139

140

141

142

143

144

145

Mgm-311

INDUSTRIAL MANAGEMENT AND HUMAN RELATIONS.

Total Contact Hours

Theory 32

T
1

P
0

C
1

AIMS The study of this subject will enable the student to develop the management skill, acquaint
him with the principles of management and human relations and develop psychological
approach to solve the labour problems.
COURSE CONTENTS
1.

INDUSTRIAL PSYCHOLOGY.
1.1
History and definition.
1.2
Nature and scope.

2 Hours

2.

LEADERSHIP
2.1
Definition and types.
2.3
Qualities of a good leader.

1 Hour

3.

MOTIVATION
3.1
Definition.
3.2
Types (Financial and non financial motives).
3.3
Conflict of motives.

4.

MORALE
4.1
Importance.
4.2
Development.
4.3
Measurement.

1 Hour

5.

HUMAN ENGINEERING.
5.1
Importance of human factor in industry.
5.2
Man-machine system.
5.3
Strategy for making allocation decisions.

1 Hour

6.

INDUSTRIAL FATIGUE AND BOREDOM.

6.1
Definition and distinction.
6.2
Psychological causes.
6.3
Objective causes.
6.4
Prevention

2 Hours

7.

INDUSTRIAL ACCIDENTS
7.1
Psychological causes.
7.2
Objective causes.
7.3
Prevention

2 Hours

8.

INDUSTRIAL PREJUDICE

2 Hours

146

2 Hours

8.1
8.2

Causes
Remedies

9.

PUBLIC RELATIONS.
9.1
Importance
9.2
Functions

2 Hours

10.

GUIDANCE AND COUNSELLING

10.1 Importance
10.2 Choice of job.
10.3 During service.

2 Hours

11.

JOB EVALUATION
11.1 Importance
11.2 Methods
11.3 Job satisfaction
11.4 Work simplification.

2 Hours

12.

INDUSTRIAL MANAGEMENT
12.1 Introduction
12.2 Functions of management.
12.3 Subdivisions of management
12.4 Objectives of industrial management.

2 Hours

13.

PERSONNEL SELECTION.
13.1 Recruitment of employees.
13.2 Training.
13.3 Effects of training on production and product cost.

2 Hours

14.

WORKING CONDITIONS.
14.1 Importance and consideration.
14.2 Effects on efficiency and per unit cost.

2 Hours

15.

TIME AND MOTION STUDY.

15.1 Concept and importance.
15.2 Sequence of motion study.
15.3 Principles of motion study.
15.4 Steps to time study.
15.5 Determination of operations time.

3 Hours

16.

QUALITY CONTROL.
16.1 Concept and advantages
16.2 Methods.

2 Hours

17.

ROLE OF FOREMAN IN MANAGEMENT.

2 Hours

147

17.1
17.2

Foreman's abilities.
Duties and functions.

BOOKS RECOMMENDED:
1
C.S. Meyers, Industrial Psychology, Oxford University Press, London.
2.
Smith Wakley, Psychology of Industrial Behaviors, Mc-Graw Hill, New York.
3.
Ghulam Hussain, Nizamat-e-Sanaat Aur Insani Rawabat, Ilmi Kitab
Khana, Urdu Bazar, Lahore.
4.
Andrew R. Megill, The Process of Management William M New Man.
5.
Richard N Omen, Management of Industrial Enterprises.

148

Mgm-311

INDUSTRIAL MANAGEMENT AND HUMAN RELATIONS.

INSTRUCTIONAL OBJECTIVES
At the completion of this course, the students will be able to:
1.

KNOW INDUSTRIAL PSYCHOLOGY.

1.1
Describe brief history if industrial psychology.
1.2
Describe in detail definition of industrial psychology.
1.3
State nature and scope of industrial psychology.

2.

KNOW LEADERSHIP.
2.1
Define leadership.
2.2
Describe types of leadership.
2.3
State qualities of a good leader.

3.

UNDERSTAND MOTIVATION.
3.1
Define motivation.
3.2
Describe financial and non financial motives.
3.3
Explain conflict of motives.

4.

KNOW MORALE.
4.1
State importance of morale.
4.2
Describe development of morale.
4.3
State the method of measurement of morale.

5.

UNDERSTAND HUMAN ENGINEERING.

5.1
Explain importance of human engineering in the industry.
5.2
Explain man-machine system.
5.3
Explain strategy for making allocation decisions.

6.

UNDERSTAND INDUSTRIAL FATIGUE AND BOREDOM.

6.1
Define fatigue and boredom.
6.2
Describe psychological causes of fatigue and boredom.
6.3
Describe objective causes of fatigue and boredom.
6.4
Explain measures to prevent fatigue and boredom.

7.

UNDERSTAND INDUSTRIAL ACCIDENTS.

7.1
Explain psychological causes of industrial accidents.
7.2
Explain objective causes of industrial accidents.
7.3
Explain measures to prevent industrial accidents.

8.

UNDERSTAND INDUSTRIAL PREJUDICE.

8.1
Define prejudice
8.2
Explain causes of industrial prejudice.
8.3
Explain remedies of industrial prejudice.

149

9.

UNDERSTAND THE SIGNIFICANCE OF PUBLIC RELATIONS.

9.1
Explain importance of public relations.
9.2
Explain functions of public relations.

10.

UNDERSTAND THE NEED FOR GUIDANCE AND COUNSELLING.

10.1 State importance of guidance and counselling.
10.2 Explain the role of guidance and counselling in choosing the job.
10.3 Describe help of guidance and counselling during service.

11.

UNDERSTAND JOB EVALUATION.

11.1 Explain importance of job evaluation.
11.2 Explain methods of job evaluation.
11.3 Explain job satisfaction.
11.4 Explain work simplification.

12.

UNDERSTAND INDUSTRIAL MANAGEMENT.

12.1 Define management.
12.2 State functions of management.
12.3 Enlist subdivision of management.
12.4 Explain objectives of industrial management.

13.

UNDERSTAND TRAINING AND ITS EFFECTS.

13.1 Describe the recruitment procedure of employees in an industrial concern.
13.2 Explain training.
13.3 Identify the kinds of training.
13.4 Explain the effects of training on production and product cost.

14.

UNDERSTAND THE EFFECT OF WORKING CONDITION ON EFFICIENCY.

15.1 Explain importance of working condition.
15.2 Describe air-conditioning, ventilation, lighting and noise.
15.3 State the effects of good working conditions on efficiency
and per unit cost.

15.

UNDERSTAND TIME AND MOTION STUDY.

15.1 Explain the concept.
15.2 Describe the importance of work study.
15.3 Explain the sequence of motion study.
15.4 State the principles of motion study.
15.5 Describe the steps for carrying out time study.
15.6 Explain the method of determination of operations time.

16.

UNDERSTAND THE METHODS OF QUALITY CONTROL.

16.1 Define quality control
16.2 State the advantages of quality control.
16.2 Explain methods of quality control.

150

17.

UNDERSTAND THE ROLE OF FOREMAN IN AN INDUSTRIAL

UNDERTAKING.
17.1 Explain ability of the foreman.
17.2 Enlist duties of foreman.
17.3 Describe functions of foreman as middle management.

151

MT-312

HYDRAULICS & HYDRAULIC MACHINES

T

P
1

C
3

2
TOTAL CONTACT HRS.
THEORY
: 32
PRACTICAL : 96
PRE-REQUISITE: ENGG:PHYSICS & APPLIED MECHANICS
AIMS:At the end of the course the students will be able to understand properties of fluids,
pressure and flow of fluids and also able to apply above to problems of total head
of water, losses of heads, flow through orifices, impact of jets etc. The hydraulic
machine portion of the course will provide the student the knowledge of water
wheels, hydraulic turbines and pumps.
COURSE CONTENTS
1.

INTRODUCTION
4 Hours
1.1.
Introduction.
1.2
Density of water.
1.3
Specific weight of water.
1.4
Specific gravity of water.
1.5
Viscosity of water
1.6
S.I. units.
1.7
Pressure head of liquids (P = wH)
1.8
Pressure.
1.8.1 Atmospheric pressure
1.8.2 Gauge
1.8.3 Absolute.
1.9
Measurement of pressure.
1.9.1 Piezometer tube.
1.9.2 Simple manometer.
1.10 Diaphragm pressure gauge.
1.11 Dead weight pressure gauge.
1.12 Calculation of simple problems on above topics by simple application of formula,
while all parameters are provided.

2.

HYDROKINEMATICS.
2.1
Introduction.
2.2
Rate of discharge.
2.3
Equation of discharge.
2.4
Equation of continuity
2.5
Total energy of liquid particles in motion
2.6
Total head of liquid particles in motion.

152

4 Hours

2.7
2.8

Bernoulli's Equation.
Types of flow, and their characteristics.

3.

FLOW METERS (VENTURIMETER).

3.1
Types of flow meters
3.2
Practical application of Bernoulli's Equation
3.3
Venturimeter,its construction
3.4
Discharge through a venturimeter
3.5
Solution of simple problems of horizontal venturimeter

4 Hours

4.

FLOW THROUGH ORIFICES

4.1
Introduction
4.2
Types of orifices.
4.3
Jet of water.
4.4
Vena contracta
4.5
Hydraulic co-efficients.
4.5.1 Cc
4.5.2 Cd
4.5.3 Cv
4.6
Experimental method for determining hydraulic coefficients.
4.7
Solution of simple problems by direct application of formulae.

3 Hours

5.

FLOW THROUGH PIPES

5.1
Introduction
5.2
Loss of head of a liquid flowing in a pipe (major & minor)
5.2.1 Loss of head due to friction
5.2.2 Loss of head due to sudden enlargement
5.2.3 Loss of head due to sudden contraction.
5.2.4 Loss of head at entrance to a pipe.
5.3
Solution of simple problems by direct application of formula, when all parameters
are given except loss of head

6.

IMPACT OF JETS.
4 Hours
6.1
Introduction
6.2
Force of Jet Impinging Normally on a fixed Plate.
6.3
Force of jet Impinging on an inclined plate
6.4
Force of jet impinging on a moving plate.
6.5
Force of jet impinging on a series of vanes
6.6.
Calculate force of jet in all above cases by simple application of formula, while
all other parameters are directly provided.

7.

WATER WHEELS.
7.1
Introduction.
7.2
Types of water wheels.
7.3
Overshot water wheel

3 Hours

153

7.4
7.5
7.6
7.7
8.

9.

10.

Solution of simple problems of overshot water wheel

Breast water wheel
Solution of simple problems of Breast water wheel
Advantages and disadvantages of water wheels.

WATER TURBINES.
8.1
Development of water turbines.
8.2
Advantages of water turbines.
8.3
Classification of water turbines.
8.4
Hydroelectric power plant.
8.4.1 Storage reservoir
8.4.2 Dams and its parts.
8.4.3 Water ways
8.4.4 Water turbines and electric generators
8.5
Pelton wheel
8.5.1 Nozzle
8.5.2 Runner and buckets.
8.5.3 Casing.
8.5.4 Breaking jet mechanism
8.7
Reaction turbine.
8.7.1 Spiral casing.
8.7.2 Guide mechanism
8.7.3 Turbine runner.
8.7.4 Draft tube
PUMPS
9.1
Introduction.
9.2
Types of pumps.
9.2.1 Centrifugal.
9.2.2 Reciprocating.
9.3
Construction and working of centrifugal pump
9.4
Construction and working of reciprocating pump
9.5
Comparison of centrifugal and reciprocating pump
9.6
Slip of a pump
9.7
Discharge of a single acting reciprocating pump (Q=LAN/60)
9.8
Solution of simple problems, by using above formula.

4 Hours

HYDRAULIC MACHINES
10.1 Types & Classification.
10.2 Hydraulic press.
10.3 Mechanical Advantage.

