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TEACHING & EVALUATION SCHEME (2010-2011)

DISCIPLINE :  MECHANICAL ENGINEERING	       SEMESTER : FIFTH (NEW)

SlNo.SubjectTeaching SchemeEvaluation SchemeTotal MarksTheoryLTPTheoryPracticalEnd ExamInternal AssesmentEnd ExamSessionalClass TestAssignmentTh1Manufacturing Tech.-III41080155100Th2Industrial Engineering41080155100TH3Ref.& air Conditioning41080155100Th4Mechanical Engg. Design41080155100Th5Inspection & Quality Control41080155100PracticalPr.1Mechanical Engg. Lab.-III006502575Pr.2Inspection & Quality Control Lab006502575Pr.3Project Seminar0025050100Grand Total205144007525150100750

















SYLLABUS
5TH  SEMESTER
MECHANICAL ENGINEERING
THEORY-1
MANUFACTURING TECHNOLOGY- III
Periods / Week: 4+1                                                      Examination : 3Hrs
Total period     : 60                                               End exams 	TH  : 80 marks
                                                                                    	 	I.A. : 20 marks
			Topic wise distribution of Periods

Sl. No.			Topics				Periods

1		Press Tools						12
2		Jigs and Fixture					12
3		Installation and testing of machine tools	12
           Special Casting and Powder Metallurgy	12
5              Non conventional machining Process		12
						Total				60 Periods

Press tools
List various types of die and punch
Explain simple, Compound & Progressive dies
Describe the various advantages & disadvantages of above dies.

Jigs and fixtures
Define jigs and fixtures
State advantages of using jigs and fixtures
State the principle of locations
Describe the methods of location with respect to 3-2-1 point location of rectangular jig
Describe various types of fixtures like screw, flat and wedge
Describe various jigs like plate, template, diameter and box types.

Installation & testing of machine tools
Explain the installation procedure of new machine tool
Describe the testing for geometric accuracy of lathe machine tool
Describe the testing for geometric accuracy of milling machine tool
Describe the testing for geometric accuracy of drilling machine tool.

Special castings and Powder metallurgy
Explain die casting method with relative advantages, disadvantages and field of application
 Describe investment casting method with relative advantages, disadvantages and field of application
Explain centrifugal casting such as true centrifugal casting, centrifuging with advantages, limitation and area of application
Define powder metallurgy process
State advantages of powder metallurgy technology technique
Describe the methods of producing components by powder metallurgy technique
Explain sintering.

Non conventional machining process
Describe the working principle and application of various non conventional machining process with line diagram
Electro chemical
Electro discharge
Plasma arc
Laser beam
Abrasive jet
Electron beam.
Ultrasonic


Recommended books:

Text Book:

1.	Workshop Technology by Hazra Choudhury   Vol.-I,II
2.	Manufacturing Technology By P. N. Rao Vol. -I, II
3.	Production Engg. , by P. C. Sharma

Reference Book:

1.	Production Technology    Hand  book
2.	Materials & Processes in manufacturing   -  De Garmo (PHI)










						






5TH  SEMESTER
MECHANICAL ENGINEERING
THEORY-2
INDUSTRIAL ENGINEERING
Periods / Week: 4+1                                                      Examination: 3Hrs
Total period     : 60                                               End exams 	TH: 80 marks
                                                                                    	 	I.A.: 20 marks

Topic wise distribution of periods

Sl.No.				Topic				       Periods

01			Motion & Time Study			08
02			Operations Research			06
03			PERT and CPM				10
04			Plant Location and Layout		06
05			Inventory Control				05
06			Estimating and Costing			06
07			Plant Maintenance				07
08			Production Planning & Control		08
09			TQM and ISO 9000/14000			04

				Total Period				60

RATIONALE:
Main objective of Mechanical and Automobile Engineering & Technology is to produce goods and services for benefit to mankind. Such productions are done utilizing various resources like Men, Materials, machines and Money. Industrial engineering is the subject which allows optimized use of such resources and hence very important for a mechanical engineering.

