Te Mech Academic Book.pdf

PRAVARA RURAL EDUCATION SOCIETY’S

SIR VISVESVARAYA INSTITUTE OF TECHNOLOGY, NASHIK(M.S.)

ACADEMIC BOOK MECH ENGG DEPT TE MECH(SEM-II)

AY 2018-19

INDEX C O M P SR I L ENo. D

B Y : M R . R A V I N D RContent A S.SHELKE

A S S T . P R O F . Page M E Cno. H ENGG DEPT

1

Academic calendar

3-4

2

Time Table

5-6

3

Subject 1

7

NUMERICAL METHODS AND OPTIMIZATION

4

(i) (ii) (iii) (iv) Subject 2

8-29

Scheme, Syllabus, Lecture Plan Course Delivery, Objectives, Outcomes Question Bank University Question papers 30

DESIGN OF MACHINE ELEMENTS - II

5

(i) (ii) (iii) (iv) Subject 3

31-51

Scheme, Syllabus, Lecture Plan Course Delivery, Objectives, Outcomes Question Bank University Question papers 52

REFRIGERATION AND AIR CONDITIONING

53-74

(i) Scheme, Syllabus, Lecture Plan (ii) Course Delivery, Objectives, Outcomes (iii) Question Bank (iv)University Question papers 6

Subject 4

75

MECHATRONICS

7

(i) (ii) (iii) (iv) Subject 5

Scheme, Syllabus, Lecture Plan Course Delivery, Objectives, Outcomes Question Bank University Question papers 94

MANUFACTURING PROCESS-II (i) (ii) (iii) (iv)

76-93

Scheme, Syllabus, Lecture Plan Course Delivery, Objectives, Outcomes Question Bank University Question papers

95-124

Sir Visvesvaraya Institute of Technology, Chincholi, Nashik Department of Mechanical Engineering TIME TABLE YEAR 2018 - 19 ( Second Semester ) Class: T.E. Mechanical, Div. A

Hall No. B-105

DAY

1

2

3

4

Time

09:30 to 10:30

10:30 to 11:30

11:30 to 12:30

13.15 to 14.15

W.E.F :17/12/2018 5 14.15 to 15.15

6

7

15:15 to 16:15

16:15 to 17:15

DME-II

Aptitude [PGA]

A3-NMO, A4-DME-II MON

RAC

MTRX

NMO

TUE

MP-II

DME-II

MTRX

WED

NMO

A1-NMO, A2-DME-II, A3-RAC, A4-MS-II

THU

RAC

DME-II

NMO

A1-DME-II, A2-NMO, A3-MS-II, A4-RAC

FRI

DME-II

NMO

MP-II

MTRX

Library

SAT

A1-MTRX, A2-AC

A1-AC, A2-MTRX

A1-MS-II, A2-RAC, A3-DME-II, A4-NMO RAC

Lecture Series B-224

MP-II

A1-RAC, A2-MS-II A3-MTRX, A4-AC

A3-AC, A4-MTRX

Lecture Series

Aptitude [SBS] Seminar

Technical (Training) Activity

Mentoring

Lecture Series

Aptitude [PGA] RAC

Name of the Class Teacher: Mrs. Yogita M. Patil Sr. No.

Theory Subject

Subject Teacher

Practical Teacher

1

NMO [Numerical Methods and Optimization]

Mr. Suyog K. Vitnor

Mr. S.K. Vitnor- A1,A2,A3, A4

2

DME-II [Design of Machine Elements-II]

Mrs. Yogita M. Patil

Mrs. Y.M. Patil- A1, A2,A3, A4

3

RAC [Refrigeration and Air Conditioning]

Mr. Pravin G. Autade

Mr. P.G. Autade- A1, A2,A3, A4

4

MTRX [Mechatronics]

Mr. Deepak M. Deshmukh

Mr. D.M. Deshmukh- A1, A2, A3, A4

5

MP-II [Manufacturing Process-II]

Mr. Shivaji R. Chaudhari

6

MS-II [Machine Shop-II]

Mr. S.R. Chaudhari- A1, A2, A3, A4

7

AC [Audit Course]

Mr. S.S. Wani- A2,A3, Mr. S.B. Shejul- A1, Mr. R.H. Hodgar- A4

8

Technical (Training) Activity [CATIA / MATLAB]

Mr. Suyog K. Vitnor

9

Aptitude

Mr. Sandeep B. Shejul / Mr. Pravin G. Autade

10

Lecture Series

Mr. Shivaji R. Chaudhari

Mr. Sagar P. Walhekar Time Table I/C

Dr. S. N. Shelke Head of Department

Prof. (Dr.) K. T. V. Reddy Principal

Sir Visvesvaraya Institute of Technology, Chincholi, Nashik Department of Mechanical Engineering TIME TABLE YEAR 2018 - 19 ( Second Semester ) Class: T.E. Mechanical, Div. B

Hall No. B-224

W.E.F :17/12/2018

DAY Time

1

2

3

4

5

6

7

09:30 to 10:30

10:30 to 11:30

11:30 to 12:30

13.15 to 14.15

14.15 to 15.15

15:15 to 16:15

16:15 to 17:15

MON

DME-II

MTRX

NMO

MP-II

Lecture Series

RAC

MP-II

MP-II

MTRX

Lecture Series

B1-NMO, B2-DME-II, B3-RAC, B4-MS-II

DME-II

NMO

Technical (Training) Activity

B1-DME-II, B2-NMO, B3-MS-II, B4-RAC

B2-RAC, B1,B3,B4-Seminar

Aptitude [SGB]

Library

Subject Teacher

Practical Teacher

B1-MS-II, B2-Seminar, B3-DME-II, B4-NMO

B2-MS-II, B3-NMO NMO

TUE

WED

DME-II

THU

RAC

FRI

DME-II

SAT

RAC

B1-MTRX, B4-AC RAC

B1-AC, B4-MTRX,

Aptitude [YMP]

NMO

Mentoring

Aptitude [SGB]

MTRX

B1-RAC, B4-DME-II B2-AC, B3-MTRX

B2-MTRX, B3-AC

Name of the Class Teacher: Mr. Sandeep B. Shejul Sr. No.

Theory Subject

1

NMO [Numerical Methods and Optimization]

Mr. Avinash S. Jejurkar

Mr. A.S. Jejurkar- B1, B2,B3, B4

2

DME-II [Design of Machine Elements-II]

Mr. Rahul H. Hodgar

Mr. R.H. Hodgar- B1, B2,B3, B4

3

RAC [Refrigeration and Air Conditioning]

Mr. Sandeep G. Bhosale

Mr. S.G. Bhosale- B1, B2,B3, B4

4

MTRX [Mechatronics]

Mr. Mahesh P. Kolhe

Mr. M.P. Kolhe- B1, B2,B3, B4

5

MP-II [Manufacturing Process-II]

Mr. Vijay L. Kadlag

6

MS-II [Machine Shop-II]

Mr. V.L. Kadlag- B1, B2,B3, B4

7

AC [Audit Course]

Mr. R.H. Hodgar- B1,B4 Mr. A.S. Jejurkar- B2,B3

8

Technical (Training) Activity [CATIA / MATLAB]

Mr. Avinash S. Jejurkar

9

Aptitude

Mr. Sandeep G. Bhosale/ Mrs. Yogita M. Patil

10

Lecture Series

Mr. Rahul H. Hodgar

Mr. Sagar P. Walhekar Time Table I/C

Dr. S. N. Shelke Head of Department

Prof. (Dr.) K. T. V. Reddy Principal

Subject-1

Numerical Methods and Optimization (302047)

Numerical Methods & Optimization TE Mechanical (2nd Semester),Session 2018-19. Scheme,Syllabus and Evaluation Guidelines of “Numerical Methods & Optimization”. Course Code 302047

Course Name Numerical Methods & Optimization

Lecture Assigned Theory 4

Practical 2

Term work -

Total 6

ExternalPracti cal

Total

80

Total

30

End Sem. Exam

50

In Sem Exam

20

Experiment assessment

Assignment

20 20

Attendance

NMO

Best of two class test

302047

Class test 2

Course Course Code Name

Class test 1

Examination Evaluation Scheme Theory &Practical Assessment Internal Assessment External Assessment

30

70

100

50

150

Syllabus Numerical Methods & Optimization[302047] Unit – I: Roots of Equation and Error Approximations Roots of Equation Bisection Method, Newton Raphson method and Successive approximation method. Error Approximations Types of Errors: Absolute, Relative, Algorithmic, Truncation, Round off Error, Error Propagation, Concept of convergence-relevance to numerical methods.

Unit – II: Simultaneous Equations Gauss Elimination Method with Partial pivoting, Gauss-Seidal method and Thomas algorithm for Tridiagonal Matrix, Jacob iteration method.

Unit – III: Optimization Introduction to optimization, Classification, Constrained optimization (maximum two constrains): Graphical and Simplex method, One Dimensional unconstrained optimization: Newton’s Method. Modern Optimization Techniques: Genetic Algorithm (GA), Simulated Annealing (SA).

Unit – IV: Numerical Solutions of Differential Equations Ordinary Differential Equations [ODE] Taylor series method, Euler Method, Runge-Kutta fourth order, Simultaneous equations using RungeKutta2nd order method. Partial Differential Equations [PDE]: Finite Difference methods Introduction to finite difference method, Simple Laplace method, PDEs- Parabolic explicit solution, Elliptic-explicit solution.

Unit – V: Curve Fitting and Regression Analysis (08 hrs.) Curve Fitting Least square technique- Straight line, Power equation, Exponential equation and Quadratic equation. Regression Analysis Introduction to multi regression analysis, Lagrange’s Interpolation, Newton’s Forward interpolation, Inverse interpolation (Lagrange’s method only).

Unit – VI: Numerical Integration (06 hrs.) Numerical Integration (1D only) Trapezoidal rule, Simpson’s 1/3rdRule, Simpson’s 3/8thRule, Gauss Quadrature 2 point and 3 point method. Double Integration Trapezoidal rule, Simpson’s 1/3rdRule.

Text :

1. Steven C. Chapra, Raymond P. Canale, Numerical Methods for Engineers, 4/e, Tata McGraw Hill Editions 2. Dr. B. S. Garewal, Numerical Methods in Engineering and Science, Khanna Publishers,. 3. Steven C. Chapra, Applied Numerical Methods with MATLAB for Engineers and Scientist, Tata Mc-Graw Hill Publishing Co-Ltd 4. Rao V. Dukkipati, Applied Numerical Methods using Matlab, New Age International Publishers

References :

1. 2. 3. 4.

Gerald and Wheatley, Applied Numerical Analysis, Pearson Education Asia E. Balagurusamy, Numerical Methods, Tata McGraw Hill P. Thangaraj, Computer Oriented Numerical Methods, PHI S. S. Sastry, Introductory Methods of Numerical Analysis, PHI.

Evaluation Guidelines

Internal Assessment (IA): NA Internal assessment will be done based on marks obtain in class test, attendance, assignment and marks secured in experiments. Class Test and assignment (CTA) [50 marks] (D): - Two class tests, 20 marks each, will be conducted in a semester and out of these two, best one will be selected for calculation of class test marks. Format of question paper is same as university. Six assignments will assess for 20 marks each and total marks will be converted to 30 marks. Experiment *80 marks+ (B): Each experiment will be evaluated for 10 marks based on student’s attendance, performance during practical and writing of journal.

Attendance (AT) [50 marks] (C): Attendance marks will be given as per university policy. External Assessment: Practical 50 Marks

Paper pattern and marks distribution for Class tests: 1. Question paper will comprise of 2 Set A, B. 2. Each Set contains 5 answer type questions of 5 mark each. All questions are compulsory. (Total 20 Marks) In Sem Examination [ 30 Marks] End Semester Examination [ 70 Marks] Paper pattern and marks distribution for End Semester Exam: As per university guidelines.

LECTURE PLAN SUBJECT: Numerical Methods & Optimization

Lect. No. 1

Topics / Sub- Topics

Unit 1

2

Introduction Numerical Method,Roots of Equation and Error Approximations Bisection Method

3

Newton Raphson method

1

1

1

6

Successive approximation method Types of Errors: Absolute, Relative, Algorithmic, Truncation, Round off Error, Error Propagation Concept of convergence-relevance to numerical methods

7

Numerical on Practical Applications

1

8

Numerical

1

9

Introduction of Simultaneous Equation

2

4 5

10

Gauss Elimination Method with Partial pivoting,

1 1

2

11

Numerical

2

12

Gauss-Seidal method

2

13

Numerical

2

14

Thomas algorithm for Tri-diagonal Matrix

2

15

Numerical

2

16

Jacob iteration method & Numerical

2

17

Introduction to optimization, Classification

3

18

Constrained optimization (maximum two constains):

3

19

Graphical and Simplex method One Dimensional unconstrained optimization: Newton’s Method

3

20

Numerical

3

21

Numerical

3

22

Modern Optimization Techniques: Genetic Algorithm (GA),

3

23

Numerical

3

24

Simulated Annealing (SA).

3

25

Introduction to Ordinary Differential Equations

4

26

Taylor series method

4

27

Numerical

4

28

Euler Method,.

4

29

, Numerical

4

30

Runge-Kutta fourth order

4

31

Numerical

4

32

Simultaneous equations using RungeKutta2nd order method

4

33

Introduction to Finite Difference method, Simple Laplace method

4

34 35 36

PDEs- Parabolic explicit solution, Elliptic explicit solution . Curve Fitting: Least square technique- Straight line, Numerical

4 5 5

37

Power equation,

5

38

Exponential equation and Quadratic equation

5

39

Introduction to multi regression analysis

5

40

Lagrange’s Interpolation

5

41

Newton’s Forward interpolation

5

42

Inverse interpolation (Lagrange’s method only).

5

43

Numerical Integration (1D only) Trapezoidal rule,

6

44

Simpson’s 1/3rdRule, Simpson’s 3/8thRule,

6

45

Gauss Quadrature 2 point and 3 point method.

