SYLLQBUS WT

 

ME- 105F                               WORKSHOP TECHNOLOGY

L       T       P                                                                                  Class Work: 50 Marks

2       0       2                                                                                         Examinations: 25 Marks

                                                                                                                 Total: 75 Marks                                                                                                                                                        Duration of Exam:  3 Hrs.

NOTE: -

1. At least ten experiments/ jobs are to be performed/ prepared by students in the semester. 

2. At least 8 experiments/ jobs should be performed/ prepared from the above list, remaining two

 May either be performed/ prepared from the above list or designed & set by the concerned

 Institution as per the scope of the syllabus of the   ‘Manufacturing Processes’ as mentioned

 Below.

Manufacturing Processes:

Introduction to Manufacturing Processes and their Classification. Industrial Safety; Introduction, Types of Accidents, Causes and Common Sources of Accident, Methods of Safety, First Aid., Objectives of Layout, Types of Plant Layout and their Advantages.

Foundry, Forming and Wielding:          

Foundry: Introduction to Casting Processes, Basic Steps in Casting Processes. Pattern: Types of Pattern and Allowances. Sand Casting: Sand Properties, Constituents and Preparation. Mould & Core making with assembly and its Types. Gating System. Melting of Metal, Furnaces and Cupola, Metal Pouring, Fettling. Casting Treatment, Inspection and Quality Control. Sand Casting Defects & Remedies.

Forming Processes: Basic Principle of  Hot & Cold Working, Hot & Cold Working Processes, Rolling, Extrusion, Forging, Drawing, Wire Drawing and Spinning. Sheet Metal Operations: Measuring, Layout marking, Shearing, Punching, Blanking, Piercing, Forming, Bending and Joining.

Welding: Introduction to Welding, Classification of Welding Processes, Gas Welding: Oxy-Acetylene Welding, Resistance Welding; Spot and Seam Welding, Arc Welding: Metal Arc, TIG & MIG Welding, Welding Defects and Remedies, Soldering & Brazing.

 

 

 

 

List  of Experiments/ Jobs

1.            To study different types of measuring tools used in metrology and determine least counts of vernier calipers, micrometers and vernier height gauges.

2.            To study different types of machine tools ( lathe, shape or planer or slotter, milling, drilling machines )

3.            To prepare a job on a lathe involving facing, outside turning, taper turning, step turning, radius making and parting-off.

4.            To study different types of fitting tools and marking tools used in fitting practice.

5.            To prepare lay out on a metal sheet by making and prepare rectangular tray, pipe shaped components e.g. funnel.

6.            To prepare joints for welding suitable of r butt welding and lap welding.

7.            To perform pipe welding.

8.            To study various types of carpentry tools and prepare simple types of at least two wooden joints.

9.            To prepare simple engineering components/ shapes by forging.

10.         To prepare mold and core assembly, to put metal in the mold and fettle the casting.

11.         To prepare horizontal surface/ vertical surface/ curved surface/ slots or V-grooves on a shaper/ planner.

12.         To prepare a job involving side and face milling on a milling machine.

Tuttorials

INSTRUCTIONS:  1 Use of unfair means and copying from the books or from fellow students is strictly prohibited.

                          2. Write answers/give reply in your own words to reflect your original contribution.

                          3. Get clarified/ addressed your doubts, queries or problems to help your self study process.

                          4. Feel free to interact/ express your views or opinion/ share your knowledge to help  others                                    learn from you only.

TUTORIAL/CASE NO.-1       SCHEDULED date ____________________­­­­­­­

Q.No.1         An open belt connects two flat pulleys. The smaller pulley is 600 mm in diameter and turns 200 revolutions per minute. The angle of lap on the pulley is 160⁰ and pulley face is 0.25. If maximum permissible tension in belt is 2500 N, calculate the power transmitted by belt.

Q.No.-2           During a tensile test on a mild steel specimen, 40 mm diameter and 200 mm long. The following data were obtained:

Extension at 40 KN load =0.0304 mm, Yield load =161 KN and length of specimen at fracture=249 mm.

                                    Determine

                                    a)    modulus of elasticity     b) percentage elongation and

                                    c)     Yield point stress.

TUTORIAL/CASE NO.-2                SCHEDULED date ____________________­­­­­­­

Q.No.-1          (a) Draw a neat diagram showing the main elements of a NC machine, and state the function served by each element.

                                    (b) Write the advantages and applications of NC machines.

Q.No.-2       (a) Explain the difference between open and closed loop system control system in relation to NC and CNC machine system. 

(b) How a CNC machine differs from a NC machine? Name the main components of a CNC

                                    system. 

