PART B: BASIC of MECHANICAL ENGINEERING

Course Objectives: The students after completing the course are expected to
• Get familiarized with the scope and importance of Mechanical Engineering in
different sectors and industries.
• Explain different engineering materials and different manufacturing processes.
• Provide an overview of different thermal and mechanical transmission systems and
introduce basics of robotics and its applications.

Course Outcomes: On completion of the course, the student should be able to

CO1: Understand the different manufacturing processes.
CO2: Explain the basics of thermal engineering and its applications.
CO3: Describe the working of different mechanical power transmission systems and power
plants.
CO4: Describe the basics of robotics and its applications.
UNIT I
Introduction to Mechanical Engineering: Role of Mechanical Engineering in Industries
and Society- Technologies in different sectors such as Energy, Manufacturing,
Automotive, Aerospace, and Marine sectors.
Engineering Materials - Metals-Ferrous and Non-ferrous, Ceramics, Composites, Smart
materials.
UNIT II
Manufacturing Processes: Principles of Casting, Forming, joining processes, Machining,
Introduction to CNC machines, 3D printing, and Smart manufacturing.
Thermal Engineering – Working principle of Boilers, Otto cycle, Diesel cycle,
Refrigeration and air-conditioning cycles, IC engines, 2-Stroke and 4-Stroke engines, SI/CI
Engines, Components of Electric and Hybrid Vehicles.
UNIT III
Power plants – Working principle of Steam, Diesel, Hydro, Nuclear power plants.
Mechanical Power Transmission - Belt Drives, Chain, Rope drives, Gear Drives and their
applications.
Introduction to Robotics - Joints & links, configurations, and applications of robotics.
(Note: The subject covers only the basic principles of Civil and Mechanical Engineering
systems. The evaluation shall be intended to test only the fundamentals of the subject.)
Textbooks:
1. Internal Combustion Engines by V.Ganesan, By Tata McGraw Hill publications (India)
Pvt. Ltd.
2. A text book of Theory of Machines by S.S. Rattan, Tata McGraw Hill Publications,
(India) Pvt. Ltd.
3. An introduction to Mechanical Engg by Jonathan Wicker and Kemper Lewis, Cengage
learning India Pvt. Ltd.
K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)
--------------------------------------------------------------------------------------------------------------------------------------

UNIT I

Introduction to Mechanical Engineering: Role of Mechanical Engineering in Industries

and Society- Technologies in different sectors such as Energy, Manufacturing,
Automotive, Aerospace, and Marine sectors.
Engineering Materials - Metals-Ferrous and Non-ferrous, Ceramics, Composites, Smart
materials.

What is Mechanical Engineering?

Before entering into the Mechanical Engineer role, let us first understand the
concept of Mechanical Engineering.

Mechanical Engineering is defined as the branch of engineering that deals with the
design, development, construction, and operation of mechanical systems and
tools. It include machines, tools, and equipment used in various industries, such
as transportation, manufacturing, power generation, and medical devices etc.

What role does a Mechanical Engineer play in our society and in Industries?
 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.

Besides, the role of a mechanical engineer in our society is contributed as:

K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)

● Power Generation: Mechanical engineers design and develop power-generating
machines such as internal combustion engines, gas turbines, and steam and wind
turbines etc
● Heating and Cooling Systems: They design and develop heating, ventilation,
refrigeration and air conditioning systems for buildings and other structures.
● Transportation: Mechanical engineers are involved in designing and developing
transportation systems, including cars, trains, airplanes, steamers and boats.
● Industrial Equipment: They design, develop and maintain industrial equipment such
as machine tools, robots, and conveyor systems & belts
● Infrastructure: Mechanical engineers play a key role in the design and maintenance
of infrastructure, including buildings, bridges, roads, and transportation systems.
Overall, Mechanical Engineers are involved in designing, building, and
maintaining the engines, machines, and structures that make modern life possible and
comfortable.

They contribute to society by using their skills to improve the safety, security,
efficiency, and comfort of the systems and devices that we rely on every day.