6

46

Double Integration :Trapezoidal rule

6

47

Simpson’s 1/3rdRule

6

48

Numerical

6

Course Delivery, Objectives, Outcomes Numerical Methods & Optimization(302047) Semester-I Course Delivery: The course will be delivered through lectures, assignment/tutorial sessions, class room Interaction, practical’s on Software and presentations. Course Objective: The objective of this course 1 Recognize the difference between analytical and Numerical Methods 2 Effectively use Numerical Techniques for solving complex Mechanical Engineering Problems. 3 Prepare base for understanding engineering analysis software 4 Develop logical sequencing for solution procedure and skills in soft computing 5 Optimize the solution for different real life problems with available constraints. 6. Build the foundation for engineering research

Course Outcomes: After completion of this course the students are expected to be able to 1.

Use appropriate Numerical methods to solve complex mechanical engineering problems

2.

Formulate algorithm & programming

3.

Use mathematical solver

4.

Generate solutions for real life problem using optimization techniques

5.

Analyze the research problem

Program Outcomes (POs): Engineering Graduates will be able to: 1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals, and an engineering specialization to the solution of complex engineering problems. 2. Problem analysis: Identify, formulate, review research literature, and analyze complex engineering problems reaching substantiated conclusions using first principles of mathematics, natural sciences, and engineering sciences. 3. Design/development of solutions: Design solutions for complex engineering problems and design system components or processes that meet the specified needs with appropriate consideration for the public health and safety, and the cultural, societal, and environmental considerations.

4. Conduct investigations of complex problems: Use research-based knowledge and research methods including design of experiments, analysis and interpretation of data, and synthesis of the information to provide valid conclusions. 5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern engineering and IT tools including prediction and modeling to complex engineering activities with an understanding of the limitations. 6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional engineering practice. 7. Environment and sustainability: Understand the impact of the professional engineering solutions in societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable development. 8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of the engineering practice. 9. Individual and team work: Function effectively as an individual, and as a member or leader in diverse teams, and in multidisciplinary settings. 10. Communication: Communicate effectively on complex engineering activities with the engineering community and with society at large, such as, being able to comprehend and write effective reports and design documentation, make effective presentations, and give and receive clear instructions. 11. Project management and finance: Demonstrate knowledge and understanding of the engineering and management principles and apply these to one’s own work, as a member and leader in a team, to manage projects and in multidisciplinary environments. 12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in independent and life-long learning in the broadest context of technological change

Contribution to outcomes will be achieved through content delivery: CO-PO Mapping:

Course Outcome s

PO1

PO2

PO3

PO4

PO5

PO6

PO7

PO8

PO9

PO10

PO11

PO12

CO1 CO2 CO3 CO4 CO5 Average

3 2 2

2

3

2

2 2 2 2

2 2 2 2 2

2 2 2 2

Justification of CO - PO Mapping CO1 WITH PO1

According to CO1 students can apply knowledge of engineering mathematics, engineering fundamentals. So itis highly correlated to PO1. CO2 WITH According to CO2 students get knowledge ofbasics of engineering PO1,PO2, mathematics, can analyze engineering problems can use modern PO5,PO12 engineering techniques So it is moderately correlated to PO1,PO2,PO5,PO12. CO3 WITH According to CO3 students get knowledge of engineering PO1,PO3,PO5,PO12 fundamentals, can develop solution to engineering problem, can use modern IT Tools and get life-long learning in technological change Soit is moderately correlated to PO1,PO3,PO5,PO12. CO4 WITH According to CO4 students can develop mathematical model of PO3,PO5,PO12 problems so it is moderately related to PO3,PO5,PO12 CO5 According to CO5 students can develop solution to engineering WITH,PO3,PO5 solution and can use modern techniques to engineering activities so it is moderately related to PO3,PO5.

NMO ASSIGNMENTS:

Assignment –I Academic Year (2018-19) Branch-TE Mechanical EngineeringDate: Semester:II Subject: Numerical Methods & Optimization

Max Marks:20M

Note: 1. All questions are compulsory 2. Bloom’s Taxanomy level: Bloom Levels (BL):1.Remember 2.Understand 3.Apply 4.Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required Q. No 1 2 3

4 5

Unit No CO Blooms as per Map Taxanomy Syllabus ped Level Solve the equation 2X – log10X = 7 using Successive 1 1 3 Approximation method. Do 4iterations Determine using Bi-Section Method root of equation 1 1 3 cos(x)-1.3x=0 with accuracy 0.01 Solve the equation ex.cos x – 1.4 sin x = 0.8 by Newton 1 1 3 Raphson method taking x=1 & doing 3 iteration Questions

Explain:1) Absolute Error, 2) Relative Error 3) Round Off 4) Truncation Error 5) Inherent Error Draw flowchart for Newton Raphson method

1

1

2

1

2

2

Assignment –II Academic Year (2018-19) Branch-TE Mechanical EngineeringDate: Semester:II Subject: Numerical Methods & Optimization Max Marks:20M Note: 1. All questions are compulsory 2. Bloom’s Taxanomy level: Bloom Levels (BL):1. Remember 2. Understand 3. Apply4. Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required

Q. No 1

2 3 4

5

Questions Solve equations using Gauss Elimination Method with partial pivoting 5x+13y++7z=14, 3x+6y+3z=0, 7x+2y+4z=5 Using gauss seidal method solve following equations 9x+4y+z=-17,x-2y-6z=14,x+6y=4 perform 4 iteration Solve the following equations using Thomas algorithm x+2y=3,2x+3y+z=4,2y-z=1 Solve the following set of linear simultaneous equation using Jacobi’s iteration method 20x+y-2x=17, 3x+20yz=-18, 2x-3y+20z=25 Write short note pitfall of Gauss elimination method & pivoting

Unit No as per Syllabu s 2

CO Ma ppe d 1

2

1

3

2

1

3

2

1

3

2

1

2

Blooms Taxanom y Level 3

Assignment –III Academic Year (2018-19) Branch-TE Mechanical Engineering Date: Semester:II Subject: Numerical Methods & Optimization Max Marks:20M Note: 1. All questions are compulsory 2. Bloom’s Taxanomy level: Bloom Levels (BL):1.Remember 2.Understand 3.Apply 4.Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required Unit No as per Syllabu s 3

CO Ma ppe d 1

Write a note on constraints, objective function, decision variables, feasible solution, optimal solution, Write short note on SA (Simulated annealing)

3

1

2

3

1

2

Maximize z=14x+20y subjected to condition, 20x+6y<=1000 & 40x+8y<=500 x,y>=0 (Simplex method) Write a short note on GA (Genetic algorithm)

3

4

3

3

1

2

Q. N o

Questions

1

Define optimization. Write its engineering application

2 3 4

5

Blooms Taxanom y Level 2

Assignment –IV Academic Year (2018-19) Branch-TE Mechanical Engineering Date: Semester:II Subject: Numerical Methods & Optimization Max Marks:20M Note: 1. All questions are compulsory 2. Bloom’s Taxanomy level: Bloom Levels (BL):1.Remember 2.Understand 3.Apply 4.Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required

Q. No 1 2 3

4

5

Unit No as per Questions Syllabu s Obtain the solution of dy/dx=3x+y2 using taylor series 4 method. Given: y(0)=1.Determine y(0.1) Use Runge Kutta 4rth order method to solve y’4 sin(y)=1, from x=0 to 0.5 in steps of h=0.1 Solve boundary value problem (d2y/dx2)4 64y+10=0.Initial conditions,y(0)=1,y(1)=1,take step size,h=1/3 compute y(1/3) & y(2/3) Use euler method with h=0.5 to solve the initial values 4 problem over the interval x=0 to 2 Dy/dx=yx2-1.1y; where y(0)=1 Second order differential equation is x2(d2y/dx2)+(x2)(dy/dx)-3y=10x, subject to consideration y(0)=0, y(0.3)=10,h=0.1. solve by FDM

4

CO Ma ppe d 1

Blooms Taxanom y Level 3

1

3

1

3

1

3

1

3

Assignment –V Academic Year (2018-19) Branch-TE Mechanical Engineering Date: Semester:II Subject: Numerical Methods & Optimization Max Marks:20M Note: 1. All questions are compulsory 2. Bloom’s Taxanomy level: Bloom Levels (BL):1.Remember 2.Understand 3.Apply 4.Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required Q. N o 1

2

3

4

5

Unit No as per Questions Syllabu s A set of values of x & f(x) are given below. Using 5 Lagranges’s interpolation formula, Find f(9).

x 5 7 11 13 17 y 150 392 1452 2366 5202 Determine constants a & b using method of least square such that y=ax+b fits following data

x 2 4 6 8 10 y 4.077 11.084 30.128 81.128 222.62 Determine constants a & b using method of least square such that y=abx fits following data

x 1 2 3 4 y 4 11 35 100 Use Langrages’s interpolation formula polynomial to the data & hence Find y(x=1)

x -1 0 2 3 y -8 3 1 12 Draw flowchart to fit an equation y=aebx

to

fit

CO Ma ppe d 1

Blooms Taxanom y Level 3

5

1

3

5

1

3

5

1

3

5

2

3

Assignment –VI Academic Year (2018-19) Branch-TE Mechanical Engineering Date: Semester:II Subject: Numerical Methods & Optimization Max Marks:20M Note: 1. All questions are compulsory 2. Bloom’s Taxanomy level: Bloom Levels (BL):1.Remember 2.Understand 3.Apply 4.Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required

Q. No

Questions

Unit No as per Syllabu s 5

CO Map ped

Blooms Taxanom y Level

4

3

1

Explain Trapezoidal rule

2

Find integration of 1/(1+x2) in the limits 0 to 1 by trapezoidal rule using 4 strips

5

4

3

3

Write flowchart for Simpsons 3/8 rule

5

2

3

4

Write flowchart for gauss legendre 2 point formula

5

2

3

5

Find double integration of f(x)=x2+y2+5 for x=0 to 2 &

5

1

3

y=0 to 2 taking increment in both x & y as 0.5.Use trapezoidal rule

Class test Question Papers Class Test –I Academic Year (2018-19) Branch-TE Mechanical Engineering Semester:II Duration:1 hour Subject: Numerical Methods & Optimization [302047]

Date:

Max Marks:20M

Note: 1. All questions are compulsory 2. Bloom’s Taxanomy level: Bloom Levels (BL):1.Remember 2.Understand 3.Apply 4.Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required Unit CO Q. Max. No as Blooms Ma N Questions Mar per Taxanom ppe o ks Syllabu y Level d s 1 Solve the equation 2X – log10X = 7 using 5 1 1 3 Successive Approximation method. Do 4iterations 2 Determine using Bi-Section Method root of 5 1 1 3 equation cos(x)-1.3x=0 with accuracy 0.01 3 Solve the equation ex.cos x – 1.4 sin x = 0.5 by 5 1 1 3 Newton Raphson method taking x=1 & doing 3 iteration

4

Explain:1) Absolute Error, 2) Relative Error 3) Round Off 4) Truncation Error 5) Inherent Error

5

1

1

2

5

Solve equations using Guass Elimination Method with patial pivoting

5

2

1

3

5x+13y++7z=14, 3x+6y+3z=0, 7x+2y+4z=5

Class Test –II Academic Year (2018-19) Branch-Mechanical Engineering Semester:II Duration:1 hour Subject: Numerical Methods & Optimization

Date:

Max Marks:20M

Note: 1. All questions are compulsory 2. Bloom’s Taxanomy level: Bloom Levels (BL):1.Remember 2.Understand 3.Apply 4.Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required

Q. N o

Questions

1

Obtain the solution of dy/dx=3x+y2 using taylor series method. Given: y(0)=1.Determine y(0.1)

2 3

4

Use Runge Kutta 4rth order method to solve y’sin(y)=1, from x=0 to 0.5 in steps of h=0.1 Solve boundary value problem (d2y/dx2)64y+10=0.Initial conditions,y(0)=1,y(1)=1,take step size,h=1/3 compute y(1/3) & y(2/3) Determine constants a & b using method of least square such that y=ax+b fits following data

Max .Mar ks

Unit No as per Syllab us

5

4

1

3

5

4

1

3

5

4

1

3

5

1

3

5

1

3

CO Blooms Ma Taxanom ppe y Level d

5 x y

5

2 4.077

4 11.08 4

6 30.12 8

8 81.12 8

10 222.6 2

A set of values of x & f(x) are given below.Using Langrages’s interpolation formula,Find f(9).

57 x y

5 150

7 392

11 1452

13 2366

17 5202

University Question Paper

Subject-2

Design of Machine Elements-II (302048)

T.E. SEM II 2018 – 2019 Scheme, Syllabus and Evaluation Guidelines Design of Machine Elements-II 302048 Course Code

Course Name

30204 8

Design of Machine Elements-II

Lecture Assigned Theory Practical 4

Tutorial

Total

-

6

2

Cours e Code

Course Name

Class test 1

Class test 2 Average of Best two class test Attendance

Experiment assessment

Term Work

In Sem Exam End Sem. Exam

Total

Oral

Total

Examination Evaluation Scheme Theory & Practical Assessment Internal Assessment External Assessment

30204 8

DMEII

2 0

2 0

100

25

30

10 0

25

150

50

5 0

70

Syllabus Design of Machine Elements-II 302048 Unit 1- Spur Gears Introduction to gears: Gear Selection, material selection, Basic modes of tooth failure, Gear Lubrication Methods. Spur Gears: Number of teeth and face width, Force analysis, Beam strength (Lewis) equation, Velocity factor, Service factor, Load concentration factor, Effective load on gear, Wear strength (Buckingham’s) equation, Estimation of module based on beam and wear strength, Estimation of dynamic tooth load by velocity factor and Buckingham’s equation. Unit 2 - Helical and Bevel Gears Types of helical and Bevel gears, Terminology, Virtual number of teeth, and force analysis of Helical and Straight Bevel Gear. Design of Helical and Straight Bevel Gear based on Beam Strength, Wear strength and estimation of effective load based on Velocity factor ( Barth factor) and Buckingham’s equation. Mountings of Bevel Gear. ( No numerical on force analysis of helical & Bevel Gear) Unit 3 - Rolling Contact Bearings Types of rolling contact Bearings, Static and dynamic load carrying capacities, Stribeck’s Equation, Equivalent bearing load, Load- life relationship, Selection of bearing life Selection of rolling contact bearings from manufacturer’s catalog, Design for cyclic loads and speed, bearing with probability of survival other than 90% Taper roller bearing: Force analysis and selection criteria. (Theoretical Treatment only) Unit 4 -: Worm Gears Worm and worm gear terminology and proportions of worm and worm gears, Force analysis of worm gear drives, Friction in Worm gears, efficiency of worm gears, Worm and worm gear material, Strength and wear ratings of worm gears (Bending stress factor, speed factor, surface stress factor, zone factor) IS 1443-1974, Thermal consideration in worm gear drive, Types of failures in worm gear drives, Methods of lubrication