2 Hours

RECOMMENDED BOOKS:
A Textbook Of Hydraulics Fluid Mechanics and Hydraulic Machines by RS Khurmi.
A Textbook by LEWITT

154

4 Hours

MT-312

HYDRAULICS & HYDRAULIC MACHINES

INSTRUCTIONAL OBJECTIVES
1.

2.

3.

4.

INTRODUCTION TO HYDRAULICS
1.1
Understand basic terms of Hydraulics
1.1.1 Define hydraulics
1.1.2 State difference between liquid & fluid
1.1.3 Enlist properties of fluid
1.1.4 Define unit weight of water, specific weight, viscosity ,pressure.
1.1.5 Describe SI units.
1.1.6 Derive pressure head (P=wH)
1.1.7 Describe types of pressure.
1.1.8 Solve simple problems
1.2
Understand Pressure Measurement Techniques.
1.2.1 Explain measurement of pressure by simple manometer.
1.2.2 Explain diaphragm pressure gauge.
1.2.3 Explain dead weight pressure gauge.
1.2.4 Solve simple problems of pressure.
HYDROKINEMATICS
2.1
Understand basics of Hydro kinematics.
2.1.1 Derive rate of discharge. [Q= a (area) x v(velocity)]
2.1.2 Equation of continuity.
2.1.2.1 Explain equation of continuity
2.1.2.2 Derive velocity head
2.1.3 Define energy/head of a liquid in motion.
2.1.4 Explain total energy/head of a liquid in motion.
2.1.5 Define Bernoulli's Theorem.
2.1.6 Explain application of Bernoulli's Equation
2.1.7 Solve problem on Bernoulli's equation
2.2
Understand Types of flow
2.2.1 Describe the types of flow
2.2.2 Differentiate between each type of flow
FLOWMETER
3.
Apply flow meters.
3.1
Name the different types of flow meters
3.2
Explain the application of each type of flow meter
3.3
Explain the principle of a venturimeter.
3.4
Explain method of for calculating discharge by a venturimeter
3.5
Solve simple problems for calculating discharge through venturimeter.
FLOW THROUGH ORIFICES.
4.
Solve problems for flow through orifices
4.1
Define Orifice
4.2
Describe types of orifices.
4.3
Define vena-contracta.
4.4
Explain the effect of water through small orifice

155

5.

6.

7.

8.

4.5
Define hydraulic coefficients.
4.6
Explain procedure for determining Cc,Cv and Cd
4.7
Solve simple problems on hydraulic coefficients.
FLOW THROUGH PIPES.
5.
Calculate Losses of heads.
5.1
Name the various losses of energy/heads during flow though pipes
5.2
Explain method of calculating loss of head due to friction
5.3
Explain method of calculating loss of head at entrance to a pipe.
5.4
Explain method of calculating loss of head due to sudden enlargement.
5.5
Explain method of calculating for loss of head due to sudden contraction.
5.6
Explain method of calculating loss of energy/head at bends/elbows
5.7
Solve simple problems for calculation of various energy/head losses by
direct application of formula
IMPACT OF JET.
Calculate force of jet.
6.1
Explain the effect of flow through nozzles
6.2
Determine the force of jet impinging normally on a fixed, flat plate.
6.3
Determine the force of jet impinging normally on an inclined flat plate.
6.4
Determine force of jet impinging on a moving flat plate.
6.5
Determine the force of jet impinging on a fixed curved vane
6.6
Determine force of jet impinging on a moving curved vane
6.7
Determine force of jet on curved vanes fixed on the vim of a wheel
WATER WHEEL.
7.1
Understand the working of water wheel
7.1.1 Explain the working of water wheel by velocity of stream.
7.1.2 Explain the working of a water wheels by weight of fluid.
7.1.3 Explain the demerits of water wheels.
7.2
Understand Overhost water Wheel.
7.2.1 Describe overshot water wheel.
7.2.2 Sketch overshot water wheel.
7.2.3 Explain formula for power of overhost wheel.
7.2.4 Solve simple problems on calculation of power of overhost water wheels.
7.3
Understand Breast Water Wheel.
7.3.1 Describe breast water wheel.
7.3.2 Sketch breast wheel.
7.3.3 Explain power calculation by breast wheel.
7.3.4 Solve simple problems on breast water wheels.
WATER TURBINES
8.1
Understand the development of water turbines
8.1.1 State the classification of water turbines
8.1.2 State the advantages of water turbines over water wheels
8.1.3 Explain the application of various types of turbines with respect to head
8.1.4 Describe advantages of water turbines
8.1.5 State classification of water turbine
8.2
Understand the speed control of turbines
8.2.1 Explain the necessity for speed control of turbines

156

9.

10.

8.2.2 Explain the various methods of speed control used for each type of turbine
8.2.3 Explain Dams with its parts
8.2.4 Explain water ways
8.2.5 Establish relationship between water turbine and electric generators
8.3
Understand the working of turbine
8.3.1 Explain the construction and working of Pelton Wheel.
8.3.2 Explain the construction and working of a Fourneyron turbine
8.3.3 Explain the construction and working of a Francis turbine
8.3.4 Explain the construction and working of a Kaplan turbine
8.3.5 State the reasons for Francis turbine by using in Pakistan.
8.4
Understand the working of Hydroelectric power plants
8.4.1 Name the Hydroelectric power plants of Pakistan
8.4.2 Explain the working of a Hydroelectric power plant with a schematic
diagram
8.4.3 Explain the merits and demerits of a hydroelectric power plant as
compared to other plants
HYDRAULIC PUMPS.
9.1
Understand the working of hydraulic pumps
9.1.1 Explain the classification of hydraulic pumps
9.1.2
State the uses of different classes of hydraulic pumps
9.1.3
Explain the construction and working of reciprocating pumps
9.1.4
Explain the construction and working of centrifugal pumps
9.1.5
State the merits and demerits of reciprocating pump as compared
to centrifugal pump
HYDRAULIC MACHINES
10.1 Understand the working of hydraulic machines
10.1.1 Explain the working of a hydraulic press
10.1.2 Explain the working of a hydraulic ram
10.1.3 Explain the working of a hydraulic accumulator
10.1.4 Solve simple problems on hydraulic machines

RECOMMENDED BOOK:
1.
A Textbook of Hydraulics and Hydraulic machines by R.S.Khurmi.
2.
Hydraulic by E. H. LEWIT

157

MT-312

HYDRAULICS & HYDRAULIC MACHINES

LIST OF PRACTICALS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
14.
15
17.
19.
20.
21.

Solve problems on pressure, intensity of pressure

Practice for calculation of discharge/flow through venturimeter
Solve problems on hydraulic press, power required to derive it, pressure head and
pressure conversions.
Practice for calculation of co-efficient of velocity, coefficient of contraction & coefficient of discharge through orifice apparatus.
Solve problems on calculations of discharge, diameters and velocities
Solve problems on pumping power against pressure
Solve problems on conversion of velocity and velocity head.
Application of Bernoulli's equation and venturimeter. (problems solving )
Practice for the calculation of loss of head due to friction by using friction in losses in
pipe apparatus.
Solve problems on head and calculation of Cd,Cv & Cc.
Practice for calculation of loss of head due to sudden enlargement, contraction and
entrance to a pipe using friction along a pipe apparatus.
Calculation of force of jet impinging on a fixed plate using impact of jet apparatus.
Solve problems on H.P of jet and impact of jet
Sketching and study of Pelton Turbine.
Sketching and study of Francis turbine.
Sketching and study of centrifugal pump.
Sketching and study of reciprocating pump.
*************************

158

MT-323

APPLIED THERMODYNAMICS & ENERGY CONSERVATION

T
2

Total contact hrs.

Theory
Practical

P
3

C
3

64
96

Pre-requisite: Applied Physics

AIMS The students the Knowledge about temperature, heat, pressure, work, energy and power.
The student will be able to understand laws of gases, Pv diagrams of cycles, classification
and working of internal combustion engines & steam engines, apply laws to cycles of
operation of IC-Engines. The energy conservation portion of the course will provide the
student the knowledge of energy conservation products and various energy management
systems.
COURSE CONTENTS
1.

INTRODUCTION:
1.1
Definition of Thermodynamics
1.2
Units
1.2.1 Fundamental units
1.2.2 Derived units
1.3
Temperature, absolute temperature and temperature scales
1.4
Heat
1.5
Work
1.6
Power
1.7
Energy, internal energy of gas, potential energy, kinetic energy
1.8
Pressure, absolute, gauge, vacuum
1.9
Laws of Thermodynamics, first law, second law.
1.10 Law of conservation of energy

2.

LAWS OF GASES
6 Hours
2.1
Perfect gases
2.2
P.V
Diagram
2.3
Boyles's law
2.4
Charles law
2.5
General gas equation
2.6
Characteristic Equation of a gas
2.7
Specific heat of a gas
2.8
Solution of simple problems by direct application of formula and providing all
missing parameters.

3.

THERMODYNAMIC CYCLES
3.1
Type of thermodynamics Processes.

159

4 Hours

6 Hours

3.2
3.3
3.4
3.5
3.6

3.7

Working of an ideal engine

Important terms for cycles
Efficiency of a cycle
Types of Thermodynamics Processes
Otto cycle
3.6.1 Pv-diagram
3.6.2 Efficiency of otto cycle
3.6.3 Calculation of efficiency, while cylinder dia length of stroke and clearance
volume are given.
Diesel cycle
3.7.1 P-V Diagram
3.7.2 Efficiency of Diesel cycle
3.7.3 Calculation of efficiency by providing all missing parameters.

4.

BOILERS
4.1
Introduction
4.2
Classification of boilers
4.3
Working of verticle boiler
4.4
Construction and working of Scotch marine boiler
4.5
Construction and working of Lancashire boiler.
4.6
Construction and working of babcock wilcox boiler.
4.7
List boiler mountings.
4.8
Calculate boiler efficiency

5.

STEAM ENGINES.
6 Hours
5.1
Introduction.
5.2
Important parts of a steam engine.
5.3
Working of a single cylinder double acting horizontal reciprocating steam engine.
5.4
Indicator diagram.
5.5
Power developed by simple steam engine.
5.6
Calculation of IHP, while Pa, L, A and N are given.

6.

STEAM TURBINES.
6.1
Impulse turbine.
6.1.1 Introduction.
6.1.2 De-Lavel impulse turbine
6.1.3 Classification
6.1.4 Advantages over reciprocating steam engine.
6.1.4 De-Lavel impulse turbine.
6.2
Reaction Turbine
6.2.1 Introduction.
6.2.2 Parson's reaction turbine.
6.2.3 Comparison between impulse and reaction turbine.

6 Hours

7.

INTERNAL COMBUSTION ENGINES.

7.1
Classification.

8 Hours

160

10 Hours

7.2
7.3

7.4

Main components of IC-Engine.

Petrol engine.
7.3.1 PV diagram.
7.3.2 2-stroke petrol engine.
7.3.3 4-stroke petrol engine.
7.3.4 Advantages and disadvantages.
7.3.5 Calculation of IHP, while Pm, L, D and N is given.
Diesel Engine
7.4.1 Pv diagram
7.4.2 2-Stroke Diesel Engine.
7.4.3 4-stroke diesel engine.
7.4.4 Advantages and disadvantages.
7.4.5 Calculation of IHP.

8.

RECIPROCATING AIR COMPRESSORS.

5 Hours
8.1
Introduction.
8.2
Classification.
8.3
Single acting reciprocating compressors.
8.4
Work done by single stage reciprocating air-compressor.
8.4.1 Work done during Isothermal compression.
8.4.2 Work done during polytropic compression.
8.4.3 Calculation of work done by the compressor (Isothermal & Polytropic),
when initial volume, initial pressure and final pressure are given

9.

REFRIGERATION.
9.1
Introduction.
9.2
Names common refrigerants.
9.3
Properties of refrigerants.
9.4
Vapour compression refrigeration.
9.5
Vapour absorption refrigeration.

10.

