Lesson Plan Semester 3 PDF

PES UNIVERSITY
DEPARTMENT OF MECHANICAL ENGINEERING

COURSE INFORMATION
B.TECH SEMESTER 3: AUGUST-DECEMBER 2017
Credit Course
Sl. Hours per week
Course Code Course Title s Type
No.
L T P S
1 UE16ME201 Material Science and Metallurgy 4 0 0 2 4 CC
2 UE16ME202 Engineering Thermodynamics 3 1 0 4 4 CC
3 UE16ME203* Mechanics of Solids 3 1 0 4 4 CC
Metal Casting and Welding

4 UE16ME204 4 0 0 2 4 CC
Processes
1
PES UNIVERSITY
COURSE INFORMATION
MATERIAL SCIENCE AND METALLURGY: UE16ME201
Faculty: Dr. MS / SRH / NR / SS No. Of Hours: 52
% of Portions covered
Chapter Title /
Class # Topics to be covered Reference
Reference Literature Cumulative
chapter
Chapter: 1
UNIT 1
Lattice, Unit cell,
Technological significance of Materials in
Basis and crystal
1 Engineering and their applications. 2% 2%
structure
Classification of engineering materials; Atomic
T1:Chapter 2,
structure of metals and bonds.
page 24-41
Chapter: 1
Lattice, Unit cell,
Fundamental concepts of Unit cell, basis, space
Basis and crystal
2 lattice, crystal lattice. perfect and imperfect 2% 4%
structure
crystal
T1:Chapter 3,
page 60-72
Chapter: 1
Lattice, Unit cell,
Bravais Lattices and Bravais systems, Lattice
Basis and crystal
3 parameters, Unit cells for cubic structures and 2% 6%
structure
HCP
T1:Chapter 3,
page 72-84
Chapter: 1
Lattice, Unit cell,
Calculations of radius, effective number of
Basis and crystal
4 atoms, co-ordination No. and Atomic packing 2% 8%
structure
factor for BCC, FCC and Simple cubic structures
T1:Chapter 3,
page 86-92
Chapter: 1
Lattice, Unit cell, Calculations of radius, effective number of
Basis and crystal atoms, co-ordination No. and Atomic Packing
5 2% 10%
structure Factor for Hexagonal Close Packed (HCP)
T1:Chapter 3, Structures
page 86-92
Chapter: 1
Lattice, Unit cell,
Basis and crystal Miller indices of planes in cubic and hexagonal
6 2% 12%
structure structures,
T1:Chapter 3,
page 73-86
Chapter: 1
Lattice, Unit cell,
Basis and crystal Miller indices of directions in cubic and
7 2% 14%
structure hexagonal structures,
T1:Chapter 3,
page 73-86
Chapter: 1
Lattice, Unit cell,
Basis and crystal Numerical problems on Miller indices of planes
8 2% 16%
structure and directions.
T1:Chapter 3,
page 104-113
2
PES UNIVERSITY
COURSE INFORMATION
Chapter : 2
Crystal Imperfections Point imperfections in crystalline solids -
9 T1: Chapter 4, vacancies, interstitials, Frankel and Schottky 2% 18%
page 114-121 defects.
Chapter : 2
Crystal Imperfections Line imperfections in crystalline solids -
10 T1: Chapter 4, dislocations, edge, screw and mixed dislocations 2% 20%
page 122-134 and their characteristics;
Chapter : 2
Crystal Imperfections
surface and volume imperfections in crystalline
11 T1: Chapter 4, 2% 22%
solids
page 135-143
Chapter : 3
Atomic Diffusion
Atomic diffusion, Types, Applications of
12 T1: Chapter 5, 2% 24%
Diffusion, diffusion mechanism,
page 156-163
Chapter : 3
Atomic Diffusion
Ficks first and second laws of diffusion, Steady
13 T1: Chapter 5, 2% 26%
and Non-steady states, Diffusivity.
page 164-167
Chapter : 3
Atomic Diffusion
14 T1: Chapter 5, Factors affecting diffusion, Numerical problems 2% 28%
page 168-175; 190-196
Chapter : 4
Mechanical
Properties and UNIT 2
15 Behavior 2% 30%
Deformation Mechanism, Types of deformations,
T1: Chapter 6,
Tensile test,
page 198-207
Chapter : 4
Mechanical
Properties and
Properties obtained from Tensile test, true stress
16 Behavior 2% 32%
& true strain,
T1: Chapter 6,
page 208-217
Chapter : 4
Mechanical
Properties and
Plastic deformation - slip and twinning; ductile
17 Behavior 2% 34%
and brittle fracture
T1: Chapter 7,
page 254-259
3
PES UNIVERSITY
COURSE INFORMATION
Chapter : 4
Mechanical
Properties and
Hardness of Materials Rockwell, Vickers &
18 Behavior 2% 36%
Brinell Hardness testing,
T1: Chapter 6,
page 221-226
Chapter : 4
Mechanical
Properties and
Strain rate effects and Impact testing, Numerical
19 Behavior 2% 38%
problems
T1: Chapter 6,
page 227-230; 239-245
Chapter : 5
Solid Solutions and UNIT 3
Phase Equilibrium
20 Phases and Phase diagram, solid solutions, 2% 40%
T1: Chapter 10,
completely soluble, Insoluble and partially
page 376-386
soluble solid solutions
Chapter : 5
Solid Solutions and
Rules governing formation of solid solutions,
Phase Equilibrium
21 Phase diagrams Basic terms, phase rule, 2% 42%
T1: Chapter 10,
cooling curves,
page 387-396
Chapter : 5
Solid Solutions and
Phase Equilibrium construction of Phase diagrams, interpretation of
22 2% 44%
T1: Chapter 11, equilibrium diagrams,
page 417-437
Chapter : 5
Solid Solutions and
Phase Equilibrium Types of Phase diagrams, Reactions in phase
23 2% 46%
T1: Chapter 10, diagrams, Lever rule
