SV COLLEGE OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

BASIC CIVIL & MECHANICAL ENGINEERING
(PART-B)
MATERIAL

BCME-PART-B
 UNIT -1
1. What are ferrous materials? list any two properties?.

 Ferrous metals are metals that consist mostly of iron and small amount of other
elements.
 Ferrous metals are prone to rusting if exposed to moisture
 Ferrous metals can also be picked up by the magnet.
 The rusting and magnetic properties in ferrous metals are both down due to the iron.
 Typically ferrous metals include mild steel, cast iron steel.

2. Write a short note on smart materials?.

 Smart materials, also called intelligent or responsive materials, designed materials

 that have one or more properties that can be significantly changed in a controlled
fashion by external stimuli, such as stress, moisture, electric or magnetic fields, light,
temperature, pH, or chemical compounds.
 Smart materials are the basis of many applications, including sensors and actuators, or
artificial muscles, particularly as electroactive polymers (EAPs).
 There are a number of types of smart material Some examples are as following.
 Piezoelectric
 Shape-memory alloys
 Photovoltaic
 Electroactive polymers
 Magnetostrictive.etc.,

3. State the different forms of energy ?.

 Energy is the ability to do work. In Scientific term, Energy is defined as the quantitative
property that is transferred to a body or physical system.
 Energy is divided into mainly two types: 1. Kinetic Energy and 2. Potential Energy.

BCME-PART-B
  They are later divided into many types based on forms of energy such as light energy,

gravitational energy, electrical energy, nuclear and many more.

4. Write any two nonferrous materials.

 When a metal is defined as non-ferrous it means that it does not have a significant
amount of iron in its chemical composition
 Another characteristic of non-ferrous metals is that they are not magnetic.
 There are a variety of non-ferrous metals in use in the industry today. Listed below are a
variety of the more popular ones:
1. Aluminum
2. Copper
3. Nickel
1. Aluminum

Aluminum is a very widely used type of non-ferrous alloy. In its unanodized form, it has a silvery
color. Without the addition of alloying elements, it is more ductile and not quite as strong as
many steels

2. Copper

BCME-PART-B
Copper is another very popular non-ferrous alloy. Copper is a metal that is somewhere between
red and brown in color. In its unalloyed state, it too is softer, more ductile, and not as strong as
carbon steel.

5. What is composite material.

 A composite material will form by mixing at least two or more insoluble materials
together. The base material is called as Matrix material and additives are called as
Reinforce materials

 In composite materials quantity of weight or volume fraction for the Matrix and
Reinforcement materials are, like as

 Metal material 60-95%

 Reinforcement material 40-at least 5%
Matrix phase
 The primary phase, having a continuous character,
 Usually more ductile and less hard phase,
 Holds the reinforcing phase and shares a load with it.
Reinforcement
 Second phase (or phases) is imbedded in the matrix in a discontinuous form,
 Usually stronger than the matrix, therefore it is sometimes called reinforcing
phase.

6. Write technologies used in Manufacturing industry?.

The following technologies is currently used in the manufacturing industry

 Robotics or Artificial Intelligence
 Big Data
 Augmented Reality
 Nanotechnology
 3D Printing
 Cloud Computing

BCME-PART-B
  Internet of Things

7. Write a short note on ceramics?

 A ceramic is a material that is neither metallic nor organic. It may be crystalline, glassy or
both crystalline and glassy. Ceramics are typically hard and chemically non-reactive and
can be formed or densified with heat.
 Ceramics are two types traditional ceramic and advanced ceramic.
 Traditional ceramics, ceramic materials that are derived from common, naturally
occurring raw materials such as clay minerals and quartz sand.
 The term advanced ceramics refers to all the products made from inorganic, high-purity
compounds through a series of specialized manufacturing processes. Advanced ceramics
can be used for various purposes due to their permeability, magnetism, insulation, and
conduction. Alumina, Aluminum Nitride, Zirconia, Silicon Nitride are the examples for
the advanced ceramics

8. What are the Sub disciplines of Mechanical Engineering?

The following are the sub disciplines of mechanical engineering: Mechanics, Thermodynamics,
Material science and Engineering, Manufacturing Engineering, Automobile Engineering and
Aero space Engineering.

9. mechanical engineering jobs in the automotive industry

1. Automotive technician
2. Mechanical designer
3. Quality assurance engineer
4. Design engineer
5. Project engineer
6. Manufacturing engineer
7. Mechanical engineer
8. Process engineer
9. Automation engineer

BCME-PART-B
10. List out types of Engineering materials?

 Engineering materials refer to a group of materials used in the construction of man-made

structures and components. The main function of engineering materials is to withstand
the applied load without failure (breaking and excessive deflection). Carbon steel, 
Aluminum, Cast Iron, Stainless Steel, Copper alloys, Plastics, Composites, Nickel alloys, DSS,
etc are examples of engineering materials.

BCME-PART-B
 UNIT – 2
1. Define Engine. What are various types of engines.?

An engine or motor is a machine designed to convert one or more forms of energy into
mechanical energy. Mechanical heat engines convert heat into work via various thermodynamic
processes

Internal Combustion Engines (IC Engines)

In IC engines, combustion of fuel takes place inside the engine cylinder .Examples: Diesel
Engines, Petrol Engines, Gas engines.

External Combustion Engines (EC Engines)

In EC engines, combustion of fuel takes place outside the working cylinder.Examples: Steam
Engines and Steam turbines

2. Define casting in manufacturing process.?

The casting process is a manufacturing method that produces desired-shape metal parts by
pouring molten metal into a mold and solidifying and cooling it to the room temperature

it’s capable of producing complex and intricate parts, irrespective of their sizes. there are
different types of casting that differ by the material and mold used.

BCME-PART-B
Different Types of Casting Process

1. Sand Casting Process

2. Gravity Die Casting
3. Investment Casting
4. Pressure Die Casting
5. Plaster Casting
6. Centrifugal Casting
7. Vacuum Casting
8. Squeezing Casting
9. Continuous Casting

3. What are four strokes in petrol engine.?

A spark-ignition engine (SI engine) is an internal combustion engine, generally a petrol engine,
where the combustion process of the air-fuel mixture is ignited by a spark from a spark plug.

Four stroke petrol engine also known as otto cycle.it requires four strokes of the piston to
complete one cycle of operation in the engine cylinder.

(1)Suction or charging stroke (2)compression stroke (3)expansion or working stroke (4) exhaust stroke

BCME-PART-B
4. Define the term refrigeration.?

The word refrigeration refers to the process of cooling space, material, or system to lower and
maintain its temperature under room temperature. Refrigeration is a type of artificial cooling.
Heat is extracted from a low-temperature reservoir and transmitted to a high-temperature
reservoir. Energy transfer work is classically powered by mechanical means, but it can also be
powered by high temperatures, magnetism, power generation, laser, or other means. Domestic
refrigerators, factory freezers, cold fusion, and air conditioning are all examples of refrigeration
applications.

5. Define machining process.?

Machining is a manufacturing process that involves shaping a piece of material to a final desired
shape by removing material in a controlled manner.

There are two main types of machining operations; conventional and non-conventional

Conventional Machining Process

Also known as traditional machining in manufacturing, this process involves the use of cutting
tools to remove excess materials from a workpiece on direct contact.

1. Turning
2. Milling
3. Drilling
4. Grinding

BCME-PART-B
Non-Conventional Machining Process

1. Electrical Discharge Machining (EDM)

2. Chemical Machining
3. Electrochemical Machining (ECM)
4. Abrasive Jet Machining
5. Ultrasonic Machining
6. Laser Beam Machining (LBM)

6. Write any two forming process.?

Forming Process also known as Metal Forming. It is a large set the of manufacturing processes by
which a raw material is converted into a product. In this process, we apply stresses that can be in
the form of tension, compression, shear, etc. to deform the raw material. Example of forming
processes are sheet metal manufacturing, forging, rolling, extrusion, wire drawing, thread rolling,
rotary swinging, and so on.

Rolling

Rolling is one of the most useful processes of forming. It falls under the bulk-forming process.
The rolling process consists of two or more two rollers in a combination with the metal plate

The main purpose of the rolling process is to reduce the thickness of the metal plates. In the
forming processes, metal is not removed.

BCME-PART-B
Forging

Forging is the process by which a metal can be heated at a very high temperature. The forging
process can be used to give a particular shape to the metal. It usually works due to the compressive
force.

7. Draw P-V and T-S diagram of Otto cycle

 The Otto cycle is an ideal thermodynamic cycle that requires 4-strokes with a piston:
Intake, Compression, Ignition, and Exhaust. The fuel and air mixture is compressed, an
electric spark ignites it, the sudden expansion pushes the piston producing a power
stroke, and the spring action of the piston pushed the combusted gas away.

BCME-PART-B
8. Write various components in hybrid vehicles.

 A hybrid vehicle is a type of car that uses two or more different power sources to move
the vehicle. The most common type of hybrid vehicle is a gas-electric hybrid, which uses
both gasoline and electricity to power the car.
 Hybrid vehicles are becoming increasingly popular as people look for ways to save
money on fuel and reduce their environmental impact.
 The hybrid car has five main components: the gas engine, the electric motor, the battery,
the power control unit, and the regenerative braking system 

9. Draw P-V and T-S diagram of Diesel cycle

 The piston, the crankshaft, and the combustion chamber are the three crucial components
we need to comprehend to grasp the fundamental workings of a Compression-Ignition
engine or

diesel engine.
 There are four processes involved in a typical diesel engine: Suction, Compression,
Expansion, and Exhaust. 

BCME-PART-B
10. Write a short note on Welding process.