ENERGY CONSERVATION
8 Hours
10.1 Energy, matter, states of matter
10.2 Source, classification & Conservation of Energy
10.3 Various checklist for different systems
10.4 Energy Management
10.5 Energy Management through preventive maintenance & Equipment scheduling
10.6 Energy Management Programme
10.7 Products of Energy Management

5 Hours

RECOMMENDED BOOKS:
1.
Text Book of Mechanical Technology (Thermal Engineering) by R.S. Khurmi.
2.
Energy Management & Conservation by Dale R Phtrick & Fardo.
3.
Applied Thermodynamics by E.H. LEWIT
4.
Thermodynamics for Engineers and Technologists by T.D. Estop and McConkey

161

MT-323

APPLIED THERMODYNAMICS & ENERGY CONSERVATION

INSTRUCTIONAL OBJECTIVES
1.

KNOW BASICS OF THERMODYNAMICS

1.1
Define Thermodynamics
1.2
Describe Fundamental units of SI
1.3
Describe Derived units of SI
1.4
Define Temperature, heat, work, power, energy and pressure
1.5
Describe laws of Thermodynamics

2.

UNDERSTAND GAS LAWS AND GENERAL GAS EQUATION

2.1
Describe Boyles law
2.2
Describe charles laws
2.3
Explain general gas equation
2.4
Explain characteristic gas equation (Derive PV=mRT)
2.5
Explain the specific heats of gases
2.6
Explain the relationship between specific heat at constant pressure and specific
heat at constant volume
2.7
Solve simple problems based on above topics

3.

THERMODYNAMICS CYCLES
3.1
Understand different thermodynamic air cycles
3.1.1 Name the different thermodynamic processes
3.1.2 Define the thermodynamic processes mentioned in 3.1.1 above
3.1.3 Explain the working of Carnot cycle
3.1.4 Describe the formula for thermal efficiency of Cornot cycle

4.

3.2

Understand Otto Cycle

3.2.1 Sketch PV diagram
3.2.2 Explain Otto cycle with the help of PV diagram
3.2.3 Derive formula for Air Standard efficiency of Otto cycle.
3.2.4 Solve simple problems based on efficiency of Otto cycle.

3.3

Understand Diesel cycle

3.3.1 Sketch PV diagram.
3.3.2 Explain diesel cycle with the help of PV diagram.
3.3.3 Derive formula for Air Standard efficiency.
3.3.4 Solve simple problems of Air Standard efficiency of diesel cycle.

BOILERS
4.1
Understand Steam

162

4.1.1

4.1.2
4.1.3
4.1.4
4.2

5.

Define the following:

a) Wet saturated steam
b) Dry saturated steam
c) Supper heated steam
Total heat contents present in the steam
Explain dryness fraction
Solve problems on steam

Understand Boilers types, their construction, working and efficiency.

4.2.1 State use of boiler.
4.2.2 Describe classification of steam boilers.
4.2.3 Explain construction and working of vertical boiler.
4.2.4 Explain construction and working multi-tubular boiler(Cochran)
4.2.5 Sketch marine boiler.
4.2.6 Describe construction and working marine boiler.
4.2.7 Sketch Lancashire boiler.
4.2.8 Describe construction and working of Lancashire boiler
4.2.9 Sketch Babcock Wilcox boiler.
4.2.10 Describe construction of Babcock & Wilcox boiler.
4.2.11 Explain types and uses of following boiler mountings and accessories:
i.
Pressure gauges
ii.
Thermometers
iii.
Water column
iv.
Low water level cutout
v.
Steam super heaters
vi.
Economizers
vii.
Air heaters
viii. High pressure cutout
ix.
Boiler blow down valve
x.
Steam safety valves
xi.
Baffle plates
xii.
Steam water walls
xiii. Boiler feed water pump and check valve
xiv.
Boiler water treatment system
xv.
Boiler feed water storage tank and heater
xvi. Steam stop, safety blow-off valve/fusible plugs
xvii. Boiler burners and ignition system
4.2.12 Describe formula of boiler efficiency.
4.2.13 Solve simple problems on boiler efficiency.

STEAM ENGINES.
5.1
Sketch and label
5.1.1 Single cylinder double acting horizontal reciprocating steam engine
5.1.2 Explain the working of the above steam engine

163

5.1.3
5.1.4
5.1.5

Describe the procedure of obtaining an engine indicator diagram of steam

engine
Explain determining IHP from an indicator diagram
Solve problems on IHP and BHP of steam engine

6.

TURBINES
6.1
Understands classification of steam turbine.
6.1.1 State classification of steam turbines
6.1.2 Describe the compounding of steam turbines.
6.1.3 Explain the working of Impulse turbine.
6.1.4 Explain the working of Reaction turbine
6.1.5 Describe the advantages of steam turbine over reciprocating steam
engines.
6.2
Understand gas turbines
6.2.1 Describe gas turbine
6.2.2 State classification of gas turbine
6.2.3 Explain cycle of gas turbine
6.2.4 Describe uses of gas turbine

7.

INTERNAL COMBUSTION ENGINES.

7.1
Understand Internal Combustion Engine.
7.1.1 Describe the main classification of IC engines.
7.1.2 Explain the main components of IC engines.
7.1.3 Explain the principle of operation of corroborator
7.1.4 Explain cooler, turbo and scavenger

8.

7.2

Understand Petrol Engine.

7.2.1 Sketch pV-diagram (actual)
7.2.2 Explain working of 2 stroke engine.
7.2.3 Explain working of 4 stroke engine.
7.2.4 Explain formula for IHP of IC engine.
7.2.5 Solve simple problems based on above formula.

7.3

Understand Diesel Engine.

7.3.1 Sketch pV-diagram (actual).
7.3.2 Explain working of 4 stroke diesel engine.
7.3.3 Solve some more problems on calculation of IHP of IC engines.
7.3.4 Describe difference between Petrol and Diesel engines.

UNDERSTAND AIR COMPRESSORS.

8.1
Describe use of air compressors.
8.2
Describe classification of air compressors.
8.3
Explain work done for a single stage reciprocating air compressor (Isothermal +
Polytropic).
8.4
Solve simple problems on work done.

164

9.

UNDERSTAND REFRIGERATION CYCLES.

9.1
Describe refrigeration.
9.2
Enlist commonly used refrigerants
9.3
Describe properties of a refrigerant.
9.4
Explain vapour compression cycle.
9.5
Explain vapour absorption cycle.

10.

ENERGY CONSERVATION
10.1 Know Energy Basics
10.1.1 Describe matter, states of matter, composition of matter
10.1.2 Describe Molecular motion, kinetic Theory
10.1.3 Describe Heat Energy, Heat transmission
10.1.4 Describe Energy and its importance
10.1.5 Describe Source of energy
10.1.6 Describe classification of Energy
10.1.7 Describe conservation of Energy
10.2 Understand various Energy Conservation checklist
10.2.1 Explain Energy conservation checklist for Heating systems
10.2.2 Explain Energy conservation checklist for Air conditioning systems
10.2.3 Explain Energy conservation checklist for Lighting system
10.2.4 Explain Energy conservation checklist for Water systems
10.2.5 Explain Energy conservation checklist for solar systems
10.3 Understand Energy Management Systems
10.3.1 Define Basic Terminology of Energy Management
10.3.2 Describe Energy Management
10.3.3 Describe Economic Aspect of Energy Management
10.3.4 Explain Energy Management Team work and Energy Audit
10.3.5 Explain Energy saving Through preventive Maintenance
10.3.6 Explain Energy saving Through Equipment Scheduling
10.3.7 Explain Energy Management Programme
10.4 Know Products for Energy Conservation
10.4.1 Enlist products for Energy conservation
10.4.2 Describe cogeneration systems
10.4.3 Describe water-pressure-Reduction valves
10.4.4 Describe computerized Energy Management systems.
******

165

MT-323

APPLIED THERMODYNAMICS & ENERGY CONSERVATION

LIST OF PRACTICALS
1.
2.
3.
4.
5.
6.
7.
8.
9
10.
11.
12.
13.
14.

96 Hours

Sketch & study of Pressure gauge

Sketch & study of water level indicator
Sketch & study of feed pump
Sketch & study of injector
Sketch & study of safety valve
(a)
Spring loaded
(b)
Dead weight
Sketch & study of simple vertical boiler and its accessories and mountings
Sketch & study of multi-tubular vertical boiler and its accessories and mountings.
Sketch and study of Scotch marine boiler and its accessories and mountings.
Sketch & study of Lancashire Boiler and its accessories and mountings.
Sketch & study of Locomotive Boiler and its accessories and mountings
Sketch & study of Babcock & Wilcox Boiler and its accessories and mountings
Sketch & study of Steam engine and its parts, accessories and mountings
Sketch & study of Internal combustion engine & its parts.
(a)
Petrol engine
(b)
Diesel engine
Sketch and study of reciprocating air compress
*************

166

MT-332

INDUSTRIAL ENGINEERING
(INDUSTRIAL PLANNING & PRODUCTION METHOD)
T
1
Total contact hrs.
Theory
32
Practical
96

P
3

C
2

AIMS At the end of this course the students will be able to :i.
Understand the fundamentals of planning of the industrial concern.
ii.
Understand and appreciate the methods generally employed in various categories
of manufacturing operations for economic production.
COURSE CONTENTS
1.

INDUSTRIAL PLANNING
1.1
Need of industrial planning
1.2
Financial planning, product planning, process planning

2.

SITE SELECTION OF INDUSTRY

2 Hours
2.1
Elements of site selection (labour availability, transportation, electricity,
availability of raw materials, consumption products

3.

PLANT LAY-OUT
3.1
Nature
3.2
Purpose
3.3
Types of plant lay-out and elements.

4.

FACTORS INFLUENCING PLANT LAY-OUT

Hours
4.1
Raw materials, machinery, tools and equipments
4.2
Man power
4.3
Movement
4.4
Service
4.5
Building, plant modification, zoning
4.6
Process requirements
4.7
Safety
a)
Man
b)
Material/machines

5.

PLANNING FOR MAINTENANCE ACTIVITIES

5.1
Maintenance plan
5.2
Forms for schedule of activities

2 Hours

6.

CLASSIFICATION OF MECHANICAL PRODUCTS

6.1
Classification and types of Mechanical products

2 Hours

167

2 Hours

2 Hours

7.

COST
7.1
Item Cost
7.2
Total Cast
7.3
Cost comparison

3 Hours

8.

PRODUCTION METHOD
8.1
Production
8.2
Types of production

2 Hours

9.

JOB ANALYSIS
9.1
Motion study
9.2
Time study

3 Hours

10.

TOTAL LABOUR TIME

10.1 Labour
10.2 Calculation of total labour time
10.3 Flow process chart
10.4 Waste time study

3 Hours

11.

PRODUCTION CONTROL
11.1 Routing
11.2 Scheduling
11.3 Despatching

3 Hours

12.

PRODUCTION TOOL
12.1 Cost control with Jigs.
12.2 Cost control with Fixture

2 Hours

13.

STORE OPERATION AND MAINTENANCE

13.1 Receipt of stores
a)
Raw material
b)
Finished material
13.2 issue of stores
13.3 Indents, store cards

2 Hours

Reference Books:
i.
Motion and time study by Ralph M. Barnes
ii.
Plant Layout and design by Moore

168

MT-332

INDUSTRIAL ENGINEERING

INSTRUCTIONAL OBJECTIVES
1.

Understand the principles of INDUSTRIAL PLANNING

1.1
Define planning
1.2
Describe need of planning in industries
1.3
Describe the steps of financial planning
1.4
Describe product Planning
1.5
Describe product planning
1.6
Describe the producer of product planning
1.7
State the factors to be considered in selection of plant and equipment

2.

KNOW THE SALIENT FEATURES OF THE SELECTION OF SITE TO A

FACTORY
2.1
Explain the factors to be considered while selecting site for factory

3.

