Mvjce Me 6 Sem

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OF MECHANICAL ENGINEERING
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06ME61 DESIGN OF MACHINE ELEMENTS II
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DEPT. OF MECHANICAL ENGINEERING
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SYLLABUS Sub Code: 06ME61 Hours / Week: 4 Total Lecture Hrs: 62 Exam Hours: 3 I A Marks: 25 Exam Marks: 100
PART - A UNIT 1: CURVED BEAMS: Stresses in curved beams of standard cross sections used in crane hook, punching presses & clamps, closed rings andlinks. (5 Hours) UNIT 2: CYLINDERS & CYLINDER HEADS: Review of Lames Equations; compound cylinders, stresses due to different types of fits, cylinder heads,flats. (5 Hours) UNIT 3: SPRINGS: Types of springs - stresses in Helical coil springs of circular and non-circular cross sections. Tension and compression springs, springs under fluctuating loads, Leaf Springs: Stresses in leaf springs. Equalized stresses, Energy stored in springs, Torsion, Belleville andRubber springs. (8 Hours) UNIT 4: SPUR & HELICAL GEARS: Spur Gears: Definitions, stresses in gear tooth: Lewis equation and form factor, Design for strength, Dynamic load and wear load. Helical Gears: Definitions, formative number of teeth, Design based on strength, dynamic and wear loads. (8 Hours) PART - B UNIT 5: BEVEL AND WORM GEARS: Bevel Gears: Definitions, formative number of teeth, Design based on strength, dynamic and wear loads. Worm Gears: Definitions, Design based on strength, dynamic, wear loads and efficiency of worm gear drives. (7 Hours) UNIT 6: CLUTCHES & BRAKES: Design of Clutches: Single plate, multi plate and cone clutches. Design of Brakes: Block and Band brakes: Self locking of brakes: Heat generation in Brakes. (7 Hours) UNIT 7: LUBRICATION AND BEARINGS: Lubricants and their properties, Mechanisms of Lubrication bearing modulus, coefficient of friction, minimum oil film thickness, Heat Generated, Heat dissipated, Bearing Materials, Examples of journal bearing and thrust bearing design. (7 Hours) UNIT 8: BELTS ROPES AND CHAINS: Flat belts: Length & cross section, Selection of V-belts, ropes and chains for different applications. (5 Hours)
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Design Data Hand Books: 1. Design Data Hand Book K. Lingaiah, McGraw Hill, 2nd Ed.2003. 2. Design Data Hand Book by K. Mahadevan and K.BalaveeraReddy, CBS Publication 3. Machine Design Data Hand Book by H. G. Patil, Shri ShashiPrakashan, Belgaum. TEXT BOOKS: 1. Mechanical Engineering Design: Joseph E Shigley and Charles R.Mischke. McGraw Hill International edition, 6th Edition 2003. 2. Design of Machine Elements: V.B. Bhandari, Tata McGraw Hill Publishing Company Ltd., New Delhi, 2nd Edition 2007. REFERENCE BOOKS: 1. Machine Design: Robert L. Norton, Pearson Education Asia, 2001. 2. Design of Machine Elements: M. F. Spotts, T. E. Shoup, L. E. Hornberger, S. R. Jayram and C. V. Venkatesh, Pearson Education,2006. 3. Machine Design: Hall, Holowenko, Laughlin (Schaums Outlines series) Adapted by S. K. Somani, Tata McGraw Hill Publishing Company Ltd., New Delhi, Special Indian Edition, 2008. 4. Machine Design: A CAD Approach: Andrew D DIMAROGONAS,
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LESSON PLAN Sub Code: 06ME61 Sub: Design of Machine Elements-II Hours / Week: 04 Total Hours: 62
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Topic To be Covered
UNIT:1 CURVED BEAMS Introduction to curved beams. Stresses in curved beams of standard cross sections used in crane hook. Stresses in punching presses and clamps. Stresses in closed rings and links. Problems UNIT:2 CYLINDERS & CYLINDER HEADS Introduction to Cylinder and Cylinder Heads Lames equation Compound cylinder Stresses due to different types of fits Stresses due to different types of cylinder heads & flats Problems UNIT:3 SPRINGS Introduction to Springs. Types of springs Stresses in Helical coil springs of circular and non-circular cross sections Tension and compression springs Springs under fluctuating loads, Energy stored in springs and problems Torsion, Belleville and Rubber springs and Problems. Leaf Springs: Stresses in leaf springs, Equalized stresses. Problems Problems UNIT:4 SPUR & HELICAL GEARS Introduction to spur and helical gears Definitions, stresses in gear tooth. Lewis equation and form factor. Design for strength, Dynamic load and wear load. Problems Helical Gears: Definitions, formative number of teeth Design based on strength, dynamic and wear loads Problems UNIT:5 BEVEL AND WORM GEARS Bevel Gears: Definitions, formative number of teeth Design based on strength, dynamic and wear loads Problems on Bevel Gears. 4
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Worm Gears: Definitions Design based on strength, dynamic and Problems wear loads and efficiency of worm gear drives Problems on worm Gears UNIT:6 CLUTCHES & BRAKES Design of Clutches: Single plate multi plate and cone clutches Problems on clutches Design of Brakes Block and Band brakes Self locking of brakes Problems on brakes Heat generation in Brakes Problems UNIT:7 LUBRICATION AND BEARINGS Lubricants and their properties Mechanisms of Lubrication Bearing modulus, coefficient of friction Minimum oil film thickness, Heat Generated, Heat dissipated Bearing Materials Examples of journal bearing and thrust bearing design UNIT:8 BELTS, ROPES AND CHAINS Introduction to Belt, Ropes and Chains Flat belts: Length & cross section Selection of V-belts Ropes and chains for different applications Problems & Previous Question Papers
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QUESTION BANK 01 How does the curvature of the beam affect the stress distribution section under bending? across its cross
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Determine the dimension of an I section of a curved beam in witch the and outer fiber stresses are numerically equal in pure bending given that bi + bo = 125mm The horizontal section of crane hook is symmetrical trapezium 100mm deep. The inner width being 60mm and outer width being 40mm, The hook carries a load of 30kn. Inner radius of the hook is 75mm, the load line is nearer to the inner surface of the hook by 25mm than the center of curvature at the critical section. Determine i. Distances from the centroidal and neutral axis. ii. Bending moment at critical section. iii. Extreme intensities of stress at critical section Design a closed coil helical spring for a service load ranging from 2250N to 2757N. The axial deflection for the load range is 6mm, assume the spring index=5, permissible shear stress is 420Mpa and modulus of rigidity is 840Gpa. Neglect the effect of stress concentration
A helical spring is used in a pressure relief valve. The spring is preloaded to relieve the pressure at 5Mpa. The diameter of the valve is 20mm. The spring has to undergo a deformation of 3mm to allow for fluid flow, the additional force caused due to this should not exceed 10% of the force required to relieve the pressure. The material for the spring is hot drawn wire having an elastic strength of 520Mpa.Under torsion. Take a factor of safety of 1.5 and determine all the dimension of the spring if the diameter of the spring is not to exceed 10mm
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Design a valve spring of a petrol engine for the following operating conditions: Spring load when valve is open = 400N Spring load when valve is closed = 250N Max. Inside dia. of spring = 25mm Length of spring when valve is open = 40mm Length of spring when valve is closed = 50mm Max strength = 400Mpa Design a helical spring for a safety valve. The valve must blow off at a pressure of 1.2 MPa and should lift by 3mm for 5% increase in pressure. The valve diameter is 60mm. The max allowable shear stress is 400MN/m2 and the modulus of rigidity is 82.7X103MN/m2 take the spring index as 8
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a. Explain equalizing the stresses in leaf springs b. A semi elliptic leaf spring used for automobile suspension consists of three fulllength leaves and 15 graduated leaves including the master leaf. The center distance between the two eyes of the spring is 1m. The maximum force that acts on the spring is 75kN. The ratio of width to thickness is 9:1 the modulus of rigidity is 80 Gpa. The leaves are pre-stressed in such a way that the force is maximum the stress induced in the spring is 450Mpa. Determine 1) the width and thickness of the leaves 2) The initial gap 3) The load required Design the leaf springs for the rear suspension of a heavy duty truck. The distance between the axles, front and rear is 6m. The weight of the loaded truck is 2MN and the center of gravity of the truck lies at 2m from the rear axle and at a height of 2m from the ground. The number of full length is 2, the material for the spring is steel with a permissible strength of 250 Mpa. The length of the spring between the eyes is 1600mm and the central band is 100mm wide. Determine the thickness and the number of graduated leaves if the width of the leaf is not to exceed 75mm. The maximum deflection of the spring is limited to 50mm. Determine also the force required to pre stress the spring An internal expanding brake has a inner surface of rim of diameter 500mm. The distance between the fulcrums is 100mm. The distance between the fulcrums and the point of application of efforts is 400mm. The brake linings sustain an angle of 1200 at the center. The material of the lining has the co-efficient of friction of 0.3 and an allowable bearing pressure of 0.5 Mpa. Determine 1) The effort required to stop the rotation of the brake drum. 2) The width of the brake lining. The brake transmits a power of 30kW at a rated speed of 1500rpm A 75kW at 3000rpm is to be transmitted by a multiple plate clutch. The plates have friction surfaces of steel and phosphor bronze alternatively run in oil. Design the clutch for 30% overload and sketch the arrangement of plates A simple band brake of drum diameter 650 mm has a band passing over it with an angle of contact of 2250 while one end of the band is connected to the fulcrum, the other end is connected to the brake lever at a distance of 410 mm from the fulcrum. The brake lever is 1100 mm long. The brake is to absorb a power of 15 kW at 720 rpm. Design the brake lever of rectangular cross section assuming the depth to be twice the width Design a centrifugal clutch with four shoes for transmitting 20kw at 1200 rpm. The speed at which engagement begins is 80% of the running speed. The inside radius of the pulley rim is 150mm. The shoes are lined with Ferodo lining for which =0.25 A single block brake with a torque capacity of 15N-m id shown in fig.1. The coefficient friction is 0.3 and the maximum, pressure on the brake lining is 1MPa. The width of the block is equal to its length. Calculate the actuating force 2) the dimension of the block 3) the resultant hinge pin reaction An automotive single-plate clutch consists of two pairs of contacting surfaces. The outer diameter of the friction disc is 270 mm. The co-efficient of friction is 0.3 and the maximum intensity of pressure is 0.3MPa. The clutch is transmitting a torque of 531 N-m, assuming uniform wear claculate1) the inner diameter of the friction disc and 2) spring force required to keep the clutch engaged 7