COURSE CONTENT:
Motion and Time Study.
Work Study
Definition, necessity, advantages
Work Study
Motion Study
Explain different types of process chart with symbols
Flow process chart
Outline process chart
Flow diagram
  Time Study
1.2.1 Explain time study
1.2.2 Explain the methods of time study
1.2.2.1 Stopwatch time study
1.2.2.2 Work sampling
1.2.3 Explain performance rating
1.2.4 Describe different types of allowances

Operations Research
Linear Programming
Formulating of linear programming
Solution of L.P.P. by graphical method.

PERT & CPM3.1  Differentiate between CPM and PERT
3.2 Define event
3.3 Define activity
3.4 Define critical activity
3.5 Define dummy activity
3.6 Define and explain critical path
3.7 Define EST
3.8 Define LST
3.9 Define EFT
3.10 Define LFT
3.11 Explain float and slack
3.12 Determine project completion time
3.13 Find out Probability of meeting scheduled date.

4.    Plant location and Layout
4.1   Describe the features governing plant location
4.2   Define plant layout
4.2.1    Describe the objective and principles of plant layout
4.2.2    Explain process layout
4.2.3    Explain product layout
4.2.4    Explain combination layout
4.2.5    Explain the storage space requirements
 Procedure of plant layout.

5.   Inventory Control
5.1   Classification of inventory
5.2   Objective of inventory control
5.3   Describe the functions of inventories
5.4   Explain economic order quantity & solve problems
5.5   Define and Explain ABC analysis.

6    Estimating and Costing
6.1 Types of cost
6.1.1 Explain fixed cost
6.1.2 Explain variable cost
6.1.3 Explain semi-variable cost
6.2 Describe elements of cost
6.3 Classify the overheads
6.3.1 Factory overhead
6.3.2 Administrative overhead
6.3.3 Selling overhead
6.3.4 Distribution overhead
6.4 Prepare simple cost sheet
6.5 Estimate cost of production and selling of products.

7    Plant maintenance
7.1 Describe the objectives of plant maintenance
7.2 Describe the duties, functions and responsibilities of plant maintenance department
7.3 Describe the types of maintenance
7.3.1 PREVENTIVE maintenance
7.3.2 Breakdown Maintenance
7.3.4 Scheduled Maintenance
7.3.5 Predictive Maintenance
7.4 Some recent developments in plant maintenance.

8    Production planning & control
8.1 Concept of process planning
8.2 Process planning procedure
8.2.1 Selection of process
8.2.2 Selection of material
8.2.3 Selection of jigs and fixtures
8.2.4 Selection tools and gauges
8.3 Concept of scheduling
8.3.1 Scheduling technique
8.3.2 Master Scheduling
8.3.3 Perpetual Scheduling
8.3.3.1 Load analysis
8.4 Concept and procedure for
8.4.1 Despatching
8.4.2 Routing
8.4.3 Progress Control.

9    TQM & ISO 9000/14000.
9.1 Overall idea about total quality management
9.2 Idea about ISO 9000/14000.
RECOMMENDED BOOKS:
Industrial Engineering & Management by O.P.Khanna, Dhanpat Rai & Sons.
Industrial Engg & Production Management : Telsang, S. Chand &Co
Industrial Engineering & Management by C.N.M Reddy, New Age International Publication.

5TH  SEMESTER
MECHANICAL ENGINEERING
THEORY-3
Refrigeration and Air Conditioning
Periods / Week: 4+1                                                      Examination: 3Hrs
Total period     : 60                                               End exams 	TH: 80 marks
                                                                                    	 	I.A.: 20 marks
 
Topic wise distribution of periods

Sl.No.				Topic				       Periods

01			Introduction to Refrigeration & air	
                      Conditioning & its application		03
02			Air refrigeration system			07
03			Vapour Compression, Refrigeration 
System & Its components & control	12
04			Refrigerants.					03
05			Vapour absorption refrigeration system	08
06			Psychrometry				08
07			Physiological Factors			03
08			Cooling Load Calculation			09
09			Air Conditioning System			07
				Total Period				60
RATIONALE:
Refrigeration is the process of cooling below surrounding temp. Air Conditioning means distribution of air after controlling its temp, humidity for human comfort.