UNDERSTAND THE PURPOSE OF PLANT LAYOUT

3.1
Describe the need and importance of plant layout
3.2
Describe the types of layout
3.3
Explain Elements of layout
3.4
Explain influence of nature of product on plant layout
3.5
Explain the merits and demerits of product layout as compared to process layout

4.

FACTORS OF PLANT LAYOUT

4.1
Understand the factors involved in plant layout
4.1.1 Describe step by step Movement of raw material from receipt to delivery
in workshop
4.1.2 State the codel space requirements for standard machine tools and
equipments
4.1.3 Describe the factors of process requirements which affect plant layout
4.1.4 Describe the factors of plant layout that should be kept in mind for
a)
future expansion
b)
plant modification
c)
safety of men, material and machine
4.2

5.

Understand the factors involved in planning for layout

4.2.1 State method of gathering data about industry.
4.2.2 Explain the importance of develop
4.2.3 Compare alternate layouts and select the correct layout

PLANNING FOR MAINTENANCE ACTIVITIES

169

5.1

Know the planning for maintenance activities

5.1.1 State the schedule for maintenance on
a) daily basis
b) weekly basis
c) monthly basis
d) quarterly basis
e) yearly basis
5.1.2 Describe the plan for emergency maintenance

5.2

Know the maintenance plan

5.2.1 Describe plan for emergency maintenance

6.

MECHANICAL PRODUCT & PLANNING

6.1
Define mechanical products
6.2
Explain role of mechanical products On planning

7.

COST AND PURCHASE CONTROL

7.1
Know the costs involved in production
7.1.1 Know the costs involved in Production
7.1.2 Define
a) Direct cost
b) Indirect cost
c) Direct material
d) Indirect material
e) Director labour
f) Indirect labour
g) Fixed cost
h) Variable cost
i) Over head expenses
7.1.3 Name the cost involved in
a) Shop cost
b) Factory cost
c) Cost to make up and sell
d) Total cost
e) Sale price
7.1.3 Explain cost comparison
7.2

8.

Understand purchase control

7.2.1 Enlist the types of purchasing
7.2.2 Define the types of purchasing identified under 7.2.1.
7.2.3 Explain the necessity of different types of purchasing
7.2.4 State the duties of purchase department
7.2.5 Explain the merits and demerits of different types of pruchasing
TYPES OF PRODUCTION
8.1
Understand types of production
8.1.1 Define

170

8.1.2
8.1.3

a)
Mass production
b)
Batch production
c)
Job order production
State the condition when each type of production is under taken
Explain the merits of each type of production listed in 8.1.1

9.

TIME STUDY
9.1
Understand time study
9.1.1 Define time study
9.1.2 Name the different methods of timing
9.1.3 State the merits and demerits of each type of timing
9.1.4 Define the various allowances that are added to get the
standard allowed time
9.2
Describe the history of Gilberth.
9.3
Instrument used in motion study like - stop watch - motion picture camera - use
of bulb - chrono - cycle graph.
9.4
Explain different symbols of micro-motion A.S.M.E. symbols and Therbliges.
9.5
Describe time study.
9.6
State history of Taylor movement.
9.7
Describe the use of time study
9.8
Describe time study equipment
9.9
State the points for time study
9.10 Explain time study with observation board.

10.

MOTION STUDY
10.1 Understand the motion study
10.1.1 Define motion study and micro motion study
10.1.2 Describe the rules for arrangement of work place for motion economy
10.1.3 Describe the rules for economic movement of human body
10.1.4 Name the equipment used for time and motion study
10.1.5 Draw the ASME symbols and therbligs for micro motion study
10.1.6 Describe
a)
flow process chart
b)
Gantt machine load chart
c)
Men and machines motion chart
d)
Left hand and right hand motion chart
10.2 Define operation, transportation inspection and maintenance time.
10.3 Estimate standard time for a job
10.4 Explain flow process chart.
10.5 Explain waste time study.
PRODUCTION CONTROL.
11.1 Understand production control
11.1.1 Define
a) Rouding
b) Schedduling
c) Dispatching

11.

171

11.2
11.3
12.

d) Follow up
11.1.2 State the information contained in a rout sheet
Explain method of receipt and issue of material.
Describe of standard forms used in stores.

INVENTORY CONTROL
12.1 Understand store operations
12.1.1
State the duties and responsibilities of a store keeper
12.1.2
Describe the forms used for receipt and issue of materials
12.2
12.2.1
12.3
12.4

13

Understand Inventory Control

Describe the duties of inventory control department
Differentiate between jig & fixture
State uses of jig & fixture in production industry

KNOW STORE OPERATION AND MAINTENANCE

13.1 Describe Issue receipt of raw product
13.2 Describe Issue receipt of finished products
13.3 Describe indent and indenting
13.4 Describe store costs

REFERENCE BOOKS:
1.
2.

Motion and Time study by RALPH M.BARNES

Plant layout and Design by MOORE

172

MT-332

INDUSTRIAL ENGINEERING

LIST OF PRACTICAL
96 Hours
1.
Sketch layout of shops of Technology
2.
Planning of shop layout
3.
Draw and discuss administrative chart
4.
Study of Institutes stores
5.
Visit of cement factory/sugar mill/Ghee/Fertilizer Factory.
6.
Preparation of process chart/flow chart
7.
Preparation the chart of symbols:
a.
ASME (American society of mechanical engineering)
b.
Therebligs
8.
Preparation of activity chart
9.
Problems on time study
10.
Preparation of process charts
11.
Preparation of man land machine charts
12.
Preparation of operation chart
13.
Visit to production factory, paper and board mills, cycle, fan, pump, sewing machine
factory, etc.
14.
Writing report critically analyzing the production process of the factory visited
15.
Preparations of a chart for calculating the actual time spent on the job.
16.
Preparation of an observation chart
17.
Preparation of a job analysis sheet

173

MT-343

MACHINE DESIGN
T
2

P
3

C
3

Total contact hrs.

Theory : 64
Practical : 96
Pre-requisite: Applied Mechanics
AIMS At the end of the course the student will:
1.
Acquire practice in analyzing stresses set-up in Machine parts.
2.
Practice design of welded joints, pressure vessels, shafts, helical springs and spur
gears.
COURSE CONTENTS
1.

SIMPLE STRESSES IN MACHINE PARTS.

8 Hours
1.1
Load and its types.
1.2
Stress and strain.
1.3
Tensile stress and strain.
1.4
Compressive stress and strain.
1.5
Modulus of elasticity.
1.6
Shear stress and strain.
1.7
Modulus of rigidity.
1.8
Stress-strain diagram.
1.8.1 Proportional limit.
1.8.2 Elastic Limit.
1.8.3 Yield Point.
1.8.4 Ultimate stress.
1.8.5 Breaking stress.
1.8.6 Percentage reduction in area.
1.9
Working stress.
1.10 Factor of safety
1.11 Solution of simple problems of the above topics by direct application of formula.

2.

PRESSURE VESSELS.
2.1
Introduction.
2.2
Classification of pressure vessels.
2.2.1 According to dimensions.
2.2.2 According to End-construction.
2.3
2.4

6 Hours

Stresses in a thin cylindrical shell due to internal pressure.

2.3.1 Hoop stress.
2.3.2 Longitudinal stress.
Calculation of thickness of cylinder by direct application of formula, while all

174

2.5
2.6
2.7
2.8
2.9

parameters are provided (eg. p, d, hoop or longitudinal stress are given).

Calculation of hoop or longitudinal stress by direct application of formula, while
p, d, t are given.
Thin spherical shells subjected to internal pressure.
Calculation of thickness of spherical shell when all other parameters are provided,
by direct application of formula
Thick cylindrical shell subjected to internal pressure.
Calculation of thickness from above formula, while all other parameters are
given.

3.

WELDED JOINTS.
8 Hours
3.1
Advantages and disadvantages.
3.2
List types of various welding joints.
3.3
Strength of transverse fillet welded joint.
3.4
Strength of parallel fillet welded joint.
3.5
Calculation of length of weld, when load, plate thickness, plate width, shear stress
are given.

4.

SCREWED JOINTS.
4.1
Introduction .
4.2
Advantages and disadvantages
4.3
Definitions.
4.3.1 Major diameter.
4.3.2 Minor diameter.
4.3.3 Pitch diameter
4.3.4 Pitch
4.3.5 Lead.
4.4
Stress in screwed fastening due to static loading.
4.5
Initial stress due to screwing up forces.
4.6
Solution of simple problem by direct formula application.
KEYS & COTTERS
5.1
Introduction.
5.2
Types of keys & cotters.
5.3
Sunk keys.
5.3.1 Rectangular
5.3.2 Square.
5.3.3 Parallel
5.3.4 Gib-head
5.3.5 Feather
5.3.6 Wood-ruff.
5.4
Forces acting on a sunk key
5.5
Strength of a sunk key.
5.6
Calculate length of sunk key by direct application of formula, while all
parameters. are directly provided.
5.7
Calculate the dia of cotter pin

5.

175

8 Hours

8 Hours

6.

SHAFTS & COUPLINGS.

12 Hours
6.1
Introduction
6.2
Material Used For Shaft
6.3
Types Of Shafts.
6.4
Standard sizes.
6.5
Stress in shafts.
6.6
Shafts subjected to twisting moment.
6.6.1 Solid shaft.
6.6.2 Hallow shaft.
6.7
Calculate diameter of solid and hollow shafts by direct application of formula.
6.8
Shafts subjected to bending moment
6.8.1 Solid shaft.
6.8.2 Hollow shaft.
6.9
Calculate diameter of solid and hollow shaft (bending only) by direct application
of formula.
6.10 Introduction of coupling
6.11 Types of couplings
6.12 Calculations of proportional sizes of Flange Coupling

7.

SPRINGS.
8 Hours
7.1
Introduction
7.2
Types of springs.
7.2.1 Helical spring.
7.2.2 Leaf spring.
7.4
Material for helical springs.
7.4.1 Solid length.
7.4.2 Free length.
7.4.3 Spring index
7.4.5 Pitch.
7.5
Stress in helical springs of circular wire, solution of problems on helical strengs of
circular wire by direct application of formula
7.6
Solution of simple problem on helical springs of circular wire by direct
application of formula with or without compression & also problems on torsion
springs & spiral spring.

8.

SPUR GEAR.
8.1
Introduction.
8.2
Friction wheels
8.3
Classification of gears.
8.4
Terminology of gears.
8.4.1 Pitch circle.
8.4.2 Pitch circle diameter.
8.4.3 Pitch point.

6 Hours

176

8.5
8.6

8.4.4 Addendum circle.

8.4.5 Dedendum circle.
8.4.6 Circular pitch.
8.4.7 Diameteral pitch.
8.4.8 Module.
8.4.9 Clearance.
8.4.10 Tooth thickness.
8.4.11 Tooth space.
System of gear teeth.
Gear material.

177

MT-343

MACHINE DESIGN

INSTRUCTIONAL OBJECTIVES
1.

2.

SIMPLE STRESSES IN MACHINE PARTS.

1.1
Review common terms of mechanics
1.1.1 Define load
1.1.2 Describe types of load
1.1.3 Define stress and strain
1.1.4 Define tensile stress and strain
1.1.5 Define compressive stress and strain
1.1.6 Describe modulus of elasticity
1.1.7. Describe modulus of rigidity.
1.1.8 State & apply relationship between modilli & poison's ratio
1.2

Interpret stress - strain diagram

1.2.1 Sketch stress strain diagram
1.2.2 Define proportional limit, elastic limit, yield point, ultimate stress,
breaking stress
1.2.3 Describe percentage reduction in area.

1.3

Apply hook's law equation to evaluate the missing parameter.