 Welding is a fabrication process that join materials like metals by using heat at high
temperatures.
 Welding is a process of permanently joining two parts by the application of heat and (or)
pressure. Filler metal may be added to the joint depending on the welding process and the
type of joint.

Welding processes are broadly divided into two types;

1. Pressure Welding Process

the heat used during the pressure welding process is much less than the melting point of the base
metal. Generally, the additional filler metal is not required during these types of welding
techniques. Resistance welding and Diffusion welding are examples of the pressure welding
process.

2. Fusion Welding Process

the Fusion welding process, joining is done by melting the base metals in the area of contact. No
external pressure or force is required during fusion welding processes and very often filler metal
is also used. The arc welding process is one of the most popular welding processes, which
belongs to the family of the fusion welding process. Commonly used fusion welding processes
are;

BCME-PART-B
 UNIT – 3
1. What are the drives used in mechanical power transmission
systems.
 Mechanical power transmission refers to the transfer of mechanical energy (physical
motion) from one component to another in machines.
 The most common drives are chain drives, belt drives, and gear drives.
 When the distance between the shafts is large, belts or ropes are used and for intermediate
distance chains can be used. For belt drive distance can be maximum but this should not
be more than ten metres for good results. Gear drive is used for short distances.

2. What is Turbine?

Turbine, any of various devices that convert the energy in a stream of fluid into mechanical energy.

Turbines are also divided by their principle of operation and can be:

 An Impulse turbine, which is driven by a high-velocity jet (or multiple jets) of water.
 A Reaction turbine. The rotor of a reaction turbine is fully immersed in water and is
enclosed in a pressure casing. The runner blades are profiled so that pressure differences
across them impose lift forces, just as on aircraft wings, which cause the runner to rotate
faster than is possible with a jet.

3. What is the advantage of nuclear power plant over thermal power

plant.

 Nuclear power stations do not contribute to carbon emissions - no CO2 is given out - it
therefore does not contribute to global warming.
 Nuclear power stations do not produce smoke particles to pollute the atmosphere or emit
gases that contribute to acid rain.
 Nuclear power is reliable. It does not depend on the weather.
 Nuclear power produces a small volume of waste (although that waste is radioactive)

BCME-PART-B
  Low Fuel Cost - The main reason behind the low fuel cost is that it requires little amount
of uranium to produce energy.

4. Write the applications of belt drive?

 Industrial machinery: Belt drives are used in a wide range of industrial machinery such
as conveyor systems, compressors, pumps, and fans.
 Automotive industry: Belt drives are used in the automotive industry to drive various
components such as the alternator, water pump, and power steering pump.
 Agriculture machinery: Belt drives are used in agricultural machinery such as combines
and harvesters to drive various components such as the threshing mechanism, grain
auger, and straw chopper.
 Home appliances: Belt drives are used in home appliances such as washing machines,
dryers, and vacuum cleaners to drive various components such as the drum, blower, and
brush roll.
 Exercise equipment: Belt drives are used in exercise equipment such as treadmills and
stationary bikes to provide a smooth and quiet means of transmitting power from the
motor to the workout mechanism.

5. Define the term Robot.

 A robot is a programmable machine that can complete a task, while the term robotics
describes the field of study focused on developing robots and automation.
 Each robot has a different level of autonomy. These levels range from human-controlled
bots that carry out tasks to fully-autonomous bots that perform tasks without any external
influences.

Types of Robots

 Humanoid robots
 Industrial robots
 Social robots
 Medical robots
 COBOTS

BCME-PART-B
6. What is air conditioning?

 Air-conditioning is that process used to create and maintain certain temperature, relative
humidity and air purity conditions in indoor spaces. This process is typically applied to
maintain a level of personal comfort.
 It's also used in industrial applications to ensure correct operation of equipment or
machinery that need to operate in specific environmental conditions or alternatively to be
able to carry out certain industrial processes, such as welding, which produce
considerable amounts of heat that needs to be disposed of in some manner.

7. What is function of boiler.

 The boiler is commonly defined as a closed vessel into which water is heated to the point
it is converted into steam at the imperative pressure.
 The main function of the boiler is either to produce hot water or steam. The Hot water
boiler heats water for the domestic or commercial purpose of heating and hot water supply,
whereas Steam boilers generate steam to power turbines for power generation and other
various industrial heating applications.

8. What is meant by chain drive?

 Chain drives are a fundamental and versatile method of power transmission widely
employed in various mechanical systems.
 They consist of a flexible looped chain that meshes with sprockets to transfer rotational
motion and power from one component to another.
 These mechanisms find extensive use in a diverse range of applications, from bicycles and
motorcycles to industrial machinery and conveyor systems, due to their efficiency,
durability, and ability to transmit significant loads over both short and long distances.

9. What is the power plant? List out any two power plants.

A power plant is an industrial facility that generates electricity from primary energy. Most power
plants use one or more generators that convert mechanical energy into electrical energy

BCME-PART-B
There are different types of Power Plants depending on the type of resource used for generating
power.

 Thermal power Plant

 Nuclear power Plant
 Hydropower Plant
 GeoThermal power Plant
 Biogas power Plant
 Biomass power Plant
 Solar power Plant
 Wind Power Plant
 Tidal power plant

10. Write about gear drive?

A gear is a toothed wheel that engages another toothed mechanism to change speed or the
direction of transmitted motion. Gears are generally used for one of four different reasons:

 To increase or decrease the speed of rotation;

 To change the amount of force or torque;
 To move rotational motion to a different axis (i.e. parallel, right angles, rotating, linear
etc.); and
 To reverse the direction of rotation.

BCME-PART-B
 UNIT-I

BCME-PART-B
1. Explain the role of Mechanical Engineering in the Aerospace and
Marine Sectors?
 Mechanical engineering combines mathematics, physics and engineering principles with
materials science to design, analyze, create, and maintenance of mechanical systems.
 It is one of the eldest and most varied of the engineering disciplines. It is the branch of
engineering that is concerned with the creation and operation of machinery.
 The mechanical engineering profession demands a good understanding of the main areas
including structural analysis, thermodynamics, mechanics, dynamics, materials science,
and electricity.

Role of Mechanical Engineering in Aerospace

1. Aircraft and Spacecraft Design: Mechanical engineers are involved in the design of
aircraft, spacecraft, and their various components, such as the airframe, propulsion
systems, landing gear, and avionics.
2. Materials Selection: Mechanical engineers work on selecting materials that can withstand
the extreme conditions of aerospace applications, such as high temperatures, high
pressures, and the vacuum of space.
3. Structural Analysis: Mechanical engineers perform stress analysis to ensure the structural
integrity and safety of aircraft and spacecraft components. They assess the effects of
forces, loads, and vibrations on structural elements and make necessary design
improvements.
4. Propulsion Systems: Mechanical engineers design and develop propulsion systems,
including jet engines for aircraft and rocket engines for spacecraft. They focus on
optimizing efficiency, thrust, and fuel consumption while adhering to stringent safety
standards

Role of Mechanical Engineering in Marine

1. Mechanical engineers provide innovative design, construction, installation and repair

solutions for all kinds of marine vehicles as well as offshore installations.

BCME-PART-B
 2. Naval Architecture and Ship Design: Mechanical engineers are involved in the design and
analysis of marine vessels, including cargo ships, passenger ships, and military vessels.
They work on the ship's hull design, propulsion systems, and overall structural integrity.

2.Explain the concepts that define the role of Mechanical Engineering

in Automotive Industry?

Mechanical engineering in the automotive industry is key to developing new types of vehicles,
updating models, repairing existing vehicles and implementing new functionalities and safety
features. There are many mechanical engineers that work on design, manufacturing and
maintenance teams for all the major automotive manufacturers.

9 mechanical engineering roles in the automotive industry

1. Automotive technician
 Automotive technicians are responsible for the maintenance of all mechanical systems,
engines, pumps and other components in production vehicles. They are also responsible
for repairing damaged or broken parts and providing routine inspection reports to ensure
the safe operation of a vehicle
2. Mechanical designer
 Mechanical designers are responsible for the design of all new models and prototypes of
vehicles. They are the people who determine a vehicle's structural layout, the type of
materials, the size and the weight.
3. Quality assurance engineer
 Quality assurance engineers are responsible for the design, development and
implementation of efficient processes and procedures for testing, developing and
implementing new components or parts. They help ensure that they meet manufacturer
and customer expectations.
4. Design engineer
 Design engineers are responsible for the design of all models and prototypes of a vehicle.
They are responsible for the selection and evaluation of materials, components, systems,

BCME-PART-B
 controls and systems integration. They design components to specifications provided by
product development teams or other engineers.
5. Project engineer
 Project engineers are responsible for overseeing the design, development, testing and
implementation of new products or new models for a vehicle intended for mass
production. They are involved in the design and development of manufacturing processes
that their team can use across many vehicles. Many of their daily responsibilities involve
strategic planning, facilitating team meetings and analyzing productivity.
6. Manufacturing engineer
 Manufacturing engineers are responsible for the design, planning and execution of new
manufacturing processes and equipment for the mass production of a vehicle. The goal of
many manufacturing engineering projects is to improve the efficiency and productivity of
manufacturing processes.
7. Mechanical engineer
 Mechanical engineers are responsible for the design, planning and execution of new
automotive components. They research and develop new designs and technologies for
existing or new vehicles. They are responsible for developing processes that their team
can use in the assembly of a vehicle or in the manufacturing of components.
8. Process engineer
 Process engineers are responsible for the design of and implementation of processes that
help the manufacturing process. They are responsible for developing and implementing
new manufacturing processes to reduce costs. Process engineers also implement new
materials, components or procedures and may help their team improve efficiency.
9. Automation engineer
 Automation engineers are responsible for the design, development and implementation
of automated systems that help manufacturing processes run efficiently. This includes the
design and development of modular components that their team can easily integrate into
the manufacturing process.

