COURSE FILE Semester VI 2017-2018bldeacet.ac.in/PDF/CourseFile/Mech/VI Semster.pdfb.l.d.e.a’s

B.L.D.E.A’s Vachana Pitama Dr.P.G.Halakatti College of Engineering & Technology, Bijapur-03

DEPARTMENT OF MECHANICAL ENGINEERING

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B.L.D.E.A’s

Vachana Pitamaha Dr. P.G. Halakatti College of Engineering & Technology,

Bijapur – 586 103

Department of Mechanical Engineering

Semester – VI

Course Title: Finite element method (15ME61)

2017-2018

COURSE FILE



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Program Educational Objectives (PEOs)

The educational objectives of the Mechanical Engineering Program are to prepare our graduates to:

1. Establish a successful career in Mechanical Engineering or related fields in Industry and

other organizations where an engineering approach to problem solving is highly valued.

2. Develop the ability among the students to synthesize the data and technical concepts for

applications to the product design.

3. Contribute significantly in a multidisciplinary work environment with high ethical standards

and with understanding of the role of engineering in economy and the environment.

4. Excel in graduate study and research, reaching advanced degrees in engineering and related

disciplines.

5. Achieve success in professional development through life-long learning.

Program outcomes (POs)

a. an ability to apply knowledge of mathematics, science, and Mechanical Engineering

b. an ability to design and conduct experiments, as well as to analyze and interpret data

c. an ability to design a mechanical system, mechanical component, or process to meet desired

needs within realistic constraints such as economic, environmental, social, political, ethical,

health and safety, manufacturability, and sustainability

d. an ability to function on multidisciplinary teams

e. an ability to identify, formulate, and solve mechanical engineering problems

f. an understanding of professional and ethical responsibility

g. an ability to communicate effectively

h. the broad education necessary to understand the impact of mechanical engineering solutions

in a global, economic, environmental, and societal context

i. a recognition of the need for, and an ability to engage in life-long learning,

j. a knowledge of contemporary issues

k. an ability to use the techniques, skills, and modern mechanical engineering tools necessary

for engineering practice.



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COURSE PLAN

Semester: VI Year: 2017-18

Subject: Finite Element Method Subject Code: 15ME61

Total No. of Lecture Hours: 54 I A Marks : 20

Exam Marks: 80 Exam Hours: 03

Lesson plan prepared by : Prof. S.S.Chappar

Prof. R.K.Kanakaraddi

Date:5/1/2018

COURSE CONTENT

Module I

Introduction to Finite Element Method:

General description of the finite element method. Engineering applications of finite element method.

Boundary conditions: homogeneous and nonhomogeneous for structural, heat transfer and fluid flow

problems. Potential energy method, Rayleigh Ritz method, Galerkin’s method, Displacement method of

finite element formulation. Convergence criteria, Discretisation process, Types of elements: 1D, 2D and

3D, Node numbering, Location of nodes. Strain displacement relations, Stress strain relations, Plain stress

and Plain strain conditions, temperature effects.

Interpolation models: Simplex, complex and multiplex elements, linear interpolation polynomials in

terms of global coordinates 1D, 2D, 3D Simplex Elements. 12Hours

Module II

One-Dimensional Elements-Analysis of Bars and Trusses: Linear interpolation polynomials in terms

of local coordinate’s for 1D, 2D elements. Higher order interpolation functions for 1D quadratic and

cubic elements in natural coordinates, , , Constant strain triangle, Four-Nodded Tetrahedral Element (TET

4), Eight-Nodded Hexahedral Element (HEXA 8), 2D isoparametric element, Lagrange interpolation

functions, Numerical integration: Gaussian quadrature one point, two point formulae, 2D integrals. Fore

terms: Body force, traction force and point loads,

Numerical Problems: Solution for displacement, stress and strain in 1D straight bars, stepped bars and

tapered bars using elimination approach and penalty approach, Analysis of trusses 12Hours

Module III

Beams and Shafts: Boundary conditions, Load vector, Hermite shape functions, Beam stiffness matrix

based on Euler-Bernoulli beam theory, Examples on cantilever beams, propped cantilever beams,

Numerical problems on simply supported, fixed straight and stepped beams using direct stiffness method

with concentrated and uniformly distributed load.

Torsion of Shafts: Finite element formulation of shafts, determination of stress and twists in circular

shafts. 08 Hours

Module IV

Heat Transfer: Basic equations of heat transfer: Energy balance equation, Rate equation: conduction,

convection, radiation, energy generated in solid, energy stored in solid, 1D finite element formulation

using vibrational method, Problems with temperature gradient and heat fluxes, heat transfer in composite

sections, straight fins. Fluid Flow: Flow through a porous medium, Flow through pipes of uniform and

stepped sections. 12 Hours



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Module V

Axi-symmetric Solid Elements: Derivation of stiffness matrix of axisymmetric bodies with triangular

elements, Numerical solution of axisymmetric triangular element(s) subjected to point loads.

Dynamic Considerations: Formulation for point mass, Consistent element mass matrix of one

dimensional bar element, truss element, lumped mass matrix of bar element, truss element. 10 Hours

Text Books:

1. Logan, D. L., A first course in the finite element method,6th Edition, Cengage

Learning, 2016.

2. Rao, S. S., Finite element method in engineering, 5th Edition, Pergaman Int. Library of

Science, 2010.

3. Chandrupatla T. R., Finite Elements in engineering, 2nd Edition, PHI, 2013.

Reference Books:

1. J.N.Reddy, “Finite Element Method”- McGraw -Hill International Edition.Bathe K. J.

Finite Elements Procedures, PHI.

2. Cook R. D., et al. “Concepts and Application of Finite Elements Analysis”- 4th Edition,

Wiley & Sons, 2003.

Prerequisites:

Elementary mathematics, Mechanics of materials.

Course Description:

The contents of the course “FEM” is designed by the members of board of studies (BOS) constituted by

VTU Belgaum.

Basically the subject deals with

Basics of finite element methods

Detailed procedure in finite element analysis

Applications of finite element method

Course outcomes:

Upon successful completion of this course you should be able to:

1. Understand the concepts behind formulation methods in FEM.

2. Identify the application and characteristics of FEA elements such as bars, beams, plane and

iso-parametric elements.

3. Develop element characteristic equation and generation of global equation.

4. Able to apply suitable boundary conditions to a global equation for bars, trusses, beams,

circular shafts, heat transfer, and fluid flow, axi symmetric and dynamic problems and solve

them displacements, stress and strains induced

Relevance of the course: The primary function of design engineer is to give size and shape to

components of machine elements. While doing so he has to check its safety by finding the stress

distribution in that element. If the geometry, material properties and loading conditions are



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simple the formulae of mechanics of materials can be used to analyze the stress. If these are

complicated, in the absence of exact methods he has to go for approximate methods like finite

element methods. As the computational capabilities of modern computers are very high, the use

of FEM is vital in industries. So it is essential to know the details of finite element analysis.

Application Areas:

Stress analysis

Fluid flow analysis

Heat transfer

Computational fluid dynamics

Unit wise plan

Course Title / Code: Finite Element Methods (15ME61)

Module: 1 Introduction to Finite Element Method & Interpolation models

Planned hours: 12

Learning Objectives:

At the end of the Unit, the student should be able to;

1. Explain the basics of theory of elasticity.

2. Discuss the need of FEA

3. Understand steps in FEA

4. Apply potential energy and virtual work methods to formulate.

5. Discuss the method of discretization.

6. Explain types and size of elements

7. Discuss interpolation models for different applications.

Lesson Plan:

Lesson No.

Topics covered Teaching

Method POs

attained COs

attained

Text/Reference Book/Chapter

No.

L1

General description of the finite

element method. Engineering

applications of finite element method

Chalk & Board

a,b,e,k

1 T1,T2,T3,R1

L2 Boundary conditions: homogeneous

and nonhomogeneous for structural,

Chalk &

Board

1 T1,T2,T3,R1



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heat transfer and fluid flow

problems.

L3 Galerkin’s method Chalk &

Board 1 T1,T2,T3,R1

L4 Displacement method of finite

element formulation. Chalk &

Board

1 T1,T2,T3,R1

L5 Convergence criteria, Discretisation

process, Chalk &

Board

1 T1,T2,T3,R1

L6 Types of elements: 1D, 2D and 3D, Chalk &

Board 2 T1,T2,T3,R1

L7 Node numbering, Location of nodes. Chalk &

Board 2

L8 Strain displacement relations, Stress

strain relations, Chalk &

Board

2 T1,T2,T3,R1

L9 Plain stress and Plain strain

conditions, temperature effects Chalk &

Board

2 T1,T2,T3,R1

L10 Simplex, complex and multiplex

elements, Chalk &

Board

2 T2,T3,R1

L11

Linear interpolation polynomials in

terms of global coordinates 1D, 2D,

3D Simplex Elements

Chalk &

Board

2 T2,T3,R1

L12 Simple numericals Chalk &

Board 2 T2,T3,R1

Assignment Questions COs attained

Explain the steps in FEA 1

Discuss the applications of FEA 1

Explain essential and natural boundary conditions with examples 1

Derive the expression for total potential energy for one dimensional bar subjected to

an axial force.

1

Obtain the equilibrium equation of the system shown in figure using principle of

minimum potential energy

1

K1

K2

K3

F



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Find the stress at x=0 and displacement at the midpoint of the rod as shown in

figure. Use Rayligh Ritz method

1

Determine the deflection at the free end of a cantilever beam of length ‘l’ carrying a

vertical load ‘p’ at its free end by Rayligh Ritz method

1

Compute the value of central deflection for the beam shown in figure, considering

trigonometric functions and Rayligh Ritz method.

1

Obtain the stress strain relations in Plane stress problem 1

Explain descretization process and different types of elements with

sketches.[element library]

2

Explain simplex, complex and multiplex elements with sketches

2

Explain node location scheme 2

L/2 L/2

P

E, I

1 unit

1 unit

2 units X

Take E=1 unit

A=1 unit



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Module: II One-Dimensional Elements-Analysis of Bars and Trusses Planned hours: 12



1.Derive shape functions for different elements.

2. Determine displacement, stress, strain and reactions in different bars.

3. Determine displacement and stress in different strusses.

Lesson Plan:

Lesson. No.


Method POs

Attained COs

Attained

Reference

book/Chapter

no.

L13 Linear interpolation polynomials

in terms of local coordinate’s for

1D, 2D elements.

Chalk and

Board

a,b,e,k

2,3 T2,T3,R1

L14

Higher order interpolation

functions for 1D quadratic and

cubic elements in natural

coordinates

Chalk and

Board 2,3 T2,T3,1

L15 Constant strain triangle, Four-

Nodded Tetrahedral Element

(TET 4),

Chalk and

Board 2,3 T2,T3,R1

L16 Eight-Nodded Hexahedral

Element (HEXA 8), 2D

isoparametric element

Chalk and

Board 2,3 T2,T3,R1

L17 Lagrange interpolation functions Chalk and

Board 2,3 T2,T3,R1

L18 Numerical integration: Gaussian

quadrature one point, two point

formulae, 2D integrals

Chalk and

Board 2,3 T2,T3,R1

L19

Force terms: Body force, traction

force and point loads,

Chalk and

Board 4 T2,T3,R1

L20 Solution for displacement, stress

and strain in 1D straight bars Chalk and

Board 4 T2,T3,R1

L21 Problems on stepped bars bars. Chalk and

Board 4 T2,T3,R1

L22 Problems on tapered bars. Chalk and

Board 4 T2,T3,R1

L23 Problems on truss. Chalk and

Board 4 T2,T3,R1

L24 Problems on truss. Chalk and

Board 4 T2,T3,R1

Assignment Questions COs

attained

Explain linear, quadratic and cubic models 2



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Define shape function. What are the properties of shape function? 2,3

Derive the shape function for bar element in global coordinate system 2,3

Derive the shape function for bar element in natural coordinate system. 2,3

Derive the shape function for quadratic bar element. 2,3

Derive the shape function for quadratic bar element. 2,3

Derive the shape function for CST element 2,3

Derive the shape function for four noded tetrahedral element 2,3

Derive the shape function for eight noded hexahedral element 2,3

Find the values of following integrals using 2point and 3point Gauss quadrature

methods

a)

1

1

1

1

32 )2( dd

b) dxx

xe x

1

1

2 ])2(

13[

c) 3

1x

dx

d) d)223( 2

1

1

3

2,3

Determine deformation, strain, stress and reactions in following bars

1 2

P

A1=2400mm2

A2=600mm2

E1=70X109 N/m2

E2=200X109 N/m2

300mm 400mm

P=200KN



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Determine deformation, strain, stress and reactions in following bars

b)

4

Determine deformation and stress in members of following truss

4

400m

m

400m

m

400m

m 2000m

m2

2000m

m2

1500m

m2

150KN

E=200GP

a

E=200GPa

P=300KN

150 300mm 150

250mm2

400mm2

P



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Module: III Beams, Shafts and Torsion of Shafts Planned Hours: 07



1.Derive Hermite shape function for beam element

2. Analyze beams with different types of loads

3. Analyze Shafts with different torque.

Lesson Plan:

Lesson. No.


Method POs

Attained COs

Attained

Reference

book/Chapter

no.

L25 Boundary conditions, Load

vector, Hermite shape functions Chalk and

Board

a,b,e,k

3 T1,T3

L26 Beam stiffness matrix based on

Euler-Bernoulli beam theory

Examples on cantilever beams

Chalk and

Board 3 T1,T3

L27 propped cantilever beams,

Numerical problems on simply

supported beams,

Chalk and

Board 4 T1,T3

L28

Numerical problems on fixed

straight and stepped beams using

direct stiffness method with

concentrated

Chalk and

Board 4 T1,T3

500mm

500mm

50KN

E=200GPa



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L29

Numerical problems on fixed

straight and stepped beams using

direct stiffness method with

uniformly distributed load

Chalk and

Board 4 T1,T3

L30 Finite element formulation of

shafts Chalk and

Board 3 T3

L31 Determination of stress and twists

in circular shafts Chalk and

Board 4 T3

L32 Numericals Chalk and

Board 4 T3


Derive Hermite Shape functions 3

A beam of length 10m, fixed at one end and supported by a roller at the other end

carries 20KN concentrated load at the centre of the span.By taking the modulus of

elasticity as 200GPa and moment of inertia as 24X10-6 m4, determine

a) Deflection under the load

b) Shear forge and bending moment on each element

4

Solve for deflections and slopes at points 2 & 3 using beam elements for the

following. Also determine the deflection at centre of the portion of the UDL

4

1m 1m

12KN/m

E=200GPa

I=4X106mm4



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Unit wise plan


Module IV : Heat Transfer and Fluid Flow Planned Hours: 06



1.Derive stiffness matrix for one dimensional heat transfer using variational method.

2.Analyze one dimensional heat transfer problems

3.Analyze flow through pipes

Lesson Plan:

Lesson. No.


Method POs

Attained COs

Attained

Reference

book/Chapter

no.

L33 Basic equations of heat transfer:

Energy balance equation

Chalk and

Board

a,b,e,k

3 T1,T2

L34 Rate equation Chalk and

Board 3 T1,T2

L35 energy generated in solid,

energy stored in solid

Chalk and

Board 3 T1,T2

L36 1D finite element formulation

using variation method Chalk and

Board 3 T1,T2

L37

Problems with temperature

gradient and heat fluxes

approach

Chalk and

Board 4 T1,T2

L38



approach

Chalk and

Board 4 T1,T2

L39



approach

Chalk and

Board 4 T1,T2

L40 Problems continued.. Chalk and

Board 4 T1,T2

L41 Flow through a porous medium Chalk and

Board 3 T1,T2

L42 Flow through pipes of uniform

sections Chalk and

Board a,b,e,k

3 T1,T2

L43 Flow through pipes of stepped

sections Chalk and

Board 4 T1,T2



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L44 Flow through pipes of stepped

sections Chalk and

Board 4 T1,T2


Explain energy balance equation 3

Explain conduction, convection and radiation 3

Derive stiffness matrix for one dimensional heat conduction using variation approach. 3

A composite wall consists of three materials as shown in fig. The outer temperature

T0 =20oC. Convective heat transfer takes place on the inner surface of the wall with T

=800oC and h=25W/m2 oC. Determine the temperature distribution on the wall.

4

Consider a brick wall of thickness L=0.3m, K=0.7W/m0C. The inner surface is at

28oC and outer surface is exposed to cold air at -15 oC. Heat transfer coefficient on

outside surface h= 40 W/m2 oC. Determine the temperature distribution within the wall

and also the heat flux through the wall. Use two element model.

4

A metallic fin with thermal conductivity K=360W/m°C, 0.1cm thick, and 10cm long

extends from a plane wall whose temperature is 235°C. Determine the temperature

distribution and amount of heat transferred from the fin to the air at 20°C with h=9

W/m2 °C. Take the width of fin to be 1m.

