__ME2K 603 : METAL CASTING & JOINING__ (common with PM2K 603)
3 hours lecture and 1 hour tutorial per week
**Module I**** (10 hours)** Introduction - solidification of metals - mechanism of solidification - solidification with predominant interface resistance - solidification with constant surface temperature - solidification with predominant resistance in mould and solidified metal - flow of molten metal in moulds - furnaces and melting practices - patterns - pattern allowance - design considerations - shrinkage and machining allowance - foundries
**Module II**** (14 hours)** Casting processes - comparison - sand casting - shell moulding - silicate bonded sand process (CO_{2} process) - expended polystyrene process - plaster mould casting - ceramic mould casting - investment casting - permanent mould casting - slush casting - pressure casting - die casting - centrifugal casting - squeeze casting - semisolid casting (rheocasting, thixoforming) - casting techniques for single crystal components - rapid solidification - residual stress - defects - inspection of castings - casting design - gating system design - risering - casting alloys - economics of casting - design rules for castings - case studies with specific examples of sand cast and permanent mould cast parts
**Module III**** (16 hours)** Classification - filler materials - consumable electrodes - liquid state - chemical - arc - resistance - electrical characteristics of the arc - analysis of metal transfer - free flight and short-circuiting metal transfer - equations for heat flow in welding - equations for temperature distribution in the Heat Affected Zone-Gas-Metal reactions - sensitivity to hydrogen porosity - weld pool solidification - contraction and residual stress crack sensitivity - dilution and uniformity of the weld deposit - solid state - liquid-solid state - *process*: OFW - SMAW - SAW- GMAW - FCAW - GTAW - PAW - ESW - EGW - RW - RSEW - HFRW - RPW - FW - SW - PEW - FOW - CW - USW - FRW - EXW - TW - EBW - LBW - DFW
**Module IV**** (12 hours)** The metallurgy of welding - metallurgy of weld metal and HAZ for carbon steels, ferritic and high alloy steels, austenitic and high alloy steels non-ferrous metals (Aluminium and its alloys, Copper and its alloys, Magnesium and its alloys) - weld quality - weldability - testing welded joints - welding design and process selection - brazing, soldering, adhesive bonding and mechanical joining processes - joining plastics - surface energy and contact angle - capillary action in brazing and soldering - residual stress and stress concentration factors in adhesive bonding
**Reference books** Flemings M.C., *“Solidification Processing”, *McGraw Hill Serope Kalpakjian, *Manufacturing Engineering & Technology, *Addison Wesley Heine R.W., Loper C.R. Jr. & Rosenthal P.C., *Principles of Metal Casting,* Tata McGraw Hill *American Welding Society,* Welding Hand Book Doyle L.E., *Manufacturing Processes and Materials for Engineers, *Prentice Hall of India *Metals HandBook- Vol.5.,* Welding Institute of Metals Lancaster J.F., “*The Metallaurgy of Welding, Brazing and Soldering”,* George Allen & Unwin Ltd.