Disciplines within mechanical engineering include but are not

limited to:

 Acoustics
 Aerospace
 Automation
 Automotive
 Autonomous Systems
 Biotechnology
 Composites
 Computer Aided Design (CAD)
 Control Systems
 Cyber security

 Design
 Energy
 Ergonomics
 Human health
 Manufacturing and additive manufacturing
 Mechanics
 Nanotechnology
 Production planning
 Robotics
K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)
  Structural analysis

What tasks do mechanical engineers do?

Careers in mechanical engineering call for a variety of tasks.

 Conceptual design
 Analysis
 Presentations and report writing
 Multidisciplinary teamwork
 Concurrent engineering
 Benchmarking the competition
 Project management
 Prototyping
 Testing

 Measurements
 Data Interpretation
 Developmental design
 Research
 Analysis (FEA and CFD)
 Working with suppliers
 Sales
 Consulting
 Customer service

K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)

Technologies in different sectors in Energy

What do mechanical engineers do in the energy sector?

Mechanical engineering: Mechanical engineers work on the design of alternative
energy systems like wind turbines and solar panels, design and optimization of
systems for extracting and processing petroleum products, electric power
generation and transmission system design, operation, and optimization.

K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)

Technologies in different sectors in Manufacturing

Manufacturing technology describes the application of tools and

processes — developed through scientific, industrial and engineering
advances — to improve the efficiency, quality and productivity of
operations.
K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)
 There are many modern manufacturing technologies, most of them
specifically relevant to 'Industry 4.0', the name given to the fourth industrial
revolution, associated with automation, data exchange, digital technology,
artificial intelligence and machine learning, and the 'Internet of Things'.

Technologies in Automotive Industry

The automotive industry comprises a wide range of companies and organizations involved in
the design, development, manufacturing, marketing, selling, repairing, and modification of motor
vehicles. The automotive industry is rapidly changing, with innovations and technology. The use
of Internet of Things (IoT), artificial intelligence (AI), machine learning (ML), data analytics to
optimise their operations has also revolutionised the industry and enhanced the customer
experience.
1. Artificial Intelligence, 2. Big Data & Analytics, 3. Human-Machine Interfaces (HMI),
4. Internet of Things, 5. Autonomous Vehicles, 6. ADAS (Advanced Driver Assistance System),
7. Electrification, 8. 3D Printing (Additive manufacturing), 9. Blockchain, 10. Online retail

K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)

Technologies in Aerospace Industry-
The aerospace industry encompasses the manufacture of a wide
range of aircraft and spacecraft products (including passenger and military
aeroplanes, helicopters, and gliders, as well as spacecraft, launch vehicles,
satellites, and other space-related items).
An aerospace manufacturer is a company or individual involved in the various
aspects of designing, building, testing, selling, and maintaining aircraft, aircraft
parts, missiles, rockets, or spacecraft. Aerospace is a high technology industry.

Aerospace engineering consists of aeronautics and astronautics and the research,

design, production, operation, or maintenance of aircraft and spacecraft involves the
work of numerous organizations.

Aerospace technology, then, refers to the construction, testing, and maintenance of

aircraft and space vehicles. Technicians may be involved in the assembly, service,
testing, operation, and repair of systems associated with dependable and reusable
space launch vehicles and related ground support equipment.

K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)

Technologies in Marine Industry-

The Maritime Industry is waterborne commerce – it's about moving people and
goods over the water. Maritime is most everything connected to the sea or
waterways throughout the world, especially in relation to navigation, shipping, and
marine engineering. The industry has a direct impact on much of our everyday
lives.It is responsible for the transportation of goods, products, and people by sea.
This includes everything from container ships, and oil tankers, to cruise ships and
passenger ferries to smaller vessels like fishing.

Marine resources include:

 biological diversity (marine biodiversity)
 ecosystem services from marine ecosystems, such as marine coastal
ecosystems and coral reefs.
 fish and seafood.
 minerals (for example deep sea mining)
 oil and gas.
 renewable energy resources, such as marine energy.

K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)

  sand and gravel.
 tourism potential.