page 387-396
Chapter : 5
Solid Solutions and
Phase Equilibrium Numerical problems on Phase diagrams and
24 2% 48%
T1: Chapter 10, invariant reactions
page 405-412
Chapter : 5
Solid Solutions and
Phase Equilibrium Numerical problems on Lever Rule and relative
25 2% 50%
T1: Chapter 11, compositions
page 443-450
Chapter : 6
Principles of
Technological significance, Nucleation,
26 Solidification 2% 52%
Applications of controlled nucleation,
T1: Chapter 9,
page 330335
4
PES UNIVERSITY
COURSE INFORMATION
Chapter : 6
Principles of
Growth mechanisms, Solidification time and
dendrite size,
T1: Chapter 9,
page 336342
Chapter : 6
Principles of
28 Solidification Solidification defects, Cast structure 2% 56%
T1: Chapter 9,
page 344350
Chapter : 6
Principles of
Numerical problems on solidification, nucleation
and growth
T1: Chapter 9,
page 365 374
Chapter : 7
Iron-Carbon UNIT 4
30 Equilibrium Diagram Phases in the Fe-C system, Invariant reactions, 2% 60%
T2: Chapter 9,
page 333 335
Chapter : 7
Iron-Carbon
critical temperatures, Microstructures of slowly
31 Equilibrium Diagram 2% 62%
cooled steels,
T2: Chapter 9,
page 336 343
Chapter : 7
Iron-Carbon Phases and microstructures of slowly cooled
32 Equilibrium Diagram hypo, hyper and eutectoid steels; 2% 64%
T2: Chapter 9, microstructures of cast irons
page 336 343
Chapter : 7
Iron-Carbon
effect of alloying elements on the Fe-C diagram,
ferrite and austenite stabilizers.
T2: Chapter 9,
page 344 345
Chapter : 7
Iron-Carbon
The TTT diagram, drawing of TTT diagram,
TTT diagram for hypo & hyper eutectoid steels
T2: Chapter 10,
page 370 380
Chapter : 7
Iron-Carbon
CCT diagram. Effect of alloying elements on
CCT diagram.
T2: Chapter 10,
page 381 390
Chapter : 8
Heat treatment of
36 Steels Annealing and its types, Normalizing, Hardening 2% 72%
T1: Chapter 13,
page 498 508
Chapter : 8
Heat treatment of
Tempering, Martempering, Austempering,
37 Steels 2% 74%
characteristics of different heat treated steels
T1: Chapter 13,
page 498 508
5
PES UNIVERSITY
COURSE INFORMATION
Chapter : 8
Heat treatment of
Surface hardening, Types, Methods like
38 Steels 2% 76%
carburizing, cyaniding.
T1: Chapter 13,
page 516 518
Chapter : 8
Heat treatment of
Surface hardening methods like nitriding, and
39 Steels 2% 78%
induction hardening,
T1: Chapter 13,
page 516 518
Chapter : 9
Hardenability of
40 Steels Hardenability concept Jominy End Quench test 2% 80%
T1: Chapter 13,
page 504 513
Chapter : 9
Hardenability of
Hardenability curves, effect of alloying elements
41 Steels 2% 82%
on hardenability curves
T1: Chapter 13,
page 504 513
Chapter : 10
Engineering Alloys UNIT 5
42 (Ferrous) Classification, Composition of plain, medium 2% 84%
T1: Chapter 13, and high Carbon steels
page 494 497
Chapter : 10
Engineering Alloys
(Ferrous) Properties and uses of plain medium and high
43 2% 86%
T1: Chapter 13, Carbon steels
page 514 515; page
519-523
Chapter : 10
Engineering Alloys
Steel designation as per AISI designation;
44 (Ferrous) 2% 88%
Designation rules.
T1: Chapter 13,
page 494497
Chapter : 10
Engineering Alloys
Properties and uses of Cast Irons gray Cast
45 (Ferrous) 2% 90%
Iron, White Cast Iron
T1: Chapter 13,
page 523 528
Chapter : 10
Engineering Alloys Properties and uses of Cast Irons Malleable
46 (Ferrous) Cast Iron & Ductile Iron and Austempered 2% 92%
T1: Chapter 13, Ductile Iron
page 523 528
Chapter : 11
Engineering Alloys
47 (Non-Ferrous) Properties and uses of light alloys - Al, Mg 2% 94%
alloys;
T1: Chapter 14,
page 540 547
6
PES UNIVERSITY
COURSE INFORMATION
Chapter : 11
Engineering Alloys
(Non-Ferrous) Properties and uses of light alloys - Ti alloys;
48 2% 96%
T1: Chapter 14, Properties and uses of Copper and its alloys
page 548 551; page
556 - 561
Chapter : 12
Ceramic and
49 Polymeric Materials Basic concepts, Types of ceramics, properties of 1% 97%
ceramics
T1: Chapter 15,
page 572 574
Chapter : 12
Ceramic and
50 Polymeric Materials Applications of ceramics, Sintered ceramics; 1% 98%
T1: Chapter 15,
page 572 581
Chapter : 12
Ceramic and
51 Polymeric Materials Classification of polymers, addition and 1% 99%
condensation polymerization,
T1: Chapter 16,
page 602 611
Chapter : 12
Ceramic and
52 Polymeric Materials Typical thermoplastics and thermosetting 1% 100%
polymers, Processes and Applications.
T1: Chapter 16,
page 612 636
Reference Books:
1. "The Science and Engineering of Materials ", Donald R Askeland and Pradeep, P. Phule, Cengage Learning,
Sixth Edition, 2010.
2. "Materials Science and Engineering: An Introduction", William D. Callister, Jr., John Wiley & Sons, Eighth
Edition, 2009.
7
PES UNIVERSITY
COURSE INFORMATION
ENGINEERING THERMODYNAMICS
LESSON PLAN
Subject Code: UE15ME203