COURSE CONTENT:
Development of refrigeration
Definition, purpose & applications of refrigeration & air conditioning
Heat pump, refrigerator, heat engine
C.O.P, unit of refrigerating effect.

Air refrigeration system
Carnot cycle reversed Carnot cycle
Brayton cycle
Closed System
Open System
Typical problems.

Vapour compression refrigeration system, its components & control
Theoretical vapour compression cycle
Effect of sub cooling & super heating
Effect of evaporator & condenser pressure
Deviation of actual cycle from theoretical cycle
Calculation of C.O.P using refrigeration tables & charts
Calculation of volumetric efficiency of reciprocating refrigerant compressor
Functions, types, specification, constructional details & selection of components & controls such as compressor, condenser, expansion valves, capillary tube, evaporator
Separator, accumulator, spray pond & cooling towers
Control devices, such as solenoid valve, thermostat, low pressure & high pressure cut out, oil safety switch, condensing water control.

Refrigerants
Definition & type of refrigerants commonly used
Describe properties
Nomenclature
Properties of NH3, air, water, CO2, R11, R22 & their application.

Vapour absorption refrigeration system
Simple vapour absorption system
Practical absorption system
Refrigerant absorption combinations
Large absorption system for water chilling
Comparison between vapour absorption & vapour compression system
Electrolux system.

Psychrometry
Properties of air-vapour mixture
Dry bulb, wet bulb, thermodynamic wet bulb, adiabetic saturation and dew point temperatures
Humidity ratio, relative humidity
Degree of saturation, enthalpy of moist air
Sling and aspiration psychrometers
Psychrometric process analysis
Cooling and dehumidification
Heating and humidification
Mixing of two air streams
Sensible heating and cooling.

Physiological Factors
Factors affecting human body
Metabolism of human body
Comfort Chart
Effective temperatures.

Cooling load calculations
Types of loads
Sensible heat, latent heat, total heat
Calculation of loads due to different sources of solar, human beings, applications, in filtration
Sensible heat factor, latent heat factor, total heat factor
Bypass factor, apparatus due point
Fresh supply and recirculated air quantities.
Air conditioning system
Describe and specification of room air conditioner and commercial conditioning system
Principle of evaporative cooling
Air cooler and desert cooler
Air distribution systems and ducting
Air filters, dampers, fans, blower, diffusers.
RECOMMENDED BOOKS:
Text Book:
1	Refrigeration and air conditioning by S.C. Domkundwara and Arora
2	Refrigeration and air conditioning by C.P Arora, TMH.
3	Refrigeration and air conditioning by R.S. Khurmi.
Reference Book
4	Refrigeration and air conditioning by P.L Ballany, Khanna pub.
5 	Refrigeration and air conditioning by M. Prasad, New Age International.


























5TH  SEMESTER
MECHANICAL ENGINEERING
THEORY-4
Mechanical Engineering Design
Periods / Week: 4+1                                                      Examination: 3Hrs
Total period     : 60                                               End exams 	TH: 80 marks
                                                                                    	 	I.A.: 20 marks

Topic wise distribution of periods

Sl.No.				Topic				       Periods
01			Introduction					08
02			Design of fastening elements		15
03			Design of shafts keys & couplings		10
04			Design of levers				06
05			Design of belt drives & pulleys		10
06			Design of screw jack			05
07			Design of closed coil helical spring	06
				Total Period				60
RATIONALE:
Machine design is the art of planning or devising new or improved machines to accomplish specific purposes. Idea of design is helpful in visualizing, specifying and selection of parts and components which constitute a machine. Hence all mechanical engineers should be conversant with the subject.

