EME-501 : MACHINE DESIGN-I

UNIT I Introduction Definition, Design requirements of machine elements, Design procedure, Standards in design, Selection of preferred sizes, Indian Standards designation of carbon & alloy steels, Selection of materials for static and fatigue loads Design against Static Load Modes of failure, Factor of safety, Principal Stresses, Stresses due to bending and torsion, Theory of failure. UNIT II Design against Fluctuating Loads Cyclic stresses, Fatigue and endurance limit, Stress concentration factor, Stress concentration factor for various machine parts, Notch sensitivity, Design for finite and infinite life, Soderberg, Goodman & Gerber criteria Riveted Joints-Riveting methods, materials, Types of rivet heads, Types of riveted joints, Caulking and Fullering, Failure of riveted joint, Efficiency of riveted joint, Design of boiler joints, Eccentric loaded riveted joint. UNIT III Shafts Cause of failure in shafts, Materials for shaft, Stresses in shafts, Design of shafts subjected to twisting moment, bending moment and combined twisting and bending moments, Shafts subjected to fatigue loads, Design for rigidity. Keys and Couplings Types of keys, splines, Selection of square & flat keys, Strength of sunk key, Couplings- Design of rigid and flexible couplings. UNIT IV Mechanical Springs Types, Material for helical springs, End connections for compression and tension helical springs, Stresses and deflection of helical springs of circular wire, Design of helical springs subjected to static and fatigue loading. Power Screws Forms of threads, multiple threads, Efficiency of square threads, Trapezoidal threads, Stresses in screws, Design of screw jack. Note: Design data book is allowed in the examination Books and References: 1. Mechanical Engineering Design Joseph E. Shigely, McGraw Hill Publications 2. Design of Machine Memebers-Alex Valance and VI Doughtie, McGraw Hill Co. 3. Machine design-M.F. Spott, Prentice Hall India 4. Machine Design-Maleev and Hartman, CBS 5. Machine design -Black & Adams, Mc Graw Hill 6. Machine Design-Sharma and Agrawal, S.K. Katara & Sons 7. Design of Machine Elements-V.B. Bhandari, Tata McGraw Hill Co.

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EME 502 : THEORY OF MACHINES - I

UNIT I Introduction Links-types, Kinematics pairs-classification, Constraints-types, Degrees of freedom of planar mechanism, Grublers equation, linkage mechanisms, inversions of four bar chain, slider crank chain and double slider crank chain. Velocity in Mechanisms Velocity of point in mechanism, relative velocity method, Velocities in four bar mechanism, slider crank mechanism and quick return motion mechanism, Rubbing velocity at a pin joint, Instantaneous center method, Types & location of instantaneous centers, Kennedys theorem, Velocities in four bar mechanism & slider crank mechanism. UNIT II Acceleration in Mechanisms Acceleration of a point on a link, Acceleration diagram, Coriolis component of acceleration, Crank and slotted lever mechanism, Kleins construction for Slider Crank mechanism and Four Bar mechanism, Analytical method for slider crank mechanism. Mechanisms with Lower Pairs Pantograph, Exact straight line motion mechanisms-Peaucelliers, Hart and Scott Russell mechanisms, Approximate straight line motion mechanismsGrass-Hopper, Watt and Tchebicheff mechanisms, Analysis of Hookes joint, Davis and Ackermann steering gear mechanisms. UNIT III FRICTION Laws of friction, Friction on inclined plane, Efficiency on inclined plane, Friction in journal bearingfriction circle, Pivots and collar friction-uniform pressure and uniform wear, Belt and pulley drive, Length of open and cross belt drive, Ratio of driving tensions for flat belt drive, centrifugal tension, condition for maximum power transmission, V belt drive. Brakes & Dynamometers Shoe brake, Band brake, Band and Block brake, Absorption and transmission type dynamometers. UNIT IV CAMS Cams and Followers - Classification & terminology, Cam profile by graphical methods with knife edge and radial roller follower for uniform velocity, simple harmonic and parabolic motion of followers, Analytical methods of cam design tangent cam with roller follower and circular cams with flat faced follower. UNIT V Gears & Gear Trains Classification & terminology, law of gearing, tooth forms & comparisons, Systems of gear teeth, Length of path of contact, contact ratio, interference & under cutting in involute gear teeth, minimum number of teeth on gear and pinion to avoid interference, simple, compound, reverted and planetary gear trains, Sun and planet gear. Books and References: 1. Theory of Machines - Thomas Bevan 2. Theory of Machines and Mechanisms- Shigley 3. Theory of Machines and Mechanisms-Ghosh & Mallik 4. Theory of Machines and Mechanisms- Rao & Dukkipati 5. Theory of Machines-S.S. Rattan 6. Kinematics of Machines-Dr. Sadhu singh 7. Mechanics of Machines V. Ramamurti 8. Theory of Machines Khurmi & Gupta 9. Theory of Machines R. K. Bansal 10. Theory of Machines V. P. Singh 11. Theory of Machines Malhotra & Gupta -3-

EME-503 : MANUFACTURING SCIENCE-II

UNIT-I A Metal Cutting and Machine Tools Metal CuttingMechanics of metal cutting. Geometry of tool and nomenclature .ASA system Orthogonal vs. oblique cutting. Mechanics of chip formation, types of chips. Shear angle relationship. Merchants force circle diagram. Cutting forces, power required. Cutting fluids/lubricants. Tool materials. Tool wear and tool life. Machinability. Dynamometer. Brief introduction to machine tool vibration and surface finish. Economics of metal cutting. UNIT-II Machine Tools (i) Lathe : Principle, construction, types, operations, Turret/capstan, semi/Automatic, Tool layout. (ii) Shaper, slotter, planer : Construction, operations & drives. (iii) Milling : Construction, Milling cutters, up & down milling. Dividing head & indexing. Max chip thickness & power required. (iv) Drilling and boring : Drilling, boring, reaming tools. Geometry of twist drills. UNIT-III Grinding & Super finishing (v) Grinding : Grinding wheels, abrasive & bonds, cutting action. Grinding wheel specification. Grinding wheel wear - attritions wear, fracture wear. Dressing and Truing. Max chip thickness and Guest criteria. Surface and Cylindrical grinding. Centerless grinding. (vi) Super finishing : Honing, lapping, polishing. Standardization & Interchangeability, Limits, Fits & Tolerance and Surfaceroughness: Introduction to Standardization & Interchangeability Limits, Fits, Tolerances and IS standards, Limitgauges, and surface-roughness. UNIT-IV B. Metal Joining (Welding) Survey of welding and allied processes. Gas welding and cutting, process and equipment. Arc welding : Power sources and consumables. TIG & MIG processes and their parameters. Resistance welding spot, seam projection etc. Other welding processes such as atomic hydrogen, submerged arc, electroslag, friction welding. Soldering & Brazing. Thermodynamic and Metallurgical aspects in welding and weld, Shrinkage/residual stress in welds. Distortions & Defects in welds and remedies. Weld decay in HAZ. UNIT-V C. Introduction to Un-conventional Machining and Welding Need & benefits, application and working principle of EDM, ECM, LBM, EBM, USM. AJM, WJM. Similarly, non-conventional welding applications such as LBW, USW, EBW, Plasma-arc welding, Diffusion welding, Explosive welding/cladding. Books 1. Manufacturing science by Ghosh and Mallik 2. Fundamentals of Metal Cutting and Machine tools by Boothroyd 3. Production Technology by R.K. Jain 4. Production Technology - H.M.T. 5. Production Engineering Science by P.C. Pandey 6. Modern Machining Processes by P.C. Pandey & H.S. Shan 7. Manufacturing science by Degarmo 8. Fundamentals of metal cutting & machine tools - Juneja & Shekhon 9. Process & materials of manufacturing - Lindburg. 10. Advanced Machining Process - VK Jain

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EME-504 HEAT & MASS TRANSFER

UNIT-1 Introduction to Heat Transfer: Concepts of the mechanisms of heat flows; Conduction, convection and radiation; Effect of temperature on thermal conductivity of materials; Introduction to combined heat transfer mechanism. Conduction :One-dimensional general differential heat conduction equation in the rectangular, cylindrical and spherical coordinate systems; Initial and boundary conditions. Steady State one-dimensional Heat conduction :Composite Systems in rectangular, cylindrical and spherical coordinates with and without energy generation; Thermal resistance concept; Analogy between heat and electricity flow; Thermal contact resistance; Critical thickness of insulation. UNIT-2 Fins: Heat transfer from extended surfaces, Fins of uniform cross-sectional area; Errors of measurement of temperature in thermometer wells. Transient Conduction:Transient heat conduction; Lumped capacitance method; Time constant; Unsteady state heat conduction in one dimension only, Heisler charts. UNIT-3 Forced Convection:Basic concepts; Hydrodynamic boundary layer; Thermal boundary layer; Approximate integral boundary layer analysis; Analogy between momentum and heat transfer in turbulent flow over a flat surface; Mixed boundary layer; Flow over a flat plate; Flow across a single cylinder and a sphere; Flow inside ducts; Empirical heat transfer relations; Relation between fluid friction and heat transfer; Liquid metal heat transfer. Natural Convection :Physical mechanism of natural convection; Buoyant force; Empirical heat transfer relations for natural convection over vertical planes and cylinders, horizontal plates and cylinders, and sphere ; Combined free and forced convection. UNIT-4 Thermal Radiation :Basic radiation concepts; Radiation properties of surfaces; Black body radiation Plancks law, Weins displacement law, Stefan Boltzmann law, Kirchoffs law; ; Gray body; Shape factor; Black-body radiation; Radiation exchange between diffuse non black bodies in an enclosure; Radiation shields; Radiation combined with conduction and convection; Absorption and emission in gaseous medium; Solar radiation; Green houseeffect. UNIT-5 Heat Exchanger :Types of heat exchangers; Fouling factors; Overall heat transfer coefficient; Logarithmic mean temperature difference (LMTD) method; Effectiveness-NTU method; Compact heat exchangers. Condensation And Boiling :Introduction to condensation phenomena; Heat transfer relations for laminar film condensation on vertical surfaces and on outside & inside of a horizontal tube; Effect of non-condensable gases; Dropwise condensation; Heat pipes; Boiling modes, pool boiling; Hysteresis in boiling curve; Forced convective boiling. Introduction To Mass Transfer :Introduction; Fick's law of diffusion; Steady state equimolar counter diffusion; Steady state diffusion though a stagnant gas film. Books: 1. Elements of Heat transfer by Bayazitouglu & Ozisik, McGraw-Hill Book Company. 2. Heat Transfer By J.P. Holman, McGraw-Hill International edition. 3. Schaum's outline of Heat Transfer by Pitts & Sisson McGraw-Hill International edition. 4. Principles of Heat Transfer by Frank Kreith, McGraw-Hill Book co. 5. Fundamentals of Momentum, Heat and Mass Transfer by James R.Welty; John Wiley & Sons (Pvt). Ltd. 6. Heat Transfer, by Vijay Gupta, New Age International (P) Ltd. Publishers 7. Heat Transfer, by Y.V.C. Rao, University Press. 8. Heat Transfer, by R. Yadav, Central Publishing House, Allahabad.

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EME-505 : I C ENGINES & COMPRESSORS

UNIT-1 Introduction to I.C Engines: Engine classification, Air standard cycles, Otto cycle, Diesel cycle, Dual cycle, Comparison of Otto, Diesel and Dual cycles, Stirling cycle, Ericsson cycles, Actual cycle analysis, Two and four stroke engines, SI and CI engines, Valve timing diagram, Rotary engines, stratified charge engine. Fuels: Fuels for SI and CI engine , Important qualities of SI and CI engine fuels, Rating of SI engine and CI engine fuels, Dopes, Additives, Gaseous fuels, LPG, CNG, Biogas, Producer gas, Alternative fuels for IC engines. Testing and Performance: Performance parameters, Basic measurements, Blow by measurement, Testing of SI and CI engines. UNIT2 SI Engines: Combustion in SI engine, Flame speed, Ignition delay, Abnormal combustion and it's control, combustion chamber design for SI engines. Carburetion, Mixture requirements, Carburetor types, Theory of carburetor, MPFI. Ignition system requirements, Magneto and battery ignition systems, ignition timing and spark plug, Electronic ignition. UNIT3 CI Engine: Combustion in CI engines, Ignition delay, Knock and it's control, Combustion chamber design of CI engines.Fuel injection in CI engines, Requirements, Types of injection systems, Fuel pumps, Fuel injectors, Injection timings. Scavenging in 2 Stroke engines, pollution and it's control. UNIT-4 Engine Cooling: Different cooling systems, Radiators and cooling fans. Lubrication: Engine friction, Lubrication principle, Type of lubrication, Lubrication oils, Crankcase ventilation. Supercharging: Effect of altitude on power output, Types of supercharging Compressors: Classification, Reciprocating compressors, Single and Multi stage compressors, Intercooling, Volumetric efficiency. Rotary compressors, Classification, Centrifugal compressor , Axial compressors, Surging and stalling, Roots blower, Vaned compressor. BOOKS: 1. Fundamentals of Internal Combustion Engine by Gill, Smith,Ziurs, Oxford & IBH Publishing CO. 2. IC Engines, by Rogowsky, International Book Co. 3. A Course in International Combustion Engines, by Mathur & Sharma, Dhanpat Rai & Sons. 4. I.C Engine Analysis & Practice by E.F Obert. 5. I.C Engine, by Ganeshan, Tata Mc Graw Hill Publishers. 6. I.C Engine, by R. Yadav, Central Publishing House, Allahabad 7. Reciprocating and Rotary Compressors, by Chlumsky, SNTI Publications, Czechoslovakia 8. Turbines, Compressors and Fans, by S.M.Yahya, Tata Mc Graw Hill Pub.

EME-551 : MACHINE DESIGN-I Lab

Note: Eight experiments out of the following are to be performed. Students are advised to use design data book for the design. Drawing shall be made wherever necessary on small drawing sheets 1. Design & drawing of Cotter joint. 2. Design & drawing of Knuckle joint 3. Design of machine components subjected to combined steady and variable loads 4. Design of eccentrically loaded riveted joint 5. Design of boiler riveted joint -6-

6. Design of shaft for combined constant twisting and bending loads 7. Design of shaft subjected to fluctuating loads 8. Design and drawing of flanged type rigid coupling 9. Design and drawing of flexible coupling 10. Design and drawing of helical spring 11. Design and drawing of screw jack

EME-553 : MANUFACTURING SCIENCE -II LAB

Say, min 8 experiments out of the following (or such experiment along-with study of the machines/processes) 1. Shear-angle determination (using formula) with tube cutting (for orthogonal) on lathe machine. 2. Bolt (thread) making on Lathe machine 3. Tool grinding (to provide tool angles) on tool-grinder machine. 4. Gear cutting on Milling machine. 5. Machining a block on shaper machine. 6. Finishing of a surface on surface-grinding machine. 7. Drilling holes on drilling machine and study of twist-drill. 8. Study of different types of tools and its angles & materials. 9. Experiment on tool wear and tool life. 10. Experiment on jigs/Fixtures and its uses 11. Gas welding experiment 12. Arc welding experiment 13. Resistance welding experiment. 14. Soldering & Brazing experiment 15. Experiment on unconventional machining. 16. Experiment on unconventional welding. 17. Experiment on TIG/MIG Welding. 18. Macro and Microstructure of welding joints, HAZ.