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a. Write a note on interference in gears b. A pair of Spur gears is to transmit 20 kW when the pinion rotates at 300 rpm. The velocity ratio is 1: 3. The allowable static stresses for the pinion and gear materials are 120 MPa and 100 MPa respectively. The pinion has 15 teeth and its face width is 14 times the module. Determine a) module ; b) face width ; and c) pitch circle diameters of both pinion and gears from standpoint of strength only, considering the dynamic loading effect only, given that : 0.912 Tooth form factor Y = 0.154 No.of .teeth 3 Velocity factor C v = where v is meters /sec 3+v 16 In a spur gear A 11KW motor running at 1450rpm drives a shaft trough a pair of spur gears with a velocity ratio is 4.5:1. Forged steel SAE 1045 pinion and CI gear are specified. Design the gear and check for the dynamic and heat load considerations 17 a. Derive an expression for beam strength of a spur gear tooth (Lewis equation) using standard notations. State the assumptions under which this equation is valid b. It is desired to transmit 11 kW from a motor shaft rotating at 1440rpm to a low speed shaft with a speed reduction of 3:1. Single stage spur gear drive is employed for this purpose. The gear teeth are 200 FDI. Pinion has 25 teeth. Starting torque is 50% higher than running torque. Both the pinion and gear are made of heat treated steel with a maximum allowable stress of 210Mpa. Design the suitable spur gear drive from the point of view of dynamic and wear strength 18 a. Derive an expression for the load carrying capacity of helical gear tooth. b. Determine the module and face width of a helical gear tooth for a helical gear pair to transmit a power of 25KW from a shaft rotating at a speed of 1500rpm to a parallel shaft to be 360rpm maintaining a center distances of 180mm 19 a. Explain clearly the meaning of formative number of teeth as referred to bevel gear. b. A pair of bevel gear is required to transmit 30 kW at 500 rpm. The output shaft is running at 200 rpm and is at right angles to input shaft. The gears are of 200 involute stub teeth. The pinion is cast steel; the safe static strength is 142 MPa. The gear is of cast iron, whose static strength is 71 MPa. Design the gear drive. 20 Design a worm drive to connect two shafts 300 mm apart and to transmit 10 kW. The transmission ratio is 20:1 and worm shaft is to make 400 rpm. The lead angle is to be within 200. The worm is made of hardened steel (0 = 210 MPa) and worm gear of phosphor bronze (0 = 105 MPa). Determine the probable temperature to which the gears may be heated and the efficiency. 21 A pair of straight bevel gears has a velocity ratio of 2:1. The pitch circle diameter of the pinion is 80 mm. 5kW power is supplied to the pinion, which rotates at 800 rpm. The pressure angle is 200. Design the gears. 22 Design a worm gear drive to transmit a power of 2kW at 1000 rpm. The speed ratio is 20 and the center distance is 200 mm. 23 Explain self-locking as referred to worm gear drive. b) Design a worm gear reducer to transmit 7.5 kW at 100 rpm. The input speed from the motor is 1500rpm. Calculate the efficiency of the drive 8 VI SEMESTER MVJCE 15
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A full journal bearing of 50mm dia And 100mm long has a bearing pressure of 1.4Mpa. Speed of journal is 900rpm and ratio of journal dia. To the diametrical clearance is 1000. The bearing is lubricated with oil whose observed viscosity at operating temperature of 75 degree C may be taken as 0.011Kg/m-s. The temperature is 35 degree C. find the amount of artificial cooli8ng required and mass of lubricating oil required, if the difference between the outlet and inlet temperature of oil is 10degreeC. Take Sp. Heat of oil as 1850J/Kg/degreeC. A 150mm dia shaft runs at 1500rpm, supporting a load of 10KN. The shaft runs in a bearing of length 1.5 times the shaft dia. The clearing ratio is 0.015. The absolute viscosity of the oil is 11cp. At its operating temperature, find the power lost in friction. Determine the dimension of the bearing and journal to support a load of 6KN at 750rpm using hardened steel journal and bronze backed babit bearing. An abundance of oil provided which has a specific gravity of 0.95 at 15.50 C and viscosity of 9.5centistrokes at 820C that may be taken to the limiting temperature of oil. Assume a clearance of 0.001mm per mm of diameter is allowed. Derive Petroffs equation for the co-efficient of friction in a lightly loaded bearing A shaft running at 600 rpm is supported in a bearing of 60mm dia and 60mm long. The viscosity of oil is 0.014Pa s and the temperature of oil is 1100C. The radial clearance is 0.03mm. Determine temperature of still air in the bearing if there is no external cooling is provided. The temperature of still air in the room is 200C A journal bearing is to be design for the main bearing of a four-stroke oil engine to sustain a load of 50KN for shaft diameter of 50mm. The engine runs at speed of 1500rpm determine i. The length and diameter of the bearing ii. Viscosity of oil to be used as lubricant, hence suggest a suitable oil iii. The co-efficient of friction of the bearing and the heat generated. Design the journal bearing for a centrifugal pump from the following data. Load on the journal=10KN, speed on the journal=900rpm, Ambient temperature=150C. A 40BC03 (SKF6308) single- row, deep groove ball bearing, which is to operate at 80 rpm is acted on by an 8KN radial load and 6KN thrust load. The outer ring rotates, and the bearing is subjected to light shock. Determine the rating and median life of the bearing in hours. Select a single- row, deep groove ball bearing to carry a radial load of 4KN, and a thrust load 5KN operating speed of 1200rpm, for an average life of 15years at 10 hours per day. Assume there are 250 working days per year. The loads are steady and the outer ring rotates. A belt with cross sectional Power of 60kw at 750rpm is to be an electric motor Give a complete to compressor transmitted from shaft at 300rpm by v belts. The approximate larger pulley diameter is 1500mm. The approximate center distance is 1650mm, and over load area of 350mm2 and weighing .001kg/cm3 and having an allowable tensile strength 2 N/mm2 is available for use. The coefficient of friction between the nearest bearing and is mounted on the shaft having a permissible shear stress of 40N/mm2 with the belt and pulley may be taken as 0.28. The driven pulley is over hung to the extent of 300mm from help of a key. The shaft, the pulley and the key are also to be designed. 9
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06ME62 MECHANICAL VIBRATION
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PART - A UNIT 1 INTRODUCTION: Types of vibrations, S. H. M, principle of super position applied to Simple Harmonic Motions. Beats, Fourier theorem and simple problems. (6 Hours) UNIT 2 UNDAMPED FREE VIBRATIONS: Single degree of freedom systems. Mass Undamped free vibration-natural frequency of free vibration, stiffness of spring elements, effect of mass of spring, Compound Pendulum. (7 Hours) UNIT 3 DAMPED FREE VIBRATIONS: Single degree freedom systems, different types of damping, concept of critical damping and its importance, study of response of viscous damped systems for cases of under damping, critical and over damping, Logarithmic decrement. (7 Hours) UNIT 4 FORCED VIBRATION: Single degree freedom systems, steady state solution with viscous damping due to harmonic force. 1) Solution by Complex algebra, Reciprocating and rotating unbalance, vibration isolationtransmissibility ratio. Due to harmonic exitation and support motion. (6 Hours) PART - B UNIT 5 VIBRATION MEASURING INSTRUMENTS & WHIRLING OF SHAFTS: Vibrometer meter and accelerometer. Whirling of shafts with and without air damping. Discussion of speeds above and below critical speeds. (6 Hours) UNIT 6 SYSTEMS WITH TWO DEGREES OF FREEDOM: Introduction, principle modes and Normal modes of vibration, co-ordinate coupling, generalized and principal co-ordinates, Free vibration in terms of initial conditions. Geared systems. Forced Oscillations-Harmonic excitation. Applications: a) Vehicle suspension. b) Dynamic vibration absorber. c) Dynamics of reciprocating Engines. (6 Hours) UNIT 7 CONTINUOUS SYSTEMS: Introduction, vibration of string, longitudinal vibration of rods, Torsional vibration of rods, Eulers equation for beams. (6 Hours) UNIT 8 NUMERICAL METHODS FOR MULTI DEGREE FREEDOM SYSTEMS: Introduction, Influence coefficients, Maxwell reciprocal theorem, Dunkerleys equation. Orthogonality of principal modes, Method of matrix iteration-Method of determination of all the natural frequencies using sweeping matrix and Orthogonality principle. Holzers method, Stodola method. (8 Hours)
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TEXT BOOKS: 1. Theory of Vibration with Applications: W.T. Thomson and MarieDillon Dahleh, Pearson Education 5th edition, 2007. 2. Mechanical Vibrations: V.P. Singh, Dhanpat Rai & Company Pvt.Ltd., 3rd edition, 2006. REFERENCE BOOKS: 1. Mechanical Vibrations: S.S. Rao, Pearson Education Inc, 4thEdition, 2003. 2. Mechanical Vibrations: S. Graham Kelly, Schaums OutlineSeries, Tata McGraw Hill, Special Indian edition, 2007. 3. Theory & Practice of Mechanical vibrations: J.S. Rao & K.Gupta, New Age International Publications, New Delhi, 2001. 4. Elements of Vibrations Analysis: Leonanrd Meirovitch, Tata McGraw Hill, Special Indian edition, 2007
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LESSON PLAN Sub Code: 06ME62 Sub: Mechanical Vibration Hours / Week: 04 Total Hours: 62
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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.
