Sem4

UNIT NO 1

Foundry: Pattern making, moulding and casting
Importance of casting as manufacturing process, advantages and disadvantages of casting processes, foundry layouts and mechanization
2. Introduction to patterns, core boxes and gating systems: types of patterns, pattern
materials, pattern making allowances, core boxes, core making, core prints, components of gating system, functions and importance of runners and risers, solidification control devices: chills, ceramics bricks, progressive and directional solidification, sand properties
(Note: Numerical treatment of gating and riser system design)
3. Hand and machine moulding
4. Melting and pouring - melting furnaces- fuel fired, electric arc and induction furnaces. Cleaning, finishing of casting, casting defects anremedies
5. Advanced casting methods: Lost wax processes, shell moulding and investment casting. Permanent mould dies casting- Die-casting, centrifugal casting, and continuous casting.
6. safety and environmental aspects of manufacturing processes.

UNIT NO 2

Metal Forming Processes
Hot, cold and worm working. Recovery and Recrystallization. Formability and parameters affecting the yield strength of materials. Classification of various metal Forming processes, their special features with respect to other manufacturing
processes. Friction and lubrication in Metal Forming processes. Stresses in Metal Forming process.
Forging: Basic operations, types of forging, forging hammers/ presses, forging stages and force calculations, die design considerations, forging applications, Defects and remedies in forging process.

UNIT NO 3

Rolling
Classification of rolling processes, rolling mill types, condition for natural entry in rolling operation, number of passes in rolling, roll bite, elongation, reduction, rolling of sheets, plates, bars, sections and tubes. Applications, defects and remedies in rolling process.
Extrusion: Equipment and principles, types of extrusion, direct, indirect, impact, continuous, hydrostatic, tube extrusion, metal flow in extrusion, Die design considerations, factors affecting extrusion load, defects and remedies in extrusion.
Drawing: Types of Drawing, Rod and wire drawing, Die Design considerations, equipment and principles of process, Tube drawing, defects and remedies in drawing.

UNIT NO 4

Joining Processes
1. Introduction, classification of joining processes
2. Arc welding- Theory, SMAW, GTAW, GMAW, FCAW, Submerged arc welding, Stud
welding, Resistance welding- Theory, spot and seam projection welding processes
, Gas welding Friction welding, Ultrasonic welding, Thermit welding, EBW and LASER welding
3. Welding defects and quality control in welding

UNIT NO 5

Design of Jigs and Fixtures
Definition, Applications, basic elements, principles and types of locating, clamping and indexing elements, auxiliary elements like tenon, setting block etc. Type of Drilling jigs and Milling fixtures-Design consideration of Jigs and fixtures with respect to different operations.

UNIT NO 6 

Press Tools
Elements of Dies and Punch set. Types of dies – simple, compound, combination and progressive dies and punches of various press working operations such as punching, blanking, drawing, bending, forming, coining etc. Design of Blanking die, Progressive die,
Calculations of clearances, center of pressure, different forces, press tonnage, strip layout, sheet utilization ratio, methods of reducing forces.

Note: 1. The unit no.V, includes drawing a jigs/ fixtures for simple objects whereas unit no. VI, includes drawing sheet on press tools.
2. The course includes numerical treatment on the appropriate modules of various units.)
Suggested list of Assignments:
Each Student has to write at least 6 assignments on entire syllabus.

Second Year B. Tech, (Mechanical Engineering) ,Semester IV
Course Code PCC 221
Course Category Professional Core Course
Course title Fluid and Turbo Machinery

Course Objectives The course is aimed at –

1.To understand impulse momentum principle and its applications
2. To learn the working principles of impulse and reaction water turbines.
3. To illustrate the concept of different types of pumps and compressor.
4.Train the students to acquire the knowledge and skill of analyzing different
turbo machines