EME-554 : HEAT & MASS TRANSFER LAB

Minimum 10 experiment of the following 1. Conduction - Composite wall experiment 2. Conduction - Composite cylinder experiment 3. Convection - Pool Boiling experiment 4. Convection - Experiment on heat transfer from tube-natural convection. 5. Convection - Heat Pipe experiment. 6. Convection - Heat transfer through fin-natural convection . 7. Convection - Heat transfer through tube/fin-forced convection. 8. Any experiment on Stefan's Law, on radiation determination of emissivity, etc. 9. Any experiment on solar collector, etc. 10. Heat exchanger - Parallel flow experiment 11. Heat exchanger - Counter flow experiment 12. Any other suitable experiment on critical insulation thickness. 13. Conduction - Determination of thermal conductivity of fluids. 14. Conduction - Thermal Contact Resistance Effect.

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COURSE PLAN ENGINEERING AND MANAGERIAL ECONOMICS EHU- 501

Course description: this course is designed to familiarize the students of B.Tech programme , with the basic principles and theories of economics which will prepare them for their roles as future managers. Unit no. 1 Competencies The objective of this unit is to provide a basic understanding of economics and how economic decisions are made. The unit also deals with the concept of science, engg and their role in economic development The objective of the unit is to provide the understanding of basic concept of demand. The unit attempts to explain the meaning and significance of elasticity of demand Contents Introduction: A brief historical perspective, definitions and classification of economics Nature and scope of economics Significance of economics Role of economics in managerial decision making Meaning of science, engineering and technology Managerial economics and its scope in engineering perspective Economic development and growth Basic concepts Demand analysis Concept of needs, wants, demand and supply Law of demand and demand determinants Reasons for shape of demand curve Exception to the law of demand Types of demand Concept of elasticity of demand and supply Price, income, cross and advertising elasticity Measurement of elasticity of demand Demand forecasting Meaning and significance of demand forecasting Methods of demand forecasting Production- meaning and production function Factors of production Law of production Law of return to scale Law of diminishing returns scale Cost concepts Short run and long run cost curves Fixed cost, variable cost, average cost, marginal cost , opportunity cost etc. -8No of Tech./lear. Lect. Acti. 06 Orientation Lectures and Classroom discussion Book & pg no. KK dewett Page no 3-8

KK dewett Page no 640-651 8 Lectures and Classroom discussion KK dewett Page no 77-91

This unit attempts to explain meaning and methods of demand forecasting and production and cost concepts

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Lectures and Classroom discussion

DN dwivedi Page no 213-239

DN dwivedi Page no 252-277 DN dwivedi Page no 293-317

The aim of this unit is to provide a thorough knowledge of market structure and pricing under different market structure.

Market structure Perfect competition meaning and features Price determination under perfect competition Imperfect competition Monopolistic meaning and features Price determination under monopolistic oligopoly meaning and features Price determination under oligopoly Monopoly meaning and features Price determination under monopoly duopoly meaning and features Price determination under duopoly

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Lectures and Classroom discussion

DN dwivedi Page no 361-417

The basic aim of the unit is to give an idea about the national income, and the various methods to measure it . this unit also tell about the inflation and business cycle.

National income, inflation and business cycle Definition of national income Methods of measuring national income Meaning of inflation Types of inflation Causes of inflation Theories of inflation Prevention of inflation Introduction of business cycle Phases of business cycle Theories of business cycle Remedial measures

Lectures and Classroom discussion

KK dewett Page no 394-406

DN dwivedi Page no 217-525 564-571

Reference Books: Koutsoyiannis A : Modern microeconomics,ELBS Managerial economics for engineering : Prof. D.N.Kakkar Managerial economics :D.N.Dwivedi Managerial economics: Maheshwari Modern economic theory: KK dewett

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ENGINEERING AND MANAGERIAL ECONOMICS EHU- 501 TUTORIAL SHEET UNIT 1 1. Discuss the development and classification of economics? 2. Should economics be treated as a science or art? 3. How is economics useful for mangers? 4. Discuss the nature and scope of economics. 5. Managerial economics is the discipline which deals with the application of economic theory to business management discuss UNIT 2 1. State and explain the Law of demand .what is its exceptions? 2. Why does a demand curve slope downward? Can a demand curve slope upward to the right under any condition? 3. Discuss the concept of price elasticity of demand along with its various types. 4. Define cross elasticity of demand and state its formula. How does such elasticity differ in case of substitutes and complementary goods? 5. Explain the various uses of concept of elasticity of demand. UNIT 3 1. Discuss briefly the various methods of demand forecasting and point out their limitations. What are the criteria of a good forecasting method?

2. Explain the concept of production function and point out its managerial uses. 3. Explain the concept of law of diminishing returns. 4. Discuss briefly different cost concept relevant to managerial decision of planning and control. 5. The long run average cost curve is L- shaped. Does this means that the economies of Scale does not exist. UNIT 4 1. Why is a firm under perfect competition regarded as price taker and not a price maker. 2. What is meant by price discrimination? State the necessary condition for price discrimination. 3. Explain various types of market structure and compare their characteristics. 4. What is meant by monopolistic competition? How does a firm take it pricing and output decision in it? 5. Define oligopoly. Explain how price and output decision are taken under oligopoly. UNIT 5 1. Define national income and Differentiate between gross National product (GNP) & Net National Product (NNP). 2. Describe the various methods of measuring national income. 3. Explain the concept of business cycle and point out its different phases. How is a business enterprise affected during those phases? 4. What is inflation? What are the causative facture to the inflation? 5. Enumerate some of the important theory of business cycle & explain any of them pointing its main features?

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COURSE PLAN MACHINE DESIGN-I EME-501

Unit No. Competencies Contents INTRODUCTION The student should be able to Understand the basic definition of machine design standards in design, preferred size, material selection designation of steel and its alloy plastic etc Definition of machine design ,Design requirements of m/c elements, Traditional design method Machine design procedure, Design methods, Standard in design, Selection of preferred size 1 Lecture cum discussion problems H Teaching Learning Activities Page Number /Reference

P(1-17)/A P(1-37)B

To describe different modes of failure , theory of failure, principle stress, stress concentration factors

BIS System of designation of Carbon Steel & alloy, plastics & 1 rubber, Selection of material for static & Fatigue loads DESIGN AGAINST STATIC LOAD Modes of failure ,Factor of safety, 1 Stress strain relationship

Understanding Endurance limit, Soderberg & Goodman criteria

Principal stress 1 Stresses due to bending & torsion 1 Theory of failure 1 DESIGN AGAINST FLUCTUATING LOAD Cyclic Stresses, Fatigue & Lecture Endurance limit, Stress 1 cum concentration discussion problems Stress concentration factors for various machine parts, Notch 1 Sensitivity. Design for finite life 1 Design for infinite life 1 Soderberg , Goodman and 1 Gerber criteria RIVETED JOINTS Rivets, Riveting methods, materials, Types of riveting heads, Types of riveted joints, Caulking & Fullering Failure of Riveted joints, Efficiency of Riveted joints Design of Boiler Joints Eccentric loaded riveted joints Lecture cum discussion problems

Lecture cum discussion problems

P(89-127)/A P(316-335)/B P(87-119)/C

P(156-194)/A P(181-223)/C

Understanding riveted joints & applications

P(281-340)/C 1 1 1

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SHAFTS Cause of failure in shafts, Materials for shafts, stresses in shafts, stresses in shafts Understand design of shaft Design of shaft subjected to twisting moment, bending moment and combined twisting & bending moments Shafts subjected to fatigue loads Design for rigidity KEYS & COUPLINGS types of keys, splines, selection of square & flat keys strength of sunk keys, types of couplings, selection of couplings design of rigid coupling design of flexible coupling SPRINGS types of springs, material for springs, end connection for spings stresses & deflection of helical spring of circular wire design of spring for static loading design of spring for fluctuating loading POWER SCREWS forms of thread, multiple threads, efficinency of square threads trapezoidal threads, stresses in screws design of screw jack

1 Lecture cum discussion problems P(P(323338)A 509557)/C

1 1 1

1 1 1 1

Understand design of keys couplings & its applications

Lecture cum discussion problems

P(340-365)A P(470-508)/C

Describe different types of springs its function applications classification And design methods of all type of springs for static and dynamic loading to have an idea about different type of threads, stresses in power screw & design of screw jack

1 1 1 1

Lecture cum discussion problems

P(389-402)/A

1 1 1

Lecture cum discussion problems

P(202-224)/A P(624-676)/C

VALUE ADDDED TOPICS: Application of vibration in Design Step function and the theorem of castigliano introduced as tools for determining deflection in machine members Determination of rigidity and strength of machine members Treatment of critical speeds of shafts. REFRENCES : Text Book A- Design of machine element B- Machine design C- Machine design Reference Book 1. Machine design 2. Design of machine element 3. Machine Design 4. Machine Design

: : : : : : :

V .B. Bhandari(TMH) J. E .Shigley(TMH) R.S. Khurmi (S.Chand) Groover Spotts Sharma &Agarwal P.Kanniahah - 12 -

MACHNIE DESIGN-I EME-501

UNIT-I, SHEET-1 1. Explain in brief Traditional design methods. Standard in size Preferred number Phases in design 2. State the advantage and drawbacks of cast iron as an engineering material 3. Discuses the factors, which govern the selection of material for a machine component. 4. Explain the term mechanical properties of material 5. (a) Discuses BIS system of designation of steel (b) Discuses BIS system of designation of cast iron (c) Discuses Indian standard designation of low and medium alloy steel. SHEET-II 1. Explain the procedure of mechanical engineering design 2. A manufacturer is interested to start his business with five different models of tractor ranging from 7.5 KW to 75 KW capacities .specify the power capacity of models there is expansion plan to further increase the number of models to ten to fulfill the task of agriculture specify the power capacity of additional model. 3. Select the suitable material for following cases, including reason (i) A shaft subjected to variable load for twisting & bending. (ii) Nut of heavy duty screw jack (iii) Spring uses in spring loaded safety valve (iv) Low speed line shaft coupling 4. What is preferred no.? How will you find the number belonging to R 10 series? 5. Write short note on the following (i) Standardization (ii) Ergonomics (iii) Design analysis (iv) Design synthesis UNIT-II, SHEET-I 1. The force acting on a bolt consists of two components an axial pull of 12 KN and a Transverse shear force of 6KN. The bolt is made of steel FeE 310 (syt-310 N/mm2) and the factor of safety is 2.5 Determine .The diameter of shaft using maximum shear theory of failure. 2. A 25 mm dia, shaft is made of forged steel 30C8 (sut = 600N/mm2) there is step in the shaft and theoretical stress concentration factor at the step is 2.1, the notch sensitivity factor is 0.84 determine the endurance strength of the shaft, if it is subjected to reversed bending. 3. A solid circular shaft, 15 mm diameter is subjected to torsional shear stress which varies from 035N/mm2. And the same tie is subjected to an axial stress that varies from -15 to + 30 N/mm2. the frequency of variation of these stress is equal to speed of shaft . The shaft is made of steel FeE 400 (sut=540N/mm2) and syt=400N/mm2) .The shaft strength is of 200N/mm2 .determine the factor of safety. 4. A bolt is subjected to direct tensile load 20KN and shear load of KN. Suggest the suitable size of bolt according to various theory of failure .If yield stress in simple tension is 360,N?mm2 Take Poission ratio is 0.25.

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5. Bending stress in a machine part fluctuates between a tensile stress of 210 MPA and compressive stress of 140 MPA .What should be the minimum ultimate tensile strength to carry this fluctuation indefinitely according to . (i) Goodman formula (ii) Soderbergs formula The fos may be assume to 1.75 assume yield point is never likely to be less than 55% or greater than 93% of the ultimate tensile strength. SHEET-II 1. A component machined from a Plate made of steel 40C6 is shown in fig. It is subjected to a completely reversed axial force of 600KN the expected reliability is 90% and factor of safety is 3. 600KN Find the plate thickness of infinite life .assume notch sensitivity factor is 0.8. fig 2 A forged steel bar 5 cm in diameter is subjected to a reversed bending stress of 300N/mm2 .the bar is made of steel 45C8 .find the life of the baqr for a reliability of 90%. 3. A machine component subjected to a flexural stress ,which fluctuates between + 300MN/m2 and 150MN/mm2 determine the value of min ultimate strength according to (i) modified Goodman relation (ii) soderberg relation Take yield strength =55 ultimate Strength Endurance strength =5 ultimate strength, and FOS=2. 4. A 50 mm dia. Shaft is made from carbon steel having ultimate tensile strength of 630N/mm2 using soderberg method calculate the fos. Assume suitable value for any other data needed. late 5. A forged steel bar 50mm in dia .Is subjected to a reverse bending stress 250 N/mm2 .the bar is made of steel 40C8 calculate the life of the bar for a reliability of 90%. 6. A cantilever beam is made of cold draw steel 40C8 is shown in fig .The force P acting at the m free end varies from -50 to + 150 N. The expected reliability is 90%, and the fos is 2. The notch 50 sensitivity factor at the fillet is 0.9 determine the dia of the fillet sectio section.

Fig. problem-1(sheet-2)Fig. problem problem-5(sheet-2) UNIT-III SHEET-I

Fig. problem-2(sheet 2(sheet-1)

1. A bolted joint is used to connect two components, the combined stiffness of the two components is twice the stiffness of the bolt .the initial tightening of the nut result in a pre load of 5 KN in the bolt .The external force of 10KN creates further tension in the bolt .The bolt is made of plane carbon steel 30C8 and the FOS is 3. There are coarse thread on the bolt .calculate the tensile stress area of the bolt and specify a suitable size for its threads. 2. An eccentrically loaded bracket is welded to the support as shown in fig .the permissible shear stress for the material is 55M/mm2 .the load is static .determine the leg dimensions for the weld. - 14 -

3. A line shaft supported two pulleys A and B is show in fig .power is supplied to the shaft by means of a vertical belt on pulley A, which is then transmitted to pulley B carrying a horizontal. The ratio of the belt Tension on tight and loose side is 3; 1 and maximum tension in either belt is limited to 2.7.KN .the shaft is made of plain carbon steel 40C8 , pulley are keyed to the shaft .Determine the shaft diameter .According to ASME code If Kb=1.5 Kt=1.

Fig..

4. A solid circular shaft ,25,mm India is welded to support by means of a fillet weld as shown in fig determine the leg dimension of the weld if the permissible shear is 95N/mm2.

