Basic Mechanical Engineering (Vel Tech)

321 Pages·2017·15.051 MB·English

by  Pravin Kumar

Basic Mechanical
Engineering
Pravin Kumar
Copyright © 2017 Pearson India Education Services Pvt. Ltd
Published by Pearson India Education Services Pvt. Ltd, CIN: U72200TN2005PTC057128,
formerly known as TutorVista Global Pvt. Ltd, licensee of Pearson Education in South Asia.
No part of this eBook may be used or reproduced in any manner whatsoever without the
publisher’s prior written consent.
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ISBN 978-93-325-7680-3
eISBN 978-93-325-7878-4
Head Office: A-8 (A), 7th Floor, Knowledge Boulevard, Sector 62, Noida 201 309,
Uttar Pradesh, India.
Registered Office: 4th Floor, Software Block, Elnet Software City, TS 140, Block 2 & 9,
Rajiv Gandhi Salai, Taramani, Chennai 600 113, Tamil Nadu, India.
Fax:  [phone], Phone: [phone]
www.pearson.co.in, Email: [email protected]
Dedicated to
My Wife and Sons
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Roadmap to the Syllabus
Vel Tech Dr. RR and Dr. SR Technical University, Chennai
Unit–I Manufacturing Techniques and Machine Elements
Introduction to Lathe and its operations, Drilling, Metal joining processes – Welding processes –
Arc and Gas welding – Brazing and soldering, Spot welding, Smithy. Sheet metal working.
Refer Chapters 1, 2 and 3
Unit–II Machine Elements
Helical and leaf springs, Cams, Types of cams and followers, Gears (spur, helical and bevel gears,
gear trains). Belt drives (types). Chain drives.
Refer Chapter 4
Unit–III Internal Combustion Engine
Introduction to Otto cycle and Diesel cycle, Principle of internal and external combustion
engines – Petrol engine, diesel engine, Two stroke and four stroke of both CI & SI engines,
emission control.
Refer Chapter 5
Unit–IV Power Plant Engineering
Introduction and classification of power plants – Working of thermal, hydroelectric, diesel,
nuclear power plants. Tidal power plant, Geo-Thermal. Introduction to steam and gas turbines.
Refer Chapters 6 and 7
Unit–V Thermal and Refrigeration Cycles
Basics of thermal power cycles – Carnot cycle. Introduction to Refrigeration – Non cyclic and
cyclic refrigeration – Principle of vapor compression refrigeration system – Principle of vapor
absorption refrigeration system. – Applications. Air-conditioning – Layout of typical domestic
Refrigerator – Window and Split, Centralized type air conditioner – Applications.
Refer Chapter 8
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Contents
Preface xv
About the Author xvii
Acknowledgements xix
1 Machine Tools 1.1
1.1 Introduction to Manufacturing Processes 1.1
1.2 Classification of Manufacturing Processes 1.1
1.2.1 Primary Shaping Processes 1.1
1.2.2 Machining Processes 1.2
1.2.3 Joining Processes 1.2
1.2.4 Processes Effecting Change in Properties 1.3
1.3 Introduction to Machine Tools 1.3
1.4 Mechanism of Metal Cutting 1.3
1.4.1 Types of Chip Formation 1.4
1.5 Geometry of Single Point Cutting Tool 1.4
1.6 Orthogonal and Oblique Metal Cutting 1.6
1.7 Lathe 1.7
1.7.1 Classification of Lathes 1.7
1.7.2 Specifications of Lathe 1.8
1.7.3 Constructional Detail of Lathe 1.8
1.7.4 Power Transmission System in Lathe Machine 1.10
1.7.5 Cutting Tools Used in Lathe 1.11
1.7.6 Types of Operations on Lathe Machine 1.11
1.8 Shaper, Slotter, and Planer 1.15
1.8.1 Shaping and Planing 1.16
