ME 6th Semester Syllabus

1. Unit 1Steam generators and boilers

   Steam generators: classification · Conventional boilers · High‑pressure boilers – Lamont, Benson, Loeffler and Velox steam generators · Performance and rating of boilers · Equivalent evaporation · Boiler efficiency · Heat balance sheet · Combustion in boilers · Super critical boilers · Fuel and ash handling · Boiler draught · Overview of boiler codes

2. Unit 2Vapour Cycles

   Phase change cycles: Vapor Carnot cycle and its limitation · Rankine cycle · Effect of boiler and condenser pressure and superheat on end moisture and efficiency of Rankine cycle · Modified Rankine cycle · Reheat cycle · Perfect regenerative cycle · Ideal and actual regenerative cycle with single and multiple heaters · Open and closed type of feed‑water heaters · Regenerative‑reheat cycle · Supercritical pressure and binary‑vapor cycle · Work‑done and efficiency calculations

3. Unit 3Gas Dynamics

   Speed of sound in a fluid · Mach number · Mach cone · Stagnation properties · One‑dimensional isentropic flow of ideal gases through variable‑area duct – Mach number variation · Area ratio as a function of Mach number · Mass flow rate and critical pressure ratio · Effect of friction · Velocity coefficient · Coefficient of discharge · Diffusers · Normal shock

4. Unit 4Air Compressors

   Working of reciprocating compressor · Work input for single‑stage compression (different compression processes) · Effect of clearance · Volumetric efficiency · Real indicator diagram · Isentropic, isothermal and mechanical efficiency · Multi‑stage compression · Inter‑cooling · Condition for minimum work done · Classification and working of rotary compressors

5. Unit 5Nozzles and Condensers

   Steam nozzles: isentropic flow of vapors · Flow of steam through nozzles · Condition for maximum discharge · Effect of friction · Super‑saturated flow · Steam condensers and cooling towers – introduction · Types of condensers · Back pressure and its effect on plant performance · Air leakage and its effect on performance of condensers · Various types of cooling towers

6. Unit 6== END OF UNITS==

1. Unit 1Introduction to stress in machine component

   Stress concentration and fatigue · Causes of stress concentration · Stress concentration in tension, bending and torsion · Reduction of stress concentration · Theoretical stress concentration factor · Notch sensitivity · Fatigue stress concentration factor · Cyclic loading · Endurance limit · S‑N curve · Loading factor · Size factor · Surface factor · Design considerations for fatigue · Goodman diagram · Modified Goodman diagram · Soderberg equation · Gerber parabola · Design for finite life · Cumulative fatigue damage factor

2. Unit 2Shafts

   Design of shaft under combined bending, twisting and axial loading · Shock and fatigue factors in shaft design · Design for rigidity of shafts · Design of shaft subjected to dynamic load · Design of keys · Design of shaft couplings

3. Unit 3Springs

   Design of helical compression springs · Design of helical tension springs · Dimensional and functional constraints for springs · Design of leaf springs · Design of torsion springs · Fatigue loading of springs · Surge in spring performance · Special spring types · Design of power screw and power nut · Differential screw design · Compound screw design · Design of simple screw jack

4. Unit 4Brakes & Clutches

   Materials for friction surfaces · Uniform pressure theory · Uniform wear theory · Design of friction clutches – disk clutches · Design of friction clutches – plate clutches · Design of friction clutches – cone clutches · Design of friction clutches – centrifugal clutches · Design of brakes – rope brakes · Design of brakes – band brakes · Design of brakes – block brakes · Design of internal expanding brakes · Design of disk brakes

5. Unit 5Journal Bearing

   Types of lubrication · Viscosity considerations · Hydrodynamic theory of bearings · Design factors for journal bearings · Temperature and viscosity effects · Reynolds' equation · Stable operation of journal bearings · Unstable operation of journal bearings · Heat dissipation and thermal equilibrium · Boundary lubrication regime · Dimensionless numbers in bearing analysis · Design of journal bearings · Rolling‑element bearings – types of rolling contact bearings · Bearing friction and power loss · Bearing life estimation · Radial loads on bearings · Thrust loads on bearings · Axial loads on bearings · Static load capacities · Dynamic load capacities · Selection of ball bearings · Selection of roller bearings · Lubrication and sealing of bearings

6. Unit 6== END OF UNITS==

1. Unit 1Energy transfer in turbo machines

   Application of first law of thermodynamics to turbo machines · Application of second law of thermodynamics to turbo machines · Moment of momentum equation and Euler turbine equation · Principles of impulse machines · Principles of reaction machines · Degree of reaction · Energy equation for relative velocities · One‑dimensional analysis of turbo machines

2. Unit 2Steam turbines

   Impulse staging and velocity/pressure compounding · Utilization factor and analysis for optimum U.F. (Curtis and Rateau stages) · Effect of blade and nozzle losses on vane efficiency · Stage efficiency and optimum efficiency analysis · Mass flow considerations and blade height design · Reaction staging: Parsons stages and degree of reaction · Nozzle efficiency, velocity coefficient, stator efficiency, carry‑over efficiency · Conditions for optimum efficiency, speed ratio, axial thrust · Reheat factor in turbines · Radial equilibrium problem · Free and forced vortex flow types · Flow with constant reaction · Governing and performance characteristics of steam turbines