Topic To be Covered
Introduction, types of vibrationfree,forced,random,torsional,longitudinal, rotational etc., Simple harmonic motion concept, phase difference principle of superposition and its derivation Beats phenomena Fourier theorem derivation for solving problem Problem solving Introduction to undamped free vibration ,examples. SDOF system Mass undamped system, natural frequency of free vibration Stiffness of spring element-series,parallel,etc,problem Effect of mass of spring ,derivation, problem Compound pendulum derivation, problem Different problem approach Different problem approach Different problem approach Introduction to damped free vibration ,examples.SDOF system Different types of damping viscous damping, Concepts of critical damping and its important Overdamping,underdamping -derivation Logarithmic decrement problem solving Problem solving Problem solving Introduction to forced vibration ,examples.SDOF system Steady state solution with viscous damping due to harmonic force Solution by complex algebra Reciprocating and rotating unbalance system with example ,derivation Vibration isolation, transmissibility ratio. Harmonic excitation, and support motion Problem approach Introduction to vibration measuring instruments Vibrometer working principle Problems on Vibrometer Accelerometer working principle Problems on Accelerometer Whirling of shafts explanation with air and without air damping Critical speed of shaft derivation , Problems on Critical speed of shaft derivation Introduction to two degrees of freedom Principle mode and normal modes of vibration Problems on Principle mode and normal modes of vibration 21
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40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62.
Topic To be Covered
Co-ordinate coupling derivation Generalized and principle co-ordinate system, initial condition Vehicle suspension, dynamic vibration absorber Problems on dynamic vibration absorber Dynamics of reciprocating engines, problem approach Problems on Dynamics of reciprocating engines Problem solving Introduction to continuous system, vibration of string derivation Longitudinal vibration of rods derivation Torsion vibration of rods, derivation, problem Eulers equation for beams derivation Introduction to multi degree of freedom Influence coefficients, Maxwell reciprocal theorem Dunker leys equation, orthogonality of principal modes Problems on Dunker leys equation, orthogonality of principal modes Methods of matrix iteration Problems on matrix iteration Holzer method, problem approach Problems on Holzer method Stodola method, problem approach Problems on Stodola method Problem approach Problem approach
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06ME63 MODELLING & FINITE ELEMENT ANALYSIS
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PART - A Unit 1 INTRODUCTION : Equilibrium equations in elasticity subjected to body force, traction forces, stress strain relations for plane stress and plane strain, Boundary conditions, Initial conditions, Eulers Lagranges equations of bar, beams, Principal of a minimum potential energy, principle of virtual work, Rayleigh-Ritz method, Galerkins method., Guass elimination Numerical integration. 07Hrs Unit 2 BASIC PROCEDURE :General description of Finite Element Method, Engineering applications of finite element method, Discretization process; types of elements 1D, 2D and 3D elements, size of the elements, location of nodes, node numbering scheme, half Bandwidth, Stiffness matrix of bar element by direct method, Properties of stiffness matrix, Preprocessing, post processing. 06Hrs Unit 3 INTERPOLATION MODELS : Introduction, Polynomial form of interpolation functionslinear, quadratic and cubic, Simplex, Complex, Multiplex elements, Selection of the order of the interpolation polynomial, Convergence requirements, 2D Pascal triangle, Linear interpolation polynomials in terms of global coordinates of bar, triangular (2D simplex) elements, Linear interpolation polynomials in terms of local coordinates of bar, triangular (2D simplex) elements, CST element. 06 Hrs Unit 4 HIGHER ORDER AND ISOPARAMETRIC ELEMENTS : Lagrangian interpolation, Higher order one dimensional elements- quadratic, Cubic element and their shape functions, properties of shape functions, Truss element, Shape functions of 2D quadratic triangular element in natural coordinates , 2D quadrilateral element shape functions linear, quadratic, Biquadric rectangular element( Nodded quad lateral element), Shape function of beam element, Hermite shape function of beam element. 07 Hrs. PART B Unit 5 DERIVATION OF ELEMENT STIFFNESS MATRICES AND LOAD VECTORS : Direct method for bar element under axial loading, trusses, beam element with concentrated and distributed loads, B matrices, Jacobian, Jacobian of 2D triangular element, quadlateral , Consistent load vector, Numerical integration. 07 Hrs. Unit 6 HEAT TRANSFER PROBLEMS : Steady state heat transfer, 1d heat conduction governing equation, boundary conditions, One dimensional element, Functional approach for heat conduction, Galerkin approach for heat conduction, hat flux boundary condition, 1D heat transfer in thin fins. 06 Hrs. 36
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Unit 7 APPLICATIONS I : Solution of bars, stepped bars, plane trusses by direct stiffness method. Solution for displacements, reactions and stresses by using elimination approach, penalty approach. 06Hrs. Unit 8 APPLICATIONS II : Solution of beam problems, heat transfer 1D problems with conduction and convection. 07Hrs. TEXT BOOKS: 1. Finite Elements in engineering, Chandrupatla T. R., 2nd Edition, PHI,2000 2. The Finite Element Method in Engineering , S. S. Rao, 4th Edition,Elsevier,2006. REFERENCE BOOKS: 1. Textbook of Finite Element Analysis, P.Seshu,PHI, 2004. 2. Finite Element Method, J.N.Reddy, McGraw Hill International Edition. 3. Finite Element Analysis, C.S.Krishnamurthy,Tata McGraw Hill Publishing Co.Ltd, New Delhi, 1995.
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LESSON PLAN Sub Code: 06ME63 Sub: Modeling and Finite Element Analysis Hours / Week: 04 Total Hours: 62
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Topic To be Covered
Equilibrium equations in elasticity subjected to body force, traction forces Stress strain relations for plane stress and plane strain, Boundary conditions, Initial conditions, Eulers Lagranges equations of bar Beams, Principal of a minimum potential energy Principle of virtual work Rayleigh-Ritz method, Galerkins method Guass elimination Numerical integration. General description of Finite Element Method Engineering applications of finite element method, Discretization process; types of elements 1D, 2D and 3D elements size of the elements, location of nodes, node numbering scheme, half Bandwidth Stiffness matrix of bar element by direct method Properties of stiffness matrix, Preprocessing, post processing. Polynomial form of interpolation functionslinear Polynomial form of interpolation functions- quadratic and cubic Simplex, Complex, Multiplex elements Selection of the order of the interpolation polynomial, Convergence requirements 2D Pascal triangle, Linear interpolation polynomials in terms of global coordinates of bar, triangular (2D simplex) elements Linear interpolation polynomials in terms of local coordinates of bar, Linear interpolation polynomials in terms of local coordinates triangular (2D simplex) elements Linear interpolation polynomials in terms of local coordinates CST element Lagrangian interpolation Higher order one dimensional elements- quadratic shape functions Cubic element and its shape functions Truss element, properties of shape functions, Shape functions of 2D quadratic triangular element in natural coordinates 2D quadrilateral element shape functions linear, quadratic 2D quadrilateral element shape functions quadratic Biquadric rectangular element (Noded quadrilateral element Shape function of beam element.. 38
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Topic To be Covered
Hermite shape function of beam element Direct method for bar element under axial loading Direct method for trusses element under axial loading, beam element with concentrated beam element with distributed loads, Jacobian matrices, Jacobian of 2D triangular element Quadrilateral, Consistent load vector,. Numerical integration Steady state heat transfer, 1D heat conduction governing equation, boundary conditions, One dimensional element, Functional approach for heat conduction Galerkin approach for heat conduction, heat flux boundary condition, 1D heat transfer in thin fins. Solution of bars, Solution of bars Solution of bars Stepped bars by direct stiffness method. Plane trusses by direct stiffness method. Solution for displacements, reactions and stresses by using elimination approach of bars Solution for displacements, reactions and stresses by using elimination approach of bars Solution for displacements, reactions and stresses by using elimination approach truss Reactions and stresses by using Penalty approach. Problems by using Penalty approach. Problems by using Penalty approach. Solution of beam problems Solution of beam problems Heat transfers 1D problem with conduction. Problem on 1D problem with conduction Heat transfers 1D problem with convection. Problem on 1D problem with convection.