Fig... section 5. The standard cross section for a flat a flat key ,which is fitted on a 50 mm dia .shaft ,is 16x 10mm .The key is transmitting 475 Nm torque from the shaft to the hub and is made of commercial steel (Syt=Syc=23oN/mm2) determine the length of key ,if the fos is 3. SHEET-II 1A Rigid coupling used to transmit 50 KW power at 300 rpm .There are 6 bolts the outer diameter of flange is 200 mm while recess diameter is 150 mm. The coefficient of friction between the flanges is .15. The bolts are made of steel 45C8 (syt=380N/mm2) and the factor of safrty is 3. Determ Determine the diameter of bolts. Assume that the bolts are in large clearance holes. 2 Find the size of rivets required for the bracket shown in fig .All the dimension are in mm. the plate is 3. thick and the rivets which are to be all of the same size are in single shear ,the permissible shear in stress be taken as 180MPA.

3. Fig. Shown all the dimension are in mm shows are arrangement to support a load of 90 KN . Suggest the suitable of weld for a permissible shear stress of 100N/mm2.

Fig - 15 -

4. Two length of mild steel tie rod having width 200mm and thickness 12.5mm ,are to be connected by means of a butt joint with double cover plates .Design the joint if the permissible stress are 80 MPA in tension, 65MPA in Shear ,160 MPA in crushing .Make the of joint. 5. A mild steel shaft transmits 23Kw at 200 rpm .It carries a central load of 900 N and is simply supported between 2.5 m apart Determine the size of shaft if allowable shear stress is 40 Mpa and max tensile or compressive stress is not exceed 56 Mpa .What is the size of shaft if it is subjected to gradually applied loads. UNIT-IV SHEET-I 1. Design a cold coiled compression helical spring subjected to a static or infrequently varying load F=1850N and deflection of 90mm .the mounting space has an dia, of 72mm. there are no special requirements to be meet by spring. 2. An automotive engine develops maximum torque at speed of 1000RPM. At this speed the power developed by the engine is 25Kw . the engine is equipped with a single plate clutch having two pair of friction surfaces ,the mean dia .of the friction disc is 190 mm and coefficient of friction is 0.35. six spring with a spring index of 6, provide the necessary axial force . the permissible shear stress can be as 50% of the ultimate tensile strength .Determine the wire dia Of the spring. 3. A helical valve spring is to be designed for an operating 100 to 150 n ie ,100N w3hen the valve is closed and 150N when open .The valve lift in the above load range is to about 7.5.mm assuming severe service and a spring index of 10, determine the size of the wire , number of the wire and pitch you would recommend. 4. A relief value must blow off a pressure of 1.25.MPA and should lift by 6% increase in pressure .the valve dia is 65 mm Design the valve spring. 5. A safety valve is loaded by tension type closed helical spring having the following data Valve dia 60mm. Minimum pressure on valve : 0.75 MPa Maximum pressure on the valve : 0.75mpa Valve lift : 3mm. Spring index : 6 Modulus of rigidity : 81370N/mm2 Permissible shear stress :600N/mm2 Design the spring. SHEET-II It is required to design a double start screw with square threads for the C clamp as shown fig .the maximum force exerted by clamp is 2. KN. It is assumed that the operator will exert a force of 200N at the handle of hand wheel .The screw is made of with Syt=300N/mm while the nut is of CI. Take the FOS =3 find the dimension of screw nut and give radio of handle from screw axis.

- 16 -

The screw of a shaft straightener exerts a load of 30KN as shown in fig the screw is square threaded of outside dia 75 mm& 6mm pitch deter mine.

force required at the rim of a 300mm dia hand wheel assuming coeff. of friction thread is 0.12. max .compressive stress in screw efficiency of the straightener. A screw jack is to lift a load of 80 KN through a height of 400mm the elastic strength of screw material in tension & compression is 200 mpa & in shear 120MPa .the material for the nut is phosphor- bronze for which elastic limit may be taken as 100MPa in tension 90MPA in compression and 80 MPa In shear,the bearing pressure between nut and screw is not to exceed 18 N/mm2 .Design and draw screw jack . What is the force required at the radius of 80 mm to raise and lower a 11KN cross bar of planer? The bar is raised and lowered by two 38mm square thread screws, having a pitch 7mm .The screw is of steel and nut is of bronze 38mm thick .the collar is steel and it is an outside dia of 75mm and inside dia of 35mm. Assume the coefficient of friction at the thread is 0.111 and the collar as 0.13. The nominal dia of a triple threaded square screw is 50mm, while the pitch is 8mm .it is use with a collar having outer dia of 100mm and inner dia is 65mm .The coeff of friction at threaded surface as well as the coller surface can be taken as 0.15. The screw is used to raise a load of 15KN .using the uniform wear theory for the collar. Calculate. torque required to raise and lower the load the force required to raiser the load if applied at a radius of 500mm. UNIT V Explain the difference between design by evolution and innovative design .cfompare the old and new design techniques ,Give examples. Give generalized need statement and specification .standard of performance and compare for the following. Matche box, Three lug top and socket, Envelope What are the three phases of product design with the help of suitable example explain the step involves in product design and development. What are the design criteria explain with the help example design for function. What are the various phases of design describe the morphplogy of design in detail. Describe and following:-Creativity and checklist Need analysis & ideation techniques. Describe the brainstorming and synectics. What are the economic factors that affect the design concept .Describe in detail in break even analysis? Describe the concept of utility and explain that hoe it can be used for design selection. What is the reliability how it can be measured describe the bath curve.

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SAMPLE PAPER MACHINE DESIGN-1 EME-501

1. Answer any TWO of the Following: Following:(a) What are Preferred Numbers? Explain their application in standardization. Give examples. (b) A manufacture is interested in manufacturing 4 different models of generating sets ranging from 5 kW to 50 kW capacities. Using R 5 series, specify the capacities of the models. If he further wishes to expand to 8 models within the same range, what will be the capacities of the additional and models? (c) What do you understand by the following designation of materials? 40 C8; 40Cr1; 35 Ni 1 Cr 60; 50 Cr 1 V23; FG 350 2. Answer any TWO of the following :(a) A machine component is subjected to bending stress which fluctuates between 300 N/mm2 tensile and l150 N/mm2 compressive in a cyclic manner. Using Goodman formula, calculate the minimum required ultimate strength of the material. Take factor of safety as 1.5 and endurance ltimate limit in reversed bending as 50% of ultimate strength. (b) A shaft transmits 5 kW at 1000 rpm. Using maximum shear strain energy theory, find the diameter of the shaft. Take yield point stress in tension as 300 N/mm2, factor of safety as 2.0, and Poissons ld ratio 0.25. (c) Write brief notes on any TWO of the following : :(i) Notch Sensitivity (ii) Endurance Limit (iii) Graphical representation of Maximum Sheer Stress Theory 3. A bracket is attached to a column by means of five rivets as shown in Fig. given below. Find the connection. Assume suitable values of permissible stresses. What will be the change in design steps / procedure if the force P is applied in a direction p perpendicular to the plane of the bracket?

Design a flange coupling to transmit 135 kW power at 120 rpm from one shaft to another. Allowable shearing stress of the bolt material is 45 N/mm2 while that of the shaft material is 55 N/mm2. The flanges are made of C.I. for which the stresses in compression and shear are 75 N/mm2 and 175 N / mm2 respectively. Suggest suitable dimensions for the shaft, bolts & coupling.( Do not design the keys.)

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4. Figure given below shows a combined spring and dead weight loaded valve. The valve diameter is 30 mm and it weighs 10 N. The weight of the lever is 25 N. The spring (free length = 100mm) is stretched up to 120 mm when loaded. Calculate the dead load P needed for the valve to just open at a pressure 3.5 N/mm2 on the valve. A 2 mm lift of the valve is needed for escape of gases. Assume spring index 6, permissible shear stress for spring wire 500 N / mm2, C = 0.84 x 105 N / mm2. Design the spring.

A 70 mm screw with square threads is used in a press. It has a maximum unsupported length of 450 mm. The screw is of C-25 steel with phosphor bronze nut. Determine(a) The safe capacity of the press, (b) The proper length of the nut, (c) The necessary tensional moment, assuming coefficient of friction in the threads as 0.13 and at the thrust collar as 0.15, which has an out side diameter of 90 mm and inside diameter of 26 mm.

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COURSE PLAN THEORY OF MACHINES - I EME-502

Unit No. Competencies Students will be able to analyze the forces acting on the machine part under static and dynamic conditions. Contents Introduction to Theory of Machines. Links, Kinematic Pairs, their types and classification. Types of Constraints. Degree of Freedom of planar mechanism, Grublers equation Linkage mechanism, inversion of four bar chain Slider Crank and double slider crank chain Crank chain continued Velocity of point in mechanism, Relative velocity method, Velocities in four bar mechanism, Slider crank mechanism and quick return motion mechanism, Rubbing velocity at a pin joint, Instantaneous center method, Types & location of instantaneous centers Kennedys theorem, Velocities in four bar mechanism Velocities in slider crank mechanism , Acceleration in Mechanisms Acceleration of a point on a link, Acceleration diagram, Coriolis component of acceleration, Crank and slotted lever mechanism Kleins construction for Slider Crank mechanism and Four Bar mechanism, Analytical method for slider crank mechanism Mechanisms with Lower Pairs :Pantograph Exact straight line motion mechanisms Paucelliers, mechanism Hart and Scott Russell mechanisms, Approximate straight line motion mechanismsGrass-Hopper, Watt and Tchebicheff mechanisms, Analysis of Hookes joint, Davis and Ackermann steering gear mechanisms FRICTION Laws of friction, Friction on inclined plane, Efficiency on inclined plane Friction in journal bearing-friction circle Pivots and collar friction-uniform pressure and uniform wear Belt and pulley drive, Length of open and cross belt - 20 H 1 1 1 Seminars 1 1 1 1 28-35 SSR 42- 45 SSR 46 SSR 49-62 SSR Teaching Learning Activities Lecture cum discussion Page no / Ref. 1-5 SSR 6-9 SSR 14-23 SSR

48,68-73 SSR

1 1 1 1 1 1 1 1 1 1 1

71- SSR 49-60 89-95 SSR 94-95 SSR 96-110 SSR 111-126 SSR 127 SSR125, 144-146 SSR 187-188 SSR 189-193 SSR 193- 196 SSR 206-217 SSR

Student will be familiarizing with the acceleration analysis of links in various mechanisms

Lecture cum discussion Seminars

II

III

Student will study about the power transmission and losses for various friction devices and also study the basic

1 1 1 1

Lecture cum discussion Seminars

276-283 SSR 314-316 SSR 294-301 SSR 330-334,340343 SSR

operational function of the various brakes and dynamometers used in day-today life.

IV

This unit aims at the description of Cams including the uses, manufacturing & design aspects. Various types of Cam profiles are to be practiced.

Ratio of driving tensions for flat belt drive Centrifugal tension, condition for maximum power transmission, V belt Brakes & Dynamometers Shoe brake, Band brake, Band and Block brake, Absorption and transmission type dynamometers CAMS Cams and Followers - Classification & terminology Cam profile by graphical methods with knife edge and radial roller follower for uniform velocity Simple harmonic for Parabolic motion of followers Analytical methods of cam design tangent cam with roller follower Circular cams with flat faced follower

1 1 1

346-347 SSR 348-355 SSR 612-632 SSR

632-634 SSR 1 Lecture cum discussion Seminars 2 1 253-255 SSR 2 1 Lecture cum discussion Seminars Experiments on gears 257 SSR 369-381 SSR 383 SSR 391-397 SSR 397,404, 405 SSR 398-404 SSR 425-440 SSR 440-444 SSR 234- 240 SSR

222-229 S.S.R

Students will study about the various types, functions and design & manufacturing aspects of gears.

Introduction of Gears & Gear Trains, Classification & terminology, Law of gearing, Tooth forms & their comparisons Systems of gear teeth, Length of path of contact, contact ratio Interference & under cutting in involute gear teeth Minimum number of teeth on gear and pinion to avoid interference Simple, compound, reverted and planetary gear trains Sun and planet gear.

1 1 1 1 1 1 1

TOPICS FOR VALUE ADDITION: Case study in Static and Dynamic Force Analysis. Recent advances in Brakes and Clutches. REFERENCES / TEXT BOOK : 1. Theory of M /c2. Theory of Machine3. Theory of Machine & Mechanism4. Mechanism & Dynamics of Machines5. Theory of Machine6. Mechanism and Machine Theory7. Theory of Machine8. Theory of Machine9. Mechanism & Machine Theory10. Theory of MachineS.S Rattan (SSR) Thomas Bevan Shiglay Mabie R.K. Bansal A.K. Ambedkar P.L. Ballaney. W.T. Green. J.S. Rao & R.V. Dukkipati (R&D) R.S. Khurmi

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THEORY OF MACHINE-1 EME 502 TUTORIAL SHEET: 1 Ques.1- Determine the degree of freedom of the following linkage / Mechanism:

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TUTORIAL SHEET: 2 Q 1- In a pin jointed four bar mechanism, as shown in fig. AB= 300mm, BC=CD=360mm, and AD= 600mm the angle BAD=60degree. The crank AB rotates uniformly at 100 rpm. Locate all I Icenters and find the angular velocity of link BC. c b

60 d fig.1 Q 2- The crank of a slider crank mechanism rotates at 300rpm the crank is 150 mm long and CRIs 600mm long. Determine: angular vel. of connecting rod, at a crank angle of 45 degree from inner dead centre position. Q 3- In a quick return motion mechanism of oscillating type link ,the distance b/w fixed centre is 80 mm and the length of driving crank is 20 mm. determine the time ratio of the working stroke to the return stroke. [ans.- 1.38 ] Q 4- In a quick return motion mechanism of the crank and slotted lever type, the ratio of maximum velocity is 2. If the length of stroke is 250 mm, find a). The length of slotted lever b). mm, The ratio of time of cutting and return stroke and the maximum cutting velocities when crank rotates at 30 degree. [ans. 375mm, 1.552, 0.294m/s] Q 5- the quick return motion mechanism of the crank and slotted lever shaping machine OA=800 slotted mm, OB= 300mm, AC= 1300 mm, CD =400mm The crank OB makes an angle of 45 with the vertical And rotate at 40 rpm in CCW direction. Find a) Velocity of ram b) Angular velocity of link AC. - 23 a