Unit 5: Belts, Rope and Chain Drives Belt drive: Materials and construction of flat and V belts, geometric relationships for length of belt, power rating of belts, concept of slip & creep, initial tension, effect of centrifugal force, maximum power condition, Selection of Flat and V-belts from manufacturer’s catalog, belt tensioning methods, relative advantages and limitations of Flat and V- belts, construction and applications of timing belts. Wire Ropes (Theoretical Treatment Only): Construction of wire ropes, lay of wire rope, stresses in wire rope, selection of wire ropes, rope drums construction and design. Chain Drives (Theoretical Treatment Only): Types of chains and its Geometry, selection criteria for chain drive, Polygon effect of chain, Modes of failure for chain, Lubrication of chains Unit 6: Sliding contact Bearings Classification of sliding contact bearing. Lubricating oils: Properties, additives, selection of lubricating oils, Properties & selection of bearing materials. Hydrodynamic Lubrication: Theory of Hydrodynamic Lubrication, Pressure Development in oil film, 2DBasic Reynolds Equation, Somerfield number, Raimondi and Boyd method, Thermal considerations, Parameters of bearing design, Length to Diameter ratio, Unit bearing Pressure, Radial Clearance, minimum oil film thickness. Books Text Books: 1) Bhandari V.B, Design of Machine Elements, Tata McGraw Hill Publication Co. Ltd. 2) Shigley J.E. and Mischke C.R., Mechanical Engineering Design, McGraw Hill Publication Co. Ltd. 3) Spotts M.F. and Shoup T.E., Design of Machine Elements, Prentice Hall International. 4) Juvinal R.C, Fundamentals of Machine Components Design, John Wiley and Sons. References Books: 1. Black P.H. and O. Eugene Adams, Machine Design, McGraw Hill Book Co. Inc. 2. Willium C. Orthwein, Machine Components Design, West Publishing Co. and Jaico Publications House. 3. Hall A.S., Holowenko A.R. and Laughlin H.G, Theory and Problems of Machine Design, Schaum’s Outline Series

4. C.S. Sharma and Kamlesh Purohit, Design of Machine Elements, PHI Learing Pvt. Ltd. 5. D. K. Aggarwal & P.C. Sharma, Machine Design, S.K Kataria and Sons 6. P. C. Gope, Machine Design: Fundamentals and Applications, PHI Learing Pvt. Ltd. 7. Design Data - P.S.G. College of Technology, Coimbatore. 8. Bhandari, V. B. Machine Design data book, Tata McGraw Hill Publication Co. Ltd. 9. K. Mahadevan, K. Balveera Reddy, Design Data Handbook for Mechanical Engineers, CBS Publishers

Evaluation Guidelines Internal Assessment (IA): [CT (20 marks)+ TA/AT (20 marks)] Class Test (CT) [20 marks]: - Two class tests, 20 marks each, will be conducted in a semester and out of these two, the average of best two will be selected for calculation of class test marks. Format of question paper is same as university TA [20 marks]: Six assignments will be conducted in the semester. Teacher assessment will be calculated based on performance in assignments, class test and pre-university test. Attendance (AT) [50 marks]: Attendance marks will be given as per university policy. Paper pattern and marks distribution for Class tests: 1. Question paper will comprise of 2 Set A, B with internal choice of questions. 2. Each Set contains 5 answer type questions of 5 mark each. All questions are compulsory. (Total 20 Marks) Pre-University Test [ 30 Marks] In Sem Examination Paper pattern and marks distribution for PUT: Same as End semester exam End Semester Examination [ 70 Marks] Paper pattern and marks distribution for End Semester Exam: As per university guidelines.

Lecture Plan Lectur e No

Topic

Unit

1.

Unit 1

2.

Unit 1 Gear Selection, material selection, Basic modes of tooth failure Gear Lubrication Methods, Important terminology

3.

Number of teeth and face width, Force analysis

Unit 1

4.

Beam strength (Lewis) equation

Unit 1

5.

Wear strength (Buckingham’s) equation

Unit 1

6.

Estimation of module based on beam and wear strength

Unit 1 Unit 1

8.

Estimation of dynamic tooth load by velocity factor and Buckingham’s equation Miscellaneous Problems

9.

Unit 2 Types of helical and Bevel gears, Terminology, Virtual number of teeth

10.

force analysis of Helical and Straight Bevel Gear

Unit 2

11.

Design of Helical and Straight Bevel Gear based on Beam Strength

Unit 2

12.

Design of Helical and Straight Bevel Gear based on Wear strength

Unit 2

13.

estimation of effective load based on Velocity factor (Barth factor)

Unit 2

14.

Buckingham’s equation

Unit 2

15.

Mountings of Bevel Gear

Unit 2

16.

Miscellaneous Problems

Unit 2

17.

Unit 3 Types of rolling contact Bearings, Static and dynamic load carrying capacities

Unit 3

7.

Unit 1

Unit 1

Unit 2

18.

Stribeck’s Equation

Unit 3

19.

Equivalent bearing load, Load- life relationship

Unit 3

20.

Selection of bearing life Selection of rolling contact bearings from manufacturer’s catalog

Unit 3

21.

Design for cyclic loads and speed

Unit 3

22.

Design for bearing with probability of survival other than 90%

Unit 3

23.

Taper roller bearing: Force analysis

Unit 3

24.

Taper roller bearing: selection criteria

Unit 3

25.

Unit 4 Unit-IV Worm and worm gear terminology and proportions of worm and worm gears

Unit 4

26.

Force analysis of worm gear drives

Unit 4

27.

Friction in Worm gears, efficiency of worm gears, Worm and worm gear material

Unit 4

28.

Strength and wear ratings of worm gears

Unit 4

29.

Thermal consideration in worm gear drive

Unit 4

30.

Types of failures in worm gear drives

Unit 4

31.

Methods of lubrication

Unit 4

32.

Miscellaneous Problems

Unit 4

33.

Unit 5 Materials and construction of flat and V belts

Unit 5

34.

geometric relationships for length of belt, power rating of belts, concept of slip & creep

Unit 5

35.

initial tension, effect of centrifugal force, maximum power condition,

Unit 5

36.

Selection of Flat and V-belts from manufacturer’s catalog,

Unit 5

37.

belt tensioning methods, relative advantages and limitations of Flat and V- belts

Unit 5

38.

Wire Ropes: Construction, lay, selection, rope drums construction and design

Unit 5

39.

Chain Drives: Types of chains and its Geometry, selection criteria for chain drive

Unit 5

40.

Chain Drives: Polygon effect of chain, Modes of failure for chain, Lubrication of chains

Unit 5

41.

Unit 6 Classification of sliding contact bearing

42.

Lubricating oils: Properties, additives, selection of lubricating oils

Unit 6

43.

Lubricating oils: Properties & selection of bearing materials.

Unit 6

44.

Theory of Hydrodynamic Lubrication

Unit 6

45.

2DBasic Reynolds Equation, Somerfield number, Raimondi and Boyd method

Unit 6

46.

Thermal considerations, Parameters of bearing design

Unit 6

47.

Length to Diameter ratio, Unit bearing Pressure

Unit 6

48.

Radial Clearance, minimum oil film thickness

Unit 6

Unit 6

Course Delivery, Objectives, Outcomes Design of Machine Elements-II (302048) Semester VI Course Delivery: The course will be delivered through lectures, assignment/tutorial sessions, class room interaction, and presentations. Course Objectives:  Enable students to attain the basic knowledge required to understand, analyze, design and select machine elements required in transmission systems.  Reinforce the philosophy that real engineering design problems are open-ended and challenging  Impart design skills to the students to apply these skills for the problems in real life industrial applications  Inculcate an attitude of team work, critical thinking, communication, planning and scheduling through design projects  Create awareness amongst students about safety, ethical, legal, and other societal constraints in execution of their design projects  Develop an holistic design approach to find out pragmatic solutions to realistic domestic and industrial problems Course Outcomes: On completion of the course, students will be able to – 1. CO1: To understand and apply principles of gear design to spur gears and industrial spur gear boxes. (L1 – Knowledge, L2 – Comprehension) 2. CO2: To become proficient in Design of Helical and Bevel Gear (L1 – Knowledge, L2 – Comprehension) 3. CO3: To develop capability to analyse Rolling contact bearing and its selection from manufacturer’s Catalogue. (L3 – Application, L4 – Analysis) 4. CO4: To learn a skill to design worm gear box for various industrial applications. (L3 – Application, L4 – Analysis) 5. CO5: To inculcate an ability to design belt drives and selection of belt, rope and chain drives. (L3 – Application, L4 – Analysis) 6. CO6: To achieve an expertise in design of Sliding contact bearing in industrial applications (L3 – Application, L4 – Analysis)

Program Outcomes (POs): Engineering Graduates will be able to: 1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals, and an engineering specialization to the solution of complex engineering problems. 2. Problem analysis: Identify, formulate, review research literature, and analyze complex engineering problems reaching substantiated conclusions using first principles of mathematics, natural sciences, and engineering sciences. 3. Design/development of solutions: Design solutions for complex engineering problems and design system components or processes that meet the specified needs with appropriate consideration for the public health and safety, and the cultural, societal, and environmental considerations. 4. Conduct investigations of complex problems: Use research-based knowledge and research methods including design of experiments, analysis and interpretation of data, and synthesis of the information to provide valid conclusions. 5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern engineering and IT tools including prediction and modeling to complex engineering activities with an understanding of the limitations. 6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional engineering practice. 7. Environment and sustainability: Understand the impact of the professional engineering solutions in societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable development. 8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of the engineering practice. 9. Individual and team work: Function effectively as an individual, and as a member or leader in diverse teams, and in multidisciplinary settings. 10. Communication: Communicate effectively on complex engineering activities with the engineering community and with society at large, such as, being able to comprehend and write effective reports and design documentation, make effective presentations, and give and receive clear instructions. 11. Project management and finance: Demonstrate knowledge and understanding of the engineering and management principles and apply these to one’s own work, as a member and leader in a team, to manage projects and in multidisciplinary environments. 12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in independent and life-long learning in the broadest context of technological change.

CO – PO Mapping PO 1

PO 2

PO 3

PO 4

PO 5

PO 6

PO 7

PO 8

PO 9

PO 10

PO 11

PO 12

PSO 1

PSO 2

PSO 3

CO30204 8-1

3

2

3

2

-

-

-

-

-

-

-

1

1

2

1

CO30204 8-2

2

2

2

2

-

-

-

-

-

-

-

1

2

2

1

CO30204 8-3

2

2

3

2

2

-

-

-

-

-

-

1

2

2

1

CO30204 8-4

2

1

1

1

1

1

-

-

-

-

-

2

2

1

2

CO30204 8-5

2

2

3

2

-

-

-

-

-

-

-

1

2

2

1

CO30204 8-6

2

2

3

2

-

-

-

-

-

-

-

1

2

2

1

Average

2

2

2

2

2

1

-

-

-

-

-

1

2

2

1

JUSTIFICATION OF CO - PO MAPPING CO1 WITH PO1

CO2 WITH PO1 AND PO2

CO3 WITH PO1, PO2 AND PO3

CO4 WITH PO1, PO3 AND PO6

CO5 WITH PO1,PO3 AND PO12

CO6 WITH PO1,PO3 AND PO12

According to CO1 students get basic knowledge of Design of Machine Elements-II. So it is moderately correlated to PO1. According to CO2 students get knowledge of basics and apply them to solve problems. So it is moderately correlated to PO1 andPO2. According to CO3 students get knowledge of engineering materials, principles and design points. So it is moderately correlated to PO1, PO2 and PO3. According to CO4 students get knowledge of terms related to design of worm gearbox, analyse and their application and safety issue from society point of view. Hence CO4 is moderately correlated to PO1, PO3 and a little to PO6. According to CO5 students get knowledge of power distribution system, designing various components as per the requirement. Calculating various performance parameters of the drives. Hence CO5 is moderately correlated to PO1, PO3 and a little to PO12. According to CO6 students get knowledge of sliding contact bearing, designing various component and application for society point of

view and industrial application. Hence CO6 is moderately correlated to PO1, PO3 and a little to PO12.

QUESTION BANK UNIT-I Q.1 Define machine design.

(CO1)

Q.2 Explain the general procedure in machine design.

(CO1)

Q.3 State general considerations in machine design.

(CO1)

Q.4 Explain different types of standard gear tooth system

(CO1)

Q.5 A spur gear pair is to be used to transmit 18 KW power from an electric motor running at 720 rpm to the machine tool expected to run exactly at 300 rpm. The pinion and gear are made of alloy steel(SUT =780 MPa) and plain carbon steel( SUT =680 Mpa) The service factor and factor of safety are 1.5 and 1.35.the face width is 12 times module for which load distribution factor is 1.4.the tooth system is 20 ͦ full depth involute system. Design the gear pair by using velocity factor and Buckingham’s equation. (CO1)

UNIT-II Q.1 Derive a relation between transverse and normal pressure angle of helical gear. (CO2) Q.2 Derive an expression for wear strength of helical gear. (CO2) Q.3 The following data is given for pair of parallel helical gear: (CO2) 1. Power transmitted -15 KW. 2. Pinion speed- 700 rpm. 3. No.of teeth on pinion-35 4. No.of teeth on gear-70. 5. Normal pressure angle-20 ͦ 6. Helix angle-23 ͦ 7. Face width-35 mm 8. Ultimate tensile strength for steel pinion and gear-650 Mpa. 9. Service factor-1.5 10.Deformation factorC-11400e Estimate a) The normal module and dimensions of pinion and gear. b) The beam strength. c) Dynamic load using buckinghams equation.

Q.4 Explain spiral bevel gears and hypoid gear with neat sketch.