BCME-PART-B
3. Explain the contributions of Mechanical Engineering to the welfare of
society?

Mechanical engineers are involved in almost every aspect of human existence and welfare,
including machines, cars and other vehicles, aircraft, power plants, automobile parts, and
manufacturing plants etc. A Mechanical Engineer plays a significant role in designing, developing,
and testing machines as well as thermal devices. It also includes systems that are essential to
many aspects of modern society and Industries. They use their knowledge of mechanics,
thermodynamics, materials science, and energy to create solutions that improve the quality of
life of people.

The role of a mechanical engineer in our society is contributed as

Infrastructure and Construction:

 Mechanical engineers are involved in designing, planning, and overseeing the

construction of infrastructure projects such as roads, bridges, buildings, and water supply
systems.
 They ensure structural integrity, safety, and efficiency in construction projects,
contributing to the development of sustainable and safe communities.

Energy and Environment:

 Mechanical engineers work on designing and improving energy generation systems,

including renewable energy technologies (solar, wind, hydropower) and traditional power
plants, to address energy demands and promote environmental sustainability.
 They develop energy-efficient solutions and advocate for sustainable practices to reduce
greenhouse gas emissions and minimize environmental impact.

Transportation:

 Mechanical engineers design and innovate transportation systems, vehicles, and

components to enhance efficiency, safety, and sustainability.

BCME-PART-B
  They work on advancements in automotive technology, aviation, rail, and public
transportation systems, contributing to improved mobility and reduced environmental
pollution.

Consumer Products and Appliances:

 Mechanical engineers design consumer goods and appliances with a focus on safety,
functionality, and energy efficiency, meeting the needs of individuals and households.
 They continually innovate and improve products to enhance user experiences and reduce
environmental impact.

Education and Research:

 Mechanical engineers engage in education and research, training future engineers and
contributing to advancements in various fields through their research and development
efforts.
 They collaborate with academic institutions, industry partners, and government agencies
to drive innovation and solve complex societal challenges.

Disaster Preparedness and Relief:

 Mechanical engineers play a role in designing and developing disaster-resistant structures

and systems to minimize the impact of natural disasters, such as earthquakes, floods, and
hurricanes.
 They contribute to emergency response efforts by designing equipment and technology
to aid in disaster relief and recovery.

Manufacturing and Production:

 Mechanical engineers optimize manufacturing processes and systems to increase

efficiency, reduce waste, and enhance productivity.
 They drive advancements in automation and robotics, improving the speed and accuracy
of manufacturing, leading to cost-effective and high-quality products.

BCME-PART-B
Healthcare and Biomechanics:

 Mechanical engineers contribute to the design and development of medical devices,

prosthetics, orthotics, and assistive technologies, improving the quality of life for
individuals with disabilities or health challenges.
 They play a vital role in healthcare facilities by designing HVAC systems, specialized
equipment, and improving the overall healthcare infrastructure

4. What is energy? Explain the different types of energy sources?

 energy is the ability of a system to perform work, but as energy exists in so many forms, it
is hard to find one comprehensive definition. It is the property of an object that can be
transferred from one object to another or converted to different forms but cannot be
created or destroyed. There are numerous sources of energy.

Sources Of Energy
Sources of energy can be classified into:
 Renewable Sources
 Non-renewable Sources
 Renewable sources of energy are available plentiful in nature and are sustainable. These
resources of energy can be naturally replenished and are safe for the environment.
Examples of renewable sources of energy are: Solar energy, geothermal energy, wind
energy, biomass, hydropower and tidal energy.
 A non-renewable resource is a natural resource that is found underneath the earth.
These type of energy resources do not replenish at the same speed at which it is used.
They take millions of years to replenish
Examples of non-renewable sources of energy are: Natural gas, coal, petroleum, nuclear
energy and hydrocarbon gas liquids.

BCME-PART-B
Types of energy

Chemical energy

stored within bonds between molecules. Sources include natural gas, gasoline, coal and batteries.
Even the food we eat is considered chemical energy.

Electrical energy

comes from tiny charged particles called electrons. A lightning bolt is one form of electrical
energy. The electricity in our homes is made by humans.

Gravitational energy

Associated with a gravitational field, like the one that surrounds the Earth. If you’ve ever fallen
down, you’ve experienced the power of gravitational energy. Gravitational energy is the reason
why riding your bike downhill is faster than riding your bike uphill.

Kinetic energy

Anything that moves is using this kind of energy. Examples include running, cycling, climbing –
even swiping your finger across your smart phone! Wind turbines capture the kinetic energy in
wind and transform it into mechanical energy.

BCME-PART-B
Mechanical energy

stored in objects by tension. When the tension is released, motion occurs. A compressed spring
contains mechanical energy as does a stretched rubber band.
Nuclear energy
stored inside tiny atoms that are invisible, but make up the elements of the entire universe.
Nuclear energy is released when atoms join together (fusion) or split (fission). The fusion reaction
in the sun provides warmth and light, while the fission reaction at a nuclear power plant creates
enough energy to power large cities.

Solar (radiant) energy

energy that comes from the movement of light.
Sound energy
produced when an object is made to vibrate producing a sound. Your voice and musical
instruments use sound energy.
Thermal (heat) energy
created from moving molecules. The energy that comes from a fire is thermal energy.

5. what is the role of mechanical engineer in manufacturing industry

Mechanical engineering contributes to the design, development, and optimization of
manufacturing processes and systems

Product Design:

 Mechanical engineers are involved in the design of products, including machinery, tools,
consumer goods, and industrial equipment. They ensure that these products are not only
functional but also cost-effective, reliable, and manufacturable.

Process Design:

 Mechanical engineers design manufacturing processes and production systems. They

develop strategies to efficiently produce products, considering factors such as material
selection, manufacturing methods, and quality control.

BCME-PART-B
Material Selection:

 Mechanical engineers choose materials that are appropriate for a specific manufacturing
process and product requirements. They consider factors like strength, durability, cost,
and environmental impact.

Quality Control:

 Mechanical engineers are responsible for quality assurance and control in manufacturing.
They design and implement inspection and testing procedures to ensure products meet
specifications and standards.

Material Selection:

 Mechanical engineers choose materials that are appropriate for a specific manufacturing
process and product requirements. They consider factors like strength, durability, cost,
and environmental impact.

Quality Control:

 Mechanical engineers are responsible for quality assurance and control in manufacturing.
They design and implement inspection and testing procedures to ensure products meet
specifications and standards.

6. What are the different types of ferrous metals, explain the basic
properties and its applications?

What is Ferrous Metal?

 Ferrous materials are those which contain iron as their main constituent. Other
constituents such as C, Mn, Si, S and P exist in varying proportions with iron(Fe) to form
various ferrous materials such as pig iron, wrought iron, cast iron, alloy steel, carbon
steel.

BCME-PART-B
WROUGHT IRON

 Wrought iron is a highly refined iron (purest iron) which possesses at least 99% of iron.
Wrought iron is produced by remelting of Pig iron in puddling furnace

Applications:-

1. In forged articles.
2. In manufacturing of iron bars, forging blooms and billets.
3. In manufacturing of water and steam pipes.
4. In manufacturing of nuts, bolts, chains, etc

CAST IRON

Cast iron is basically an alloy of iron and carbon and is obtained by re-melting of pig iron with
coke, lime stone and steel scrap in a Cupola furnace.

BCME-PART-B
Types of Cast Iron

A. Gray Cast Iron (C = 3.0 – 3.5 %)

B. White Cast Iron (C = 1.75 – 2.3 %)
C. Malleable Cast Iron (C = 2.0 – 3.0 %)
D. Nodular or Ductile Cast Iron (C = 3.2 – 4.2 %)

A. Grey Cast Iron:-

 This is obtained by allowing the molten metal to cool and solidify slowly. On solidifying,
the iron is present with the carbon in the form of graphite flakes. It gives gray color
fracture due to presence of graphite.

Applications:- Machine tool structures, pipes, pipe fitting, manhole covers, piston, cylinder
head, etc.

BCME-PART-B
7. Write a short notes on a) Smart materials b) Ceramics?

a) Smart materials

Smart materials are materials that are manipulated to respond in a controllable and reversible
way, modifying some of their properties as a result of external stimuli such as certain mechanical
stress or a certain temperature, among others

TYPES OF SMART MATERIALS

Piezoelectric materials

 They can convert mechanical energy into electrical energy and vice versa. For example,
they change their shape in response to an electrical impulse or produce an electrical
charge in response to an applied mechanical stress.

Shape memory materials

 They have the ability to change the shape, even returning to their original shape, when
exposed to a heat source, among other stimuli.

Chromoactive materials

 They change colour when subjected to a certain variation in temperature, light, pressure,
etc. Nowadays, they are used in sectors such as optics, among others.

Magnetorheological materials

 They change their properties when exposed to a magnetic field. For example, they are
currently used in shock absorbers to prevent seismic vibrations in bridges or skyscrapers.

Photoactive materials

 There are several types: electroluminescents emit light when they are fed with electrical
impulses, fluorescents reflect light with greater intensity and phosphorescents are able to
emit light after the initial source has ceased.

BCME-PART-B
b) Ceramics

A ceramic is an inorganic, non-metallic solid mainly based on oxide, nitride, boride, or carbide
that are shaped and then fixed at high temperatures. Ceramic is hard, brittle, heat-resistant, and
corrosion-resistant.