3. Unit 3Water turbines and centrifugal pumps

   Classification of water turbines (Pelton, Francis, Kaplan) · Vector diagrams and work‑done analysis for water turbines · Draft tubes and governing of water turbines · Classification of centrifugal pumps and advantages over reciprocating pumps · Definitions of manometric head, gross head, and static head · Vector diagram and work‑done for centrifugal pumps · Dimensional analysis and similarity for water turbines and pumps · Unit and specific quantities for pump and turbine performance · Selection criteria for machines · Hydraulic, volumetric, mechanical and overall efficiencies · Main and operating characteristics of pumps and turbines · Cavitation phenomena in pumps

4. Unit 4Rotary fans, blowers and compressors

   Classification based on pressure rise (centrifugal and axial flow machines) · Centrifugal blowers: vane shape, velocity triangle, degree of reaction, slip coefficient, size and speed, vane stresses, efficiency, characteristics, fan laws · Centrifugal compressors: vector diagrams, work done, temperature and pressure ratios, slip factor, work input factor, pressure coefficient, dimensions of inlet eye, impeller and diffuser · Axial flow compressors: vector diagrams, work‑done factor, temperature and pressure ratios, degree of reaction, dimensional analysis, characteristics, surge phenomenon, polytropic and isentropic efficiencies

5. Unit 5Power transmitting turbo machines

   Application and general theory of power‑transmitting turbo machines · Torque ratio, speed ratio, slip and efficiency · Velocity diagrams for power transmission · Fluid coupling and torque converter characteristics · Positive displacement machines versus turbo machines and their distinction · Positive displacement pumps with fixed and variable displacement · Hydrostatic systems: hydraulic intensifier, accumulator, press, crane

1. Unit 1Introduction to Computer Engineering

   Methods to solve engineering problems – analytical, numerical, experimental, their merits and comparison · Discretization into smaller elements and effect of size/shape on accuracy · Importance of meshing and boundary conditions · Computer Aided Engineering (CAE) and design, chain‑bumping‑stages vs concurrent‑collaborative design cycles · Computer as enabler for concurrent design and Finite Element Method (FEM) · Degree of freedom (DOF) · Mechanical systems with mass, damper and spring · Stiffness constant $K$ for tensile, bending and torsion · Practical applications of FEA in new design, optimisation/cost‑cutting and failure analysis

2. Unit 2Types of Analysis

   Types of analysis in CAE: static (linear/non‑linear), dynamic, buckling, thermal, fatigue, crash NVH and CFD · Review of normal, shear, torsion, stress‑strain relations · Types of forces and moments, tri‑axial stresses, moment of inertia · Meshing strategies: 1‑D, 2‑D, 3‑D elements and element length · Force‑stiffness and displacement matrix formulation · Rayleigh‑Ritz and Galerkin FEM formulations · Analytical and FEM solution for a single rod element and a two‑rod assembly

3. Unit 32 D‑Meshing

   Two‑dimensional meshing and elements for sheet work and thin shells · Effect of mesh density and biasing in critical regions · Comparison between triangular and quadrilateral elements · Quality checks: Jacobian, distortion, stretch, free edge, duplicate node and shell normal

4. Unit 43 D‑Meshing

   Three‑dimensional meshing and elements (only 3 DOF) · Algorithm for triangle‑to‑tetrahedron conversion, floating and fixed triangles · Quality checks for tetrahedral meshing · Brick meshing and associated quality checks · Special elements and techniques, introduction to weld, bolt, bearing and shrink‑fit simulations · CAE and test data correlations · Post‑processing techniques

5. Unit 5Optimization

   Review of linear optimisation · Process and product optimisation · Design for Manufacturing (DFM) aspects in product development · Use of morphing technique in FEA · Classical design for infinite life and design for warranty life · Warranty yard meetings and functional roles · Climatic conditions and design abuses · Case studies

1. Unit 1Introduction to product design

   Product life-cycle · Product policy of an organization · Selection of a profitable product · Product design process · Product analysis

2. Unit 2Value engineering in product design

   Advantages and applications in product design · Problem identification and selection · Analysis of functions · Anatomy of function · Primary versus secondary versus tertiary/unnecessary functions · Functional analysis using Functional Analysis System Technique (FAST) · Case studies

3. Unit 3Introduction to Product design tools

   Quality Function Deployment (QFD) · Computer Aided Design (CAD) · Robust design · Design for X (DFX) · Design for Manufacturing (DFM) · Design for Assembly (DFA) · Ergonomics in product design

4. Unit 4DFMA guidelines

   Product design for manual assembly · Design guidelines for metallic products · Design guidelines for non‑metallic products · Manufacturing processes such as casting, machining, injection molding, etc.