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QUESTION BANK 1. Define a shape function. 2. What are the properties that the shape function should satisfy? 3. Explain linear interpolation 4. What are interpolation functions? 5. What is symmetric banded matrix? 6. Derive the Hermite shape functions for a beam elements. 7. Derive the shape functions fro a CST element and also the displacement matrix. 8. Explain the convergence criteria with suitable examples and compatibility requirements in FEM. 9. Derive the expression for stiffness matrix for a 2-D truss elements. 10. For a four nodded quadrilateral element, derive an expression for Jacobian matrix. 11. Derive the shape function for a 3 noded triangular element. 12. Explain Simplex, complex and multiplex elements. 13. Explain 2D Pascal triangle 14. With an example, explain node numbering and element connectivity for a ID bar. 15. Using Potential energy approach, obtain the element stiffness matrix for a ID bar element. 16. Derive [BT ] fro a two nodded one dimensional heat element (conduction) 17. Determine the nodal displacements 18. Determine the stress in each material 19. Determine the reaction forces. 20. Solve the following system of simultaneous equations by Gaussian elimination method. x1 - 2x2 + 6x3 = 0 2x1 + 2x2 + 3x3 = 3 -x1 + 3x2 = 2
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06ME64 MECHATRONICS & MICROPROCESSOR
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SYLLABUS Sub Code: 06ME64 Hours / Week: 4 Total Lecture Hrs: 62 PART A Unit 1 INTRODUCTION OF MECHATRONICS: Introduction of Mechatronics systems, Measurement system, control systems, microprocessor based controllers, Mechatronics approach and their associated problems. Examples and discussion on typical systems. 07 Hrs Unit 2 REVIEW OF TRANSDUCERS: Introduction of Transducers, Classifications, light sensors, selection of selectors, and inputting data by switches, their merits and demerits. 06 Hrs Unit 3 ELECTRICAL ACTUATION SYSTEMS: Electrical systems, Mechanical switches, solid state switches, solenoids, DC & AC motors, Stepper motors and their merits and demerits. 06 Hrs Unit 4 SIGNAL CONDITIONING: Introduction to signal conditioning. The operational amplifier, Protection, Filtering, Wheatstone bridge, Digital signals Multiplexers, Data acquisition, Introduction to Digital system processing Pulse-modulation. 07 Hrs PART B Unit 5 INTRODUCTION TO MICROPROCESSORS: Evaluation of Microprocessor, Organization of Microprocessors (Preliminary concepts), basic concepts of programming of microprocessors. Review of concepts Boolean algebra, Logic Gates and Gate Networks, Binary & Decimal number systems, memory representation of positive and negative integers, maximum and minimum integers. Conversion of real numbers, floating point notation, representation of floating point numbers, accuracy and range in floating point representation, overflow and underflow, addition of floating point numbers, character representation. 07 Hrs Unit 6 Logic function, Data word representation. Basic elements of control systems 8085A processor architecture terminology such as CPU, memory and address, ALU, assembler data registers, Fetch cycle, write cycle, state, bus, interrupts. Micro Controllers. Difference between microprocessor and micro controllers. Requirements for control and their implementation in microcontrollers. Classification of micro controllers. 07 Hrs Unit 7 ORGANIZATION & PROGRAMMING OF MICROPROCESSORS: Introduction to organization of INTEL 8085-Data and Address buses, Instruction set of 8085, programming the 8085, assembly language programming. 06 Hrs Exam Hours: 3 I A Marks: 25 Exam Marks: 100
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Unit 8 CENTRAL PROCESSING UNIT OF MICROPROCESSORS: Introduction, timing and control unit basic concepts, Instruction and data flow, system timing, examples of INTEL 8085 and INTEL 4004 register organization. 06 Hrs
Text Books: 1. Microprocessor Architecture, Programming And Applications With 8085/8085A R.S. Ganokar, Wiley Eastern. 2. Mechatronics W.Bolton, Longman, 2Ed, Pearson Publications, 2007. Reference Books: 1. Mechatronics Principles & applications by Godfrey C.Canwerbolu, Butterworth Heinemann 2006. 2. Mechactrionics Dan Necsulescu, Pearson Publication, 2007. 3. Introduction Mechatronics & Measurement systems, David.G. Aliciatore & Michael.B.Bihistaned, Tata McGraw Hill, 2000. 4. Mechatronics: Sabri Centinkunt, John Wiley & Sons Inc. 2007. 5. Mechatronics: Nitaigour Premchand Mahalik. Tata McGraw Hill, 2003
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LESSON PLAN Sub Code: 06ME64 Sub: Mechatronics and Microprocessor Period 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. (PART-A) Introduction to mechatronic systems Measurement systems and basic functions and applications. Open control system with example. Close control system with example. control systems applications. Microprocessor based controllers. Mechatronics application i.e Automatic camera & washing machine Mechatronics application i.e Automatic Engine system Definition and classification of transducers. Characteristics of transducer and sensors. Definition and classification of sensors. Principle and working of Eddy current sensors. Principle of working and applications proximity sensors. Principle of working and applications Hall effect sensors. Principle of working and applications of light sensors Electrical actuation systems introduction. Mechanical switches Relay working principle. Solid-state switches, types. Diode and its characteristics. Transistor and its characteristics. Traic and characteristics. Types of field effect sensors. MOSFET constructions. SCR and its characteristics. D.C Motor, principle and constriction details. Types of D.C Motors Brush less type D.C Motor. 50
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Hours / Week: 04 Total Hours: 62 Remarks
Topic to be covered
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A.C.Motors and its Types Definition of Stepper Motors. Types of stepper motors PM stepper motor Variable Reluctance stepper motor. Hybrid stepper motor. (PART-B) Introduction to microprocessors Evolution of Microprocessor. Organization of Microprocessors. Basic concepts of programming of microprocessors. Review of concepts Boolean algebra . Logic Gates and Gate Networks. Binary & Decimal number systems. Conversion of real numbers. Representation of floating point numbers Introduction to organization of INTEL 8085 Microprocessor. 8085A processor architecture terminology . Requirements for control and their implementation in microcontrollers Data and Address buses. Instruction set of 8085. Programming the 8085. Introduction, timing and control unit basic concepts. Instruction and data flow, system timing Examples of INTEL 8085 and INTEL 4004 register organization. (PART-A) Introduction to signal conditioning The operational amplifier. Protection, Filtering. Wheatstone bridge and its working Digital signals Multiplexers.
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Data acquisition system. Introduction to Digital system processing Pulse-modulation. ADC & DAC Difference between ADC & DAC Revision Revision
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QUESTION BANK 1. Define measurement and measurement system. 2. Explain the function of signal conditioner. 3. Define the term MECHATRONICS with the help of block diagram. 4. Give an example of measurement system and compare with elements of generalized measurements. 5. Define open loop control system, explain the neat diagram with an example of open loop system 6. Define closed loop control system, explain the neat diagram with an example of closed loop system. 7. Enumerate the difference between closed loop and open loop system. 8. What sequential control illustrate with an example. 9. Explain with block diagram the working of microprocessor-controlled washing machine. 10. Explain how microprocessors are use full in automatic camera. 11. Define sensor and transducer. 12. What is meant by detect transducer? Give an example. 13. What is meant by performance transducers? 14. What are the terminologies associated with the performance of transducers. 15. Explain the static characteristics of transducers. 16. Explain the dynamic characteristics of transducers. 17. How the transducers are classified. 18. Explain the Hall effect transducers. 19. Explain the light sensor with their classified. 20. Explain with sketch inputting data by switches. 21. Explain microprocessor based digital control system. 22. Explain digital numbering system. 23. Explain Binary and hexadecimal numbering system. 24. Explain the Logic functions & Data word representation 25. What are the basic elements of control system? 26. Explain with neat sketch 8085A Processor architecture Terminology. 27. Explain the Microprocessor with a neat diagram. 28. Enumerate the difference between Microprocessor and micro controllers. 29. What is meant by Electrical actuating system? 30. What are the Devices used in electrical actuator system. 31. Name solid-state switches and explain? 32. What are diodes? What is meant by forward and reverse bias diode? 33. Explain the working of thyristors with a block diagram. 34. What is Polar transistor? What is the difference configuration of Transistor? 35. What is D.C motor? Explain the principle of working of a D.C Motor. 36. Explain with a circuit diagram and characteristics curves, shunt wound D.C Motors. 37. Explain with neat sketch the feed back control system using PMW? 38. Explain a block diagram the basic principle of variable speed A.C motors. 39. What is meant Stepper motor and what are its performance characteristics. 40. What is meant by hybrid stepper motor? 41. Explain the specification terms of stepper motor. 42. What is meant by hydraulic actuation system? 43. Explain with a neat sketch principle of variable reluctance stepper motor 44. Explain with neat sketch working of hydraulic system. 53 MVJCE
45. Enumerate the difference between pneumatic and hydraulic system. 46. What are the Different types of OP-Amps? Explain each of them with neat Sketch. 47. What are the Characteristics of ideal operational Amplifier? 48. What is an Amplifier and Operational Amplifier? 49. What is the difference between passive and active filters? 50. Explain with neat Circuit diagram and instrumentation amplifier. 51. Explain with neat Circuit diagram the application of Comparators. 52. Explain with neat Circuit diagram the use of Amplifier in Audio CD Player?