Course Outcomes Upon completion of this course, student should be able to –

1. To design and calculate different parameters for turbo machines.
   2. To understand thermodynamics and kinematics behind turbo machines.
   3. To formulate design criteria.
   4. To understand the concept of centrifugal and axial compressors.   Unit
   No.
   Course Content:-
   I Impulse Water Turbines:- 
   Introduction to turbo machinery, Classifications, Machines classification of water
   turbines, Pelton wheel, its construction and working, velocity triangles. Pelton wheel
   design bucket dimensions, number of buckets, jet diameter, wheel diameter, jet
   ratio, speed ratio, number of jets, calculation of efficiency, power, discharge etc.
   Governing of Pelton wheel.
   (Note: The chapter includes numerical treatment on the appropriate topics.)
   6 hours
   II Reaction Water Turbines
   Principle of operation, construction and working of Francis and Kaplan Turbine, effect of
   modification of velocity triangles on runner shape, draft tube, calculation of various
   efficiencies, power, discharge, blade angles, runner dimensions etc. Governing of Francis
   and Kaplan turbine. Draft tube-types and analysis. Compare the impulse and reaction
   turbines with each other.
   6 hours             Centrifugal Pumps
   Working principles, Construction, various heads, multistage pumps, velocity
   triangles, minimum starting speed, cavitation, MPSH and NPSH. Methods of priming
   calculations of efficiencies, discharge, blade angles, head, power required, impeller
   dimensions etc.
   (Note: The chapter includes numerical treatment on the appropriate topics.)
   6
   IV Similarity Principles
   Model testing, unit quantities, Specific speed of turbine (Pelton wheel, Francis
   turbine, Kaplan turbine), specific speed of pumps. Prediction of performance at
   other operating conditions. Performance characteristics of Turbines and pumps.
   (Note: The chapter includes numerical treatment on the appropriate topics.)
   6
   V Air compressors
   Application of compressed air , classification of compressor, reciprocating compressors,
   construction , work input, necessity of cooling , isothermal efficiency, heat rejected,
   effect of clearance volume, volumetric efficiency, necessity of multi staging,
   construction, optimum intermediate pressure for minimum work required, after cooler,
   Roots blower and vane blower (descriptive treatment)
   (Note: The chapter includes numerical treatment on the appropriate topics.)
   6
   VI Rotodyanamic Air Compressors
   Centrifugal compressor- velocity diagram, pre whirl, slip factor, performance
   calculations. Axial flow compressors- velocity diagram, degree of reaction, polytropic
   efficiency, surging, chocking, stalling, performance, comparison with centrifugal. Screw
   compressors.
   (Note: The chapter includes numerical treatment on the appropriate topics.)
   Suggested list of Tutorials and Assignments:
   Each Student has to write at least 6 assignments on entire syllabus.
   6
   Text Books
   1. “Fluid Mechanics & Hydraulic Machines”, Dr. R.K. Bansal, Laxmi Publications LTD, revised 9th
   Edition
   2. “Steam and gas Turbines”, R. Yadav, Central Publishing House, Allahabad, 6th Edition , 1997 .
   3. “Gas Turbines”, V. Ganeshan, Published by TMH Education Pvt. Ltd. , 3rd Edition.
   4. “Thermal Engg.”, Kumar vasant dani, Khanna publisher
   5. “Thermal Engg.”,P.L. Balleny, Khanna publisher. , 20th Edition
   Reference Books
   1. “Hydraulic Machines” V.P. Vasantdani
   2. “Fluid flow machines” N.S. Govindrao
   3. “Turbo machines” S.M. Yahya
   4. “Fluid power Engineering” D.S. Kumar
   5. “Steam and gas Turbines” R. Yadav
   6. "Fluid Mechanics",White McGraw Hill Publication
   7. "Advanced Fluid Engineering", Murlidhar, Narosa Publication.
   8. "Fundamentals of fluid mechanics", G.S.Sawhney I.K. International Publishing House Pvt.
   Limited, New-Delhi, 2008 New York
   9. "Mechanics of Fluid",Irving Shames McGraw Hill Publication