TUTORIAL/CASE NO.-3        SCHEDULED date ____________________­­­­­­­

Q.No.-1           It is desired to compress 10 kg of gas from 1.5 m³ to 0.3 m³ at constant pressure of 15-bar. During this compression process, the temperature rises from 20⁰ C to 150⁰ C and increase in internal energy is 3250KJ. Calculate the work done, heat interaction and change in enthalpy during the process. Also work out the average value of specific heat at constant pressure.

Q.No.-2           Distinguish between a heat engine, a heat pump and a refrigerator.  

TUTORIAL/CASE NO.-4       SCHEDULED date ____________________­­­­­­­

Q.No.-1           (a) Describe, with a neat schematic arrangement, the working of a simple vapour compression refrigeration cycle. Represent the cycle on p-v and T-S plots.

(b) Draw a neat sketch of a centrifugal pump and explain how does it operates?

Q.No.-2        Draw a well labelled neat sketch of a lathe machine and state the functions of its different parts.        

Assignments

INSTRUCTIONS:           1. copying from the books or from assignments prepared by fellow students is strictly prohibited.

                                                2. Write answers in your own words to reflect your original contribution. Refer my BLOG.

                                    3. Make  a file and put the answers in it

ASSIGNMENT NO.-1                  issue date          1.2.2013                 due date              8.2.2013                                RETURN DATE

                                   

Q.No.-1             What is power Transmission? Write the devices and sketch them with their types. Write the factors for choosing the appropriate drive.

                       

Q.No.-2             What is a gear train and train value? Derive the velocity ratio of each train.

           

ASSIGNMENT NO.-2                  issue date          8.2.2013                                due date              15.2.2013              RETURN DATE

Q.No.-1             An open belt connects two flat pulleys. The smaller pulley is 600 mm in diameter and turns 200 rpm. The angle of lap on the pulley is 160 degree and coefficient of friction between belt and pulley face is 0.25. If maximum permissible tension is 2500 N, calculate the power transmitted.

Q.No.-2             A spur gear having 60 teeth is mounted on a shaft of an electric motor running at 1200 rpm. A  parallel counter shaft is required to run in the opposite direction by a simple gear train in mesh. If the speed reduction is 4 and circular pitch of gears is 30 mm, calculate the number of teeth and speed in the counter shaft. Also calculate the centre distance between the gears.

                       

ASSIGNMENT NO.-3                  issue date        18.2.2013 due date      22.2.2013(partly)     RETURN DATE

Q.No.-1             Calculate Modulus of elasticity, Yield stress, Ultimate stress and % elongation and contraction from the following data of a specimen test:

Specimen dia 20 mm, length 50 mm, elongation 0.05 mm, proportion limit load 100 kN, Yield load 115 kN, Ultimate load 200 kN. After rupture length 6.67 cm and dia 1.72 cm..

                                                                                               

Q.No.-2             a)   Give some day- to- day examples on laws of thermodynamics, stress & strain          

b) Manometer measures the pressure of a tank as 250 cm of mercury, density of Hg is      13.6x10³ kg/ m³. Atmosphere pressure is 101 kPa.Calculate tank press in MPa.

c) Considered a gas enclosed in piston-cylinder arrangement. The gas initially at a pressure of 150 k Pa and occupies volume of of 0.03 m³. Gas heated until the volume increased to 0.01 m³. Calculate WD, if volume of gas is inversely proportional to pressure. 

ASSIGNMENT NO.-4                  issue date                                          due date                                              RETURN DATE

                       

Q.No.-1             A Pelton wheel is required to develop 6 Mw, while working under head of 300 m. It rotates with a speed of 550 rpm. Assuming jet ratio is 10and overall efficiency 85% calculate i) dia of pelton wheel ii) quantity of water i.e. flow iii) number of jets. Assume suitable VR and velocity coefficient.

Q.No.-2             a) Make sketch of Lathe, Milling & Shaper machine tools and name the main parts.

                       

b) What is rating of refrigeration?

i) The capacity of the system is 12 tons what is cooling rate of machine?

ii) 250 litres of drinking water is required per hour at 10ºC. Would the use of 1.5 ton refrigerating system be justified, if water is available at 30ºC.

iii) A refrigerating machine takes1.25 kw and produces 25 kg/ hr of ice at 0ºC from water at 30ºC. Determine refrigerating effect, tonnage and COP. Sp heat of water is =4.18 kJ/ kg K, Enthalpy of solidification of water from and at 0ºC=335 kJ/ kg.

                       

c) Download the questions from my blog and answer from my notes posted on blog.