TUTORIAL SHEET NO.:- 3 Q 1- in a 4 bar mechanism, the length of the various links are AB= 190mm, BC=CD= 280 mm, AD= 500mm and <BAD = 55 degree. The crank AB rotates at 10 rad/sin CW dir. Determine a) the acceleration of link BC and CD b) the angular acceleration of BC and CD. Q 2- In a slider crank mechanism the length of various link are : OA = AC = 200 mm , AB = 600 mm, <AOB = 30 degree. The crank rotates at 10 rad/sec. determine: a) the acceleration of the connecting rod AB b) acceleration of slider B c) Acceleration of a point C in AB. Q 3- In a crank & slotted lever type quick return motion mechanism the crank is rotates at 120 rpm determine: A). vel. of ram at D B). magnitude of coriolis acceleration component C). acceleration of ram at D. AB=200mm, OC= 800 mm, CD= 600mm, OA = 300mm Q 4- the crank of a engine 300mm long rotates at a uniform speed of 300rpm .the ratio of CR length to the crank radius is 4. Determine using Kleins construction: a) Acceleration of the piston b) Angular acceleration of the rod c) acceleration of a point x on the CR at 400mm from the crank pin .the crank position is 60 degree from inner dead centre. Q 5- from the above question find analytically, the acceleration of the piston and angular acceleration of rod. TUTORIAL SHEET NO.:- 4 Q1 Two shafts are connected by a hooks joint have their axes inclined at 20degree .the driving shaft rotates at 1500 rpm and the driven shaft carries a flywheels of mass 15 kg and radius of gyration of 10 cm find the maximum torque in the driven shaft if it is assumed that the shaft are torsion ally rigid. Q2 Two shafts are to be connected by a hooks joint. The driving shaft is rotates at a uniform speed of 500rpm and the speed of driven shaft must be 475 and 525 rpm. Determine the maximum permissible angle b/w the shafts? Q 3 Two shaft s are connected by hooks joint, the driving shafts rotates uniformly at 500 rpm .if the total permissible variation in the speed of the driven shaft is not to exceed +- 6% of the mean speed , find the greatest permissible angle b/w the centre lines of the shaft. Q4 The angle b/w the axes of 2 shaft connected by universal joint is 20 degree. The driving shaft rotates at uniformly speed of 240rpm the driven shaft carries a steady load of 9kw. Calculate the radius of gyration of the flywheel of the driven shaft having mass 50 kg and the output torque of the driven shaft does not vary by more than 20% of the input shaft? Q5 In a Davis steering gear, the distance b/w the pivots of the front axles is 1.2meter. and the wheel base is 2.7 meter find the inclination of the track arm to the longitudinal axis of the car ,when it is moving along the straight path? TUTORIAL SHEET NO.:- 5 Q1. A belt drive is required to transmit to 10KW from a motor running 600rpm, the belt is 12mm thick and has a mass density of 0.001gm/cm3. Safe stress in the belt is not to exceed 2.5 N/mm2 Diameter of the driving pulley is 250mm whereas the speed of driven pulley is 220RPM. The two shafts are 1.25mm apart. .The coefficient of friction is 0.25. Q2. What is the difference between brakes & dynamometers? Q3. Explain the function of band brakes. Q4.A cone clutch with a semi cone angle of 150 transmits 1.0KW at 600rpm.The normal pressure intensity between the surfaces in contact is not to exceed 100N/m2 .The width of the function surface is half of the mean diameter .Assume coefficient of friction 0.3determine. The outer and inner diameter of the plate. The axial force to engage the clutch. Q5.Describe with the help if a neat sketch the principle of operation of an internal expanding shoes break .What are the leading & trailing shoes of an internal expanding shoe brake?. - 24 -

Q6. A car moving a level road at a speed of 50km and has a wheel base 2.8 meter. Distance of C.G. from ground level 600mm & the distance of C.G from rear wheel 1.2 meter .Find distance traveled by the car before coming to rest when brakes are applied, to the rear wheels to the front wheels The coefficients of friction between the types & the road may be taken as 0.6. TUTORIAL SHEET: 6 1. A cam is to give the following motion to a knife-edged follower : (i) Outstroke during 60 of cam rotation; (ii) Dwell for the next 30 cam rotation; (iii) Returned stroke during next 60 of cam rotation and (iv) dwell for the remaining 210 of cam rotation. The stroke of the follower is 40 mm and the minimum radius of the cam is 50 mm. The follower moves with uniform velocity during both the out stroke and return strokes. Draw the profile of the cam when the axis of the follower passes through the axis of the cam shaft. 2. A cam is to give the following motion to a knife edged follower : (i) Out stroke during 60 of cam rotation; (ii) Dwell for the next 30 of cam rotation; (iii) Return stroke during next 60 of cam rotation and (iv) Dwell for the remaining 210 of cam rotation. The stroke of the follower is 40 mm and the minimum radius of the cam is 50 mm. the follower moves with uniform velocity during both the out stroke and return strokes. Draw the profile of the cam when the axis of the follower is offset by 20 mm from the axis of the cam shaft. 3. Draw the profile of the cam operating a knife edged follower from the following data: (a) It lifts the follower through 3.75 cm during its 60 rotation with S.H.M. (b) The follower remains at rest for next 40 rotation of the cam. (c) The follower then descends to its original position during 90 rotation of the cam with S.H.M. (d) The follower remains at rest for the rest of the revolution. The least radius of cam is 5 cm. If the cam rotates at 300 r.p.m., find maximum velocity and acceleration of the follower during ascent and descent. 4. A cam is to be designed for a knife edge follower with the following data : (a) Cam lift = 40 mm during 90 of cam rotation with simple harmonic motion. (b) Dwell for the next 30. (c) During the next 60 of cam rotation, the follower returns to its original position with simple harmonic motion. (d) Dwell during the remaining 180. Draw the profile of the cam when (a) The line of stroke of the follower passes through the axis of the cam shaft ,and (b) The line of stroke is offset 20 mm. from the axis of the cam shaft. The radius of the base circle of the cam is 40 mm. Determine the maximum velocity and acceleration of the follower during its ascent and descent, if the cam rotates at 240 r.p.m. 5. A cam, with a minimum radius of 25 mm, rotating clockwise at a uniform speed is to be designed to give roller follower, at the end of a valve rod, motion described below : (a) To raise the valve through 50 mm during 120 rotation of the cam. (b) To keep the valve fully raised through next 30. (c) To lower the valve during next 60; and (d) To keep the valve closed during rest of the revolution i.e. 150. The diameter of the roller is 20 mm and the diameter of the cam shaft is 25 mm. Draw the profile of the cam when (a) the line of stroke of the valve rod passes through the axis of the cam shaft, and (b) the line of stroke is offset 15 mm from the axis of the cam shaft. The displacement of the valve, while being raised and lowered, is to take place with S.H.M. Determine the maximum acceleration of the valve rod when the cam shaft rotates at 100 r.p.m.. Draw the displacement, the velocity and the acceleration diagrams for one complete revolution of the cam. - 25 -

6. Design a cam for operating the exhaust valve of an oil engine. It is required to give equal uniform acceleration and retardation during opening & closing of the valve each of which corresponds to 60 of cam rotation. The valve must remain in the fully open position for 20 of cam rotation. The lift of the valve is 37.5 mm and the each radius of the cam is 40 mm. The follower is provided with a roller of radius 20mm and its line of stroke passes through the axis of the cam. 7. A cam rotating clockwise at a uniform speed of 1000 r.p.m. is required to give a roller follower the motion as defined below : (a) Follower to move outward though 50 mm during 120 of cam rotation, (b) Follower to dwell for next 60 of cam rotation, (c) Follower to return to its starting position during next 90 of cam rotation , (d) Follower to dwell for the rest of the cam rotation. The minimum radius of the cam is 50 mm and the diameter of roller 10 mm. The line of stroke the follower is offset by 20 mm from the axis of the cam shat. If the displacement of the follower takes place with uniform and equal acceleration and retardation on both the outward and return stokes, draw profile of the cam and find the maximum velocity and acceleration during out stroke and return stroke. TUTORIAL SHEET: 7 1. A pair of spur wheels with 14 and 21 teeth is of involute profile and pressure angle 16. Find maximum addenda on the pinion and gear wheel to avoid interference if module is 6 mm. Also find the maximum velocity of sliding on either side of the pitch if pinion runs at 330 r.p.m. (Ans: 605.98 mm/sec, 908.97 mm/sec) 2. A pair of 20 full depth involute spur gears having 30 and 50 teeth respectively of module 4 mm is in mesh. The smaller gear rotates at 1000 r.p.m. Determine: 1. sliding velocities at engagement and a disengagement of a pair of teeth, and 2. contact ratio. (Ans: 3.518 m/sec, 5.736 m/sec, 5) 3. A 20 involute pinion with 20 teeth drives a gear having 60 teeth. Module is 8 mm and addendum of each gear 10 mm. (i) State whether interference occurs or not, (ii) Find the length of path of approach and arc of approach if pinion is the driver. (Ans: Interference will not occur, 29.1mm) 4. A pair of involute spur gear with 16 pressure angle and pitch of module 6 mm is in mesh. The number of teeth on pinion is 16 and its rotational speed is 240 r.p.m. When the gear ratio is 1.75, find in order that the interference is just avoided; (i) The addenda on pinion and gear wheel 1; (ii) The length of path of contact; and (iii) The maximum velocity of sliding of teeth on either side of the pitch of point. (Ans: 10.76mm, 4.56mm, 38.39mm, 1043mm/sec, 471mm/sec) 5. A pinion having 30 teeth drives a gear having 80 teeth. The profile of the gears is involute with 20 pressure angle, 12 mm module and addendum 10 mm. Find the length of path of contact, are of contact and contact ratio. (Ans: 52.26mm, 55.61mm, 1.47) 6. Find the length of arc of contact and maximum sliding velocity between mating gear teeth if: Module pitch = 4.25 mm, Addendum = 1 module, Pressure angle = 20, r.p.m. of pinion = 150, No. of teeth on gears = 24 and 33. (Ans: 21.86mm) 7. A pair of gears, having 40 and 30 teeth, respectively is of 25 involute form. The addendum length is 5 mm and module pitch is 2.5 mm. If the smaller wheel is driver and rotates at 1500 r.p.m., find the velocity of sliding at the point of engagement and at the point of disengagement.(Ans: 2.75m/sec, 2.66m/sec)

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- 27 -

- 28 -

COURSE PLAN MANUFACTURING SCIENCE-II EME-503

Unit-I A. Metal Cutting and Machine Tools Objective: provide the concept & analysis of Metal removal processes Lect. Topics No. 1. Introduction & course preview Metal Mechanics of metal cutting. 2. Cutting Geometry of tool and nomenclature .ASA system Orthogonal vs. oblique cutting. Mechanics of chip formation, 3. types of chips. Shear angle relationship. Merchants force circle diagram 4. 5. 6. Cutting forces, power required. Cutting fluids/lubricants. Tool materials. Tool wear and tool life. Machinability. Dynamometer(Measurement of forces) Brief introduction to machine tool vibration and surface finish Economics of metal cutting.

Reference P485-493(A) P140-151 (B) P493-498(A) P152-159 (B) P498-504(A) P160-172(B) -DoP954-960( C ) P505-509(A) P173-187(B) & P924-927( C) P180-189(B) P913-916 ( C ) P196-201(B) P515(A) P190-195(B)

7. 8. 9.

Unit-II Machine Tools Objective: Provides insight for various machine tool principle, operations and construction P218-324(B) 10. (i) Lathe : Principle, construction, types, operations, o Turret/capstan P330-373(B) o Semi/Automatic 11. Tool layout. (ii) Shaper, P459-526(B) Construction, operations & drives. 12. slotter, planer : (iii) P529-582(B) Construction, 13. Milling : Milling cutters, P578(B) up & down milling. P583-594(B) Dividing head & indexing. 14. Max chip thickness & power required. P387-428(B) 15. (iv) Drilling, boring, reaming tools. Drilling Geometry of twist drills. 16. and boring Value Introduction to CNC machines added Topic

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Unit-III (a) Grinding & Super finishing (v) Grinding : P611-623(B) Introduction Grinding wheels, abrasive & bonds, 17. Cutting action. Grinding wheel specification. P624-628(B) Grinding wheel wear o Attritions wear, 18. o Fracture wear. Dressing and Truing. 653 19. Max chip thickness and Guest criteria. P634-641(B) Surface and cylindrical grinding. 20. Center less grinding. (vi) Super P827-834(C) Honing, lapping, polishing. 21. finishing : Value added Topic Introduction to gear manufacturing Unit-III (b) Standardization & Interchangeability, Limits, Fits & Tolerance and Surface roughness: Standardization Introduction to Standardization & 22. & Interchangeability Interchangeability P323-344(A) Limits, Fits, Tolerances 23. P345-368(A) IS standards, Limit-gauges, Surface-roughness. Unit-IV B. Metal Joining (Welding) Objective: Provide with the knowledge of various welding processes including applications advantages and limitations P339-350 ( C) Introduction 25. Survey of welding and allied processes. Welding P356-360( C) Gas welding and cutting, process and 26. equipment. P363-371( C) Arc welding: Power sources and 27. consumables. 28. TIG & MIG processes and their parameters. P374-378( C) P351-355( C) Resistance welding 29. o spot, seam projection etc. P351-355( C) Resistance welding (Contd.) 30. spot, seam projection etc. Other welding processes such as P373(C) o atomic hydrogen, 31. P372(C) o submerged arc, P386(C) o electroslag, . Other welding processes such as P393(C) o friction welding. 32. P411-415(C) Soldering & Brazing . Thermodynamic and Metallurgical aspects in Pp344(C) welding and weld,. 33. Shrinkage/residual stress in welds. P403(C) Distortions & Defects in welds and P346(C) remedies. 34. Weld decay in HAZ(Heat affected Zone). 24. - 30 -

Unit-V C. Introduction to Un-conventional Machining and Welding Objective : Update with non traditional technology Un Need & benefits, application and working conventional principle of 35. Machining o Electro Discharge Machining (EDM) o Electro Chemical Machining (ECM) Need & benefits, application and working principle of 36. o Laser Beam Machining (LBM) o Electron Beam Machining (EBM) Need & benefits, application and working principle of 37. o Ultra sonic Machining (USM) o Abrasive Jet Machining (AJM) o Water Jet Machining (WJM) Un Need & benefits, application and working conventional principle of non-conventional welding 38. Welding applications such as o Laser Beam Welding (LBW) o Electron Beam Welding (EBW) Need & benefits, application and working principle of non-conventional welding applications such as 39. o Ultra sonic Welding (USW) o Plasma-arc welding, Need & benefits, application and working principle of non-conventional welding 40. applications such as o Diffusion welding, o Explosive welding/cladding.