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VTU QUESTION PAPERS
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06ME65 HEAT & MASS TRANSFER
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PART-A UNIT-1 INTRODUCTORY CONCEPTS AND DEFINITIONS: Modes of heat transfer: Basic laws governing conduction, convection and radiation heat transfer; thermal conductivity; heat transfer coefficient; radiation heat transfer; combined heat transfer mechanism. Boundary conditions of 1st, 2nd and 3 rd kind. CONDUCTION: Derivation of general three dimensional conduction equation in Cartesian coordinate, special cases, discussion on 3-D conduction in cylindrical and spherical coordinate system (No derivation). One dimensional conductional equations in rectangular, cylindrical and spherical coordinates for plane and composite walls. Overall heat transfer coefficient. Thermal contact resistance. 7 hours UNIT-2 VARIABLE THERMAL CONDUCTIVITY: Derivation of heat flow and temperature distribution in plane wall. Critical thickness of Insulation without heat generation, Thermal resistance concept & its importance. Heat transfer in extended surfaces of uniform cross-section without heat generation, Long fin, short fin with insulated tip and fin connected between two heat sources. Fin efficiency and effectiveness. Numerical problems. 6 hours UNIT-3 ONE-DIMENSIONAL TRANSIENT CONDUCTION: Conduction in solids with negligible internal temperature gradient (lumped systenm analysis), Use of Transient temperature charts (Heislers charts) for transient conduction in slab, long cylinder and sphere; use of Transient temperature charts for transient conduction in semi-infinite solids. Numerical problems. 6 hours UNIT-4 CONCEPTS AND BASIC RELATIONS IN BOUNDARY LAYERS:Flow over a body velocity boundary layer; critical Reynolds number; general expressions for drag coefficient and drag force; thermal boundary layer; general expressions for local heat transfer coefficient; Average heat transfer coefficient; Nusselt number. Flow inside a duct-velocity boundary layer, hydrodynamic entrance length and hydro dynamically developed flow; flow through tubes (internal flow)(discussion only). Numerical based on empirical relation given in data handbook. FREE OR NATURAL CONVECTION: Application of dimensional analysis for free convection- physical significance of Grashoff number; use of correlations of free convection in vertical, horizontal; and inclined flat plates, vertical and horizontal cylinders and spheres, Numerical problems. 7 hours
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PART-B UNIT-5 FORCED CONVECTIONS: Application of dimensional analysis for forced convection. Physical significance of Reynolds, Prandtl, Nusselt and Stanton numbers. Use of various correlations for hydro dynamically and thermally developed flows inside a duct, use of correlations for flow over a flat plate, over a cylinder and sphere. Numerical problems. 6 hours UNIT-6 HEAT EXCHANGERS: Classification of heat exchangers; overall heat transfer coefficient, fouling and fouling factor; LMTD, Effectiveness-NTU methods of analysis of heat exchangers. Numerical problems. 6 hours UNIT-7 CONDENSATION AND BOILING: Types of condensation (discussion only) Nusselts theory for laminar condensation on a vertical flat surface; use of correlations for condensation on vertical flat surfaces, horizontal tube and horizontal tube banks; Reynolds number for condensate flow; regimes of pool boiling correlations. Numerical problems. Mass transfer definition and terms used in mass transfer analysis, Ficks First law of discussion (no numericals). 7 hours UNIT-8 RADIATION HEAT TRANSFER: Therma radiation; definitions of various terms used in radiation heat transfer; Stefan-Boltzman law,Kirchoffs law, Plancks law and Weins displacement law. Radiation heat exchange between two parallel infinite black surfaces, between two parallel infinite gray surfaces; effect of radiation shield; intensity of radiation and solid angle; lamberts law; radiation heat exchange between two finite surfacesconfiguration factor. Numerical problems. 7 hours
Text Books: 1. Heat & Mass transfer, by Tirumaleshwar, Pearson-2006 2. Heat transfer, by P.K. Nag, Tata Mc Graw Hill 2002 Reference Books: 1. Heat transfer, a practical approach, Yunus A- Cengel Tata Mc Graw Hill 2. Principles of heat transfer by Kreith Thomas Learning 2001 3. Fundamentals of heat and mass transfer by Frenk P. Incropera and David P. Dewitt, John Wiley and sons. 4. Heat and Mass Transfer,by B K Venkanna, Ellite Publisher, Mangalore.
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LESSON PLAN Sub Code: 06ME65 Sub: Heat and Mass Transfer Hour Topics to be covered No 1. INTRODUCTORY CONCEPTS AND DEFINITIONS: Modes of heat transfer: Basic laws governing conduction,; 2. convection and radiation heat transfer, thermal conductivity 3. Heat transfer coefficient; radiation heat transfer 4. Combined heat transfer mechanism. Boundary conditions of 1 st, 2 nd and 3 rd kind 5. CONDUCTION: Derivation of general three dimensional conduction equation in Cartesian coordinate 6. Special cases, discussion on 3-D conduction in cylindrical and spherical coordinate system (No derivation). 7. One dimensional conductional equations in rectangular, cylindrical and spherical coordinates for plane and composite walls. 8. Overall heat transfer coefficient. Thermal contact resistance. 9. VARIABLE THERMAL CONDUCTIVITY: Derivation of heat flow and temperature distribution in plane wall. Hours / Week: 04 Total Hours: 52 Remarks
10. Critical thickness of Insulation without heat generation, Thermal resistance concept & its importance. 11. Heat transfer in extended surfaces of uniform cross-section without heat generation, 12. Long fin, short fin with insulated tip and fin connected between two heat sources. 13. Fin efficiency and effectiveness,Numerical problems. 14. ONE-DIMENSIONAL TRANSIENT CONDUCTION: Conduction in solids with negligible internal temperature gradient (lumped system analysis) 15. Use of Transient temperature charts (Heislers charts) for transient conduction in slab, 16. Use of Transient temperature charts for transient conduction in semi-infinite solids. 17. Long cylinder and sphere; Numerical problems. 18. CONCEPTS AND BASIC RELATIONS IN BOUNDARY LAYERS: Flow over a body velocity boundary layer; 19. Critical Reynolds number; general expressions for drag coefficient and drag force; thermal boundary layer; 20. General expressions for local heat transfer coefficient; Average heat transfer coefficient; Nusselt number. 60
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21. Flow inside a duct-velocity boundary layer, hydrodynamic entrance length and hydro dynamically developed flow; 22. Flow through tubes (internal flow)(discussion only). Numerical based on empirical relation given in data handbook. 23. FREE OR NATURAL CONVECTION: Application of dimensional analysis for free convection- physical significance of Grashoff number; 24. Use of correlations of free convection in vertical vertical and horizontal cylinders and spheres, Numerical problems 25. FORCED CONVECTIONS: Application of dimensional analysis for forced convection. , horizontal; and inclined flat plates,. 26. Physical significance of Reynolds, Prandtl, Nusselt and Stanton numbers. 27. Use of various correlations for hydro dynamically and thermally developed flows inside a duct, 28. Use of correlations for flow over a flat plate, over a cylinder and sphere. Numerical problems. 29. HEAT EXCHANGERS: Classification of heat exchangers overall heat transfer coefficient,; 30. fouling and fouling factor; LMTD, Effectiveness31. NTU methods of analysis of heat exchangers. Numerical problems. 32. CONDENSATION AND BOILING: Types of condensation (discussion only) 33. Nusselts theory for laminar condensation on a vertical flat surface; 34. use of correlations for condensation on vertical flat surfaces, 35. horizontal tube and horizontal tube banks; 36. Reynolds number for condensate flow 37. ; regimes of pool boiling correlations. 38. Numerical problems. 39. Mass transfer definition and terms used in mass transfer analysis, 40. Ficks First law of discussion (no numericals). 41. RADIATION HEAT TRANSFER: Thermal radiation; 42. Definitions of various terms used in radiation heat transfer; 43. Stefan-Boltzman law,Kirchoffs law,. 44. Plancks law and Weins displacement law 61
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45. Radiation heat exchange between two parallel infinite black surfaces, between two parallel infinite gray surfaces; 46. Effect of radiation shield; intensity of radiation and solid angle; 47. Lamberts law; radiation heat exchange between two finite surfacesconfiguration factor. 48. Numerical problems. 49. Numerical problems. 50. Revision. 51. Revision. 52. VTU Question Papers.
Text Books: Fundamentals of heat and mass transfer, Incropera and Dewitt Heat Transfer, J P Holman Heat Transfer. Ozisik Heat Transfer P K Nag Heat transfer Yunus a Cengel.
