Elements of Mechanical Engineering – Module 1

MODULE 1:
Introduction to Mechanical Engineering (Overview only):

Role of Mechanical Engineers in Industries and Society- Emerging Trends and Technologies in different
sectors such as Energy, Manufacturing, Automotive, Aerospace and Marine sectors and contribute to
the GDP

Steam Formation and Application:

Formation of steam and thermodynamic properties of steam (Simple Problems using Steam Tables),
Applications of steam in industries namely, Sugar industry, Dairy industry, Paper industry, Food
processing industry for Heating/Sterilization, Propulsion/Drive, Motive, Atomization, Cleaning,
Moisturization, Humidification

Energy Sources and Power Plants:

Review of energy sources; Construction and working of Hydel power plant, Thermal power plant,
nuclear power plant, Solar power plant, Tidal power plant, Wind power plant.

Principles of Turbo-machines:

Principle and Operation of Hydraulic turbines namely, Pelton Wheel Turbine, Francis Turbine and
Kaplan Turbine. Introduction to working of Centrifugal Pumps.

1 Role of Mechanical Engineers in Industries and Society

• Mechanical engineering is the branch of engineering which deals with the design,
manufacturing, maintenance and testing of machines. It is also considered as one of the most
diverse and versatile disciplines of engineering. Mechanical engineering also includes the
application of mechanics, material science, applied mathematics and physics.

• With the rise of modern technology, mechanical engineering has witnessed new found
importance with more and more students opting to learn less explored domains of robotics,
mechatronics, nanotechnology, etc.

• Mechanical also developed machine and tool that produce product that range from sport
equipment to pharmaceutical devices, medical devices, personal computers, humidifiers,
dehumidifiers, automobile engines, robotic arms, electrical power plants and solar driers.
Mechanical engineer usually touches all section of life.

2 Emerging Trends and Technologies

2.1 Biotechnology.
Including biopharma; tissue engineering/regenerative medicine; synthetic biology; and bio-inspired
manufacturing using self-assembly.

2.2 Nanotechnology.
Including carbon nanotubes; Nano composite structural materials; Nano electronics; nanotechnology-
based coatings; nanoparticles; and Nano-tagging.

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2.3 Micro technology.

Including micro tooling (for replication) manufacturing and micro-systems in machine tools and
products.

2.4 Information and communication technology (ICT) in manufacturing systems.

Including intelligent mechatronic systems for automation and robotics (e.g. self-adapting
components) and advancement of grid computing for manufacturing.

2.5 Advanced materials.

Including advanced composites and “meta materials”.

3 Role of Mechanical Engineers

3.1 Materials and metals industry –
This job role demands the design, development and testing of a wide variety of complex
mechanical system. This will include the entire life cycle maintenance of the mechanical items
that are used in the plant. A few of those are gas and steam turbines, pipework, valves, fans,
coals mills and so on.

3.2 Rail industry –

The overhead line systems need specifications to be written, designs to be reviewed and
technical queries to be answered which falls in the interest of mechanical engineers. Some of
them diversify and become track engineers which entails the same functions, but the focus
shifts to the track systems.

3.3 Chemical industry –

The main function of mechanical engineers in the chemicals industry is to deliver
improvements in reliability, offer technical support that include a variety of automated
production equipment such as conveyors, pipework, robotics, pumps, industrial ovens, valves
and so on.

3.4 Construction industry-

The role of mechanical engineers in this sector is the designing of the ventilation, smoke
ventilation systems, heating, and air conditioning systems that are installed in buildings. The
range of their projects can include offices, shopping malls, universities, railway stations and
hospitals. They take on additional technical discipline responsibilities in coordination with the
requirements of the clients.

3.5 Electronics industry-

The role of mechanical engineers in this industry is primarily concerned with designing
machines that produce power. The types of machines are internal combustion engines, steam
and gas turbines, electric generators. The power consuming machines such as air conditioners
and refrigerators are also included. The elevators and escalators that are used inside buildings
are designed by mechanical engineers.

