MECHANICAL - JNTU HYDERABAD II YEAR / I SEM

Introduction: Basic Concepts : System, Control volume, Surrounding, Boundaries, Universe, Types of systems, Macroscopic and microscopic viewpoints, Concept of continuum, Thermodynamic equilibrium, State. Property, Process, Exact and inexact differentials, Cycle – Reversibility – Quasi - static process, Irreversible process, Causes of irreversibility – Energy in state and in transition, Types, Displacement and other forms of work, Heat, Point and path functions, Zeroth law of thermodynamics – Concept of temperature – Principles of thermometry – Reference points – Constant volume gas thermometer – Scales of temperature, Ideal gas scale.

PMM-1 – Joule’s experiments – First law of thermodynamics – Corollaries – First law applied to a process – Applied to a flow system – Steady flow energy equation. Limitations of the first law – Thermal reservoir, Heat engine, Heat pump, Parameters of performance, Second law of thermodynamics, Kelvin-Planck and Clausius statements and their equivalence/ corollaries, PMM of second kind, Carnot’s principle, Carnot cycle and its specialities, Thermodynamic scale of temperature, Clausius inequality, Entropy, Principle of entropy increase – Energy equation, Availability and irreversibility – Thermodynamic potentials, Gibbs and Helmholtz functions, Maxwell relations, – Elementary treatment of the third law of thermodynamics.

Pure substances, P-V-T surafces, T-s and h-s diagrams, Mollier charts, Phase transformations – Triple point at critical state properties during change of phase, Dryness fraction – Clausius – Clapeyron equation – Property tables, Mollier charts – Various thermodynamic processes and energy transfer – Steam calorimetry. Perfect gas laws – Equation of state, Specific and universal gas constants – Various non-flow processes, Properties, End states, Heat and work transfer, Changes in internal energy – Throttling and free expansion processes – Flow processes.

Deviations from perfect gas model – Vander Waal’s equation of state – Compressibility charts – Variable specific heats – Gas tables. Mixtures of perfect gases – Mole fraction, Mass friction, gravimetric and volumetric analysis – Dalton’s law of partial pressure, Avogadro’s laws of additive volumes – Mole fraction, Volume fraction and partial pressure, Equivalent gas constant and molecular internal energy, Enthalpy, sp. heats and entropy of mixture of perfect gases and vapour, Atmospheric air – Psychrometric properties – Dry bulb temperature, Wet bulb temperature, Dew point temperature, Thermodynamic wet bulb temperature, Specific humidity, Relative humidity, Saturated air, Vapour pressure, Degree of saturation – Adiabatic saturation, Carrier’s equation – Psychrometric chart.

Power cycles : Otto, Diesel, Dual combustion cycles, Sterling cycle, Atkinson cycle, Ericsson cycle, Lenoir cycle – Description and representation on P-V and T-S diagram, Thermal efficiency, Mean effective pressures on air standard basis – Comparison of cycles. Refrigeration Cycles : Brayton and Rankine cycles – Performance evaluation – Combined cycles, Bell-Coleman cycle – Vapour compression cycle – Performance evaluation.

CASTING Steps involved in making a casting, Advantage of casting and its applications; Patterns – Pattern making, Types, Materials used for patterns, pattern allowances, Properties of moulding sands, Methods of melting – Crucible melting and cupola operation – Defects in castings ; Principles of gating – Requirements – Types of gates, Design of gating, systems – Riser – Function, Types of riser and riser design, casting processes – Types – Sand moulding, Centrifugal casting, Die-casting, Investment casting, Shell moulding ; Solidification of casting – Solidification of pure metal, Directional solidification.

WELDING Classification – Types of welds and welded joints, Gas welding – Types, Oxy-fuel gas cutting – Standard time and cost calculations. Arc welding, Forge welding, Submerged arc welding, Resistance welding, Thermit welding.

Inert gas welding – TIG welding, MIG welding, Friction welding, Friction stir welding, Induction welding, Explosive welding, Laser welding; Soldering and Brazing; Heat affected zone in welding. Welding defects – Causes and remedies; Destructive and non-destructive testing of welds.

Hot working, Cold working, Strain hardening, Recovery, Recrystallisation and grain growth. Sheet metal operations: Stamping, Blanking and piercing, Coining, Strip layout, Hot and cold spinning – Bending and deep drawing. Rolling fundamentals – Theory of rolling, types of rolling mills and products. Forces in rolling and power requirements. Drawing and its types – Wire drawing and Tube drawing– Types of presses and press tools. Forces and power requirement in the above operations.

EXTRUSION OF METALS Basic extrusion process and its characteristics. Hot extrusion and cold extrusion – Forward extrusion and backward extrusion – Impact extrusion – Extruding equipment – Tube extrusion, Hydrostatic extrusion. Forces in extrusion. FORGING PROCESSES Forging operations and principles – Tools – Forging methods – Smith forging, Drop forging – Roll forging. Forging hammers: Rotary forging – Forging defects – Cold forging, Swaging, Forces in forging operations. High Energy Rate Forming Processes : Limitations, Principles of Explosive Forming, Electro-hydraulic Forming, Electro-magnetic forming and rubber pad forming.

