - Dhanpat Rai & Sons 4. Richard L. Little : Welding and Welding Technology - Tata McGraw Hill Publishing Limited 5. V.M. Radhakrishnan : Welding Technology & Design – New Age Publishers 6. R. L. Agarwal : Welding Engineering - Khanna Publishers 7. R. S. Parmar : Welding Engineering and Technology - Khanna Publishers 8. R. S. Parmar : Welding Processes and Technology - Khanna Publishers 9. N. K. Srinivasan : Welding Technology - Khanna Publishers 10. P. N. Rao : Manufacturing Technology : Foundry, Forming and Welding - Tata Mc Graw Hill Publishing Company Limited.


RENEWABLE SOURCES OF ENERGY

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Total Contact hrs.: 45 Theory: 45 Practical : 0 Pre requisite: AE 402 Credit: 3


RATIONALE: Automobiles are run by burning petroleum fuel (petrol and diesel). However, burning of any fossil fuel including petroleum causes environmental pollution. Automobiles consumes the largest part of petroleum fuel and thus contributes greatly to atmospheric pollution. Moreover, another great concern is that the source of petroleum is limited, and under the present rate of usage it is possibly going to be used up in less than a century! With this background, scientists and engineers, all over the world are frantically looking for non-conventional fuels or sources of energy, which are renewable in nature and non-polluting. A few of these non-conventional sources of energy are now seriously being tried out for powering automobiles. It is therefore, important that the present day automobiles engineers should become acquainted with the basic knowledge of different types of non-conventional sources of energy in general, and a few particular ones which are being progressively used in the field of automobiles.

AIM: To have a clear understanding about limitations and problems of using fossil fuel and nuclear fuel for generation of energy. Students will also be aware about the scope of various renewable sources of energy (RSE)-their advantages and disadvantages. They shall have an understanding about the technological status of each of these new sources and the challenges for making these sources useable in a large scale. Students shall also be aware of particular applications of RSE in the field of automobile. UNIT TOPIC/SUB-TOPIC HRS. TOTAL

HRS. 1.0 INTRODUCTION 5

1.1 Importance of energy in today’s life 1.2 Problems of using fossil fuels:

i) Global Worming ii) Acid Rain iii) Particle Emission iv) Availability


1.3 Brief description of different non-conventional sources of energy: i) Solar, ii) Bio-Mass, iii) Wind, iv) Tidal, v) Geothermal, vi) Fuel Cell.

1.4 Different units of Energy and Power as used in Power-Engineering and their equivalence.

2.0 SOLAR ENERGY 10

2.1 Advantages and disadvantages of Solar Energy. 2.2 Solar radiation: radiation spectrum; direct and diffused radiation;

density of solar radiation; solar radiation measurements. 2.3 Solar Thermal Devices:

i) Liquid flat plate collectors; their construction and uses. ii) Focusing type collectors and uses. iii) Solar water heater, solar cooker, solar dryer, solar still.

2.4 Thermal Energy Storage, Solar Pond. 3.0 SOLAR PHOTOVOLTAICS 10

3.1 Basic principles of a PV cell: semiconductor and doping; p-n junction; PV effect; Silicon cells.

3.2 Solar cell characteristics: current-voltage characteristics of a silicon PV cell, solar storage battery; efficiency.

3.3 Applications of Photovoltaics: Remote Power, Roof-top PV Systems; PV Power Plants; Satellite Solar Power; Automobiles; Road lighting; PV lantern; water pumping.

4.0 BIO-MASS 10

4.1 Biomass as a fuel: estimates of world biomass energy consumption; energy content of different biofuels;

4.2 Extraction Processes: Direct burning; thermochemical processes- pyrolysis, gaisification and liquifaction.

4.3. Bio-chemical conversion-Biogas Anaerobic digestion: biogas plants; (digester); gasifers. Special features for biofuel engines.

4.4 Energy from refuse: municipal solid waste; landfill gas. 4.5 Energy crops: woody crops; agricultural wastes; ethanol from sugar

cane; vegetable oils; Biodiesel.

5.0 WIND ENERGY 4

5.1 Wind system: Earth’s wind system; energy in wind. 5.2 Wind Turbines: Horizontal and vertical axis wind turbines; aerofoil

and aerodynamic forces; how a wind turbine works; major technological challenges; wind farm.

