MECHANICAL Sem-5

UNIT I - FUNDAMENTAL CONCEPTS IN DESIGN

Introduction to the design process - factors influencing machine design, selection of materials based on mechanical properties - Preferred numbers- Direct, Bending and torsional loading- Modes of failure - Factor of safety – Combined loads – Principal stresses – Eccentric loading – curved beams – crane hook and ‘C’ frame- theories of failure – Design based on strength and stiffness – stress concentration – Fluctuating stresses – Endurance limit –Design for finite and infinite life under variable loading - Exposure to standards

UNIT II - DESIGN OF SHAFTS AND COUPLINGS

Shafts and Axles - Design of solid and hollow shafts based on strength, rigidity and critical speed – Keys and splines – Rigid and flexible couplings

UNIT III - DESIGN OF TEMPORARY AND PERMANENT JOINTS

Threaded fasteners - Bolted joints including eccentric loading, Knuckle joints, Cotter joints – Welded joints- Butt, Fillet and parallel transverse fillet welds – welded joints subjected to bending, torsional and eccentric loads, riveted joints for structures - theory of bonded joints

UNIT IV - DESIGN OF ENERGY STORING ELEMENTS AND ENGINE COMPONENTS

Types of springs, design of helical and concentric springs–surge in springs, Design of laminated springs - rubber springs - Flywheels considering stresses in rims and arms for engines and punching machines-- Solid and Rimmed flywheels- connecting rods and crank shafts

UNIT V - DESIGN OF BEARINGS AND MISCELLANEOUS ELEMENTS

Sliding contact and rolling contact bearings - Hydrodynamic journal bearings, Sommerfeld Number, Raimondi & Boyd graphs, -- Selection of Rolling Contact bearings –Design of Seals and Gaskets

UNIT I - BASICS OF METROLOGY

Measurement – Need, Process, Role in quality control; Factors affecting measurement - SWIPE; Errors in Measurements – Types – Control – Measurement uncertainty – Types, Estimation, Problems on Estimation of Uncertainty, Statistical analysis of measurement data, Measurement system analysis, Calibration of measuring instruments, Principle of air gauging- ISO standards

UNIT II - MEASUREMENT OF LINEAR, ANGULAR DIMENSIONS, ASSEMBLY AND TRANSMISSION ELEMENTS

Linear Measuring Instruments – Vernier caliper, Micrometer, Vernier height gauge, Depth Micrometer, Bore gauge, Telescoping gauge; Gauge blocks – Use and precautions, Comparators – Working and advantages; Opto-mechanical measurements using measuring microscope and Profile projector - Angular measuring instruments – Bevel protractor, Clinometer, Angle gauges, Precision level, Sine bar, Autocollimator, Angle dekkor, Alignment telescope. Measurement of Screw threads - Single element measurements – Pitch Diameter, Lead, Pitch. Measurement of Gears – purpose – Analytical measurement – Runout, Pitch variation, Tooth profile, Tooth thickness, Lead – Functional checking – Rolling gear test

UNIT III - TOLERANCE ANALYSIS

Tolerancing– Interchangeability, Selective assembly, Tolerance representation, Terminology, Limits and Fits, Problems (using tables IS919); Design of Limit gauges, Problems. Tolerance analysis in manufacturing, Process capability, tolerance stackup, tolerance charting

UNIT IV - METROLOGY OF SURFACES

Fundamentals of GD & T- Conventional vs Geometric tolerance, Datums, Inspection of geometric deviations like straightness, flatness, roundness deviations; Simple problems – Measurement of Surface finish – Functionality of surfaces, Parameters, Comparative, Stylus based and Optical Measurement techniques, Filters, Introduction to 3D surface metrology- Parameters

UNIT V - ADVANCES IN METROLOGY

Lasers in metrology - Advantages of lasers – Laser scan micrometers; Laser interferometers Applications – Straightness, Alignment; Ball bar tests, Computer Aided Metrology - Basic concept of CMM – Types of CMM – Constructional features – Probes – Accessories – Software – Applications – Multi sensor CMMs.

Machine Vision - Basic concepts of Machine Vision System – Elements – Applications - On-line and in process monitoring in production - Computed tomography – White light Scanners