Faculty: RP/AM
No. of Hours: 52
Class Chapter Title / % of Portions covered

No. Reference Topics to be covered Reference
Literature Cumulative
chapter
1 Chapter 1: Unit I
Introduction Definition of engineering thermodynamics;
T1: page 1-7 examples of systems like steam power plant, IC
engines, domestic refrigerator, room air 2 2
conditioner, and fuel cells which require the
knowledge of thermodynamics for their
performance evaluation
2 Chapter 1: Description of matter macroscopic description
Introduction and microscopic description; thermodynamic
T1: page 8-9 system, surroundings and the system boundary; 2 4
closed system, open system (control volume)
and isolated system
3-4 Chapter 1: Thermodynamic properties, processes and
Introduction cycles; homogeneous and heterogeneous
T1: page 10-15 systems; thermodynamic equilibrium; quasi- 4 8
static process; pure-substance; concepts of
continuum.
5 Chapter 2: Thermal equilibrium; Zeroth law of
Temperature thermodynamics; concept of temperature;
T1: page 26-28 measurement of temperature thermometric 2 10
property, scale of temperature, reference points,
comparison of different types of thermometers
6 Chapter 2: Ideal gas; gas thermometers; ideal gas
Temperature temperature; Celsius temperature scale; 2 12
T1: page 29-33 illustrative examples.
78 Chapter 3: Work Mechanics definition of work and its limitations
and Heat for analyzing thermodynamic system;
Transfer thermodynamics definition of work;
T1: page 41-46 characteristics of work transfer; classification of
4 16
work; general expression for mechanical
displacement work (pdV work); expressions for
mechanical displacement work for different
quasi static processes
9 Chapter 3: Work Expressions for other forms of work; net work 2 18
8
PES UNIVERSITY
COURSE INFORMATION
and Heat transfer between a system and its surroundings;