Properties of Ceramics

1. Ceramics have high hardness.

2. They are brittle and have poor toughness.

3. They have a high melting point.

4. They have poor electrical and thermal conductivity.

5. They have low ductility.

6. They have a high modulus of elasticity.

7. They have high compression strength.

8. They show optical transparency to a variety of wavelengths.

Application of Ceramics

1. Silicon carbide and tungsten carbide are technical ceramics that are used in body armor,
wear plates for mining, and machine components due to their high abrasion resistance.
2. Uranium oxide (UO2) is a ceramic that is used as a nuclear reactor fuel.
3. Zirconia is a ceramic that is used to make ceramic knife blades, gems, fuel cells, and
oxygen sensors
4. Barium titanate is a ceramic that is used to make heating elements, capacitors,
transducers, and data storage elements.
5. Stealite is a ceramic that is used as an electrical insulator.

BCME-PART-B
8. What is a composite? Write the Properties and applications of
composites.?

A composite material (also called a composition material or shortened to composite, which is the
common name) is a material which is produced from two or more constituent materials. These
constituent materials have notably dissimilar chemical or physical properties and are merged to
create a material with properties unlike the individual elements.

Composite material

Matrix phase
The primary phase, having a continuous character, is called matrix. Matrix is usually more
ductile and less hard phase. It holds the dispersed phase and shares a load with it.

Dispersed (reinforcing) phase

 The second phase (or phases) is embedded in the matrix in a discontinuous form. This
secondary phase is called dispersed phase. Dispersed phase is usually stronger than the
matrix, therefore it is sometimes called reinforcing phase.

BCME-PART-B
  Many of common materials (metal alloys, doped Ceramics and Polymers mixed with
additives) also have a small amount of dispersed phases in their structures, however they
are not considered as composite materials since their properties are similar to those of
their base constituents (physical properties of steel are similar to those of pure iron).
 There are two classification systems of composite materials. One of them is based on the
matrix material (metal, ceramic, polymer) and the second is based on the material
structure:

Classification of composites(based on matrix material)

Metal Matrix Composites (MMC)
Metal Matrix Composites are composed of a metallic matrix (aluminum, magnesium, iron,
cobalt, copper) and a dispersed ceramic (oxides, carbides) or metallic (lead, tungsten,
molybdenum) phase.

Ceramic Matrix Composites (CMC)

Ceramic Matrix Composites are composed of a ceramic matrix and embedded fibers of
other ceramic material (dispersed phase).

Polymer Matrix Composites (PMC)

Polymer Matrix Composites are composed of a matrix from thermoset (Unsaturated

Polyester (UP), Epoxiy (EP)) or thermoplastic (Polycarbonate (PC), Polyvinylchloride, Nylon,
Polysterene) and embedded glass, carbon, steel or Kevlar fibers (dispersed phase).

Classification of composites(based on reinforcing material structure)

Particulate Composites

Particulate Composites consist of a matrix reinforced by a dispersed phase in form of particles.

1. Composites with random orientation of particles.

2. Composites with preferred orientation of particles. Dispersed phase of these materials
consists of two-dimensional flat platelets (flakes), laid parallel to each other

BCME-PART-B
Fibrous Composites

1. Short-fiber reinforced composites. Short-fiber reinforced composites consist of a matrix

reinforced by a dispersed phase in form of discontinuous fibers (length < 100*diameter).
i. Composites with random orientation of fibers.
ii. Composites with preferred orientation of fibers.
2. Long-fiber reinforced composites. Long-fiber reinforced composites consist of a matrix
reinforced by a dispersed phase in form of continuous fibers.
i. Unidirectional orientation of fibers.
ii. Bidirectional orientation of fibers (woven).

Laminate Composites

When a fiber reinforced composite consists of several layers with different fiber orientations, it is
called multilayer (angle-ply) composite.

Properties of the composites:

1.high strength to weight ratio

2.Light weight
3. Fire resistant

4. Electrical properties

5. chemical and weathering resistance

6.Low thermal conductivity

7.Manufacturing Economy
Applications of composites

 automobiles industries: Automobile parts like components of engine, spray nozzle, mud
guards,tires etc
 Aeronautical applications: structural components like wings, body & stabilizer and fuel of
aircraft, rocket army missiles in military etc
 Marine applications: shaft, hulls, spars and other part of ships
 Safety equipment like helmets

BCME-PART-B
  Sport equipment like tennis rockets, golf sticks, other safety equipment
 Communication Industry like preparation of antennae and electronic circuit boards 

9. What is a Metal? Write its classification and mention its properties

and applications?

Metals are the most commonly used class of engineering material. Metal alloys are especially
common, and they are formed by combining a metal with one or more other metallic and/or non-
metallic materials. The combination usually occurs through a process of melting, mixing, and
cooling.

Metals are classified into two main categories: (i) Ferrous metals which have iron as the main
constituent, and (ii) Non-Ferrous metals, where in iron is not the main constituent.

BCME-PART-B
Ferrous metals

Ferrous metals are metals that contain iron as the primary element, such as stainless steel. They
are known for their mechanical properties, such as high tensile strength. They are also magnetic
and can be easily shaped or formed.

Properties

Ferrous metals share some basic properties, including being prone to rust and being magnetic.
The list of common ferrous metal properties include:

 Durable
 Good tensile strength
 Good electrical conductivity
 Low corrosion resistance
 Silver in colour
 Recyclable
 Usually magnetic

Wrought iron:

Wrought iron is a tough, malleable, and ductile material that is used for decorative purposes in
construction, such as in ornamental railings, gates and fences. It is also used for structural
components, such as in the form of beams and columns.

Cast iron:

Cast iron is a strong, brittle and corrosion-resistant material that is used in the construction of
pipes, valves, and fittings for plumbing and heating systems. Cast iron is also used for manhole
covers, grates, and other drainage components due to its high resistance to wear and tear.

BCME-PART-B
Non Ferrous metals

When a metal is defined as non-ferrous it means that it does not have a significant amount of
iron in its chemical composition.

Examples of Non-Ferrous Metals

There are a variety of non-ferrous metals in use in the industry today. Listed below are a variety
of the more popular ones:

Aluminum

Copper

Nickel

Aluminum

Aluminum is a very widely used type of non-ferrous alloy. it has a silvery color. Without the
addition of alloying elements, it is more ductile and not quite as strong as many steels. However,
through the addition of alloying elements and heat treating or work hardening, aluminum can
achieve very high strengths. Aluminum is lighter than steel. Common applications of aluminum
include marine equipment such as boat lifts and docks; aerospace equipment such as airplane
body material; construction material such as beams and rails; and certain types of cookware.

Copper

Copper is another very popular non-ferrous alloy. Copper is a metal that is somewhere between
red and brown in color. In its unalloyed state, it too is softer, more ductile, and not as strong as
carbon steel. Common applications of pure copper and its alloyed forms include electrical
components such as wires, terminals, and other types of connectors; currency such as the United
States or Canadian penny (although just as a coating); pipe for plumbing, tooling, and decorative
work.

BCME-PART-B
10. Distinguish between the following Ferrous and Non-Ferrous metals.

BCME-PART-B
 UNIT-II

BCME-PART-B
1. What is mean by casting? Explain the principles of casting with a neat sketch.

 Casting is a manufacturing process where molten material (metal, plastic, or other

substances) is poured into a mould cavity, which takes the shape of the desired object.
Once the material solidifies, the mould is removed, leaving behind the finished product.

Principles of Casting
1. Mold Preparation:

o Mold Material: The choice of mould material (sand, metal, ceramic) depends on the
cast material and the desired product complexity.

o Mold Design: The mould must be designed to replicate the desired shape accurately
and have appropriate venting and gating systems.

o Mold Cavity: The mould cavity is the space within the mould where the molten
material will solidify.

2. Molten Material Preparation:

o Heating: The material is melted to a specific temperature, ensuring it has the

correct fluidity for filling the mould.

o Alloying: In metal casting, alloys may be added to improve strength, durability, or

corrosion resistance.

3. Pouring:

o Gating System: The molten material is poured into the mould through a gating
system that distributes it evenly.

o Risers: Risers are additional cavities in the mould that compensate for shrinkage
during solidification.

4. Solidification:

o Cooling: The molten material cools and solidifies, taking the shape of the mould
cavity.

BCME-PART-B
 o Shrinkage: As the material cools, it shrinks, which can cause defects if not
accounted for.

5. Mold Removal:

o Breaking: The mould is broken or removed to extract the finished product.

o Finishing: The product may require additional finishing processes like machining,
polishing, or coating.

2. what is meant by joining process and explain the different types of joining
process.
Joining processes are techniques used to connect or combine different materials, components, or parts
into a single unit. These processes are essential in various industries, including manufacturing,
construction, and repair.
Types of Joining Processes
Joining processes can be broadly classified into two categories:
1. Mechanical Joining:
Fastening: This involves using mechanical elements to hold parts together.
o Bolts and nuts: The most common method, using threaded fasteners to connect parts.
o Screws: Similar to bolts, but often have a head that prevents rotation.
o Rivets: Permanent fasteners that are expanded after insertion.
BCME-PART-B
 o Pins and keys: Used to align and position parts.
o Press-fitting: Parts are forced together due to interference fits, creating a tight connection.
o Clamping: Parts are held together using clamps or other devices.
o Welding: Using heat and pressure to melt the edges of two materials and fuse them together.
2. Non-Mechanical Joining:
 Adhesives: Using a bonding agent to join materials.
o Glues: Used for joining materials like wood, paper, and plastics.
o Epoxy resins: Strong adhesives suitable for metals, ceramics, and composites.
 Soldering: Using a low-melting-point alloy to join metals, often with a flux.
 Brazing: Similar to soldering but using a higher-melting-point alloy.
 Diffusion bonding: Joining materials at a high temperature and pressure, causing atoms
to diffuse across the interface.
 Ultrasonic welding: Using high-frequency vibrations to create a bond between materials.