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QUESTION BANK
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06ME665 NON TRADITIONAL MACHINING
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PART - A Unit 1 INTRODUCTION: History, Classification, comparison between conventional and Nonconventional machining process selection. Water Jet Machinery: Principal, Equipment, Operation, Application, Advantages and limitations of water Jet machinery 06 Hrs Unit 2 MECHANICAL PROCESS: Ultrasonic machining (SUM): Introduction, equipment, tool materials & tool size, abrasive slurry, cutting tool system design:- Magnetostriction assembly, Tool cone (Concentrator), Exponential concentrator of circular cross section & rectangular cross section, Hallow cylindrical concentrator. Mechanics of cutting-Theory of Miller & Shaw., Effect of parameter: Effect of amplitude and frequency and vibration, Effect of grain diameter, effect of applied static load, effect of slurry, tool & work material, USM process characteristics: Material removal rate, tool wear, Accuracy, surface finish, applications, advantages & Disadvantages of USM. 08 Hrs Unit 3 ABRASIVE JET MACHINING (AJM): Introduction, Equipment, Variables in AJM: Carrier Gas, Type of abrasive, size of abrasive grain, velocity of the abrasive jet, mean No. abrasive particles per unit volume of the carrier gas, work material, stand off distance (SOD), nozzle design, shape of cut. Process characteristics-Material removal rate, Nozzle wear, Accuracy & surface finish. Applications, advantages & Disadvantages of AJM. 06 Hrs Unit 4 ELECTROCHEMICAL AND CHEMICAL METAL REMOVAL PROCESS: Electrochemical machining (ECM): Introduction , study of ECM machine, elements of ECM process : Cathode tool, Anode work piece, source of DC power, Electrolyte, chemistry of the process, ECM Process characteristics Material removal rate, Accuracy, surface finish, ECM Tooling: ECM tooling technique & example, Tool & insulation materials, Tool size Electrolyte flow arrangement, Handling of slug, Economics of ECM, Applications such as Electrochemical turning, Electrochemical Grinding, Electrochemical Honing, deburring, Advantages, Limitations. 06 Hrs PART B Unit 5 CHEMICAL MACHINING (CHM) : Introduction, elements of process, chemical blanking process : Preparation of work piece, preparation of masters, masking with photo resists, etching for blanking, accuracy of chemical blanking, applications of chemical blanking, chemical milling (contour machining): process steps masking, Etching, process characteristics of CHM: ;material removal rate accuracy, surface finish, Hydrogen embrittlement, advantages & application of CHM . 06 Hrs
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Unit 6 THERMAL METAL REMOVAL PROCESSES: Electrical discharge machining (EDM) introduction, machine, mechanism of metal removal, dielectric fluid, spark generator, EDM tools (electrodes) Electrode feed control, Electrode manufacture, Electrode wear, EDM tool design choice of machining operation electrode material selection, under sizing and length of electrode, machining time. Flushing pressure flushing suction flushing, side flushing, and pulsed flushing synchronized with electrode movement, EDM process characteristics: metal removal rate, accuracy surface finish, Heat affected Zone. Machine tool selection, Application EDM accessories / applications, electrical discharge grinding, Traveling wire EDM. 08 Hrs Unit 7 PLASMA ARC MACHINING (PAM): Introduction, equipment non-thermal generation of plasma, selection of gas, Mechanism of metal removal, PAM parameters, process characteristics. Safety precautions, Applications, Advantages and limitations. 05 Hrs Unit 8 LASER BEAM MACHINING (LBM): Introduction, equipment of LBM mechanism at metal removal, LBM parameters, Process characteristics, Applications, Advantages limitations ELECTRON BEAM MACHINERY (EBM): Principles, equipment, operations, applications, advantages and limitation of EBM. 07 Hrs
TEXT BOOKS: 1. Modern machining process, by PANDEY AND SHAH, TATA McGraw Hill 2000 2. New technology by BHATTACHARAYA 2000 REFERENCE BOOKS: 1. Production Technology, by HMT TATA McGraw Hill. 2001 2. Modern Machining Process by ADITYA. 2002 3. Non-Conventional Machining by P.K.Mishra, The Institution of Engineers (India) Test book series, Narosa Publishing House 2005.
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LESSON PLAN Sub Code: 06ME665 Sub: Non Traditional Machining Period Topics to be covered 1. Introduction :History 2. Classification of NTM Comparison btw conventional & Non conventional machining 3. process 4. Abrasive Jet Machining :Introduction 5. AJM Equipment 6. Variables in AJM 7. Continuation 8. Process characteristics of AJM 9. Applications ,Adv& Disadv 10. Electro chemical Machining : Introduction 11. Study of ECM 12. Elements of ECM Process 13. Chemistry of process 14. ECM Process characteristics 15. ECM Tooling technique and example ,Tool and insulation materials 16. Electrolyte Flow arrangement ,handling of slug 17. Economics of ECM ,Applications of ECM 18. EC turning ,EC grinding ,EC honing deburring 19. Advantages and limitations 20. Chemical Machining: Introduction 21. Elements of process, Chemical blanking process Preparation of work piece, preparation of masters, masking with 22. photo resists 23. Etching for blanking ,Accuracy of chemical blanking 24. Applications of chemical blanking 25. Chemical milling: Process steps-masking ,etching 26. Process characteristics of CHM 27. Hydrogen Embritlement ,Adv and application of CHM 28. Ultra sonic machining : Introduction 29. Equipment 30. Tool materials& tool size 31. Abrasive slurry 32. Cutting tool system design 33. Mechanics of cutting ,Theory of miller and shaw 34. Effect of parameter 35. USM process characteristics 36. Adv and Disadv, Applications of USM 37. Electrical discharge machining: introduction, equipment 38. Mechanism of metal removal 39. Dielectric fluid, Spark generator 79
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Hours / Week: 04 Total Hours: 62 Remarks
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EDM tools Electrode feed control Electrode manufacture ,Electrode wear EDM tool design Choice of machining operation, electrode material selection ,under sizing and length of electrode Flushing technique :pressure flushing ,suction flushing EDM process characteristics Applications of EDM Electrical discharge grinding Traveling wire EDM Plasma arc machining : Introduction ,equipment Non thermal selection of gas Mechanism of metal removal Pam parameters ,process characteristics Safety precautions ,Applications Adv and disadv Laser Beam Machining :introduction Equipment of LBM ,mechanism of metal removal LBM parameters ,process characteristics Applications ,Advantages and limitations Electron Beam Machining priciples,equipment,operations Applications ,adv and disadv of EBM Revision Revision
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QUESTION BANK ULTRA SONIC MACHINING 1. What is ultrasonic machining? USM is a mechanical material removal process in which the material is removed by repetitive impact of abrasive particles carried in liquid medium on to the work surface, by a shaped tool, Vibrating at ultrasonic frequency. 2. What are the advantages of USM? Advantages High accuracy and good surface finish No heat generation during machining Capability of drilling circular and non-circular holes in very hard materials. No thermal effects on mechanical work piece. Non-conductive materials can be machined. 3. What are the Disadvantages of USM? Tool wear Frequent turning is required Low material removal rate. Not economical for soft materials. Not suitable for heavy stock removal. 4. What are the applications of USM? Almost all the material can be machined except some soft materials. Diamond, Tungsten, Tungsten carbide, and synthetic ruby can be successfully machined. USM can be used for drilling, grinding, profiling, coining, threading and even for welding. For preparing wire drawing dies and tool room items. Used in jewellery for shaping jewels Drilling of screw threads and curved holes in brittle materials. 5. What are the components of USM? Ultrasonic transducer Concentrator Tool Abrasive slurry Abrasive feed mechanism Tool feed mechanism 6. What is ultrasonic transducer? The device used for converting any type of energy into ultrasonic wavers or vibration is called ultrasonic transducer. 7. Write short noted on piezoelectric crystals? Piezoelectric crystals are used foe inducing ultrasonic vibrations since they posses the capability of changing their dimensions to the given electrical energy or in other sense they have the capability converting electrical energy into mechanical vibrations. 81
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8. What is magnetostrictive effect? It is the one in which the material changes its dimension is in response to a magnetic field. 9. What are the magnetostrivtive materials employed in USM? Nickel, Iron cobalt called as permendum , iron aluminum called as alter. 10.What is the purpose of concentrator used in USM? The main purpose of the concentrator is to increase the amplitude of the vibration obtained from the transducer. 11. What is abrasive Slurry? The abrasive slurry is nothing but a mixture of abrasive grains and the carrier fluid, generally water. 12. What are the different types of concentrators? Conical Type Exponential type Stepped type. 13. What are the characteristics of carrier fluid? Good wetting characteristic High thermal conductivity Non-toxic and non-corrosive. Should have low viscosity. 14. What are the elements of Carrier Fluid? Act as a coolant. Act as an acoustic bond between the work piece and the tool. Helps efficient transfer of energy. Act as medium to carry the abrasive machined materials and worm abrasives 15. What are the types of feed mechanisms used in USM? Spring type Counter weight type Motor type Pneumatic and hydraulic type ABRASIVE JET MACHINING 1.Define AJM? It is the material removal process where the material is removed or machined by the impact erosion of the high velocity stream of air or gas and abrasive mixtrue, which is focused on to the work piece. 2. How does AJM differ from conventional sand blasting process? AJM differ from the conventional sand blasting process in the way that the abrasive is much finer and effective control over the process parameters and cutting. Used mainly to cut hard and brittle materials, which are thin and sensitive to heat. 82
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3. What are the advantages of AJM process? Low capital cost Less vibration. Good for difficult to reach area. No heat is genera6ted in work piece. Ability to cut intricate holes of any hardness and brittleness in the material. Ability to cut fragile, brittle hard and heat sensitive material without damage. 4. What are the applications of AJM? For abrading and frosting glass, it is more economical than acid etching and grinding. For doing hard suffuses, safe removal of smears and ceramics oxides on metals. Resistive coating etc from ports to delicate to withstand normal scrapping Delicate cleaning such as removal of smudges from antique documents. Machining semiconductors such as germanium etc. 5.Write the Disadvantages of AJM process? Low metal removal rate. Due to stay cutting accuracy is affected. Parivles is imbedding in work piece. Abrasive powder cannot be reused. 6. Give the formula for find the material remove rate for brittle metal? MRR = 1.04 ( MV3/2 / 1/4H3/4 ) 7.Give a summary of the abrasive of their application for different operation? ABRASIVE (1) Aluminium (2) Silicon Carbide. (3) Glass Heads (4) Crushed glass APPLICATION Cleaning, Cutting and Deburrig Faster cleaning, Cutting. Matt polishing, cleaning Peening and cleaning.