Contd: & Important questions

    Dear Students,                                                          Dtd:  8.1.2013 
    I know exam is on 11.1.2013 and go through the following on tomorrow and day after
 Fig. 2 Block diagram of a lathe-principal parts of lathe machine, Operations involved on the machines 
Taper turning methods.  Principals of working of a shaper, principal parts of a shaper- Fig. 31 shaping operations (1.5.7) 
Principal of working of a planer:   Types of planing machine and parts of planer (Fig. 35) and that of milling machine.(Fig. 41)and drilling machine ( Fig 59).......
Single point cutting tool (Fig. 76) .    Chip formation & types of chips.(1.10.9), (1.10.10)
Refer highlights of Chapter 1 for answers page # 1.62           Refer Vineet Jain's book.
Important Questions:  are shown in dark black.
(Q Nos are1,4,6,8,9,10,11,13,15,16,18,21,22,25,27,32,34,35,37,39,42,43,45,46)
 1. What is thermodynamic and the  laws on which it is based?
 2. What is thermodynamic equilibrium and explain types?
 3. Write short note on heat and work.
 4. Explain the Zeroth law of Themodynamic. 
 5. Explain i) Constant volume process ii) Constant pressure process iii) Isothermal process iv) Adiabatic process
 6. State the second law of thermodynamic with Kelvin Plank and Clausius statements.
 7. Explain third law of thermodynamics.
 8. Explain the Enthalpy, Internal Energy and Entropy. 
 9. Study graph on properties of steam.
10  What are types of steam i.e. Wet steam, Dry steam, Saturated steam and Superheated steam?
11  What dryness fraction? How do we get dryness fraction?
12. What are the properties of steam? (specific press, specific volume, specific temp, specific enthalpy, specific entropy and specific internal energy.
13. What is steam table and mollier chart. Numerical explained in class.
14. What is boiler? which factors effect the boiler selection?
15. What is Refrigeration and Air conditioning?
16. What do you mean by rating of refgrigerating machine? What is TR?
17. Explain COP.
18. Explain simple vapour compression refrigeration system/ cycle (VCRS or VCRC).
19. Whart are the elements/ parts of VCRC? 
20. What is refrigerant? and classify refrigerants.
21  What is Psychrometry and the chart shows?
22. Write short note on human comforts.
23 .What are hydraulic machines? give examples.
24  What is hydraulic turbine and pump? classify turbines and pumps.
25. Explain impulse and reaction turbine.
26. Define: Tangential, axial, radial and mixed flow turbines.
27. Explain the construction & working of a Pelton wheel/ turbine.with a neat diagram.
28 .Explain the construction & working of a Francis turbine.with a neat diagram. 
29. Explain the construction & working of a Kaplan turbine.with a neat diagram.
30 .Explain sp. speed and What is range of specific speed? 
31. What is draft tube?
32. What is Centrfugal and Reciprocating pump? Differentiate.
33. What is priming? Why is it necessary?
34. What do you mean by power transmission? State the methods and devices.
35. Explain belt drives with neat sketches  and material of the belt
36. What is slip and how it affects the velocity ratio?
37. What is velocity ratio? Give an expression for open and crossed belt drive.
38. Derive tension ratio and power transmission derivation.
39. Explain clutch, gear drives and classifications for both.
40. Explain single and multiple clutch with diagrams.
41. Explain stresses, strains, Hook's law, young modulus, Modulus of elasticity, bulk modulus and modulus of rigidity.
42. What is poisson's ratio?
43. Draw a typical stress-strain diagram/ curve for a ductile specimen.
44. Define factor of safety and its significance.
45. Establish relationship between E, G and K.
46. Stresses on compound bar.
47. What is beam?
 Refer my BLOG and Book for answers, which are not on blog.. 
.     

Manfacturing System

Dear BME Students,

Since I am on vacation leave, my material is in college. I will join college on monday dtd: 7.1.13 and I will post important questions on tuesday.
Most of the chapters are on the blog.

Manufacturing Process:
It is not only simple manufacturing.. Priming shaping,  Machining,  Surface finishing,  Joining  and Changing the properties of material of the product. Manufacturing System cosists of following:

1.  Manufacturing Support System                    
2   Quality Control System                                              Refer fig 1 on page 8.1 of Vineet Jain's Book.
3.  Material Handling System
4.   Automation and Control Technologies 

Production System is the collection of people, equipment and procedures for manufacturing operation of a company or organisation. Producing any product has to be attained by the following:
Ordering, Tendering, Stores & Inventory, Purchase, Transportation, Material handling, Production methods i.e. process-lines Inspection, Despatch, Loading/ unloading. Now a days these all activities are controlled by computerisation and on fingure tips.
Study Chapter 8 of the jain's book.

Prepare Lathe, Shaper and Milling machines.
What to do?    Write machine tools as dictated in class, parts of machine, Line Diagram (Figure), Main operations, specification and safety precautions.

Difference between Shaper & Planner    and     between  Shaper and Slotter

Most important question on NC macihine ( fig 10)  page 8.10 ( important mediums)  fig 15. Procedure of production through NC  Classification and advatages of NC machine.   Difference of NC & CNC