P430-459(C)

P461 (c) P486(C) P469-480(C)

P392(C)

P392(C) P390(C)

P394(C) P393(C)

References: (A) A Text Book of Production Engineering by P.C. Sharma (S.Chand) (B) A course in Workshop Technology Vol. II by B.S Raghuwanshi (Dhanpat Rai & Co.) (C) Production Technology by R.K.Jain 15th Ed(Khanna Publisher)

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MANUFACTURING SCIENCE -II EME-503 UNIT I & II Q.1 Draw a merchant circle diagram and drive expression to show Relationship among the different forces acting on the cutting tool and different parameter involved in the metal cutting. Q.2 Define theory of Mechanism of chip formation and differentiate between different types of chip. Q.3 Distinguish between orthogonal and oblique metal cutting process with suitable diagrams? Q.4 During an orthogonal cutting test, the observations made are: tl=0.25mm, t2=1.2mm,'w=2.5mm, =O, FC=900 N, FT= 810 N.Calculate the mean shear strength of the work material. Q.5 Define the mechanics of chip formation with formulas? Q.6 Derive the shear angle formula from mechanism of clip formation? Q.7 Define tool life and its dependence on the different factors with diagrams? Q.9 Define the types and working of a lathe? Q10 Derive the formula for maximum chip thickness for milling and Grinding? Q.11A mild steel block of 20 mm width is being milled using a straight slab milling culture with 20 teeth, 50 mm diameter and 10 radial rake. The feed velocity of the table is 15 mm/min. and the culture rotates at 60 rpm. If a depth of cut of 1 mm is used, what will be the power and 8 amp. Q.12 Estimate the torque and thrust force when drilling a solid block of mild steel with a normal twist drill Given D = 20 mm Ts work material = 400 N/mm2 N = 240 rpm f = 0.25 mm/rpm Q.13 Estimate the grinding force during surface grinding of a 25 mm wide mild steel block with a depth of cut of 0.05 mm. The diameter of the wheel is 200 mm and N = 3000 rpm The no. of grits/mm2 is measured and found to be 3. The feed velocity of the table is 100 mm/min? Q .14 A knurled thumb screw as shown in Fig. 1 is to be produced from a brass rod of 16 mm dia. The analysis of the component gives the following sequence. Draw Tool Layout .

Operation Turn the external dia of M8 Knurl Cut the external thread Form the head shape

Tool Hollow Mill Knurling tool Threading die Form tool

Tool Position Turret Turret Turret Rear cross

Parting off Parting off tool Front Cross slide Q.15 A 600 mm long job diameter 150 mm of AISI 4140 steel is to turned with a depth of cut 1.5 mm and feed rate of 0.25 mm/rev. the following data is applicable for the problem: Labour Cost per hour : Rs. 12/Machine Overhead per Hour : Rs. 40/Grinding Cost per Hour : Rs. 15/Grinding machine overhead per Hour : Rs. 50/Idle time : 5 minutes Taylors tool life equation is given by VTn =475. The operation is carried out using tungsten carbide brazed tools with following details. Initial cost : Rs. 60/- Grinding time : 5 minutes /edge Tool change time : 2 minutes and there are 9 grinds per tool before salvage. - 32 -

Find the optimum cutting speed, tool life and cost of operation using the criteria of minimum production cost. Assume missing data , if needed. UNIT III Q.1 Explain the Grinding process and classify the Grinding wheel. Q.2 (i) Define the Grinding wheel with specifying the properties of a grinding wheel? (ii) Define Loading, Glazing Q 3 With neat sketch explain the methods for the flat and cylindrical grinding. Q 4 What do you understand by Dressing and Tuning operation? Q 5 Why truing and dressing are necessary? Describe a few methods of dressing a grinding wheel. Q .6 Explain center less grinding with neat sketch. Q.7 Write the short Notes on the following: (i) Super finishing operations (ii) Dressing of grinding wheel (iii) Honing operation (iv) Lapping operation. Q.8 Describe the "Indian Standards" method of specifying a grinding. wheel by taking concrete example. Q 9 With the help, of a neat diagram, explain the construction and working of Center less grinding. Q 10 What is lapping? How is it done? How lapping and honing differ? UNIT-IV: METAL JOINING Q 1. Describe the principle of Resistance welding. Give reason why spot Welding is so commonly used in automotive bodies and home appliances. Q 2. Name some applications for (i) Flash Welding (ii) TIG Welding (iii) Gas Welding Q 3. What are the thermodynamic and metallurgical aspects in welding and Weld? Q 4. What are welding detects? Explain any three with their causes and remedies. Q 5 What do you mean by weld decay ? Explain HAZ? Q 6. Explain the gas welding and cutting process with its advantages and, limitations. Q7. What do you understand by resistance welding? Briefly explain spot, seam and projection welding Processes. Q 8. Explain different type of defects in welding process and what will you do to avoid these defects Q 9. What do you understand by Arc welding? Differentiate between TIG and MIG. Q 10. Explain Electro-slag welding with its applications. Q 11. Write the working principle of Friction welding with its advantages and disadvantages. Q.12 Define different welding operations briefly? UNIT-V : INTRODUCTION TO UN-CONVENTIONAL MACHINING AND WELDING Q.1 How do you' classified the common unconventional machining methods? Give a list of such operations. Q 2 What is EDM? Give its principle with the help of neat sketch. Q.3 What is laser beam machining? Explain the principle of operations. Advantages and disadvantages. Q 4 What are the main parameters to be considered while selecting a particular Processing. Q.5 Explain any non-conventional Machining Process used for the Material which is the conductor of electricity. Q.6 Explain working Principle and benefits of abrasive jet Machining Process. Q.7 Write down the working principle of non conventional welding process which is presently used for the welding of glass. Q.8 What is the advantage of Non conventional Machining and welding process? Q.9 Explain working principle of EDM Process and discuss its advantages and disadvantages. Q.10 Explain the working principle, advantages and applications of ultrasonic welding process. Q.11 Define ultrasonic machining and Abrasive jet machining. - 33 -

MODEL PAPER MANUFACTURING SCIENCE II EME -503 TIME : 3 HOUR NOTE : (i) Answer ALL questions. (ii) All questions carry equal marks. 1. Answer any FOUR parts of the following :(a) For an orthogonal cutting, show that tan s = tan b cot s. Here s is the side cutting edge angle and b and s are the back rake and side rake angles. (b) For an orthogonal cutting, show that the shear angle and the chip thickness ratio can be related as, Tan = TOTAL MARKS : 100

Where is rake angle of the tool. (c) Stating assumptions, derive the expression for Merchants shear angle relationship. (d) While straight turning of carbon steel by a Tungsten-Cobalt steel tool, it was observed that the tool-life was 60 minutes for cutting speed of 50m / min. Determine the tool- life for cutting speed of 40m/ min, using Taylors tool-life equation, taking the index as 0.143. (e) Why is Crater formed at some distance above the tool tip on the rake face? (f) What is Machinability? How is machinability of a material expressed? 2. Answer any FOUR parts of the following:(a) What are the differences between an Automatic lathe and a Capstan lathe? (b) What are the various methods available for taper turning on a lathe? Explain their specific advantages and limitations. (c) Describe the operation of the quick return motion in a mechanical shaper. (d) Show that for a plain slab milling using a straight cutter the average uncut chip thickness, t a v , can be expressed as,

cos , 1 sin

t av

where is feed velocity of the table in mm / min, N is cutter rpm, is the number of teeth in the cutter, d is the depth of cut and D is the cutter diameter (e) What are the differences between Compound indexing and Differential indexing? (f) Giving a labelled diagram, explain the important features of the geometry of a twist drill. 3. Answer any FOUR parts of the following:(a) What do you understand by any two of the following terms used in reference with grinding? (i) Structure (ii) Grade (iii) Bond (b) Distinguish between the terms, glazing and loading of the grinding wheel. (c) How are grinding wheels specified? (d) What are the wear mechanisms of a grinding wheel? - 34 -

f NZ

d D

(e) What is Lapping? How does it differ from honing? (f) What are the steps to be considered while planning the tool layout for a Turret of Capstan lathe? 4. Answer any FOUR parts of the following :(a) Describe the principles of oxy- acetylene gas welding technique. Also, give the equipments and tools used in the process. (b) Briefly explain the coding method for the coated electrodes used in manual are welding. (c) What is Resistance Seam Welding Process? Describe in brief. (d) What are different types of flames obtained in an oxy-acetylene welding process? Why is neutral flame extensively used? (e) What is electro-slag welding process? Explain in brief. (f) Explain TIG process of are welding. How does it differ from MIG process of are welding? 5. Answer any FOUR parts of the following:(a) What is the principle of Electro Discharge Machining (EDM)? Give the product application of EDM. (b) Explain the principle of working of Ultrasonic Machining. Also, give its applications and limitations. (c) Describe the principle of Electron Beam welding. Also, give its scope of applications. (d) Write a brief note on Laser Beam Machining. (e) Explain the principle of working of Electrochemical Machining process. Also, derive the expression for material removal rate in Electro-chemical Machining. (f) Write a brief note on explosive welding, giving its merits and demerits.

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COURSE PLAN HEAT AND MASS TRANSFER EME-504

UNI T NO. COMPETENCIES Understand the Basics of conduction, convection and radiation, including Fourier's Law, Newton's Law of Cooling and the StefanBoltzmann Law. Recognize when a onedimensional conduction model is adequate and be able to solve such problems using analytical means; e.g., by solving a differential equation or applying a network model, where appropriate. Understand the concept of DC electrical network analogies for steady state and transient conduction Apply numerical methods to transient one-dimensional and steady state twodimensional problems including deriving the appropriate heat balance equations for a representative volume for both cases. CONTENTS Introduction to Heat Transfer: Concept of heat flow mechanism: Conduction, Convection & radiation. Effect of temperature on thermal conductivity of Material Introduction to combined heat transfer mechanism. Conduction. One dimensional general differential heat conduction equation in rectangular coordinate system. Same in Cylindrical and spherical coordinate systems. Initial and boundary conditions in conduction. Steady state One Dimensional Heat Conduction Composite systems in rectangular, cylindrical and spherical coordinates. Thermal resistance, concept, analogy between heat and electricity flow. Thermal contact resistance Calculation of critical thickness of insulation Fins Heat transfer from extended surfaces. Fins of uniform cross sectional area. Errors of measurement of temperature in thermometers wells. Transient conduction Transient heat conduction Lumped capacitance method Time constant Unsteady state heat conduction in one dimension only Heisler chart HR S 1 1 1 3.13.105/5 1 2 1 184262/3 68-72/7 Lecture cum discussion 76-76/7 TEACHING LEARNING ACTIVITIES Experiments on the Conduction, Convection, and Radiation. PAGE NO / REF. 1.11.5/5

1 1 1 1

153/7

1 1 1

Lecture cum discussion

263294/3 156156/7

Seminars

II

1 1 2 1

358455/3

210239/7

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III

Understand the physics underlying both the forced and free convection processes and have an appreciation for the effects of various fluid properties and flow parameters on that process. Apply empirical and analytical correlations for external and internal forced and free convection.

IV

Apply standard techniques to find the radiative exchange among opaque surfaces, including the determination of view factors from charts and software and use of the DC network model for radiative exchange among black and gray surfaces

Forced Convection: Basic concepts: Hydrodynamic boundary layer, thermal boundary layer, Approximate integral boundary layer analysis. Analogy between momentum and heat transfer in turbulent flow over a flat surface. Mixed boundary layer Flow over a flat plate, across single cylindrical & sphere. Flow inside duct, empirical heat transfer relation. Relation between fluid friction and heat transfer. Liquid metal heat transfer. Natural Convection: Physical mechanism of Natural convection, buoyant force. Empirical heat transfers relations for natural convection over vertical planes And cylinders, Horizontal plates, Cylinders and sphere. Combined free and forced convection Thermal Radiation: Basic radiation concepts: radiation properties of surface, black body relation planks law. Wein s displacement law, Stefan Boltzmann law, Kirchoffs law. Gray body ; shape factor Black body radiation Radiation exchange between diffuse non-blackbodies in an enclosure Radiation shields Radiation combined with conduction and convection; Absorbtion and emission in gaseous medium. Solar radiation Green house effect Heat Exchangers: Types of Heat Exchangers. Fouling factor and overall heat transfer coefficient Logarithmic mean temperature difference method Effectiveness and NTU method. Compact heat exchangers Condensation and Boiling: Introduction to condensation - 37 -

3 1

Lecture cum discussion

456505\3

Seminars 2 1 1 1 2 Experiments on the Convection

626696/3

1 2 1 1

Lecture cum discussion 2 Seminars 1 1 1 1 1 1 1 Experiments on the Radiation

753785/3

865870/3 792801/3

Understanding of concept, various design parameter and effectiveness of Heat exchangers. Study the phenomena of condensation and boiling Concept and understanding of Mass

1 1 1 1

Experiments on the Heat Exchangers Lecture cum discussion

9031020/3

690699/7 697752/3

Seminars 1

Transfer

phenomena, heat transfer relation for laminar film condensation on vertical surfaces and on horizontal tube. Effect of non condensable gases; Dropwise condensation Heat pipes, Boiling Modes pool boiling Hysteresis in boiling curves Forced convective boiling Introduction to Mass Transfer : Flicks law of diffusion, Steady State Equimolar counter diffusion & through a stagnant gas film.

2 1 1 3 10211035

1 2

REFERENCES: 1. Heat Transfer - J.P Holman 2. Fundamental of Heat and Mass Transfer - R.C.Sachdeva 3. Schaums Outline By Heat Transfer - Pitts & Sission 4. Engineering Heat Transfer - M.M.Rathore 5. Heat and Mass Transfer - R.K.Rajput 6. Heat and Mass Transfer - Dr. D.S.Kumar 7. Heat Transfer - P.K.Nag 8. Heat Transfer - Cengel 9. A Text Book of Heat and Mass Transfer Arora-,Domkundwar

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HEAT AND MASS TRANSFER EME-504 TUTORIAL SHEET- 1 1. A domestic oven has a composite wall formed by 0.5 cm thick chrome-nickel (k = 19 W/m K) sheet supported by 1 cm thick asbestos (k = 0.1105 W/m K) sheet. In steady-state operation the hot gases inside the oven are at 350C while the atmospheric air is at 30C. The convection heat transfer coefficients at the inside surface and outside surface of the oven are 100 W/m2 K and 15 W/m2 K, respectively. Determine the rate of heat losses per unit area, through the oven wall. 2. Draw the thermal circuit for Problem 1. 3. A furnace has a composite wall, the details of which are presented in Fig.1. Determine the rate of heat transfer per metre length of the composite wall.

