Basic Mechanical Engineering (Vel Tech)

Description

Title Copyright Dedication Roadmap to the Syllabus Contents Preface About the Author Acknowledgements Chapter 1 Machine Tools 1.1 Introduction to Manufacturing Processes 1.2 Classification of Manufacturing Processes 1.2.1 Primary Shaping Processes 1.2.2 Machining Processes 1.2.3 Joining Processes 1.2.4 Processes Effecting Change in Properties 1.3 Introduction To machine tools 1.4 Mechanism of Metal Cutting 1.4.1 Types of Chip Formation 1.5 Geometry of Single Point Cutting Tool 1.6 Orthogonal and Oblique Metal Cutting 1.7 Lathe 1.7.1 Classification of Lathes 1.7.2 Specifications of Lathe 1.7.3 Constructional Detail of Lathe 1.7.4 Power Transmission System in Lathe Machine 1.7.5 Cutting Tools Used in Lathe 1.7.6 Types of Operations on Lathe Machine 1.8 Shaper, Slotter, and Planer 1.8.1 Shaping and Planing 1.8.2 Constructional Detail of Shaper 1.8.3 Slotter Machine 1.8.4 Crank and Slotted Arm Quick Return Mechanism 1.8.5 Specification of Shaper 1.8.6 Constructional Detail of Planer 1.8.7 Fast and Loose Pulleys Driving Mechanism of Planer 1.8.8 Specifications of Planer 1.8.9 Difference Between Shaper and Planer 1.9 Drilling Machine 1.9.1 Driving Mechanism in Drilling Machine 1.9.2 Drill Bit 1.9.3 Specifications of a Drilling Machine 1.9.4 Operations Performed on Drilling Machine 1.9.5 Advanced Types of Drilling Machine 1.10 Boring 1.10.1 Specification of Boring Machines 1.11 Milling Machines 1.11.1 Constructional Detail of Milling Machine 1.11.2 Basic Milling Operations 1.11.3 Nomenclature of Milling Cutter 1.12 Grinding and Surface Finishing Processes 1.12.1 Grinding Wheel Specification 1.12.2 Methods of Grindings 1.12.3 Types of Grinding Machines 1.12.4 Advantages of Grinding 1.12.5 Surface Finishing Processes Summary Multiple Choice Questions Fill in the blanks Review Questions Chapter 2 Primary Shaping and Joining Processes: Casting and Welding 2.1 Introduction to casting processes 2.2 Classification of Casting Process 2.3 Sand Casting 2.3.1 Steps in Sand Casting 2.3.2 Pattern Making 2.3.3 Types of Pattern 2.3.4 Mould Making 2.3.5 Properties of Mouldings Sands 2.3.6 Hand Tools Used in Moulding (Figure 2.14) 2.3.7 Moulding Procedure 2.3.8 Gating System 2.3.9 Chills 2.3.10 Chaplets 2.3.11 Cores 2.3.12 Sand Testing 2.4 Special Casting Methods 2.4.1 Gravity/Permanent Mould Casting 2.4.2 Slush Casting 2.4.3 Pressed or Carthias Casting 2.4.4 Die Casting 2.4.5 Low-pressure Casting 2.4.6 Centrifugal Casting 2.4.7 Lost-wax Precision Casting Method 2.4.8 Shell Moulding 2.5 Casting Defects 2.6 Surface Cleaning of the Casting 2.7 Introduction to welding processes 2.7.1 Definition of Welding 2.8 Classification of Welding Process 2.9 Gas Welding 2.9.1 Oxyacetylene Welding 2.9.2 Gas Welding Methods 2.10 Electric Arc Welding 2.10.1 Functions of Electrode Coatings 2.10.2 Ingredients of Electrode Coating 2.10.3 Selection of Electrodes 2.10.4 Specifications for Electrodes 2.11 Types of Electric Arc Welding 2.11.1 Carbon Arc Welding 2.11.2 Shielded Metal Arc Welding (SMAW) 2.11.3 Metal Inert Gas Arc Welding (MIG)/Gas Metal Arc Welding (GMAW) 2.11.4 Tungsten Inert Gas Arc Welding (TIG)/Gas Tungsten Arc Welding (GTAW) 2.11.5 Submerged Arc Welding (SAW) 2.11.6 Electroslag Welding 