Transfer definition of heat transfer; characteristics of
T1: page 48-56 heat transfer; illustrative examples.
10 Chapter 3: Work Illustrative examples Heat and Work Transfer
and Heat 2 20
Transfer
11-12 Chapter 4: Unit II
First Law of First law for a closed system undergoing a
Thermodynamics cyclic process; first law for a closed system
T1: page 69-76 undergoing a non-cyclic process; energy a
property of a system; different forms of stored 4 24
energy; definition of a pure substance; two-
property rule for a pure substance; specific heat
at constant pressure and specific heat at
constant volume;
13 Chapter 4: First law for an isolated system; perpetual
First Law of motion machine of first kind; illustrative
2 26
Thermodynamics examples.
T1: page 77-78
14-15 Chapter 5: Control volume; law of conservation of mass
First Law and first law equation for a steady state steady
Applied to Flow flow system; application of steady flow
4 30
Processes equation to systems like turbines,
T1: page 87-92 compressors/pumps, heat exchangers,
nozzles/diffusers, throttle valve
16 Chapter 5: Comparison of steady flow energy equation
First Law with Euler and Bernoulli equations; first law
Applied to Flow equation for unsteady flow open systems 2 32
Processes
T1: page 95-99
17 Chapter 5: Illustrative examples
First Law
2 34
Applied to Flow
Processes
First Law
2 36
Applied to Flow
Processes
First Law
2 38
Applied to Flow
Processes
First Law
2 40
Applied to Flow
Processes
9
PES UNIVERSITY
COURSE INFORMATION
21-22 Chapter 6: Unit III

Second Law of Limitations of first law; qualitative differences
Thermodynamics between heat and work; Cyclic heat engine;
T1: page 117-124 energy reservoirs; performance of a direct heat
engine and Kelvin-Planck statement of second 4 44
law; reversed heat engine- refrigerator and heat
pump; coefficient of performance for a
refrigerator and for a heat pump; Clausius
statement of second law;
23-24 Chapter 6: Equivalence between the two statements;
Second Law of illustrative examples
4 48
Thermodynamics
T1: page 117-124
25 Chapter 6: reversibility and irreversibility; causes which
Second Law of make a process irreversible and types of
2 50
Thermodynamics irreversibility;
T1: page 117-124
26-27 Chapter 6: definition of a reversible heat engine;
Second Law of corollaries of second law of thermodynamics;
2 52
Thermodynamics reversibility and irreversibility as applied to a
T1: page 125-135 non-cyclic process;
28-30 Chapter 6: Kelvins absolute scale of temperature;
Second Law of illustrative examples.
4 56
Thermodynamics
T1: page 135-141
31-32 Chapter 7: UNIT: IV
Entropy Introduction to Entropy; Clausius inequality (or
T1: page 157-162 Clausius theorem); Entropy as a property of a
4 60
system; Temperature entropy plot and its
usefulness in analyzing thermodynamic
processes;
32-33 Chapter 7: Entropy change for an irreversible process;
Entropy principle of increase of entropy ; applications of
T1: page 164-178 principle of increase of entropy heat transfer 8 68
through a finite temperature difference, mixing
of two fluids
34-35 Chapter 7: Maximum work obtainable from two identical
Entropy bodies at two different temperatures and
T1: page 164-178 maximum work obtainable from a finite body
8 68
and a thermal energy reservoir; entropy
generation in closed and open systems;
illustrative examples
36-37 Chapter 7: Carnot cycle on T-s diagram and expression for
Entropy Carnot efficiency; 8 76
T1: page 180-183
38-39 Chapter 7: Tds relations and their significance (first and 8 76
10
PES UNIVERSITY
COURSE INFORMATION
Entropy second law combined), Isentropic process;

T1: page 180-183 illustrative examples.
40 Chapter 8: Introduction to concepts of available energy and

Availability unavailable energy; quality of energy; dead 2 78
T1: page 200-210 state; availability;
41-42 Chapter 8: Availability analysis for closed and open
Availability systems; second law efficiency; illustrative
6 84
T1: page 212-222 examples.
43-45 Chapter 9: UNIT V