Factors to Consider in Choosing a Joining Process:

 Material properties: The type of materials being joined.
 Required strength and durability: The load and environmental conditions the joint must
withstand.
 Cost: The cost of the joining process and materials.
 Aesthetics: The appearance of the joint.
 Production speed: The time required to complete the joining process.
 Joint integrity: The reliability and longevity of the joint.

3. Distinguish in between Conventional Machining and CNC Machining

Feature Conventional CNC Machining
Machining

Control Manual control by an Computer numerical control

operator

Accuracy Lower accuracy Higher accuracy

Precision Lower precision Higher precision

Flexibility Less flexible More flexible

BCME-PART-B
 Repeatability Lower repeatability Higher repeatability

Productivity Lower productivity Higher productivity

Complexity Limited to simpler Can produce complex shapes

shapes

Cost Lower initial cost Higher initial cost

Maintenance More frequent Less frequent maintenance

maintenance

Operator Requires skilled Requires skilled programmer

Skill operator and operator

4 (a) What is meant by forming? List the different types of forming processes.

Forming is a manufacturing process that shapes materials into desired forms by applying external forces.
This can be done through various methods, including bending, drawing, stamping, forging, and extrusion.
Types of Forming Processes
1. Bending: This process involves deforming a material into a curved or angular shape. It can be done using
machines like press brakes or hand tools.

2. Drawing: In drawing, a material is pulled through a die to reduce its cross-sectional area and create a
specific shape. This process is commonly used to produce wires, tubes, and rods.

3. Stamping: This process involves using a die to press a material into a desired shape. It is widely used in the
production of sheet metal components, such as car body panels and appliances.

4. Forging: This process involves shaping a material by hammering or pressing it while it is hot. Forging is
used to produce large, complex components like crankshafts and gears.

5. Extrusion: In extrusion, a material is forced through a die to create a specific shape. This process is used to
produce long, continuous shapes like pipes, bars, and profiles.

BCME-PART-B
 (b) Write short notes on smart manufacturing
Smart manufacturing is a technological approach that leverages digital technologies
to optimize and improve manufacturing processes. It involves the integration of
various technologies, such as the Internet of Things (IoT), artificial intelligence (AI),
big data analytics, and automation, to create a connected and intelligent
manufacturing ecosystem.

Key benefits of smart manufacturing include:

 Increased efficiency through automation and data-driven decision-making.

 Improved quality due to real-time monitoring and analysis of production data.

 Enhanced flexibility to adapt to changing market demands and product designs.

 Reduced costs through optimized resource utilization and waste reduction.

 Improved sustainability by minimizing energy consumption and environmental impact.

Examples of smart manufacturing technologies:

 IoT sensors for real-time data collection.

 AI for predictive maintenance and quality control.

 Robotics and automation for efficient production processes.

 3D printing for rapid prototyping and customization.

5. Briefly explain the 3D Printing process with a neat diagram?

3D printing, also known as additive manufacturing, is a process where a three-dimensional object is

created by adding layer upon layer of material. This is a significant departure from traditional
manufacturing methods that involve removing material (e.g., machining, carving).
The Basic Process:
1. Digital Design: A 3D model of the desired object is created using computer-aided design (CAD)
software.

2. Slicing: The 3D model is sliced into hundreds or thousands of thin, two-dimensional cross-
sections.

BCME-PART-B
 3. Printing: A 3D printer builds the object layer by layer, following the instructions from the sliced
model. The material used can vary widely, including plastics, metals, ceramics, and even
biological materials.

Common 3D Printing Technologies:

 Fused Deposition Modeling (FDM): The most common type, it involves extruding heated plastic
filament layer by layer.

 Stereolithography (SLA): A laser is used to cure liquid resin layer by layer, solidifying the
desired shape.

 Selective Laser Sintering (SLS): A laser is used to fuse powdered material, such as nylon or
metal, layer by layer.

 Selective Laser Melting (SLM): Similar to SLS, but it uses a higher-power laser to melt metal
powder, creating a denser and stronger object.

Key components:
 Extruder: Melts and extrudes the filament.

 Build plate: The platform where the object is built.

 Nozzle: The opening through which the filament is extruded.

 Frame: The structure that supports the other components.

BCME-PART-B
Advantages of 3D Printing:
 Customization: Allows for the creation of highly customized products.

 Rapid prototyping: Can produce prototypes quickly and efficiently.

 Complexity: Can create complex geometries that are difficult to manufacture using traditional
methods.

 Material diversity: Can use a wide range of materials, including metals, plastics, and ceramics.

Disadvantages of 3D Printing:
 Speed: Can be slower than traditional manufacturing methods for large-scale production.

 Cost: The initial cost of 3D printers can be high.

 Material limitations: Some materials may be more challenging to print than others.

 Surface finish: May require additional finishing processes to achieve a smooth surface.

BCME-PART-B
6. Describe the working and functions of water tube boiler with neat
sketch.?
 A water tube boiler is such kind of a boiler, where the water is heated inside the tubes and
the hot gases surrounded them.
 It is the opposite of Fire tube boiler, where hot gasses are passed through the tubes which
are surrounded by water.

Working Principle of Water tube boiler

BCME-PART-B
 La-Mont boiler

 Water in the lower drum and in the riser connected to it, is heated and steam is produced
in them which comes to the upper drums naturally.
 In the upper drum the steam is separated from water naturally and stored above the water
surface.

BCME-PART-B
 The colder water is fed from feed water inlet at upper drum and as this water is heavier
than the hotter water of lower drum and that in the riser, the colder water push the hotter
water upwards through the riser.
 So there is one convectional flow of water in the boiler system.
 More and more steam is produced the pressure of the closed system increases which
obstructs this convectional flow of water and hence rate production of steam becomes
slower proportionately.
 Again if the steam is taken trough steam outlet, the pressure inside the system falls and
consequently the convectional flow of water becomes faster which result in faster steam
production rate.
 In this way the water tube boiler can control its own pressure.
 Hence this type of boiler is referred as self controlled machine.

Types of Water Tube Boiler:

1. Babcock & Wilcox boiler

2. Stirling boiler
3. La-Mont boiler
4. Benson boiler
5. Yarrow boiler
6. Loeffler boiler

Advantage of Water tube boiler:

 There are many advantages of water tube boiler due to which these types of
boiler areessentially used in large thermal power station.
 Larger heating surface can be achieved by using more numbers of water tubes.
 Due to convectional flow, movement of water is much faster than that of fire tube boiler,
hence rate of heat transfer is high which results into higher efficiency.
 Very high pressure in order of 140 kg/cm2 can be obtained smoothly.

BCME-PART-B
7. Distinguish between CI engines and SI engines?

Sl SI Engine CI Engine
No.
1. SI engine is known as the Spark Ignition CI engine is known as the
engine. Combustion Ignition engine.
2. The fuel used here is Gasoline or Petrol. In CI engine the fuel used is Diesel.

3. The compression ratio is 6 to 9. The compression ratio is high

around 15 to 20.
4. This is light in weight because of the low This is heavy in weight because of the
pressure developed here. high pressure developed here.
5. Low vibration and Noise here. Here more vibration and noise.
6. SI engine works on the Otto cycle. CI engine works on the Diesel cycle.
7. The speed is higher in the SI engine. The speed is low in the CI engine.
8. Thermal efficiency is low or average. Thermal efficiency is high.

9. Air and fuel are used during the intake but here only air is used during the
process intake process.
10. This is kind of cheaper in price. This we get higher in price.

11. This is also called a constant volume cycle. This is called a constant pressure
cycle.
12. Petrol fuel has a high self-ignition Diesel fuel has a self-ignition
temperature. temperature but it’s low.
13. Knocking takes place at the end of the Knocking takes place at the
combustion. beginning of the combustion.
14. A homogenous mixture of fuel. A heterogeneous mixture of fuel.

15. Petrol fuel is used in aerospace and Diese fuel used in heavy vehicles
automobiles. such as lorries, buses, and trucks,
more.
16. SI engine fitted with carburetor and spark CI engine fitted with injection or fuel
plug. injected pump.
17. Here ignition of air-fuel mixtures takes But here air-fuel take place by
place by an electric spark produced by a injection of fuel into the hot
spark plug. compressed air.
18. Temperature range here 250 to 300- In CI engine Temperature 600 to 700
degree celsius. degree celsius.
19. In the SI engine, Specific fuel Here in the CI engine, the specific
consumption is more. fuel consumption is less

BCME-PART-B
8. Explain various components and working of Hybrid vehicles with neat
sketch.?

Key components of a Hybrid Electric Vehicle

 As mentioned before, an HEV combines a conventional engine and electric powertrain.

Hence, you can find engine-related and electric powertrain components in an HEV. Below
are the key components of a Hybrid Electric Vehicle.

Internal combustion engine:

 The primary power source of an HEV is a conventional engine. Hence, it is the main
component responsible for propelling the vehicle. An HEV cannot run alone on an electric
powertrain without an engine.

Electric motor:

 The secondary power source of an HEV is the electric motor. It assists the engine during
initial acceleration to improve performance and fuel economy. It runs on electrical energy
stored in the battery pack. It can also charge the battery when the vehicle is braking or
coasting via the regenerative braking system.

Battery pack:

 A battery pack powers the electric motor. Basically, it acts as a fuel tank for the battery,
wherein it stores the electrical energy via regenerative braking and the generator driven by
the IC engine. The battery pack can also power auxiliary electrical components such aslights.