(CO2)

Q.5 A spur gear pair is to be used to transmit 18 KW power from an electric motor running at 720 rpm to the machine tool expected to run exactly at 300 rpm. The pinion and gear are made of alloy steel(SUT =780 Mpa) and plain carbon steel( SUT =680 Mpa) The service factor and factor of safety are 1.5 and 1.35.the face width is 12 times module for which load distribution factor is 1.4.the tooth system is 20 ͦ full depth involute system. Design the gear pair by using velocity factor and Buckingham’s equation. (CO2) UNIT-III Q.1 What are the application of rolling contact bearing and sliding contact bearing? (CO3) Q.2 Why are taper roller bearings used in pairs?

(CO3)

Q.3 A ball bearing is operating on a work cycle consisting of three parts of radial load of 3000N at 1400 rpm for one quarter cycle, a radial load of 5000 N at 720 rpm for one half cycle and radial load of 2500N at 1400 rpm for the remaining cycle.The expected life of the bearing is 10000 h. calculate the dynamic load carrying capacity of the bearing.

(CO3)

Q.4 Explain the designation of rolling contact bearing.

(CO3)

Q.5 Derive the Stribeck’s equation for static capacity of rolling contact bearing. (CO3) UNIT-IV Q.1 Explain with neat sketch the difference single enveloping and double enveloping worm gear pair.

(CO4)

Q.2 Write a short notes on thermal consideration in worm gear pair.

(CO4)

Q.3 why two dissimilar materials are used for worm and worm wheel. (CO4) Q.4 Explain force analysis of worm gear pair.

(CO4)

Q.5 A worm down type 2/52/10/4 worm gear transmits 10KW power from worm shaft rotating at 720 rpm to the worm gear pair. The coefficient of friction between the worm and worm gear pair is 0.04 while the normal pressure angle is 20 ͦ. (CO4) UNIT-V Q.1 Discuss applications of wire ropes.

(CO5)

Q.2 Derive relations between velocity and initial tension of belt of maximum power

transmission Capacity.

(CO5)

Q.3 Derive the condition for maximum power transmitting capacity of belt drive based on belt strength and friction capacity.

(CO5)

Q.4 Explain the procedure of selection of flat belt from Manufacturer catalogue.` (CO5) Q.5 Explain neat sketch of rope drum.

(CO5)

UNIT-VI Q.1 What are different types of lubricants used for sliding contact bearings? (CO6) Q.2 A Babbit lined steel back bush bearing is used to support a shaft of diameter 50 mm. The radial load on the bearing is 3550 N. The oil filter restricts a clearance at the bearing as 40 microns. The length of the bearing is 50 mm. Shaft rotates at 950 rpm. The oil used as a viscosity of 60 cP at operating temperature

(CO6)

Calculate, Coefficient of friction Minimum oil film thickness Q.3 What are desirable properties for a material of sliding contact bearings. (CO6) Q.4 Suggest the suitable rolling contact bearing for the following applications. (CO6)

CLASS TEST- I (AY 2018-19) Branch-TE Mechanical Date: / /2018 Semester: II Duration: 1 hour Subject: Design of Machine Elements (302048) Max Marks: 20M Note: 1. All questions are compulsory 2. Bloom’s Taxanomy level: Bloom Levels (BL):1.Remember 2.Understand 3.Apply 4.Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required Unit No Q. Max. CO Blooms as per N Questions Mark Map Taxanom Syllabu o s ped y Level s 1 Solve any two of the following:

a. Explain the term effective load with reference to spur gear. How to estimate the effective load for spur gear tooth. b. State and explain various modes of failure of gear tooth. c. What is formative number of gear tooth for bevel gear. Derive expression for same. 2

3 4

A spur gear pair is to be used to transmit 18 KW power from an electric motor running at 720 rpm to the machine tool expected to run exactly at 300 rpm. The pinion and gear are made of alloy steel(SUT =780 MPa) and plain carbon steel( SUT =680 MPa) The service factor and factor of safety are 1.5 and 1.35.the face width is 12 times module for which load distribution factor is 1.4.the tooth system is 20 ͦ full depth involute system . Design the gear pair by using velocity factor and Buckingham’s equation . Explain why involute profile is preferred over cycloidal profile for gear tooth Derive an expression for beam strength of spur gear tooth. Also state assumptions made.

05

1

CO1

2,3

05

1

CO1

2,3

05

2

CO1

1,2

05

2

CO1

2,3

UNIVERSITY QUESTION PAPER

Subject-3

Refrigeration and Air Conditioning (302049)

T.E. SEM II 2018 – 2019 Scheme, Syllabus and Evaluation Guidelines Refrigeration & Air Conditioning 302049 Course Code 302049

Course Name

Lecture Assigned Theory 3

Refrigeration & Air Conditioning

Practical 2

Tutorial -

Average of two class test

Attendance

Teacher assessment

End Sem. Exam

Total

Internal

External

Total

RAC

Prelim

302049

Class test 2

Course Course Code Name

Practical

Class test 1

Examination Evaluation Scheme Theory Internal Assessment Ext

Total 5

20

20

70

20

5

5

70

100

-

25

25

SYLLABUS Unit I: Applications of Refrigeration and Air Conditioning and Refrigerants: A] Applications : Domestic Refrigerator, Domestic Air Conditioners, Automotive Air Conditioners, Evaporative coolers, water coolers, Commercial Refrigeration- Dairy, Cold storage, Ice plant, Commercial Air Conditioning-Multiplex, Hospitals. B] Refrigerants : Classification of refrigerants, Designation of refrigerants, Desirable properties of refrigerants, environmental issues, Ozone depletion and global warming, ODP, GWP & LCCP, selection of environment friendly refrigerants, secondary refrigerants, anti-freeze solutions, Zeotropes and Azeotropes, refrigerant: recovery reclaims, recycle and recharge. Unit II: Vapour Refrigeration Systems A] Vapour compression systems: Working of simple vapour compression system, representation of vapour compression cycle (VCC) on T-s and P-h diagram, COP, EER, SEER, IPLV, NPLV, effect of operating parameters on performance of VCC, actual VCC, methods of improving COP using flash chamber, sub-cooling, liquid vapour heat exchanger, comparison of VCC with Reverse Carnot cycle. B] Vapour absorption systems : Introduction, Working of simple vapour absorption system (VAS), desirable properties of binary mixture (aqua-ammonia), performance evaluation of simple VAS (simple numerical treatment), actual VAS, Li-Br absorption system, three fluid system (Electrolux refrigeration), applications of VAS, comparison between VCC and VAC.

Unit III: Multiple pressure Refrigeration Systems :

Introduction, need of multistage system, Intermediate pressure, two stage compression with flash gas removal and liquid intercooler, single compressor with multiple evaporator: individual and multiple expansion valves, individual compressors, cascade system: application and numerical(numerical only by using p-h chart), Introduction to cryogenics (Linde - Hampson cycle) and applications (no numerical treatment) Unit IV: Psychrometry and Air conditioning load estimation A] Psychrometry: Basic Psychrometry and processes, BPF of coil, ADP, adiabatic mixing of two air streams, SHF, RSHF, GSHF, ESHF. Factors contributing to cooling load, Numerical based on load analysis . B] Human Comfort : Thermodynamics of human body, comfort and comfort chart, factors affecting human comfort, concept of infiltration and ventilation, indoor air quality requirements. Unit V: Air Conditioning Systems : A] Air Conditioning Systems : Working of summer, winter and all year round AC systems, all air system, all water system, air water system, variable refrigerant flow and variable air volume systems, unitary and central air conditioning. B]Components of refrigeration and air conditioning systems : Working of reciprocating, screw and scroll compressors, working of air cooled, water cooled and evaporative condensers, working of DX, Flooded, Forced feed evaporators, Expansion devices – Capillary tube, TXV, EXV, operating and safety controls. Unit VI : Air Distribution Systems: A] Ducts : Classification of ducts, duct material, pressure in ducts, flow through duct, pressure losses in duct (friction losses, dynamic losses), air flow through simple duct system, equivalent diameter, Methods of duct system design: equal friction, velocity reduction, static regain method (numerical on duct system design) B] Air handling unit :

Air handling unit, Fan coil unit, types of fans used air conditioning applications, fan laws, filters, supply and return grills, sensors (humidity, temperature, smoke). Books: Text Books: 1. Arora C. P., Refrigeration and Air Conditioning, Tata McGraw-Hill. 2. Manohar Prasad, Refrigeration and Air Conditioning, Willey Eastern Ltd, 1983. 3. McQuiston, ― Heating Ventilating and air Conditioning: Analysis and Design‖ 6th Edition, Wiley India . 4. Arora and Domkundwar, Refrigeration & Air Conditioning, Dhanpatrai& Company, New Delhi . 5. Khurmi R.S. and Gupta J.K., Refrigeration and Air conditioning, Eurasia Publishing House Pvt. Ltd, New Delhi,1994. 6. Ballaney P.L., Refrigeration and Air conditioning, Khanna Publishers, New Delhi, 1992. References Books: 1. Dossat Ray J, Principles of refrigeration, S.I. version, Willey Eastern Ltd, 2000 . 2. Stockers W.F and Jones J.W., Refrigeration and Air conditioning, McGraw Hill International editions 1982. 3. Threlkeld J.L, Thermal Environmental Engineering, Prentice Hall Inc., New Delhi 4. Aanatnarayan, Basics of refrigeration and Air Conditioning, Tata McGraw Hill Publications . 5. Roger Legg, Air Conditioning System Design, Commissioning and Maintenance . 6. ASHRAE & ISHRAE handbook.

EVALUATION GUIDELINES Internal Assessment (IA): [CT(20 marks)+ TA/AT (10 marks)] Class Test (CT) [20 marks]: - Three class tests, 20 marks each, will be conducted in a semester and out of these three, the average of best two will be selected for calculation of class test marks. Format of question paper is same as university TA [5 marks]: Three/four assignments will be conducted in the semester. Teacher assessment will be calculated based on performance in assignments, class test and pre-university test. Attendance (AT) [5 marks]: Attendance marks will be given as per university policy. Paper pattern and marks distribution for Class tests: 1. Question paper will comprise of 3 Section A, B and C with internal choice of questions. 2. Section A contains 5 short answer type questions of 1 mark each. All questions are compulsory. (Total 5 Marks) 3. Section B contains 4 medium answer type questions of 2.5 marks each. All questions are compulsory. (Total 10 marks) 4. Section C contains 1 long answer type questions of 5 marks. (Total 5 marks) Pre-University Test [ 70 Marks] Paper pattern and marks distribution for PUT: Same as End semester exam End Semester Examination [ 70 Marks] Paper pattern and marks distribution for End Semester Exam: As per university guidelines.

LECTURE PLAN

Lect. No.

Lecture

Unit

Unit 1 Unit 1

2.

Domestic Refrigerator, Domestic Air Conditioners, Automotive Air Conditioners Evaporative coolers, water coolers

3.

Commercial Refrigeration- Dairy, Cold storage, Ice plant

Unit 1

4.

Commercial Air Conditioning-Multiplex, Hospitals

Unit 1

5.

Classification of refrigerants, Designation of refrigerants

Unit 1

Desirable properties of refrigerants, environmental issues, Ozone depletion and global warming ODP, GWP & LCCP, selection of environment friendly refrigerants secondary refrigerants, anti-freeze solutions, Zeotropes

Unit 1

Azeotropes, refrigerant: recovery reclaims, recycle and recharge Unit 2

Unit 1

Working of simple vapour compression system, representation of vapour compression cycle (VCC) on T-s and P-h diagram Numerical on above concepts

Unit 2

COP, EER, SEER, IPLV, NPLV, effect of operating parameters on performance of VCC actual VCC, methods of improving COP using flash chamber

Unit 2

sub-cooling, liquid vapour heat exchanger, comparison of VCC with Reverse Carnot cycle Introduction, Working of simple vapour absorption system (VAS), desirable properties of binary mixture (aquaammonia) performance evaluation of simple VAS (simple numerical treatment), actual VAS, Li-Br absorption system three fluid system (Electrolux refrigeration) applications of VAS, comparison between VCC and VAC

Unit 2

1.

6. 7. 8. 9.

10. 11. 12. 13. 14. 15. 16. 17.

Unit 1

Unit 1 Unit 1

Unit 2

Unit 2

Unit 2

Unit 2 Unit 2

Unit 3 Unit 3

21.

Introduction, need of multistage system, Intermediate pressure two stage compression with flash gas removal and liquid intercooler single compressor with multiple evaporator: individual and multiple expansion valves individual compressors, cascade system: application

22.

numerical(numerical only by using p-h chart)

Unit 3

Introduction to cryogenics (Linde - Hampson cycle) and applications Unit 4

Unit 3

24.

Basic Psychrometry and processes

Unit 4

25.

BPF of coil, ADP, adiabatic mixing of two air streams

Unit 4

26.

SHF, RSHF, GSHF, ESHF

Unit 4 Unit 4

30.

Factors contributing to cooling load, Numerical based on load analysis Thermodynamics of human body, comfort and comfort chart factors affecting human comfort concept of infiltration and ventilation, indoor air quality requirements Working of summer, winter and all year round AC systems

31.

all air system, all water system, air water system

Unit 4

32.

variable refrigerant flow and variable air volume systems

Unit 4

33.

unitary and central air conditioning

Unit 4

18. 19. 20.

23.

27. 28. 29.

Unit 3 Unit 3 Unit 3

Unit 4 Unit 4 Unit 4

Unit 5 34.