Properties of Avogadros law; equation of state for a gas;
Gases and Gas ideal gas; equations of state 6 90
Mixtures
T1: page 273-288
46-48 Chapter 9: UNIT V
Properties of Properties of mixtures of gases- Daltons law
Gases and Gas and Gibbs law- internal energy, enthalpy ,
6 90
Mixtures specific heats and entropy of a mixture of
T1: page 273-288 gases; illustrative examples.
49-50 Chapter 10: p-v and p-T diagrams for a pure substance; T-s
Properties of and h-s diagrams for a pure substance;
Pure Substances quality/dryness fraction ; steam tables and 6 96
T1: page 289-295 charts for thermodynamic properties;
Illustrative examples
51-52 Chapter 10: Measurement of steam quality; illustrative
Properties of examples, Clausius - Clayperon Equation
4 100
Pure Substances
T1: page 320-351
T1: Text Book: Engineering Thermodynamics (Fourth Edition), P.K.Nag, TMH publishing Co.
Ltd., 2008
Reference Book: Thermodynamics - An Engineering Approach , Yunus Cengel & Michael

Boles, TMH Publishing Co. Ltd, 2008
11
PES UNIVERSITY
COURSE INFORMATION
UE16ME203: MECHANICS OF SOLIDS (4-0-0-0-4)

Faculty: Dr. KSS/ HS/ KM/ BKK No. of Classes: 52
Class Chapter Title / % of Portions covered

No. Reference Topics to be covered Reference
Literature Cumulative
chapter
Unit 1: Chapter 1:
Review of basics Basics of axial and multi-axial loading
T1: Chapters 1 and
1 2% 2%
2
Sections: 1.1:1.6,
1.11, 2.1:2.8, 2.12
Unit 1: Chapter 1: Factor of safety, Stress-Strain diagram,
Review of basics Numerical problems,
2 2% 4%
T1: Chapter 2
Sections: 2.1:2.8
Unit 1: Chapter 1: Statically indeterminate problems
Review of basics
3 2% 6%
T1: Chapter 2
Sections:2.9
Unit 1: Chapter 1: Statically indeterminate problems
Review of basics
4 2% 8%
T1: Chapter 2
Sections:2.9
Unit 1: Chapter 1: Dilatation-Bulk modulus, Relation among E,
Review of basics Nu and G, Saint-Venants principle, Stress
5 T1: Chapter 2 2% 10%
Sections:2.13:2.15, concentrations
1.17
Unit 1: Chapter 2: Numerical problems
6 Review of basics 2% 12%
T1: Chapter 2
T1: Chapter 2
T1: Chapter 2
Unit 1: Chapter 3: Problems involving temperature changes
Thermal Stresses
9 2% 17%
T1: Chapter 2
Sections:2.10
Unit 1: Chapter 3: Problems involving temperature changes
Thermal Stresses
10 2% 19%
T1: Chapter 2
Sections:2.10
Unit 2: Chapter 3: Shear and Bending-Moment Diagrams
Analysis and Design
of Beams For
11 2% 21%
Bending
T1: Chapter 5
Sections:5.2
12 Unit 2: Chapter 3: Standard cases 2% 23%
12
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COURSE INFORMATION
Analysis and Design