2.11.7 Atomic Hydrogen Welding 2.11.8 Plasma Arc Welding 2.12 Resistance Welding 2.12.1 Resistance Spot Welding 2.12.2 Resistance Seam Welding 2.12.3 Resistance Projection Welding 2.12.4 Flash Welding 2.12.5 Percussion Welding 2.12.6 Resistance Butt Welding 2.13 Unconventional Welding Methods 2.13.1 Laser Beam Welding (Light Amplification by Stimulated Emission of Radiation) 2.13.2 Electron Beam Welding 2.13.3 Ultrasonic Welding 2.13.4 Thermit Welding 2.14 Welding Allied Processes 2.14.1 Soldering 2.14.2 Brazing 2.14.3 Braze Welding 2.15 Welding Defects Summary Multiple Choice Questions Fill in the blanks Review Questions Chapter 3 Mechanical Working of Metals, Sheet Metal Work, and Powder Metallurgy 3.1 Introduction to Smithy 3.1.1 Major Tools used in Smithy Shop 3.2 Introduction of Mechanical Working process 3.2.1 Advantages of Mechanical Working Process Over Other Manufacturing Processes 3.3 Rolling 3.3.1 Terminology 3.3.2 Types of Rolling Mills 3.3.3 Rolling Defects 3.4 Forging 3.4.1 Advantages of Forging Processes 3.4.2 Disadvantages of Forging Processes 3.4.3 Different Types of Forging 3.5 Extrusion 3.5.1 Hot Extrusion 3.5.2 Cold Extrusion 3.5.3 Impact Extrusion 3.6 Wire Drawing 3.7 Bar Drawing 3.8 Tube Drawing 3.9 High Energy Rate Forming 3.9.1 Explosive Forming 3.9.2 Electrohydraulic Forming 3.9.3 Electromagnetic Forming 3.10 Thread Rolling 3.11 Piercing or Seamless Tubing 3.12 Some Other Forming Processes 3.13 Introduction of sheet metal Process 3.14 Sheet Metal Joints 3.15 Materials Used for Sheet Metal 3.16 Hand Tools used in Sheet Metal Work 3.17 Sheet Metal Operations 3.17.1 Shearing 3.17.2 Bending 3.17.3 Stretch Forming 3.17.4 Deep Drawing 3.17.5 Hot Spinning 3.18 Introduction of Powder Metallurgy 3.19 Manufacturing of Metal Powders 3.19.1 Characteristics of Metal Powder 3.19.2 Methods of Production 3.20 Blending/Mixing of Powders 3.21 Compacting 3.22 Sintering 3.23 Finishing Operations 3.24 Advantages of Powder Metallurgy 3.25 Limitations of Powder Metallurgy 3.26 Applications of Powder Metallurgy Summary Multiple Choice Questions Fill in the blanks Review Questions Chapter 4 Machine Elements 4.1 Introduction 4.2 Belt Drive 4.2.1 Type of Belt Cross-sections 4.2.2 Velocity Ratio 4.2.3 Creep 4.2.4 Open-belt Drive 4.2.5 Crossed-belt Drive 4.2.6 Ratio of Tensions 4.2.7 Effect of Centrifugal Force on Belt Drive 4.3 Rope Drive 4.4 Chain Drive 4.4.1 Chain Length 4.4.2 Types of Chain 4.5 Gear Drive 4.5.1 Gear Terminology 4.5.2 Law of Gearing 4.5.3 Forms of Teeth 4.6 Classification of Gears 4.6.1 Parallel Shafts 4.6.2 Intersecting Shaft 4.7 Gear Trains 4.7.1 Simple Gear Train 4.7.2 Compound Gear Train 4.7.3 Reverted Gear Train 4.7.4 Planetary or Epicyclic Gear Train 4.7.5 Sun and Planet Gear 4.8 Springs 4.8.1 Applications of Springs 4.8.2 Types of Springs 4.8.3 Materials used for Springs 4.8.4 Shear Stress in Helical Springs 4.8.4 Deflection in Helical spring 4.8.5 Series and Parallel Connection of Helical Springs 4.8.6 Deflection in Leaf Spring 4.9 Cam AND Follower 4.9.1 Cam Nomenclature 4.9.2 Types of Cams 4.9.3 Types of Followers 4.9.4 Displacement, Velocity, and Acceleration Diagram of Followers Summary Multiple Choice Questions Fill in the blanks Review Questions Problems for Practice Chapter 5 Internal