8.Write the formula for find the MRR for ductile materials? MRR = 0.5 ( MV2 / H) 9. What are the Process parameters affecting the MRR in AJM? Gas Pressure. Velocity of Particles. Abrasive mass flow rate. Mixing ratio. Nozzle Tip Distance. 10. What are the disadvantages of using abrasives again and again? Cutting ability of the abrasives decreases after the large Contamination of wears materials clogging the nozzle and the cutting unit orifices. 83
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11. What are the different types of nozzles heads used in AJM? Right angle head. Straight head. 12. Why oxygen should not be used in AJM? Oxygen should not be used because of fire hazard problem. 13. What are the different types abrasives used in AJM? Aluminium oxides, silicon carbides, Crushed glass, Sodium bicarbonate, Dolomite. 14. Reuse of abrasives is not recommended in AJM. why? Reuse of abrasives is not recommented since the cutting ability of abrasive decrease after the usage and also the contamination of wear materials clogging the nozzle and the cutting unit orifice.
LASER BEAM MACHINING 1.What is Laser? It is acronym of light amplification by stimulated emission of radiation. 2.What is Maser? Laser can be melt diamond when focused by lens system. The energy density being of two order 100,000 KW/cm2. This energy is due to atoms that have light energy level. When such an atom impinge with electromagnetic waves having resonant frequency. 3.What are the characteristics of Laser beam? 1.Material removal 2.Material shaping 3.Welding 4.Thermo kinetic change. 4.What are the gases commonly used in LASER? The gases commonly used are: He, Ne, Argon, Co2 etc. 5.What are the advantages of Laser drilling? No physical contact between work root pair hence there is no possibility if breakage or wear of root. Precision location is ensured by focusing of the beam Large aspect ratio can be achieved. 6.What are the characteristics of Laser used in Laser machining? 1. Can be focused to maximum intensity or to lower intensity as needed. 2. Can be moved rapidly on the work. 3. Remote cutting over long standoff distances.
7.What are the fundamentals of photons used in Laser? In the Laser the photons are in ground state at 0 oC they are brought to the excited state by means of absorption of energy by temperature change, collision etc. 84
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8.What are the emission lines? The atoms when this they are bringing down goes to the excited state by stimulated emission and emit photons within 10 nano secs. They have the same wavelength as the excited photons. 9.What is the Maser principle? The energy density of laser with 100,000Kw/cm2. The atoms at this state will impinge with electrons waves having resonate frequency. This is known as maser. 10.What is population inversion? If the atoms in the excited state are greater than that of the ground state then it is known as population inversion. 11.How does Laser melting works? It melts and vaporizes the unwanted material by means of narrow pulsed laser operating at 2 to 100pilses/sec Because of this high accuracy is not possible to micro sized holes. 12.What is solid state Laser? Solid state Laser is the Lasers, which consist of a hot nat, which may be crystalline solid/ glass, doped with an active material whose atoms provide the lasing action. ELECTRON BEAM MACHINING 1) Define EBM? It is the thermo-electrical material removal process on which the material is removed by the high velocity electron beam emitted from the tungsten filament made to impinge on the work surface, where kinetic energy of the beam is transferred to the work piece material, producing intense heat, which makes the material to melt or vaporize it locally. What is the characteristic of the electron beam? High concentrated energy. Deep penetration into the metals. Low distortion. Any material either conductive or non-conductive can be processed. 3) Write the application of electron beam? - Thin film machining. - Surface treatment. - Engraving metals and non-metals. - Cutting of materials. 4) What are the main elements of the EBM equipment? Electron Gun. Beam focusing and deflecting units. Work Table. Vacuum chamber 5) What is the function of magnetic lens used in EBM? It converges the beam into a narrow spot into the work piece. 85
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6) What are the two types of EBM? (i) Thermal type. (ii) Non-thermal Type. 7) Explain the thermal type EBM? In this type the electron beam is used to heat the material up to the point where it is selectively vaporized. 8)Explain Non-thermal type EBM? In this type, the EBM produces a chemical reaction. 9) Write the advantage of EBM? (i) High accuracy. (ii) Any type of material can be processed. (iii) No mechanical or thermal distortion. (iv) No physical or metallurgical damage results. 10) Write the disadvantages of EBM? (i) High cost of equipment. (ii) Skilled operator is required for operation. (iii) Limited to 10mm material thickness. 11) Write any four application of EBM? (i) Micro machining application on materials. (ii) Drilling of apertures for electron microscope. (iii) Drilling of holes in ruby and diamond crystal.
12) Write the Richardson-Dushman Equation? J=At2 e- (EW/KT) J = Current Density A =constant (120 Amphere/cm2deg2) K =Boltzman Constant (1.3x10-23 J/K) T = Absolute temperature (Kelvin) W =work function (Volts) 13) Write general formula for focal length of a magnetic lens? f/(S + D) = 25V/(NT)2 V =Electron accelerating voltage NT =Ampere turns in the lens winding S =pole piece separation D =Bore diameter F =focal length 14) Why vacuum is needed in EBM? 1) To reduce corrosion 2) To get correct focusing
15) What is the drawback of electron beam machining? One major diameter of electron beam welding has been the requirement of high degree of vacuum essential or satisfactory operation of this process because of degassing. 86
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ELECTRO CHEMICAL MACHINING 1) Define ECM? It is the controlled removal of metals by the anodic dissolution in an electrolytic medium, where the work piece (anode) and the tool (cathode) are connected to the electrolytic circuit, which is kept, immersed in the electrolytic medium. 2) Write the Faradays first law of electrolysis? The amount of any material dissolved or deposited is proportional to the quantity of electrolyte passed. 3) Write the Faradays second law of electrolysis? The amount of different substances dissolved or deposited by the same quantity of electricity are proportional to their chemical equivalent weight. 4) Write Ohms law? Current, I = V/R V = Voltage R = resistance 5) What are the factors that influence oxidation in ECM? (i) Nature of work piece. (ii) Type of electrolyte. (iii) Current density. (iv) Temperature of the electrolyte. 6) What are the materials used to make the tool electrode? Copper and copper alloys, titanium, aluminum, brass, bronze, carbon, Monel and reinforced plastic. 7) What are the main functions of electrolysis in the ECM? i) For completing the electric circuit between the tool and the work piece and to allow the reaction to proceed efficiently. ii) To remove the products of machining from the cutting region. iii) To carry away the heat generated during the chemical reaction. iv) To avoid ion concentration at the work piece- tool gap. 8) What are the properties are expected from the electrolysis used in the ECM? i) High thermal conductivity. ii) Low viscosity and high specific heat. iii) Should chemically stable even at high temperature. iv) Should be non-toxic and non-corrosive. 9) What are the electrolysis commonly used in ECM? 15 -20 % Nacl in water, sodium nitrate, potassium nitrate, sodium sulphate, sodium chromate and potassium chloride.
10) What are the results, which is in improper selection of electrolyte in ECM? (i) Low machining rate. (ii) Over cut and stray cutting. 87
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11) What are the methods generally used to filter the electrolyte? (i) Running the system until it is contaminated completely and replace it. (ii) Centrifugal separation. (iii) Sedimentation. (iv) Use of clarifiers. 12) What are the characteristics of a good ECM tool? (i) It should be a good conductor of electricity and heat. (ii) Easily machinable. (iii) Resistant to chemical reaction. (iv) It offers resistance to the high electrolyte pressure. 13) What are the problems that occur while improperly selecting the electrolyte flow? Cavitations, stagnation and vortex formation. 14) What are the parameters that affect the MRR? (i) Feed rate. (ii) Voltage. (iii) Concentration of the electrolyte. (iv) Temperature of the electrolyte. (v) Current density. (vi) Velocity of the electrolyte. 15) How the current density affect the MRR? Current density is controlled not only by the amount of current but also by the size of the gap between the tool and the work piece. A small gap results in high current density, which in turn produce more material removal. 16) What are the advantages of ECM? ECM is simple, fast and versatile method. Surface finish can be extremely good. Fairly good tolerance can be obtained. 17) What are the limitations of ECM? Large power consumption and the related problems. Sharp internal corners cannot be answered. Maintenances of higher tolerances require complicated contours. 18) What are the applications of ECM? ECM is used for sinking, profiling and contouring, multi hole drilling, trepanning, broaching, honing, steel mill applications, surfacing, sawing, contour machining of hand to hand machine materials. ELECTO CHEMICAL GRINDING 1.Define ECG. ECG is the material removal process in which the material is removed by the combination of Electro- Chemical decomposition as in ECM process and abrasive due to grinding. 2. Which material is used to make the grinding wheel? Metal bonded diamond (or) Aluminum oxide. 3.What are the important functions of abrasive particles used in ECG? It acts as insulator to maintain a small gap between the wheel and work piece. They are electrolysis products from the working area. To cut chips if the wheel should contact the work piece particularly in the event of power failure. 88
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4.What are the advantages of ECG? i) No thermal damage to work piece. ii) Wheel wear is negligible. iii) No distortion of the work piece. 5.What are the disadvantages of ECG? High capital costs, because of the special wheel tool. Power consumption is quite high. Electrolyte is corrosive. 6.What are the limitations of ECG? 1.The work material must be conductive. 2.Nit suitable for machining soft material. 3.Require dressing tools for preparing the wheels. 7.What is the application of ECG? 1.Precision grinding of hand metals economically. 2.Grinding Carbide cutting tools inserts. 3.To grind end mill cutters more precisely.