of Beams For
Bending
T1: Chapter 5
Sections:5.2
Unit 2: Chapter 3: Standard cases
Analysis and Design
of Beams For
13 2% 25%
Bending
T1: Chapter 5
Sections:5.2
Analysis and Design
14 of Beams For 2% 27%
Bending
T1: Chapter 5
Analysis and Design
Bending
T1: Chapter 5
Analysis and Design
Bending
T1: Chapter 5
Unit 2: Chapter 4: Introduction, Deformation in a Symmetric
Pure Bending Member in pure Bending
17 2% 33%
T1: Chapter 4
Sections:4.1, 4.3
Unit 2: Chapter 4: Deformation in a Symmetric Member in pure
Pure Bending Bending
18 2% 35%
T1: Chapter 4
Sections:4.1, 4.3, 4.4
Unit 2: Chapter 4: Stresses and Deformations in the Elastic Range
Pure Bending
19 2% 37%
T1: Chapter 4
Sections:4.1, 4.3, 4.4
Unit 2: Chapter 4: Stresses and Deformations in the Elastic Range
Pure Bending
20 1% 38%
T1: Chapter 4
Sections:4.1, 4.3, 4.4
21 Pure Bending 2% 40%
T1: Chapter 4
22 Pure Bending 2% 42%
T1: Chapter 4
Unit 3: Chapter 5: Introduction, Determining shearing stress in a
Shearing Stress in beam
23 Beams 2% 44%
T1: Chapter 6
Sections:6.1, 6.3
24 Unit 3: Chapter 6: Shear stress distribution in Rectangular cross 2% 46%
Shearing Stress in
13
PES UNIVERSITY
COURSE INFORMATION
Beams sections
T1: Chapter 6
Sections:6.4
Unit 3: Chapter 6: Shear stress distribution in T cross sections
Shearing Stress in
25 Beams 2% 48%
T1: Chapter 6
Sections:6.4
Unit 3: Chapter 6: Shear stress distribution in I beam cross
Shearing Stress in sections
26 Beams 2% 50%
T1: Chapter 6
Sections:6.4
Shearing Stress in
27 2% 52%
Beams
T1: Chapter 6
Unit 3: Chapter 6: Introduction, Deformation of a Beam under
Deflection of Beams Transverse Loading
28 2% 54%
T1: Chapter 9
Sections:9.1, 9.2
Unit 3: Chapter 6: Equation of the Elastic Curve
Deflection of Beams
29 2% 56%
T1: Chapter 9
Sections:9.3
Unit 3: Chapter 6: Using Singularity Functions to Determine the
Deflection of Beams Slope and Deflection of a Beam, Area moment
30 2% 58%
T1: Chapter 9
Sections:9.6, 9.9 method,
31 Deflection of Beams 2% 60%
T1: Chapter 9
32 Deflection of Beams 2% 62%
T1: Chapter 9
Unit 4: Chapter 7: Introduction, Stability of Structures, Eulers
Columns Formula for Pin-Ended Columns
33 1% 63%
T1: Chapter 10
Sections:10.1:10.3
Unit 4: Chapter 7: Extension of Eulers Formula to Columns with
Columns Other End Conditions, Empirical formula
34 2% 65%
T1: Chapter 10
Sections:10.4
35 Columns 2% 67%
T1: Chapter 10
36 Columns 2% 69%
T1: Chapter 10
Unit 4: Chapter 7: Introduction, Deformations in a Circular Shaft,
Torsion Numerical problems
37 2% 71%
T1: Chapter 3
Sections:3.1, 3.3
38 Unit 4: Chapter 7: Stresses in the Elastic Range, Design of 2% 73%
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COURSE INFORMATION
Torsion Transmission Shafts

T1: Chapter 3
Sections:3.4, 3.7
39 Torsion 2% 75%
T1: Chapter 3
40 Torsion 2% 77%
T1: Chapter 3
Unit 4: Chapter 8: Introduction, Strain Energy, Strain Energy
Energy Methods density, Elastic strain, Energy for normal
41 2% 79%
T1: Chapter 11
Sections:11.1:11.4 stresses
Unit 4: Chapter 8: Elastic strain energy for shearing stresses,
Energy Methods Numerical Problems
42 2% 81%
T1: Chapter 11
Sections:11.5
Unit 5: Chapter 8: Transformation of plane stress
Transformation of
43 stresses 2% 83%
T1: Chapter 7
Sections:7.1, 7.2
Unit 5: Chapter 8: Principal stresses, Maximum shearing stress
Transformation of
44 stresses 2% 85%
T1: Chapter 7
Sections:7.3
Unit 5: Chapter 9: Mohrs circle for plane stress
Transformation of
45 stresses 2% 87%
T1: Chapter 7
Sections:7.4
Transformation of
46 1% 88%
stresses
T1: Chapter 7
Transformation of
47 2% 90%
stresses
T1: Chapter 7
Transformation of
48 2% 92%
stresses
T1: Chapter 7
Unit 5: Chapter 9: Stresses in thin and thick walled pressure
49 Pressure Vessels vessels 2% 94%
R1: Chapter 4
Unit 5: Chapter 9: Stresses in thin and thick walled pressure
50 Pressure Vessels vessels, Numerical problems 2% 96%
R1: Chapter 4
51 Pressure Vessels 2% 98%
R1: Chapter 4
52 Unit 5: Chapter 9: Numerical problems 2% 100%
15
PES UNIVERSITY
COURSE INFORMATION
Pressure Vessels
R1: Chapter 4
Text Book:
T1: Mechanics of Materials (In SI Units), Ferdinand P Beer, E Russell Johnston, Jr John T
DeWolf 3rd Edition, TATA McGraw Hill. (Ch. Nos. 1,2,3,4,5,6,7,9,10,11), Special Indian Edition,
2009.
Reference Books:
1. Strength of Materials, S Ramamrutham, Dhanpat Rai Publications Reprint 2005.
2. Strength of Materials, I.B. Prasad Khanna Publishers, 8th Edition 1989.
16
PES UNIVERSITY
COURSE INFORMATION
METAL CASTING & WELDING PROCESSES: 14ME205
Faculty: NK/CRK/NR/UM
Test 1 portions Unit 1 and 2
Test 2 portions Unit 3 and 4
% of Portions covered
Chapter Title /
Class # 3. Topics to be covered Reference
Reference Literature Cumulative
chapter
UNIT 1
Concept of manufacturing process and
its importance
Classification of manufacturing process,
1 2 2
Principles of casting,
variety of components produced by
casting process
Advantages, limitations & applications
of metal casting,
2 2 4
Foundry Types,
different sections of a foundry.
steps involved in casting.
Introduction to patterns,
Patterns and Pattern Making: Difference
between pattern and casting, functions
of pattern, material used for pattern,
2 6
3 classification of pattern.
One piece pattern, split pattern, drag and
cope pattern, match plate pattern, loose
piece pattern, Sweep pattern, skeleton
pattern, gated pattern, segmental pattern.
Pattern materials. Pattern allowances
4 and their importance, Type of patterns 2 8
materials, color coding of patterns
5 Sand moulding, 2 10
types of moulding sands,
green sand, parting sand, backing and
facing sand.
moulding sand ingredients
base sand.
binders and additives.
17
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COURSE INFORMATION
Type of sand moulding green sand, dry