4

Derive element stiffness matrix and equation for one dimensional fluid flow. 3

Determine a) The fluid head distribution along the length of the coarse gravelly

medium of length 0.762 m, b) The velocity in the upper part, c) The volumetric flow

rate in the upper part. The fluid head at the top is 0.254m and that at the bottom is

0.0254m. Let the permeability coefficient be Kxx=0.0127m/s. Assume a cross

sectional area of 0.646X10-3m2.

4

0.3m 0.15m 0.15m

K1 K2 K3

T0 =20oC.

K1=20W/moC

K2=30W/moC

K3=50W/moC

h=25W/m2 oC

T =800 oC

h

T



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Unit wise plan


Module V

Axi-symmetric Solid Elements & Dynamic Considerations Planned Hours: 12



Analyze axisymmetric bodies

Analyze dynamic problems

Lesson Plan:

Lesson. No.


Method POs

Attained COs

Attained

Reference

book/Chapter

no.

L45 Derivation of stiffness matrix of

axisymmetric bodies with

triangular elements

Chalk and

Board

a,b,e,k

3 T1,T3

L46

Numerical solution of

axisymmetric triangular

element(s) subjected to point

loads

Chalk and

Board 4 T1,T3

L47 Numericals continued.. Chalk and

Board 4 T1,T3


Board 4 T1,T3


Board 4 T1,T3

L50 Formulation for point mass Chalk and

Board 3 T1,T3

L51 Consistent element mass matrix

of one dimensional bar element Chalk and

Board 3 T1,T3

L52 Consistent element mass matrix

of one dimensional truss element Chalk and

Board 3 T1,T3

L53 Lumped mass matrix of bar

element Chalk and

Board 3 T1,T3

L54 Lumped mass matrix of, truss

element. Chalk and

Board 3 T1,T3



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Derive stiffness matrix for axisymmetric body with triangular element 3

A long cylinder of inside diameter 80mm and outside diameter 120mm snuggly fits in

a hole over its full length. The cylinder is then subjected to an internal pressure of

2MPa. Using 2 elements on the 10mm length shown, find the displacement at the inner

radius. Take E=200GPa and µ=0.3

4

Derive the expression for element mass matrix of a solid body with distributed mass. 3

Write the properties of Eigen values and Eigen vectors. 3

Derive element mass matrix for bar element. 3

Derive element mass matrix for truss element. 3

Determine the Eigen values and eigenvector for the stepped bar shown in fig.when it is

subjected to axial vibrations.

l/2 l/2

E,2A,ρ E,A,ρ

4

For a bar element obtain lumped mass matrix 3

2 1



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Semester – VI

Course Title: Computer Integrated Manufacturing

(15ME62)

2017-2018


COURSE FILE

Prof. B.M.ANGADI

Module Coordinator Prof.Ramesh M.Nyamagoudar

NNuM.Nyamagoudar Course Coordinator



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The educational objectives of the Mechanical Engineering Program are to prepare our graduates

to:








disciplines.



l. an ability to apply knowledge of mathematics, science, and Mechanical Engineering

m. an ability to design and conduct experiments, as well as to analyze and interpret data

n. an ability to design a mechanical system, mechanical component, or process to meet desired



o. an ability to function on multidisciplinary teams

p. an ability to identify, formulate, and solve mechanical engineering problems

q. an understanding of professional and ethical responsibility

r. an ability to communicate effectively

s. the broad education necessary to understand the impact of mechanical engineering solutions


t. a recognition of the need for, and an ability to engage in life-long learning,

u. a knowledge of contemporary issues

v. an ability to use the techniques, skills, and modern mechanical engineering tools necessary


Department of: Mechanical Engineering

Program: B.E (Mechanical Engineering)

Course Title:CIM Course Code:15ME62

Theory: Practical: x



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Prerequisites to this course:

(Course title with course codes)

Maths Productio

n Tech

CNC Robotics

Program Outcomes

(POs) a b c d E f g h i j k l m

x x x x x x x

Mapping of Course

Outcomes with POs

2,4

1,2

,3,4

,5

,6

4

1,2

,3

2,3

,4,5

,6

4

1 t

o 8

Course category

Bas

ic

Sci

ence

s

Gen

eral

/

Hu

man

itie

s

Gen

eral

Core

Elective G-A G-B G-C G-D G-E G-F

x

Teaching Methods: PPT OHP Face to

Face

Guest

Lecture

Video

lecture

Demo

(Lab

visit)

Seminars Industrial

Visits

Units I to X I,II,III,VI,

VII

II,IV,

V,VI,

VII

VIIi 1 to 8 Vii,

Vii,IX,X

Continuous Assessment Internal assessment tests Assignment Tutorial

03 03

Contents beyond

syllabus to meet POs:

Topics POs attained

1.Videos

2. Animations

3.Industrial visit

A,b,c,h,I,k

Approved by: Module Coordinator Prof B M Angadi

Program coordinator Prof S B Koulagi

Achieving Intended Course Learning Outcomes

The following skills are directly or indirectly imparted to the students in the following

teaching and learning methods:

Sl.No. Course

Learning

Outcomes

Possible capabilities, skills,

expertise gained (codes)

Means of imparting the

curriculum

1 CO1 Kn, PS, PSS Class room lectures

2 CO2 PSS, Un Class room lectures

3 CO3 PSS, AS Class room lectures

4 CO4 PSS,PS Class room lectures



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5 CO5 AK, PS Lab visit

Possible capabilities, skills, expertise gained Code

Knowledge Kn

Understanding (Comprehension) Un

Problem solving skills (application skills) PSS

Practical skills (application skills) PS

Analytical skills AS

Synthesis skills SS

Written communication skills WCS

Verbal/oral communication skills VCS

Presentation skills PS

Leadership skills LS

COURSE PLAN


Subject: Computer Integrated Manufacturing Subject code: 15ME62

Total Teaching Hours: 50 I A Marks:20


Lesson Plan Prepared by: Prof:Ramesh

M.Nyamagoudar Date:01/01/2018

Course Content

PART-A

Module-1.

1.Introduction to CIM and Automation: Automation in Production Systems,

automated manufacturing systems- types of automation, reasons for automating,

Computer Integrated Manufacturing, computerized elements of a CIM system,

CAD/CAM and CIM. Mathematical models and matrices: production rate,

production capacity, utilization and availability, manufacturing lead time, work-in-

process, numerical problems. 5 HOURS

2. Automated Production Lines and Assembly Systems: Fundamentals, system

configurations, applications, automated flow lines, buffer storage, control of

production line, analysis of transfer lines, analysis of flow lines without storage,

partial automation, analysis of automated flow lines with storage buffer,

fundamentals of automated assembly systems, numerical problems. 5 HOURS

10 Hours



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Module – 2

3. CAD and Computer Graphics Software: The design process, applications of

computers in design, software configuration, functions of graphics package,

constructing the geometry. Transformations: 2D transformations, translation,

rotation and scaling, homogeneous transformation matrix, concatenation, numerical

problems on transformations. 5HOURS.

4. Computerized Manufacture Planning and Control System: Computer Aided

Process Planning, Retrieval and Generative Systems, benefits of CAPP, Production

Planning and Control Systems, typical activities of PPC System, computer integrated

production management system, Material Requirement Planning, inputs to MRP

system, working of MRP, outputs and benefits, Capacity Planning, Computer Aided

Quality Control, Shop floor control. 5HOURS

10 Hours

Module - 3

5. Flexible Manufacturing Systems: Fundamentals of Group Technology and

Flexible Manufacturing Systems, types of FMS, FMS components, Material

handling and storage system, applications, benefits, computer control systems, FMS

planning and design issues, Automated Storage and Retrieval Systems, AS/RS and

Automatic parts identification systems and data capture. 5HOURS

6. Line Balancing: Line balancing algorithms, methods of line balancing, numerical

problems on largest candidate rule, Kilbridge and Wester method, and Ranked

Positional Weights method, Mixed Model line balancing, computerized line

balancing methods. 5 HOURS

10 Hours

Module - 4.

7. Computer Numerical Control: Introduction, components of CNC, CNC

programming, manual part programming, G Codes, M Codes, programming of

simple components in turning, drilling and milling systems, programming with

canned cycles. Cutter radius compensations. 5 HOURS

8. Robot Technology: Robot anatomy, joints and links, common robot

configurations, robot control systems, accuracy and repeatability, end effectors,

sensors in robotics. Robot programming methods: on-line and off-line methods.

Robot industrial applications: material handling, processing and assembly and

inspection. 5 HOURS

10 Hours



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Module – 5

9. Additive Manufacturing Systems: Basic principles of additive manufacturing,

slicing CAD models for AM, advantages and limitations of AM technologies,

Additive manufacturing processes: Photo polymerization, material jetting, binder

jetting, material extrusion, Powder bed sintering techniques, sheet lamination, direct

energy deposition techniques, applications of AM. Recent trends in manufacturing,

Hybrid manufacturing. 5 HOURS

10. Future of Automated Factory: Industry 4.0, functions, applications and

benefits. Components of Industry 4.0, Internet of Things (IOT), IOT applications in

manufacturing, Big-Data and Cloud Computing for IOT, IOT for smart

manufacturing, influence of IOT on predictive maintenance, industrial automation,

supply chain optimization, supply-chain & logistics, cyber-physical manufacturing

systems. 5 HOURS

10 Hours

Course Outcomes:

After studying this course, students will be able to:

CO1 Able to define Automation, CIM, CAD, CAM and explain the differences

between these concepts. Solve simple problems of transformations of entities on

computer screen.

CO2 Explain the basics of automated manufacturing industries through mathematical

modelsand analyze different types of automated flow lines.

CO3 Analyze the automated flow lines to reduce down time and enhance

productivity.

CO4 Explain the use of different computer applications in manufacturing, and able to

prepare part programs for simple jobs on CNC machine tools and robot

programming.

CO5 Visualize and appreciate the modern trends in Manufacturing like additive

manufacturing, Industry 4.0 and applications of Internet of Things leading to

Smart Manufacturing.

Text Books:

1. Automation, Production Systems and Computer-Integrated Manufacturing, by Mikell P

Groover, 4th Edition, 2015, Pearson Learning.

2. CAD / CAM Principles and Applications by P N Rao, 3rd Edition, 2015, Tata McGraw-Hill.

3. CAD/CAM/CIM, Dr. P. Radhakrishnan, 3rd edition, New Age International Publishers, New

Delhi.

Reference Books:

1. “CAD/CAM” by Ibrahim Zeid, Tata McGraw Hill.



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2. “Principles of Computer Integrated Manufacturing”, S.Kant Vajpayee, 1999, Prentice Hall of

India, New Delhi.

3. “Work Systems And The Methods, Measurement And Management of Work”, Groover M.

P.,Pearson/Prentice Hall, Upper Saddle River, NJ, 2007.

4. “Computer Automation in Manufacturing”, Boucher, T. O., Chapman & Hall, London, UK,

1996.

5. “Introduction to Robotics: Mechanics And Control”, Craig, J. J., 2nd Ed., AddisonWesley

Publishing Company, Readong, MA, 1989.

6. Internet of Things (IoT): Digitize or Die: Transform your organization. Embrace the digital

evolution. Rise above the competition, by Nicolas Windpassinger, Amazon.

7. "Internet of Things: A Hands-on Approach", by Arshdeep Bahga and Vijay Madisetti

(Universities Press)

8. Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing,

2nd Ed. (2015), Ian Gibson, David W. Rosen, Brent Stucker

9. “Understanding Additive Manufacturing”, Andreas Gebhardt, Hanser Publishers, 2011

10. Industry 4.0: The Industrial Internet of Things, Apress, 2017, by Alasdair Gilchrist

Scheme of Examination:

Assessment Marks

CAI 20

SEE 80

Total 100

INTERNAL ASSESSMENT SYALLABUS

I I.A – MODULE I AND II

II I.A - MODULE III NAD IV

III I.A - MODULE V

Course Description:

Overview of the course

The contents of the course “Computer Integrated Manufacturing (CIM)” is designed by

the members of the Boards of Studies (BoS) constituted by Visveswaraya Technological

University (VTU) Belgaum.

Basically, CIM course deals with:

Types of automation, CIM, processing in manufacturing , Production concepts

Mechanized and automated flow lines and It also deals with transfer mechanisms.

Design and analysis of Assembly lines and line balancing

Design and analysis Automated Assembly Systems



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Computerized Manufacturing Planning System

CNC Machining Centers

Robotics

Relevance of the course:

The main purpose of studying this subject is to have knowledge of various techniques

used for manufacturing. These techniques should be used to get higher productivity with lower

cost of manufacturing and hence automation is necessary. Automation helps to improve

equipment utilization, labor utilization and the overall productivity rate. This importance of

automation through design, manufacturing and analysis should be practically implied to transfer

lines and their efficient usage, line balancing, material handling systems, group technology,

flexible manufacturing systems, computerized planning CNC part programming, robotics etc.

Application Areas:

Manufacturing industries

Automotive industries

Ancillary industries

Assembly operations

Material Handling

This subject would be helpful in finding out the efficiency of the department and labor,

there by determining the idle times of the same so that effective action can be taken. It helps in

designing as well as selecting correct type of AFL’s for different types of work-part transport in

manufacturing industries.

Prerequisites:

This subject requires the student to know about basics of production, manufacturing, and

manufacturing systems. It also needs to have a prior knowledge of simple laws of probability for

analysis of transfer lines.

Module wise lesson plan

Course title and code: Computer Integrated Manufacturing (15ME62)

MODULE.1 : 1.Introduction to CIM and Automation

2. Automated Production Lines and Assembly

Systems:

Planned hours: 10

Learning objectives: The student will be able to

1. Explain the concept of Automation, Types of automation, CIM and the reasons why

companies install automated system.

2. Discuss the production concepts which provide mathematical models for computing

MLT, Rp, WIP, TIP etc.



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3. Explain the Fundamentals, system configurations, applications, automated flow lines,

buffer storage, control of production line, analysis of transfer lines,

4. analysis of flow lines without storage, partial automation, analysis of automated flow

lines with storage buffer, fundamentals of automated assembly systems,

Lesson Schedule:

Lecture

No. Topics Covered

Teaching

Method

PO

attained

COs

attained

Reference

Book/Chapter

No

L1 Introduction, automation

definition

Chalk and

Board

a,b,e

k

1 T1/1

L2 Types of automation Chalk and

Board 1 T1/1

L3 CIM, processing in

manufacturing

Chalk and

Board 1 T1/1

L4 Production concepts,PR Chalk and

Board 1 T1/2

L5 system configurations,

applications,

Chalk and

Board 1 T1/2

L6

automated flow lines, buffer

storage, control of production

line, analysis of transfer lines,

Chalk and

Board 1 T1/2

L7 analysis of flow lines without

storage, partial automation

Chalk and

Board 1 T1/2

L8 analysis of automated flow

lines with storage buffer,

Chalk and

Board 1 T1/2

L9 Fundamentals of automated

assembly systems

Chalk and

Board 1 T1/2

L10 numerical problems. Chalk and

Board 1 T1/2

Assignments:

Questions COs

attained

1. What is automation? explain different types. 1

2. Derive an expression for MLT. 1

3. Explain various reasons for automation. 1

4. Explain analysis of flow lines without storage, 1

5. Define Various production concepts such as WIP,PC,PU,MLT Etc 1



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6. Explain the buffer storage 1

7. A production unit is operated for 48 hrs/week at its full capacity. Its

production rate is 5 units /hr .During a certain week the unit produced 200

good parts and was idle for remaining time.

1

8. Determine the PC and PU. 1

9. There are 4 machines in a plant .the set up and operation time for each

machine is shown below .the batch size is 150 and the avg non operation time

is 6 hrs. Determine the MLT and the production rate for operation number 2

1



Module 2:3.CAD and Computer Graphics Software:

4.Computerized Manufacture Planning and

Control System:

Planned hours: 10


1. Explain Computer aided Process Planning, Retrieval and Generative Systems,

2. Write the benefits of CAPP,

3. Explain inputs of MRP

4 .what are the functions of graphics package,

4. Explain 2D transformations, translation, rotation and scaling,

Lesson Schedule:

Lecture

No. Topics Covered

Teaching

Method

PO

attained

COs

attained

Reference

Book/Chapter

No

L11

The design process,

applications of computers in

design

Chalk

and

Board

a,b,e,

k

2 T1/18

L12

software configuration

functions of graphics

package, constructing the

geometry.

Chalk

and

Board

2 T1/18

L13 Transformations: 2D

transformations

Chalk

and

Board

2 T1/18

L14

translation, rotation and

scaling, homogeneous

transformation matrix,

Chalk

and

Board

2 T1/18



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concatenation,

L15 numerical problems on

transformations

Chalk

and

Board

2 T1/18

L16 Computer Aided Process

Planning,

Chalk

and

Board

2 T1/18

L17

Retrieval and Generative

Systems, benefits of CAPP,

Production Planning and

Control Systems,

Chalk

and

Board

2 T1/18

L18

typical activities of PPC

System, computer integrated

production management

system, Material Requirement

Planning,

Chalk

and

Board

2 T1/18

L19

Inputs to MRP system, working

of MRP, outputs and benefits,

Capacity Planning,

Chalk

and

Board

2 T1/18

L20 Computer Aided Quality

Control, Shop floor control.