Generator:

 It is an essential component found in the series hybrid vehicle. We will touch upon what
series hybrid is in the upcoming sections. A generator draws power from the IC engine to
power the electric motor and charge the battery pack. In simple words, a generator
converts mechanical energy into electrical energy.

BCME-PART-B
Transmission:

 Typically, hybrid vehicles use conventional transmissions similar to petrol or diesel cars. It
transmits the power produced by the IC engine to the drive shaft. The basic working
principle of transmission remains the same, even in an HEV. It is one of the crucial
components required to propel the vehicle.

Fuel tank:

 Similar to a conventional car, hybrid electric vehicles also have a fuel tank to store the
conventional fuel. With the electric powertrain involved in a hybrid car, the fuel
consumption will be comparatively less than a vehicle purely relying on an IC engine .

9. Explain the working principle of Four stroke S.I engine with a neat
sketch?

Four stroke spark ignition engine working principle

A four-stroke engine is an internal combustion engine that utilises four distinct piston strokes
(intake, compression, power, and exhaust) to complete one operating cycle. A complete operation
in a four-stroke engine requires two revolutions (7200) of the crankshaft. In this article, let’s study
the four-stroke engine.

BCME-PART-B
PARTS OF A FOUR STROKE ENGINE

Piston

In an engine, a piston transfers the expanding forces of gas to the mechanical rotation of the
crankshaft through a connecting rod.

Crankshaft

A crankshaft is a part that converts the reciprocating motion to rotational motion.

Connecting Rod

It transfers motion from a piston to a crankshaft, acting as a lever arm

Flywheel

The flywheel is a rotating mechanical device that is used to store energy.

BCME-PART-B
Inlet and Outlet Valves

It allows us to enter fresh air with fuel & to exit the spent air-fuel mixture from the cylinder.

Spark Plug

It is a device that delivers electric current to the combustion chamber, which ignites the air-fuel
mixture leading to the abrupt gas expansion.

Four stroke spark ignition engine is given below in 4 steps,

1. Suction stroke: Suction stroke starts when piston is at top dead center and about to move
downwards. During suction stroke inlet valve is open and exhaust valve is closed. Due to low
pressure created by the motion of the piston towards bottom dead center, the charge consisting
of fresh air mixed with the fuel is drawn into cylinder. At the end of suction stroke the inlet valve
closes.

2. Compression stroke: During compression stroke, the compression of charge takes place by
return stroke of piston, i.e. when piston moves from BDC to TDC. During this stroke both, inlet
and exhaust valve remain closed. Charge which is occupied by the whole cylinder volume is
compressed up to the clearance volume. Just before completion of compression stroke, a spark
is produced by the spark plug and fuel is ignited. Combustion takes place when the piston is
almost at TDC.

3. Expansion or power stroke: Piston gets downward thrust by explosion of charge. Due to high
pressure of burnt gases, piston moves downwards to the BDC. During expansion stroke both inlet
and exhaust valves remains closed. Thus power is obtained by expansion of products of
combustion. Therefore it is also called as ‘power stroke’. Both pressure as well as temperature
decreases during expansion stroke

4. Exhaust stroke: At the end of expansion stroke the exhaust valve opens, the inlet valve remains
closed and the piston moves from BDC to TDC. During exhaust stroke the burnt gases inside the
cylinder are expelled out. The exhaust valve closes at the end of the exhaust stroke but still some
residual gases remains in cylinder.

BCME-PART-B
Advantage of four strokes S.I. Engine:-

1. High volumetric efficiency over a wide engine speed.

2. Low pressure losses in the exhaust system.

3. Effective control of the charging efficiency through appropriate valve timing and intake system
design.

Disadvantage of four strokes S.I. Engine:-

1. High complexity of the valve mechanism control.

2. Reduce power because the work is creating only every second shaft rotation.

10. Differentiate between Otto and Diesel cycle ?

Otto cycle

BCME-PART-B
  1-2 (Adiabatic process): In this process compression takes place, as the piston moves
from BDC to TDC increasing its temperature
 2-3 (Isochoric process): In this process, ignition is taking place, combustion happens
when the piston is at TDC and pressure increases at a constant volume.
 3-4 (Adiabatic process): In this process expansion is taking place, the heat produced due
to the combustion pushes the piston down which rotates the crankshaft.
 4-1 (Isochoric process): In this process, heat rejection is taking place at constant volume.
 The compression ratio of the otto cycle is 8 to 12.
 The efficiency of otto cycle is

Diesel cycle
 1-2 In this process suction takes place
 2-3 (Adiabatic process) In this process compression takes place. Both the inlet and
exhaust valves are closed and the compression takes place which is much higher than
that of an otto cycle. This increases the pressure and temperature.

BCME-PART-B
  3-4 (Isobaric process) In this process, fuel is added, and combustion occurs due to high
temperature, while maintaining a constant pressure because the volume is also
increasing.
 4-5 (Adiabatic process) In this process expansion takes place, due to combustion the
piston moves from TDC to BDC and power is generated.
 5-2 (Isochoric process) In this process, heat rejection is taking place at constant volume
 Compression ratio is 14 to 22
 Efficiency of diesel cycle is

BCME-PART-B
 UNIT-III

BCME-PART-B
1. Briefly explain the elements and working of Hydro Electric Power
plant with neat sketch

The process of utilizing hydropower to generate energy is referred to as hydroelectricity. The

gravitational force of falling water is used to generate hydropower. There is no water used in the
energy generating process.

Working Principle of Hydroelectric Power Plant

 The energy is generated by harnessing the gravitational force of water. The first thing
which is needed is an elevated dam to prevent the flow of water and collect it in one
location.
 When all of the liquid is collected, a significant amount of prospective energy is held in
the water. The floodgates are then opened, allowing high-pressure water to flow.
 Potential energy is transformed into kinetic energy when water moves. When rushing
water strikes the turbine blades, the kinetic energy of the water is turned into
mechanical energy. This turbine is then linked to a generator.
 The generator in the powerhouse creates energy while the turbine quickly turns. The
water flows into the river, by lowering the water level in the dam. This level will rise once
again as a result of natural precipitation. As a result, it is a non-depletable natural
resource.

The diagram above depicts a typical hydroelectric power plant structure and its major
components.

Dam and Reservoir:

 The dam is built on a wide river in mountainous terrain to guarantee enough water
storage at height. Behind the dam is a big reservoir. The reservoir’s water level (called the
water head) controls how much potential energy is stored in it.

BCME-PART-B
Control gate:

 Water from the reservoir is permitted to flow via the penstock into the turbine through
the control gate. A control gate can be used to regulate the amount of water discharged
into the penstock.

Penstock:

 It is a massive steel pipe that transports water from the reservoir to the turbine. Water’s
potential energy is transformed into kinetic energy when it flows down through the
penstock owing to gravity.

Water Turbine:

 The water turbine receives water from the penstock. An electric generator is mechanically
linked to the turbine. The kinetic energy of the water powers the turbine, which drives
the generator.

BCME-PART-B
  Water turbines are classified into two types: impulse turbines and reaction turbines. Large
heads are handled by impulse turbines, whereas low and medium heads are handled by
reaction turbines.

Generator:

 It is mechanically linked to the turbine shaft and is placed in the powerhouse. When the
turbine blades revolve, they drive the generator, which generates energy, which is then
improved for transmission with the support of a transformer

Advantages and Disadvantages of Hydroelectric Power Plant

Advantages

 Rainwater is kept in the dam. As a result, it is regarded as a renewable energy source.

 Dam construction aids in the irrigation of local farmers while also aiding in flood
management.
 This way of generating power produces no pollutants

 Their operating costs are quite minimal.

Disadvantages

 Hydropower facilities require a large investment with a low rate of return.

 Dams are only permitted in specific places.
 A large portion of farmland is underwater.

2. Discuss in detail working principle of Nuclear Power plant with neat

sketch.?

Nuclear power plants are basically a kind of nuclear energy station in which the nuclear reactor
produces electricity from the heat generated when atoms are split inside a nuclear reactor. This

BCME-PART-B
process is referred to as nuclear fission or simply fission.

Main Components of the Nuclear Power Plant:

Fuel:

 Uranium is the fundamental fuel. Typically pellets of uranium oxide (UO2) are organized
in cylindrical tubes to form fuel rods.

Core:

 A reactor core is the part of a nuclear reactor, including the nuclear fuels where the
nuclear reactions occur, and the heat is generated.

Coolant:

 A liquid coursing through the core so as to transfer the heat from it. In light water
reactors the water moderator works likewise as a primary coolant.

BCME-PART-B
Moderator:

 Material in the core of the reactor which basically slows down the neutron's speed
released from fission with an objective so that they cause more fission. It is generally
water, however it might be heavy water or graphite.

Control rods or blades:

 These are made up of neutron-absorbing material such as hafnium, cadmium or boron,

and are embedded or removed from the core to regulate the rate of reaction, or to stop
it.

Containment

 The construction around the reactor and related steam generators which is basically
intended to safeguard it from outside interruptions and to shield those outside from the
impact of radiation in case of any serious glitches or malfunction inside. It is generally a
thick concrete and steel structure.

Turbine:

 The steam generated in the steam generator is allowed to pass to the turbine and work
is done by the expansion of steam in the turbine

Cooling tower

 Cooling towers are basically large boxes designed with an objective to maximize
evaporation of water.

Advantages:

 As a small amount of fuel can generate a huge amount of power, thus nuclear power is a
cheap source of electricity.
 Nuclear power plants require less space as compared to any other power station of the
similar size.