1.3.1 Define working stress
1.3.2 Define factor of safety
1.3.3 Describe working/safe/design/permissible stress/allowable stress
1.3.4 Compute modulus of elasticity using Hook's Law
1.3.5 Solve simple problems on Stress, strain, Poisson's Ratio & modulli

INTRODUCTION TO PRESSURE VESSELS

2.1
Know basic concepts of pressure vessels.
2.1.1 Define pressure vessel
2.1.2 Describe types of pressure vessels
2.1.3 Describe pressure vessel according to end-construction
2.1.4 Describe pressure vessel according to dimensions.
2.1.5 Describe the use of pressure vessels
2.1.6 Define hoop stress
2.1.7 Define longitudinal stress
2.1.8 Describe formula of longitudinal stress
2.2
Solve problems on hoop stress in designing thin cylinders
2.2.1 State all parameters used in hoop stress formula (P, d, t, , ft.)
2.2.2 State hoop stress formula (ft, = pd/2tn)
2.2.3 Compute thickness of thin cylinder, while p,d, ft, and are given.
2.2.4 Compute hoop stress, when p, d, t, are know
2.2.5 Compute diameter of thin cylinder when p, t, ft, are provided.
2.3

Solve problem on longitudinal stress in designing thin cylinders.

178

2.3.1
2.3.2
2.3.3
2.3.4
2.3.5

3.

2.4

Understand spherical shell

2.4.1 Describe spherical shell formula
2.4.2 Explain terminology of the formula
2.4.3 Compute thickness of spherical shell

2.5

Solve problems of thick cylinder.

2.5.1 Describe formula
2.5.2 Explain terms used in the formula
2.5.3 Compute any one missing parameter of the formula when all others are
provided.

WELDED JOINTS.
3.1
Understand welded joints.
3.1.1 State advantages & disadvantages of welded joints.
3.1.2 Describe welding processes
3.1.3 Explain types of welded joints
3.2

4.

State all parameters use in longitudinal stress formula (p,d, t, n, ft )

Describe hoop and longitudinal stress formula
Compute longitudinal stress, when p,d, t and are given
Compute thickness of thin cylinder when p, d, ft, and are provided.
Describe the importance of hoop stress in designing thin cylinders.

Apply formula for calculation of length of weld for parallel and transverse
fillet welded joint
3.2.1 Describe formula used for transverse fillet welded joints.
3.2.2 Explain terms used in the formula
3.2.3 Compute length of weld from above formula
3.2.4 Describe formula for parallel fillet welded joint.
3.2.5 Explain terms used in formula
3.2.6 Compute length of weld from above formula

SCREWED JOINTS
4.1
Understand screwed joints.
4.1.1 Describe advantages of screwed joints
4.1.2 Describe disadvantages of screwed joints.
4.1.3 Define various terms used in screw joints.
4.1.4 State difference between major and minor diameters.
4.1.5 Name stresses set-up due to screwed joints.
4.1.6 Explain initial stresses due to screwing up forces.
4.1.7 Calculate stress set-up due to inial tightening
4.2
Solve problems on stresses in the bolts due to external forces.
4.2.1 Describe tensile stress effect
4.2.2 Explain formula
4.2.3 Describe shear stress effect
4.2.4 Explain formula

179

4.2.5
5.

KEYS & COTTERS

5.1
Understand keys, Cotters and their types.
5.1.1 Define key & cotter
5.1.2 Explain types of keys commonly used
5.1.3 Sketch various types of sunk keys
5.1.4 Explain the forces acting on a sunk key.
5.1.5 Explain cotter pins & their uses
5.2

6.

Solve simple problems based on above two types of formula

Solve problems on determining length of sunk keys.

5.2.1 Explain formula for calculation of length of a sunk key
5.2.2 Describe various terms used in formula.
5.2.3 Compute length of sunk key when all other parameters are provided.

SHAFTS & COUPLINGS

6.1
Understand shafts and their types.
6.1.1. Define shaft
6.1.2 Describe material used for shaft
6.1.3 Describe standard sizes of shafts
6.1.4 Explain types of shafts.
6.2

Solve problems on design of solid shaft subjected to bending moments and

twisting moments
6.2.1 State formula for design of solid shaft subjected to twisting moment
6.2.2 Explain terms used in the formula
6.2.3 Solve simple problems based on above formula
6.2.4 State formula for design of solid shaft subjected bending moment.
6.2.5 Explain terms used in the formula
6.2.6 Solve simple Problems

6.3

Solve problems on design of hollow shafts subjected to bending moments and

twisting moments
6.3.1 State formula for hollow-shafts subjected to twisting moment
6.3.2 Explain terminology of above formula
6.3.3 Solve simple problems based on above formula
6.3.4 Describe formula for hollow shafts subjected to bending moment
6.3.5 Explain terminology of formula
6.3.6 Solve simple problems based on formula of hollow shafts subjected to
bending moment only.
Understand coupling & their types
6.4.1 Describe coupling
6.4.2 Classify couplings
6.4.3 Solve problems on calculation of size & no. of bolts in flange coupling
6.4.4 Solve problems on proportional sizes of flange coupling

6.4

180

7.

UNDERSTAND SPRINGS
7.1
Describe function of springs in machine elements
7.2
Describe types of springs.
7.3
State material used for springs.
7.4
Explain terminology used for springs.
7.5
Explain stresses induced in helical springs of circular wire
7.6
Solve simple problems on Helical spring

8.

UNDERSTAND PROBLEMS ON GEARS

8.1
Describe friction wheels.
8.2
State classification of gears.
8.3
Explain terminology of gears commonly used in gear design.
8.4
Explain systems of gear teeth
8.5
Describe different types of materials for a variety of gear types
8.6
Solve simple problems to calculate diametral pitch, circular pitch, no. of teeth,
module etc.

RECOMMENDED BOOK:
1.
A Text book of Machine Design by R.S. Khurmi.
2.
A Text book on Machine Design by Winston

181

MT-343

MACHINE DESIGN

LIST OF PRACTICALS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

96 hours

Solve problems on calculation of stress, strain, modulus of elasticity, % elongation, %

reduction, FOS, ultimate stress, bearing stress.
Design of simple compression members
Design of simple tension members
Calculate force required to punch a hole.
Solve problems for calculation of thickness of Thin cylinders.
Solve problems in calculating thickness for Thick cylinders.
Solve problems for calculating thickness of Spherical shell.
Calculate length of weld for welded joint.
Solve problems on stress setup due to initial tightening of screws by direct application of
formula.
Sketch various types of sunk keys & cotters.
Calculate length of a sunk key by direct application of formula.
Calculate diameter of solid shafts subjected to twisting moment.
Calculate diameter of hollow shafts subjected to twisting moment.
Calculate diameter of solid shaft subjected to bending moment & calculate dia of shaft
subjected to both bending & twisting.
Calculate diameter of hollow shafts subjected to bending moment only.
Calculate Helical spring wire-diameter by direct formula application in different
situations & also simple calculations on helical, torsion & spiral spring.
Solve problems on calculation of size and number of bolts in flange coupling.
Sketch spur gear indicating various terms on sketch of spur gears.

182

MT-353

TOOLS DESIGN AND MAKING

T
2

P
3

C
3

Total contact hrs.

Theory
64
Practicals
96
Pre-requisite Drawing & CAD I, Engg. Drawing & CAD II
AIMS At the end of the course, student should be able to:
1.
Know the importance of tool design and tool making
2.
Principles of designing jigs and Fixtures with their types.
3.
Design dies and punches, cutting tools.
4.
Understand manufacturing operation like blanking Piercing, Bending, Drawing
and Forming.
COURSE CONTENTS
1.

JIGS AND FIXTURES DESIGN.

1.1
Classification of jigs & fixtures.
1.2
Details of jigs & fixtures.
1.3
Material of jigs & fixtures.
1.4
Design Procedure.
1.5
Jig support locking pin, jig feet, Nuts, spring, washers.
1.6
Clamping and locating devices, stoppers.

2.
TOLERANCE AND ALLOWANCE.
Hours
2.1
Fits and its classification.
2.2
Tolerance.
2.3
Allowances.
3.

PRESS AND PRESS - WORK.

3.1
Introduction to terminology.
3.2
Mechanical press.
3.2.1 O.B Press.
3.2.2 Screw Press.
3.3
Hydraulic Press.
3.4
Multi Operation Press.

4.

MANUFACTURING OPERATIONS.
4.1
Blanking.
4.2
Piercing.
4.3
Bending.
4.4
Drawing.
4.5
Forming/embossing.

4 Hours

8 Hours

183

10 Hours

5.

CUTTING TOOL DESIGNS.

5.1
Classification of cutting tool.
5.2
Single and multi edge cutting tool.
5.3
Carbide tipped cutting tool.

6.

PUNCHES AND DIE-DESIGN.

6.1
Classification of punches.
6.2
Types of punches.
6.3
Types of Dies.
6.4
Punch and die design procedure.

10 Hours

7.

STEEL USED IN TOOL MAKING

7.1
SAE & AISI standards
7.2
Chemical composition
7.3
Heat treatment of tool-steel

10 Hours

8.

CAMS & FOLLOWERS

8.1
Cams & its types
8.2
Followers & its types
8.3
Cam profile design

10 Hours

RECOMMENDED BOOK:
1.
Tool Design by Donaldson.

184

6 Hours

MT-353

TOOLS DESIGN AND MAKING

INSTRUCTIONAL OBJECTIVES (MT-353)

1.

2.

JIGS AND FIXTURE DESIGN

1.1
Understand Jigs and Fixture Design
1.1.1 Define jigs and fixture
1.1.2 Distinguish between jigs and fixtures
1.1.3 Explain jigs
1.1.4 Explain fixtures
1.2

Understand different parts of jigs & Fixtures

1.2.1 Describe parts of jigs
1.2.2 Explain function of each part
1.2.3 Describe parts of fixtures
1.2.4 Explain function of each part

1.3

Understand different materials used in jigs and fixture

1.3.1 Enlist different materials
1.3.2 Describe the properties of each with respect to jigs and Fixtures
1.3.3 Select the best material

1.4

Understand design procedure.

1.4.1 Out line the design detail
1.4.2 Convert the outline into concrete form.

1.5

Understand jig support, Locking pin, jig feet, nuts, spring and washers.
1.5.1 Enlist different types of jig supports
1.5.2 Explain each with the help of sketch
1.5.3 Enlist different types oflocking pins
1.5.4 Explain each with the help of sketch
1.5.5 Enlist different types ofjig feet
1.5.6 Explain each with the help of sketch
1.5.7 Enlist different types ofnuts, spring washers.
1.5.8 Explain each

1.6

Understand clamping, locating devices, stoppers.

1.6.1 Enlist different types of clamping devices.
1.6.2 Explain each with the help of sketch
1.6.3 Enlist different types of locking device
1.6.4 Explain each with the help of sketch
1.6.5 Enlist different types of stoppers
1.6.6 Enlist each with the help of sketch

TOLERANCE AND ALLOWANCES.

185

3.

4.

2.1

Understand fits/its classification

2.1.1 Define fit
2.1.2 Describe types of fits
2.1.3 Explain uses of different types of fits.

2.2

Understand tolerance
2.2.1 Define tolerance
2.2.2 Describe different types of tolerance
2.2.3 Select tolerance for shaft and holes

2.3

Understand allowances.
2.3.1 Explain importance of allowances
2.3.2 Explain negative allowance.

PRESS AND PRESS WORK

3.1.
Knows the basic terminology
3.1.1 Enlist different terms used in press work.
3.1.2 Describe briefly each term
3.2

Understand basic principles of OB press

3.2.1. List different parts
3.2.2 Explain functions of each part and working principle

3.3

Understand Screw Press

3.3.1 List different parts.
3.3.2 Explain function of each part.

3.4

Understand the principle and working of hydraulic press

3.4.1 Enlist parts of hydraulic press
3.4.2 Explain function of each part
3.4.3 Explain overall working of a hydraulic press
3.4.4 Describe uses of hydraulic press

3.5

Understand Multi operation press

3.5.1 Describe difference between the single & multi-operation press
3.5.2 Enlist uses of multi operation press.
3.5.3 Explain the working of multi operation press
3.5.4 Explain press-tonnage, stroke, shut height and Die-space

MANUFACTURING OPERATIONS
4.1
Understand blanking operations
4.1.1 Define blanking
4.1.2 Name the steps in blanking operation in sequence
4.1.3 Explain the blanking operation.
4.2

Understand piercing operations

186

4.2.1
4.2.2
4.2.3

5.

