TRAINING DETAILS

Day: 1
Date: 25. 03.2014
Topics Covered

Stress
Strain
Types of Stress And Strain
Youngs Modulus
Factor of safety
Deformation

Stress:
Stress is Force Acting per Unit area or a resistive Force
offered Against the Force Applied.
Types of stress:

Tensile Stress (It is Caused By Pull Load)

Compressive Stress(It is Caused By Push Load)
Shear Stress(It is caused At Surface )
Thermal Stress(Due to Temperature)

Strain:

Strain is caused Due to Stress. It is The Ratio

between Change In dimensions And Original
Dimension. It has no units

Deformation:
The change in Dimension is called
Deformation

Elastic Limit:
It is Point Where Stress and strain Ration Is
constant .Between this Limit the Material
Behaves Elastically

Yield Point:
It is the point where the Material started
Deforming Plastically

Ultimate Stress:
It is the Maximum Stress Which A material
can with Stand

Youngs Modulus:
Within The Elastic Limit Stress is Directly
Proportional to Strain. It is Hookes Law.
Proportional Constant is known as Yongs
Modulus

Factor of Safety:
It is ratio between Ultimate Stress and
Working Stress. While Designing, Factor of
safety is very important. The Average 5
must be maintained.

Day: 2
Date: 26.03.2014
Topics Covered
Stress Strain Curve
Structural And its Basics

Stress-Strain Curve

Stress strain curve is used while designing

for any material .Under Load test this curve
is drawn to find the elastic limit, yield point,
Ultimate Stress and breaking Point etc.

Structural and its Basics:

To build a structure we need some Profile
like

Beams
Channels
Angles
HSS(Hallow structural section)
Plates

Beams:
Beam Is Structural member which is
supported and carries load which is Right
angle to the length. Mostly I beam is used
because it has high moment of inertia

These beams are specified by Indian

Standard As
ISMB 100 (Indian Standard Medium
Beams)
ISJB 125 (Indian Standard junior Beams)
ISLB 150 (Indian Standard Light Beams)
ISWB 200 (Indian Standard Weight
Beams)
ISHB 225 (Indian Standard Heavy
Beams)
100 Specifies the depth of the section

Channel:
Channel is a constructional material with cross section
as C shape

Channel are specified by Indian Standard as

o ISMC 100 (Indian Standard medium

channel)
o ISJC 150 (Indian Standard junior
Channel)
o ISLC 200 (Indian Standard light
channel

Angle:
Angle is also a constructional material with a Cross
section L

Hallow Structured Section:

Hallow Structured Section Is a constructional Material
which is a closed section .e.g.-steel pipe, tube.

Parallel flange Beams and columns are specified by

British and European Standards such as

 UC 152*152*23 (British Standard)

UB 533*210*82(British Standard)
IPEA 600 (European Standard)
HPE 400 (European standard)

Types of beams By Supports:

Simply supported
Overhanging
Cantilever
Fixed
Continuous

Plates:
Plates are ordinary sheet or plates of various thickness.
Its thickness is selected according to the load applied.
Types of Load Acting on Beams:
Concentrated load or Point load
Uniformly distributed load
Uniformly varying load

Moment of Inertia

Moment of inertia of a body is defined as the resistance

offered against the rotation or capacity of cross section
against bending.

Day: 3
Date: 27.03.2014
Topics covered
Material and its selection
Carbon steel
Alloy Steel

Carbon Steel:
Carbon steel is an alloy of iron and carbon which carbon are
the main alloying materials. Other materials are added such as
manganese, copper, silicon in low maximum percentage.
According to The carbon content there are three categories

S.n
o
1.
2.
3.
4.