1.8.2 Constructional Detail of Shaper 1.16
1.8.3 Slotter Machine 1.17
1.8.4 Crank and Slotted Arm Quick Return Mechanism 1.17
1.8.5 Specification of Shaper 1.18
1.8.6 Constructional Detail of Planer 1.18
1.8.7 Fast and Loose Pulleys Driving Mechanism of Planer 1.19
1.8.8 Specifications of Planer 1.20
1.8.9 Difference Between Shaper and Planer 1.20
viii Contents
1.9 Drilling Machine 1.21
1.9.1 Driving Mechanism in Drilling Machine 1.21
1.9.2 Drill Bit 1.21
1.9.3 Specifications of a Drilling Machine 1.22
1.9.4 Operations Performed on Drilling Machine 1.22
1.9.5 Advanced Types of Drilling Machine 1.24
1.10 Boring 1.25
1.10.1 Specification of Boring Machines 1.25
1.11 Milling Machines 1.25
1.11.1 Constructional Detail of Milling Machine 1.26
1.11.2 Basic Milling Operations 1.26
1.11.3 Nomenclature of Milling Cutter 1.29
1.12 Grinding and Surface Finishing Processes 1.29
1.12.1 Grinding Wheel Specification 1.29
1.12.2 Methods of Grindings 1.32
1.12.3 Types of Grinding Machines 1.32
1.12.4 Advantages of Grinding 1.35
1.12.5 Surface Finishing Processes 1.35
Summary 1.37
Multiple Choice Questions 1.39
Fill in the Blanks 1.41
Review Questions 1.42
2 PriMary shaPing and Joining
Processes: casTing and Welding 2.1
2.1 Introduction to Casting processes 2.1
2.2 Classification of Casting Process 2.2
2.3 Sand Casting 2.2
2.3.1 Steps in Sand Casting 2.3
2.3.2 Pattern Making 2.4
2.3.3 Types of Pattern 2.5
2.3.4 Mould Making 2.7
2.3.5 Properties of Mouldings Sands 2.9
2.3.6 Hand Tools Used in Moulding 2.10
2.3.7 Moulding Procedure 2.11
2.3.8 Gating System 2.12
2.3.9 Chills 2.13
2.3.10 Chaplets 2.13
2.3.11 Cores 2.13
2.3.12 Sand Testing 2.15
2.4 Special Casting Methods 2.16
2.4.1 Gravity/Permanent Mould Casting 2.16
2.4.2 Slush Casting 2.16
2.4.3 Pressed or Carthias Casting 2.16
2.4.4 Die Casting 2.17
Contents ix
2.4.5 Low-pressure Casting 2.18
2.4.6 Centrifugal Casting 2.19
2.4.7 Lost-wax Precision Casting Method 2.20
2.4.8 Shell Moulding 2.21
2.5 Casting Defects 2.22
2.6 Surface Cleaning of the Casting 2.24
2.7 Introduction to Welding Processes 2.24
2.7.1 Definition of Welding 2.24
2.8 Classification of Welding Process 2.26
2.9 Gas Welding 2.26
2.9.1 Oxyacetylene Welding 2.27
2.9.2 Gas Welding Methods 2.30
2.10 Electric Arc Welding 2.30
2.10.1 Functions of Electrode Coatings 2.32
2.10.2 Ingredients of Electrode Coating 2.32
2.10.3 Selection of Electrodes 2.33
2.10.4 Specifications for Electrodes 2.33
2.11 Types of Electric Arc Welding 2.33
2.11.1 Carbon Arc Welding 2.33
2.11.2 Shielded Metal Arc Welding (SMAW) 2.34
2.11.3 Metal Inert Gas Arc Welding (MIG)/Gas Metal
Arc Welding (GMAW) 2.34
2.11.4 Tungsten Inert Gas Arc Welding (TIG)/Gas Tungsten
Arc Welding (GTAW) 2.35
2.11.5 Submerged Arc Welding (SAW) 2.36
2.11.6 Electroslag Welding 2.37
2.11.7 Atomic Hydrogen Welding 2.38
2.11.8 Plasma Arc Welding 2.38
2.12 Resistance Welding 2.39
2.12.1 Resistance Spot Welding 2.40
2.12.2 Resistance Seam Welding 2.41
2.12.3 Resistance Projection Welding 2.41
2.12.4 Flash Welding 2.42
2.12.5 Percussion Welding 2.43
2.12.6 Resistance Butt Welding 2.43
2.13 Unconventional Welding Methods 2.44
2.13.1 Laser Beam Welding (Light Amplification by Stimulated
Emission of Radiation) 2.44
2.13.2 Electron Beam Welding 2.45
2.13.3 Ultrasonic Welding 2.46
2.13.4 Thermit Welding 2.47
2.14 Welding Allied Processes 2.47
2.14.1 Soldering 2.47
2.14.2 Brazing 2.47
2.14.3 Braze Welding 2.47