3.6 Biomechanical engineering-

In this field, the musculoskeletal system of the human body is viewed as a mechanical
structure that can undergo certain motions and stresses. The principles of force, energy and
motion are being concern, mechanical engineers use their knowledge of design, manufacture,

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and operational processes to advance the world around us, improve safety, ability to manage
economic with strength and enjoyment throughout the world.

4 Different sectors in Mechanical Engineering

4.1 The Energy Sector
• It is one of the major inputs required for economic development of any country and in
developing countries, the energy sector assumes a critical importance in view of the ever-
increasing energy needs requiring huge investments.

• Mechanical engineers in the energy industry to design and operate fossil fuel, hydroelectric,
conventional, nuclear, and cogeneration power plants. They are involved in all aspects of the
production and conversion of energy from one form to another.

• Mechanical engineers can work in every stage of renewable energy development and
distribution. Research different materials and study material interactions for use in renewable
energy, potentially leading to the development of new systems, technologies and
infrastructure for generating and distributing power.

4.2 The Manufacturing Industry

• Internet of things in manufacturing- The Internet of Things (IoT) is a network of physical
devices that are embedded with sensors and, software that make them the “eyes and ears”
in a vast range of use cases. From home automation (intelligent thermostats, connected
doorbells, smart coffee makers) to industrial automation (electric vehicles, robotics, medical
imaging) IoT is everywhere, talking to each other, receiving and sharing data amongst
themselves without any human or computer interaction.

• Big data- Some examples of different types of big data in manufacturing are productivity data,
sensors on machines and power consumption information from different machinery. It can
also be integrated from outside partners or vendors. Big data in manufacturing becomes
valuable only if one centralized view can be created. This is the “hub” into which all data must
flow.

• Automation and Artificial Intelligence in manufacturing- Manufacturers are already deploying

automation on the factory floor as well as in their offices. We will continue to see the
expanding usage of artificial intelligence in manufacturing for productivity improvements. AI
will power demand planning, inventory planning, logistics and production scheduling.

• Additive manufacturing or 3D printing- Additive manufacturing, so-called because it adds

material in layers to create an object, uses CAD software or 3D object scanners for digitally 3
d printing machine parts. It deposits material in layers, in precise geometric shapes. Parts can
then be stored as design files in virtual inventories to be produced whenever needed, which
is known as distributed manufacturing. Transportation distances and costs are reduced and
inventory management is simplified by storing digital files.

• Augmented Reality: Touchless Service Model- With the manufacturing sector beginning to
explore VR, the potential for this manufacturing technology, in assembly processes,
maintaining equipment and improved decision making is huge. For instance, factories could
use augmented reality (AR) glasses to project data such as layouts, assembly guidelines,
possible malfunction sites, or serial numbers for parts, enabling faster and easier workflows.

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4.3 The Automotive Industry

• This industry is one of the fastest growing and has therefore opened up numerous job
opportunities. The role of a mechanical engineer spans the design, manufacturing and
maintenance of motor vehicles. With the advancement in technology when breakthrough
ideas like driverless cars, pod-based transportation systems, bullet trains, are being
considered. Top companies and automobile brands are investing a lot on research and
recruiting skilled and passionate mechanical engineers.

• The need to replace various composites, plastics and aluminum alloys with sheet-metal steel,
which is essential to the torque of an electric motor and minimizing the overall loss of its
energy as heat.

• The increased demand for lithium-ion (Li-ion) batteries. Navigant Research estimated the
market for vehicle-specific Li-ions at $7.8 billion in 2015 and projected it would reach $30.6
billion in 2024.

• The design, testing and installation of the different infrastructures supporting EVs. For
example, mechanical engineers may contribute to the roadside charging stations necessary
for recharging an EV on the go.