**Sessional work assessment** 2 tests 2x15 = 30 2 assignments 2x10 = 20 Total marks = 50
**University examination pattern** Q I - 8 short type questions of 5 marks each, 2 from each module Q II - 2 questions A and B of 15marks each from module I with choice to answer any one Q III - 2 questions A and B of 15marks each from module II with choice to answer any one Q IV - 2 questions A and B of 15marks each from module III with choice to answer any one Q V - 2 questions A and B of 15marks each from module IV with choice to answer any one
**ME2K 604 : THERMAL ENGINEERING I**
3 hours lecture and 1 hour tutorial per week
**Module I**** (14 hours)**
**Internal combustion engines** - classification - four stroke and two stroke engines - spark ignition and compression ignition engines - value timing diagram - thermodynamic analysis of air standard cycles - Otto, diesel and duel combustion cycles - engine testing - performance and characteristics of constant speed and variable speed engines - heat balance test - Morse test - retardation test - actual engine cycles - effect of dissociation - variable specific heats and heat losses - scavenging - objectives - effects and methods
**Module II**** (13 hours)**
**Systems and components of IC engines **- fuel systems - ignition systems - cooling - starting - lubrication - governing of IC engines - supercharging of SI and CI engines - turbocharging - exhaust emissions of IC engines - alternate potential engines - free piston engine - Wankel engine and stratified charged engine - automotive transmission system and its components
**Module III**** (12 hours)**
**Combustion in IC engines **- flame propagation - normal and abnormal combustion - detonation - pre ignition - after burning - HUCR - fuel rating - additives in petrol - combustion chambers of SI engines - combustion in CI engines - phase of normal combustion - diesel knock - effect of engine variables on diesel knock - cetane number - additives in diesel - combustion chambers of CI engines
**Module IV**** (13 hours)**
**Gas turbine plants **- open and closed cycles - thermodynamic cycles - regeneration - reheating - intercooling - efficiency and performance of gas turbines - rotary compressors - analysis - centrifugal and axial flow compressors - combustion chambers of gas turbines - cylindrical - annular and industrial type combustion chamber design - combustion intensity - combustion efficiency - pressure loss combustion process and stability loop - axial flow turbines - elementary and vortex theories - design of nozzles and blades for turbines - limiting factors in turbine design
**Reference books** Rogowsky, *“Elements of Internal Combustion Engines”,* Tata McGraw Hill Gill, Smith & Ziurys, *“Fundamentals of Internal Combustion Engines”, *Oxford and IBH Maleev, “*Internal Combustion Engine Theory and Design*” McGraw Hill Judge, “*Modern Petrol Engines*,” Chapman & Hall Benson & Whitehouse, “*Internal Combustion Engines*” Vol. I & II, Pergamon press Mathur & Mehta, “*Thermodynamics and Heat Power Engineering*”, Vol. I & II Cohen & Rogers, “*Gas Turbine Theory*,” Longmans
**Sessional work assessment** 2 tests 2x15 = 30 2 assignments 2x10 = 20 Total marks = 50
**University examination pattern** Q I - 8 short type questions of 5 marks each, 2 from each module Q II - 2 questions A and B of 15marks each from module I with choice to answer any one Q III - 2 questions A and B of 15marks each from module II with choice to answer any one Q IV - 2 questions A and B of 15marks each from module III with choice to answer any one Q V - 2 questions A and B of 15marks each from module IV with choice to answer any one
**ME2K 605 : MACHINE DESIGN I**
3 hours lecture and 1 hour tutorial per week
**Module I**** (13 hours)** Introduction to design - steps in design process - design factors - tolerances and fits - principles of standardisation - selection of materials - strength of mechanical elements - stress concentration - theories of failure - impact load - fatigue loading - consideration of creep and thermal stresses in design
**Module II**** (13 hours)** Threaded fasteners - thread standards - stresses in screw threads - preloading of bolts - bolted joints - eccentric loading - gasketed joints - analysis of power screws - *keys*: types of keys and pins - stresses in keys and pins - design of keys - design of cotter and pin joints - riveted joints - stresses in riveted joints - strength analysis - boiler and tank joints - structural joints
**Module III**** (13 hours)** Welded joints - types of welded joints - stresses in butt and fillet welds - torsion and bending