6.

Define piercing
Name the steps in piercing operations
Explain the piercing operation

4.3

Understand bending operation

4.3.1 Define bending
4.3.2 name the steps in bending operation
4.3.3 Explain the bending operation

4.4

Understand drawing operation

4.4.1 Define drawing
4.4.2 Name steps in drawing operation
4.3.3 Explain the drawing operation

4.5

Understand forming & embossing.

4.5.1 Define forming & embossing.
4.5.2 Name the steps in forming & embossing.
4.5.3 Explain forming & embossing.

CUTTING TOOL DESIGN.

5.1
Understands cutting tools.
5.1.1 Define cutting tools.
5.1.2 Define different angles of cutting tool.
5.1.3 Identify material used.
5.2

Understand Cutting edges.

5.2.1 Distinguish between single and multi cutting edges
5.2.2 Explain uses of single and multi edges.
5.2.3 Describe the material used.

5.3

Understand Carbide Tipped cutting tool (CTCT).

5.3.1 Describe C.T.C.T.
5.3.2 Explain advantages.
5.3.3 Explain uses of CTCT

PUNCHES AND DIE DESIGN.

6.1
Understand punches.
6.1.1 Define punch.
6.1.2 Describe types of punches.
6.1.3 Explain single & compound punches
6.1.4 Enlist material used for punch.
6.2

Understand Dies.
6.2.1 Define Die.
6.2.2 Describe types of die.

187

6.2.3
6.3

7.

Understand die and punch design procedure.

6.3.1 Describe die and punch design.
6.3.2 Outline design details.
6.3.3 Explain the design procedures.
6.3.4 Describe constructing a simple single punch die
6.3.5 State precision-ness

STEEL USED IN TOOL MAKING

7.1
Understand SAE, AISI steel classification
7.1.1 State SAE & AISI
7.1.2 Explain chemical composition of SAE & AISI steels
7.1.3 Describe SAE & AISI steel
7.2

8.

Enlist material used for dies.

Understand Heat-treatment of Tool-steel.

7.2.1 State annealing of tool steel
7.2.2 Explain hardening of tool steel
7.2.3 Explain tempering of tool steel
7.2.4 Explain the need of heat treating tool steel

CAMS & FOLLOWERS

8.1
Understand cam & its uses
8.1.1 Define cam
8.1.2 Explain types of cams.
8.1.3 Explain uses each type of cam.
8.2

Understand followers & its uses

8.2.1 Define follower
8.2.2 Explain types of followers
8.2.3 Compare types of followers

8.3

Understand profiles of cams

8.3.1 Explain various profiles of cams
8.3.2 Describe the methods of drawing cam profiles

RECOMMENDED BOOK
1.
Tool Design by Donaldson

188

MT-353

TOOLS DESIGN AND MAKING

LIST OF PRACTICALS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

96 Hours

Sketching of angle jig

Sketching of milling fixture.
Sketching of turning fixture.
Sketching of different standard parts of jig & fixture.
Application of unilateral tolerance for different sizes of
shafts and holes
Application of bilateral tolerance for different sizes of shafts and holes
Sketching of OBI press with its nomenclature
Sketch; of screw press with it nomenclature.
designing of stock strip for making washer of 40 mm. Outer diameter (Blanking
operation) and 20 mm. inner dia (piercing operation).
Sketching of the operated die for (bending, drawing, forming) operation.
sketch of a single point cutting tools for lathe machine with its nomenclature sketching.
Sketching of a carbide tipped cutting tool
Sketching of multi point cutting tool (twist drill of 25mm size)
Sketching of a blanking die for making a blank of 30 mm diameter and 2mm thick round
workpiece.
sketching of a progressive die for making washer of 40mm outer diameter and 20mm
minor diameter and 2mm thickness.
Sketch of different types of cams
Sketch of different types of followers
Cam profile design
Practical-18 continued
Practical-18 continued

189

MT-362

MATERIALS TESTING AND HEAT TREATMENT

T
1

Total contact hrs

Theory
Practicals

P
3

C
2

32
96

Pre-requisite: Mechanics, Metallurgy

AIMS After going through this course, student will be able to :
1.
Understand Destructive & non-destructive Test
2.
Understand working of testing equipment
3.
Know the basic Theories of heat Treatment processes
4.
Understand common heat treatment processes
5.
Understand common heat treatment processes of non ferrous metals
COURSE CONTENTS
(A)

MATERIAL TESTING

1.

INTRODUCTION
1.1
Mechanical properties of materials
1.1.1 Hardness
1.1.2 Toughness
1.1.3 Ductility
1.1.4 Brittleness
1.1.5 Elasticity
1.1.6 Plasticity
1.2
Destructive and non destructive tests
1.3
List of destructive and non-destructive tests

2 Hours

2.

DESTRUCTIVE TEST
2.1
Hardness tests
2.1.1 Brinell hardness test
2.1.2 Rockwell hardness test
2.2
Izod impact test
2.3
Tensile test
2.4
Bending test
2.5
Shear test
2.6
Torsion test
2.7
Fatigue test

3 Hours

3.

NON-DESTRUCTIVE TESTS
3.1
X-Ray method
3.2
Magnetic method

3 Hours

190

3.3

Gamma-Ray method

(B)

HEAT TREATMENT

4.

IRON-CARBIDE DIAGRAM
4.1
Iron carbide diagram
4.2
Phase diagrams
4.3
Effect of heating on steel
4.4
Effect of cooling on steel

4 Hours

5.

HEAT TREATMENT EQUIPMENT

5.1
Construction of pyrometers
5.2
Working of pyrometers.
5.3
Construction of heat treatment furnaces
5.4
Working of furnaces
5.5
Construction of metallurgical microscope
5.6
Working of metallurgical microscope

5 Hours

6.

HEAT TREATMENT PROCESSES

6.1
Annealing & Normalizing
6.2
Hardening by quenching
6.3
Tempering
6.4
Hardenability

5 Hours

7.

CASE HARDENING PROCESSES

7.1
Carburizing (pack,gas,liquid)
7.2
Nitriding
7.3
Cyaniding
7.4
Flame & induction hardening

5 Hours

8.

HEAT TREATMENT OF NON-FERROUS METALS AND CAST IRON

8.1
Heat Treatment of cast iron
8.2
Non-ferrous metals & alloys
8.3
Annealing of Non-ferrous & Precipitation hardening

5 Hours

RECOMMENDED BOOKS:
1.
Elements of Heat Treatment by ENOS & Fontaine.
2.
Engineering materials (The testing of Materials) by AW Judge.
3.
Testing & Inspection of Engg Materials by Davis, Troxell and Wirkocil.

191

MT-362

MATERIALS TESTING AND HEAT TREATMENT

INSTRUCTIIONAL OBJECTIVES (MT-362)

1.

INTRODUCTION
1.1
Know mechanical properties of materials.
1.1.1 Enlist the mechanical properties of materials (Hardness, toughness,
Ductility Malleability, Brittleness, Elasticity & plasticity).
1.1.2 Define each property.
1.2

Knows Destructive Tests

1.2.1 Enlist destructive tests.
1.2.2 Define each test.

1.3

Knows Non Destructive Tests

1.3.1 Enlist non destructive tests.
1.3.2 Define each test.

2.

DESTRUCTIVE TESTS
2.1
Understand Hardness tests
2.1.1 Enlist types of hardness tests.
2.1.2 Enlist parts of Brinell hardness testing machine.
2.1.3 Explain Working of Brinell hardness testing machine.
2.1.4 Explain preparation of specimen for Brinell hardness testing machine
2.1.5 Explain the measurement of impression by microscope for Brinell test
2.1.6 Describe relevant calculations.
2.1.7 Enlist parts of Rockwell hardness testing machine.
2.1.8 Explain working of Rockwell hardness testing machine.
2.1.9 Explain preparation of Specimen for Rockwell hardness testing machine
2.1.10 State correct dial reading procedure
2.1.11 Enlist the difference between Brinell and Rockwell hardness testing
machine
2.2

Understand the principles of Impact Machine

2.2.1 Enlist parts of Izod Impact machine
2.2.2 Explain function of each part
2.2.3 Explain working principle
2.2.4 Explain preparation of specimen
2.2.5 State correct dial reading technique

2.3

Understand the principle of Tensile / Universal Testing Machine

2.3.1 Describe tensile testing machine
2.3.2 Enlist different parts of tensile testing machine & Extensometer
2.3.3 Describe different function of tensile testing machine
2.3.4 Explain the preparation of standard tensile test specimen for mild steel
2.3.5 Explain the procedure of tensile test of mild steel

192

2.3.6
2.3.7
2.3.8
2.3.9

3.

Explain the stress strain curve obtained in a tensile test

Explain the calculation involved in a tensile test
State correct dial reading procedure
State need of correct holding of specimen on machine

2.4

Understand Bending Test

2.4.1 Describe bending
2.4.2 Explain bending test

2.5

Understand Shear test

2.5.1 Describe shear stress.
2.5.2 Explain shear tests (simple, punch shear)

2.6

Understand Torsion Testing Machine and Torsion Test

2.6.1 Define torque
2.6.2 Describe Torsion
2.6.3 Explain shafts subjected to Twisting Moment
2.6.4 Explain working of Torsion testing machine
2.6.5 Explain procedure of Torsion test

2.7

Understand Fatigue Testing Machine and Fatigue test

2.7.1 Define Fatigue
2.7.2 Describe cyclic loading
2.7.3 Explain effect of Fatigue on metals and Fatigue failure
2.7.4 Explain working of Fatigue Testing Machine
2.7.5 Explain procedure for Fatigue test

NON DESTRUCTIVE TESTS

3.1
Understand the X-Ray Technique
3.1.1 Enlist advantages of X-Ray test & disadvantages
3.1.2 Explain the basic principle of X-Ray test
3.1.3 Explain the equipment used
3.1.4 Enlist the safety measures adapted in X-Ray method
3.1.5 Explain the use of X-Ray method for casting & welded joints
3.2

Understand Gamma Ray Method

3.2.1 Enlist advantages & disadvantages of Gamma Rays method
3.2.2 Explain basic principle used
3.2.3 Explain equipment used
3.2.4 Enlist safety measures
3.2.5 Explain the uses of Gamma Ray Methods for castings and welded joints

3.3

Understand Magnetic Methods

3.3.1 Enlist advantages/disadvantages
3.3.2 Explain the equipment used
3.3.3 Explain the basic principle

193

3.3.4
B.

5.

Explain crack detection procedure

HEAT TREATMENT
4.1
Understand heat treatment of steel
4.1.1 Describe heat treatment of steel
4.1.2 Explain constituents of steel
4.1.3 Describe allotropic nature of steel
4.1.4 Explain change of structure on heating
4.1.5 Explain Role of heating rate
4.1.6 Distinguish between micro & macro structure
4.2

Understand phase diagram

4.2.1 Define phase diagram
4.2.2 Explain importance of phase diagram
4.2.3 Name different phases
4.2.4 Explain different phases

4.3

Understand Iron Carbide Diagram

4.3.1 Sketch iron carbide diagram
4.3.2 Describe its importance in heat treatment of steel
4.3.3 Explain iron carbide diagram in heat treatment of steel
4.3.4 Name different phases in diagram
4.3.5 Explain different phases in diagram

4.4

Understand effect of cooling of steel

4.4.1 Explain the change of structure on cooling
4.4.2 Explain the importance of rate of cooling
4.4.3 Enlist different methods of cooling
4.4.4 Explain each method of cooling and its effect

HEAT TREATMENT PROCESSES

5.1
Understand Annealing
5.1.1 Define purpose of annealing
5.1.2 Enlist steps taken in annealing
5.1.3 Explain each step
5.2
Understand Hardening
5.2.1 Describe purpose of hardening
5.2.2 Enlist steps taken for hardening
5.2.3 Explain each process
5.3
Understand Tempering
5.3.1 Define purpose of tempering
5.3.2 Enlist step taken for tempering
5.3.3 Explain each process
5.4
Understand Quenching
5.4.1 Define purpose of quenching
5.4.2 Define different media, used for quenching

194

6.