BCME-PART-B
  Nuclear power is most economical and efficient to produce large capacities of power.
 Since, a large amount of nuclear fuel is available(e.g. Uranium, Plutonium and Thorium
etc.) so, a nuclear power plant can produce electrical energy for thousands of years.
 Nuclear Power Plants are generally very neat and clean when compared with a steam
power plant

Disadvantages

 Initial installation cost of the Nuclear plant is very high when compared to the other
power stations(like Solar or wind power stations).
 Nuclear fuel is very expensive(because of its rare nature) and it is challenging to control.
 Specialized knowledge is expected to operate such a type of plant. So, the salary bill and
other maintenance costs will be higher to operate such plants.
 As discussed in the last section, nuclear energy is clean. However, radioactive nuclear
waste contains exceptionally poisonous chemicals like pellets of uranium and plutonium
are used as fuel. There is a chance to spread radioactive contamination from this kind of
plant.
 Nuclear Reactors do not respond effectively with the fluctuating load demand. Thus it is
not suited for varying the load.

3. Define the term Robot and explain the different links and joints
used in robots with neat sketches. The manipulator of an industrial
robot consists of a series of joints and links.?

 Robot anatomy deals with the study of different joints and links and other aspects of the
manipulator's physical construction.
 A robot is a machine especially one programmable by a computer capable of carrying out a complex
series of actions automatically. A robot can be guided by an external control device, or
the control may be embedded within.
 A robotic joint provides relative motion between two links of the robot.

BCME-PART-B
 This joint-link-numbering scheme is further followed for all joints and links in the robotic systems.

Nearly all industrial robots have mechanical joints that can be classified into following five types
as shown in Figure below

BCME-PART-B
a) Linear joint (type L joint)

 The relative movement between the input link and the output link is a translational sliding
motion, with the axes of the two links being parallel

b) Orthogonal joint (type U joint)

 This also has a translational sliding motion, but the input and output links are
perpendicular to each other during the move.

c) Rotational joint (type R joint)

 This type provides rotational relative motion, with the axis of rotation perpendicular to
the axes of the input and output links.

BCME-PART-B
d) Twisting joint (type T joint)

 This joint also involves rotary motion, but the axis or rotation is parallel to the axes of the two
links.

e) Revolving joint (type V-joint, V from the “v” in revolving)

 In this type, axis of input link is parallel to the axis of rotation of the joint. Axis of the
output link is perpendicular to the axis of rotation.
BCME-PART-B
4. Explain with neat sketch the working principle of Diesel Engine
Power plant. write its advantages and disadvantages.
 An electric power generating station in which the chemical energy of diesel is converted
into electrical energy is known as diesel power plant. In other words, the diesel power
plant is a power generating plant in which diesel engine is used as the prime mover for
the generation of electrical energy.
 In a diesel power plant, the diesel engine is used as the prime mover to drive an
alternator. The diesel (fuel oil) burns inside the engine and the products of this
combustion acts as the working agent to produce mechanical energy. The diesel engine
drives an electric generator which converts the mechanical energy into electrical energy.

Components, Working & Schematic Diagram of Diesel Power Plant

BCME-PART-B
  A diesel engine is the main component of a diesel power plant. It is used to generate
mechanical power in form of rotation energy with the help of the combustion of diesel.
An alternator is connected to the same shaft as the diesel engine.
1. Diesel engine
2. Air intake system
3. Exhaust system
4. Cooling water system
5. Fuel supply system
6. Lubrication system
7. Diesel engine starting system

Diesel engine

 A diesel engine is the main component of a diesel power plant. It is used to generate
mechanical power in form of rotation energy with the help of the combustion of diesel.
An alternator is connected to the same shaft as the diesel engine.

Air intake system

 This system supplies necessary air to the engine for fuel combustion. It consists of a pipe
for supplying of fresh air to the engine. Filters are provided to remove dust particles from
air because these particles can act as an abrasive in the engine cylinder.

Exhaust System

 While combustion of diesel, gases are produced. The system that is used to remove these
gases is known as an exhaust system. The exhaust system aims to discharge gases from
the engine into the atmosphere.

Cooling Water System

 In an IC engine, 22-30% of energy is lost in form of heat energy. And to avoid overheating
of the engine, it requires a cooling system. There are two types of cooling systems; Direct
cooling, Indirect cooling

BCME-PART-B
  Direct cooling is also known as air cooling and indirect cooling is also known as water
cooling

Fuel Supply System

 In a diesel power plant, as the name suggests, diesel is used as a fuel. The fuel supply
system has to perform the below functions.
 Depending upon the capacity of the engine and supply hours, the storage tank is
required to store the diesel.
 Before supplying fuel to the engine, the fuel must be filtered and it does not contain any
impurities.
Lubrication System
 The engines run on high load conditions and cause friction loss in case if the lubrication
system fails. Therefore, the lubrication system is necessary for the IC engine and it
requires an adequate quantity of oil reach to all parts of the engine.
 The lubrication system prevents direct contact between two metals and will reduce the
wear and tear in moving parts. The below-listed components of the IC engine must be
lubricated;

Advantages of Diesel Power Plant

 The layout of a diesel power plant is quite simple.

 A diesel power plant requires less space because the number and size of its auxiliary
equipment is small.
 A diesel power plant can be started quickly and it can pick up the load in a short time.
 A diesel power plant requires less water for cooling.
 For the same capacity, the overall cost of a diesel power plant is much less than that of a
thermal power plant.
 For the same capacity, the thermal efficiency of a diesel power plant is higher than that
of a thermal power plant.
 A diesel power plant requires less staff for the operation.
 A diesel power plant can be installed at any place.
 A diesel power plant does not have any standby losses.

BCME-PART-B
Disadvantages of Diesel Power Plant

 As the diesel (fuel oil) is costly, thus the diesel power plant has high running cost.
 The diesel power plant can only be used to generate small power.
 The cost of lubrication of a diesel engine is generally high.
 The diesel power plant does not work satisfactorily under overload conditions for a long
period of time.
 The maintenance cost of a diesel power plant is generally high.

5. Give complete note on working principle of a Thermal power plant

with neat diagram

 Thermal power plants are power stations which convert heat energy into electric
energy. Thermal power plant is a collective term which includes fossil fuels, geothermal,
solar and nuclear power plants as well as waste incineration plants.

 In Thermal Power plants, the heat of combustion of fossil fuel (Coal, oil, or gas) is utilized
by the boiler to turn water into steam with high pressure and temperature. The coal is
broken into pieces for easy combustion to heat the water in the boiler. From the boiler,
the steam is passed through the superheater to increase the pressure and made to hit the
turbines.
 The steam produced is used in driving the steam turbines or sometimes steam engine
coupled generators and electrical energy is generated.
 The steam generating plant consists of a boiler and other auxiliary equipment for the
utilization of flue gases. It is the major part of the power plant where steam is generated.

Boiler:

 The heat developed due to the combustion of coal is utilized in the boiler for converting
the water into steam at high temperatures and pressure.

BCME-PART-B
 

Components of thermal power plants

steam condenser

 The steam condenser is a device that converts low pressure exhaust steam from the
turbine into the water.

Steam Turbines

 A steam turbine is a rotating machine that converts the heat energy of steam into
mechanical energy. The superheated steam from the superheater is fed to the turbine
which will convert heat energy into mechanical energy.

Alternator (or) Generator:

 An alternator is coupled to the same shaft of the turbine which will convert the
mechanical energy of the turbine into electrical energy. The electrical energy developed
by the alternator is delivered to the bus bars through the transformer, circuit breakers,
and isolators.

BCME-PART-B
Advantages:

 Making Energy from Thermal Power plants is easy.

 The fuel used (coal) is cheap.
 Thermal Power Plant can be set up anywhere near fuel and water supply.
 It requires less space as compared to the hydroelectric power station.

Dis-Advantages:

 Thermal Power Plants use Fossil Fuels to generate electricity, and these fossil fuels causes
pollution.
 A large water source is required to convert water into steam.
 It has low overall efficiency, Its maintenance cost is high.
6(a).Explain about the Robot configurations with neat sketches?

 Basically the robot manipulator has two parts viz.

 A body-and-arm assembly with three degrees-of-freedom and A wrist assembly with two
or three degrees-of-freedom.
 For body-and-arm configurations, different combinations of joint types are possible for a
three-degree-of-freedom robot manipulator.

Five common body-and-arm configurations are outlined below.

BCME-PART-B
(a) Polar configuration

 It consists of a sliding arm L-joint, actuated relative to the body, which rotates around
both a vertical axis (T-joint)and horizontal axis (R-joint).
 Used for spot welding and manipulation (Handling) of heavy loads

(b) Cylindrical configuration

 It consists of a vertical column. An arm assembly is moved up or down relative to the

vertical column.
 Arm can be moved in and out relative to the axis of the column. Common configuration
is to use a T-joint to rotate the column about its axis.
 An L-joint is used to move the arm assembly vertically along the column, while an Ojoint
is used to achieve radial movement of the arm.
 Used for loading and unloading on machine tools.

BCME-PART-B
(C) Cartesian co-ordinate robot
 It is also known as rectilinear robot and x-y-z robot. It consists of three sliding joints, two
of which are orthogonal O-joints
 Configuration provides rectangular work envelope.
 Used for assembly, palletizing and machine tool loading.

BCME-PART-B
(d) Jointed-arm (or)articulated

 It is similar to the configuration of a human arm.

 It consists of a vertical column that swivels about the base using a T-joint. Shoulder joint
(R-joint) is located at the top of the column.
 The output link is an elbow joint (another R joint).

(e) SCARA

 Its full form is ‘Selective Compliance Assembly Robot Arm'.