Working of reciprocating, screw and scroll compressors

Unit 5

35.

working of air cooled, water cooled condenser

Unit 5

36.

evaporative condensers, working of DX evaporator

Unit 5

37

Flooded, Forced feed evaporators

Unit 5

38

Expansion devices – Capillary tube

Unit 5

39

TXV, EXV, operating and safety controls

Unit 5

Unit 6 40

Classification of ducts, duct material

Unit 6

41

pressure in ducts, flow through duct

Unit 6 Unit 6

45

pressure losses in duct (friction losses, dynamic losses), air flow through simple duct system equivalent diameter, Methods of duct system design: equal friction velocity reduction, static regain method (numerical on duct system design) Air handling unit, Fan coil unit

46

types of fans used air conditioning applications, fan laws

Unit 6

filters, supply and return grills, sensors (humidity, temperature, smoke) Numericals

Unit 6

42 43 44

47 48

Unit 6 Unit 6 Unit 6

Unit 6

COURSE DELIVERY, OBJECTIVES, OUTCOMES Refrigeration & Air Conditioning (302049) Semester V Course Delivery: The course will be delivered through lectures, assignment/tutorial sessions, class room interaction, and presentations. Course Objectives:  Learning the fundamental principles and different methods of refrigeration and air conditioning.  Study of various refrigeration cycles and evaluate performance using Mollier charts and/ or refrigerant property tables.  Comparative study of different refrigerants with respect to properties, applications and environmental issues.  Understand the basic air conditioning processes on psychometric charts, calculate cooling load for its applications in comfort and industrial air conditioning.  Study of the various equipment-operating principles, operating and safety controls employed in refrigeration air conditioning systems Course Outcomes: On successful completion of the course, the student will be able to 1. CO1: - Illustrate the fundamental principles and applications of refrigeration and air conditioning (L1 – Knowledge, L2 – Comprehension) 2. CO2: Obtain cooling capacity and coefficient of performance by conducting test on vapour compression refrigeration systems.(L2 – Comprehension, L3 – Application) 3. CO3: Present the properties, applications and environmental issues of different refrigerants(L1 – Knowledge, L2 – Comprehension) 4. CO4: Calculate cooling load for air conditioning systems used for variousapplications(L3 – Application, L4 – Analysis) 5. CO5: Operate and analyze the refrigeration and air conditioning systems. (L3 – Application, L4 – Analysis) 6. CO6: To study the basic properties of air and various psychrometric processes. (L1 – Knowledge, L2 – Comprehension)

PROGRAM OUTCOMES (POS): Engineering Graduates will be able to: 1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals, and an engineering specialization to the solution of complex engineering problems. 2. Problem analysis: Identify, formulate, review research literature, and analyze complex engineering problems reaching substantiated conclusions using first principles of mathematics, natural sciences, and engineering sciences. 3.Design/development of solutions: Design solutions for complex engineering problems and design system components or processes that meet the specified needs with appropriate consideration for the public health and safety, and the cultural, societal, and environmental considerations. 4.Conduct investigations of complex problems: Use research-based knowledge and research methods including design of experiments, analysis and interpretation of data, and synthesis of the information to provide valid conclusions. 5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern engineering and IT tools including prediction and modeling to complex engineering activities with an understanding of the limitations. 6.The engineer and society: Apply reasoning informed by the contextual knowledge to assess societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional engineering practice. 7. Environment and sustainability: Understand the impact of the professional engineering solutions in societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable development. 8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of the engineering practice. 9. Individual and team work: Function effectively as an individual, and as a member or leader in diverse teams, and in multidisciplinary settings. 10. Communication: Communicate effectively on complex engineering activities with the engineering community and with society at large, such as, being able to comprehend and write effective reports and design documentation, make effective presentations, and give and receive clear instructions. 11.Project management and finance: Demonstrate knowledge and understanding of the engineering and management principles and apply these to one’s own work, as a member and leader in a team, to manage projects and in multidisciplinary environments. 12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in independent and life-long learning in the broadest context of technological change.

CO – POMapping PO1

PO2

PO3

PO4

PO5

PO6

PO7

PO8

PO9

PO 10

PO 11

PO 12

C0302044-1

3

-

-

-

-

-

-

-

-

-

-

-

C0302044-2

2

1

-

-

-

-

-

-

-

-

-

-

C0302044-3

2

-

-

-

-

1

3

-

-

-

-

-

C0302044-4

2

2

2

-

-

-

-

-

-

-

-

-

C0302044-5

2

-

-

2

2

-

-

-

-

-

-

-

C0302044-6

2

-

2

-

-

-

-

-

-

-

-

-

Average

2

1

2

2

2

1

3

-

-

-

-

-

JUSTIFICATION OF CO - PO MAPPING CO1 WITH PO1

CO2 WITH PO1 AND PO2

CO3 WITH PO1,PO6 AND PO7

CO4 WITH PO1,PO2 AND PO3

CO5 WITH PO1,PO4 AND PO5

According to CO1 students get fundamental knowledge of Refrigeration and Air Conditioning. So it is strongly correlated to PO1. According to CO2 students get knowledge of VCCand apply them to solve problems. So it is moderately correlated to PO1 andPO2. According to CO3 students get knowledge properties, applications and environmental, health issues of different refrigerants. So it is moderately correlated to PO1,PO6 and strongly correlated with PO7 According to CO4 students get knowledge related to cooling load for air conditioning systems used for various applications Hence CO4 is moderately correlated to PO1, PO2,PO3 According to CO5 students get knowledge of Operation and analyze the refrigeration and air conditioning systems. Hence CO5 is moderately correlated to PO1, PO4 and PO5.

CO6 WITH PO1,AND PO3

According to CO6 students get knowledge of properties of air and various psychrometric processes which is helpful for design air conditioning system. Hence CO6 is moderately correlated to PO1and PO3.

QUESTION BANK Unit No. 1 1. Explain with neat sketch Automotive Air conditioners. CO1 2. Explain the need of air conditioning for multiplex facilities. CO1 3. Explain the role of refrigeration system in dairy plant CO1 4. Discuss the necessity of phasing out of CFC refrigerants. List the alternative refrigerants. CO3 5. Explain the benefits of Secondary refrigerants. What is selection criteria of secondary refrigerants? CO3 6. Give important conditions of Montreal and Kyoto protocol. CO3 Unit No. 2 1. The temperature limits of an ammonia refrigerating system are 25 oC and -10o C. If the gas is dry at the end of compression. Calculate the COP assuming no undercooling of the liquid ammonia. CO2 2. In an absorption system heating, cooling and refrigeration takes place at 150 oC, 30oC, and -20oC resp. Find the theoretical COP of the system. If the generator temperature is increased to 190oC and evaporator temperature is decreased to - 30oC, find the percentage change in theoretical COP. CO2 3. A 5 TR refrigerating machine based on R-134a simple saturated vapour compression cycle operates between 12oC and 50oC. Temperature after subcooler is less by 5oC.Determine 1. COP 2.Power per ton 3.Mass circulation of refrigerant in kg/hr. CO2 4. Draw the neat schematic of practical Li-Br absorption system. List the various components with their function in brief. CO5 5. What is the basic function of a compressor in a vapour compression refrigeration system? How this function is achieved in vapour absorption system. CO5

Unit No. 3 1. Write a note on Cascade refrigeration. CO5 2. What do you understand by Cryogenics? Mention Applications. CO1 3. Mention with the help of p-h charts various combination of evaporators and compressors in vapour compression system. CO5

4. Two separate evaporators E1 (10 TR) and E2 (20 TR) at temperatures 5 oC and 15oC resp. Common condenser is at temperature 38oC. The liquid from the condenser is saturated. After evaporator E2, pressure reducing valve bring the pressure to the suction pressure of the compressor. Single compressor and individual expansion valves are used in the system. Make the neat flow diagram and a cycle diagram on R134a p-h chart. Calculate Power required to run the system and COP of the system. 5. Ice factory produces 20 tonnes of ice per day from and at 0oC. The evaporator temperature is -8oC and condenser temperature of 30oC. Refrigerant R-12 is subcooled by 5oC before throttling. Suction vapours are superheated by 2 degree. If the single acting twin cylinder compressor has speed of 1000 rpm, L:D ratio is 1.5. Find – a. COP CO2 b. Condenser capacity including subcooling c. Stroke length, if volumetric efficiency of compressor is 94.5% Unit No. 4 1. Define: RSHF, GSHF and ESHF. Explain the procedure to draw the lines of RSHF, GSHF and ESHF on psychrometric chart. CO6 2. Elaborate in detail factors contributing cooling load. CO4 3. Write a note on Human Comfort Chart . CO6 o 4. If the total barometric pressure is 97 kPa and DBT = 36 C and DPT = 15oC, from fundamentals find the properties of moist air. CO6 o o 5. DBT of air 32 C and WBT is 20 C, is passed through cooling coil at 5oC saturation temperature. The heat extracted by coil is 14 kW; and air flow rate is 42.5 m 3 /min. Using Psychrometric chart Find DBT and WBT of air leaving coil,By pass factor of cooling coil CO6 o 6. An Air-conditioned space is maintained at 25 C DBT and 50% RH. The outside conditions are 40oC DBT and 25oC WBT. The space has sensible heat gain of 24.5 kW. Conditioned air is supplied to the space as saturated air at 10oC. The equipment consists of an air washer. The air entering the air washer comprises 25% outside air. Calculate the following. a. Volume flow rate of air supplied to space b. Latent heat gain of space c. Cooling load of air washer CO4

Unit No. 5 1. Draw constructional diagram of TXV and explain its working. What are the limitations of TXV. CO5 2. Explain with neat sketch All Year Air Conditioning System CO6 3. Write a note on Variable Refrigeration Flow system. CO1 4. Explain the working of Single Screw Compressor. What are the advantages of it over reciprocating compressor? CO1

Unit No. 6 1. Explain Equal friction method of Duct design. List its advantages and disadvantages. CO6 2. Write a note on Fan Laws. CO6 3. A circular duct of 40 cm diameter is used to carry air in an air conditioning system at a velocity of 440 m/min. If this duct is to be replaced by a rectangular duct of aspect ratio of 1.5, find out the size of rectangular duct for equal friction method. When a. Velocity of air in two ducts is same b. The discharge rate of air in two ducts is same CO6 If f=0.015, find out the pressure loss per 100 m length of the duct. Take density of air = 1.15 kg/m3. 4. A rectangular duct of 0.15 m *0.12 m is 20 m long and carries standard air at the rate of 0.3 m3 /s. Calculate the total pressure required at the inlet of the duct to maintain this flow and the air power required. Take friction factor, f=0.005 CO6

Class Test –I Academic Year (2018-19) Branch-TE Mechanical Semester: IIDuration: 1 hour Subject: Refrigeration and Air Conditioning (302049)

Date: Max Marks: 20M

Note: 1. All questions are compulsory 2. Bloom’s Taxanomy level: Bloom Levels (BL):1.Remember 2.Understand 3.Apply 4.Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required Q. No 1

2 3 4

Questions A Refrigeration system operates on reversed carnot cycle. The higher temp of refrigerant in the system is 350C & lowest temp is -150C.The capacity is 12 tonnes.Neglect all losses. Determine 1)C.O.P (2) Heat rejected from the system per hour.(3) Power required. Explain (1) ODP(2)GWP (3)LCCP Explain I) Domestic Refrigerator II)Automotive air conditioners Write short note on selection of Environment friendly refrigerants

Max. Marks 05

Unit No as per Syllabus 1

CO Map ped CO1

Blooms Taxanomy Level

2

05 05 05

1

CO3

2

CO2

2

CO3

2 1 1

Class Test –IAcademic Year (2018-19) Branch-TE Mechanical Semester: IIDuration: 1 hour Subject: Refrigeration and Air Conditioning (302049)

Date: Max Marks: 20M

Note: 1. All questions are compulsory 2. Bloom’s Taxanomy level: Bloom Levels (BL):1.Remember 2.Understand 3.Apply 4.Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required Q. No

Max. Marks

Questions

Unit No as per Syllabus 1

CO Map ped CO1

1

CO1

Blooms Taxanomy Level 1

1

Define (1) COPR (2)COPHP (3)EER (4)SEER (5)TR

2

What is sub-cooling and superheating ? Discuss the effect of vapour superheating and liquid sub-cooling on performance of vapour compression refrigeration system.

05

3

Explain Li-Br absorption system

05

2

CO2

2

4

Compare the COP of an ammonia refrigeration cycle operates between – 20°C and 30°C. in following two cases.

05

2

CO2

1

05

1) Wet compression, in which vapour leaving the compressor is dry saturated.

2

2) Dry Compression, in which vapour entering the compressor is dry saturated. Assume compression to be isentropic and no subcooling of liquid refrigerant. Take Cpl = 4.6 kJ/kgk, Cpv = 2.8 kJ/kgk. Use following properties for refrigerant Temp – 20°C 30°C.

Sp. Enthalpy(kj/Kg) hf 89.8 323.1

hfg 1330.2 1145.8

Sp.Entropy (KJ/KgK) hg 1420.0 1468.9

Sf 0.3684 1.2037

Sg 5.6244 4.9842

Class Test –IIAcademic Year (2018-19) Branch-TE Mechanical Semester: IIDuration: 1 hour Subject: Refrigeration and Air Conditioning (302049)

Date: Max Marks: 20M

Note: 1. All questions are compulsory 2. Bloom’s Taxanomy level: Bloom Levels (BL):1.Remember 2.Understand 3.Apply 4.Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required Q. No 1

2 3 4

Questions

Max. Marks

Derive equation of COP for the two stage compression with flash gas removal and liquid intercooler with schematic and 05 P-h diagram Mention any two applications of cryogenics. 05 Explain air washer and possible psychometric processes 05 with it . A mixture of dry air and water vapour is at a temperature of 21°C under a total pressure of 736 mm Hg. The dew point temperature is 15°C. Find:i) Partial pressure of water 05 vapour ii) Relative humidity iii) Humidity ratio iv)Enthalpy of air per kg of dry air v) Specific volume of dry air per kg of dry air.