Chalk

and

Board

2 T1/18

Assignments:

Questions COs

attained

1. What is design process and write the applications of computers in design 2

2. What are the functions of graphics package 2

3. Explain constructing the geometry. 2

4. Explain 2D transformations, translation, rotation and scaling 2

5. Explain Process Planning, Retrieval and Generative Systems, benefits of CAPP 2

6. What is Production Planning and Control Systems, 2

7. Explain MRP 2

8. Explain inputs of MRP 2

9. Explain Capacity planning 2



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Module 3: 5.Flexible Manufacturing Systems:

6. Line Balancing:

Planned hours: 10


1. Demonstrate the assembly operations.

2. Construct precedence diagrams

3. Balance the line using different methods.

4. What is FMS?

5. What are the types of FMS?

Lesson Schedule:

Lecture

No. Topics Covered

Teaching

Method

PO

attained

COs

attained

Reference

Book/Chapter

No

L21

Fundamentals of Group

Technology and Flexible

Manufacturing Systems

Chalk

and

Board

b,e,k

k

3 T1/18

L22

types of FMS, FMS

components, Material

handling and storage system

Chalk

and

Board

3 T1/18

L23

Applications, benefits,

computer control systems,

FMS planning and design

issues,

Chalk

and

Board

3 T1/18

L24 Automated Storage and

Retrieval Systems,

Chalk

and

Board

3 T1/18

L25

AS/RS and Automatic parts

identification systems and

data capture

Chalk

and

Board

3 T1/18

L26 Line balancing algorithms,

methods of line balancing,

Chalk

and

Board

3 T1/18

L27 Numerical problems on

largest candidate rule

Chalk

and

Board

3 T1/18

L28 , Kilbridge and Wester

method, and Ranked

Chalk

and 3 T1/18



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Positional Weights method Board

L29 Mixed Model line balancing

Chalk

and

Board

3 T1/18

L30 computerized line balancing

methods

Chalk

and

Board

3 T1/18

Assignments:

Questions COs

attained

1. What is line balancing what is its necessity. 3

2. Explain the terminology of line balancing. 3

3. Explain briefly various methods of line balancing. 3

4. Draw the precedence diagram and by using largest candidate rule, kilbridge

and westers, ranked positional weight method balance the line and calculate

the balance delay.

3

5. What is FMS? 3

6. What are the types of FMS?



Module 4: 7. Computer Numerical Control:

8. Robot Technology

Planned hours: 10


1. Discuss the concepts of manufacturing with CNC machining centers.

2. Develop part programs for milling and turning operations.

3. Analyze the Robot configurations

4. Discuss the Robot motions

5. Develop Robot programming

Lesson Schedule:

Lecture

No. Topics Covered

Teaching

Method

PO

attained

COs

attained

Reference

Book/Chapter

No

L31 Introduction, components of

CNC

Chalk

and

a,b,k 4 T1/17



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Board

L32

CNC programming, manual

part programming, G Codes,

M Codes

Chalk

and

Board

4 T1/17

L33

programming of simple

components in turning,

drilling and milling systems

Chalk

and

Board

4 T1/17

L34 programming with canned

cycles

Chalk

and

Board

4 T1/17

L35 Cutter radius compensations.

Chalk

and

Board

4 T1/17

L36 Robot anatomy, joints and

links

Chalk

and

Board

4 T1/17

L37 common robot configurations,

robot control systems

Chalk

and

Board

4 T1/17

L38

accuracy and repeatability,

end effectors, sensors in

robotics

Chalk

and

Board

4 T1/17

L39 Robot programming methods:

on-line and off-line methods

Chalk

and

Board

4 T1/17

L40

Robot industrial applications:

material handling, processing

and assembly and inspection.

Chalk

and

Board

4 T1/17

Assignments:

Questions COs

attained

1. What is a CNC and what are elements of CNC? 4

2. What is CNC Machining center? 4

3. Explain fundamental steps involved in part programming? 4

4. Write Programs for milling and turning? 4

5.What is meant by Robot Configuration? 4

6.Explain different robot motions? 4

7.Explain about end effectors of robots? 4



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8.Explain about Robot sensors and applications of robots? 4



Module 5:: 9.Additive Manufacturing Systems:

10. Future of Automated Factory:

Planned hours: 08


1. Explain the concepts of Additive manufacturing systems

2. Discuss the future of automated factory

Lesson Schedule:

Lecture

No. Topics Covered

Teaching

Method

PO

attained

COs

attained

Reference

Book/Chapter

No

L41

Basic principles of

additive

manufacturing, slicing

CAD models for AM,

Chalk and

Board

a,e,k

5 T1/19

L42

advantages and

limitations of AM

technologies, Additive

manufacturing

processes:

Chalk and

Board 5 T1/19

L43

Photo polymerization,

material jetting, binder

jetting, material

extrusion

Chalk and

Board 5 T1/19

L44

Powder bed sintering

techniques, sheet

lamination, direct

energy deposition

techniques,

applications of AM

Chalk and

Board 5 T1/19

L45

Recent trends in

manufacturing, Hybrid

manufacturing

Chalk and

Board 5 T1/19

L46 Industry 4.0, functions Chalk and

Board 5 T1/10



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L47

applications and

benefits. Components

of Industry 4.0,

Internet of Things

(IOT),

Chalk and

Board 5 T1/10

L48

IOT applications in

manufacturing, Big-

Data and Cloud

Computing for IOT,

IOT for smart

manufacturing,

Chalk and

Board 5 T1/10

L49

influence of IOT on

predictive

maintenance, industrial

automation, supply

chain optimization,

supply-chain &

logistics,

Chalk and

Board 5 T1/10

L50

cyber-physical

manufacturing

systems.

Chalk and

Board 5 T1/10

Assignments:

Questions COs attained

1. Explain the Basic principles of additive manufacturing 5

2. Write the advantages and limitations of AM technologies 5

3. Explain Recent trends in manufacturing and Hybrid manufacturing 5

4. Explain internet of things 5

5. Explain supply-chain & logistics 5

6. Explain cyber-physical manufacturing systems. 5

… End of Computer Integrated Manufacturing Lesson Plan …



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Semester – VI

Course Title: Heat Transfer (15ME63)

2017 - 2018


COURSE FILE

Dr. R. G. Tikotkar

Module Coordinator

Prof. R. S. ELLUR

Course Coordinator

Prof. S. B. Koulagi

Program Coordinator



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Program: BE Mechanical

Course Title: HEAT TRANSFER Course Code:15ME63

Theory: Practical:


(Course title with course

codes)

Program Outcomes

(POs) a b c d e f g h i j k l m

-- --

Mapping of Course

Outcomes with Pos

1,2

,3,4

,5

1,2

,34

,5

1,2

,3,4

,5

1,2

,3,4

,5

1,2

,3,4

,5

Course category

Bas

ic

Sci

ence

s

Gen

eral

/

Hum

anit

ies

Gen

eral

Core

Elective G-A G-B G-C G-D G-E G-F


face

Guest

Lecture

Video

lecture

Demo

(Lab visit)

Seminars Industrial

visits

Module I,II,III,IV,V,


3 3

Contents beyond


Topics POs attained

1.

2.

3.

Approved by: Module Coordinator Dr. R.G.Tikotkar

Program coordinator Prof. S.B.Koulagi











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disciplines.


Program Outcomes (POs)

w. an ability to apply knowledge of mathematics, science, and mechanical engineering

x. an ability to design and conduct experiments, as well as to analyze and interpret data

y. an ability to design a mechanical system, mechanical component, or process to meet desired



z. an ability to function on multidisciplinary teams

aa. an ability to identify, formulate, and solve mechanical engineering problems

bb. an understanding of professional and ethical responsibility

cc. an ability to communicate effectively

dd. the broad education necessary to understand the impact of mechanical engineering solutions


ee. a recognition of the need for, and an ability to engage in life-long learning,

ff. a knowledge of contemporary issues

gg. an ability to use the techniques, skills, and modern mechanical engineering tools necessary


hh. competence to adopt technical knowledge and managerial skill in planning projects and

deployment of resources

Course Plan

Semester: VI Year: 2017 - 18

Course Title Heat Transfer Course Code 15ME63

Total Teaching Hours 54 Teaching hours/week 3 + 2

Internal Assessment Marks 20 Semester Examination Marks 80

Course Plan prepared by Dr. R. G. Tikotkar, Prof. R. S. Ellur & Prof. M. D. Kulkarni

Course Content

Module - I

Introductory concepts and definitions: Modes of heat transfer: Basic laws governing

conduction, convection, and radiation heat transfer; Thermal conductivity; convective heat

transfer coefficient; radiation heat transfer combined heat transfer mechanism, Types of

boundary conditions. General Heat Conduction Equation: Derivation of the equation in (i)

Cartesian, (ii) Polar and (iii) Spherical Co-ordinate Systems.

Steady-state one-dimensional heat conduction problems in Cartesian System: Steady-

8 Hours



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state one dimensional heat conduction problems (i) with and without heat generation and (ii)

with and without varying thermal conductivity - in Cartesian system with various possible

boundary conditions, Thermal Resistances in Series and in Parallel.

Module -II

Critical Thickness of Insulation: Concept, Derivation, Extended Surfaces or Fins:

Classification, Straight Rectangular and Circular Fins, Temperature Distribution and Heat

Transfer Calculations, Fin Efficiency and Effectiveness, Applications.

Transient [Unsteady-state] heat conduction: Definition, Different cases - Negligible

internal thermal resistance, negligible surface resistance, comparable internal thermal and

surface resistance, Lumped body, Infinite Body and Semi-infinite Body, Numerical

Problems, Heisler and Grober charts.

9 Hours

Module - III

Numerical Analysis of Heat Conduction: Introduction, one-dimensional steady

conduction, one dimensional unsteady conduction, two-dimensional steady and unsteady

conduction, the difference equation, boundary conditions, solution methods, cylindrical

coordinates and irregular boundaries.

Thermal Radiation: Fundamental principles - Gray, White, Opaque, Transparent and Black

bodies, Spectral emissive power, Wien’s, Rayleigh-Jeans’ and Planck’s laws, Hemispherical

Emissive Power, Stefan-Boltzmann law for the total emissive power of a black body,

Emissivity and Kirchhoff’s Laws, View factor, Net radiation exchange in a two-body

enclosure, Typical examples for these enclosures, Radiation Shield.

9 Hours

Module - IV

Forced Convection: Boundary Layer Theory, Velocity and Thermal Boundary Layers,

Prandtl number, Governing Equations – Continuity, Navier-Stokes and Energy equations,

Boundary layer assumptions, Integral and Analytical solutions to above equations, Turbulent

flow, Various empirical solutions, Forced convection flow over cylinders and spheres,

Internal flows –laminar and turbulent flow solutions, Forced Convection Cooling of

Electronic Devices.

Free convection: Laminar and Turbulent flows, Vertical Plates, Vertical Tubes and

Horizontal Tubes, Empirical solutions.

8 Hours

Module - V

Heat Exchangers: Definition, Classification, applications, LMTD method, Effectiveness –

NTU method, Analytical Methods, Fouling Factors, Chart Solution Procedures for solving

Heat Exchanger problems: Correction Factor Charts and Effectiveness-NTU Charts, compact

heat exchangers. Heat Transfer with Phase Change:

Introduction to boiling, pool boiling, Bubble Growth Mechanisms, Nucleate Pool Boiling,

Critical Heat Flux in Nucleate Pool Boiling, Pool Film Boiling, Critical Heat Flux, Heat

Transfer beyond the Critical Point, filmwise and dropwise Condensation, heat pipes,

entrainment, wicking and boiling limitations.

9 Hours

TEXT BOOKS:

T1 Principals Of Heat Transfer, Frank Kreith, Raj M. Manglik, Mark S. Bohn, Seventh Edition,



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Cengage learning, 2011.

T2 Heat transfer, a practical approach, Fifth edition, Yunus A. Cengel Tata Mc Graw Hill.

REFERNCE BOOKS:

R1 Heat And Mass Transfer, Kurt C, Rolle, second edition, Cengage learning.

R2 Heat Transfer, M. Necati Ozisik, A Basic Approach, McGraw Hill, New York, 2005.

R3 Fundamentals of Heat and Mass Transfer, Incropera, F. P. and De Witt, D. P., 5th Edition, John

Wiley and Sons, New York, 2006.

R4 Heat Transfer, Holman, J. P., 9th Edition, Tata McGraw Hill, New York, 2008.


Two questions to be set from each module. Students have to answer five full questions, choosing at least

one full question from each module.

Assessment Marks

Internal Assessment tests 20

VTU Semester examination 80

Total 100

COURSE DESCRIPTION:

1. Overview of the course

Heat transfer is the flow of thermal energy driven by thermal non-equilibrium, commonly

measured as a heat flux, i.e. the heat flow per unit time at a control surface. This course focuses on the

problems and complexities of heat and mass transfer and emphasizes on analysis using correlations. The

course assumes basic understanding of thermodynamics and fluid mechanics and exposure to differential

equations and methods of solution.

The contents of the course “Heat and Mass Transfer” is designed by the members of the Board of

Studies (BoS) constituted by Visvesvaraya Technological University (VTU) Belgaum.

Basically, Heat and Mass Transfer course deals with:

Conduction Heat Transfer

Variable thermal conductivity

Transient Conduction Boundary layers

Convection (Free & Forced)

Heat Exchangers

Boiling & Condensation

Radiation heat transfer 2. Relevance of the Course:

Heat transfer theory is used to compute heating/cooling rate in heat transfer problems, or to

compute temperature fields and heat fluxes, or to compute required dimensions or properties for heat

insulation or conduction. Heat and mass transfer occur in coupled form in most production processes and

chemical-engineering applications of a physical, chemical, biological or medical nature. Very often they

are associated with heating and cooling, boiling, condensation and combustion processes and also with

fluids and their flow fields.

3. Application areas:



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Heat-transfer problems arise in many industrial and environmental processes, particularly in

energy utilization, thermal processing, chemical processing and thermal control.

4. Prerequisite:

This subject requires the knowledge of fundamentals of Thermodynamics and Fluid Mechanics.

5. Course Outcomes:

At the end of the course, the student should be able to

1. Understand the basic modes of heat transfer

2. Compute temperature distribution in steady-state and unsteady-state heat conduction.

3. Understand and interpret heat transfer through extended surfaces.

4. Explain the principles of radiation heat transfer and understand the numerical formula for heat

conduction problems.

5. Interpret and compute forced and free convective heat transfer.

6. Design heat exchangers using LMTD and NTU methods.

7. Explain the phenomenon of boiling and condensation on different surfaces.


Course title and code: Heat Transfer (15ME63)

Module 1 Planned hours: 08

Learning objectives: At the end of this chapter student will understand

1. Discuss heat transfer and compare three modes of heat transfer

2. Explain the desirable thermal properties for a given class of thermal applications

3. Derive 3-D heat conduction equation and use it for solution of heat transfer problems.

4. Discuss Boundary conditions (BC) of first, second and third kinds.

5. Formulate problems connected to heat conduction associated to different Boundary conditions

6. Determine temperature distribution, interface temperatures and heat flow rate across slab.

Lesson Plan:

Lecture

No. Topics covered

Teaching

Method

PO’s

Attained

CO’s

Attained

Reference

Book/

Chapter No.

L1

Introductory concepts and definitions: Modes of

heat transfer: Basic laws governing conduction,

convection, and radiation heat transfer; Thermal

conductivity; convective heat transfer

coefficient; radiation heat transfer combined heat

transfer mechanism,

Chalk and

Board

a,b,c,e,i

1, 2 R1/1

T2/1

L2 Types of boundary conditions. General Heat

Conduction Equation: Derivation of the equation

in Cartesian coordinate system.

Chalk and

Board 1, 2

T2/1

R1/2

L3 Derivation of the equation in Polar and Spherical

coordinate systems.

Chalk and

Board 1, 2

R1/2

T2/2

L4 Steady-state one-dimensional heat conduction

problems in Cartesian System with heat

generation.

Chalk and

Board 1, 2

R1/2

T2/3

T1 Tutorial 1 Chalk and

Board 1, 2

R1/2

T2/3


problems in Cartesian System without heat

Chalk and

Board 1, 2

R1/2

T2/3



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generation.


problems in Cartesian System with varying

thermal conductivity.

Chalk and

Board 1, 2

R1/2

T2/3


problems in Cartesian System without varying

thermal conductivity.

