Applications of measuring instruments-functional elements of an instrument-instrument as transducer-generalized measuring instrument-generalized mathematical model of measuring systems-zero order, first order and second order instruments-classification of instruments- input output configurations-methods of correction fr spurious inputs -stati calibration and determination of bias systematic error and random error-stati and dynamic characteristics,potentiometer transducer as a zero order instrument-analysis of its loading error- mercury n glass thermometer as a first order instrument-step, ramp, frequency response-seismic instrument as a second order instrument.
Measurement of strain : strain gauge classification –un bonded and bonded strain gauges-gauge factor-strain rosettes-temperature compensation-calibration. Measurement of force : multiple lever system fr weighing- load cells-temperature sensitivity calibration- ballistic weighinghydraulic and pneumatic load cells. Measurement of Torque: water brek-Heenan and Froude hydraulic dynamometer-beam and strain gauge transmission dynamometer. Measurement of Temperature : pressure thermometer-RTDs-compensation fr lead resistance thermocouplesfive laws of thermocouples and their applications-series and parallel connected thermocouplespyrometry-optical pyrometer-infrared pyrometry-total radiation pyrometers.Air pollution measurements : gas chromatography-ORSAT’s apparatus. Nuclear instrumentation: Gieger Muller Counter-ionization chamber-scintillation counter.Acoustical measurements : basic acoustical parameters-sound pressure-sound pressure levelpower- intensity-power level-microphones-sound level meter.
Principles of automatic control : transfer functions, transient response of second order systems,steady state response and error constants. Mathematical modeling of dynamic systems: state space representation of dynamic systems- mechanical systems, electrical systems, analogue systems, electro mechanical systems, liquid level systems, thermal systems, and robot arm systems, proportional, integral, derivative control.
Stability analysis of linear systems: concepts of stability, characteristic equations, stability,analysis, determination of stability by Routh-Hurwitz criterion, Root locus, frequency response using Bode plot, and stability from Bode plot, Nyquivist criteria.Control system components: DC and AC servo motors, tacho generators, synchros and stepper motors.
Force analysis of plane motion mechanism: Static force analysis, analysis of four bar chain, slider crank mechanism, stati force analysis wth friction. Dynamic force analysis: D'Alembert's principle, inertia forces, dynamic force analysis of four bar and slider crank mechanism, Shaking forces, gear force analysis of spur, helical and bevel gears,Dynamics of reciprocating engines, equivalent masses, inertia force n single engine,bearing loads n single cylinder engine.
Flywheels: Inertia torque-turning moment diagrams for multi-cylinder engines, steam engines, coefficient of fluctuation of speed and energy, flywheel mass calculation.Gyroscopes: motion of a rigid body n 3 dimension, Gyrodynamics, gyroscope and gyroscopic couple, Gyroscopic effects on ships, aircrafts and automobiles.Governors: Terms used n governors, Porter, Proell, Hartnell governors, sensitiveness of governors, stability, isochronous governor, hunting, effort and power of governor,controlling force, coefficient of insensitiveness.
Balancing: Static and dynamic balancing, balancing of several masses in a plane,balancing of rotating masses n several planes, balancing of several masses n several planes. Condition of complete balancing of an engine, reciprocating and rotating parts,locomotive balancing, hammer blow, variation n tractive effort, swaying couple, Multicylinder inline engines, Radial and V-engines, Balancing machines and principles of working
Belt and Rope drives: Ratio of belt tensions, power transmitted, Centrifugal tension,initial tension, flat and V-belts and ropes.Clutches: Analysis of single plate, multi plate and cone clutch.Brakes: Analysis of different types of brakes-block brakes, band and internal expanding brakes, condition of self locking, power transmitted and heat generated.Dynamometers: Rope brake dynamometers, belt transmission dynamometers
Introduction to design: Steps in design process, design factors, practical considerations in design, selection of materials, strength of mechanical elements, theories of failure impact load, shock load, fatigue loading, effects of surface, size, temperature and stress concentration, consideration of creep and thermal stress n design.
Detachable joints: design of screws, standards, thread stresses, preloading of bolts,fatigue and shock load, eccentric loading. Power screws, mechanism of power screws, thread stresses, efficiency of power screws, types of keys, stresses n keys, design of socket and spigot joint, Gib and cotter, knuckle joints, design of rigid couplings and flexible couplings.
Riveted joint: Stresses in riveted joint, design of riveted joints with central and eccentric loads, boiler and tank joints, structural joints.Springs: stresses n helical springs, deflection of helical compression and tension springs,springs subjected to fatigue loading, concentric and helical torsion spring, critical frequency of springs, leaf springs, design of automotive leaf springs.
Welded joints: types of welded joints, stresses, design of welded joints subjected to axial, torsional and bending loads, welds subjected to fluctuating loads.Power shafts: stresses n shafts, design of stati loads, combined stresses, reversed bending and steady loads, design of shafts based on deflection and strength, critical speed of shafts.