SIMPLE STRESSES AND STRAINS Elasticity and plasticity – Types of stresses and strains – Hooke’s law – Stress – Strain diagram for mild steel – Working stress – Factor of safety – Lateral strain, Poisson’s ratio and volumetric strain – Elastic moduli and the relationship between them – Bars of varying section – Composite bars – Temperature stresses. Strain energy – Resilience – Gradual, Sudden, Impact and shock loadings.

SHEAR FORCE AND BENDING MOMENT Definition of beam – Types of beams – Concept of shear force and bending moment – S.F and B.M diagrams for cantilever, Simply supported and overhanging beams subjected to point loads, U.D.L., Uniformly varying loads and combination of these loads – Point of contra flexure – Relation between S.F., B.M and rate of loading at a section of a beam.

FLEXURAL STRESSES Theory of simple bending – Assumptions – Derivation of bending equation: M/I = f/y = E/R neutral axis – Determination of bending stresses – Section modulus of rectangular and circular sections (solid and hollow), I,T, Angle and channel sections – Design of simple beam sections. SHEAR STRESSES Derivation of formula – Shear stress distribution across various beams sections like rectangular, Circular, Triangular, I, T angle sections.

PRINCIPAL STRESSES AND STRAINS Introduction – Stresses on an inclined section of a bar under axial loading – Compound stresses – Normal and tangential stresses on an inclined plane for biaxial stresses – Two perpendicular normal stresses accompanied by a state of simple shear – Mohr’s circle of stresses – Principal stresses and strains – Analytical and graphical solutions. THEORIES OF FAILURE Introduction – Various theories of failure – Maximum Principle Stress Theory, Maximum Principle Strain Theory, Strain Energy and Shear Strain Energy Theory (Von Mises Theory).

TORSION OF CIRCULAR SHAFTS Theory of pure torsion – Derivation of Torsion equations: T/J = q/r = Nθ/L – Assumptions made in the theory of pure torsion – Torsional moment of resistance – Polar section modulus – Power transmitted by shafts – Combined bending and torsion and end thrust – Design of shafts according to theories of failure. THIN CYLINDERS Thin seamless cylindrical shells – Derivation of formula for longitudinal and circumferential stresses – Hoop, Longitudinal and Volumetric strains – Changes in dia, And volume of thin cylinders – Thin spherical shells.

Crystal Structure : Unit cells, Metallic crystal structures, Ceramics, Imperfection in solid: Point, Line interfacial and volume defects, Dislocation strengthening mechanisms and slip systems, Critically resolved shear stress.

Alloys,Substitutional and interstitial solid solution- Phase diagrams: Interpretation of binary phase diagram and microstructure development, Eutectic, Peritectic, Peritectoid and Montectic reactions. Iron-carbide phase diagram and microstructural aspects of Ledeburite, Austenite, Ferrite and Cementite, Cast iron

Heat treatment of Steel: Annealing, Normalising, Hardening, Tempering and Spheroidising, Isothermal transformation diagram for Fe-C alloys and microstructures development.

Continuous cooling curves and interpretation of final microstructures and properties – Austempering, Martempering, Case hardening, Carburizing, Nitriding, Cyaniding, Carbo-nitriding, Flame and induction hardening, Vacuum and plasma hardening

Alloying of steel, Properties of stainless steel and tool steels, Maraging steels-Cast irons, Grey, White, malleable and spheroidal cast irons - Copper and copper alloys (Brass, bronze and cupro-nickel) Aluminium and AI-Cu-Mg alloys- Titanium alloys

Basic Probability Probability Spaces, Conditional Probability, Independent Events and Bayes’ Theorem. Random Variables: Discrete and Continuous Random Variables, Expectation of Random Variables, Moments, Variance of Random Variables.

Probability Distributions Binomial, Poisson, Evaluation of Statistical Parameters for These Distributions, Poisson Approximation to the Binomial Distribution. Continuous Random Variables and Their Properties, Distribution Functions and Density Functions, Normal and Exponential, Evaluation of Statistical Parameters for These Distributions.

Testing of Hypothesis Test of Significance: Basic of Testing of Hypothesis. Null and Alternate Hypothesis, Types of Errors, Level of Significance, Critical Region. Large Sample Test for Single Proportions, Difference of Proportions, Single Mean, Difference of Means, Small Sample Tests: Test for Single Mean, Difference of Means and Test for Ratio of Variances.

Complex Variables (Differentiation) Limit, Continuity and Differentiation of Complex Functions, Analyticity, Cauchy-Riemann Equations (without proof), Finding Harmonic Conjugate; Elementary Analytic Functions (Exponential, Trigonometric, Logarithm) and Their Properties.

Complex Variables (Integration) Line Integral, Cauchy’s Theorem, Cauchy’s Integral Formula, Zeros of Analytic Functions, Singularities, Taylor’s Series, Laurent’s Series; Residues, Cauchy Residue Theorem, Conformal Mappings, Mobius Transformations and Their Properties.