The Trends include –

1. Artificial Intelligence – Digital Cargo And Bay Arrangement Optimization
2. Big Data Analysis 3. IoT on Vessels 4. Digital Route Management of Ships
5. Smart Manoeuvring Control / Autonomous Control 6. Smart Propulsion
Systems 7. Integrated Control Systems 8. Smart Defence Technology
9. Blockchain technology 10. Robotics / Drones / 3D Printing

Engineering Materials - Metals-Ferrous and Non-ferrous, Ceramics,

Composites, Smart materials.

K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)

K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)
Metals are opaque, lustrous elements that are good conductors of heat and
electricity. Most metals are malleable and ductile and are, in general, denser
than the other elemental substances.

FERROUS METALS
The word 'ferrous' comes from the Latin word 'ferrum,' which means 'iron. '
Ferrous metals include steel, cast iron, as well as alloys of iron with other
metals (such as with stainless steel).

NoN- FERROUS METALS

Non-ferrous metals are alloys or metals that do not contain any appreciable
amounts of iron. All pure metals are non-ferrous elements, except for iron (Fe),
which is also called ferrite from the Latin 'ferrum,' meaning “iron.”

CERAMICS
Ceramics are generally made by taking mixtures of clay, earthen elements, powders,
and water and shaping them into desired forms. Once the ceramic has been shaped, it
is fired in a high temperature oven known as a kiln. Often, ceramics are covered in
decorative, waterproof, paint-like substances known as glazes.
There are three main types of pottery/ceramic. These are earthenware, stoneware and
porcelain.

Ceramics can withstand high temperatures, are good thermal insulators, and do not
expand greatly when heated.

Ceramics are also used to make objects as diverse as spark plugs, fiber optics, artificial
joints, space shuttle tiles, cooktops, race car brakes, micropositioners, chemical sensors,
K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)
self lubricating bearings, body armor, and skis.

Ceramic Properties
 hard,
 wear-resistant,
 brittle,
 refractory,
 thermal insulators,
 electrical insulators,
 nonmagnetic,
 oxidation resistant,

K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)

COMPOSITES-
Composites are simply a combination of two or more constituent materials
with different physical or chemical properties. When combined, they produce
a material with characteristics different from their original properties. The two
main components within a composite are the matrix and fiber.
Composites are now being used in vehicle and equipment applications,
including, panels, frames, interior components and other parts. Some
composite infrastructure applications include buildings, roads, bridges and
pilings.
Other key advantages include:
 As molded dimensional accuracy. Tight tolerance, repeatable moldings. ...
 Chemical Resistance.
 Consolidated Parts and Function.
 Corrosion Resistance.
 Design Flexibility.
 Durable.
 High Flexural Modulus to Carry Demanding Loads. High Impact Strength.
 High Performance at Elevated Temperatures.

K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)

  Composites are used in a wide variety of markets, including aerospace, architecture,
automotive, energy, infrastructure, marine, military, and sports and recreation.
Aerospace. ...
 Appliance/Business. ...
 Automotive/Transportation/Farm/Construction. ...
 Civil Infrastructure. ...
 Construction. ...
 Corrosive Environments, Electrical and Marine

Smart materials
Smart materials, also called intelligent or responsive materials, are 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. It
aims to minimize waste and increase efficiency in the use of natural resources.
Smart materials have properties that react to changes in their environment. This
means that one of their properties can be changed by an external condition, such
as temperature, light, pressure, electricity, voltage, pH, or chemical compounds.

K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)

K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)
 Several notable types of smart devices are smartphones, smart speakers,
smart cars, smart thermostats, smart doorbells, smart locks, smart
refrigerators, phablets and tablets, smartwatches, smart bands, smart
keychains, smart glasses, and many others. Smart devices are all of the
everyday objects made intelligent with advanced compute, including AI and
machine learning, and networked to form the internet of things (IoT).
This list of benefits smart technology can offer may be an eye opener.
 Smart Technology Helps Conserve Energy. ...
 Offers Convenience At Various Levels. ...
 Offers An Unprecedented Level Of Security. ...
 Offers Peace of Mind to Vulnerable people and their caregivers. ...
 Saves money

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K Rajesh MTech (Mech), MTech (Cse), PGDE, PGDIPR (PhD)