COURSE CONTENTS (in terms of specific objectives):
Introduction
State the factors governing the design of machine elements
State types of loads
Define working stress, yield stress, ultimate stress & factor of safety
State mechanical properties of the material of the product
Preliminary idea of failure of material due to fatigue & creep.
Describe design procedure

Design of fastening elements
State nomenclatures, form of threads & specifications
Describe nature of loads and failure of bolt subjected to initial stresses due to screwing up, stresses due external forces, stresses due to combined force and stresses due to shear load
Determine dimensions of bolt and nut by using empirical formula(Hexagonal & Square nut)
Design eye bolt for a given load by empirical relation
State types of welded joints
State advantages of welded joints over other joints
     Determine strength of welded joints for eccentric loads
     State types of riveted joints
     Describe failure of riveted joints
Determine strength & efficiency of riveted joints
Design riveted joints for pressure vessel
Design cotter joint.

Design of shafts, Keys & Couplings
  State function of shafts
  State materials for shafts
  Design solid & hollow shafts to transmit a given power at given rpm based   on
Strength
Shear stress
Combined bending & tension
Rigidity
Angle of twist
Deflection
Modulus of rigidity
  State standard size of shaft as per I.S.
  State function of keys, types of keys & material of keys
  Describe failure of key, effect of key way
  Design rectangular sunk key considering its failure against shear & crushing
  Design rectangular sunk key by using empirical relation for given diameter  of shaft
    State specification of parallel key, gib-head key, taper key as per I.S.
State function of coupling and types of couplings
Determine the dimension for a C.I flange coupling and coupling bolts for a  given torque by using empirical relations.

Design of levers
State types of levers and their function.
Design hand lever foot lever & bell crank lever.

Design of belt drivers and pulleys:
State types of belt drives & pulleys.
State formula for length of open and crossed belt, ratio of driving and driven side tension, centrifugal tension and relation between centrifugal tension and tension on tight side for maximum power transmission.
Determine belt thickness and width for given permissible stress for open and crossed belt considering centrifugal tension.
Explain types of pulleys for flat belts:
Cast iron pulley.
Steel pulley.
Fast and loose pulley.
Design a cast iron pulleys using empirical formula only.
Dimensions of pulley.
Dimensions and number of arms.
Dimension of hub.
Problems.
Design a screw jack using empirical formula.
Problem.

Design a closed coil helical spring of round rod.
Materials used for helical spring.
Standard size spring wire. (SWG)
Terms used in compression spring.
Stress in helical spring of a circular wire.
End connection for helical tension spring.
Deflection of helical spring of circular wire.
Eccentric loading of spring.
Buckling of compression spring.
Surge in spring.
Problems.
RECOMMENDED BOOKS:
Text Book:
Machine Design by R.S.Khurmi and Gupta, Eurasia publishing House.
A  Text book of Machine Design by Sharma and Agarwala, S.K.Kataria & Sons.
Design of Machine elements by K Ganesh Babu, K Srithar, TMH
Reference Book:
Machine Design By R.B.Gupta, Satya Prakashan.
Elements of Machine Design by Panday and Shah, Charotar Publishing Housing.
Machine Design by P. Kannaiah , SCITECH Publisher




















5TH  SEMESTER
MECHANICAL ENGINEERING
THEORY-5
Inspection & Quality Control 
Periods / Week: 4+1                                                      Examination: 3Hrs
Total period     : 60                                               End exams 	TH: 80 marks
                                                                                    	 	I.A.: 20 marks

Topic wise distribution of periods

Sl.No.				Topic			 	Periods
01			Inspection				12
02			Measurement & Gauging		12
03			Statistical Quality Control		12
04			Standards & Codes			12
05			Instrumentation			12
				Total Period			60
RATIONALE:
Diploma holders in this course required to measure and inspect for ensuring quality of product. For this purpose, knowledge & skills about standards of measurement, limits, fits & tolerances, types of inspection & various measuring instruments, SQC & quality standards are necessary.
Course Contents:
Inspection
Introduction, units of measurements, standards for measurement and inter changeability
International, national & company standard, line & wavelength
Limits, fits & tolerances: study of natural variability of process. Indian standards on limits, fits and tolerance, transition & interference. Positional tolerances: maximum material condition usage of standards for deciding tolerance
Planning of inspection: what to inspect? When to inspect? Who should inspect? Where to inspect?
Types of inspection: remedial, preventive & operative inspection, incoming in process & final inspection
Study of factors influencing the quality of manufacture.