Chalk and

Board 1, 2

R1/ 1&2

T2/1,2&3

L8 Thermal Resistances in Series and in Parallel. Chalk and

Board 1, 2

R1/ 1&2

T2/1,2&3


Board 1, 2

R1/ 1&2

T2/1,2&3

Assignment questions:

1. Define and explain the different modes of heat transfer. 1

2. Define thermal conductivity, convection and radiation heat transfer coefficient. 1

3. Identify modes of heat transfer: Room lighting using tube-lights, water heating using

electric heater. 1

4. What are the different types of boundary conditions? Explain with neat sketches. 1, 2

5. Derive an expression for the temperature distribution and the rate of heat transfer for a plane. 1, 2

6. Derive an expression for the rate of heat transfer for composite plane. 1, 2

7. A temperature difference of 500˚C is applied across a fireclay brick 10cm thick with thermal

conductivity 1.0 W/m˚C. Determine the heat transfer rate per square meter area. 1, 2

8. A temperature difference of 100˚C is applied across a cork board 5cm thick with thermal

conductivity 0.04 W/m˚C. Determine the heat transfer rate across 3-m2 area per hour. 1, 2

9. Obtain expression for 3-D heat conduction equation in Cartesian, Polar and Spherical coordinate

systems. 1, 2

10. Water at a mean temperature of 20˚C flows over a flat plate at 80˚C. If the heat transfer coefficient

is 200 W/m2 ˚C, determine heat transfer per square meter of the plate over 5h. 1, 2

11. A thin metal plate 0.1m by 0.1m is placed in a large evacuated container whose walls are kept at

300K. The bottom surface of the plate is insulated, and the top surface is maintained at 500K as a

result of electric heating. If the emissivity of the plate is 0.8, what is the rate of heat exchange

between the plate and the walls of the container take =5.67X10-8W/m2 K4.

1, 2

12. A small hot surface at a temperature of 430 K with an emissivity of 0.8 dissipates heat by radiation

into the surrounding at a temperature of 400 K. If this radiation is characterized by radiation heat

transfer coefficient hr calculate its value.

1, 2

13. An industrial furnace made of fire clay brick (L1=0.25m, k1=1.0 W/moC) and is insulated using

insulation of k= 0.05 W/moC. Determine thickness of the layer to limit the heat loss to 1000W/m2

when the inside surface of the wall is maintained at 1030 oC and the outside surface at 30 oC A wall

is constructed of 10cm thick layer of brick (k=0.69 W/moC),1.5 cm thick fibre insulating board

(k=0.0.048 W/moC),followed by a 5cm layer of glass wool (k=0.038 W/moC) and 1.5cm thick

insulating board k=0.048 W/moC. Heat transfer coefficient on both sides is 12W/m2 Determine

overall heat transfer coefficient U.

1, 2



Module -2 Planned hours: 09



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Learning objectives: At the end of this chapter student will understand 1. Discuss the importance of critical thickness of insulation & the importance thermal contact

resistance concept.

2. Discuss the heat transfer in extended surfaces of uniform cross-section without heat generation

for long fin, short fin and tip insulated.

3. Discuss the fin efficiency and effectiveness.

4. Explain the transient heat conduction in solids with negligible internal temperature gradient

(Lumped system analysis).

5. Discuss the use of Transient temperature charts (Heisler’s charts) for transient conduction in slab,

long cylinder and in sphere

Lesson Schedule:

Lecture

No. Topics covered

Teaching

Method

PO’s

Attained

CO’s

Attained

Reference

Book/

Chapter No.

L9 Critical Thickness of Insulation, Concept,

Derivation,

Chalk and

Board

a,b,c,e,i

3 R1/3

R4/2

L10 Extended Surfaces or Fins: Classification.

Straight Rectangular and Circular Fins,

Chalk and

Board 3

R1/3

R4/2


Board 3

R1/3

R4/2

L11 Temperature Distribution and Heat

Transfer Calculations,

Chalk and

Board 3

R1/3

R4/2

L12 Fin Efficiency and Effectiveness,

Applications.

Chalk and

Board 3

R1/3

R4/2


Board 3

R1/3

R4/2

L13 Transient [Unsteady-state] heat

conduction: Definition, Different cases -

Negligible internal thermal resistance

Chalk and

Board 3

R1/3

R4/2

L14 Negligible surface resistance, comparable

internal thermal and surface resistance,

Chalk and

Board 3

R1/3

R4/2

L15 Lumped body, Infinite Body and Semi-

infinite Body

Chalk and

Board 3

R1/3

R4/2

L16 Numerical Problems Chalk and

Board 3

R1/3

R4/2

L17 Heisler and Grober charts. Chalk and

Board 3

R1/3

R4/2


Board 3

R1/3

R4/2


1. Define the terms Critical thickness of insulation, Fin efficiency, Contact and thermal

resistances. 3

2. Classify the fins 3

3. Copper plate fins of rectangular cross section having thickness 1mm, height 10mm and 3



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thermal conductivity 380 W/moC are attached to a plane wall maintained at 230 oC. Fins

dissipate heat by convection into the ambient air at 30 oC with a heat transfer coefficient of

40 W/m2 oC. Fins are spaced at 8mm (ie125 fins/m). Assume negligible heat loss from the fin

tip to determine fin efficiency, Area weighted fin efficiency. Net rate of heat transfer per m2 of

the wall surface, heat transfer rate without fins.

4. What do you mean by Lumped System Analysis? Obtain an expression for temperature distribution for

this system in terms of Biot and Fourier numbers. 3

5. Define Biot and Fourier number. Explain their significance. 3

6. A solid copper sphere of 10cm diameter [ρ=8954kg/m3 Cp=383J/kg C, k=386 W/moC] initially at a

uniform temperature of 250oC is suddenly immersed in a well stirred fluid which is maintained at a

uniform temperature of 50 oC.The heat transfer coefficient of the fluid and sphere is 200 W/m2 oC.

check if the lumped system analysis is suitable and hence determine the temperature of the block

t=5,10,15 min after the immersion (Ans=120, 74.5 &53 oC).

3

7. Using the lumped analysis determine the time required for the solid steel[ρ=7833kg/m3 Cp=0.46 kJ/kg

C, k=54 W/moC sphere of 5cm diameter to cool from 600 oC to 200 oC if it is exposed to air stream at

50 oC having a heat transfer coefficient of 100 W/m2 oC (Ans= 6min 34 S).

3

8. A 12mm diameter mild steel sphere (K=42.5W/mK) is placed in an air stream at 27˚C and the

corresponding heat transfer coefficient is 114 W/m2˚C. Calculate time taken to cool sphere from 540 ˚C

to 95˚C and Instantaneous heat transfer rate two minutes after commencement of cooling. For mild

steel:Density=7850 kg/m3 Sp. heat=475J/kgk Thermal diffusivity=0.043m2/hr.

3

9. A 0.10m thick brick wall (α=0.5X10-6 m2/s, k=0.69W/m˚C and ρ=2300kg/m3) is initially at Ti=230˚C.

The wall is suddenly exposed to an environment at T∞=30˚C with a heat transfer coefficient h=60

W/m2˚C. By using the transient temperature charts, Determine the centre temperature at 0.5, 2 and 4h

after exposure to the cooler ambient, surface temperature at 0.5 and 2h, and Energy removed from the

plate per square meter during 0.5h.

3

10. Consider a slab of thickness 10cm, a cylinder of diameter 10 cm and a sphere of 10 cm diameter each

made of steel (α=1.6X10-5 m2/s, k=61W/m˚C )and initially at uniform temperature of 300 ˚C. Suddenly

they are all immersed into a well stirred bath at 50˚C.The heat transfer coefficient between the fluid and

surface is1000 W/m2 oC. Calculate the time required for the centers of the solids to cool to 80˚C.

3




Learning objectives: At the end of this chapter student will understand.

1. Learn how to formulate and solve steady and unsteady state1D and 2D heat conduction problems.

2. Explain the conceptual features of radiation heat transfer and its applications.

3. Discuss terms involved in Radiation process & quantify the process of Radiation.

4. Discuss laws of shape factor and determining radiation heat exchanges between different

geometries of surfaces and enclosures. 5. Formulate radiation heat transfer for practical application.

Lesson Schedule:



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Lecture

No. Topics covered

Teaching

Method

PO’s

Attained

CO’s

Attained

Reference

Book/

Chapter No.

L18

Numerical Analysis of Heat Conduction:

Introduction, one-dimensional steady

conduction

Chalk and

Board

a,b,c,e,i

4 R4/3

L19 One dimensional unsteady conduction Chalk and

Board 4 R4/3

L20 Two-dimensional steady and unsteady

conduction,

Chalk and

Board 4 R4/3

L21 The difference equation, boundary

conditions

Chalk and

Board 4 R4/3

L22 Solution methods, cylindrical coordinates

and irregular boundaries.

Chalk and

Board 4 R4/3


Board 4 R4/3

L23

Thermal Radiation: Fundamental principles

- Gray, White, Opaque, Transparent and

Black bodies, Spectral emissive power,

Chalk and

Board 4

R1/4

T2/4

L24

Wien’s, Rayleigh-Jeans’ and Planck’s

laws, Hemispherical Emissive Power,

Stefan-Boltzmann law for the total

emissive power of a black body

Chalk and

Board 4

R1/4

T2/4

L25

Emissivity and Kirchhoff’s Laws, View

factor, Net radiation exchange in a two-

body enclosure,

Chalk and

Board 4

R1/4

T2/4

L26 Typical examples for these enclosures,

Radiation Shield

Chalk and

Board 4

R1/4

T2/4


Board 4

R1/4

T2/4

Assignment:

1. When numerical solution adopted for a problem? What are its advantages and limitations? 4

2. Explain the method of handling an irregular boundary while writing finite difference equations. 4

3. One face of a slab of thickness 1 cm (k = 20 W/m°C), is maintained at 40°C and the other surface is

subjected to a convection heat transfer with a fluid at 100°C with a heat transfer coefficient of 4000

W/m2°C. There is uniform internal heat generation in the slab at a rate of 8 x 107 W/m3.

a) Dividing the slab into 5 equally spaced sub-regions, find the temperatures at the different nodes.

Assume one dimensional, steady state conduction.

b) If the left surface is insulated, what is the temperature on that surface in steady state?

4

4. Explain the following laws as applied to radiation: i) Stefan Boltzman law ii) Plank’s Distribution law

iii) Wein’s Displacement law iv) Kirchoff’s law. 4

5. Determine the radiative energy emitted between 2-10μm wavelengths by a 1x1m grey surface at 600 K

which has an emissivity of 0.8. 4

6. A tungsten filament is heated to 2300K.What fraction of the total energy is emitted in the wave length

range of 0.4 to 0.8 μm? 4

7. A black body at 1111K is emitting into air. Calculate the wavelength at which black body 4



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emissive power is maximum and energy emitted over wave length limits 1-10 μm and 10-20

μm.

8. A small surface of area 8 cm2 is subjected to radiation of constant intensity I=105 W/m2.Sr over a solid

angle subtended by 30,20 . Calculate energy emitted by surface. 4

9. Determine average emmissivity of filament at 3000K for entire wavelengths using given data

212101 5.01.05.005.0 toformtofor 4

10. Calculate the heat dissipated by radiation through a 0.2-m2 opening of a furnace at 1100K into

an ambient at 300K. Assume both the furnace and the ambient to be black bodies. 4





1. Discuss the applications of dimensional analysis for forced convection.

2. Discuss the physical significance of Reynolds, Prandtl, Nusselt and Stanton numbers.

3. Discuss the use the various correlations for hydro dynamically and thermally developed flows inside a duct.

4. Discuss the various correlations for flow over a flat plate, over a cylinder and sphere.

5. Explain the velocity and thermal boundary layers & its importance in convection heat transfer.

6. Discuss the expressions for heat transfer coefficient, lift and drag coefficients.

7. Derive expressions for friction factor and pressure drop for laminar flow through tubes.

8. Explain the free or natural convection, Application of dimensional analysis for free convection- physical

significance of Grashoff number.

9. Discuss the use of correlations of free convection in vertical, horizontal and inclined flat plates, vertical and

horizontal cylinders and spheres

Lesson Schedule:

Lecture

No. Topics covered

Teaching

Method

PO’s

Attained

CO’s

Attained

Reference

Book/

Chapter No.

L27

Forced Convection: Boundary Layer

Theory, Velocity and Thermal Boundary

Layers, Prandtl number,

Chalk and

Board

a,b,c,e,i

5 R4/6

T2/6

L28 Governing Equations – Continuity, Navier-

Stokes

Chalk and

Board 5

R4/6

T2/9

L29

Energy equations, Boundary layer

assumptions, Integral and Analytical

solutions to above equations

Chalk and

Board 5

R4/6

T2/9

L30 Turbulent flow, Various empirical

solutions,

Chalk and

Board 5

R4/6

T2/9


Board 5

R4/6

T2/9

L31

Forced convection flow over cylinders and

spheres, Internal flows –laminar and

turbulent flow solutions

Chalk and

Board 5

R4/9

T2/9



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L32 Forced Convection Cooling of Electronic

Devices.

Chalk and

Board 5

R4/9

T2/9

L33 Free convection: Laminar and Turbulent

flows, Vertical Plates, Vertical Tubes

Chalk and

Board 5 R4/7

L34 Horizontal Tubes, Empirical solutions. Chalk and

Board 5 R4/7


Board 5

R4/6

T2/9


1. Explain the thermal boundary layer. Distinguish between developing and developed hydrodynamic

flow through pipes. 5

2. Determine the thickness of thermal boundary layer, local drag coefficient and local shear stress at a

distance of 0.5 m from the leading edge of a flat plate for the boundary layer flow of air at 77 oC and a

velocity of 2m/s.

5

3. Atmospheric air at 27oC flows with a free stream velocity of 10 m/s along a flat plate 4m long.

Compute the drag coefficient at 2 and 4m from the leading edge. Assume an all turbulent boundary

layer, determine the drag force exerted per 1m width of plate.

5

4. Air at 0.6 atm and -15 oC flows with a free stream velocity of 120m/s over the wing of an airplane. The

wing is 2m long in the direction of flow and can be regarded as a flat plate. Determine the local drag

coefficient and the shear stress at the trailing edge of the wing. What is the drag force per meter width

of the wing?

5

5. Determine the thickness of the thermal boundary layer and the local heat transfer coefficient at a

distance of 1m from the leading edge of a flat plate for the flow of air at 77oC and velocity 4m/s at

pressures of 0.5, 1.0 and 2 atmosphere.

5

6. Explain Hydrodynamic and thermal boundary layer with reference to flow over flow heated plate. 5

7. Explain the following Dimensionless number and their physical significance:

(i) Reynolds number, (ii) Prandtl number, (iii) Nusselt number 5

8. Write short notes on (any two): (i) Biot number and Fourier and their significance.

(ii) Hydrodynamic and Thermal boundary layer 5

9. Air at 30oC is flowing over 2 cm long plate maintained at 70oC at m/s. Determine heat transfer from the

plate. 5

10. A highly viscous fluid flows through a 5 cm I.D. pipe at rate 50 kg/hr. Fluid passes through 1 m long

heated section where a constant flux of 1000 Wm2 is supplied. Calculate the final temperature of liquid

if initial temperature is 40oC. Obtain the maximum wall temperature. Assume properties of liquid as, P

= 1500 kg/m3, Cp = 1.675 kJ/kg K, ks = 0.865 W/mK.

5

11. Water at 20oC is to be heated by passing it through the tube. Surface of tube is maintained at 90oC. The

diameter of tube is 4 cm while its length is 9 m. Find the mass flow rate so that exit temperature of

water will be 60oC. The properties of water are p = 995 kg/m3, Cp = 4.175 kJ/ kg K, K = 0.64 W/mK. ,

V = 0.62 x 10-6 m2/s, B = 4.25 x 10-3K-1

Use the correlation Nu = 0.023* (Re)0.8. (Pr)0.3

5

12. In a certain process, castor oil at 30oC flows past a flat plate. The velocity of oil is 0.08 m/sec.The

length of the plate is 5 m. The plant is heated uniformly and maintained at 90oC. Calculate the

following: (i) Hydrodynamic and thermal boundary layer thickness at the trailing edge of plate. (ii)

Total drag force per unit width on one side of the plate. Use the following correlation: Nu = 0.332

(Rel)1/2 . (Pr)1/3 Take properties as,

P = 956.8 kg/m3, k = 0.213 W/ moK, a = 7.2 x 10-8 m2 /s, v = 0.65 x 10-4 m2 /s.

5

13. In a certain process, castor oil at 30oC flows past a flat plate. The velocity of oil is 0.08 m/sec. he

length of the plate is 5 m. The plate is heated uniformly and maintained at 90oC. Calculate the 5



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following:

(a) Hydrodynamic and Thermal Boundary layer thickness at the trailing edge of plate.

(b) Total drag force per unit width on one side of the plate Use following

correlation:- Nu = 0.332 (Rel)1/2 (Pr)1/3

Take properties as, p=956.8kg/m3, k =0.2132 W/moK, a =7.2 X 10-8m2/s, v = 0.65 X 10-4 m2/s.





1. Discuss the classification of heat exchangers based on flow and mode of heat Exchanger and the

different terms associated with heat exchanger.

2. Explain the LMTD equations for parallel and counter flow type heat exchangers.

3. Discuss the fouling and fouling factor in an exchanger.

4. Explain the, NTU, effectiveness of heat exchangers with specified operating conditions

5. Discuss the terms associated with condensation and boiling and use co-relations for film wise

condensation on plane surfaces, horizontal tubes and tube-banks.