Fig. 1 4. The composite wall of Problem-3 is used in the construction of a furnace. The hot gases in the furnace are at 8500C, while the air on the outer side of the furnace is at 30C. If the inside and outside convective heat transfer coefficients are 70 W/m2-K and 15 W/m2-K, determine the rate of heat transfer per m length of the wall, from the hot gases to air. 5. It is required to reduce the heat loss from a furnace wall by doubling the thickness of the insulating brick work. Initially the temperatures of the inner and outer surfaces of the insulating brick are 480C and 180C, respectively. The atmospheric air is at 30C. Calculate the percentage decrease in heat loss because of doubling of the thickness of insulating brick. 6. A steel pipe of 5 cm OD is covered with 0.5 cm asbestos (k = 0.1105 W/m-K) followed by 0.5 cm thick glass wool (k = 0.038 W/m-K) insulation. Ii was found that the insulation temperature reached a steady-state value of 40C, while the pipe surface is at 150C and the atmospheric air to which the insulated pipe is exposed is at 25C. Determine the temperature at the interface of the asbestos and glass wool and the film coefficient between the glass wool and atmospheric 7. The inner surface of a thick invar (k = 10.7 W/m-K) cylinder of ID = 2 cm, and OD = 12 cm is held at 15.0C while the outer surface is at 50C. Calculate the temperatures at r = 2 cm, 3 cm, 4 cm and 5 cm. 8. In a steam radiator saturated steam at 120C flows through a carbon-steel (k = 4 W/m K) tube of 1.5 cm ID and 2.5 cm OD. The radiator is placed in a room in which the air is at 5C. The convection heat transfer coefficient between the condensing steam and tube is 4000 W/m2-K. Calculate the temperature of the inner and outer surfaces of the tube and the rate of heat transfer from steam to air per m length of the tube. - 39 -

9. Steam at 125C is to be transported through a carbon-steel pipe of ID = 5 cm and OD = 6 cm. To reduce heat losses it is to be insulated with asbestos (k= 0.1105 W/m K) so that the rate of heat loss from steam to the atmospheric air is not more than 50 W/m of the pipeline. The atmospheric air is at 25C and the film coefficient between air and the insulation is 10 W/m2-K. Determine the thickness of insulation. Assume that the outer surface of the steel pipe is at 125C. TUTORIAL SHEET- 2 1. The thermal conductivity of a material is determined by using the experimental setup shown in Fig.1. A current of 15 amperes at 220 V is passed through the electrical resistance and the temperatures of the hot and cold surfaces are measured by the thermocouples. At steady-state, the temperatures are recorded as 150C and 50C. Determine the thermal conductivity of the material. 2. The experimental setup shown in Fig.1 is used in measuring the thermal conductivity of a different material. The thermocouples recorded the temperatures as 150C and 50C while the surrounding air is at 30C. The convection heat transfer coefficient between the outer surface and the surrounding air under these conditions is 20 W/m2-K. The current passing through the electrical resistance could not be measured as the ammeter failed. Determine the thermal conductivity of the material.

Fig. 1 3. An electrical heater uses 5 m length and 2 mm diameter wire to dissipate 500 W in air at 30C. The convection heat transfer coefficient between the wire surface and air is 20 W/m2-K. (a) Determine the temperature of the wire. (b) Determine the temperature of the wire if 3 mm thick rubber (k = 0.16320 W/m2-K ) insulation is used, assuming that the film coefficient between the rubber surface and air is 20 W/m2 K (c) Calculate the temperature of the wire if the thickness of rubber insulation is equal to the critical thickness of insulation. 4. Freon-12 at -40C is flowing through a copper tube of 1 cm OD. The atmospheric air is at 30C and the film coefficient between the tube surface and air is 10 20 W/m2-K. An engineer wanted to reduce the heat losses and added 6 mm thick asbestos (k = 0.1105 W/m K) insulation to the tube. Determine the percent reduction in the heat loss due to the added insulation. Assume that the outer surface of the tube is at -40C. 5. Rework Problem-4 if the thickness of insulation is 9 mm. 6. 20 A thick walled spherical vessel of ID = 30 cm and OD = 40 cm made of bronze (k = 26 W/mK) is filled with saturated steam at 120C. If the outer surface of the vessel is maintained at 90C, determine the rate of heat transfer from the vessel, assuming that the inner surface is at 120C. - 40 -

7. If the inner and outer surfaces of a spherical vessel of inside and outside radii ri and ro are maintained at Ti and To, respectively, determine the temperature profile in the wall of the vessel. 8. A spherical vessel of ID = 40 cm and OD = 45 cm is covered with 5cm thick plaster (k = 0.48 W/m-K). The thermal conductivity of the vessel material is 73 W /m-K. If the inner surface of the vessel is kept at I50C while the outer surface is exposed to air at 30C, determine the rate of heat transfer from the vessel. The outside film coefficient is 5W/m2-K. TUTORIAL SHEET -3 1. A very long aluminium pin fin of 2 cm diameter is attached to a surface at 300C, while the fin surface is exposed to an environment at 25C. Calculate the rate of heat transfer from the fin if the medium is (a) Flowing liquid with a heat transfer coefficient of 200 W/m2-K. (b) Flowing. air with h = 20 W/m2-K. (c) Stagnant air with h = 5 W/m2- K. 2. An aluminium rectangular fin of length 50 cm, width 20 cm and thickness 2 mm is attached to a wall at 350C and the end of the fin is insulated. The fin surface is exposed to an environment at 25C with h = 10 W/m2-K. Calculate the temperature of the fin (a) at a distance of 25 cm from the base and (b) at the insulated end. (c) Also calculate the rate of heat transfer from the fin. 3. One end of a long, 2 cm diameter metal rod of unknown thermal conductivity is maintained at 400C by keeping it in a furnace, while the rod's surface is exposed to air at 25C. The convection heat transfer coefficient from the surface is 10 W/m2-K. Once the steady-state is reached, the temperature of the rod at a distance of 60 cm from the hot end is 100C. Determine the thermal conductivity of the metal. 4. One end of a long copper rod of 3 cm diameter is maintained at 400C, while the rest of the rod is exposed to an environment at 25C. In steady-state, the temperature of the rod at a distance of 50 cm from the hot end is found to be 120C. Determine the average value of the convection heat transfer coefficient from the surface to the environment. 5. One end of a long copper (k = 386 W/m-K) rod of 3 cm diameter is maintained at a constant temperature by placing it in a furnace, while the rest of the rod is exposed to an environment at 25C. In steady-state, the temperatures at two different locations 25 cm apart along the length of the rod are found to be 200C and 100C, respectively. Calculate the heat transfer coefficient from the rod's surface to the environment. 6. One end of a wrought-iron (k = 59 W/m-K) rod of 30 cm length and 3 cm diameter is attached to a wall at 300C, while the second end is insulated. The surface of the rod is exposed to an environment at 25C and the convection heat transfer coefficient from the surface to the environment is 15 W/m2K. Determine (a) The temperature of the insulated end and (b) The rate of heat transfer from the rod. 7. The handle of a ladle used for pouring molten metal is 50 cm long and is made of 5 x 5 cm solid carbon-steel (k = 54 W/m K). The end of the handle is covered with a thick layer of insulating material. To reduce the temperature at the point of grip, it is proposed to form a hollow handle of the same size by using 1 cm thick carbon-steel plates. If the surrounding air is at 30C and the convection heat transfer coefficient is 10 W/m2-K, determine the percent reduction in the temperature at the grip point. - 41 -

TUTORIAL SHEET -4 1. One of the ends of two long rods of the same diameter, one made of copper (k = 386 W/m-K) and the other of nickel-steel (k = 19 W/m-K), are attached to a surface which is maintained at a high temperature. The surfaces of both the rods are exposed to the same environment. At steady-state, the temperature of the copper rod at a distance of 50 cm from the hot end is found to be 100C. At what distance from the hot end would the same temperature be attained in the nickel-steel rod? 2. One end of an aluminium rod of 2 cm diameter and 50 cm length is attached to a wall at 200C, and the rest of the rod is exposed to an environment at 25C. The other end of the rod is losing heat to the environment. If the heat transfer coefficient to the environment is 5 W/m2-K, determine (a) The temperature at the end of the rod and (b) The rate of heat transfer from the rod. 3. An aluminium rectangular fin of length 50 cm, width 20 cm and thickness 2 mm is attached to a wall at 350C and the end of the fin is insulated. The fin surface is exposed to an environment at 25C with h = 10 W/m2-K. Calculate the temperature of the fin (a) at a distance of 25 cm from the base, and (b) at the insulated end. (c) Also calculate the rate of heat transfer from the fin. (d) Calculate the efficiency. 4. An aluminium rod of 2 cm diameter and 30 cm length is used as a fin. The heat transfer coefficient from the fin to the environment is 10 W /m2-K. 'Calculate the fin efficiency assuming that the fin is (a) Of finite length but the end is insulated, and (b) Of finite length and loses heat through its end also. 5. The temperature of steam flowing through a pipe is measured as 150C with a thermometer placed in a thermometer well. Sketch the thermometer well. The pipe surface is at 50C and the convection heat transfer coefficient between the thermometer-well and steam is 600 W/m2-K. The thermal conductivity of the thermometer well is 54 W/m-K. Estimate the true temperature of steam, assuming that the thermometer well is an infinitely long fin. 6. Rework Problem-5 assuming that the thermometer-well is a finite length fin with an insulated end. 7. Rework Problem-5 assuming that the thermometer well is a finite length fin with heat losses from the end also. 8. Two walls A and B are maintained at temperatures TA and TB, respectively. One end of a metal rod of length t' is embedded in wall-A while the other end to wall-B. The rod loses heat by convection to the environment at T. Derive expression to determine the (a) temperature distribution in the rod, and (b) total heat lost by the rod. 9. Derive the expression to determine the heat transferred from the wall-A described in the Problem-8. 10. Two walls 1 m apart are kept at 200C and 100C, respectively. If the walls are by a 2 cm diameter brass (k = 111 W/m-K) rod and the rod loses by convection (h = 10 W/m2-K) to the ambient air at 25C, determine the heat transferred from the brass rod to air.

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TUTORIAL SHEET -5 1 A large vertical plate 5 m high is maintained at 100C and exposed to air at 30C. Calculate the convection heat transfer coefficient. 2 A vertical isothermal fiat plate at 100C is exposed to air at 20C and 100 kPa. Plot the free convection velocity profiles as a function of distance from the plate surface at x positions of 20 cm and 40 cm. 3 Plot the free convection boundary layer thickness as a function of x for the vertical plate of Problem-2. Consider the laminar portion only. 4 A vertical fiat plate is maintained at 100C and exposed to air at 25C. At a distance of 30 cm from the leading edge of the plate the boundary layer thickness is 3 cm. Estimate the thickness of the boundary layer at a distance of 50 cm from the leading edge. 5. A vertical plate 2 m x 2 m is maintained at 80C and exposed to air at 10C and atmospheric pressure. Calculate the heat lost by convection from the plate. 6. If the plate of Problem-1 is exposed to helium at the same conditions, determine the heat lost by the plate. 7. A large vertical plate 2 m high is maintained at 100C. This plate is exposed to air at 10C. Determine the heat transfer coefficient at heights of 0.5 m, 1.0 m, and 2 m. Also calculate the average heat transfer coefficient for the plate. 8. A vertical metal plate 1 m x 1 m is receiving a constant heat flux of 600 W/m2. One side of the plate is insulated and the other side is exposed to air at 10C and atmospheric pressure. What will be the average temperature of the plate? 9. A 25 cm x 25 cm vertical plate fitted with an electrical heater which provides a constant heat flux of 1 kW/m2 is immersed in water at 10C. Calculate the heat transfer coefficient and the average temperature of the plate. 10. A horizontal rod of 5 cm diameter is maintained at a constant surface temperature of 70C by submerging it in water at 20C. Calculate the heat lost by free convection per unit length of the rod. 11. Describe briefly the hydraulic and thermal boundary over a flat plate when a free stream of fluid flows longitudinally over it. 12. Derive an expression for heat transfer coefficient for laminar flow inside a tube, given that its wall temperature is constant throughout. 13. What is the physical significance of the following non dimensional numbers in convective heat transfer? (a) Reynolds Number (b) Grashoff Number (c) Nusselt Number

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TUTORIAL SHEET -6 1. A copper wire of 1 mm diameter is maintained at a constant temperature of 75C by passing electric current. The wire is exposed to atmospheric air at 25C. Calculate the rate of heat transfer by convection, per m length of the wire. 2. Steam is flowing through a horizontal pipe of 3 cm OD which is exposed to atmospheric air at 20C. The surface temperature of the pipe is 150C. Calculate the heat lost by free convection per m length of pipe. 3. Condensing steam at 120C is to be used inside a 5 cm diameter horizontal pipe to provide heating in a room where the ambient air is at 5C. The total heating requirement is 3 kW. What length of pipe would be required to provide the necessary heating? 4. Calculate the rate of free convection heat transfer from a 5 cm the surface of which is maintained at 90C while it is exposed to air at 20C. 5. A sphere of 5 cm diameter is maintained at 50C and submerged in 10C. Calculate the heat transfer coefficient. 6. Air at 100 kPa and 100C is heated while it is flowing through a 2 cm at a velocity of 10 m/s. Calculate the convection heat transfer coefficient 7. Water at an average bulk temperature of 10C flows inside a tube of 5 mm diameter with a velocity of 10 cm/s. The surface of the maintained at 70C and the tube is 1 m long. Calculate the rate transfer to the water. 8 Water flowing through a tube of 1 cm diameter is heated from 20C to 300C while the tube surface is maintained at 700C. If the mass flow rate of water through the tube is 0.5 kg/s, calculate the length of the tube. 9. Calculate the convective heat transfer coefficient for water flowing at a velocity of 3m/s in an annulus formed by a 2cm OD tube and 3cm ID tube. The water enters the tube at 300C. TUTORIAL SHEET-7 1 .In a parallel-flow double-pipe heat exchanger, the hot fluid enters the heat exchanger at 90C and leaves it at 50C, while the cold fluid enters the heat exchanger at 20C and leaves it at 40C. Calculate the LMTD. 2. In a counter-current double-pipe heat exchanger, the hot fluid enters at 200C and leaves at 100C, while the cold fluid enters the heat exchanger at 20C and leaves it at 80C. Calculate the LMTD. 3. A counter-current double-pipe heat exchanger with an overall heat transfer coefficient of 800 W/m2-K is used to cool 10 kg/s of oil from 150C to 50C. The cooling water enters the heat exchanger at 25C and leaves at 40C. The specific heats of oil and water are 3.4 kJ/kg-K and 4.2 kJ/kg-K, respectively. Calculate the rate of heat transfer and the heat transfer area of the heat exchanger. 4. A double-pipe heat exchanger with an overall heat transfer coefficient of 400 W/m2-K is to be used to cool 10 kg/s of oil from 110C to 50C. Cooling water is available at 20C and the water should leave the heat exchanger at 40C. The specific heats of oil and water are 3.1 kJ/kg-K and 4.2 kJ/kg-K, respectively. Determine the heat transfer area for (a) a counter-current flow heat exchanger and for (b) a parallel-flow heat exchanger. - 44 -