PLASMA ARC WELDING

1. Define plasma Plasma is defined as the gas, which has been heated to a sufficiently high temperature to become ionized. 2. What are the advantages of plasma arc welding? a. Exothermic oxidation takes place. b. DC power supply 3. What are the metals that can't be machined by plasma arc machining? a. Stainless steel b. Monel c. Super alloys 4. What is the basic heating phenomenon that takes place in plasma arc welding? The basic heating phenomenon that takes place at the work piece is a combination of anode heating due to direct electron bombardment recombination of molecules on the work piece. 5. How does the basic plasma is generated. The basic plasma is generated by subjecting a stream of gas to the electron bombardment of the electric arc. 6. How the initial ionization is accomplished in plasma arc machining. A high voltage arc established between electrode and nozzle accomplishes initial ionization. 7. Why does gas formed in plasma do in P.A.M? This gas stabilizes the arc and prevents it from diverging.
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8. How another source of heating achieved in P.A.M It is desirable to achieve a third source of heating by injecting oxygen into work area to take advantage of exothermic oxidation. 9. Write the principle of P.A.M Once the material has been raised to molten point the high velocity gas stream blows the material away. 10.Write the circuitry details in PAM. + ve terminal connected to work piece and -- ve terminal connected to electrode.
12. Which type of power supply is used in P.A.M DC power supply is used. 13. Which part is constricted by plasma? Nozzle duct is constricted by plasma.
WATER JET MACHINING 1. What are the properties of water jet machining about effect cutting action? High pressure, high velocity jet of water. 2. What are the types of units and its purpose used in water jet cutting system? a. Pump -- to generate high pressure b. Machining unit-- to actually cut the material with the jet nozzle. c. Filtration unit -- to clear the water after use. 3. Why we are using the diamond nozzle. a. High hardness metal b. Working life is more compared to other jewel nozzle such as ruby or sapphire. 4. Why do you select proper cutting fluid in WJM? Cutting fluids mainly depends on the operation requirement, quality of finish, cutting speed and overall cost 5. Does there is any environmental effects while using the water jet machining. There is no environmental pollution such as dust suspended in the air because the water jet drains any dust simultaneously When cutting. 6. What are the advantages of WJC over conventional cutting methods? a. Because of point cutting WJC is able to cut materials almost any pattern. b. Material loss due to machining is minimum. c. WJC will not burn surfaces or produces a heat an affected zone. d. No environmental pollution.
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7. What are the applications of WJM? *Aero space *Automobile *Paper pulp industries 8. What are the commonly used additives in WJM? 1.Crly cerine 2.Polyethylene oxide 3.Long chain polymers 9. What is optical tracing system? It employs an optical scanner that traces a line drawing and produces electronic signals that control the X-rays.
ELECTRICAL DISCHARGE MACHINING 1. Define electrical discharge machining? EDM is the controlled erosion of electrically conductive materials by the initiation of rapid and repetitive spark discharge between the electrode tool to the cathode and work to anode separated by a small gap kept in the path of dielectric medium. This process also called spark erosion. 2. What are functions of dielectric fluid used in EDM? 1.It acts as an insulating medium 2.It cools the spark region and helps in keeping the tool and work piece cool. 3.It maintains a constant resistance across the gap. 4.It carries away the eroded metal particles. 3. Basic requirement of dielectric fluid used in EDM? 1.Stable Dielectric strength. 2.It should have optimum viscosity. 3.It should have high flash point. 4.It should be chemically stable at high temperature and neutral. 5.It should not emit toxic vapours.
4 What the dielectric fluids commonly used in EDM? 1.Petrolium based hydrocarbon fluids. 2.Parafin, white sprite, transformer oil. 3.Kerosine, mineral oil. 4.Ethylene glycol and water miscible compounds. 5. What are the prime requirements of tool material in EDM? 1.It should be electrically conductive. 2.It should have good mach inability. 3. It should have low erosion rate. 4. It should have low electrical resistance. 91
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6. Name some of the tool material used in EDM? 1.Copper, brass, alloys of Zinc &tin. 2.Hardend plain carbon steel 3.copper tungsten, silver tungsten, tungsten 4.Copper graphite and graphite. 7. What is the process parameter efficiency the MRR? 1.Energy discharge 2.Capacitance. 3.Size of work piece. 4.M/c tool design 8. Write the formula for finding the energy discharge in EDM? W=(1/2) X EIT W-discharge energy I-Current T-time E-voltage 9. What is the effect of capacitance in EDM? Increasing the capacitance causes the discharge to increase and increase both the peak current and discharge time. 10. How do you increase the inductance of the circuit? A piece of iron or steel be allowed to lodge between the leads it would increase the inductance of the circuit and reduce the M/C rate. 11. Define W/T ratio? It is the ratio of volume of work removed to the volume of tool removed. 12. What is cycle time? It is the sum of discharge time and waiting time. 13. Define over cut? It is the discharge by which the machined hole in the work piece exceeds the electrode size and is determined by both the initiating voltage and the discharge energy. 14. Define Rehardening? While metal heated to a temperature above the critical and then rapidly cooled by the flowing dielectric fluid the metal is rehardened. 15. What is recast metal? Metal heated to a temperature above the melting point and which is not displaced by the action of the spark discharge, resoldifies as recast metal. 16. Explain electrode wear? A crater is produced in the electrode, which is likewise dependent on the electrode material and the energy of the discharge. 92
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17. What are types of power supply circuits used in EDM? 1.R-Ccircuit. 2.Rotary impulse generator. 3.Controlled pulse (vacuum tube). 4.Oscillator controlled pulse. 5.Transister pulsed circuit. 18. What are the design factors to be considered while selecting the machine tool? 1.Number of parts to be produced. 2.Accuracy. 3.Size of work piece. 4.Size of electrode. 5.Depth of cavity. 19. Why the servo controlled system is needed in EDM? EDM requires that a constant arc gap be maintained between the electrode and the work piece to obtain maximum machining efficiency. Therefore EDM tool in corporate some form of servo control. 20. Define wear ratio? Wear ratio=Work piece material removed/Loss of electrode material.
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VTU QUESTION PAPERS
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06ME67 COMPUTER AIDED MODELLING & ANALYSIS LAB
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SYLLABUS Sub Code: 06MEL67 Hours/week: 4 Total Hours: 52 PART - A Study of a FEA package and modeling stress analysis of a. Bars of constant cross section area, tapered cross section area and stepped bar 6 Hours b. Trusses (Minimum 2 exercises) 3 Hours c. Beams Simply supported, cantilever, beams with UDL, beams with varying load etc (Minimum 6 exercises) 12 Hours PART - B a) b) Stress analysis of a rectangular plate with a circular hole 3 Hours IA Marks: 25 Exam Hours: 03 Exam Marks: 50
Thermal Analysis 2D problem with conduction and convection boundry conditions(Minimum 2 exercises) 6 Hours Fluid flow Analysis Potential distribution in the 2 D bodies 3 Hours Dynamic Analysis 1) Fixed fixed beam for natural frequency determination 2) Bar subjected to forcing function 3) Fixed fixed beam subjected to forcing function 9 Hours
c) d)
REFERENCE BOOKS: 1. A first course in the Finite element method by Daryl L Logan, Thomason, Third Edition 2. Fundaments of FEM by Hutton McGraw Hill, 2004 3. Finite Element Analysis by George R. Buchanan, Schaum Series Scheme for Examination: One Question from Part A One Question from Part B Viva-Voce
20Marks (05 Write up +15) 20Marks (05 Write up +15) 10 Marks
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06ME68 HEAT & MASS TRANSFER LAB
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SYLLABUS Sub Code: 06ME68 Hours / Week: 4 Total Lecture Hrs: 52 I A Marks: 25 Exam Hours: 3 Exam Marks: 100
EXPT. NO.
NAME OF THE EXPERIMENT
Part - A
01 02 03 04 05 06 EMISSIVITY MEASUREMENT OF RADIATING SURFACES HEAT TRANSFER THROUGH FORCED CONVECTION HEAT TRANSFER THROUGH COMPOSITE WALLS HEAT TRANSFER THROUGH PIN FIN THERMAL CONDUCTIVITY OF METAL BAR HEAT TRANSFER BY NATURAL(FREE) CONVECTION
Part - B
07 08 09 10 11 STEFAN BOLTZMAN APPARATUS Vapor Compression Refrigerator PARALLEL FLOW HEAT EXCHANGER COUNTER FLOW HEAT EXCHANGER AIR CONDITIONER TRAINER
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06ME61 DESIGN OF MACHINE ELEMENTS II

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