Types

Composition

Low carbon steel

C- 0.05% to 0.25%
Mn up to 0.4%
Medium Carbon steel C-0.29% to 0.54%
Mn -0.6% to 1.65%
High Carbon Steel
C-0.55% to 0.95%
Mn-0.3% to 0.9%
Very High Carbon
C-0.96% to 2.1%
Steel

Alloy steel:
Alloy Steel is steel in which two or more alloying
substance is added other than carbon to achieve the
desired properties. It has two types

Low alloy steel-Alloying elements less than 10.5%

High Alloy steel-Alloying elements more than 10.5%

Grades and Standard:

(31.03.2014)
Materials

Carbon steel

Alloy steel

Plate/sheets

SA 515 Gd60,70

SA 387 Gd 11,12

Pipe

SA 106 Gd B

SA 335 P 11,12

Tube

SA 106 Gd A1

SA 213 T 11,12
___

Structural

IS2062
___

Rod
Bolt, Nut,
Washer

SA 105
ISI363,64,67

Day: 4
Date: 28.03.2014
Topics covered
1. Stain less Steel

___

2. Hastelloy
3. First angle projection and third angle projection

1. Stainless steel:
A Stainless steel is a steel alloy of minimum 10.5%of
chromium in mass.It is rust less and inoxydable
Commonly Used Grades:
SS 304

SS316

SS304L

SS316L

SS304H

SS3CR12

SS204

SS430

SS303

SS441

Types of Stainless Steel:

i.
ii.
iii.
iv.
v.

Ferrritic
Austenitic
Martensitic
Duplex
Precipitation Hardening

i. Ferritic:
o
o
o
o
o
o
o

400 Series
Chromium is much (27%)
High resistance to corrosion
They are magnetic
Cannot be hardened by heat treatment
Used in sea water
Used for making car trim and Exhaust system

ii. Martensitic:
o
o
o
o
o
o

Similar to ferritic,but carbon content differ i.e., 1%

High strength
Moderate corrosion Resistance
Molybdenum and nickel is added
Harder and little Magnetic
Used in spindle, knifes, Shaft, surgical instrument

iii. Austentic:
o
o
o
o

Most common steel

Corrosion resistance
Ductile and Malleable
Used in kitchen sinks and chemical equipments

iv. Duplex:

Formed by mixing the basic components of austenitic

and ferriticsteel
o
o
o
o
o

It contains Higher level of chromium

Simple to weld
Easily formed to specific shapes
Best quality
Used for tools and machinery in marine condition

v. Precipitation Hardening:
Basically Austenitic by adding other elements to get
desired properties .once added it become extremely
tough, durable and hard wearing.
Used in Aircrafts Parts and Pumps

2. Hastelloy:
Hastelloy is the alloy of nickel, chromium, and
molybdenum.It has high oxidation resistance, fabric
ability, and high temperature strength

Composition:

Ni -55%

Fe -4 - 7%

Mo -15 - 17%

W -3 - 4.5%

Cr -14.5 - 16.5%

Uses:

Pollution Control
Chemical processing
Waste treatment
Marine Engineering
Pulp and paper production

Standard used for Hastelloy is

C276
Grades and Standard :
( 31.03.2014)
Materials
Plate/sheets

Stainless Steel
SA 240 (GRADE)

Pipe

SA 312(GRADE)
SA 268

Tube
Structural
Rod

SA 276(GRADE)

Bolt, Nut, Washer

AISI 316 (washer)

A193 B7 (Bolt)
A194 B8 (nut)

Using Grades:

SS
SS
SS
SS

204
304
316
316L

Properties of
materials:
i. Physical properties
ii. Mechanical properties
iii. Thermal properties

i. Physical properties:

conductivity
Tensile Strength
Yield Strength
Melting point
Freezing point

ii. Mechanical properties:

Hardness
Toughness

iii. Thermal property:

Entropy
Enthalpy

3. First Angle and Third Angle

projection:
First Angle
Object lies in the first quadrant
The views are different from third angle
Viewer-object-plane of projection

Third Angle projection

The object lies in third quadrant
The views are different from first angle
Viewer-plane of projection-object

Symbol for Projection:

Day: 5 & 6
Date: 29.03.2014 & 31.03.2014

Topics Covered:

Unit conversions

Standards and Grades

Unit conversion
1.Pressure
2.Flow rates
3.Temperature

1. Pressure
1pascal=0.00014503 Psi
1Bar=14.503 Psi
1Psi=0.06896 bar
1 bar=100000 N/ m

2. Flow rates
1 liter/hour=0.26417 gallon/hour
1 gallon/hour=3.785 litre/hour
1millilitre/hour=0.001litre/hour

 1millilitre/hour=0.00026417 gallon/hour
1litre/hour=1000 millilitre/hour
1 cubic metre/sec=3600000 kg/hour