6. Discuss the different boiling processes and use co-relations for solve physical problems.

7. Explain the utility of condensation and Boiling in problems of heat transfer.

8. Discuss the mass transfer and Fick’s law of diffusion.

Lesson Schedule:

Lecture

No. Topics covered

Teaching

Method

PO’s

Attained

CO’s

Attained

Reference

Book/

Chapter No.

L35 Heat Exchangers: Definition, Classification,

applications,

Chalk and

Board

a,b,c,e,i,

6 R4/10

L36 LMTD method Chalk and

Board 6 R4/10

L37 Effectiveness – NTU method, Chalk and

Board 6 R4/10

L38

Analytical Methods, Fouling Factors, Chart

Solution Procedures for solving Heat

Exchanger problems: Correction Factor Charts

Chalk and

Board 6 R4/10

L39 Effectiveness-NTU Charts, compact heat

exchangers.

Chalk and

Board 6 R4/10


Board 6 R4/10

L40

Heat Transfer with Phase Change:

Introduction to boiling, pool boiling, Bubble

Growth Mechanisms

Chalk and

Board 7 R4/9

L41 Nucleate Pool Boiling, Critical Heat Flux in

Nucleate Pool Boiling, Pool Film Boiling,

Chalk and

Board 7 R4/9

L42 Critical Heat Flux, Heat Transfer beyond the

Critical Point

Chalk and

Board 7 R4/9

L43

filmwise and dropwise Condensation, heat

pipes, entrainment, wicking and boiling

limitations

Chalk and

Board 7 R4/9



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Board 7 R4/9


1. Give the classification of heat exchangers based on flow and mode of heat exchanger. 6

2. Derive an expression for LMTD for a Parallel and Counter flow heat exchanger. 6

3. Derive an expression for Effectiveness for a Parallel and Counter flow heat exchanger. 6

4. A copper pipe (K=350 w/mk) of 17.5mm inner diameter and 20mm outside diameter conveys water and

oil flows through the annular passage between this pipe and a steel pipe. On the water side, the film co-

efficient is 4600 w/m2k and the fouling factor is 0.00034m2k/w. The corresponding values for the oil side

are 1200w/m2k and 0.00086 m2k/w. Calculate the overall heat transfer coefficient between the water and

oil, based on outside surface area of inner pipe.

6

5. A shell and tube heat exchanger is to cool oil(Cp=2000J/kgk) flowing at 6kg/s from 65 ˚C to 35˚C by

using water of 10kg/s flow rate with inlet temperature 20˚C.Average heat transfer coefficient

Um=600w/m2k. Calculate heat transfer area for a parallel flow and counter flow arrangement.

6

6. Steam condenses at 60˚C on shell side of a steam condenser while cooling water flows inside tubes at

3kg/s.The inlet and outlet temperatures of water are 20˚C and 50˚C respectively. The overall heat

transfer coefficient Um=2000w/m2k. Calculate the surface area required.

6

7. Derive an expression for average heat transfer coefficient using Film Condensation theory on a vertical

surface. 7

8. List the assumptions made in the derivation of the Film Condensation theory. 7

9. Differentiate between drop-wise and film-wise condensation process. 7

10. Explain with a neat sketch the various regimes of the Pool-Boiling curve. Write the appropriate

equations for each regime. 7

11. Air free Saturated stream at Tv=90˚C (P=70.14Kpa) condenses on the outer surface of a 1.5 m long,

2.5cm OD vertical tube maintained at a uniform temperature of Tw=70˚C. Assuming film condensation,

calculate the average condensation heat transfer coefficient hm over the entire length of the tube,

condensate film thickness and condensate Reynolds number at the bottom of the tube, and the total rate

of condensation at the tube surface.

7

12. Saturated air-free stream at Tv=50˚C (P=12.35Kpa) condenses on the outer surface of a 1m

long, 2.5cm OD vertical tube maintained at a uniform temperature of Tw=30˚C. Assuming film

condensation, calculate the average condensation heat transfer coefficient hm over the entire

length of the tube and the total rate of condensation at the surface of the tube.

7

… End of Heat Transfer Lesson Plan …



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Semester – VI

Course Title: Design of Machine Elements-II (15ME64)

CBCS

2017-2018



COURSE FILE

Prof. S.S.CHAPPAR

Module Coordinator

Prof. S.R.BIRADAR & Prof .R.N .JEERAGAL

Course Coordinator



of 89








disciplines.



ii. an ability to apply knowledge of mathematics, science, and Mechanical Engineering

jj. an ability to design and conduct experiments, as well as to analyze and interpret data

kk. an ability to design a mechanical system, mechanical component, or process to meet desired



ll. an ability to function on multidisciplinary teams

mm. an ability to identify, formulate, and solve mechanical engineering problems

nn. an understanding of professional and ethical responsibility

oo. an ability to communicate effectively

pp. the broad education necessary to understand the impact of mechanical engineering solutions


qq. a recognition of the need for, and an ability to engage in life-long learning,

rr. a knowledge of contemporary issues

ss. an ability to use the techniques, skills, and modern mechanical engineering tools necessary


Department of: MECHANICAL ENGINEERING

Program: B.E.MECHANICAL ENGINEERING (REGULAR)

Course Title: Design of machine Elements-II Course Code:15ME64

Theory: Practical:



codes)

Mechanics of

materials

(15ME34)

Material

science &

Metallurgy

(15ME32)

Kinematics

of machine

(15ME42)

Dynamics of

machine

(15ME52)

Design of

machine

elements –I

(15ME54)

Program Outcomes

(POs) a b c d e f g h i j k

X X X X X X X

√



of 89

Mapping of Course

Outcomes with POs

1,2

,3,4

,5,6

,7,8

1,2

,3,4

,5,6

,7,8

1,2

,3,4

,5,6

,7,8

1,2

,3,4

,5,6

,7,8

1,2

,3,4

,5,6

,7,8

1,2

,3,4

,5,6

,7,8

1,2

,3,4

,5,6

,7,8

Course category

Bas

ic

Sci

ence

s

Gen

eral

/

Hu

man

itie

s

Gen

eral

Core

Elective G-D G-T G-P G-M

X X

Teaching Methods: PPT OHP

Face to

face

Guest

Lecture

Video

lecture

Demo

(Lab visit) Seminars

Industrial

visits

Module 1 to 5


03 03

Contents beyond syllabus

to meet POs:

Topics POs attained

Approved by: Module Coordinator Prof. S.S.CHAPPAR

Program coordinator Prof. S.B.KOULAGI

Achieving Intended Course Learning Outcomes

The following skills are directly or indirectly imparted to the students in the following

teaching and learning methods:

Sl.No. Course

Learning

Outcomes

Possible capabilities, skills,

expertise gained (codes)

Means of imparting the curriculum

1 CO1 Kn, Un, PSS,AS Class room lectures, Assignments,

Tutorials


Tutorials


Tutorials


Tutorials


Tutorials


Tutorials

7 CO7 Kn,PS Class room lectures, Assignments,

PPT



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8 CO8 Kn,Un, PSS,AS,LS Class room lectures, Assignments,

Tutorials

Course Plan


Course Title Design Of Machine

Elements-II

Course Code 15ME64

Total Teaching Hours 50 Teaching hours/week 05

Internal Assessment Marks 20 Semester Examination Marks 80

Course Plan prepared by Prof S R Biradar

Prof R N Jeeragal

Date

Course Content

PART-A

Module-1

Curved Beams: Stresses in curved beams of standard cross sections used in crane

hook, punching presses & clamps, closed rings and links.

Cylinders & Cylinder Heads: Review of Lame’s equations; compound cylinders,

stresses due to different types of fit on cylinders; cylinder heads and flats.

8

Hours

Module-2

Belts: Materials of construction of flat and V belts, power rating of belts, concept of

slip and creep, initial tension, effect of centrifugal tension, maximum power condition.

Selection of flat and V belts- length & cross section from manufacturers’ catalogues.

Construction and application of timing belts.

Wire ropes: Construction of wire ropes, stresses in wire ropes, and selection of wire

ropes. (Only theoretical treatment)

Chain drive: Types of power transmission chains, modes of failure for chain, and

lubrication of chains. (Only theoretical treatment)

Springs: Types of springs, spring materials, stresses in helical coil springs of circular

and non-circular cross sections. Tension and compression springs, concentric springs;

springs under fluctuating loads.

Leaf Springs: Stresses in leaf springs, equalized stresses, and nipping of leaf springs.

Introduction to torsion and Belleville springs.

10

Hours

Module-3

Possible capabilities, skills, expertise gained Code

Knowledge Kn

Understanding (Comprehension) Un

Problem solving skills (application skills) PSS

Practical skills (application skills) PS

Analytical skills AS

Synthesis skills SS

Written communication skills WCS

Verbal/oral communication skills VCS

Presentation skills PS

Leadership skills LS



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Gear drives: Classification of gears, materials for gears, standard systems of gear

tooth, gear tooth failure modes and lubrication of gears.

Spur Gears: Definitions, stresses in gear tooth: Lewis equation and form factor, design

for strength, dynamic load and wear.

Helical Gears: Definitions, transverse and normal module, formative number of teeth,

design based on strength, dynamic load and wear.

Bevel Gears: Definitions, formative number of teeth, design based on strength,

dynamic load and wear.

12

Hours

Module-4

Worm Gears: Definitions, types of worm and worm gears, and materials for worm and

worm wheel. Design based on strength, dynamic, wear loads and efficiency of worm

gear drives.

Design of Clutches: Types of clutches and their applications, single plate and multi-

plate clutches. (Numerical examples only on single and multi-plate clutches)

Design of Brakes: Types of Brakes, Block and Band brakes, self locking of brakes, and

heat generation in brakes.

10

Hours

Module-5

Lubrication and Bearings: Lubricants and their properties, bearing materials and

properties; mechanisms of lubrication, hydrodynamic lubrication, pressure development

in oil film, bearing modulus, coefficient of friction, minimum oil film thickness, heat

generated, and heat dissipated. Numerical examples on hydrodynamic journal and thrust

bearing design.

Anti friction bearings: Types of rolling contact bearings and their applications, static

and dynamic load carrying capacities, equivalent bearing load, load life relationship;

selection of deep grove ball bearings from the manufacturers’ catalogue; selection of

bearings subjected to cyclic loads and speeds; probability of survival.

10

Hours

DESIGN DATA HAND BOOK

Design Data Hand Book – K. Mahadevan and Balaveera Reddy,CBS Publication

TEXT BOOKS:

[1] Richard G. Budynas, and J. Keith Nisbett,“Shigley's Mechanical Engineering Design”,

McGraw-Hill Education, 10thEdition, 2015.

[2] Juvinall R.C, and Marshek K.M, “Fundamentals of Machine Component Design”, John

Wiley & Sons, Third Edition, Wiley student edition, 2007.

[3] V. B. Bhandari, “Design of Machine Elements”,4th Ed., Tata Mcgraw Hill, 2016.

REFERENCES:

[1] Robert L. Norton “Machine Design- an integrated approach”, Pearson Education, 2ndedition.



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[2] Spotts M.F., Shoup T.E “Design and Machine Elements”, Pearson Education, 8th edition,

2006.

[3] Orthwein W, “Machine Component Design”, Jaico Publishing Co, 2003.

[4] Hall, Holowenko, Laughlin (Schaum’s Outline Series), “Machine design” adapted by

S.K.Somani, Tata McGraw Hill Publishing Company Ltd., Special Indian Edition, 2008.

[5] G. M. Maithra and L.V.Prasad, “Hand book of Mechanical Design”, Tata McGraw Hill, 2nd

edition,2004.


Two questions to be set from each module. Students have to answer five full questions, choosing

one full question from each module.

Assessment Marks



Total 100

Assignment: Course work includes a Design project. Design project should enable the students

to design a mechanical system (like single stage reduction gearbox with spur gears, single stage

worm reduction gear box, V-belt and pulley drive system, machine tool spindle with bearing

mounting, C-clamp, screw jack, single plate clutch,etc.) A group of students (maximum number

in a group should be 4) should submit assembly drawing and part drawings, completely

dimensioned, indicating the necessary manufacturing tolerances, surface finish symbols and

geometric tolerances wherever necessary. Design project must be completed using appropriate

solid modeling software. Computer generated drawings must be submitted. Design calculations

must be hand written and should be included in the report.

Design project should be given due credit (5 marks) in internal assessment.

COURSE DESCRIPTION:

1. Overview of the course

The contents of the course “DESIGN OF MACHINE ELEMENTS-II (DME-II)” is designed

by the members of the Board of Studies (BoS) constituted by Visveswaraya Technological

University (VTU) Belgaum.

Basically, DME-II course deals with:

Design of curved beams ,Cylinders and cylinder heads

Design of gears, belt drives, wire ropes chain drive.

Design of springs, clutches and Brakes.

Design of bearings



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2. Relevance of the Course:

Technical considerations of mechanical component design are largely centered on two

main areas of concern: Stress-strain-strength relationships involving the bulk of a solid member

and Surface phenomenon including friction, lubrication, wear and environmental deterioration.

This course provides the students the ability to identify, formulate, and solve engineering

problems using modern engineering tools. The course also helps in designing a system, system

component, or process to meet desired needs within realistic constraints such as economic,

environmental, social, ethical, health and safety, manufacturability, and sustainability. This course

is a prerequisite to subjects like Elements of mechanical engineering, material science ,mechanics

of materials, Kinematics of machine, Dynamic of machinery, Machine design-I,

Hence, this course is a necessity and has much relevance to Mechanical Engineering Program

3. Application areas:

The basic principles of the course, DME-II is applied in mechanical engineering design theory to

identify and quantify machine elements in the design of commonly used mechanical systems. It

is applicable in various problems associated with machine component, efficiency of the system

etc

4. Prerequisite: This subject requires the knowledge of Engineering mathematics, Elements of

mechanical engineering, mechanics of materials, Kinematics of machine, Dynamic of machinery,

machine design-I, material science .

Course outcomes: Student will be able to

CO1 Apply engineering design tools to product design.

CO2 Design mechanical systems involving springs, belts and pulleys.

CO3 Design different types of gears and simple gear boxes for different applications.

CO4 Design brakes and clutches.

CO5 Design hydrodynamic bearings for different applications.

CO6 Select Anti friction bearings for different applications using the manufacturers,

catalogue.

CO7 Develop proficiency to generate production drawings using CAD software.

CO8 Become good design engineers through learning the art of working in a team with

morality and ethics.


Course title and code: DESIGN OF MACHINE ELEMENTS-II (15ME64)

Module1:CURVED BEAMS, CYLINDERS & CYLINDER HEADS Planned hours: 08

Learning objectives: Student will be able to



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1. Analyze the stresses in curved beams of standard cross sections used in different applications.

2. Distinguish between the straight and curved beams.

3 .Evaluate stress distribution in compound cylinder and cylinder heads.

4. Evaluate stress induced due to different fits.

5. Design the cylinders as per the applications.

Lesson Schedule:

Lecture

No

Topics Covered Teaching

Method

Po’s

Attained

Co’s

Attained

Reference

Book/Chapter

No

L1

CURVED BEAMS:

Introduction,

comparison between

straight and curved

beam and applications.

Chalk & Board a,b,c,e, h ,i,k 1,7,8 T1,T2

R1,R3,R4

L2

Stresses in curved

beams of standard cross

sections used in crane

hook and problems on

it .

Chalk & Board a,b,c,e,h ,i,k 1,7,8 T1,T2

R1,R3,R4

L3

Stresses in punching

presses and problems

on it.


R1,R3,R4

L4

Stresses in clamps ,

closed rings and links

and problems on it


R1,R3,R4

L5

CYLINDERS &

CYLINDER HEADS:

Review of Lame’s

Equations, compound

cylinders


R1,R3,R4

L6

Stresses due to

different types of fits

on cylinders

and problems on it

Chalk & Board

a,b,c,e, h ,i,k 1,7,8 T1,T2

R1,R3,R4

L7 Stresses due to cylinder

heads and its problems.


R1,R3,R4



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L8 Stresses due to flats and

its problems.


R1,R3,R4

Assignment Questions

Question.

Number

Assignment questions COs

attained

1 What are the assumptions made in finding stress distribution for a curved

member and Differentiate straight and curved beam.

1,7,8

2 Derive an expression for stress distribution due to bending moment in curved

beam.

1,7,8

3 Derive Lame’s equation for compound cylinders. 1,7,8

4 A crane hook has a section of trapezoidal. The area at critical section is

115*((75+25)/2) mm2. The hook carries a load of 10Kn and inner radius of

curvature is 60mm. calculate the max tensile, compressive and shear stress

1,7,8

5 A cast steel cylinder of 300mm internal dia is to contain liquid at a pressure

of 12.5Mpa. it is closed at both ends by unstayed flat cover plates rigidly

bolted to the shell flange. Determine the thickness of the cover plates if the

stress is 75 MPa.