5.3 Merit and limitations of Wind Energy.


6.0 FUEL CELLS 6

6.1 Introduction to fuel cell. Advantages of fuel cell. 6.2 Types of fuel cells; Principles and operation of fuel cell. 6.3 Performance characteristics: Voltage-current density; power per cell;

cell efficiency. 6.4 Uses of fuel cell in automobiles. 6.5 Hydrogen as a fuel.

REFERENCE BOOKS:

1. D.Mukherjee and S.Chakrabarti : Fundamentals of Renewable Energy Systems-

New Age International Publishers. 2. S.P.Sukhatme: Solar Energy Principles of Thermal Collection and Storage- Tata

Mc-graw Hill. 3. G.N.Tiwari and S.Suneja : Solar Thermal Engineering Systems- Narosa

Publishing House 4. H.P.Garg & J.Prakash: Solar Energy- Tata Mc-Graw Hill 5. S.Rao & B.B.Parulekar: Energy Technology –Khanna Publishers 6. G.Boyle (ed): Renewable Energy: Power for a Sustainable Future- Oxford

University Press 7. Booklet on Short Course on Renewable Energy –NITTTR, Kolkata 8. Renewable Energy- Twidell & Weir, 2nd Edition 9. Renewable Energy- Sorenson. 10. D. S. Chauhan, S. K. Srivastava: Non-Conventional Energy Resources – New

Age International Publishers


LIST OF EQUIPMENT FOR DIFFERENT LABORATORIES AND WORKSHOPS

AUTOMOBILE ENGINEERING A. Fluid Mechanics & Fluid Machines 1. Pressure Gauge – various types and ranges 2. Manometers – different type 3. Inclined Tube Manometer 4. Pitot – Tube 5. Venturimeter 6. Orifice meter 7. Test rig (hydraulic) for measurement of pipe friction and flow measurement 8. Various open channel notches 9. Apparatus for study of laminar and turbulent flow 10. Impact of jet apparatus 11. Pelton wheel 12. Universal pump testing unit 13. Reciprocating pump set 14. Centrifugal pump set 15. Francis Turbine 16. Kaplan Turbine 17. Air Compressor 18. Gear pump 19. Pipes and pipe fittings – screwed and welded type. B. Drawing & Design 1. CAD Work stations 2. Plotter 3. Printers 4. Digitizer 5. Scanner 6. Auto CAD or equivalent latest CAD software 7. Drafting Boards 8. Models of different Geometrical objects in full and cut sections 9. Standard drafting instruments 10. Different Mechanical Components/devices-original or model C. Workshops

C.1 Carpentry Shop : 1. Jig saw 2. Drilling

machine(Bench type)

3. Bench grinder 4. Sets of hand Tools 5. Carpentry Bench

with vices

6. Clamps, hold fasts etc.

7. Wood turning lathe 8. Measuring tools and

gauges 9. Planing & Jointing

Machine


C.2 Smithy & Sheet Metal Shop : 1. Hearth with Blower 2. Anvil 3. Leg vice 4. Swage block 5. Hammers & various

tools and guages 6. Hand shear 7. Sheet bending

machine(press brake)

8. Pipe bending device 9. Pipe threading die

set 10. Circle cutting

machine 11. Pipe vice 12. Plumbers tool kit 13. Spray gun 14. Compressor(small)

C.3 Machine Shop: 1. Centre Lathe – gap

bed type 2. All geared head

lathe 3. Turret lathe 4. CNC Trainer lathe 5. CNC mill trainer 6. Pillar drill 7. Radial drill 8. Universal milling

machine 9. Tool post grinder 10. Surface grinder 11. Centreless grinder 12. Power hack saw 13. Shaping machine 14. Slotting machine

15. Boraching machine 16. Single spindle

automatic lathe 17. Planning

machine(small size) 18. Set of various tools

for above machines 19. Set of measuring

instruments 20. Machine tool testing

kit 21. Various drilling jigs 22. Air compressor 23. Crankshaft grinder

(car & trucks) 24. Horizontal Borer,

50mm mandrel

C.4 Fitting Shop : 1. Marking tables 2. Surface plate 3. Measuring Inst. 4. Marking

Instruments 5. Fitting hand tools 6. Tap and die set 7. Bench drill

8. Bench grinder 9. Working tables with

vices 10. Hand press 11. Hand drilling

machine 12. Power hack saw 13. Hand grinder

C.5 Foundry Shop : 1. Pit furnace for heat

treatment 2. Induction hardening

machine 3. Oil fired furnace 4. Muffle furnace 5. Crucibles 6. Core Box 7. Platform weigh Mac. 8. Drying oven