1 cubic meter/sec=1000 kg/sec

3. Temperature
1 degree Celsius=33.8 F
1 Fahrenheit=-17.22 degree Celsius

Day: 7
Date: 01.04.2014
Topics Covered:
1. Welding
2. Types of weld joints
3. Nomenclature of weld
4. Edge preparation
5. Welding symbol
6. Welding machines
7. Welding Process

Welding:
Welding is the process of joining two similar materials by
heating process.

Types of weld Joints:

Weld joints can be classified according to
Type of weld
Position of work piece
Length of weld
By Type of weld it can be classified into

Butt weld
Fillet Weld
Plug weld
Slot weld
Seam weld
Spot weld

By the position of weld

Butt joint
Lap joint
T joint
Corner joint
Edge joint

By the length of the weld:

Continuous Weld
Intermittent Weld
o Chain Both Sides
o Staggered

Weld Nomenclature:

Welding Symbols:

Edge preparation:
It is the preparation before welding to increase the strength of the weld

Welding Process:
Arc Welding Process:

Atomic Hydrogen Welding

Carbon Arc Welding
Gas metal Arc welding
Plasma Arc welding

Oxy Fuel Gas Welding:

Oxy acetylene Welding
Oxy Hydrogen Welding

Resistance Welding:
Resistance Spot Welding
Resistance Seam Welding
Other Welding Process:
Electron Beam Welding
Laser Beam Welding

Types of welding Machines:

TIG welding Machines
MIG welding Machines
SMAW Welding Machines
Oxy-fuel Welding Machines

Day: 8
Date: 02.04.2014
Topics Covered:

Drilling
Milling
Grinding
Shaping

Drilling:
Drilling is the process of creating a hole in a work piece using drill
bit.

Types of Drilling:

Spot Drilling
Centre Drilling
Deep hole drilling
Gun Drilling
Trepanning
Micro drilling
Vibration Drilling

Spot Drilling:
Spot drilling is the process of drilling a hole which guide
the final hole.

Centre Drilling:
The purpose of center drilling, it acts as the center for various
operations.

Deep Hole Drilling:

Deep hole drilling is used where the length of the hole is 10 times
greater than the dia of the hole.

Gun Drilling:
Gun drilling is used to drill small dia holes .The ratio may be more
than 300:1.

Trepanning:
Trepanning is the process of creating larger dia holes.

Micro drilling:
Micro Drilling is the process of creating a Hole with dia less than
0.5mm.

Vibration Drilling:
Drilling is done by the vibration of drill bits.

Types of drilling Machines

Portable Drilling Machines

Sensitive Drilling machines
Up-right drilling Machines
Radial Drilling Machines
Gang drilling Machines
Multiple spindle Drilling Machines
Deep Hole Drilling Machine

Milling:
Milling is the process of removing material using multi point
cutting tool

Types of Milling Machines:

Horizontal Milling machines
Vertical Milling machines
Plain Milling machines
Universal Milling machines
Omniversal Milling machines
Simplex Milling machines
Duplex Milling machines
Triplex Milling machines

Grinding Machines:
Grinding is a process of machining using abrasive
grinding wheels to remove small chips

Types of Grinding Machines:

Portable grinder
Abrasive belt grinder
Plain Centre type Cylindrical Grinder
Centre less grinder
Internal Centre less Grinder
Planetary grinder
Surface grinder

Abrasives in Grinding Wheels:

Sand Stones
Emery
Diamonds

Corundum
Aluminum oxide
Silicon Carbide

Shaping Machines:
Shaping is the kind of reciprocating machine which
uses a single point cutting tool to remove metals.