Unit No as per Syllabus 3

CO Map ped CO5

Blooms Taxanomy Level 2

3 4

CO1 CO6

4

CO6

1 1

2

Class Test –IIAcademic Year (2018-19) Branch-TE Mechanical Semester: IIDuration: 1 hour Subject: Refrigeration and Air Conditioning (302049)

Date: Max Marks: 20M

Note: 1. All questions are compulsory 2. Bloom’s Taxanomy level: Bloom Levels (BL):1.Remember 2.Understand 3.Apply 4.Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required Q. No 1

2 3

4

Questions

Max. Marks

Unit No CO as per Map Syllabus ped 05 and an individual 3 CO5 A multi evaporator refrigeration system with individual compressors expansion valves using R-22 as the refrigerant as shown in Fig. Neglecting undercooling of liquid and superheating of vapour refrigerant. Find i) Power required to run the system. ii) COP 05 3 CO1 Explain Cascade refrigeration system with schematic and p-h diagram 05 4 CO6 Define and explain followingi) Dew point temperature ii)Specific humidity iii)Partial pressure of water vapour iv) Wet Bulb Temperature. 05 4 CO6 A commercial shop has following loads: Room sensible heat : 58.15 kW Room latent heat : 14.54 kW. The summer outside and inside design conditions are : Outside: 40°C DBT, 27°C WBT Inside: 25°C DBT, 50% RH. 70 m3/min of ventilation air is used. Determine the following if the bypass factor of the cooling coil is 0.15. Find i) Ventilation load ii) Grand total heat iii) Grand sensible heat factor iv) Effective room sensible heat factor v) Apparatus dew point

Blooms Taxanomy Level 2

2 1

3

UNIVERSITY QUESTION PAPER

Subject-4

Mechatronics (302050)

T.E. SEM II 2018 – 2019 Scheme, Syllabus and Evaluation Guidelines Mechatronics 302050 Course Code

Course Name

Lecture Assigned

302050 Mechatronics

Theory

Practical

3

-

Tutorial

Total

1

4

5

70

100

-

25 25

Total

5

External

20

Internal

20

Total

Attendance

Mechatronics 20

Course Name

Teacher assessment End Sem. Exam

Average of Best two class test

302050

Class test 2

Course Code

Class test 1

Examination Evaluation Scheme Theory Practical Internal Assessment Ext

Syllabus Mechatronics 302050 UNIT 1: Introduction to Mechatronics, Sensors & Actuators Introduction to Mechatronics and its Applications; Measurement Characteristics: Static and Dynamic; Sensors: Position sensors- Potentiometer, LVDT, incremental Encoder; Proximity sensors-Optical, Inductive, Capacitive; Temperature sensor-RTD, Thermocouples; Force / Pressure Sensors-Strain gauges; Flow sensors-Electromagnetic; Actuators: Stepper motor, Servo motor, Solenoids; Selection of Sensor & Actuator.

UNIT 2: Block Diagram Representation Introduction to Mechatronic System Design; Identification of key elements of Mechatronics systems and represent into Block Diagram; Open and Closed loop Control System; Concept of Transfer Function; Block Diagram & Reduction principles; Applications of Mechatronic systems: Household, Automotive, Industrial shop floor.

UNIT 3: Data Acquisition Introduction to Signal Communication & Types- Synchronous, Asynchronous, Serial, Parallel; Bit width, Sampling theorem, Aliasing, Sample and hold circuit, Sampling frequency; Interfacing of Sensors / Actuators to Data Acquisition system; 4 bit Successive Approximation type ADC; 4 bit R-2R type DAC; Current and Voltage Amplifier. UNIT 4: Programmable Logic Control Introduction to PLC; Architecture of PLC; Selection of PLC; Ladder Logic programming for different types of logic gates; Latching; Timers, Counter; Practical examples of Ladder Programming. UNIT 5:

Frequency Domain Modelling and Analysis

Transfer Function based modeling of Mechanical, Thermal and Fluid system; concept of Poles & Zeros; Stability Analysis using Routh Hurwitz Criterion; Bode Plots: Introduction to Bode Plot, Gain Margin, Phase Margin, Relative Stability Analysis, Frequency Domain Parameters-Natural Frequency, Damping Frequency and Damping Factor; Mapping of Pole Zero plot with damping factor, natural frequency and unit step response.

UNIT VI: Control System Proportional (P), Integral (I) and Derivative (D) control actions; PI, PD and PID control systems in parallel form; Unit step Response analysis via Transient response specifications: Percentage overshoot, Rise time, Delay time, Steady state error; Manual tuning of PID control; Linear Quadratic Control (LQR).

References: Books:

1) Black P.H. and O. Eugene Adams, Machine Design, McGraw Hill Book Co. Inc. 2) Willium C. Orthwein, Machine Components Design, West Publishing Co. and Jaico Publications House. 3) Hall A.S., Holowenko A.R. and Laughlin H.G, Theory and Problems of Machine Design, Schaum’s Outline Series. 4) C. S. Sharma and Kamlesh Purohit, Design of Machine Elements, PHI Learing Pvt. Ltd. 5) D. K. Aggarwal & P. C. Sharma, Machine Design, S.K Kataria and Sons 6) P. C. Gope, Machine Design: Fundamentals and Applications, PHI Learing Pvt. Ltd. 7) Design Data - P.S.G. College of Technology, Coimbatore. 8) Bhandari, V. B. Machine Design data book, Tata McGraw Hill Publication Co. Ltd. 9) K. Mahadevan, K. Balveera Reddy, Design Data Handbook for Mechanical Engineers, CBS Publishers. 10) K.P. Ramchandran, G.K. Vijyaraghavan, M.S. Balasundaram, Mechatronics: Integrated

Evaluation Guidelines Internal Assessment (IA): [CT (20 marks)+ TA/AT (10 marks)] Class Test (CT) [20 marks]: - Three class tests, 20 marks each, will be conducted in a semester and out of these three, the average of best two will be selected for calculation of class test marks. Format of question paper is same as university TA [5 marks]: Three/four assignments will be conducted in the semester. Teacher assessment will be calculated based on performance in assignments, class test and pre-university test. Attendance (AT) [5 marks]: Attendance marks will be given as per university policy. Paper pattern and marks distribution for Class tests: 1. Question paper will comprise of 3 Section A, B and C with internal choice of questions. 2. Section A contains 5 short answer type questions of 1 mark each. All questions are compulsory. (Total 5 Marks) 3. Section B contains 4 medium answer type questions of 2.5 marks each. All questions are compulsory. (Total 10 marks) 4. Section C contains 1 long answer type questions of 5 marks. (Total 5 marks) Pre-University Test [ 30 Marks] Paper pattern and marks distribution for PUT: Same as End semester exam End Semester Examination [ 70 Marks] Paper pattern and marks distribution for End Semester Exam: As per university guidelines.

78

Lecture Plan Lecture No

Topic

Unit

1.

Unit 1 Unit – I Introduction to Sensors & Actuators Introduction to Mechatronics

Unit 1

2.

Measurement characteristics: - Static and Dynamic

Unit 1

3.

Sensors: Position Sensors: - Potentiometer, LVDT, Encoders; Proximity sensors:- Optical, Inductive, Capacitive

Unit 1

4.

Motion Sensors:- Variable Reluctance; Temperature Sensor: RTD, Thermocouples

Unit 1

5.

Force /Pressure Sensors:- Strain gauges; Flow sensors: Electromagnetic

Unit 1

6.

Actuators: Stepper motor, Servo motor, Solenoids

Unit 1

Identification of key elements of mechatronics systems and represent into block diagram (Electro-Mechanical Systems),

Unit 2

Concept of transfer function,

Unit 2

Block diagram reduction principles,

Unit 2

Applications of mechatronics systems,

Unit 2

:- Household Automotive,).

Unit 2

Shop floor (industrial

Unit 2

7. 8. 9. 10. 11. 12 Unit 3 Unit – III Data Acquisition & Microcontroller System Interfacing of Sensors / Actuators to DAQ system,

Unit 3

13. Bit width, ,

Unit 3

Sampling theorem,

Unit 3

Aliasing,

Unit 3

14. 15 16 79

Sample and hold circuit

Unit 3

Sampling frequency DAC (R-2R), Current and Voltage Amplifier.

Unit 3

Unit 4 PLC Programming Introduction,

Unit 4

Architecture,

Unit 4

Ladder Logic programming

Unit 4

different types of logic gates

Unit 4

Latching, Timers,

Unit 4

Counter, Practical Examples of Ladder Programming,

Unit 4

25.

Unit –V Modelling and Analysis of Mechatronics System System modeling (Mechanical, Thermal and Fluid)

Unit 5

22.

Stability Analysis via identification of poles and zeros,

Unit 5

23.

Time Domain Analysis of System

Unit 5

24.

estimation of Transient characteristics

Unit 5

25.

, Overshoot,damping factor,

Unit 5

damping

Unit 5

frequency, Rise time,

Unit 5

Frequency Domain

Unit 5

Analysis of System and Estimation of frequency domain

Unit 5

parameters such as Natural Frequency

Unit 5

17 18

19. 20. 21 22. 23 24

26 27 28 29 30

Damping Frequency and Damping Factor

Unit 5

31 Unit –VI Unit 6 32. 80

P, PI, PD and PID control systems, Unit 6 33.

Transient response:- Percentage overshoot, Rise time, Delay time,

Unit 6

Steady state error,

Unit 6

PID tuning (manual).

Unit 6

34. 35 36

Unit 6 37 38 39 39

Unit step Response analysis via Transient response specifications: Percentage overshoot,

Unit 6

Steady state error; Manual tuning of PID control

Unit 6

Rise time, Delay time

Unit 6 Unit 6

40

Linear Quadratic Control (LQR).

Course Objectives: • Understand key elements of Mechatronics system, representation into block diagram • Understand concept of transfer function, reduction and analysis • Understand principles of sensors, its characteristics, interfacing with DAQ microcontroller • Understand the concept of PLC system and its ladder programming, and significance of PLC systems in industrial application • Understand the system modeling and analysis in time domain and frequency domain. • Understand control actions such as Proportional, derivative and integral and study its significance in industrial applications

COURSE OUTCOMES (CO) On completion of the course, students will be able to – • Identification of key elements of mechatronics system and its representation in terms of block diagram • Understanding the concept of signal processing and use of interfacing systems such as ADC, DAC, digital I/O • Interfacing of Sensors, Actuators using appropriate DAQ micro-controller • Time and Frequency domain analysis of system model (for control application) • PID control implementation on real time systems • Development of PLC ladder programming and implementation of real life system.

Program Outcomes (POs): Engineering Graduates will be able to:

81

1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals, and an engineering specialization to the solution of complex engineering problems. 2. Problem analysis: Identify, formulate, review research literature, and analyze complex engineering problems reaching substantiated conclusions using first principles of mathematics, natural sciences, and engineering sciences. 3. Design/development of solutions: Design solutions for complex engineering problems and design system components or processes that meet the specified needs with appropriate consideration for the public health and safety, and the cultural, societal, and environmental considerations. 4. Conduct investigations of complex problems: Use research-based knowledge and research methods including design of experiments, analysis and interpretation of data, and synthesis of the information to provide valid conclusions. 5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern engineering and IT tools including prediction and modeling to complex engineering activities with an understanding of the limitations. 6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional engineering practice. 7. Environment and sustainability: Understand the impact of the professional engineering solutions in societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable development. 8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of the engineering practice. 9. Individual and team work: Function effectively as an individual, and as a member or leader in diverse teams, and in multidisciplinary settings. 10. Communication: Communicate effectively on complex engineering activities with the engineering community and with society at large, such as, being able to comprehend and write effective reports and design documentation, make effective presentations, and give and receive clear instructions. 11. Project management and finance: Demonstrate knowledge and understanding of the engineering and management principles and apply these to one’s own work, as a member and leader in a team, to manage projects and in multidisciplinary environments. 12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in independent and life-long learning in the broadest context of technological change.

82

CO – PO Mapping PO 1

PO 2

PO 3

PO 4

PO 5

PO 6

PO 7

PO 8

PO 9

PO1 0

PO1 1

PO1 2

PSO 1

PSO 2

PSO 3

3

2

3

2

-

-

-

-

-

-

-

1

1

2

1

2

2

2

2

-

-

-

-

-

-

-

1

2

2

1

CO3020 50-3

2

2

3

2

2

-

-

-

-

-

-

1

2

2

1

CO3020 50-4

2

1

1

1

1

1

-

-

-

-

-

2

2

1

2

CO3020 50-5

2

2

3

2

-

-

-

-

-

-

-

1

2

2

1

CO3020 50-6

2

2

3

2

-

-

-

-

-

-

-

1

2

2

1

Average

2

2

2

2

2

1

-

-

-

-

-

1

2

2

1

CO3020 50-1 CO3020 50-2

JUSTIFICATION OF CO - PO MAPPING CO1 WITH PO1

According to CO1 students get basic knowledge of Mechanical Engineering. So it is moderately correlated to PO1.

CO2 WITH PO1 AND PO2

According to CO2 students get knowledge of basics and apply them to solve problems. So it is moderately correlated to PO1 andPO2.

CO3 WITH PO3

According to CO3 students get knowledge of engineering So it is moderately correlated to PO3.

CO4 WITH PO1,

According to CO4 students get knowledge of terms related to Mechatronics, & their application and

CO5 WITH PO3

According to CO5 students get knowledge of moderately correlated to PO3,

83

QUESTION BANK UNIT-I Q.1: Give any two definitions of Mechatronics. Explain the scope and importance of Mechatronics and applications. CO1 Q.2: Explain different types of dynamic characteristics of measurement systems such as a) Response time b) Rise time c) Settling time CO1 Q.3: Differentiate between static and dynamic characteristics of measuring instruments. Explain the following. a) b) c) d)

Hysteresis Sensitivity Drift accuracy? CO1

Q.4: Compare an LVDT with a potentiometer as a position sensor. What are advantages and disadvantages of using an LVDT? CO1 Q.5: What is meant by Temperature Compensation in Strain Gauges and how it is done? CO1 Q.6: What are encoders? Its Types? Explain basic operation of rotary encoder. CO1

UNIT-II Q1: Compare Open Loop and Closed Loop Control System with respect to definition, block diagram and application.CO1 Q.2: Discuss the significance of the transfer function approach when modelling a mechanical system. CO1 Q.3: Write various Block diagram reduction principles CO1 Q.4: Using a suitable block diagram explain the working of Automatic Washing Machine CO1 Q5: Using a suitable block diagram explain the working of Automatic Conveyor System CO1 Q6: Figure shown below is a block diagram. Simplify and find the Relation between C(s)/R(s). CO1

Q.7: Use block diagram algebra to reduce the block diagram shown in Figure CO1

84

UNIT-III 1. 1 Write a short note on Analog to Digital Conversion. CO2 2. Explain significance of sampling theorem. . CO2 3. How Sample and Hold circuit is useful for Analog to Digital Conversion, explain. . CO2

4. Explain the detailed functioning of Data Acquisition System with the help of a detailed block diagram. . CO2 5. Using a suitable circuit diagram explain the working of a voltage and current amplifier. . CO2

UNIT-IV Q.1: Brief the selection of PLC CO6 Q.2: What is Ladder Logic programming? CO6 Q.3: Explain with truth tables and symbols, different types of logic gates CO6 Q.4: What is latching? Why to use Latching? CO6 Q.5: What are Timers and its types? Explain with the applications CO6

UNIT-V Q.1 What do you understand by Transfer Function? CO4

Q.2: Explain modeling of Mechanical with the building blocks elements CO4 Q.3: Explain the Thermal and Fluid system modeling with the building blocks CO4 Q.4: What are Poles & Zeros? Explain their significance CO4 Q.5: What is Routh Hurwitz Criterion for stability Analysis CO4

UNIT-VI Q.1: What is control system and its types? CO5

Q.2: Explain Proportionalcontrol action (P)?, CO5 Q.3 Explain Integral control action (I)? CO5 Q.4: Explain Derivative control actions(D) ?CO5 Q.5: Explain control action PI ?CO5

85

CLASS TEST-I QUESTION PAPER

CLASS TEST- I

(AY 2018-19)

Branch: Mechanical Engineering

Date:

Semester: I

Duration: 1 hour

Max. Marks: 20M Subject: Mechatronics Note: 1. All Questions are compulsory 2. Bloom’s Taxonomy level: Bloom Levels (BL) : 1. Remember 2. Understand 3. Apply 4. Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required. Quest ion No. 01.