1,7,8

6 Design a shrink fit joint to join two cylinders of dia 150mm*200mm and

200mm*250mm. maximum tangential stress in the components due to shrink

fitting is to be limited to 40MPa. Also determine the axial force necessary to

disengage the joint if the length of the joint is 200mm and the max power can

be transmitted at rated speed of 1000rpm. The cylinder material has modulus

of elasticity 210 GPa and Poisson’s ratio 0.3

1,7,8

7 Determine the value of thickness t in the T-cross section of a curved beam

shown in fig. such,that the normal stress due to bending at the extreme

inner & outer fibers is numerically equal.

100 40

Centre line of curvature

100

t

150

1,7,8

8 A curved beam with a circular central line has trapezoidal cross section and it

is subjected to pure bending in its plane of symmetry. The face 100 mm is the

1,7,8



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concave side of the beam and is 100 mm from the center of curvature and the

load line. If the depth of the trapezoidal is 100 mm, find the proper value of

the other parallel face to the concave side to make extreme fibre stress in

tension and compression numerically equal

9 A high pressure cylinder consist of an inner cylinder of ID and OD of

200mm and 300mm respectively. It is jacketed by an outer cylinder of OD

400mm. the difference between the OD of inner cylinder and inner dia of

jacket before assembly is 0.25mm. E=0.2 GPa. Calculate the shrinkage

pressure and stresses induced in the cylinder due to shrinkage pressure. In

service the cylinder is further subjected to an internal pressure of 200 Mpa.

Plot the resultant stress distribution.

1,7,8

10 A cast iron cylinder of internal dia 200mm and thickness 50mm is subjected

to a pressure of 5 Mpa. Calculate the tangential and radial stresses at the

inner , middle and outer surface

1,7,8

11 A closed ring is made of 40mm dia rod bend to a mean radius of 85mm. if the

pull along the diameter is 10,000N, determine the stress induced in the

section of the ring along which it is divided into two parts by the direction of

pull.

1,7,8

12 Determine the max stress induced in a ring of 50 mm dia rod subjected to a

compressive load of 20 KN. The mean dia of the ring is 100 mm.

1,7,8

13 A chain link made of 40mm diameter rod is semi circular at each end, the

mean diameter of which is 80mm. the straight sides of the links length are

also equal to 80mm. if the link carries load of 90kN, estimate the tensile and

compressive stresses in the link along the section of load line. Also find the

stresses at a section 90o away from the load line.

1,7,8



Module 2: BELTS, ROPES AND CHAINS and SPRINGS Planned hours:10


1. Design flexible transmission systems (Belt, wire ropes and Chain drive).

2. Compute an expression for the ratio of tension in flat and V belt drive.

3.Design the different types of belts and compute the velocity, centrifugal stress, capacity,

dimension of belt ,correct centre distance and initial tension in the belt

4. Design the rope drive and compute rising & lowering the load and efficiency of the rope drive.

5. Design the chain drive and compute pitch of chain, no of teeth on the sprockets, pitch

diameter, no of strands in a chain, length of chain and correct centre distance.



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6. Design the different types of springs for various applications.

Lesson Schedule:

Lecture

No

Topics Covered Teaching Method Po’s

Attained

Co’s

Attained

Reference

Book/Chapter

No

L9

Belts. Introduction,

Materials of

construction of flat ,V

belts and Power rating

of belts.

Chalk & Board a,b,c,e, h ,i,k 2 T1,T2

R1,R3,R4

L10

Concept of slip and

creep, initial tension,

effect of centrifugal

tension, maximum

power condition, and

problems


R1,R3,R4

L11

Selection of flat and V

belts- length & cross

section from

manufacturers’

catalogues.

construction and

application of timing

belts.


R1,R3,R4

L12

Wire ropes:

construction of wire

ropes, stresses in wire

ropes, and selection of

wire ropes


R1,R3,R4

L13 Problems on wire ropes Chalk & Board a,b,c,e, h ,i,k 2 T1,T2

R1,R3,R4

L14

Chain drive: Types of

power transmission

chains, modes of failure

for chain, and

lubrication of chains.


R1,R3,R4

L15 Problems on chain

drive


R1,R3,R4



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L16

Springs: Types of

springs, spring

materials, stresses in

helical coil springs of

circular and non-

circular cross sections


R1,R3,R4

L17

Tension and

compression springs,

concentric springs;

springs under

fluctuating loads and

problems on it.


R1,R3,R4

L18

Leaf Springs: Stresses

in leaf springs,

equalized stresses, and

nipping of leaf springs.

Introduction to torsion

and Belleville springs

and problems on it.


R1,R3,R4


Question.

Number


attained

1 What are the advantages of V belt drive over flat belt drive?

2

2 Give the advantages and disadvantages of V- belt drives 2

3 Derive an expression for the following, a)Ratio of belt tensions b) length of

belt C) Power transmitted by belt drive.

2

4 Design a V-belt for transmitting 75kW with the following specifications:

Speed of driver pulley = 1440 rpm, Speed of driven pulley = 400 rpm, Center

distance = 2500mm Service condition = 16 hrs/day.

2

5 Design a chain drive to actuate a compressor from a 14.5 kW electric motor

at 970 rpm, the compressor rpm being 330. Minimum center distance should

be 550 mm. The chain tension may be adjusted by shifting the motor on rails.

The compressor is to work 16 hours / day.

2

6 An 8 X 19 (9/9/1) steel wire rope is used to lift a load 15kN from a depth of

1000m. The maximum speed of rope is 2.5m/s and the acceleration is

1.5m/sec2 when starting under no slack conditions. Determine the size of the

rope required

2



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7 Select a wire rope for an elevation in a building where the total lift is 40m.

The rope velocity is 100m/min and fall speed is to be reached in 2 meter. The

lifting sheaves are to be of the traction type. The elevation car weighs 10 kN

and passengers weigh 20 kN. Assume a factor of safety=10

2

8 Select a suitable chain drive to transmit 30kW from an electric motor to a line

shaft. Motor shaft diameter is 60mm, motor rpm = 1200, line shaft rpm = 250

and center distance is adjustable from 600 mm. Service is 10 hrs per day and

6 days per week. Good lubrication is expected. The sprocket on motor shaft

has 21 teeth

2

9 Design a roller chain to transmit power from a 20 kW motor to a

reciprocating pump. The pump is to operate continuously 24 hours per day.

The speed of the motor is 600 rpm and that of the pump is 200 rpm. Find: a.

Number of teeth on each sprocket; b. Pitch and width of the chain

2

10 A laminated semi elliptical leaf spring under a central load of 10KN is to

have an effective length of 1m and is to deflect not more than 50mm. the

spring has 8 leaves, two of which are full length, and have been prestressed

so that all leaves have the same stress after the full load has been applied. All

the leaves have the same width and thickness. The max stress in the leaves is

not to exeed 35 Kg/mm2. Determine

i) the width and thickness of leaves ii) central bolt load

iii) Initial gap between the full length and graduated leaves before assembly.

2

11 Two helical springs are nested and are in a concentric manner, with ane

inside other. Both the springs have the same free length and carry a total load

of 5500 N. the details are as bellow

Outer inner

No. active turns 8 12

Wire dia 16mm 12mm

Mean coil dia 128mm 84mm

Determine the max load carried by each spring, total deflection of spring

and max stresses in each spring.

2



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Module 3: GEAR DRIVES, SPUR GEARS, HELICAL GEARS AND

BEVEL GEARS

Planned

hours: 12


1. Design of transmission system with different type of gears.

2. Select suitable materials for gears.

3. Explain Terminology of gear and law of gearing.

4. Compute Beam strength of spur gear teeth or Lewis equation.

5. Design of Spur gear, Helical gear and Bevel gear based on the strength, dynamic load and wear.

Lesson Schedule:

Lecture

No


Method

Po’s

Attained

Co’s

Attained

Reference

Book/Chapter

No

L19

Gear drives:

Classification of gears,

material for gears,

standard systems of

gear tooth.

Chalk & Board a,b,c,e, h ,i,k 3,7 T1,T2

R1,R3,R4

L20

Gear tooth failure

modes and lubrication

of gears.


R1,R3,R4

L21

SPUR GEARS:

Definitions, stresses in

gear tooth


R1,R3,R4

L22 Lewis equation and

form factor


R1,R3,R4

L23 Design based on

strength


R1,R3,R4

L24 Design for dynamic

and wear load.


R1,R3,R4

L25

Helical Gears:

Definitions, transverse

and normal module

,Formative number of


R1,R3,R4



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teeth

L26 Design based on

strength


R1,R3,R4


and wear load.


R1,R3,R4

L28

Bevel Gear:

Definitions, Formative

number of teeth.


R1,R3,R4

L29 Design based on

strength


R1,R3,R4


and wear load.


R1,R3,R4


Question.

Number


attained

1 Derive an expression for beam strength of spur gear. 3,7

2 Explain Lewis form factor. 3,7

3 Define formative no. of teeth as applied to helical gear and explain its

importance.

3,7

4 What is interference in gears? Explain the methods to avoid interference. 3,7

5 List the advantages of helical gear. 3,7

6 Define the following: a) Pitch angle b) Face angle c) Root angle d) Back

cone distance, and e) Crown height for bevel gears

3,7

7 Design a pair of spur gears to transmit 20kw power operating 8 to 10 hrs/day

sustaining medium shock, from a shaft rotating at 1000rpm to a parallel shaft

which is to rotate at 310rpm. Assume the number of teeth on pinion to be 31

and 200 full depth involute tooth profile. The material for pinion is C40 steel

untreated stress is 206MPa and gear is cast steel 0.2% C whose stress is

137Mpa. Check the design for dynamic load if load factor is 522N/mm and

also for wear load take K=0.279 MPa. Suggest the suitable hardness.

3,7

8 Design a pair of helical gears to transmit power of 15KW at 3200rpm with

speed reduction 4:1 pinion is made of cast steel 0.4% C untreated. Gear

made of high grade CI helix angle is limited to 260 and not less than 20 teeth

are to be used on either gear. Check the gears for dynamic and wear

considerations.

3,7

9 Design a pair of spur gear to transmit power of 20KW from a shaft rotating at

1000rpm to a parallel shaft which rotate at 310 rpm. Assume no. of teeth on

pinion 31 and 200 full depth tooth form

3,7



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10 A pair of bevel gears connects two shafts at right angles and transmits 9 kW.

Determine the required module and gear diameters for the following

specifications: -

PARTICULARS PINION GEAR

Number of teeth 21 60

Material Steel Grey Cast Iron

BHN 200 160

Allowable Static

Stress

85 MPa 55 MPa

Speed 1200

rpm

420 rpm

Tooth profile 14.50

composite

14.50

composite

Check the gears for dynamic and wear loads.

3,7


Course title and code: DESIGN OF MACHINE ELEMENTS-I (15ME64)

Module 4: WORM GEARS AND DESIGN OF CLUTCHES AND BRAKES Planned hours: 10


1. Explain Terminology of worm gear and self locking in worm gearing.

2. Design of worm gear for strength, dynamic load, wear load.

3. Design of clutches and their applications.

4. Design of Brakes and their applications.

5. Determine the heat generation in the brakes.

Lesson Schedule:

Lecture

No


Method

Po’s

Attained

Co’s

Attained

Reference

Book/Chapter

No

L31

Worm Gears:

Definitions, types of

worm and worm gears,

materials for worm and

worm wheel.


R1,R3,R4

L32 Design based on Chalk & Board a,b,c,e, h ,i,k 3 T1,T2



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strength R1,R3,R4

L33

Design based on

dynamic and wear

loads.


R1,R3,R4

L34 Efficiency of worm

gear drives.


R1,R3,R4

L35

CLUTCHES: Types

of clutches and their

applications,Design of

Single plate Clutches


R1,R3,R4

L36 Design of multi plate

Clutches

Chalk & Board a,b,c,e,h ,i,k 4 T1,T2

R1,R3,R4

L37

Design of Brakes:

types of brakes, Block

brake and


R1,R3,R4

L38 Design of Band brakes. Chalk & Board a,b,c,e,h ,i,k 4 T1,T2

R1,R3,R4

L39 Self locking of brakes Chalk & Board a,b,c,e,h ,i,k 4 T1,T2

R1,R3,R4

L40 Heat generation in

Brakes


R1,R3,R4

Assignment Questions:

Question.

Number


attained

1 A worm gear type is required to transmit 15kW at 500 rpm of the worm. The

velocity ratio is 25:1. The center distance should be around 500 mm. Design

the worm gear train. The material of the gear is phosphor bronze and that of

the worm is hardened steel. Determine also the efficiency of the drive

3

2 Design a 200 Involute worm and gear to transmit 10kW with worm rotating at

1440 rpm and to obtain a speed reduction of 12:1. The distance between the

shafts may be about 240 mm. Axial pitch of threads may be around 25 mm.

Take service factor=2. Gear is made of chilled phosphor bronze having

allowable stress of 100MPa. Check the design for heat dissipation, not

allowing temperature rise by more than 400C above environmental

temperature. Assume =0.025 and heat dissipating capacity k=0.35 kcal/hr

3

3 Compute torque transmitted by Disc clutch or plate clutch. 4

4 A multi-disc clutch has three discs on the driving shaft and two on the driven

shaft. The outside diameter of the disc is 240mm. Inside diameter is 120mm.-

4



of 89

Assuming uniform wear and coefficient of friction is 0.3. Determine the

maximum axial intensity of pressure between the discs for transmitting 25kW

at 1600 rpm

5 A band brake acts on 3/4th of the circumference of a drum of 450mm

diameter, which is keyed, to the shaft; the band brake provides a braking

torque of 225Nm. One end of the band is attached to a fulcrum pin of the

lever and the other end to a pin 100mm from the fulcrum. If the operating

force is applied at 500mm from the fulcrum and the coefficient of friction is

0.25, find the operating force acting downwards when the drum rotates in

the counter clockwise direction. Also find the width of the band if its

thickness is 1.5mm and working stress is 70N/mm2.

4

6 A differential band brake has an operating lever 225mm long. The ends of

the brake band are attached so that their operating arms are 38mm and

150mm long. The brake drum dia is 600mm, the arc of contact is 3000, the

brake band is 3mm thick, and 100mm wide, coefficient of friction between

the band and drum is 0.22. a) Find the least force required at the end of the

operating lever to subject this band to a stress of 56N/mm2. b) What is the

torque applied to the brake drum shaft? c) Is brake self-locking. [Ref. Fig.

No.1]

4

7 An internal expending brake has an inner surface of rim of diameter 500mm.

The distance between the fulcrums 100mm. The distance between the

fulcrums and the point of application of efforts is 400mm. The brake linings

sustain an angle of 120o at the centre. The material of the lining has the co-

efficient of friction of 0.3, and an allowable bearing pressure of 0.5 MPa.

Determine, a) The effort required to stop the rotation of the brake drum b)

The width of the rake lining. The brake transmits a power of 30kW at a rated

speed of 1500r/min.

4

8 A simple band brake is used to stop rotation of the brake drum mounted on a

shaft transmitting 40 kW at a speed of 1500 rpm. Select a suitable material

4



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and design brake lever, band and fulcrum pin. =2250. Drum diameter,

D=50mm, length of lever = 1100mm. Distance between the two ends of a

band where they are fixed on the lever=300mm. Force is acting in

downwards direction at extreme end of lever



Module 5: LUBRICATION AND BEARINGS and ANTI

FRICTION BEARINGS

Planned hours: 10


1. Define lubrication & types of lubricants.

2. Define bearing and its classification of bearings.

3. Compute Petroff’s equation for coefficient of friction for hydrodynamic bearing.

4. Select the bearings subjected to cyclic loads and speeds.

5. Design a journal bearing, thrust bearing and anti frictions bearings.

Lesson Schedule:

Lecture

No

Topics Covered Teaching Method Po’s

Attained

Co’s

Attained

Reference

Book/Chapter

No

L41

Lubrication and

Bearings: Lubricants and

their properties, bearing

materials and their

properties.


R1,R3,R4

L42

Mechanisms of

Lubrication,

hydrodynamic

lubrication, pressure

development in oil film.


R1,R3,R4

L43 Bearing modulus,

coefficient of friction


R1,R3,R4

L44

minimum oil film

thickness, Heat

Generated, Heat

dissipated.


R1,R3,R4

L45 Examples on

hydrodynamic journal


R1,R3,R4



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and thrust bearing design

L46

Ant friction bearings:

Types of rolling contact

bearing and their

applications.


R1,R3,R4

L47 Static and dynamic load

carrying capacities.


R1,R3,R4

L48 Equivalent bearing load

and load life relationship.


R1,R3,R4

L49

Selection of deep groove

ball bearing from

manufactures catalogue.


R1,R3,R4

L50

Selection of bearings

subjected to cyclic load

and speed, probability of

survival.


R1,R3,R4

Assignment Questions:

Question.