Types of Shaper Machines:

Horizontal Shaper
Vertical Shaper
Universal Shaper
Push Cut Shaper
Draw Cut Shaper

Day: 9
Date: 03.04.2014

 Topics Covered:
Basic Concepts of Thermodynamics
Laws of thermodynamics

Basic Concept of
Thermodynamics:
Thermodynamics is study of heat and its relation to
work and energy. Thermo-Heat, Dynamics-Power
System, Surrounding, Boundary:

Thermodynamic system, or system, is defined as a

quantity of matter or a region in space chosen for
study.
The region outside the system is called the
Surroundings.

The real or imaginary surface that separates the

system from its surroundings is called the

Boundary.

 Types of System:
The system in which the energy transfer and
mass transfer takes place is called Open
system e.g. Compressor
The system in which only energy transfer
takes place is called Closed System. Here
mass transfer doesnt takes place.
The System which doesnt exchange any
energy and matter is called Isolated
system

Types of Energies:

Potential energy is the energy stored within

the object e.g. Energy stored in the spring, dam etc.

PE= mass g height

Kinetic energy is the energy of motion. Every

object in motion has kinetic energy

 Internal energy is the energy associated with the

internal molecules of the substance.

Laws of Thermodynamics:
First law of thermodynamics states that
net work transfer is equal net heat transfer
i.e. energy can neither can created nor
destroyed
Second law by kelvin plank says that
it is impossible to construct a heat power
engine which works on a cyclic process
which converts the absorbed heat from a
reservoir into equivalent amount of work.
Second law by clausius says that it is
impossible to transfer heat from cold body to
hot body without the use of external work.
Third law says that the entropy of the
perfect crystal at absolute zero temperature
is zero

Day: 10
Date: 04.04.2014
Topics Covered:

Entropy
Enthalpy
Specific heat
Internal Energy
Latent Heat
Sensible Heat
Dimensioning Rules

Enthalpy:
Enthalpy is the sum of internal energy and flow work
H
=
U
+

P
V

H- Enthalpy
U-Internal Energy
P-pressure
V- Volume

Entropy:
Entropy is the thermodynamic property and it depends upon the
change in temperature by heat transfer
S
=
Q
/
T

S- Entropy

Q- Heat Transfer

T- Temperature

Internal Energy:

 It is the total energy Possessed by a body .Thus internal energy

is the sum of potential energy and kinetic energy of the
molecules of the body.

Specific Heat:

Specific heat is the heat required to raise the

temperature of the unit mass of the substance to one degree
Celsius.

Latent Heat;
It is the amount of heat released or absorbed during the change
of state of substance at constant temperature.

Sensible Heat:
Sensible heat is the energy required to change the temperature
of a substance with no phase change.

Dimension Rules:
1. Avoid placing any dimensions inside the part unless there is
no other option.
2. Avoid dimensioning to hidden features.
3. Avoid contact of values.
4. Always place dimension to the most descriptive view.

 5. Dimension rounded corners & arc features as radial.

6. If same value is repeated many times, then use a general
note.
7. Always dimension holes in their circular view
8. Dimension cylindrical object as diameter in their rectangular
view.
9. For metric dimensions less than 1mm does place a zero at
decimal Point.
10. For inches dimensions less than 1 don't place a zero
introduction at decimal Point.
11. Overall dimensions should be outside of smaller
dimensions.
12. Do not duplicate dimensions to avoid using on necessary.
13. Dimension line should never intersect other dimension line.
14. Center Line should not extend from view to view.
15. Arrow heads 3mm X 1mm.

Day: 11
Date: 05.04.2014

 Topics Covered:

Conduction
Convection
Radiation
Cooling
Lubricants

Conduction:

The transfer of heat from one substance to

another by direct contact.
Examples:
Touching the Hot Pan
Touching the Hot substance

Convection:

Convection is the movement of molecules

within fluids
Examples:
Boiling of Water and Convection happened between the
molecules

Radiation:

Energy that is radiated or transmitted in the

form of rays. It is the heat transfer by electromagnetic
waves.
Examples:

Microwave oven
Light Bulb
Heat from a Fire

Cooling:

Cooling is for removal of heat produced by the

moving parts and Burning of fuel by the circulation of the
coolant.

Properties of the coolants:

High heat transfer rate

high boiling point
Low melting point
Low power requirements for pumping
Non-toxic
Non-reactive.