7.

8.

5.4.3 Explain the effect of quenching in each media

HEAT TREATMENT EQUIPMENT
6.1
Understand heat treatment furnaces
6.1.1 Describe heat treatment furnaces
6.1.2 Enlist different furnaces used
6.1.3 Describe the difference between heat treatment furnace and other furnaces
6.1.4 Describe different parts of a furnace
6.1.5 Explain working of furnaces
6.1.6 State safe use of Furnaces
6.2
Understand Pyrometer
6.2.1 Define pyrometer
6.2.2 Enlist types of pyrometers
6.2.3 Enlist different parts of Thermocouple type and optical pyrometer
6.2.4 Explain working principle of pyrometer
6.3
Understand Metallurgical microscope
6.3.1 Describe microscope
6.3.2 Describe metallurgical microscope
6.3.3 Enlist parts of microscope
6.3.4 Explain each part
6.3.5 Explain working principle
6.3.6 Explain microstructure-study with microscope
CASE HARDENING PROCESSES
7.1
Understand carburizing
7.1.1 Define case hardening
7.1.2 List different case hardening process
7.1.3 Define carburizing
7.1.4 Explain carburizing with types
7.1.5 Describe cyaniding & Nitriding
7.1.6 Explain cyaniding & Nitriding
7.1.7 Describe flame hardening & Induction
7.1.8 Explain flame hardening & Induction hardening
UNDERSTAND HEAT TREATMENT OF NON-FERROUS METALS, ALLOYS
AND CAST IRON
8.1
Explain heat-Treatment of cast Iron
8.2
Explain heat-Treatment of Non-Ferrous metals and alloys
8.3
Explain precipitation hardening
8.4
Explain Annealing of Non-Ferrous metals

RECOMMENDED BOOKS:
1.
Elements of Heat Treatment By Ends and Fontaine
2.
Engineering Material (The testing of materials) By A.W Judge
3.
The Testing and Inspection of Engineering Materials By Davis, Troxell, Wiskocil

195

MT-362

MATERIALS TESTING AND HEAT TREATMENT

LIST OF PRACTICALS

96 Hours

A.

MATERIAL TESTING.
1.
Practice for Brinell hardness test.
2.a) Practice for Rockwell hardness test for B-scale hardness.
2.b) Practice for Rockwell hardness test for C-scale hardness.
3.
Practice for Izod and Charpy test on cast-iron, Aluminum and mild steel standard
test specimens.
4.
Practice for Tensile test on universal testing machine on standard specimen and
observe necking & yield point, calculate % elongation, % reduction in area.
5.
Compression Test on timber or cast iron.
6.
Practice for Bending and Shear test on universal testing machine.
7.
Practice for Torsion test on torsion testing machine.
8.
Practice for Fatigue test on fatigue testing machine.

B.

HEAT TREATMENT
9.
Sketch Metallurgical Microscope indicating its various parts.
10.
Practice for working of Metallurgical microscope.
11.
Practice for Etching of specimen.
12.
Study grain size micro-structure of mild steel specimen.
13.
Practice for Flame hardening & Quenching and study of grain structure.
14.
Practice for Annealing and study grain structure.
15.
Practice for Normalizing and study grain structure.
16.
Practice for Pack carburizing and study grain structure.
17.
Practice for heat treatment of Non-ferrous metals & cast iron and study grain
structure.
************

196

MT-374

WORKSHOP PRACTICE-III
(ADVANCE MACHINE SHOP & PROJECTS)
T
2

P
6

C
4

Total contact hours

Theory
64
Practical
192
Pre-requisite: Workshop II
AIMS At the end of this course the students will be able to:
(i)
Operate Milling, Shapers, Planner and grinding machines.
(ii)
Prepare Mechanical projects.
(iii)
Write project report.
COURSE CONTENTS
1.

MILLING MACHINE CONSTRUCTIONS

1.1
Types and construction
1.2
Parts and their functions
1.3
Care & maintenance
1.4
Safety Practices
1.5
Attachments and Accessories

3 Hours

2.

WORK HOLDING DEVICES

2.1
Vices and hold downs.
2.2
Compound angle Set up

3 Hours

3.

MILLING CUTTERS
3.1
Types of cutters.
3.2
High steel cutters.
3.3
Carbide Tipped cutters.
3.4
Positive and negative rakes
3.5
Angles and clearances.
3.6
Cutting speeds and feeds.

4 Hours

4.

MILLING OPERATIONS
4.1
Climb and conventional milling.
4.2
Plain Milling.
4.3
Side Milling.
4.4
Face Milling.
4.5
End Milling.
4.6
Slotting
4.7
Straddle Milling.
4.8
Sawing
4.9
Gang Milling.

4 Hours

197

5.

6.

7.

8.

9.

10.

11.

GEAR CUTTING & GEAR CALCULATIONS

5.1
Gear Terminology
5.2
Computation and Formulae.
5.3
Indexing & Indexing Calculations.
5.3.1 Plain indexing.
5.3.2 Differential indexing.
5.4
Spur gear cutting (plain & Differential)
HELICAL MILLING
6.1
Lead of gear.
6.2
Lead of Machine
6.3
Computation and Formulae.
6.4
Helical gear cutting, left hand, Right hand.
HOBBING MACHINE.
7.1
Introduction.
7.2
Types.
7.3
Construction.
7.4
Working.
GRINDING WHEELS.
8.1
Abrasives.
8.1.1 Natural.
8.1.2 Synthetic.
8.2
Grade and Structure.
8.3
Standard wheel shapes and application.
8.4
Bonds and Bonding methods.
8.5
Selection of grinding wheel.
8.6
Inspection, handling and storage.
8.7
Truing and dressing
PRECISION GRINDING MACHINES.
9.1
Types and construction.
9.2
Principles & functions.
9.3
Holding Devices and accessories.
9.4
Grinding fluids.
GRINDING OPERATIONS
10.1 Surface grinding.
10.2 Cylindrical grinding.
10.3 Internal grinding.
10.4 Form grinding.
10.5 Centre-less grinding.
10.6 Tool and cutter grinding.
10.6.1 Clearance grinding of cutters.
10.6.2 Drill grinding.
10.6.3 End mill grinding.
HYDRAULIC POWER TRANSMISSION
11.1 Introduction.
11.2 Advantages of Hydraulic transmission.
11.3 Elements of Hydraulic systems.

198

6 Hours

5 Hours

4 Hours

8 Hours

4 Hours

6 Hours

8 Hours

11.4
11.5
11.6
12.

Cross fed mechanism.

Rapid traverse and feed circuit.
Hydraulic oil requirements.

PROJECTS
12.1 Introduction.
12.2 Necessity & need of projects.
12.3 Planning a project.
12.4 Detail and Assembly drawings of project.
12.5 Material Requirements of project.
12.6 Preparation of projects.
12.7 Projects & Projects report.
(a)
Surface gauge
(b)
Miniature Collect chuck.
(c)
Rack & gear Assembly.
(d)
Watch maker's Lathe
(e)
High speed gear box.
(f)
Drill press miniature model
(g)
Loose tail stock.
(h)
Air compressing Foot pump.
(i)
Lathe Tool post (square type)
(j)
Job supporting Screw Jack.

199

9 Hours

MT-374

WORKSHOP PRACTICE-III

INSTRUCTIONAL OBJECTIVES
1.

UNDERSTAND MILLING MACHINE CONSTRUCTION, TYPES,

ATTACHMENTS AND ACCESSORIES
1.1
State the working principle of Milling machine
1.2
State different types of Milling Machine
1.3
Explain the construction of universal Milling machine
1.4
Describe the functions of milling machine parts
1.5
Explain the care and maintenance of milling machine
1.6
State the safety practices for operating the milling machine
1.7
Describe the uses and necessity of attachments and accessories
(a)
Dividing Head
(b)
Vertical head
(c)
Rotary table
(d)
Slotting attachment
(e)
Rack cutting attachment

2.

UNDERSTAND THE USE OF WORK HOLDING DEVICES

2.1
Describe the use of vice
2.2
Describe the hold down devices
2.3
Describe the use of chuck
2.4
Explain the construction and use of machine
2.5
Explain the use of universal vice
2.6
Describe the compound angle setting procedure of universal vice

3.

MILLING CUTTERS:
3.1
Understand the milling cutters and their uses for a particular application
3.1.1 Classify milling cutters with respect to holding
position
3.1.2 Describe materials of milling cutters
3.1.3. Explain positive and Negative Rake angles and clearances
3.2

4.

Calculate the speed and feed of cutters for different situations

3.2.1 Calculate spindle RPM for different metals
3.2.2 Select suitable cutting speed

UNDERSTAND MILLING OPERATIONS

4.1
Differentiate climb and conventional milling
4.2
Explain plain milling operation
4.3
Explain side milling operation
4.4
Explain face milling operation
4.5
Explain end milling operation
4.6
Explain slotting milling operation
4.7
Explain straddle milling operation

200

5.

6.

7.

8.

4.8
Explain gauge milling operation
4.9
Explain sawing/slitting milling operation
GEAR CUTTING & GEAR CALCULATIONS
5.1
Understand gear calculation
5.1.1 Calculate gear blank size
5.1.2 Calculate gear Module
5.1.3 Calculate No. of teeth
5.1.4 Calculate full depth and clearances
5.2
Understand plain & differential indexing
5.2.1 Explain the plain indexing method and its calculations
5.2.2 Describe the differential indexing method and its calculations
5.2.3 Practice spur gear cutting by
(a)
Plain indexing method
(b)
Differential indexing method
5.3
Apply skill in gear cutting
5.3.1 Explain holding a blank for gear cutting
5.3.2 Explain outing a cutter in arbor
5.3.3 Describe to feed cutter of blank
5.3.4 Explain the necessity of proper depth of cut
APPLIES SKILL IN HELICAL GEAR CUTTING
6.1
Explain bed of gear
6.2
Explain bed of machine
6.3
Calculate gear blank size
6.4
Calculate no of teeth of a helical gear
6.5
Calculate correct module
6.6
Select correct cutter No
6.7
Explain table setting for helical milling
6.8
Calculate gear ratio for helical cutting
6.9
Practice cutting helical gear
(a)
Left hand
(b)
Right hand
UNDERSTAND HOBBING MILLING
7.1
Describe the working principle of hobbing milling machine
7.2
Describe the construction and working principle of vertical hobbing machine
7.3
Describe the construction and working of horizontal hobbing machine
7.4
Explain the construction differential vertical hobbing machine
7.5
Describe the working of differential vertical hobbing machine
UNDERSTAND THE SELECTION AND USES OF GRINDING WHEELS
8.1
Define abrasives
8.2
Differentiate Natural and synthetic abrasives
8.3
classify the Natural and synthetic abrasives
8.4
Describe grade of standard grinding wheel
8.5
Identify grinding wheel shapes
8.6
State the application of grinding wheels with respect to shape
8.7
Describe the bonds
8.8
Explain bonding methods

201

9.

10.

11.

12.