5. Unit 5Rapid Prototyping

   Needs of rapid prototyping · Advantages of rapid prototyping · Working principles of Stereolithography (SLA) · Working principles of Laminated Object Manufacturing (LOM) · Working principles of Selective Laser Sintering (SLS)

1. Unit 1Introduction

   Need and importance · Basic concepts · Structure and classification of industrial robots · Terminology of robot motion · Motion characteristics · Resolution · Accuracy · Repeatability · Robot applications

2. Unit 2End Effectors and Drive Systems

   Drive systems for robots · Salient features and comparison of drive systems · Different types of end effectors · Design of end effectors · Applications of end effectors

3. Unit 3Sensors

   Sensor evaluation and selection · Piezoelectric sensors · Linear position and displacement sensing · Revolvers · Encoders · Velocity measurement · Proximity sensing · Tactile sensing · Compliance and range sensing · Image processing and object recognition

4. Unit 4Robot Programming

   Teaching of robots · Manual programming · Walk‑through programming · Teach pendant programming · Offline programming concepts · Programming languages for robots · Applications of robot programming

5. Unit 5Safety and Economy of Robots

   Work‑cycle time analysis · Economics and effectiveness of robots · Safety systems and devices · Testing methods and acceptance rules for industrial robots

1. Unit 1Introduction to Optimization

   Engineering application of Optimization · Statement of an Optimization problem · Optimal problem formulation · Classification of Optimization problems · Optimum design concepts · Definition of Global and Local optima · Optimality criteria · Review of basic calculus concepts · Global optimality

2. Unit 2Linear programming methods for optimum design

   Review of Linear programming methods for optimum design · Post optimality analysis · Application of LPP models in design and manufacturing

3. Unit 3Optimization algorithms for solving unconstrained optimization problems

   Gradient based methods · Cauchy's steepest descent method · Newton's method · Conjugate gradient method

4. Unit 4Optimization algorithms for solving constrained optimization problems

   Direct methods · Penalty function methods · Steepest descent method (constrained) · Engineering applications of constrained and unconstrained algorithms

5. Unit 5Modern methods of Optimization

   Genetic Algorithms · Simulated Annealing · Ant colony optimization · Tabu search · Neural-network based optimization · Fuzzy optimization techniques · Applications of modern optimization methods · Use of Matlab to solve optimization problems

1. Unit 1Solar Radiation

   Extra-terrestrial and terrestrial solar radiation · Solar radiation measuring instruments and prediction methods · Solar thermal conversion basics · Flat plate collectors: liquid and air types · Theory of flat plate collectors and selective coating · Advanced flat plate collectors and concentrators · Optical design of solar concentrators · Solar water heating systems · Solar dryers, solar stills, solar cooling and refrigeration · Solar photovoltaic principles · Photovoltaic device fabrication technologies · Applications of solar cells in PV generation systems · Organic photovoltaic cells

2. Unit 2Wind Energy

   Wind speed distribution metrology and statistics · Weibull, Rayleigh, and Normal distributions for wind speed · Measurement of wind data · Energy estimation of wind regimes · Wind energy conversion principles · Types and classification of wind energy conversion systems (WECS) · Power, torque, and speed characteristics of wind turbines · Power curve of wind turbine and capacity factor · Matching wind turbine with wind regimes · Applications of wind energy

3. Unit 3Production of Biomass

   Photosynthesis pathways (C3 & C4) and biomass production · Biomass resource assessment and CO\textsubscript{2} fixation potential · Classification of biomass · Physicochemical characteristics of biomass as fuel · Biomass conversion routes: biochemical, chemical, thermochemical · Biochemical conversion: anaerobic digestion and biogas production mechanism · Types of digesters and design of biogas plants · Operation and maintenance of biogas plants, manure utilization · Biomass gasification: types and power generation · Cost‑benefit analysis of power generation by gasification

4. Unit 4Small Hydropower Systems

   Overview of micro, mini, and small hydro systems · Hydrology and turbine elements · Assessment and design criteria of hydro power · Site selection and civil works for hydro projects · Speed and voltage regulation of hydro generators · Investment issues, load management, and tariff collection · Distribution and marketing of hydro power · Ocean energy resources and routes · Ocean thermal energy conversion (OTEC) systems and principles · Ocean wave energy and tidal energy conversion principles

5. Unit 5Geothermal Energy

   Origin and types of geothermal energy deposits · Site selection for geothermal power plants · Hydrogen as an energy source, production and storage · Fuel cell types and subsystems · Principles of fuel cell operation and basic thermodynamics

1. Unit 12D Drawing and Sketching

   Layout and sketching of different geometries · Drawing environment in AUTOCAD · Elements of drawing and draw commands · 3D functions in AUTOCAD · 2D: Figures for practice using AutoCAD · ISOMETRIC drawing for practice using AutoCAD · 3-D solid figures using AUTOCAD

2. Unit 23D Modeling and Assembly

   Introduction to CREO 3.0 · Learning different Operations like Threading, Sweep, Swept‑blend. · Modeling & Assembling

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