Contents

1 Basics of Mechanical Engineering

1.1 1.2 1.3 1.4 1.5 Introduction Basic concepts Units of engineering quantities Friction Summary

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1 2 5 6 9

Mechanical Drawings
A 2.1 2.2 2.3 B 2.4 2.5 2.6 2.7 C 2.8 2.9 2.10 D 2.11 E 2.12 2.13 F 2.14 2.15 G 2.16 2.17 H 2.18 2.19 2.20 2.21 I 2.22 2.23 2.24 Types of lines and letters used in drawings Types of lines Lettering in the drawings Summary for Section A Projections What is projection? Pictorial projections Concept of cutting plane and sectional views Summary of Section B Dimensioning Different systems of dimensioning Dimensioning practices Summary of Section C Assembly drawings Summary of Section D Welded joints Types of welded joints Summary of Section E Bolt, nut and screw fasteners Introduction Summary of Section F Keys, keyways and keyed assemblies Types of keys Summary of Section G Tolerance, limits and fits Concept of tolerance Concept of limits Concept of fit Summary of Section H The role of CAD and CAM Use of computers for preparation of drawings CAD software Computer Aided Manufacturing (CAM)

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11 11 14 15 15 15 17 18 23 23 23 23 25 25 26 26 27 29 29 29 31 31 32 33 34 34 35 36 37 38 38 38 39

2.25 J 2.26 2.27

Summary of Section I Office practice Drawing number and part name Summary of Section J

39 39 39 40

Engineering Materials
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 Mechanical properties of materials Processing of metals and alloys Stress and strain in metals Normal stress and shear stress Tensile and hardness testing Stress and strain diagram Alloy production and properties Fracture of metals Corrosion types and control Summary

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41 43 46 48 48 52 55 60 64 65

Mechanical Design
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 Introduction Codes and standards Design considerations Factory of safety Mechanical components Fasteners/screwed joints Fastener failure Compression members Summary

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67 70 70 76 77 105 111 115 120

Mechanical Engineering Codes and Standards

5.1 5.2 5.3 5.4 5.5 5.6 5.7 Need for standardization Overview of standards Benefits of standardization Mechanical engineering standards ISO 9000/1 Six-sigma Summary

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124 124 125 126 126 128 129

Manufacturing
6.1 6.2 6.3 6.4 6.5 6.6 6.7 Foundry processing Heat treatment Hot working of metals Cold working of metals Pressing Numerical control Sawing

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131 134 135 137 139 142 146

6.8 6.9 6.10 6.11 6.12 6.13 6.14

Broaching Shapers and shaping Welding Brazing Computer-aided manufacturing Manufacturing processes in oil and gas industry Summary

146 147 147 148 149 150 150

Mechanical Automation
7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 Sensors and actuators Differential transformers Velocity and motion Fluid pressure measurement Liquid flow measurement Liquid level measurement Temperature measurement Light sensors Selection of sensors Pneumatics and hydraulics Control valves Cylinders Electrical actuation Electrical drives Electrical machines Gear motors Control systems Summary

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151 159 162 164 165 166 167 169 169 169 171 175 177 179 180 185 186 191

Fluid Engineering
8.1 8.2 8.3 8.4 8.5 8.6 8.7 Pumps Compressors Turbines Flow in pipes Thermodynamics Reversibility Summary

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193 206 211 218 225 232 232

Maintenance of Machinery
9.1 9.2 9.3 9.4 9.5 9.6 9.7 The need for maintenance Types of maintenance Maintenance strategies Failure How to select your maintenance plan Predictive maintenance techniques Summary

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235 236 237 238 239 240 248

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Theory of Heat Transfer

10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 Heat basics Heat transfer Laws of Thermodynamics Thermal cycles Heat cycles Heat pumps Air conditioning Summary

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249 251 253 255 262 265 267 268

Exercises Answers

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