6 2 12
sand and skin dried, co2 moulding
Properties of Moulding sand

refractoriness, adhesiveness and
7 collapsibility, green strength dry 2 14
strength compressive strength shear
strength, hot strength
flowability, permeability clay content
tensile strength grain fineness sieve
8 2 16
analylsis. Mould and core hardness,
moisture content
Hand Molding
Moulding machines
9
Jolt type 2 18
Squeeze type
Jolt squeeze type machine
Sand slinger and sand mullers
Cores definition, need, types and

10 method of making core binders core 2 20
boxes.
UNIT 2 Gating System,
Principles of gating system,
11 Pouring cups and basins. 2 22
Sprues, gates characteristics, types of
gates bottom, top and parting line gate
Gating ratio, pressurized and

unpressurized gating system, effect of
12 gating ratio. 2 24
problems
Turbulence in gating, metal flow rate

13 and velocity, design criteria for pouring 2 26
basin
14 2 28
Design of gating system objectives
achieved from a good design, defects
due to improper gating.
18
PES UNIVERSITY
COURSE INFORMATION
Metal flow rate and velocity calculations

Bernoullis theorm, Design for sprue,
15 2 30
pouring time, design of runner and
gates. problems
16 Chokes- problems 2 32
Principles of Risering: Introduction,

17 Functions of a riser, types of risers, riser 2 34
and directional solidification
Increasing riser efficiency, chills,

2 36
18 padding,
Design, Riser shape, riser size,
Chvorinovs rule, riser location
19 2 38
and riser feeding distance.
Problems on risers
Solidification of casting concept
20 phase diagram, heat treatment 2 40
and fettling.
UNIT 3 Melting furnaces and Practices: I
Types
21 Cupola- cupola design, preparation of 2 42
cupola, charging the cupola, cupola
zones
Computing the cupola metal charge and
22 simple problems. 2 44
Electric furnace- direct and indirect

23 2 46
Induction furnace core type and coreless

24 2 48
type
25 Reverberatory 2 50
26 Bessemer furnace 2 52
19
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COURSE INFORMATION
27 Crucibles 2 54
Ladle Metallurgy: Different degassing

28 2 56
techniques, gas scavenging
Desulphurization, liquid metal

29 2 58
cleanliness
30 and inoculation 2 60
UNIT 4
Special casting methods

31 Introduction. Permanent mould casting, 2 62
gravity die casting and
32 pressure die casting, hot chamber 2 64
33 pressure die casting, cold chamber 2 66
Centrifugal casting de Lavand process,

34 2 68
semi-centrifugal casting, centrifuging.
Plaster mould casting, anitioch process

35 2 70
Slush casting and squeeze casting
Continuous casting, Investment casting

36 2 72
37 Thixocasting casting Shell moulding 2 74
38 Defects in Castings- their causes and 2 76

remedies
20
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Quality control in Foundries-