Measurement & Gauging
Basic principles used in measurement & gauging, mechanical, optical, electrical & electronic
Study of various measuring instruments like: Calipers, micrometers, dial indicators, surface plate, straight edge, try square, protectors, sine bar and clinometers, comparators-mechanical, electrical & pneumatic. Slip gauges, tool room microscope & profile projector. Talysurf . Limit gauges: plug ring, snap, taper, thread, height, depth, form, wire & their applications for linear, angular, surface, thread & gear measurements, tolerances. Geometrical parameters & errors
Errors & their effect on quality, concept of errors, measurement of geometrical parameter such as straightness, flatness & parallelism
Study of procedure for alignment test on lathes, Drilling & milling machines
Testing & maintenance of measuring instruments.

Statistical quality Control
Basic statistical concepts, empirical distribution and histograms, frequency, mean, mode, standard deviation, normal distribution, binomial & Poisson (No mathematical derivations)
Introduction to control charts, namely X, R, P & C Charts & their applications.
Sampling plans, Selection of sample size, method of taking samples, frequency of samples
Inspection plan format & test report
Concept of total quality management (TQM).

Standards & Codes
National & International Codes
ISO-9000, concept & its evolution & implications.

Instrumentation
Measurement of mechanical quantities such as displacement, vibration, frequency, pressure, temperature, humidity by electro mechanical transducers of resistance, capacitance & inductance type.
RECOMMENDED BOOKS:
Statistical quality Control by M.Mahajan.
Engineering Metrology by R.K.Jain.
Engineering Metrology by R.K.Rajput.
Production Planning Control & Management K.C.Jain & Agrwal.

















5TH  SEMESTER
MECHANICAL ENGINEERING

PR.1.Mechanical Engineering Lab.-III

Periods / Week: 06                                                      Examination: 4Hrs
Total period     : 90                                               End exams 	Pr : 50 marks
                                                                                            Sessional : 25 marks



Theory of M/C Lab:-
Determination of centrifugal force of a governor. (Hartnell / Watt/Porter)
Study & demonstration of static balancing apparatus.
Study & demonstration of journal bearing apparatus.
Study & demonstration of CAM analysis apparatus.

Refrigeration & Air Conditioning Lab.
To Study the Construction features of 
Domestic refrigerator  
Water cooler 
Window A.C.
Split A.C.
Performance analysis of a refrigeration tutor.
Performance analysis of A.C. tutor.


















5TH  SEMESTER
MECHANICAL ENGINEERING

PR.2. Inspection & Quality Control Lab.

Periods / Week: 06                                                      Examination: 4Hrs
Total period     : 90                                               End exams 	Pr : 50 marks
                                                                                            Sessional : 25 marks





Linear measurements.

Determination of the thickness of  MS flat to an accuracy of 0.02 mm using Vernier Caliper.
Determination of the inside diameter of a bush component to an accuracy of 0.02 using Vernier caliper.
Determination of diameter of a cylindrical component to an accuracy of 0.01mm using micrometer & check the result with digital micrometer.
Determine the heights of gauge blocks or parallel bars to accuracy of 0.02mm using vernier height gauge & check the result with digital Vernier height gauge.
Determine the thickness of MS plates using slip gauges.

Angular measurement:

Determination of angel of Machined surfaces of components using sine bar with slip gauges.
Measurement of V-thread dimensions.
Measurement of spur gear tooth dimensions.














5TH  SEMESTER
MECHANICAL ENGINEERING

PR.3.- Project Seminar

Periods / Week: 02                                                      		Total	: 100 
Total period     :	                                               	End exam.	Pr : 50 marks
                                                                                            Sessional : 50 marks


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