Combustion Engines 5.1 Introduction 5.2 Classification of IC Engines 5.3 Basic Structure of IC Engines 5.3.1 Nomenclature 5.4 Working Principle of IC Engines 5.4.1 Four-stroke Spark Ignition Engine 5.4.2 Four-stroke Compression Ignition Engine 5.4.3 Two-stroke Spark Ignition Engine 5.4.4 Two-stroke CI Engine 5.4.5 Comparison Between Four-strokes and Two-strokes Engines 5.4.6 Comparison Between SI and CI Engines 5.4.7 Comparison Between Otto Cycle and Diesel Cycle 5.5 Valve Timing Diagrams 5.5.1 Valve Timing Diagram for Four-strokes SI Engines 5.5.2 Port Timing Diagram for Two-strokes SI Engines 5.5.3 Valve Timing Diagram for Four-strokes CI Engine 5.6 Otto Cycle 5.7 Diesel Cycle 5.8 Dual Cycle 5.9 Engine Performance Parameters 5.10 Vehicle Emissions 5.10.1 Types of Emissions 5.11 Emission Control Summary Multiple Choice Questions Fill in the blanks Review Questions Problems for Practice Chapter 6 Power Plant Engineering and Sources of Energy 6.1 Introduction 6.2 Prime Movers 6.2.1 Historical Development of Prime Movers 6.3 Power Plant Engineering 6.3.1 Thermal Power Plant 6.3.2 Hydroelectric Power Plant 6.3.3 Nuclear Power Plant 6.4 Diesel Power Plant 6.4.1 Working Principle of the Diesel Power Plant 6.4.2 Applications of the Diesel Engine Power Plant 6.5 Tidal Power Plant 6.5.1 Tidal barrage 6.5.2 Tidal Turbine 6.5.3 Tidal Fences 6.6 Geo-Thermal Power Plant 6.6.1 Dry Steam Power Plant 6.6.2 Flash Steam Power Plant 6.6.3 Binary Cycle Power Plants 6.7 Sources of Energy 6.7.1 Renewable Energy 6.7.2 Non-renewable Energy Summary Multiple Choice Questions Review Questions Chapter 7 Steam Engine, Steam and Gas Turbines 7.1 Introduction to Steam Power Systems 7.2 Steam Engines and Their Working Principles 7.2.1 Modified Rankine Cycle: Theoretical Indicator Diagram 7.2.2 Rankine Cycle 7.3 Steam Turbine 7.3.1 Classification of Steam Turbine 7.3.2 Compounding of Impulse Turbine 7.3.3 Impulses-reaction Turbine (Reaction Turbine) 7.3.4 Differences Between Impulse and Reaction Turbines 7.3.5 Losses in Steam Turbines 7.3.6 Governing of Steam Turbines 7.4 Gas Turbines 7.4.1 Classification of Gas Turbine 7.4.2 Applications of Gas Turbines 7.4.3 Gas Turbine Cycle with Regenerator 7.4.4 Gas Turbine Cycle with Reheating and Intercooling Summary Multiple Choice Questions Fill in the blanks Review Questions Problems for Practice Chapter 8 Refrigeration and Air Conditioning 8.1 Introduction 8.2 Refrigerator and Heat Pump 8.3 Components of Refrigeration System 8.3.1 Evaporator 8.3.2 Compressor 8.3.3 Condenser 8.3.4 Expansion Valve 8.4 Types of Refrigeration Systems 8.4.1 Air-refrigeration System 8.4.2 Vapour Compression Refrigeration System 8.4.3 Absorption Refrigeration Cycle 8.5 Type of Refrigerants 8.5.1 Domestic Refrigerator 8.6 Types of Refrigerators 8.6.1 Top-mount Refrigerators 8.6.2 Side-by-Side Mount Refrigerators 8.6.3 Bottom-mount Freezers 8.6.4 French-door Refrigerators 8.7 Psychrometry 8.8 Psychrometric Processes 8.8.1 Psychrometric Chart 8.9 Air Washers 8.10 Human Comfort Conditions 8.11 Air Conditioners 8.11.1 Window Air Conditioner 8.11.2 Split Air Conditioner 8.11.3 Difference between Split and Window ACs 8.11.4 Central Air Conditioner Summary Multiple Choice Questions Review Questions Problems for Practice Index