Number


attained

1 Design a journal bearing to support a load of 10000N at 800 rpm using a harden

steel journal and bronze backed babbit bearing. The bearing is relieved for 200 from

the journal to the load line. Assuming oil temperature of 850C. Determine also i)

heat generated ii) work of friction. Assume SAE 40 oil used

5

2 Design a journal bearing for a centrifugal pump running at 1440 rpm.

Diameter of the journal is 100mm and the load on the bearing is 20 kN. The

value of p

ZN is equal to the value given in the table given in Data handbook

for centrifugal pump

5

3 A Journal bearing is to be designed for the main bearing of a four-stroke oil engine

to sustain a load of 50 KN for shaft diameter of 50 mm. The engine runs at the sped

of 1500rpm. Determine 1) The length and diameter of the bearing II) The viscosity

of oil to be used as lubricant and hence suggest a suitable oil. III) The co-efficient of

friction of the bearing IV) the heat generated.

5

4 Explain the significance of the bearing characteristic number in the design of sliding

contact bearings

5

5 A turbine shaft 6mm in diameter rotates at a speed of 10000 rpm. The load on each

bearing is estimated at 2kN and the length of the bearing is 80mm. Taking radial

clearance as 0.05mm and SAE-20 oil for lubrication determine the coefficient of

friction, power loss, minimum film thickness and the oil flow rate. The temperature

of the bearing is not to exceed 500 C.

5

6 What is the importance of bearing characteristic number in design of bearing? 5



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7 Design a bearing and journal to support a load of 4800 N at 650 rpm using a

hardened steel journal and bronze backed Babbitt bearing. The bearing is lubricated

by oil rings. Take oil temperature as 800C and room.

5

8 A machine shaft supported n two identical taper roller bearings A& B is shown in

fig. it is subjected to redial force of 30KN and thrust force of 10KN. The thrust is

taken by bearing A alone. The shaft rotates at 300 rpm. The machine is

intermittently use and the expected life L10th of the bearings is 4000 h. the minimum

acceptable diameter of the shaft, were the bearings are mounted, is 60 mm. select

the suitable taper roller bearings for the shaft.

6



of 89

B.L.D.E.A’s


BIJAPUR – 586 103


Semester – VI

Course Title: Metal Forming (15ME653)

Course plan Year: 2017-18

COURSE FILE

Course Coordinator Prof. L.N.Karadi

Prof. S.M.Vijapur

Program coordinator

Prof. S B Koulagi

Module Coordinator

Dr. G.V.Patil



of 89

Department of: Mechanical Engineering

Program: Mechanical Engineering

Course Title: Metal Forming

Course Code:

Theory: Practical:



codes)

Engineering

Mechanics

14CIV13/23

Mathematics

14MAT11/21

Material

science and

Metallurgy

10ME32/42

Mechanics-of

Materials

10ME34

Program Outcomes

(POs) a b c d e f g h i j

k

Mapping of Course

Outcomes with Pos

Understand the

concept of different

metal forming

process.

Approach metal

forming processes

both analytically and

numerically

Design metal forming

processes

Develop approaches

and solutions to

analyze metal

forming processes

and the associated

problems and flaws

Bas

ic

Sci

ence

s

Gen

eral

/

Hu

man

itie

s

Gen

eral

Core

Elective Group A

(Design

Engineering)

Group B

(Thermal

Engineering

)

Group C

(Production

Engineering)

Group D ( Management

Engineering)


face

Guest

Lecture

Video

lecture

Demo

(Lab visit)

Seminars Industrial

visits

Module I-V II - V



of 89

Continuous

Assessment

Internal assessment tests Assignment Tutorial

03 03

Contents beyond


Topics POs attained

Approved by: Module Coordinator DR.G.V.Patil

Program coordinator Prof.S.B.Koulagi



1. Establish a successful career in Mechanical Engineering or related fields in Industry and other

organizations where an engineering approach to problem solving is highly valued.



3. Contribute significantly in a multidisciplinary work environment with high ethical standards and

with understanding of the role of engineering in economy and the environment.


disciplines.



tt. an ability to apply knowledge of mathematics, science, and Mechanical Engineering

uu. an ability to design and conduct experiments, as well as to analyze and interpret data

vv. an ability to design a mechanical system, mechanical component, or process to meet desired



ww. an ability to function on multidisciplinary teams

xx. an ability to identify, formulate, and solve mechanical engineering problems

yy. an understanding of professional and ethical responsibility

zz. an ability to communicate effectively

aaa. the broad education necessary to understand the impact of mechanical engineering

solutions in a global, economic, environmental, and societal context

bbb. a recognition of the need for, and an ability to engage in life-long learning,

ccc. a knowledge of contemporary issues

ddd. an ability to use the techniques, skills, and modern mechanical engineering tools

necessary for engineering practice.



of 89

Subject Title: Metal Forming Subject Code: 15ME653

Total No. of Lecture Hrs: 50 Max. I. A. Marks: 20

Max. Marks: 80 Duration of Exams: 3Hrs

Prepared by: Prof. L.N.Karadi & V.V.Nagathan Date:

Course Content

MODULE -1

Introduction to Metal Forming: Classification of metal forming processes, advantages

and limitations, stress-strain relations in elastic and plastic deformation. Concepts of true

stress, true strain, triaxial & biaxial stresses. Determination of flow stress, principal

stresses, yield criteria and their significance, Tresca & Von-Mises yield criteria, concepts

of plane stress & plane strain. Deformation mechanisms, Hot and Cold working processes

and its effect on mechanical properties.

10

Hrs.

MODULE -2

Effects of Parameters: Metallurgical aspects of metal forming slip, twinning mechanics

of plastic deformation, Effects of Temperature, strain rate, friction and lubrication,

hydrostatic pressure in metalworking, Deformation zone geometry, workability of

materials, Residual stresses in wrought products.

Forging: Classification of forging processes. Forging machines equipment. Expressions

for forging pressures & load in open die forging and closed die forging by slab analysis,

concepts of friction hill and factors affecting it. Die-design parameters. Material flow lines

in forging, forging defects, residual stresses in forging. Simple problems.

10Hrs.

MODULE -3

Rolling: Classification of rolling processes. Types of rolling mills, expression for rolling

load. Roll separating force. Frictional losses in bearing, power required in rolling, effects

of front & back tensions, friction, friction hill. Maximum possible reduction. Defects in

rolled products. Rolling variables. Simple problems. Drawing: Drawing equipment &

dies, expression for drawing load by slab analysis, power requirement. Redundant work

and its estimation, optimal cone angle & dead zone formation, drawing variables, Tube

drawing, classification of tube drawing. Simple problems.

10Hrs.

MODULE -4

Extrusion: Types of extrusion processes, extrusion equipment & dies, deformation,

lubrication & defects in extrusion. Extrusion dies extrusion of seamless tubes. Extrusion

variables. Simple problems.

Sheet Metal Forming: Forming methods dies & punches, progressive die, compound die,

combination die. Rubber forming. Open back inclinable press (OBI press), piercing,

blanking, bending, deep drawing, LDR in drawing, Forming limit criterion, defects of

drawn products, stretch forming. Roll bending & contouring. Simple problems.

10 Hrs

MODULE -5

High Energy Rate Forming: Methods & Powder Metallurgy: High Energy Rate Forming

Methods: Principles, advantages and applications, explosive forming, electro hydraulic

forming, Electromagnetic forming.

10 Hrs



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Powder Metallurgy: Basic steps in Powder metallurgy brief description of methods of

production of metal powders, conditioning and blending powders, compaction and

sintering application of powder metallurgy components, advantages and limitations.

TEXT BOOKS:

1. Mechanical metallurgy (SI Units), G.E.Dieter, McGraw hill Pub-2001

2. Production Technology (Manufacturing process, technology and Automation), R.K Jain,

Khanna Publishers-2004.

3. Manufacturing Science, Amithab Gosh & A.K.Malik, East-West press 2001.

4. Production Technology Vol-II by O. P. Khanna & Lal, Dhanpat Rai Publications-2012.

5. A Course in Workshop Technology Vol: 1, Manufacturing Process, B.S Raghuwanshi,

Published by Dhanpat Rai & Co (P) Ltd.-2014.

REFERENCE BOOKS:

1. Materials & Process in Manufacturing – E.Paul, Degramo, J.T.Black, Ranold, A.K.Prentice-hall of

India 2002

2. Elements of Workshop Technology Vol:1, S.K.Hajra Choudhury, Media Promoters & Publishers

Pvt Ltd.-2008.

3. Fundamentals of Manufacturing Processes by Lal G K , Narosa

4. Textbook of Production Engineering by P. C. Sharma, S Chand & Company Ltd.

5. Manufacturing Process – III by Dr K. Radhakrishna

Prerequisites:

This subject requires the basic knowledge of Mechanics, Mathematics, Material science and

Metallurgy and Mechanics of materials.

Overview of the course:

The course content is designed to provide the knowledge and skills required to become an

efficient engineer by equipping students with a manufacturing perspective. It involves basic

understanding of various metal forming processes like forging, extrusion, rolling, wire drawing, deep

drawing, sheet metal operations, etc. The course also deals with modern forming methods like exclusive

forming, electro hydraulic forming and electromagnetic forming. Powder metallurgy principles are also

dealt in detail as a part of MP-III.

Course Outcomes(CO’s): After completing this course the student will be able to

1. Outline classification of metal working processes and analyze Mechanics of metal forming

process.

2. Identify the effects of various parameters and Residual stresses in metal working. Discuss the

classification of forging processes, and analyze the expression for forging pressures and load in

open as well as closed die forging.

3. Explain types of rolling mills, power required in rolling, and Discussing the drawing equipments

and dies, and analyze the expression for drawing stress.

4. Explain the extrusion processes, equipments and dies, outline the extrusion of seamless tube and

extrusion variables. Identify the forming methods and explain the same.

5. Explain the various high energy rate forming methods and describe briefly the methods of

production of metallic powder in powder metallurgy.



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Relevance of the course:

Mechanical Engineers are involved in every aspect right from designing a component to

manufacturing them. They are supposed to have thorough knowledge of the manufacturing processes by

which mechanical components are produced with high quality and economy. The student should learn the

different types of metal forming processes as some of the parts like sheet metals of different thickness,

wires of different sizes; different metal mixture components etc are manufactured by these processes.

Metal forming also shares major part in today’s manufacturing scenario along with metal removal, metal

joining and Metal casting processes.

Application areas:

For most countries manufacturing is the most significant activity for nation’s wealth creation and

overall prosperity. For example the sheet metal produced by metal forming processes is used to build the

body of the vehicles. Graduates from our program may find positions as manufacturing engineer in many

production fields in different countries.

Chapter wise plan

Course code and Title: 15ME653 Metal Forming

MODULE -1 - Introduction to Metal Forming Planned

Hours: 10

Learning Objectives: At the end of the chapter student should be able to

1. Explain the classification of metal working processes in detail.

2. Explain the distinguishing features and characteristics of wrought products.

3. Explain the unique advantages and limitations of metal working processes.

4. Explain the significance of true stress and true strain in the plastic flow of metals and deformation

processing.

5. Explain Biaxial and Triaxial state of stresses. Calculate the principal stresses and strains.

6. Explains Von – Mises and Tresca yield criteria and determine the flow stress.

7. Explain the plane stress and plane strain concepts and apply the same in predicting the

deformation loads / pressures.

8. Explain the hot working, cold working and warm working – their relative merits and demerits.

Lesson Schedule:

Lecture

No.

Portion to be covered per lecture (class) Teaching

method

Pos

attained

Cos

attained

Reference

book/

chapter No

L1 Classification of metal working processes,

Characteristics of wrought products

Chalk &

Board

a,e,i,k

1 T1/15

R5/1

L2 Advantages and limitations of metal working

processes

Chalk &

Board 1

T1/15

R5/1

L3 Concepts of true stress, true strain, tri-axial

& biaxial stresses

Chalk &

Board 1, 2

T1/15

R5/2

L4 Determination of flow stress. Principal

stresses, Tresca & Von- mises yield criteria

Chalk &

Board 1,2

T1/15

R5/2

L5 Concepts of plane stress & plane strain. Chalk & 1,2 T1/15



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Brief description of methods of metal

deformation analysis.

Board R5/2

L6 Hot and Cold working processes and its

effect on mechanical properties.

Chalk &

Board 1

T1/15

R5/1

L7 Problems Chalk &

Board 1,2

T1/15

R5/2

L8 Problems Chalk &

Board 1,2

T1/15

R5/2

L9 Problems Chalk &

Board 1,2

T1/15

R5/2

L10 Problems Chalk &

Board 1,2

T1/15

R5/2

Assignment questions COs attained

1. Discuss briefly the classification of metal working

processes. 1

2. Distinguish clearly between Hot working and Cold

working. 1

3. Enumerate and explain briefly the unique characteristics of

wrought products. 1

4. Explain the advantages and limitations of metal working

processes. 1

5. Define true stress and true strain and establish the

relationships between engineering stress and strains. 1,2

6. A mild steel specimen of rectangular c/s having a length of

100 mm is extended to 120 mm. neglecting the elastic

deformation and taking the material as isotropic;

determine true strains along the length, width and

thickness.

1,2

7. At a certain point in a piece of elastic material, there are

normal stresses of 40 N/mm2 (Tensile) and 30 N/mm2

(Compression) on two planes at right angles to one another

along with this shear stress of 20 N/mm2 on the same

planes. If the loading on the material is increased so that

stress reach values of K. find the maximum value of K if

the maximum direct stress in the material not to exceed

100 N/mm2 and maximum shear stress not to exceed 70

N/mm2

1,2


MODULE -2 - Effects of Parameters & Forging Planned

Hours: 10




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1. Explain the effects of strain rate, effects of friction and the importance of lubrication in

metalworking.

2. Explain the importance of deformation zone geometry on the yield pressure, how the hydrostatic

pressure can be utilized in enhancing the workability of brittle materials.

3. Analyse the complex technological concept of workability – concerns, factors and workability

limits. The residual stresses that are generated by non – uniform plastic deformation – their

effects and remedies.

Lesson Schedule:

Lecture

No.

Portion to be covered

per lecture (class)

Teaching

method

Pos attained Cos attained Reference

book/

chapter No

L10 Effects of temperature &

strain rate

Chalk &

Board

a,e,i,k.

1 T1/15

R5/1

L11 Ef fec t of friction and

lubrication

Chalk &

Board 1

T1/15

R5/1

L12 Hydrostatic pressure in

metalworking

Chalk &

Board 1

T1/15

R5/2

L13

Deformation zone

geometry, workability of

materials, Residual

stresses in wrought

products.

Chalk &

Board

1 T1/15

R5/1

L14

Classification of forging

processes and forging

machines

Chalk &

Board/ Video

1 T1/16

R5/3

L15

Expressions for forging

pressures & load in open

die forging and closed die

forging by slab analysis

Chalk &

Board 2,3

T1/16

R3/3

L 16

Concepts of friction hill

and factors affecting it,

Die-design parameters

Chalk &

Board 2,3 T1/16

R3/3

L 17

Material flow lines in

forging. Forging defects,

Residual stresses in

forging

Chalk &

Board 1

T1/16

R3/3

L 18 Numericals Chalk &

Board 2, 3

T1/16

R3/3


Board 2, 3

T1/16

R3/3


Board 2, 3

T1/16

R3/3



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1. Explain briefly i) friction and lubrication ii)

hydrostatic pressure iii) deformation zone geometry

iv) workability v) residual stresses in wrought

products.

1

2. What is friction hill? Explain briefly the factors

affecting it? 1

3. What are the typical defects observed in forging?

Explain the reasons briefly. 1

4. Write briefly on residual stresses in forging. 1

5. A block of lead 25 mm x 25 mm 150 mm is pressed

between flat dies to a size 6.25 mm x 100 mm x 150

mm. If the uniaxial flow stress is 0 = 6.9 MPa and

= 0.25. Determine the pressure distribution over the

150 mm dimension and the total forging load.

2, 3

6. A circular disc of lead of radius 150 mm and thickness

50 mm is forged to half of its original thickness by

open die forging. Determine the maximum forging

force if the coefficient of friction between the job and

die is 0.25. The average shear yield stress of lead is 4

N/mm2

2, 3


Module 3. Rolling & Drawing Planned

Hours: 10


1. Explain the classification of rolling process. Types of Rolling mills, Hot and Cold Rolling and

Rolling of Bars and Shapes.

2. Explain the forces and geometrical relationship in rolling and derive the expression for rolling

load.

3. Explain Roll separating force, role of friction and limiting conditions and frictional losses in

bearings etc.,

4. Explain the effect of front and back tension, friction, roll diameter and other rolling variables.

5. Explain the importance of friction – friction hill, maximum possible reduction and the defects in

rolled products.

Lesson Schedule:

Lecture

No.

Portion to be covered per

lecture (class)

Teaching

method


book/

chapter No

L21

Classification of rolling

processes, Types of rolling

mills, expression for

Chalk &

Board/

Video

a,e,i,k. 1 T1/17

R3/4



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Rolling load

L22

Roll separating force.

Frictional losses in

bearing etc, power

required in rolling

Chalk &

Board 1,2,3

T1/17

R3/4

L23

Effects of front & back

tensions, frictions, friction

hill. Maximum possible

reduction

Chalk &

Board 1,2,3

T1/17

R3/4

L24

Defects in rolled

products. Rolling

variables,

Chalk &

Board 1 T1/17

R3/4

L25 simple problems Chalk &

Board 2, 3

T1/17

R3/4

L 26 simple problems Chalk &

Board 2, 3

T1/17

R3/4

L 27

Drawing equipment & dies.