5. In a heat exchanger, cold water enters at 30C and leaves at 60C. Dry saturated steam at 100C enters the heat exchanger and the condensate leaves at 100C. Calculate the LMTD for (a) a counter-flow double-pipe, heat exchanger and (b) a parallel-flow double-pipe heat exchanger. (c) Calculate the modified LMTD for a shell-and tube heat exchanger with one shell pass and two tube passes. 6. Calculate the correction factor for LMTD for Problem-5 if a shell-and-tube heat exchanger with two shell passes and four tube passes is used. 7. It is desired to cool 0.5 kg/s of oil from 105C to 45C by using an equal flow rate of cooling water: The cooling water is available at 20C. The specific heats of oil and water are 2.8 kJ/kg-K and 4.2 kJ/kg-K. Two double-pipe heat exchangers are available, Heat exchanger-1: U = 500 W/m2-K; A = 4.5 m2 Heat exchanger-2: U = 800 W/m2-K; A = 2.m2 Which heat exchanger should be used? 8. It is desired to cool 0.5 kg/s of oil (Cp = 2.8 kJ/kg-K) from 100C to 60C by using cold water at 20C. The cooling water is to leave the heat exchanger at 40C. If a cross-flow heat exchanger with both fluids unmixed and having an overall heat transfer coefficient of 600 W/m2-K is to be employed, determine the heat transfer surface area required. 9.. It is required to cool 0.5 kg/s of oil from 110C to 50C using a counter-current double-pipe heat exchanger. The cooling water is available at 25C and can leave at 35C. The oil flows through the inner copper tube of 12 mm diameter, 1.5 m length and water flows through the annulus. The internal diameter of the outer tube is 30 mm. The inner tube of 3 mm thickness is made of copper. Use the Ditus-Boelter equation to estimate the convection heat transfer coefficients and determine the overall heat transfer coefficient of the heat exchanger. For oil, = 864 kg/m3; Cp = 2.4 kJ/kg-K; = 0.85 X 10 -4 m2/s; k = 0.16 W/m-K 10. A shell-and-tube heat exchanger with one shell pass and two tube passes having a overall heat transfer coefficient of 1000 W/m2K and a heat transfer area of 10 m2 is to be used to cool 2 kg/s of a liquid (Cp = 3 kJ/kg-K) from 200C using 5 kg/s of cooling water at 25C. Determine the outlet temperatures of the liquid and cooling water. 11. In a counter-current double-pipe heat exchanger, 0.4 kg/s of oil (Cp = 2.2 kJ/kg-K) is cooled from 120C using 1 kg/s of water which enters at 25C. The heat exchanger has an overall heat transfer coefficient of 600 W/m2-K and a heat transfer area of 3 m2. Calculate the exit temperatures of the oil and cooling water. Also determine the total heat transfer rate. TUTORIAL SHEET -8 1. A small spherical vessel of OD = 6 cm is covered with asbestos (k = 0.1105 W/m-K) and left in the atmospheric air at 30C. The film coefficient between air and asbestos is 5 20 W/m2-K. If it is desired to maximize the heat transfer rate from the contents of the vessel to the air, determine the thickness of asbestos cover needed. 2. An electrical furnace uses a 10 cm thick chrome-nickel plate (k = 19 W/m-K) as a heating element. Heat is uniformly generated in the plate at a rate of 10 MW/m3 and both the surfaces of the plate are maintained at 250C. Determine the temperature at the centre of the plate. 3. The heating element used in an electrical oven can be treated as a long cylinder with uniform heat generation. If a tungsten-steel (k = 54 W/m-K) rod of 1 cm diameter and 1 m length is used as a heating element with a uniform heat generation of 10 MW/m3 and the air surrounding the heating element is at 120C, calculate the surface temperature of the rod and the temperature at the , centre of the rod assuming that the film coefficient between air and the heating element is 100 W/m2-K. - 45 -

4. It is desired to use 1 m long tungsten-steel rod (k = 54 W/m-K) as a heating element to dissipate 100 kW in a fluid at 10C.If the maximum allowed temperature in the rod is 750C, determine the diameter of the heating element, assuming that the film coefficient between the heating element and the fluid is 2000 W/m2-K. 5. Suppose the outer surface of a sphere of radius ro, with uniform heat generation, is maintained at temperature To. Derive a relation to determine the temperature distribution in the sphere. 6. A current-carrying wire of 3 mm diameter is to be insulated with rubber (k= 0.163 W/m-K) to increase the current-carrying capacity of the wire. If the convection heat transfer coefficient from the rubber surface to air is 10 W/m2-K, determine the critical thickness of insu1ation. 7. A carbon-steel (k = 54 W/m-K) pipe of OD = 6 cm carrying steam at 300C is to be insulated to reduce heat losses. The outer surface of the pipe may be assumed to be at 300C. It is desired to use 1 cm thick asbestos (k = 0.1105 W/m-K) and 1 cm thick glass wool (k = 0.038 W/m-K) insulation. The atmospheric air is at 30C and the film coefficient between the insulating layer and air is 10 W/m2-K. Determine which insulating material should be used as the first layer of insulation. 8. A 3 mm diameter nickel-chromium (k =.19 W/m-K) wire of 1 m length has been used as a heating element by applying 30 V. The outer surface of the wire is maintained at 100C. Calculate the temperature at the centre of the wire. The electrical resistivity of the wire is 6 x 10-50 ohm-cm. 9. An aluminium-alloy (k = 200 W/m-K) electrical cable of 3 cm diameter carrying an electric current of 200 A is exposed to air at 30C. The resistivity of the cable is 3 x 10-6 ohm-cm. Calculate the temperature at the centre of the cable, if the outside surface is at 60C. TUTORIAL SHEET -9 1. A furnace is provided with a glass window which transmits 90 percent of the incident radiation in the wavelength range 0.35 to 2.7 m. Estimate the percent of the furnace's radiation which the glass will transmit, assuming that the furnace is a black body at 1800 K. 2. Two parallel concentric discs have d1 = 10 cm and d2 = 4 cm and are spaced 6 cm apart. Determine the shape factors F12 and F21. 3. Two parallel black plates 0.5 m x 1 m are kept 2 m apart and they face each other. One plate is held at 600 K while the other plate is maintained at 400 K. Calculate the radiant heat exchange between the plates. 4. A domestic oven has the shape of a cubical box of side length 0.5 m. Determine the shape factors (a) Between the bottom surface and one side wall, and (b) Between the top and bottom surfaces. 5. A bathroom of 2 m x 3 m has a ceiling height of 3 m. A small drain is located in the floor in the middle of the bathroom. Determine the fraction of energy leaving the ceiling which strikes the drain. 6. A sphere of radius rl is completely enclosed in a sphere of radius r2. Determine the shape factors F12 and F21. 7. An infinitely long cylinder of radius rl is enclosed by another cylinder of radius r2. Determine the radiation shape factors F21 and F21

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8. Two parallel black plates of 0.3 m x 0.6 m are separated by a 2 m. One plate is maintained at 1000 K while the other plate is held at 800K. These plates are placed inside a large hall, the walls of which are at 300 K. The plates exchange heat with each other and with the hall only. Draw the radiation network and indicate the thermal resistances on the network. 9. Determine the net heat transfer from each plate and to the room for Problem-8. 10. Draw the equivalent electrical circuit for Problem 10. 11. Two parallel real surfaces of size 0.3 m x 0.5 m are placed 1 m apart. One plate with emissivity 0.3 is held at 300C while the other plate with emissivity 0.45 is held at 200C. These plates are placed in a large room, the walls of which are at 10C. Determine the net heat transfer rate to the room. 12. Draw the equivalent electrical circuit for Problem-11. 13. A steel pipe of 2 cm OD is maintained at 300C by passing superheated steam through it. The emissivity of the pipe's surface is 0.6. The pipe is passing through a room which is at 17C. Determine the rate of radiative heat transfer from the pipe to the room per unit area of the pipe wall. 14. A spherical vessel of ID = 28 cm is filled with ice at 0C. This vessel is placed in another spherical vessel of ID = 30 cm and the space between the two vessels is completely evacuated. If the emissivity of the inner vessel is 0.1 and that of the outer vessel is 0.05, and the outer vessel is at a temperature of 40C, determine, the amount of ice which melts in 10 hours. The latent heat of fusion of water at 0C is 333.3 kJ/kg. 15. It is desired to estimate the percentage reduction in the radiative heat transfer by the addition of a radiation shield in between two parallel plates. The emissivity t of each plate is 0.4. Determine the percent reduction in radiation heat transfer if a black plate is used as a radiation shield in between the plates. 16. Rework Problem-15 if a well-polished aluminium plate with = 0.05 is used as a radiation shield. 17. The large parallel plates held at temperatures Tl and T2 are facing each other and are set apart. If nradiation shields are inserted between the plates while \the plates are still maintained at Tl and T2, determine the ratio of the radiation energy transfer rate with shields to the radiation energy transfer in the absence of the shields. Assume that the emissivities of the plates and shields are equal.

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MODEL PAPER HEAT & MASS TRANSFER TIME : 3 HOURS Attempt All Questions, All Questions carry equal marks. 1. Attempt any two of the following question: (a). For a cylindrical wall, discuss the effect of variation of insulation radius on the thermal resistance.What do you understand by contact resistance ? What are the various boundary conditions for conduction? (b). Discuss Fouriers Law of Heat Conduction. Why a negative sign is inserted in its expression? Derive an expression for thermal resistance of cylindrical wall. An electrical wire of diameter 10mm and a resistance per unit length of 10-4 /m is coated with an insulation of thermal conductivity K= 0.20 W /m K. The surrounding air temperature is 27oC and h = 10 W / m2 K. If the insulation has a maximum allowable temperature of 177oC, what is the maximum possible current that may be passed by the wire? TOTAL MARKS : 100

(c)

2. Attempt any two of the following questions : (a) For a plane wall subjected to uniform volumetric heat generation and exposed to a fluid at same temperature on both the sides, derive an expression for temperature distribution within the wall and prove that the heat generated is equal to the heat lost from the sides .Assume one dimensional case. Balls of 12 mm diameter are annealed by heating to 877oC and then slowly cooling to 127oC in an air at a temperature of 52oC and h = 20 W/ m2 K. Calculate the time required for the cooling process. For the balls take : p = 7800 kg / m3, k = 40 W/m K, c = 600 J/kg K What do you understand by the corrected length of a fin? Derive and expression for the temperature distribution and heat transfer rate for a rectangular fin with insulated tip.

(b)

(c)

3. Attempt any two of the following questions : (a) What do understand by the followings, answer by two only : (i) Laminar free convection over a vertical surface. (ii) Grashof Number and Rayleigh Number. The bulk mean or cup mean temperature (for internal flow). A circular cylinder of radius 12.5 mm is initially at 150oC and is suddenly exposed to oil at 80oC, which moves at a velocity of 2 m/s in cross flow over the cylinder. What is the initial rate of heat loss per unit length of the cylinder? For the oil take : (At T = 353 K ) = 38.1 x 10-6 m2/s, Pr = 501, k = 0.138 W / m K; (At Ts = 423 K ) Prs = 98. Prove that the local convection coefficient for the thermally fully developed internal flow of a fluid with constant properties is independent of axial location.

(b)

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4. Attempt any two of the following questions: What do you understand by the followings, answer any two only : Radiosity Kirchhoffs Law Colored surface A cylindrical cavity of 3 mm radius is drilled to a depth of 24 mm in a diffuse, gray material having an emissivity of 0.8 and a uniform temperature of 1000 K. Determine the radiant power leaving the power leaving the opening of the cavity (The opening of the cavity may be approximated as a black body at 0 K). The outer surface of a tube of 100 mm diameter is maintained at 120oC by the passage of steam through its interior. A radiation shield is installed around the tube, with an air gap of 10 mm between the tube and the shield. The shield is at a temperature of 35oC The tube and shield are diffuse, gray surfaces with emissivities of 0.10, respectively . What is the radiant heat transfer (neglect convection ) from the tube per unit length? 5. Attempt any two of the following questions : 1. (a) A double pipe counter flow heat exchanger is used to cool 10,000 kg /h of an oil (cp = 2095 J /kg K) from 80oC to 50oC using 8,000 kg / h of water (cp = 4180 J/ kg K ) entering at 25o C. Find the heat exchanger area required with an overall heat transfer coefficient of 300 W/ m2 K. (b)With the help of Pool boiling curve discuss nucleate boiling. OR Discuss the physical mechanism of condensation on vertical plate. (c) Answer any two of following : (i) What do you understand by compact heat exchangers? (ii) State and discuss Ficks Law. Derive an expression for LMTD of counter flow heat exchanger. Some Correlations and constants for Heat Transfer :The Zhukaukus relation for cross flow over a circular cylinder is : NuD = C (ReD)m (Pr /Prs)1/4 (All the properties except Prs are to be evaluated at T) Where, n = 0.37 for Pr 10, and n = 0.36 for Pr 10 C = 0.26 & m = 0.6 for Re between 103 and 2 x 105 C = 0.51 & m = 0.7 for Re between 40 and 1000 2. Stefan Boltzmann Constant : = 5.670 x10-8 W / m2 K4 3. Heat Generated by current carrying conductor: Q = I2 R

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COURSE PLAN I. C. ENGINES & COMPRESSORS EME-505

UNIT NO KNOWLEDGE INPUT This unit gives the basic information related to the internal combustion engines basic functions related to the engine cycles viz Otto cycle, Diesel cycle etc. I. C. Engines special characteristics information related to the fuel as well as the S.I. engines. Types of fuel used in both the engines & classification of the engines fuels Testing & Performances of S.I. & C.I. engines LECT. NO 1 2 3 REF. SUPPORTING CONTENT AUTHOR & AID PAGE NO. Introduction to I.C. engines Black board A- pp 1-5 Classification of the engines A- pp 17-18 Air standard cycles ,otto cycle A- pp 54-62 Diesel cycle, Dual Cycle A- pp 68-72 Comparision of Otto, Deisel A- pp 74-76 Dual cycles. Erricsion cycle ,Stirling cycle A- pp 59-60 Actual cycle analysis A- pp 152 two stroke & four stroke eng. Black board A- pp 24-30 S.I. engines & C.I. engines A- pp 30 OHP Valve timing diagram A- pp 559 rotary engines &stratified eng. Fuels for SI & CI engines, qualities of C.I, SIfuels & ratings dopes & additives used in Black board engine fuels Gaseous & alternative fuels. LPG, CNG, Bio gas & Producer gas fuels. testing & performance: Performance parameters & basic measurements Blow by measurement, Testing of SI & CI Engines Combustion in SI Engines, flame speed & Ignition delay Abnormal combustion & its control Combustion chamber design for SI engines Carburetion , mixture requirements Theory of Carburettor & its type MPFI types of ignition system, A- pp 797 A- pp263-327

4 5 6 7 8

A- pp 310 A- pp 328-347

10

A- pp 619

11 This unit gives knowledge of S.I. engines related to their combustion & fuel mixture requirement, failure related to the combustion & remedies. S. I. engine ignition types & requirements. Combustion chamber design. 12 13

A- pp 663-669 A- pp164-177 A- pp 177 -198

14 15

A- pp 361-372 Black board A- pp 373-381 A- pp A- pp 451-460

16

17 18

Magneto Ignition system Battery Ignition and ignition system requirement Ignition timing & spark plug - 50 -

A- pp449 A- pp 462-470

,Electronic ignition CI Engines: It gives knowledge of C.I. engines related to its combustion & fuel mixture req,,its failure related to the combustion & remedies. C.I. Engine control. Scavenging in 2 stroke engines. Pollution & its combustion chamber design. 19