02.

Questions

Give any two definitions of Mechatronics. Explain the scope and importance of Mechatronics and applications. Explain different types of dynamic characteristics of measurement systems such as

Max. Mark s 05

Unit no. as per syllabus

CO Mapped

Bloom’s Taxonomy Level

1

1

2

05

1

1

2

05

2

1

2

05

2

1

2

a) Response time b) Rise time c) Settling time CO1 03.

Compare Open Loop and Closed Loop Control System with respect to definition, block diagram and application.

04.

Discuss the significance of the transfer function approach when modelling a mechanical system

86

CLASS TEST-II QUESTION PAPER

CLASS TEST- II

(AY 2018-19)

Branch: Mechanical Engineering Semester: I

Duration: 1 hour

Subject: Mechatronics

Max. Marks: 20M

Note: 1. All Questions are compulsory 2. Bloom’s Taxonomy level: Bloom Levels (BL) : 1. Remember 2. Understand 3. Apply 4. Create 3. All questions are as per course outcomes 4. Assume suitable data wherever is required. Question No.

Questions

Max. Marks

Unit no. as per syllabus

CO Mapped

Bloom’s Taxonomy Level

01.

What is Programmable Logic Controller? Explain in detail architecture of PLC

05

4

6

2

02.

Brief the selection of PLC

05

4

6

2

03.

What do you understand by Transfer Function?

05

5

4

3

04.

Explain Proportionalcontrol action (P)

05

6

5

3

87

Mechatronics Assignment

Assignment No.1 UNIT-I Q.1: Give any two definitions of Mechatronics. Explain the scope and importance of Mechatronics and applications. CO1 Q.2: Explain different types of dynamic characteristics of measurement systems such as d) Response time e) Rise time f) Settling time CO1 Q.3: Differentiate between static and dynamic characteristics of measuring instruments. Explain the following. e) f) g) h)

Hysteresis Sensitivity Drift accuracy?

Q.4: Compare an LVDT with a potentiometer as a position sensor. What are advantages and disadvantages of using an LVDT? CO1 Q.5: What is meant by Temperature Compensation in Strain Gauges and how it is done? CO1

Assignment No II UNIT-II Q.1: What is a block diagram? Explain representation of a system using block diagram. Explain advantages and disadvantages of block diagram representation

CO1

Q.2: Compare Open Loop and Closed Loop Control System with respect to definition, block diagram and application.

CO1

Q.3: Discuss the significance of the transfer function approach when modelling a mechanical system. Q.4: Write various Block diagram reduction principles

CO1

CO1

Q.5: Using a suitable block diagram explain the working of Automatic Washing Machine

CO1

Assignment No III UNIT-III 1. Write a short note on Analog to Digital Conversion. CO2 2. Explain significance of sampling theorem. CO2 3. How Sample and Hold circuit is useful for Analog to Digital Conversion, explain. CO2

88

4. Explain the detailed functioning of Data Acquisition System with the help of a detailed block diagram. CO2 5. Using a suitable circuit diagram explain the working of a voltage and current amplifier. CO2

Assignment No IV Q.1: What is Programmable Logic Controller? Explain in detail architecture of PLC CO6 Q.2: Brief the selection of PLC CO6 Q.3: What is Ladder Logic programming? CO6 Q.4: Explain with truth tables and symbols, different types of logic gates? CO6 Q.5: What is latching? Why to use Latching? CO6

Assignment No V UNIT-V Q.1 What do you understand by Transfer Function? CO4

Q.2: Explain modeling of Mechanical with the building blocks elements CO4 Q.3: Explain the Thermal and Fluid system modeling with the building blocks CO4 Q.4: What are Poles & Zeros? Explain their significance CO4 Q.5: What is Routh Hurwitz Criterion for stability Analysis CO4

Assignment No VI UNIT-VI Q.1:What is control system and its types? CO5

Q.2: Explain Proportionalcontrol action (P), CO5 Q.3 Explain Integral control action (I) CO5 Q.4: Explain Derivative control actions(D) CO5 Q.5: Explain control action PI CO5

89

UNIVERSITY QUESTION PAPERS

90

91

92

Subject-5

Manufacturing Process-II (302051)

93

T. E. (Even Semester), Session 2018-2019 Part A: Scheme, Syllabus and Evaluation Guidelines, of “Manufacturing Process II (302051)”

Subject Code Subject Name

Teaching Scheme

Credits Assigned

(Hrs.)

302051

Manufacturin g Process - II

Theory

Practical

Tutorial

Theory

Practi cal

Tutorial

Total

3hrs

0 hrs

--

3

0

--

03

Examination Evaluation Scheme Theory

70

00

00

00

00

00

Final Marks out of

00

Assignment Marks

Class Test 1

Marks based Theory Attendance Marks Secured in all experiments

Total 100

Best of two Class Test

30

Class Test 2

30205 Manufacturi 1 ng Process II

End Sem. Exam

Course Name

Insemister examination

Cours e code

Practical Assessment

External Assessment

00

94

Syllabus Manufacturing Process II (302051) . Unit – I Theory of Metal cutting (07hrs) Single point cutting tool: Tool geometry, Mechanics of shearing (orthogonal and oblique), Shear plane angle, Shear stress, strain and Shear strain rate. Process parameters and their effect on machining. Merchant’s circle of forces (analytical) Estimation of shear force, Normal shear force, Friction force, Normal friction force, Material Removal Rate (MRR), Cutting power estimation, Calculation of Total power and Specific energy. Introduction to tool dynamometers. Machinability - Factors affecting machinability, Tool life, Tool wear, Types of tool wear and remedial actions, Cutting fluid and their types, Effect of process parameters on tool life, Taylor's tool life equation (Derivation along with numerical). Unit – II Machine tools and their application (07 hrs) Drilling machine: Types of drills and operations. Twist drill geometry, Types of drilling machine, Tool holder. Machining time calculations. Milling machine: Types of milling machines, Cutter-types and geometry and their applications. Universal dividing head, Methods of Indexing: Simple, Compound, Differential. (Numericals based on simple and compound Indexing).Machining time calculations Broaching: Introduction to broaching, Broach tool geometry, Planner and Boring Machines: Introduction. Unit – III Finishing processes (07hrs) Grinding machines Introduction: Types and Operations of grinding machines. Grinding wheel – Shapes, Designation and selection, Mounting, Balancing and Dressing of grinding wheels, Machining time calculation for cylindrical and plunge grinding. Super-finishing processes – Introduction to Honing, Lapping, Buffing and Burnishing. (Construction, working and controlling parameters) Unit – IV Advanced Machining Processes (07 hrs) Introduction, classification of advanced machining processes. Electric Discharge Machining (EDM), LASER Beam Machining (LBM), Abrasive Jet Machining (AJM), Ultra Sonic Machining (USM) and Electro Chemical Machining (ECM),Introduction to micro machining. Unit –V CNC Technology (07 hrs) Introduction, Classification, Construction and working of NC, CNC, DNC and machining center. CNC axes and drives. Automatic Tool Changer (ATC) and Automatic pallet changer (APC) CNC Programming: Word address format (WAF) –ISO Standards, G & M codes, Type of CNC Control systems, Manual part programming (plain milling and Turning ), Subroutine, Canned cycles.

95

Unit –VI Jigs and fixtures (07 hrs) Concept of degree of freedom, 3-2-1 principle of location, General guidelines to design Jigs and fixtures, advantages of jig and fixtures Jigs: Definition. Elements of jig with the types, Location guidelines, Principles of clamping, Principles of guiding element, Channel jig, Template jig, Plate jig, Angle plate jig, Turn over jig, Box jig, and Latch type jig. Fixtures: Definition. Elements of fixtures, Location guidelines, Principles of clamping, Principles of setting element, Turning fixture, Welding fixture, Milling fixture, Introduction to Assembly and Inspection fixtures. Indexing fixtures. Concept, elements and advantages of modular fixture, Pokayoke concept in jigs and fixtures. Books: Text: 1. S. K Hajra Choudhury , Elements of workshop technology – Vol. II,, Media Promoters And Publishers, Mumbai 2. Amitabh Ghosh and Asok kumar Mallik, Manufacturing science, Ellis Horwood Ltd 3. Mikell. P. Grover, Fundamentals of Modern Manufacturing, Pearson Publications 4. P. C. Sharma, Production Engineering, S. Chand Publication References: 1. Production technology –HMT, Tata McGraw Hill publication 2. Lindberg, Roy A., Processes and materials of manufacture, P H I Learning 3. Serope Kalpakjian and Steven R. Schmid, Manufacturing Processes for Engineering Materials, Pearson Education, Fourth Edition. 4. G. K Lal, Fundamentals of Design and Manufacturing, Alpha Science International Ltd(2005) 5. M.C Shaw, Metal Cutting Principles, Oxford university press 6. Yoram Koren , Numerical Control of Machine Tools Khanna Publication 7. P. K Mishra, Non- conventional machining, Narosa Publishing House 8. V. K Jain, Advanced machining processes , Allied Publisher, New Delhi 9. M. H. A Kempster, An Introduction to Jig and Tool Design, ELBS 10. P. H. Joshi, Jigs and fixtures , Tata McGraw Hill 11. P. N. Rao, CAD/CAM Principles and Applications, McGraw Hill Education, Third Edition. 12. Cyrll Donaldson, George H. LeCain and V. C. Goold, Tool design, Tata McGraw- Hill. Third Edition

96

Evaluation Guidelines: . Internal Assessment (IA): [CT (20 marks) + Assignment Marks (120 marks) + Marks Based on theory attendance (50 Marks) + Marks Secured in all experiments (80 Marks)] Class Test (CT) [20 marks]: - Two class tests, 20 marks each, will be conducted in a semester and best of two will be selected for calculation of class test marks. Format of question paper is same as university. Assignment Marks (120 marks): Six assignments will be conducted in a semester. Assignment marks will be calculated on the basis of performance in assignments. Marks Based on theory attendance (Out 50 Marks): Attendance marks will be given based on attendance percentage at the end of semester as per university policy. Marks Secured in all experiments (80 Marks): Marks secured in all experiment will be given by assessing each experiment for 10 Marks. 10 Marks distribution is as follows 3 Marks: For attendance in the respective experiment. 4 Marks: For performance in the respective experiment. 3 Marks: For journal writing of the respective experiment Paper pattern and marks distribution for Class tests: 1. Question paper will contain 4 short answer type questions of 05 mark each. All questions are compulsory. (Total 20 Marks) Paper pattern and marks distribution for University Exam: 1. Paper pattern and marks distribution for Insem Exam: As per university guidelines. (Total 30 Marks)

2.

Paper pattern and marks distribution for End Semester Exam: As per university guidelines. (Total 70 Marks)

Lecture Plan 97

Manufacturing Process II (302051)

Lect. No.

1

2 3 4 5

Topics / Sub- Topics Introduction to syllabus : Unit – I: Theory of Metal cutting Single point cutting tool: Tool geometry, Mechanics of shearing (orthogonal and oblique) Shear plane angle, Shear stress, strain and Shear strain rate. Process parameters and their effect on machining. Merchant’s circle of forces (analytical) Estimation of shear force, Normal shear force, Friction force, Normal friction force, Material Removal Rate (MRR), Cutting power estimation, Calculation of Total power and Specific energy. Introduction to tool dynamometers. Machinability - Factors affecting machinability, Tool life, Tool wear, Types of tool wear and remedial actions

6

Cutting fluid and their types, Effect of process parameters on tool life, Taylor's tool life equation (Derivation along with numerical).

7

Numericals on Tool Life Unit – II Machine tools and their application

8 Drilling machine: Types of drills and operations 9

Twist drill geometry, Types of drilling machine, Tool holder.

10

Machining time calculations.

11

Milling machine: Types of milling machines, Cutter-types and geometry and their applications.

12

Universal dividing head, Methods of Indexing: Simple, Compound, Differential

13

Numericals based on simple and compound Indexing).Machining time calculations

14

Broaching: Introduction to broaching, Broach tool geometry, Planner and Boring Machines: Introduction.

15

Unit Test I Unit – III Finishing processes

16

Grinding machines Introduction: Types and Operations of grinding machines 98

17

Grinding wheel – Shapes, Designation and selection

18

Mounting, Balancing and Dressing of grinding wheels,

19

Machining time calculation for cylindrical grinding.

20

Machining time calculation for plunge grinding.

21

Super-finishing processes – Introduction to Honing

22

Lapping, Buffing and Burnishing. (Construction, working and controlling parameters)

24

Unit – IV Advanced Machining Processes :Introduction, classification of advanced machining processes. Principle, Working, Process Parameters, Advantages, Limitations and Applications of various AMP. Electric Discharge Machining (EDM),

25

Variants of Electric Discharge Machining (EDM),

26

LASER Beam Machining (LBM),

27

Abrasive Jet Machining (AJM),

28

Ultra Sonic Machining (USM)

29

Electro Chemical Machining (ECM)

30

Unit Test II

23

Unit –V CNC Technology 31 Introduction, Classification, Construction and working of NC 32

CNC, DNC and machining center.