Expression for drawing

loads by slab analysis,

Power requirement

Chalk &

Board 1,2, 3,4

T1/19

R3/6

L 28

Redundant work and its

estimation, optimal cone

angle & dead zone

formation

Chalk &

Board 2,3

T1/19

R3/6

L 29

Drawing variables, Tube

drawing, C lassification of

T ube d rawing

Chalk &

Board 1 T1/19

R3/6

L 30

Simple Numericals Chalk &

Board 2,3

T1/19

R3/6


1 Discuss briefly the classification of rolling processes

and rolling mills. 1

. 2. Write a brief note on i) defects in rolled products

ii) friction mill in rolling. 1

3 Establish the relation for maximum draft in rolling

(h) max = 2 R. 1, 2

4 Determine the maximum possible reduction for cold

rolling a 300 mm thick slab when = 0.08 and the roll

diameter is 600 mm. What is the maximum reduction

on the same mill for hot rolling where = 0.5?

2, 3



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5 With a neat sketch explain the features of a drawing

die 1

6 Write briefly on i) Redundant work in drawing ii)

optimal cone angle 1, 2

7 With usual notations establish the following

relationship in case of plane strain strip drawing

through a tapered die. 2, 3

8 What is the maximum reduction possible per pass in

drawing aluminium rod through a die of semi die

angle 240, coefficient of friction µ = 0.01 2, 3


Module 4. Extrusion & Sheet Metal Forming Planned

Hours: 10

Lecture

No.

Portion to be covered

per lecture (class)

Teaching

method


book/

chapter No

L31

Types of extrusion

processes, Extrusion

equipment & dies,

deformation

Chalk &

Board

a,e,i,k.

1 T1/18

R3/5

L32 Lubrication & defects in

extrusion

Chalk &

Board 1

T1/18

R3/5

L33 Extrusion dies & Extrusion

of seamless tubes.

Chalk &

Board/ Video

1 T1/18

R3/5

L34 Extrusion variables Chalk &

Board 1

T1/18

R3/5

L35 Simple Numerical Chalk &

Board 2, 3

T1/18

R3/5

L 36

Forming methods, dies &

punches, Rubber forming

open back inclinable press

(OBI press)

Chalk &

Board/ Video

1

T1/20

R3/7

L 37

Piercing & blanking,

bending, deep drawing,

LDR in drawing

Chalk &

Board/ Video

1

T1/20

R3/7

L 38

Forming limit criterion,

defects drawn products

stretch forming

Chalk &

Board 1

T1/20

R3/7

L 39 Roll bending & contouring,

Simple Numerical

Chalk &

Board 1,2,3

T1/20

R3/7



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L 40 Simple Numerical

Chalk &

Board 2,3

T1/20

R3/7


1. With neat sketches explain the different types of extrusion

processes. 1

2. Write briefly on the following

i) Defect in extrusion

ii) Extrusion of tubes

iii) Production of seam less pipes and tubing.

1

3. With a neat sketch explain extrusion die. 1

4.Explain briefly the classification of sheet metal parts 1

5.Explain briefly the following

i) Shearing and blanking

ii) Bending

iii) Rubber forming

iv) Stretch forming

v) Notching & Nicking

1

6.With a neat sketch, explain the construction and working of

a progressive die. 1

7.Distinguish clearly between a progressive die and a

compound die 1

8.Discuss briefly on the presses used in high production

volume sheet metal forming 1


Module 5. High Energy Rate Forming & Powder Metallurgy Planned

Hours: 10

Lecture

No.

Portion to be covered per

lecture (class)

Teachi

ng

method


book/

chapter No

L41

Principles advantages and

applications of Explosive

forming

Chalk &

Board/

Video

a,e,i,k.

1 R3/7

L42


applications of Electro

hydraulic forming

Chalk &

Board/

Video

1 R3/7

L43


applications of Electromagnetic

forming,

Chalk &

Board/

Video

1 R3/7



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L44 Basic steps in Powder metallurgy Chalk &

Board 1

T5/21

R3/8

L45 Brief description of methods of

production of metal powders,

Chalk &

Board 1

T5/21

R3/8

L 46 Conditioning and blending of

powders.

Chalk &

Board 1

T5/21

R3/8

L 47

Compaction methods Chalk &

Board/

Video

1 T5/21

R3/8

L 48 Sintering methods Chalk &

Board 1

T5/21

R3/8

L 49 Application of powder

metallurgy components.

Chalk &

Board 1

T5/21

R3/8

L 50 Advantages & Limitations Chalk &

Board 1

T5/21

R3/8


1. What is HERF? Explain the principles and advantages

of HERF. 1

2. Describe briefly the principle, process characteristics and applications

of explosive forming process. 1


of electro – hydraulic forming process. 1


of electro – magnetic forming process. 1

5. Discuss the basic steps in powder metallurgy. 1

6. Enumerate and explain any two of the methods of production of metal

powders. 1

B.L.D.E.A’s




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BIJAPUR – 586 103


Semester – VI

Course Title: Total Quality Management (15ME662)

2017-2018

COURSE FILE



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disciplines.



eee. an ability to apply knowledge of mathematics, science, and Mechanical Engineering

fff. an ability to design and conduct experiments, as well as to analyze and interpret data

ggg. an ability to design a mechanical system, mechanical component, or process to meet

desired needs within realistic constraints such as economic, environmental, social, political,

ethical, health and safety, manufacturability, and sustainability

hhh. an ability to function on multidisciplinary teams

iii. an ability to identify, formulate, and solve mechanical engineering problems

jjj. an understanding of professional and ethical responsibility

kkk. an ability to communicate effectively

lll. the broad education necessary to understand the impact of mechanical engineering solutions


mmm. a recognition of the need for, and an ability to engage in life-long learning,

nnn. a knowledge of contemporary issues

ooo. an ability to use the techniques, skills, and modern mechanical engineering tools

necessary for engineering practice.

COURSE PLAN

Semester: VII Year: 2014-15

Subject: Total Quality Management Subject Code: 15ME662

Total No. of Lecture Hours: 40 I A Marks : 20


Lesson plan prepared by : Prof. B.M.Angadi

Date:04/01/2018



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COURSE LEARNING OBJECTIVES:

This course enables students to

1. Understand various approaches to TQM

2. Understand the characteristics of quality leader and his role.

3. Develop feedback and suggestion systems for quality management.

4. Enhance the knowledge in Tools and Techniques of quality management

COURSE CONTENT

Module – 1 . 08 Hours

Principles and Practice: Definition, basic approach, gurus of TQM, TQM Framework,

Awareness, defining quality, historical review, obstacles, benefits of TQM.

Quality Management Systems: Introduction, benefits of ISO registration, ISO 9000 series

of standards, ISO 9001 requirements

Module – 2 08Hours

Leadership: Definition, characteristics of quality leaders, leadership concept, characteristics

of effective people, ethics, the Deming philosophy, role of TQM leaders, implementation,

core values, concepts and framework, strategic planning communication, decision making,

Module – 3

Customer Satisfaction and Customer Involvement:

Customer Satisfaction: customer and customer perception of quality, feedback, using customer

complaints, service quality, translating needs into requirements, customer retention, case studies.

Employee Involvement – Motivation, employee surveys, empowerment, teams, suggestion

system, recognition and reward, gain sharing, performance appraisal, unions and employee

involvement, case studies.

Module – 4 08 Hours

Continuous Process Improvement: process, the Juran trilogy, improvement strategies, types

of problems, the PDSA Cycle, problem-solving methods, Kaizen, reengineering, six sigma,

case studies.

Statistical Process Control : Pareto diagram, process flow diagram, cause and effect

diagram, check sheets, histograms, statistical fundamentals, Control charts, state of control,

out of control process, control charts for variables, control charts for attributes, scatter

diagrams, case studies

Module – 5 08 Hours

Tools and Techniques: Benching marking, information technology, quality management

systems, environmental management system, and quality function deployment, quality by

design, failure mode and effect analysis, product liability, total productive maintenance.

TEXT BOOKS:

1. Total Quality Management: Dale H. Besterfield, Publisher -Pearson Education India,

ISBN: 8129702606, Edition 03.

2. Total Quality Management for Engineers: M. Zairi, ISBN:1855730243, Publisher: Wood

head Publishing



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REFERENCE BOOKS:

1. Managing for Quality and Performance Excellence by James R.Evans and Williuam M

Lindsay, 9th edition, Publisher Cengage Learning.

2 A New American TQM, four revolutions in management, Shoji Shiba, Alan Graham, David

Walden, Productivity press, Oregon, 1990

3. Organizational Excellence through TQM, H. Lal, New age Publications, 2008

Reference Books:

1. Engineering Optimization Methods and Applications, A Ravindran, K, M.Ragsdell,

Willey India Private Limited,2nd Edition,2006.

2. : Introduction to Operations Research- Concepts and Cases, F.S. Hillier. G.J.

Lieberman, 9th Edition, Tata McGraw Hill. 2010.


Two question to be set from each module. Students have to answer five full questions,

choosing at least one full question from each module

Prerequisites:

The students should have knowledge of Production Management, Industrial Organizational

Management and Operation Management.

Overview of the Course:

The course content is designed to provide the knowledge and skills required to become an efficient

Engineer by equipping students with a holistic approach towards Quality of Product and Managing the

Quality of Product involving;

1) Knowing what is meant by Quality in terms of Quality of a product

2) Understanding the importance of Quality and its maintenance

3) Study about the different methods to manage the Total Quality

4) Innovate and implement the methodologies to Improving the Quality of a product

The entire course structure is composed of understanding the meaning of Quality, Total quality,

importance of Quality, Quality control and continuous quality improvement.

The course deals with;

1) Basic know-how of Quality/Total quality/Quality control and its importance/historical review/basic

approach.

2) Contributions of TQM Gurus in terms of Evolution of TQM.

3) Quality cost and Economics of Quality cost.

4) Pro-active and Re-active improvements are different tools and techniques used in TQM

5) Kaizen, Re-engineering, Six-Sigma, Benchmarking, 5S, 3M, Poka yoke.

6) Importance and usages of QFD and FMEA.

7) Quality Management systems like ISO-9000 and ISO-14000.

8) Different ways of measuring the acceptance quality level.

COURSE OUTCOMES:

Student will be able to

1. Explain the various approaches of TQM

2. Infer the customer perception of quality

3. Analyze customer needs and perceptions to design feedback systems.



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4. Apply statistical tools for continuous improvement of systems

5. Apply the tools and technique for effective implementation of TQM.

Relevance of the Course:

Manufacturing is the prime area for Mechanical Engineers. Manufacturing process is not only oriented to

manufacturing a product but more important is of “a quality product”. No doubt the mechanical engineers

should concentrate on the manufacturing process in the shop floor but also take care of quality of process

which should bring out a quality production.

Students should learn about Quality, Quality Control, Total Quality and improving the quality

continuously. For this mechanical engineers should learn, the different tools developed and followed by

the Japanese industries, which have succeeded in achieving the best quality products. Contributions of

great Quality Gurus have to be understood and implementing the same can also be put-forth. In all,

quality control engineers should try to reduce the wastage in the production and improve the efficiency of

the total production.

In this regard, mechanical engineers are involved in understanding “the need of the customer“ and then

struggle to fulfill his requirements in terms of his expectations and much more. Manufacturing involves i)

procuring raw material ii) conversion of raw material into finished goods. Here supplier and vendor are

also considered as the partners of the business. Otherwise achieving the goal of “customer satisfaction”

becomes very difficult. It begins with the knowledge provided by Gurus of Quality: Shewart, Juran,

Deming, Feigenbaum, Crosby, Ishikawa and Taguchi, who developed principles and practices along with

tools and techniques. These techniques are popularly used in the product or service realization activity.

The feedback from the customer helps to continually improve the product, service or organization system

as a whole.

Application Areas:

In the present era of globalization and liberalization, the competition in the market has increased neck

to neck. Any industry or any product to survive in the market, it should be of good quality and at lower

price. Complete satisfaction of the customer is main objective of Quality management.

Real time applications of TQM are:

1) Manufacturing Sector

2) Service sector

3) Inventory management

4) Supply Chain Management

5) Logistics Management

6) Technology Management

7) Process Management

8) Knowledge Management

9) Database Management



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Module wise plan

Course Title / Code: Total Quality Management

Module - 1 Planned Hours: 08

Lesson Plan:

Lesson.

No. Topics covered

Teaching

Method

POs

Attained

COs

Attained

L1 Definition, basic approach, Chalk and

Board

f, g, i, j, k

1

L2

gurus of TQM, TQM

Framework,

awareness, defining quality,

PPT 1

L3 historical review, obstacles,

benefits of TQM.

Chalk and

Board 1

L4 Quality Management

Systems: Introduction,

benefits of ISO registration

Chalk and

Board 1

L5 ISO 9000 series

of standards

Chalk and

Board 1

L6 ISO 9001 requirements. Chalk and

Board 1

L7

ISO 9001 requirements. PPT 1

L8 ISO 9001 requirements.

PPT 1

S.No Assignment Questions COs attained

01 Explain historical review of TQM 1

02 Discuss contributions of gurus of TQM 1

03 List out ISO 9001 requirements. 1



Lesson Plan:

Lesson.

No. Topics covered

Teaching

Method

POs

Attained

COs

Attained

L9 Definition, characteristics of

quality leaders

Chalk and

Board f, g, i, j, k 2

L10 leadership concept, PPT 2



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characteristics

of effective people,

L11 ethics, the Deming

philosophy

Chalk and

Board 2

L12 role of TQM leaders Chalk and

Board 2

L13 implementation,

core values,

Chalk and

Board 2

L14 concepts and framework Chalk and

Board 2

L15 strategic planning

communication, PPT 2

L16 decision making PPT 2


01 List and explain characteristics of quality leaders 2

02 Explain Deming philosophy 2

03 Explain concepts and framework of total quality management 2



Lesson Plan:

Lesson.

No. Topics covered

Teaching

Method

POs

Attained

COs

Attained

L17 Customer Satisfaction: Chalk and

Board

f, g, i, j, k

3

L18 customer and customer

perception of quality PPT 3

L19 feedback, using customer

complaints,

Chalk and

Board

L20

service quality, translating

needs into requirements,

customer retention, case

studies

Chalk and

Board 3

L21

Employee Involvement –

Motivation, employee

surveys, empowerment

Chalk and

Board 3

L22

teams, suggestion

system, recognition and

reward,

Chalk and

Board 3

L23 gain sharing, performance

appraisal PPT 3

L24 unions and employee

Involvement, case studies. PPT 3



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01 Explain customer’s perception of quality with examples. 3

02 Briefly explain the different types of teams. 3



Lesson Plan:

Lesson.

No. Topics covered

Teaching

Method

POs

Attained

COs

Attained

L25 Continuous Process

Improvement: process

Chalk and

Board

f, g, i, j, k

4

L26

the Juran trilogy,

improvement strategies, types

of problems,

PPT 4

L27 PDSA Cycle, problem-

solving methods

Chalk and

Board 4

L28

Kaizen, reengineering, six

sigma,

case studies.

Chalk and

Board 4

L29 Pareto diagram, process flow

diagram,

Chalk and

Board 4

L30 cause and effect

diagram, check sheets,

Chalk and

Board 4

L31

histograms, statistical

fundamentals, Control charts,

state of control,

out of control process,

PPT 4

L32

control charts for variables,

control charts for attributes,

scatter

diagrams, case studies

PPT 4


01 Explain Jurans triology 4

02 Explain PDSA cycle. 4

03 Explain Kaizen, six sigma and Reengineering. 4



Lesson Plan:

Lesson.

No. Topics covered

Teaching

Method

POs

Attained

COs

Attained

L33 Benching marking,

information technology,

Chalk and

Board f, g, i, j, k 5

L34 quality management PPT 5



of 89

systems, environmental

management system,

L35 quality function deployment Chalk and

Board 5

L36 quality by

design,

Chalk and

Board 5

L37 failure mode and effect

analysis

Chalk and

Board 5

L38 product liability, Chalk and

Board 5

L39 Total productive

maintenance. PPT 5

L40 Total productive

maintenance. PPT 5


01 Explain tools and techniques used in TQM 5

Syllabus for the internal Assessment Tests (Tentative):

Test Units/Modules COs attained

Internal Assessment Test-I Module 1, 2. 1, 2

Internal Assessment Test-II Module 3, 4. 3,4

Internal Assessment Test-III Module 5. 5

Test pattern: Three questions will be given and students have to answer any two full questions.

Each question carries 12.5 marks.

Evaluation Scheme:

Assessment Marks


Assignments/Quiz/seminar 05


Total 100

COURSE FILE Semester VI 2017-2018bldeacet.ac.in/PDF/CourseFile/Mech/VI Semster.pdfb.l.d.e.a’s

Documents

Transcript of COURSE FILE Semester VI 2017-2018bldeacet.ac.in/PDF/CourseFile/Mech/VI Semster.pdfb.l.d.e.a’s