Combustion in C.I. engine & ignition delay 20 21 knock & its control & combustion chamber design fuel injection in CI engines & its requirement

Black board

A- pp 214-222

A- pp 228-231 Black board A- pp 418-448

22

23 24 25 . 4 Knowledge related to engine cooling ,lubrication & its various types, Supercharging: is covered in the unit Compressors are also described to study their different types.

types of injection systems, fuel pump, injectors & injector timings Scavenging in 2 strokes engines

A- pp 423 A- pp 427-433 A- pp 561-570

26 27

28

29 30 31

32 33 34

Pollution & its control A- pp 728-774 Introduction of Engine A- pp 519,540, heating & engine cooling 549-552 Different Cooling system types ,radiator types & cooling fans Engine friction & engine A- pp 486-495 lubrication Black board 496-500 lubrication principle & A- pp 496-500, lubrication types Lubricating 508-512 Oils, Crank Case Ventilation Super charging, Effect of A- pp 579, altitude on power output, 589-608 Types of supercharging Reciprocating compressors B- pp 1174 single stage & multi stage B- pp1174-1181 Inter-cooling ,volumetric B- pp efficiency 1196,1191 Rotary Compressors B- pp 1173 ,classification, Centrifugal Black board & Compressor Axial Compressors, Surging & OHP B- pp 1281Stalling 1292 Roots Blower & Vaned B- pp 1271Compressor. 1280

REFERENCES: A Internal Combustion Engines by Mathur, M.L. & Sharma, R.P. B. Thermal Engineering by R.K. Rajput

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I. C. ENGINES & COMPRESSORS EME-505 TUTORIAL SHEET-1 Q-1 An engine working on Otto cycle has the following conditions, Pressure at the beginning of compression is 1 bar and pressure at the end of compression is 11 bar. Calculate the compression-ratio and air standard efficiency. Take = 1.4 Ans. 5.54; 0.496 In an engine working on ideal Otto cycle the temperature at the beginning and end of compression are 500 C and 3730 C. Find the compression-ratio and the air-standard efficiency of the engine. Take = 1.4 Ans. 5.66; 50% In an Otto cycle air at 170C and 1 bar is compressed adiabatically until the pressure is 15 bar. Heat is added at constant volume until the pressure rises to 40 bar. Calculate the air-standard efficiency, the compression and the mean effective pressure for the cycle. Take Cv= 0.717 kJ/kg-K; and Ro= 8.314 kJ/kg-K Ans. 6.91; 53.9 %; 5.70 bar Fuel supplied to an SI engine has a calorific value 42000 kJ/kg. The pressure in the cylinder at 30 % and 70 % of the compression stroke is 1.3 bar and 2.6 bar, respectively. Assuming that the compression follows the law pV1.3 = constant. Find the compression-ratio. If the relative efficiency of the engine compared with the air-standard efficiency is 50 %. Calculate the fuel consumption in kg/kwh. Ans. 4.68; 0.373 kg/kwh A gas engine working on the Otto cycle has a cylinder of diameter 200mm and stroke 250mm. The clearance volume is 1570 cc. Find the air-standard efficiency. Assume Cp = 1.004 kJ/kg-K and Cv = 0.717 kJ/kg-K Ans. 51.2 % TUTORIAL SHEET-2 A 4-stroke, 6-cylinder oil engine develops 80 kw at 2500 rpm. The sfc is 0.245 kg/kwh. Find the quantity of fuel injected by the nozzle(per cycle per cylinder) in the combustion chamber. Ans. (4.355 x 10-5 kg) A 4-stroke, 8-cylinder oil engine develops 360 kw when running at 800 rpm and consumes 240 gm/kwh. The pressure of air in cylinder at the beginning of injection and at the end of injection is 40 bar and 60 bar, respectively. The injection pressure at the beginning and end of the injection is 200 bar and 600 bar, respectively. Determine the diameter of the nozzle hole if the injection is carried out during 120 rotation of the crank. Take Cdf= 0.6, f = 800 kg/m3. The ambient pressure and temperature are 1.013 bar and 270 C. Assume effective pressure difference causing the fuel injection as average pressure difference during the injection period. Ans. 1.27mm A 6-cylinder, 4-stroke oil engine develops 200 kw at 1200 rpm, and consumes 0.3 kg/kwh. Determine the diameter of injector orifice if the injection pressure is 200 bar and combustion chamber pressure is 40 bar. The injection is carried out for 300 rotation of the crank.Take Cdf= 0.7, f = 900 kg/m3. Each nozzle on a cylinder is having single orifice. Ans. 0.85 mm A spark ignition engine working on ideal Otto cycle has the compression-ratio of 6. The initial pressure and temperature of air are 1 bar and 370C. The maximum pressure in the cycle is 30 bar. For a unit flow, calculate (i) pressure, volume, and temperature at various salient points of the cycle, and (ii) the ratio of heat supplied to the heat rejected, Take = 1.4 and Ro = 8.314 kJ/kg-K Ans.(V1=V4=0.889m3;p2=12.3bar;V2=V3=0.148m3;T2=634.8K;T3=1548K;p4=2.44bar;2.04)

Q-2

Q-3

Q-4

Q-5

Q-1

Q-2

Q-3

Q-4

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Q-5

In an Otto cycle the pressure and temperature at the beginning of compression are 1 bar and 370C, respectively. Calculate the theoretical thermal efficiency of this cycle if the pressure at the end of the adiabatic compression is 15 bar. Peak temperature during the cycle is 2000 K. Calculate, (i) heat supplied per kg of air, (ii) work done per kg of air, and (iii) the pressure at the end of adiabatic expansion. Ans (952.2 kJ/Kg; 513.2 kJ/kg; 2.98 bar) Take = 1.4; Cv= 0.717 kJ/kg-K TUTORIAL SHEET-3

Q-1

Q-2

Q-3

Q-4

A carburetor is adjusted to give air-fuel ratio of 14:1 at sea level (1.03 bar and 270C). Find the air-fuel ratio at 5000m altitude if the air temperature and pressure decrease as, t = (ts.l - 0.0065 h), and h = 19200 log10 (1.03/p). Ans (10.99) A simple carburetor has a venture throat of 20mm, fuel orifice of 1.25mm, and nozzle lip of 5mm. Find the air-fuel ratio for a carburetor depression of 0.07 bar. What will be the effect on AF ratio if nozzle lip is neglected? Take, Cda= 0.85; Cdf = 0.66, a=1.2 kg/m3; f = 750 kg/m3. Ans (13.22; 13.18) A single cylinder 4-stroke oil engine develops 20 kw at 1200 rpm. Its sfc is 0.30 kg/kwh. The fuel density is 860 kg/m3. The fuel injection is carried out during 300 rotation of the crank. The average fuel injection pressure and pressure in the combustion chamber are 120 bar and 30 bar. Find the diameter of the nozzle, if four orifices are used in the nozzle. Take Cdf = 0.65 Ans. 0.40 mm A 4-stroke, 6-cylinder oil engine operates on AF of 20. The diameter and stroke of the cylinder are 10 cm and 14 cm, respectively. The volumetric efficiency is 0.8. The conditions at the beginning of compression are 1 bar and 300 K. Determine the amount of fuel that can be injected in each cylinder per cycle. If the speed of engine is 1500 rpm, injection pressure is 150 bar, air pressure during fuel injection is 40 bar, and injection is carried out for 200 crank rotation, determine the diameter of the fuel orifice assuming only one orifice is used. Take Cdf= 0.67, f = 760 kg/m3, R= 287 J/kg-K. Ans. 0.58 mm A 8-cylinder, 4-stroke diesel engine has a power output of 375 kw at 800 rpm. The fuel consumption is 0.235 kg/kwh. The pressure in the cylinder at the beginning of injection is 35 bar and the maximum cylinder pressure is 60 bar. The injector is expected to open at 210 bar and the maximum pressure at the injector is set to be almost 600 bar. Calculate the orifice area and the velocity of injected fuel if the injection takes place over 120 crank angle. Assume the coefficient of discharge for the injector orifice 0.6, specific gravity of fuel as 0.85 and the ambient pressure 1.013 bar. Take effective pressure difference to be the average pressure difference over the injection period. Ans (1.24mm2, 174 m/s)

Q-5

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TUTORIAL SHEET-4 Q1 A 10cmx12cm, 4-cylinder, 4-stroke engine running at 2000rpm has a carburetor venture with a 3cm throat. Determine the carburetor depression assuming volumetric efficiency of 70%. Assume density of air to be 1.2kg/m3 and coefficient of flow 0.8. Ans (0.0363 bar) A 4-cylinder, 4-stroke SI engine ( cylinder dia 10cm, stroke 12cm, volumetric efficiency 0.80) has its carburetor venture diameter 3cm. The engine runs at 4000rpm. Calculate the suction at the throat if the coefficient of air flow is 0.9. If the ambient pressure and temperature is 1bar and 300 K, and the density of fuel is 780kg/m3, estimate the fuel jet diameter for an air-fuel ratio of 15:1. Ans (0.1433bar; 1.72mm) Determine the size of the fuel orifice to give a 12:1 air-fuel ratio, if venture throat is 3.4 cm diameter and vacuum in the venture is 6.33 cm Hg. Assume, Cda = Cdf= 1, and air temperature and pressure at carburetor entrance to be 1.013 bar and 160C. The fuel orifice is at the same level as that of fuel in the float chamber. Take, f = 750 kg/m3. Ans (0.189 cm) A single jet carburetor is to supply 6.1 kg/min of air and 0.41 kg/min of petrol of specific gravity 0.77. The air is initially at 1.013 bar and 160C. Assuming isentropic coefficient for air 1.35, determine, (a) dia of the venture if air speed is 91 m/s and velocity coefficient of venture is 0.84, (b) the dia of jet if the pressure drop at the jet is 0.8 times the pressure drop at the venture. Take, Discharge coefficient for jet as 0.66. Ans (3.51mm; 20.8mm) In a simple carburetor, the throat diameter is 25mm and the main jet diameter is 1.2mm. The coefficient of discharge for air and fuel flow is 0.85 and 0.65, respectively. The gasoline surface is 6mm below the throat. Estimate the minimum velocity of air required to start the fuel flow. The ambient conditions are, 1bar, 298K, and f = 760 kg/m3. Ans(8.75m/s) TUTORIAL SHEET-5 A single stage reciprocating compressor receives air @ 25 m3/min at 1 bar and 250C and discharges it at 15 bar. Assume the value of index for compression as 1.35 and volumetric efficiency 0.75. Determine, (a) the theoretical power required, (b) the piston displacement per min, and (c) maximum air temperature. Ans (165kw; 33.33m3/min; 600K) Determine, (a) the motor power, and (b) the cylinder dimensions of a 4-cylinder double acting reciprocating compressor to compress 25m3/min of air at 1bar and 250C up to a pressure of 15bar. Take clearance volume=5%; n=1.35; length=1.2 diameter; rpm = 300; mech. efficiency= 0.8 Ans(206.2 kw; 25.6 cm; 30.73 cm) Determine the power required by a 2-stage reciprocating compressor which receives air @ 3m3/min at 1 bar and discharges at 10 bar. Assume that proper intercooler pressure is used, and intercooling is prefect. Take n=1.35 Ans (12.3 kw) A multistage reciprocating compressor has to be designed to supply air at 135 bar while condition are1.03 bar and 150C. The value of compression index may be assumed as 1.35. Due to practical reasons the intercoolers are not able to cool the air below 450C while the maximum temperature allowable in the system is 1200C. Calculate the number of stages that are necessary in the compression, and the rate of cooling water circulated per kg of air. Take Cp = 1kJ/kg-K Ans (5; 14kg/ kg of air) A carburetor is designed to supply an air-fuel ratio of 14.5: 1. The depression at the venture is expected to be 0.15bar under normal conditions. When the air cleaner is fitted the pressure drop across the air cleaner is 20mm of mercury. Calculate the air-fuel ratio under this new condition. Ans(13.167 a rich mixture - 54 -

Q-2

Q-3

Q-4

Q-5

Q-1

Q-2

Q-3

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TUTORIAL SHEET-6 Q-1 A single stage reciprocating air compressor has a swept volume of 2000 cm3 and runs at 800 rpm. It operates on a pressure-ratio of 8 and has a clearance of 5% of the swept volume. The ambient conditions are 101.3 kPa and 150C. The polytropic compression and expansion index is 1.25. Calculate, (a) indicated power, (b) volumetric efficiency, (c) mass flow rate, (d) FAD, (e) isothermal efficiency, (f) the actual power needed to drive the compressor, if mechanical efficiency is 0.85. Ans(5.47 kw; 78.6%; 1.54 kg/min; 1.26 m3/min; 80.7%; 6.44 kw) A 2-stage air reciprocating compressor with perfect intercooling takes in air at 1 bar pressure and 270C. The law of compression in both the stages is pv1.3 = constant. The compressed air is delivered at 9 bar from the HP cylinder to an air receiver. Calculate, (a) the minimum work done, and (b) the heat rejected to the intercooler per kg of air. Ans(214.16kJ/kg; 86.99 kJ/kg) A single acting 2-stage air reciprocating compressor deals with 4m3/min of air at 1.013 bar and 150C with a speed of 250 rpm. The delivery pressure is 80 bar. Assuming complete intercooling, find (a) the minimum power required by the compressor, and (b) bore & stroke of the compressor. Take, piston speed = 3m/s; mech.efficiency = 75%; volumetric efficiency = 80% per stage; n = 1.25; and neglect clearance Ans (49.34 kw; L= 36 cm, DHP=26.6 cm, DLP=8.9cm) A 3-stage single acting reciprocating compressor has a LP cylinder of 450mm bore and 300 mm stroke. The clearance volume of LP cylinder is 5% of the swept volume. Intake pressure and temperature are 1bar and 180C, respectively. The delivery pressure is 15 bar, intermediate pressures are ideal, and intercooling is perfect. The compression and expansion index can be taken as 1.3. Estimate, (a) the intermediate pressures, (b) the effective swept volume of LP cylinder, (c) the temperature and volume of air delivered per stroke at 15 bar, and (d) the work done per kg of air. Take R = 0.29 kJ/kg-K. Ans(2.466 bar, 6.08 bar; 0.0453 m3, 358.8 K; 0.0037 m3; 254.3 kJ) In a simple carburetor the gasoline in the float chamber stands 6mm below the nozzle opening. The engine consumes 6.4 kg of fuel hour. The fuel jet diameter is 1.25mm and the discharge coefficient of fuel orifice is 0.64. If the air-fuel ratio is 16:1, estimate (a) the air velocity at the throat, (b) throat area, and (c) the pressure drop in cm of water. Assume, Discharge coefficient for air 0.85, ambient conditions; 1bar, 250C, f = 770 kg/m3 Ans( 76.45m/s; 3.87 m2; 0.95bar)

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