9. Sand puller 10. Sand sieves 11. Moulding boxes 12. Adles 13. Tool kits 14. Quenching tank 15. Permeability tester 16. Portable grinder 17. Fetling machine


C.6 Welding Shop : 1. Welding

(Transformer) sets 2. Welding (Rectifier)

sets 3. Spot welding

machine 4. Gas cutting machine 5. Brazing equipment

and accessories

6. Soldering irons. 7. MIG Welding set 8. TIG welding set 9. Portable flame

cutting machine 10. Welding accessories

& safety equipment.

D. Automobile Engineering

1. Separating and Throttling Calorimeter 2. Bomb Calorimeter 3. Orsat Gas Analysis Apparatus 4. Four Cylinder 4 stroke Diesel Engine Test Rig 5. Four Cylinder 4stroke Petrol Engine Test Rig 6. Four wheeler 7. Two wheeler 8. Demonstration Cut Section car model Model with special colour scheme to distinguish the following systems : i) Transmission i.e. gear box ii) Electrical System iii) Fuel System iv) Lubrication System v) Suspension System vi) Braking System vii) Steering System viii) Ignition System 9. Automobile Systems / Components for demonstration i) Transmission System (Cut section) ii) Clutch Assembly iii) Hydraulic Brake Drum Assembly iv) Steering wheel Mechanism with wheels v) Power Brake system vi) Power steering system vii) Motor cycle Engine viii) Rear Wheel Assembly complete with Differential ix) Front wheel Assembly x) Set of Pistons (5 types) xi) Propeller shaft xii) Radiator xiii) Self Starter (Lucus TVs) xiv) Dynamo and Alternator xv) Distributor xvi) Set of Spark plugs xvii) Fuel Pumps(Mechanical & Electrical xviii) Fuel Injector (diesel and petrol) xix) Set of Carburators of different models xx) Shock Absorber (assorted)


xxi) Brake Cylinder xxii) Master cylinder xxiii) Head light Assembly xxiv) Speed meter Assembly xxv) Automatic Transmission with Torque converter (cut section) xxvi) Car Tyre with Tube (3 Types) xxvii) Silencer with catalytic converter for car xxviii) 12 v Batteery xxix) Ignition coil 10. Equipment, Tools &Testing Kits a) Mechanical Jack 3 T. Capacity b) Hydraulic Jack 5 T Capacity c) Hydraulic Car Lift 3000 Kg Capacity x 1750 mm lift d) Set of Garage Tools i)

ii) iii) iv) v) vi) vii) viii) ix)

Piston Ring Compressor Piston Ring Expander Set of Pliers, spanners and screw Drivers Bush Removing kit Plug Spanner Tappet Spanner Set Box Spanner Set Tap & Die Set Body Repair Tool Kit

e) Hydraulic Mobile crane 1 Ton capacity f) Spark plug Tester : Bench type gap 0.5 to 2mm , Adopter sizes-

10.12.14 and 18 mm g) Wheel Balancing Machine: Suitable for 10" to 24" rim diameter;

Balancing speed 200 rpm; Rim width : 1.5" to 20" h) Battery charger 6-12v, 0-6 Amps i) Electrical Test Bench for cut out, Regulator and Dynamo Testing :

TVS - Lucas make or equivalent j) Exhaust Gas Analyser: for CO: Range-0 to 10%, Resolution 0.1%.

for HC : Range- 10,000ppm, Resolution 10ppm k) Two Arm Puller l) Chain Pulley Block 1ton capacity m) Coil and Condenser n) Tachometer o) Compressor : 15 Cfm, 2stage compressor, Working pressure 12

Kg /Cm2 Receiver 250 litres, motor 5 HP, complete with pressure switch, safety valve, pressure gauge, non- return valve, air cooled after cooler, inter cooler and air delivering valve and other standard accessories (motor starter)

p) Reciprocating Pump with motor : Capacity 30 lpm, 5 Kg/Cm2 q) High Pressure Hose Pipe with plain nozzle : 2x 10 mtrs, 15 NB

Size, 7Kg/Cm2 . 11 Fuel, lubricants, raw materials, and miscellaneous materials necessary

for running of the equipment (As necessary.)

AUTOMOBILE ENGINEERING DIPLOMA PROGRAM

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