Destructive testing for Mechanical
39 properties - tensile, compression, shear, 2 78
bending, impact, hardness and torsion.
Non destructive testing
40 x-ray, dye penetration, ultra sonic and 2 80

magnetic particle test.
UNIT 5 Welding and allied processes:

Introduction to welding. Classification
of welding processes, concept of weld.
Brazing and soldering
41 Differences between welding brazing 2 82
and soldering.
Welding Symbols, Welding Positions,

Edge Preparation for welding.
Electric arc welding, metal arc welding,

arc blow, use of AC and DC for welding
42 2 84
welding polarity, Comparison between
AC and DC for welding, arc welding
electrodes.
Resistance spot welding, Resistance butt
welding, resistance flash welding,
42 resistance seam welding, projection 2 86
welding.
Gas welding oxy-acetylene welding

chemical reaction in gas welding, flame
characteristics gas torch construction
44 2 88
and working, forward and backward
welding and
equipments gas cylinders.
45 Safety during welding 2 90
46 Special welding processes: 2 92

GTAW- TIG welding - tungsten arc
MIG / GMAW (co2) welding metal
arc
21
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submerged arc welding, SAW

47 electro slag welding, 2 94
electro gas welding.
stud arc welding,
plasma arc welding,
48 2 96
atomic hydrogen welding,
Thermit welding
Friction and frication stir welding
Explosive welding laser welding
49 Metallurgical aspects in Welding, 2 98
structure solidification and structure of
the weld.
Welding inspection methods - NDT
50 Welding defects causes and prevention 2 100
HAZ and residual stress
51 Revision 2
52 Revision 2
Text Book:
1. A Text book of Foundry Technology by O P Khanna, Dhanpat Rai Publications, Edition
1996.
2. A course in Workshop Technology, Volume I, Manufacturing processes by B.S.
Raghuwanshi, Dhanpat Rai & Co. (P) Ltd publishers. 2005
Reference Book:
1. Principles of Metal Casting, second edition, by, Richard W. Heine, Carl R. Loper Jr and
Philip C, Rosenthal, Tata McGraw Hill Publication.
2. Welding and Welding Technology, by Richard L. Little, 37th Reprint, 2009, Tata McGraw Hill
Publication.
22

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PES UNIVERSITY

DEPARTMENT OF MECHANICAL ENGINEERING

1 UE16ME201 Material Science and Metallurgy 4 0 0 2 4 CC

2 UE16ME202 Engineering Thermodynamics 3 1 0 4 4 CC

3 UE16ME203* Mechanics of Solids 3 1 0 4 4 CC

Metal Casting and Welding

MATERIAL SCIENCE AND METALLURGY: UE16ME201

Faculty: Dr. MS / SRH / NR / SS No. Of Hours: 52

Subject Code: UE15ME203

Class Chapter Title / % of Portions covered

and Heat transfer between a system and its surroundings;

21-22 Chapter 6: Unit III

Entropy second law combined), Isentropic process;

40 Chapter 8: Introduction to concepts of available energy and

43-45 Chapter 9: UNIT V

Reference Book: Thermodynamics - An Engineering Approach , Yunus Cengel & Michael

UE16ME203: MECHANICS OF SOLIDS (4-0-0-0-4)

Class Chapter Title / % of Portions covered

Analysis and Design

Torsion Transmission Shafts

METAL CASTING & WELDING PROCESSES: 14ME205

Type of sand moulding green sand, dry

Properties of Moulding sand

Cores definition, need, types and

Gating ratio, pressurized and

Turbulence in gating, metal flow rate

Metal flow rate and velocity calculations

Principles of Risering: Introduction,

Increasing riser efficiency, chills,

Electric furnace- direct and indirect

Induction furnace core type and coreless

Ladle Metallurgy: Different degassing

Desulphurization, liquid metal

Special casting methods

32 pressure die casting, hot chamber 2 64

33 pressure die casting, cold chamber 2 66

Centrifugal casting de Lavand process,

Plaster mould casting, anitioch process

Continuous casting, Investment casting

37 Thixocasting casting Shell moulding 2 74

38 Defects in Castings- their causes and 2 76

Quality control in Foundries-

Non destructive testing

40 x-ray, dye penetration, ultra sonic and 2 80

UNIT 5 Welding and allied processes:

Welding Symbols, Welding Positions,

Electric arc welding, metal arc welding,

Gas welding oxy-acetylene welding

45 Safety during welding 2 90

46 Special welding processes: 2 92

submerged arc welding, SAW

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