 It is similar in construction to the jointer-arm robot, except the shoulder and elbow
rotational axes are vertical.
 A typical three-degree-of-freedom wrist joint is depicted in Figure. Roll joint is
accomplished by use of a T-joint.
 Pitch joint is achieved by recourse to an R-joint. Yaw joint, a right-and-left motion, is
gained by deploying a second R-joint

BCME-PART-B
6.(B)What are the applications of robots?
1. Arc Welding

 Arc welding, or robot welding, became commonplace in the 1980s. One of the driving
forces for switching to robot welding is improving the safety of workers from arc burn and
inhaling hazardous fumes.

2. Spot Welding

 Spot welding joins two contacting metal surfaces by directing a large current through the
spot, which melts the metal and forms the weld delivered to the spot in a very short time
(approximately ten milliseconds).

3. Materials Handling

 Material handling robots are utilized to move, pack and select products. They also can
automate functions involved in the transferring of parts from one piece of equipment to
another. Direct labor costs are reduced and much of the tedious and hazardous activities
traditionally performed by human labor are eliminated.

BCME-PART-B
4. Machine Tending

 Robotic automation for machine tending is the process of loading and unloading raw
materials into machinery for processing and overseeing the machine while it does a job.

5. Painting

 Robotic painting is used in automotive production and many other industries as it

increases the quality and consistency of the product. Cost savings are also realized
through less rework.

6. Picking, Packing and Palletizing

 Most products are handled multiple times prior to final shipping. Robotic picking and
packaging increases speed and accuracy along with lowering production costs.

7. Assembly

 Robots routinely assemble products, eliminating tedious and tiresome tasks. Robots
increase output and reduce operational costs.

8. Mechanical Cutting, Grinding, Deburring and Polishing

 Building dexterity into robots provides a manufacturing option that is otherwise very
difficult to automate. An example of this is the production of orthopedic implants, such
as knee and hip joints. Buffing and polishing a hip joint by hand can normally take 45-90
minutes while a robot can perform the same function in just a few minutes.

9. Gluing, Adhesive Sealing and Spraying Materials

 Sealer robots are built with numerous robotic arm configurations that enable the robot
to apply adhesives to any type of product.

10. Other Processes

 These include inspection, waterjet cutting and soldering robots .

BCME-PART-B
7. Explain working principle of Steam Power plant with neat sketch.
State it’s advantages and disadvantages

Steam power plant

A steam powerplant converts the chemical energy of the fossil fuels(coal, oil, gas) or fissile fuels
( Uranium, Thorium) into electrical energy.

Steam powerplant basically working on Rankine cycle, steam is produced in the boiler by utilizing
the heat of fuel combustion, that steam is expanded through the steam turbine, that steam
turbine drives the generator which converts the mechanical energy of the turbines in to electrical
energy.

Thermal power plant

 In Thermal Power plants, the heat of combustion of fossil fuel (Coal, oil, or gas) is utilized
by the boiler to turn water into steam with high pressure and temperature. The coal is
broken into pieces for easy combustion to heat the water in the boiler. From the boiler,
the steam is passed through the superheater to increase the pressure and made to hit the
turbines.
 The steam produced is used in driving the steam turbines or sometimes steam engine
coupled generators and electrical energy is generated.
 The steam generating plant consists of a boiler and other auxiliary equipment for the
utilization of flue gases. It is the major part of the power plant where steam is generated.

Components of thermal power plants

Boiler:

 The heat developed due to the combustion of coal is utilized in the boiler for converting
the water into steam at high temperatures and pressure.

BCME-PART-B
Super Heater:

 The steam produced from the boiler is wet and if this steam passes through the steam
turbine, the turbines may get damaged. In order to avoid this condition the steam
produced from the boiler is further heated at Super Heater.
 The main function of a superheater in a boiler is to increase the temperature of the steam
above the boiling point of water by utilizing the heat from the flue gases.

Economiser:

 An economiser in a boiler is essentially a feed water heater. The feed water is fed to the
economiser before supplying to the boiler. The main function of an economiser is that it
will increase the temperature of feed water by utilizing the heat from the hot flue gases.

BCME-PART-B
Air Preheater:

 It is placed in between the boiler and the economizer. It increases the temperature of the
air supplied for coal burning by deriving heat from flue gases.

steam condenser

 The steam condenser is a device that converts low pressure exhaust steam from the
turbine into the water.

Steam Turbines

 A steam turbine is a rotating machine that converts the heat energy of steam into
mechanical energy. The superheated steam from the superheater is fed to the turbine
which will convert heat energy into mechanical energy.

Alternator (or) Generator:

 An alternator is coupled to the same shaft of the turbine which will convert the
mechanical energy of the turbine into electrical energy. The electrical energy developed
by the alternator is delivered to the bus bars through the transformer, circuit breakers,
and isolators.

Advantages:

 Making Energy from Thermal Power plants is easy.

 The fuel used (coal) is cheap.
 Thermal Power Plant can be set up anywhere near fuel and water supply.
 It requires less space as compared to the hydroelectric power station.

Dis-Advantages:

 Thermal Power Plants use Fossil Fuels to generate electricity, and these fossil fuels causes
pollution.
 A large water source is required to convert water into steam.
 It has low overall efficiency.
 Its maintenance cost is high.
BCME-PART-B
8. Distinguish Steam and Nuclear Power plants and their
applications.?

BCME-PART-B
9. What is a Gear? Explain various Gear drives with it’s applications?
A gear is a toothed wheel that engages another toothed mechanism to change speed or the direction
of transmitted motion. Gears are generally used for one of four different

reasons:

 To increase or decrease the speed of rotation;

 To change the amount of force or torque;
 To move rotational motion to a different axis (i.e. parallel, right angles, rotating, linear
etc.); and
 To reverse the direction of rotation.

SPUR GEARS:

Spur gears are used to transmit power between two parallel shafts. The teeth on these gears are
cut straight and are parallel to the shafts to which they are attached.

Spur Gears

Characteristics:

 Simplest and most economical type of gear to manufacture

 Speed ratios of up to 8 (in extreme cases up to 20) for one step (single reduction)
design; up to 45 for two step design; and up to 200 for three-step design.

Limitations:

 Not suitable when a direction change between the two shafts is required.
 Produce noise because the contact occurs over the full face width of the mating teeth
instantaneously.
BCME-PART-B
Applications:

 Spur gears find use most often in applications such as clocks, washing machines and
dryers, as well as “gear pumps” which can be used to displace/transport fluids.
 Gear pumps are most commonly used in hydraulic power applications and applications
handling viscous, potentially dangerous chemicals.

HELICAL GEARS

 Helical gears resemble spur gears, but the teeth are cut at an angle rather than parallel to
the shaft axis like on spur gears.
 The angle that the helical gear tooth is on is referred to as the helix angle. The angle of
helix depends upon the condition of the shaft design and relative position of the shafts.
 To ensure that the gears run smoothly, the helix angle should be such that one end of the
gear tooth remains in contact until the opposite end of the following gear tooth has found
a contact. For parallel shafts, the helix angle should not exceed 20 degrees to avoid
excessive end thrust.

Helical gears

Characteristics:

The longer teeth cause helical gears to have the following differences from spur gears of the same
size:

 Tooth strength is greater because the teeth are longer than the teeth of spur gear of
equivalent pitch diameter

 Can carry higher loads than can spur gears because of greater surface contact on the teeth
BCME-PART-B
  Can be used to connect parallel shafts as well as non-parallel, non-intersecting shafts.
 Quieter even at higher speed and are durable.

Application of Helical Gears

 Automotive transmissions: Helical gears are often used in automotive transmissions to

transmit power from the engine to the drive wheels.
 Industrial machinery: Helical gears are commonly used in industrial machinery, such as
conveyor belts, mixers, and pumps, to transmit motion and power between different
machine components.
 Aerospace: Helical gears are used in many aerospace applications, such as aircraft landing
gear and satellite control systems.
 Robotics: Helical gears are often used in robotics applications to provide precise, smooth
motion and power transmission between different robot parts.

BEVEL GEARS

 This is a toothed rotating device designed to help transfer shaft power between two
intersecting shafts (either perpendicularly or at an angle).
 The result is a change in the direction of rotation and the shaft torque. Bevel gears can
also be used to decrease or increase torque while creating the opposite effect on the
angular speed.

Bevel gears

BCME-PART-B
 Applications of Bevel gears

 Automotive industry: Here, it is applied in both front and rear axle assembly, allowing the
wheels to rotate at varying speeds.
 Heavy-duty equipment: Bevel gears are preferred for most heavy-duty equipment, where
it is used either for propulsion or running auxiliary units.
 Aviation: Helicopters rotors and airplane accessory gearbox drives use bevel gears.
 Industrial equipment: A lot of industrial equipment, from speed reducers to cooling tower
fans, can use bevel gears.

10.Differentiate between Belt drive, Chain drive and Gear drive with
examples?

S.N BELT DRIVE CHAIN DRIVE GEAR DRIVE

o
1 Main element Pulleys, belt Main element Sprockets, Main element Gears
chain
2 Slip may occur No-slip No-slip
3 Suitability For the large center Suitability For the moderate Suitability For the short center
Distance center distance
Distance
4 Large Space requires Moderate Space requires Less Space requires
5 Simplest Design, manufacturing, Simplest Design, Complicated Design,
Complexity manufacturing, manufacturing,
Complexity complexity
6 Failure of the belt does not Failure of a chain may not Failure of gear may
cause the further seriously damage the cause serious break
damage of machine machine. down in the
machine.
7 Less Life Moderate Life Long Life

BCME-PART-B
8 Lubrication Not required Lubrication required Requires proper
lubrication
9 Less Installation cost Moderate Installation cost More Installation cost
10 Used For low-velocity ratio Used For moderate velocity Used For high velocity
Ratio Ratio

BCME-PART-B