4.4 The Aerospace Industry

• Aerospace industry – This industry has witnessed a lot of innovations and discoveries. Flying
cars to reusable satellites, rockets are now not unheard of as technology is progressing so is
the demand for newer inventions. Numerous job roles are being offered here ranging from
design, to manufacture to testing to R&D. The mechanical engineers get a chance to employ
the principles of physics to aeromodelling and dynamics to improve the design and efficiency
in systems.

• Additive Manufacturing Consolidates and Lightweights Aerospace Parts. Autonomous Flight

Systems Will Be the Future of the Aerospace. Industry Advances in materials have led to a
variety of possibilities for aerospace companies. The majority of this has been seen through
the increased use of carbon nanotubes and graphene, providing several benefits.

• The most notable of these have been seen by making planes more efficient by reducing weight
and less fuel consumption. As a result, there can be a lower cost associated with traveling.

• 3D Printing: The cost reduction seen with 3D printers; companies can see significantly less
time spent on the R&D phase. By doing so, firms will reduce the time it takes to design a
product and release it to the market.

4.5 The Marine Industry

• Mechanical engineers in this industry design and build or operate and maintain equipment
and marine vessels. These engineers design, install, or maintain engines, shafts, boilers and
propellers. They could be a part of the team that enforces regulations for air and sea pollution
or be a part of designing futuristic cleaner ships. Marine engineering is a specialized branch of
mechanical engineering devoted to the design and operation of systems, both mechanical and
electrical, needed to propel a ship.

• The complex mechanical systems are designed, developed and tested by the mechanical
engineers in this sector. This is done through the use of 3D modelling and a variety of analysis
tools, that ensure that the thermal properties, manufacture, mass, structural integrity, cost of

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the equipment and its assembly are in accordance with the operating environments of land,
air and sea.

• Advances in shipbuilding, propulsion, smart shipping, advanced materials, big data and
analytics, robotics, sensors and communications in conjunction with an increasingly skilled
workforce are all having monumental shifts in how the maritime industry are approaching
new challenges and opportunities.

5 GROSS DOMESTIC PRODUCT – GDP

• GDP- It is the Total market value of the goods and services produced by a country’s economy
during a specified period of time. It includes all final goods and services—that is, those that
are produced by the economic agents located in that country regardless of their ownership
and that are not resold in any form. It is used throughout the world as the main measure of
output and economic activity.

• GDP per capita (also called GDP per person) is used as a measure of a country’s standard of
living. A country with a higher level of GDP per capita is considered to be better off in
economic terms than a country with a lower level.

• Each country prepares and publishes its own GDP data regularly. In addition, international
organizations such as the World Bank and the International Monetary Fund (IMF) periodically
publish and maintain GDP data for many countries.

• Its scope includes the process and policies by which a nation improves the economic, political,
and social well-being of its people. Its focus is not only on methods of promoting economic
growth and structural change, but also on improving the potential for the mass of the
population, for example, through health and education and workplace conditions, whether
through public or private channels.

• Economic development is the increase in the amount of people in a nation’s population with
sustained growth from simple, low-income economy to a modern, high-income economy.

• The Indian engineering sector accounts for 5 percent of India's GDP. Rising domestic demand,
increasing investment and growth opportunities, favorable government policies and global &
domestic focus on establishing low-cost plants have propelled the engineering sector to
greater heights. The contribution the engineering sector to India’s GDP over the three years
can be categorized on the basis of cost, the manufacturing segment and pure engineering
industry.

• In the last few years alone, the engineering and machinery sector has played a crucial role in
boosting the Indian economy and also contributed towards the promotion of associated
industrial sectors of the country.

• An impressive 39 per cent of India’s engineering goods and services were exported to the US
and Europe in 2013-14 and 30 per cent to other Asian countries

• India has emerged as a global engineering hub. Several global manufacturing majors have
partnered with Indian firms in setting up successful engineering units across the country.

• With the entry of foreign players, competition has further increased, spurring domestic
investment in technology to significantly improve production quality and capacity.

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Increasingly, domestic players are securing ISO 9,000accreditation to further strengthen their
position in the global market.

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