8.9
Describe selection of grinding wheel
8.10 Explain the inspection methods of grinding wheels
8.11 Demonstrate truing and dressing method
UNDERSTAND THE WORKING OF PRECISION GRINDING MACHINE,
HOLDING DEVICES AND CUTTING FLUIDS
9.1
Enlist precision grinding machines
9.2
Describe the construction & working of cylindrical grinding machine
9.3
Describe the construction & working of surface grinding machine
9.4
Describe the Construction & working of Universal grinding machine
9.5
Describe the Construction & working tool and cutter grinding machine
9.6
Describe the holding devices and accessories of above said machines
9.7
Describe the grinding fluids
UNDERSTAND GRINDING OPERATIONS
10.1 Explain surface grinding operation
10.2 Explain Cylindrical grinding operation
10.3 Explain Internal grinding operation
10.4 Explain form grinding operation
10.5 Explain Centre-less grinding operation
10.6 Explain the grinding of Drills
10.7 Explain the grinding of Milling cutter
UNDERSTAND THE HYDRAULIC POWER TRANSMISSION IN MACHINES
11.1 Explain the necessity of Hydraulic power transmission
11.2 Advantages of Hydraulic power transmission
11.3 Describe the elements of Hydraulics system
11.4 Describe feed mechanism of Hydraulic power driven machine
11.5 Explain rapid traverse and feed circuit system
11.6 Explain the Hydraulic oils
PRODUCE SIMPLE MECHANICAL PROJECTS APPLYING KNOWLEDGE
AND SKILL OF WORKSHOP COURSES
12.1 Describe the concept, necessity and need of projects
12.2 Explain procedure and method of producing projects
12.3 Prepare detail and assembly drawing of projects to be prepared
12.4 Explain the material requirement for the projects to be prepared
12.5 Estimate the cost of projects including pattern making casting, raw material and
machining & over heads etc
12.6 Prepare the project taken in hand
12.7 Write a complete project report comprising :(a)
Drawings
(b)
Procedure
(c)
Material lists
(d)
Process charts
(e)
Cost
(f)
Difficulties faced

202

MT-374

WORKSHOP PRACTICE-III

LIST OF PRACTICALS

192 Hours

A)

ADVANCE MACHINE SHOP

1.
2.
3.
4.
5.
6.
7.
8.
9.

Plain Milling operation

Slotting on Flat surface
Slitting an round work
Rock cutting work (spur & Helical)
Super gear cutting
(a)
Plain indexing Method
(b)
Differential indexing Method
Helical gear cutting Left hand & Right hand
Cylindrical grinding operation
Surface grinding
Tool & cutter grinding

B)

PROJECTS

10.

LIST OF FURTHER PROJECTS:

i.
Surface gauge
ii.
Miniature collet chuck
iii.
Rack & gear assembly
iv.
Watch Maker lathe
v.
High speed gear
vi.
Drill press & grinder Model
vii.
Loose tail stock
viii. Air compressing foot pump
ix.
Lathe tool part (square type)
x.
Job supporting screw jack.
***************

203

MT-382:

COMPUTER INTEGRATED MANUFACTURING (CIM)

T
1
Total contact hours
Theory
32
Practical
96
Pre-requisite :
Workshop I, Workshop II, CAD I, CAD II

P
3

C
2

AIMS At the end of the course the student will be able to understand computer aided designing
and manufacturing. He must also be aware of Programming and operating CNC Lathe.
Acquire the knowledge of Computer Integrated Manufacturing with Configurations of
CAD, CAM & ROBOTICS.
COURSE CONTENTS
1.

INTRODUCTION TO CIM.
1.1
CADD/CAM
1.2
CADD/CAM system
1.3
CAE/CAM system
1.4
CAM Technology
1.5
ROBOT
1.6
CAM/CADD Characteristics
1.7
Numerical controls (N.C.)
1.8
ROBOTICS
1.9
Robot components
1.10 Flexible Manufacturing

2 Hours

2.

NUMERICAL CONTROLS.
2.1
Description
2.2
Measurement fundamentals
2.3
Types of numerical control system.
2.3.1 Open loop Systems
2.3.2 Closed loop systems
2.4
Types of controls
2.4.1 Point to point positioning
2.4.2 Continuous path control
2.5
Input media
2.5.1 Punched cards
2.5.2 Punched Tape
2.5.3 Types of standard punched tapes
2.5.4 Tape coding
2.5.5 Tape preparation

4 Hours

3.

ADVANTAGES & DISADVANTAGES OF NC MACHINES

3.1
Advantages
3.2
Disadvantages

2 Hours

204

3.3

Recent advancement in numerical control

4.

COMPUTER CONTROL
4.1
Computerized numerical control-CNC
4.2
Direct numerical control-DNC
4.3
Advantages of C N C
4.4
Advantages of D N C

3 Hours

5.

MANUAL NC PROGRAMMING
5.1
Absolute dimensioning system
5.2
Incremental dimensioning system

2 Hours

6.

N C LANGUAGE
6.1
Tape format
6.2
Information block
6.2.1 Information in blocks
6.2.2 Sequence number
6.3
Preparatory functions
6.4
Feed rate
6.5
Miscellaneous functions
6.6
Manual NC programme writing procedure
6.7
Punching the NC Tape.

6 Hours

7.

COMPUTER ASSISTED MANUFACTURING.

7.1
N C PROGRAMMING
7.2
CNC PROGRAMMING
7.2.1 Sample CNC programme
7.3
Practicing on CNC Lathe
7.3.1 Parallel turning
7.3.2 Step turning
7.3.3 Taper Turning

6 Hours

8.

PRACTICING ON CNC TURNING/MILLING MACHINE (EMCO COMPACT

CNC/ANY AVAILABLE CNC MACHINE IN THE SHOP).
4 Hours
8.1
Requirements for practicing
8.2
Hints for working with CNC Lathe/Milling Machine.

9.

FIELDS OF CNC APPLICATION

9.1
CNC lathe
9.2
CNC Milling Machine
9.3
CNC Drilling Machine
9.4
CNC Grinding Machine
9.5
CNC Measuring Equipment
9.6
CNC Punch machines
9.7
CNC Bending Machines
9.8
CNC Shaping Machines

1 Hour

205

9.9
9.10
9.11
9.12
9.13
10.

CNC Welding Machines

CNC Painting Machine
CNC Wood Working Machines
CNC Assembling units (Robots)
CNC Drawing Machines

PREPARATORY FUNCTIONS SPECIFIC TO EMCO 5 CNC.

10.1 G FUNCTIONS
10.2 M FUNCTIONS
10.3 EMCO PROGRAMME SHEET.

2 Hours

Text Book:
1.
Understanding CAD/CAM By DANIEL J BOWMAN ANNETTE C.BOWMAN (BPB
Publication)
2.
Manual EMCO 5-CNC AUSTRIA.

206

MT-382

COMPUTER INTEGRATED MANUFACTURING (CIM)

INSTRUCTIONAL OBJECTIVES
1.

KNOW COMPUTER INTEGRATED MANUFACTURING (CIM)

1.1
Describe growth of Automation
1.2
Describe CAD/CAM
1.3
Describe CAD/CAM Systems
1.4
Describe CAE/CAM Systems

2.

UNDERSTAND HISTORY OF CIM & CAM TECHNOLOGIES

2.1
State History of CAD/CAM, Computer, transistor interactive computer graphics
2.2
Explain CAM Technologies
2.3
Explain CAM Language
2.4
Explain CAM Language Computability
2.5
Establish relation of Robot with CAM
2.6
Explain CAD/CAM Characteristics
2.7
Explain computer graphic work-station
2.8
Explain common Data Base for linking CAD & CAM
2.9
Explain concepts of Group Technology and its Benefits
2.10 Explain CAD/CAM soft ware

3.

UNDERSTAND NUMERICAL CONTROL

3.1
Describe Numerical control (NC)
3.2
Describe early NC development
3.3
Describe Computer Numerical control (CNC)

4.

UNDERSTAND ROBOTICS
4.1
Describe Robotics
4.2
Explain Robot components
4.3
Explain Hard ware features of Robot
4.4
Construct Robot Arm geometries

5.

UNDERSTAND FLEXIBLE MANUFACTURING

5.1
Describe Flexible Manufacturing (FM)
5.2
Explain Flexible Manufacturing advantages
5.3
Explain Flexible Manufacturing Decision factors

6.

UNDERSTAND THE INPUT DEVICES FOR CAD/CAM

6.1
Describe sources of input
6.2
Describe Keyboards
6.3
Describe EBCDIC and ASCII
6.4
Describe Programmable function Box
6.5
Describe Data with cursor types (digitizing cursor, mouse, stylus)
6.6
Explain Digitizer types
6.7
Explain sonic digitizer & light pen

207

6.8
6.9
6.10
6.11

Explain Digitizing scanners

Describe scanning and conversion
Explain scanning process
Explain voice data-Entry

7.

UNDERSTAND OUTPUT DEVICES OF CAD/CAM

7.1
Describe Hard Copy devices
7.2
Describe pen-plotters
7.3
Describe plotters vs. Printers
7.4
Explain types of plotters
7.5
Explain types of Printers

8.

UNDERSTAND CAM DEVELOPMENTS

8.1
Describe Data-base Management
8.2
Identify importance of standardization
8.3
Describe early CAD development
8.4
Identify soft wares for CAD/CAM
8.5
Describe early CAM development
8.6
Explain Numerical control
8.7
Explain APT soft ware for CAM
8.8
Explain CAM soft ware Acquisition method

9.

DESCRIBE ARTIFICIAL INTELLIGENCE (AI)

9.1
Describe Al
9.2
Describe Al and CAM
9.3
Describe Al and CAD

10.

UNDERSTAND NUMERICAL CONTROL (NC)

10.1 Describe NC
10.2 Describe measurement fundamentals
10.3 Explain types of Numerical control system (over-loop, closed loop)
10.4 Explain point-to point positioning and continuous-path control
10.5 Identify importance of punched tape in NC and its types
10.6 Explain Tape coding and Tape preparation

11.

UNDERSTAND NC OPERATION
11.1 Describe NC operation
11.2 Describe advantages of NC machines
11.3 Describe dis-advantages of NC machines
11.4 Explain recent advances in Numerical controls

12.

UNDERSTAND COMPUTERIZED NUMERICAL CONTROL (CNC)

12.1 State types of computer control
12.2 Explain CNC
12.3 Explain DNC
12.4 Explain advantages of CNC and DNC

208

13.

UNDERSTAND NC PROGRAMMING
13.1 Describe manual NC-Programming
13.2 Explain absolute dimensioning system
13.3 Explain Incremental dimensioning system
13.4 Explain NC Programming Code

14.

KNOW NC LANGUAGE
14.1 Describe Tape Format
14.2 Describe Information Blocks
14.3 Describe Sequence number
14.4 Describe feed Rate
14.5 Describe Miscellaneous Functions
14.6 Describe Nc Program writing Procedure (manual)

15.

UNDERSTAND COMPUTER-ASSISTED NC PROGRAMMING

15.1 Review of NC Programming languages
15.2 Understand a pre-programmed CNC programming example
15.3 Practice the example on CNC lathe machine
15.4 Develop CNC program for parallel turning on CNC lathe machine
15.5 Develop CNC Program for Taper turning
15.6 Develop CNC Program for step turning

RECOMMENDED BOOKS:
1.
Understand CAD/CAM by Bowman & Bowman
2.
Manual of COMPACT S CNC, Emco MAID and CO. Austria

209

MT-382

COMPUTER INTEGRATED MANUFACTURING (CIM)

LIST OF PRACTICALS
1-2
3-4
5-6
7-8
9-11
12-15
16-19
20-23
24-27
28-30

96 Hours

Introduction to CNC Lathe machine

Study of observance of safety while operating the machine
Study of programming CNC lathe Machine
Study of procedure for coding and saving program
Study & working of CNC Machine
Preparation of sample job-i from pre-developed program supplied with the CNC lathe
Machine/self developed program.
Preparation of sample job-ii from pre-developed program supplied with the CNC lathe
Machine/self developed.
Practice to prepare program of parallel turning and job preparation.
Practice to prepare program of step turning and job preparation.
Practice to prepare program of taper turning and job preparation.

210