Introduction to heat transfer – basic modes of heat transfer – conduction heat transfer – energy balance – integral and differential approaches – general heat conduction equation n Cartesian, cylindrical and spherical coordinates – initial and boundary conditions –one-dimensional steady state conduction wth heat generation – conduction shape factor –temperature dependence ;of thermal conductivity – applications like extended surface heat transfer and critical insulation thickness – two dimensional steady state heat conduction – examples – unsteady state heat conduction n one dimension – lumped heat capacity system – semi-infinite solids wih sudden and periodic change n surface temperature – numerical methods n conduction problems.
Convective heat transfer – Newton’s law of cooling – thermal boundary layer – Prandtl number – hydrodynamic and thermal boundary layer equations – laminar forced convection heat transfer from flat plates – internal flow and heat transfer – fully developed laminar flow n pipes – turbulent forced convection – Reynolds’ analogy –natural convection – natural convection heat transfer from vertical plates – condensation and boiling – film and drop wise condensation – film boiling and pool boiling introduction to multiphase flow and heat transfer. Diffusion and convective mass transfer.
Radiative transfer – electromagnetic radiation spectrum – thermal radiation – black body,grey body and coloured body – monochromatic and total emissive power – Planck’s law – Stefan-Boltzman law – Wien’s displacement law – absorptive – reflectivity –transmissivity – emissivity – Kirchhoffs identity – radiation exchange between surfaces –shape factor – shape factors fr simple configurations – heat transfer n the presence of re-radiating surfaces – radiation shields – surface and shape resistances – electrical network analogy.
Heat Exchangers: Type of heat exchangers, Logarithmic mean temperature difference(LMTD, analysis using fouling factors, derivation of LMTD fr parallel flow and counter flow heat exchangers, effectiveness, NTU method of heat exchanger analysis, fouling factors, simple design problems.
Cutting tools: Geometry of cutting tools and tool nomenclature, single point and multiple point cutting tools and used fr turning, milling, drilling and broaching, cutting tool materials and their properties, grinding wheels and their selections.
Metal Cutting : Mechanics of chip formation, types of chips, mechanism of orthogonal cutting, velocity relationship, cutting forces, factors affection cutting forces, tool dynamometers, cutting force and power analysis, turning, drilling, milling and broaching, thermal aspects of machining, cutting fluids and their selection.
Mach inability and tool life: Tool wear and tool life, tool life equations, tool life specification and criteria, tool life testing, effect of machining parameters on tool life,machinability, variables affecting machinability, machinability index. Economics of Machining: Selection of optimal machining conditions, productivity of machine tools
Jigs and Fixtures: Basic principle, elements of jigs and fixtures, location and clamping,3-2-1 method of location, principles of pin location, radial location, v-location, cavity location, Types of clamps-strap, cam, screw, latch, wedge, and toggle clamps, hydraulic and pneumatic clamps, design considerations common to jigs and fixtures, drill jigs- leaf,box, plate and indexing jigs, milling fixtures.Press working and die block design
Fundamentals of CAD: Role of computers in design, geometric modelling- wireframe and solid,modelling, engineering analysis-FEM, design review and evaluation, automated drafting, design data base, softwares used n CAD, data exchange between CAD and CAM. Fundamentals of CAM: Definition of automation, levels of automation, high volume discrete parts production,Detroit type of automation, transfer machines, analysis of automated flow lines, assembly machines, flow line balancing, line balancing.
Computer Numerical Control: basic theory of numerical control, advantages of NC, open and closed loop system, information flow and control theory, classification of CNC machine tools,position control and continuous path control, principles of displacement measurement, digital linear and rotary displacement transducer, analog displacement measuring system. CNC part programming: Manual programming, work piece modelling and computer aided part programming, G and M functions, canned cycles, CAPP languages, structure and use of major CAPP languages, programming n APT.
Design features of CNC machines: Special design features to match machine tools to numerical control system CNC tooling: ATC, APC, features of CNC systems fr lathes and machining centre. Testing of NC machine tools, statc and dynamic errors.
Basic concepts of Robotics: Introduction, basic structure of Robots, resolution, accuracy, and repeatability. Classification and structure of Robotic systems: PTP and CP systems, control loops of robotic systems, types of robots Drives and Control systems: hydraulic systems, DC servo motors, control approaches of Robots. Applications of Robots: handling, loading and unloading, welding, spray painting, assembly, machining. Programming: manual teaching, lead– through teaching, programming languages. Sensors and Intelligent Robots: introduction to Robotic sensors, vision systems, range detectors, force and torque sensors. Advanced concepts n automation: direct numerical control, CAE, CIM, FMS, computer integrated manufacturing –basic concepts of AI and expert systems fr manufacturing automation