1. 11O105 BASICS OF CIVIL AND MECHANICAL ENGINEERING Prepared by Mr. C. Ayyasamy Assistant Professor Department of Mechanical Engineering Bannari Amman Institute of Technology

2. 11O105 BASICS OF CIVIL AND MECHANICAL ENGINEERING Objectives -basic knowledge in the field of Mechanical Engineering -focusing on generation of power from various natural resources -know about various types of Boilers and Turbines used for power generation

3. Unit IV Engineering Materials and Manufacturing Processes Classification of Engineering materials, Mechanical properties and uses of cast iron, steel, and High Speed Steel. Introduction to casting process, Green sand moulding - Pattern, Melting furnaces - Cupola and Electric Furnace. Metal Forming - Forging Process. Introduction to Arc and Gas Welding. Centre Lathe - Specifications - Principal parts - Operations - Straight turning, Step turning, Taper turning methods, Knurling, Thread cutting methods, Facing, Boring, and Chamfering - Lathe tools and Materials. Drilling – Radial drilling machine - Specification and Operation.

4. Product - satisfy the functional requirements Product function is interdependent Selection of Material Manufacturing Processes Design Concepts Product Function

5. MATERIALS

8. Vessels and Boiler

9. MetallicNon Metallic Composites Materials Inorganic Organic Non-ferrous Ferrous Selection of material Knowledge about types of materials and their properties Cast iron (>2%C) Gray White Ductile Malleable Plastics, rubber Wood,paper Steel (<2%C) Plain carbon (Low,Medium,High) Alloy steel (Stainless steel, HSS) Metals Copper Nickel Aluminium Chromium Alloys Brass Bronze Duraluminium Asbestos, Glass Concrete, Cement Fiber matrix Metal matrix

10. 10 Based on data provided in Tables 9.1(b), 9.2(b), 9.3, and 9.4, Callister’s Materials Science and Engineering, Adapted Version. Steels Plain carbon Alloy low carbon <0.25 wt% C Med carbon 0.25-0.6 wt% C high carbon 0.6-1.4 wt% C Usesauto structure. sheet bridges towers press. vessels crank shafts bolts hammers blades pistons gears wear application. wear application. drills saws dies high T application. turbines furnaces V. corros. resistant increasing strength, cost, decreasing ductility

11. quantities that characterize the behavior of a material in response to physical phenomena other than mechanical forces. e.g. density, weight electric resistance (Electricity) thermal conductivity (Heat transfer) melting temperature Mechanical properties Physical properties quantities that characterize the behavior of a material in response to external or applied forces. Material properties

12. Mechanical properties 1 Strength – Resistance to deform

14. Mechanical properties

15. Stress-Strain Diagram Strain ( ) (  L/Lo) 4 1 2 3 5 Stress (F/A) Elastic Region Plastic Region Strain Hardening Fracture ultimate tensile strength Slope=E Elastic region slope =Young’s (elastic) modulus yield strength Plastic region ultimate tensile strength strain hardening fracture necking yield strength

16. 16 Stress-Strain Test specimen machine

17. 17

18. 18 1. Initial2. Small load3. Unload Elastic means reversible. Elastic Deformation

19. 19 1. Initial2. Small load3. Unload Plastic means permanent. Plastic Deformation (Metals)

20. Mechanical properties 2 Stiffness – Resistance to bending

21. Mechanical properties 3 Elasticity – Ability of the metal to deform under load and return to its original shape and size when load is removed

22. Mechanical properties 4 Plasticity 5 Malleability – Plastic deformation under compressive load

23. Mechanical properties 6 Ductility – Ability of the material to stretch under tensile load.

24. 24 Malleability -property of a material to be deformed by compression without cracking or rupturing. -Load may be applied slowly or suddenly -determine whether the material will be suitable for forging or rolling into thin sheet. High Malleability material : Silver Low Malleability material :Nickel

25. Mechanical properties 7Hardness – Ability to withstand scratch

26. Mechanical properties 8Fatigue – Failure when subjected to repeated load Wind turbines are subject to fluctuating winds, and hence fluctuating forces. This is particularly the case if they are located in a very turbulent wind climate. fluctuating winds,turbulent

27. Mechanical properties 9Toughness – Amount of energy absorbed before fracture 10Creep – Slow and progressive deformation of metal with time under a constant stress. Creep become important at elevated temperature.

28. Tensile test Young's Modulus Hook’s law (elastic limit) Ductile 0.002 brittle Ultimate Tensile Strength : Highest value of stress on the stress-strain curve. Modulus of Resilience: Stored energy per unit volume that the material can absorb without yielding.

29. 29 ANNEXURE II – MIND MAP

30. 30 1.How the materials are classified? 2.How cast iron differ from steel in carbon content? 3.Define alloy and steel? 4.Define the term heat treatment. 5.How can you classify iron and steel? 6.What are the factors affecting mechanical properties. 7.What are the properties that can be determined by tensile test. 8.How will you choose the material for industrial application? 9.When the materials attain their required properties. 10.What is the use of cast iron? 11.What is the use of steel? ANNEXURE IV - QUESTIONS

31. 31 ANNEXURE V - QUESTIONS

32. Hidden Picture Puzzles

33. This is an optical illusion of a different type. Find the seven hearts in this picture!!!!!!

34. Answer is!!! 1.In the water 2.In the mountain 3.Trees 4.Swans 5.Sky 6.On the balloon, and 7.Back in the grass with water in it

35. Thank you