in welded joints - welds subjected to fluctuating loads - design of welded machine parts and structural joints - springs: stresses in helical springs - deflection of helical springs - extension, compression and torsion springs - design of helical springs for static and fatigue loading - critical frequency of helical springs - stress analysis and design of leaf springs
**Module IV**** (13 hours)** Power shafting - stresses in shafts - design for static loads - reversed bending and steady torsion - design for strength and deflection - design for fatigue loading - critical speed of shafts - stresses in couplings - design of couplings
**Text book** Shigley J.E., *Mechanical Engineering Design*, McGraw Hill Book Company **Reference books** Siegel, Maleev & Hartman, *Mechanical Design of Machines*, International Book Company Phelan R.M., *Fundamentals of Mechanical Design,* Tata McGraw Hill Publishing Co. Ltd. Doughtie V.L., & Vallance A.V., *Design of Machine Elements*, McGraw Hill Book Company Juvinall R.C. & Marshek K.M., *Fundamentals of Machine Component Design,* John Wiley **Data hand books (allowed for reference during examinations)** Prof. Narayana Iyengar B. R. & Dr Lingaiah K., *Machine Design Data Handbook,* Vol. I &II P.S.G., Tech., *Machine Design Data Handbook*
**Sessional work assessment** 2 tests (best 2 out of 3 tests conducted) 2x15 = 30 2 assignments 2x10 = 20 Total marks = 50
**University examination pattern** Q I - 8 short type questions of 5 marks each, 2 from each module Q II - 2 questions A and B of 15marks each from module I with choice to answer any one Q III - 2 questions A and B of 15marks each from module II with choice to answer any one Q IV - 2 questions A and B of 15marks each from module III with choice to answer any one Q V - 2 questions A and B of 15marks each from module IV with choice to answer any one
**ME2K 606A : OPTIMISATION TECHNIQUES** (common with AI2K/CE2K/EC2K/EE2K/IC2K/PM2K 606A)
3 hours lecture and 1 hour tutorial per week
**Module I****: Linear programming I (13 hours)** Systems of linear equations and inequalities - convex sets - convex functions - formulation of linear programming problems - theory of simplex method - simplex algorithm - Charne’s M method - two phase method - duality in linear programming - dual simplex method
**Module II****: Linear programming II (13 hours)** Sensitivity analysis - parametric programming - bounded variable problems - transportation problem - development of the method - integrality property - degeneracy - unbalanced problems - assignment problem - development of the Hungarian method - routing problems
**Module III****: Nonlinear programming (13 hours)** Mathematical preliminaries of non-linear programming - gradient and Hessian - unimodal functions - convex and concave functions - role of convexity - unconstrained optimization - Fibonacci search - golden section search - optimal gradient method - classical optimisation - Lagrange multiplier method - Kuhn-Tucker conditions - quadratic programming - separable convex programming - Frank and Wolfe method
**Module IV****: Dynamic programming & game theory (13 hours)** Nature of dynamic programming problem - Bellman’s optimality principle - cargo loading problem - replacement problems - multistage production planning and allocation problems - rectangular games - two person zero sum games - pure and mixed strategies - 2m and m2 games - relation between theory of games and linear programming
**Reference books** Bazarra M.S., Jarvis J.J. & Sherali H.D., ‘*Linear Programming and Network Problems*', John Wiley Bazarra M.S., Sherali H.D. & Shetty C.M., ‘*Nonlinear Programming, Theory and Algorithms', *John Wiley Hadley G., ‘*Linear Programming*', Addison Wesley Hillier F.S. & Lieberman G.J. ‘*Introduction to Operations Research'*, McGraw Hill Ravindran A., Phillips D.T. & Solberg J.J., *Operations Research Principles and Practice*, John Wiley Taha H.A., *Operations Research, An introduction*, P.H.I. Wagner H.M., ‘*Principles of Operations Research with Application to Managerial Decisions'*, P.H.I.
**Sessional work assessment** Assignments 2x10=20 2 tests 2x15=30 Total marks =50
**University examination pattern** Q I - 8 short type questions of 5 marks each, 2 from each module Q II - 2 questions A and B of 15marks each from module I with choice to answer any one Q III - 2 questions A and B of 15marks each from module II with choice to answer any one Q IV - 2 questions A and B of 15marks each from module III with choice to answer any one Q V - 2 questions A and B of 15marks each from module IV with choice to answer any one |