Types of cooling system:

Liquid Cooling
1. Thermo syphon Cooling System
2. Forced Circulation cooling System

Air Cooling

Lubrication:

Lubrication is the process to reduce wear between

moving parts using lubricants.

Properties of the Lubricants:

It should have High Viscosity

Its Oiliness Should be High
It should have High Flash Point
It should be Volatile
It Should Posses Delergency Property
It should Posses Demulsibility

Types of Lubricating System:

Pet roil system

Pressure lubrication System
Splash type Lubrication System
Semi pressure Lubrication System

Day: 12&13
Date: 07.04.2014
Topics Covered:

Properties of fluids
Types of flow
Flow through pipes and its losses
Pumps and its types
Pipe standard as per ANSI B16.10

Properties of fluid:
1. Density or Mass Density

Density of the substance is the mass per unit volume

2. Weight Density

Weight density is the weight per unit volume

3. Specific volume

Specific volume is the ratio of the volume to its mass.It is the

reciprocal of Density

4. Specific gravity

It is the ratio of the density of the substance to the density of the

standard substance

5. Compressibility

It is the Ability to compress a substance by Pressure

6. Vapour pressure

Vapour pressure is the pressure exerted by the vapour in

thermodynamic equilibrium to its phase in a closed system.

7. Cohesion

Cohesion is the property attraction of the like molecules of the

substance

8. Adhesion

Adhesion is the property of the substance for the attraction

between dislike molecules

9. Surface tension

The cohesive force between the liquid molecules is responsible

for the phenomenon surface tension. It is the property of the surface of
the liquid allows resisting the external force

10.Capillarity

Capillarity is the rise or fall of the liquid in the small tube of

small internal dia is inserted into the tube

11.Viscosity

It is the resistance offered by the liquid to flow

Types of flow:
Steady flow:
In this type of flow, liquid properties like viscosity, density, pressure
doesnt change at any point with respect to time

Non Steady Flow:

In this type of flow, liquid properties like viscosity, density, pressure
change at any point with respect to time

 Uniform flow:
Uniform flow is the flow where the velocity of the fluid is constant

Non-Uniform Flow:
It is the flow where the velocity of the fluid is variable.

Turbulent Flow:
Flow of fluid is Zigzag, flow layers intersect each other .

Laminar Flow:
Flow layers are parallel to each other throughout the flow.

Flow through Pipes:

Flow through pipes is flow of fluids through closed conduit, Due to

pressure it occupies the whole space, if it occupies the whole space it is
called pipe flow and when its flow with the space it is called channel
flow.

Losses in flow through pipes:

Loss in head due to pipe friction.

Loss in head due to sudden enlargement.
Loss in head due to sudden contraction.
Loss of head due to entry into pipe.
Loss of head due to exit from pipe.
Loss of head due to obstruction.
Loss of head due to change in direction.
Loss of head due to Gradual enlargement or contraction.

Loss of head due to various pipe fitting.

Pump and its types:

Pumps
Positive
Displacement
Reciprocatin
g

Rotary

Screw
Lobe
Gear

Kinetic

Flexible
Impeller
Progressing
Cavity

Piston
Diaphrag
m
Plunger

Peristaltic

Roller
Vane

Positive displacement pumps:

Turbine
Centrifugal

 This type of pumps makes a trapping of fixed amount of

fluid and forcing the trapped amount into the Discharge.

Characteristic of positive Displacement

pumps:
Positive Displacement pump can theoretically produce
the same flow at given rpm.So it is the constant flow
device .On increase in pressure leakage happens.
It cannot be operated when discharge valve closes. It
may damage the pump.
Relief valve and safety valve is required at discharge side
to avoid damage of pumps.
Characteristic curve for Positive Displacement
Pumps:

The dashed line shows actual positive displacement pump performance. This
line says that the discharge pressure of the pump increases, some amount of liquid
will leak from the discharge, reducing the flow rate of the pump. The rate at which
liquid leaks from the discharge to its suction is called Slippage.

Positive Displacement Pumps are used when

1) Viscosity of the fluid is low

2) High efficiency is needed.
3) We used variable viscosity application.
4) Suction lift application is needed.