33

CNC axes and drives. Automatic Tool Changer (ATC) and Automatic pallet changer (APC)

34

CNC Programming: Word address format (WAF) –ISO Standards, G & M codes)

35

Type of CNC Control systems, Manual part programming ( Turning )

36

Type of CNC Control systems, Manual part programming (plain milling)

37

Subroutine, Canned cycles Unit –VI Jigs and fixtures

38 Concept of degree of freedom, 3-2-1 principle of location

99

39

Jigs: Definition. Elements of jig with the types, Location guidelines

40

Principles of clamping, Principles of guiding element, Channel jig, Template jig, Plate jig

41

Fixtures: Definition. Elements of fixtures, Location guidelines

42

Principles of setting element, Turning fixture, Welding fixture, Milling fixture

43

Introduction to Assembly and Inspection fixtures. Indexing fixtures. modular fixture, Pokayoke concept

44

Preliminary exam

Note: In case of shortage of lectures we can replace some tutorial/practical session for completion of syllabus

100

Course Delivery, Objectives, Outcomes Assessment and Evaluation, and CO mapping with the POs

Manufacturing Process I (202041) Semester: II Pre-requisite: Manufacturing Process I (202041) Basic Mechanical Engineering (102013)

Course Delivery: The course will be delivered through lectures, assignment sessions, class room interaction, Practical and presentations. Course Objective: 1.To analyze and understand the metal cutting phenomenon 2. To select process parameter and tools for obtaining desired machining characteristic 3. To understand design of manufacturing processes. 4. To analyze the effect of process parameter with respect to defined process characteristic

Course Outcomes: On completion of the course, learner will be able to– CO1..Student should be able to apply the knowledge of various manufacturing processes. CO2. Student should be able to identify various process parameters and their effect on processes. CO3. Student should be able to design and analyze various manufacturing processes and tooling. CO4. Student should be able to figure out application of modernization in machining. CO5. Students should get the knowledge of Jigs and Fixtures so as to utilize machine capability for variety of operations. Programs Outcomes (POs):

Engineering Graduates will be able to: 1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals, and an engineering specialization to the solution of complex engineering problems.

101

2. Problem analysis: Identify, formulate, review research literature, and analyze complex engineering problems reaching substantiated conclusions using first principles of mathematics, natural sciences, and engineering sciences. 3. Design/development of solutions: Design solutions for complex engineering problems and design system components or processes that meet the specified needs with appropriate consideration for the public health and safety, and the cultural, societal, and environmental considerations. 4. Conduct investigations of complex problems: Use research-based knowledge and research methods including design of experiments, analysis and interpretation of data, and synthesis of the information to provide valid conclusions. 5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern engineering and IT tools including prediction and modeling to complex engineering activities with an understanding of the limitations. 6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional engineering practice. 7. Environment and sustainability: Understand the impact of the professional engineering solutions in societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable development. 8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of the engineering practice. 9. Individual and team work: Function effectively as an individual, and as a member or leader in diverse teams, and in multidisciplinary settings. 10. Communication: Communicate effectively on complex engineering activities with the engineering community and with society at large, such as, being able to comprehend and write effective reports and design documentation, make effective presentations, and give and receive clear instructions. 11. Project management and finance: Demonstrate knowledge and understanding of the engineering and management principles and apply these to one’s own work, as a member and leader in a team, to manage projects and in multidisciplinary environments. 12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in independent and life-long learning in the broadest context of technological change.

CO-PO Mapping Course Outcomes

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12

CO1

3

2

2

2

-

-

-

-

-

-

1

1

CO2

3

3

3

3

1

-

-

-

-

-

-

1

CO3

2

2

3

2

-

-

-

-

-

-

-

1

CO4

2

2

2

2

3

-

-

-

-

-

-

1

CO5

3

3

1

1

1

-

-

-

-

-

-

1

Justification of CO - PO Mapping 102

CO1 With PO1

CO1 is aligned with PO1 and as it related to Understanding engineering

CO2 With PO1 , PO2,PO3 and PO4

CO2 is to understand various process parameters and their effect on process. Hence it is strongly correlated to PO1, PO2,PO3 and PO4

CO3 With PO3 CO4 With P05 CO5 With PO1,PO2

fundamentals.It is moderately related to PO2,PO3 and PO4.

CO3 deals with design and analyze various manufacturing processes and tooling. So it is strongly correlated with PO3 and Moderately correlated with PO1, PO2 ,PO4. CO4 is application of modernization in machining. So it is strongly aligned with PO5 and moderately correlated PO1,PO2,PO3,PO4. CO5 is related to Jigs and fixtures to utilize machine capacity. It is strongly correlated to engineering knowledge (PO1) and problem analysis (PO2.)It is slightly related to CO3,CO4,CO5 and CO12.

QUESTION BANK UNIT NO I Q.1.Sketch a single point cutting tool and show on it various tool elements and tool angles, Give the function of each tool element. List the various tool angles and discuss their significance. CO1 Q.2 Prove the relation between Chip thickness ratio, Rake angle and Shear plane angle. CO2 Q.3 What is machinability? Explain different factors affecting it. CO2 Q4.Sketch a merchant circle force diagram and explain the different quantities involved. CO1 Q5. State the various assumptions made in development of Merchants force circle. CO1 Q6. What is tool life ? Explain the relation between tool life and cutting speed. CO2 Q7. A tool life of 60 min is obtain at a cutting speed of 25 m/min and 6 min at 40 m/min. Determine the i) Taylor’s tool life equation ii) Cutting speed for 5 min tool life. CO2 Q8. In an orthogonal turning of steel bar with 80 mm dia on lathe with the following data: Cutting speed : 110 m/min, Back rake: 100 , feed rate = 0.20 mm/rev, cutting force = 1200 N, Feed force = 450 N , chip thickness : 0.4 mm.Calculate: Shear angle, Coefficient of friction, Cutting power. CO2 Q9.During machining of C2 steel with 0-10-6-6-8-90-1 (ORS) shaped triple carbide cutting tool the following observations have been made CO2 103

Depth of cut = 2mm , feed = 0.2mm/rev , Speed 200m/min,Tangential force = 1600 N Feed trust force = 800 N, Cip thickness = 0.39 mm Calculate : (1) Sear force (2) Normal force at shear plane (3) Friction force (4) Kinetic coefficient of friction (5) Specific cutting energy. Q10. Derive expressions for cutting speed and tool life for minimum cost criterion. CO3

UNIT NO 2 Q.1 Explain the construction, working of radial drilling machine with neat block diagram. CO1 Q2.Draw a neat labelled sketch of sensitive drilling machine. Explain its construction and working. CO1 Q3.Explain operations of drilling machine. Sketch spot facing and trepanning operation. CO1 Q4.Calculate the machining time required for producing 20 holes on MS plateof 40 mm thickness with the following data. CO2 i)drill diameter = 30mm ii) Cutting speed = 25 m/min iii) Feed = 0.1 mm/rev iv) Overrun = 0.5 x drill diameter (mm) Q5. Explain Universal milling machine. Q.6 Index for 87 division (use compound indexing method) CO1 Q7.Classify milling cutters. CO1 Q8. Differentiate between up milling and down milling. CO1 Q9. Write short note on gear milling. CO1 104

Q10. With the help of neat sketch explain the arrangement of universal dividing head. CO1 Q11.Describe compounding indexing with suitable sketch. CO1 Q12 Explain various types of broaching machines. CO1 Q.13 With neat sketch explain terminology of pull type internal broach. CO1

UNIT NO 3 Q.1 Explain the center less grinding with the principle, construction and working. CO3 Q 2 Describe different types of surface grinders with simple sketches CO3 Q.3 Explain the meaning of each letter mentioned on the following grinding wheel CO3 W-A-10-E-5-V-25 Q4 Explain the meaning of grinding wheel signature. CO3 26-C-60-M-7-V-28 Q5 List various bonds of grinding wheel and briefly describe the same. CO3 Q6 How is grinding wheel selected? Outline various factors that influence its selection. CO3 Q7 Explain thread grinding. CO3 Q.8 Explain dressing, truing and balancing of grinding wheel. CO3 Q.9 For rough grinding operation, determine the machining time required when cutting speed is 25 m/min, dia of work is 45 mm, depth of cut is 0.03 mm , stock is 0.6 mm for 220 mm long work piece with face width of wheel as 70mm. CO2 Q10."Hard grinding wheel recommended for soft work material and soft grinding wheel for hard material’ comment. CO3 Q11.Explain mounting of grinding wheel with neat sketch. CO3

105

Q12..Differentiate between honing and lapping. CO3 UNIT NO 4 Q1.Explain the ECM process (with neat sketch) with its advantages, limitations and applications. CO2 Q1.Explain the AJM process (with neat sketch) with its advantages, limitations and applications. CO2 Q1.Explain the EDM process (with neat sketch) with its advantages, limitations and applications. CO2 Q1.Explain the USM process (with neat sketch) with its advantages, limitations and applications. CO2 Q1.Explain the LBM process (with neat sketch) with its advantages, limitations and applications. CO2 Q2)What is the necessity for non conventional machining processes? Enlist the requirements that demand the use of advanced machining processes. CO4 Q3)What is the function of abrasive slurry in USM? Explain how the abrasive selection is

.

made

CO2 Q4) What are the factors that influence material removal rate in AJM? CO2

UNIT NO 5 Q.1 CO4

Explain CNC machines with neat sketch. State its advantages and limitations.

106

Q.2 Explain meaning of 2 axis, 3 axis, 5 axis CNC machines. CO4 Q.3 Draw block diagram of DNC system and compare DNC and CNC system CO4 Q.4 Explain the following codes: G03, M30, G90, M08 CO4 Q.5 Explain machining center with neat sketch. CO4 Q.6 Write a part program for component shown in fig. Assume that spindle aped of 400 rpm and feed is 0.3 mm/rev. CO4

Q7.Draw and explain block diagram of NC machine system CO4 Q8.Explain with neat sketch open loop and closed loop system in CNC machines. CO4 Q9.Explain CNC machine with sketch. Also explain special constructional features of CNC machine tools. CO4 Q10.Explain the following codes: CO4 G90 G02 G40 G82 G90 G02 G63 G41 G01 G94 G91 G00 G03 Q11.Write short notes on M codes CO4 UNIT NO 6 Q.1 Define jig and fixture. Differentiate between them with suitable examples. CO5 Q.2 Write short note on modular fixture. CO5 Q.3 List various types of locating device used in jig and fixture. Explain any one in detail. CO5 Q.4 Draw and explain diamond pin locator. CO5 Q.5 What is 3-2-1 location principle? Explain with neat sketch. CO5 107

Q.6 Design and draw drilling jig for drilling the 10 mm dia. Hole in the component shown in fig. CO5

108

Class test Question Papers

Class Test -01 (AY 2018-19) Branch: SE Mechanical Semester: II Subject: Manufacturing Process II (302051)

Date: Duration: 1 hour Max. Marks: 20M

Note: 1. Attempt all Questions in Section A 2. Attempt any three questions in section B 3. All questions are as per course outcomes 4. Assume suitable data wherever is required. Bloom’s Taxonomy level: Bloom Levels (BL) : 1. Remember 2. Understand 3. Apply 4. Create

Q.No

Max. Marks

Questions

Unit No Blooms CO as per Taxanomy Mapped Syllabus Level

Section A 1 a)

b)

c)

Tools used on Lathe, Shaper or planer are called as __________ cutting tools. (a)Single point (b)Multipoint (c)Two point Discontinuous chips are produced while machining ______ material (a)Ductile (b)Brittle Cutting forces of tool during machining are measured with the help of _________. (a) Micrometer.

1

1

1

2

1

1

1

2

1

1

1

2

1

2

1

2

1

2

1

2

(b) Vernier calliper (c) Dynamometer. d)

Following operation cannot be done on drilling machine (a) Boring (b) Broaching (c) counter boring (d) countersinking

e)

Milling machine uses __________ type of cutting tool

109

(a)Single point (b)Multipoint (c)Two point Section -B Q.2 Q.3

Prove the relation between Chip thickness ratio, Rake angle and Shear plane angle. A tool life of 60 min is obtain at a cutting speed of 25 m/min and 6 min at 40 m/min. Determine the i) Taylor’s tool life equation ii) Cutting speed for 5 min tool life.

Q.4

Differentiate between up milling and down milling with neat sketch

Q.5

Q4.Calculate the machining time required for producing 20 holes on MS plateof 40 mm thickness with the following data.

5

1

2

2

5

1

2

3

5

2

1

2

5

2

2

3

i)drill diameter = 30mm ii) Cutting speed = 25 m/min iii) Feed = 0.1 mm/rev iv) Overrun = 0.5 x drill diameter (mm)

110

Class Test -02 (AY 2018-19) Branch: SE Mechanical Semester: II Subject: Manufacturing Process II (302051)

Date: Duration: 1 hour Max. Marks: 20M

Note: 1. Attempt all Questions in Section A 2. Attempt any three questions in section B 3. All questions are as per course outcomes 4. Assume suitable data wherever is required. Bloom’s Taxonomy level: Bloom Levels (BL) : 1. Remember 2. Understand 3. Apply 4. Create

Q.No

Max. Marks

Questions

Unit No Blooms CO as per Taxanomy Mapped Syllabus Level

Section A 1 a)

b)

c)

d)

e)

1.Grinding wheels must be balanced for proper operation. State whether the statement is true or False (a)True (b)False Transverse grinding is used for jobs with lengths _______ the width of the wheel. (a)smaller than (b) greater than (c) equal to For machining the material by Electrical discharge machining process , work piece material need not be a good conductor of electricity. Stare whether the statement is true or false. (a)True (b)False In abrasive jet machining standoff distance does not have an impact on MRR. State whether the statement is true or False a)True (b)False By Electro chemical machining non conducting materials cannot be machined. State whether the statement is true or False

1

3

1

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1

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2

1

4

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1

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05

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3

a)True (b)False Section -B Q.2

Explain the meaning of grinding wheel signature. 26-C-60-M-7-V-28

111

Q.3

Q.4

Q.5

For rough grinding operation, determine the machining time required when cutting speed is 25 m/min, dia of work is 45 mm, depth of cut is 0.03 mm , stock is 0.6 mm for 220 mm long work piece with face width of wheel as 70mm. What is the necessity for non conventional machining processes? Enlist the requirements that demand the use of advanced machining processes. Explain AJM process (with neat sketch) with its advantages, limitations and applications

05

3

2

3

05

4

4

2

05

4

2

2

112

University Question Papers

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