UNIT 1

OVERVIEW OF MECHANICAL ENGINEERING

SCOPE OF MECHANICAL ENGINEERING
1. Explain the contribution of mechanical engineering to the welfare of the society.
Mechanical engineering is the discipline that applies engineering physics and material sciences principles
to design,analyse,manufacture and maintain mechanical system.
Various disciplines of Mechanical engineering
1. Applied mechanics 2.Dynamics 3.Fluid Mechanics 4.Thermodynamics 5.Heat transfer
6.Production Technology
Fields of employment :
1.Technology 2.Science 3.Exploration 4.Military
contribution of mechanical engineering to the welfare of the society.
1. The energy solution. Society of today badly needs more power. We have huge shortage of electricity, especially
in underdeveloped countries. Prices of fuel oil are going up. As a Mechanical engineer you need to find a green way
to generate power.
2. The transportation solution. Millions of people die every year while traveling. Safety has to be priority while
designing new vehicles.
3. Cost effective products. There are many who can't afford to buy basic things that are required for day to day
living. You need find better machines and processes that will reduce prices.
4. And above all society wants you to be the leader. You shall bring the change society needs. Society doesn't know what
she wants. She knows how to choose. It's your duty to give her better options.

Mechanical engineering covers development and implementation of solutions to energy and water needs of the
society with minimal environmental impact.
Mechanical engineers contribute to the society by designing, manufacturing and maintaining mechanical devices
for broad range of applications in all forms of industry.
Mechanical engineers also develops materials and measurements that contributes to research, economic and
management dimensions that support the industrial activities.
Mechanical engineering principles are employed in wide range of industries such as power generation,
manufacturing, energy repair and maintanence,automation and control robotoics,electronics,nano technolog,food
industries,petroleum,aero space,etc,.

Specialized sub divisions in mechanical engineering

1. Production engg.2.Automobile engg. 3.Energy engg.
Production engineering:
It is the combination of manufacturing technology, engineering sciences with material sciences. It has a wide
range of engineering practices and it is aware of management challenges related to production.

Goals of production engineering are to accomplish the production process in the smoothest, most effective and
economic way.
It comprises of the application of casting, machining process, joining process, metal cutting, tool design,
automation jigs, die and mold design, design of machine tools, automation.

INDUSTRIAL ENGG

MANUFACTURING MANAGEMENT
ENGINEERING PRINCIPLES

PRODUCTION
ENGINEERING

Production Engineer Responsibilities and Duties

 Plan and coordinate production engineering processes on daily basis to produce high
Manufacturing or Production Engineering
quality products.
Manufacturing or Production Engineering is the subset / specialization of a Mechanical Engineering.
 Develop process improvements to effectively utilize equipment and materials to
Mechanical Engineering with the focus only on Machine Tools, Materials Science, Tribology, and
Quality Control is known as Manufacturing Engineering. Professional manufacturing engineers are
 maximize production.
 Develop operational strategies to achieve production and financial objectives.
 Identify unsafe operations and practices and report the same to Manager immediately.
 Establish safety procedures and environmental regulations for employees.
 Provide engineering support for production and maintenance activities to ensure
maximum production.
 Perform engineering analysis to reduce downtime and outages.
 Evaluate current production activities and make recommendations for improvements.
 Implement cost reduction initiatives while maintaining high quality standards.
 Develop operating instructions and equipment specifications for production activities.
 Provides training and guidance to team members to accomplish production goals.

 Stay current with product specifications, engineering technology and production processes.
 Develop best practices to improve production capacity, quality and reliability.
 Investigate problems, analyze root causes and derive resolutions.
 Aid in budget preparation and monitor expenses and profitability.

Energy Engineering:
It is the field of engineering dealing with energy efficiency services, facility management, plant engineering,
environmental compliance and alternative energy technology.

It is the most recent engineering discipline.

Combines the knowledge from the field of physics, chemistry, mathematics with economic and environmental
engineering practices. Energy engineers apply their skills to increase efficiency and further develop renewable sources of
energy.
Main job is to find the most efficient and sustainable way to operate buildings and manufacturing processes.
Energy engineers audits the use of energy in those processes and suggests ways to improve the systems.

Advanced lighting, Better insulation, efficient heating and cooling properties of buildings.
1. Hydro 2.Solar 3.Bio-mass 4.Geo thermal 5.ONGE

Responsibilities:
1. You will be need to Design, develop and built renewable energy technologies.
2. Combine renewable energy pattern with existing power systems.
3. Arrange new supplies and negotiate traffic with fuel provider
4. Carry out site inspection and energy surveys
5. Design and select equipments.
6. Use mathematical and computer model to complete design and specification calculations
7. Carry out lab experiments and adapt them to the large scale
8. Prepare detail schedule of work, feasibility studies and cost estimates
9. Check site and ground conditions for the installation of renewable technologies such as wind turbines.
10. Keep up dates with legislation and environmental standards
11. Develop technical expertise in all matters.

Skills for mechanical engineers:

1. Responsible for the safe and efficient operation of internal combustion engines, steam and gas turbines.
2. Investigate equipment failures and difficulties to diagnose faulty operation and make recommendation to
maintenance crew.
3. Assist drafters: CADD or drafting equipment and software.
4. Provide feedback to design engineer on customer problems and needs.
5. Oversee the installation,operation,maintanence and repair of machines and equipments to ensure they
are installed and functioning according to specification.

APPLICATION:
1. Modern electric, wireless, Nuclear technology and tesla coil which has seen widely used in radio, television sets and
other electronic equipment.
2. GPS, dynamic, flight simulations.
3. Steam engine, rotary engine and copying system
4. Heat pump, steam & gas turbines
5. Aerodynamics.

ENERGY ENGG:
Energy engineering or energy systems engineering is a broad field of engineering dealing
with energy efficiency, energy services, facility management, plant engineering, environmental compliance
and alternative energy technologies. Energy engineers are also employed by the fields of oil and natural
gas
extraction.

We divide our energy use among four economic sectors: residential, commercial, transportation, and industrial.
Heating and cooling our homes, lighting office buildings, driving cars and moving freight, and manufacturing the
products we rely on in our daily lives are all functions that require energy.
Energy systems engineers oversee complex energy conversion and distributionsystems, work to
improve energy storage systems, and manage the efficient use of energy in building, manufacturing,
and processing systems Assess the environmental impact of alternative energy systems.
As an energy engineer, you'll be involved with the production of energy through natural resources, such as the
extraction of oil and gas, as well as from renewable or sustainable sources of energy, including biofuels,
hydro, wind and solar power.
Thermal Engineering is controlling heating or cooling processes in an enclosed environment or an open
environment using various equipments. It involves the science of thermodynamics, fluid mechanics, heat and mass
transfer.
Applications:
The most common example is air conditioning(Home & car). You need extensive knowledge of thermal
engineering for designing a compressor/condenser/evaporator coil/insulation used in any air conditioning unit.
Refrigerators too use the same principles. Well to be frank it can be used in ’n’ number of ways like we
utilize thermal energy for generation of electricity, for heating purposes ( it can be water heating, space heating,
etc.), refrigeration system (vapour absorption types), etc.

Automobile engineering is the one of the stream of mechanical engineering. It deals with the various types
of automobiles, their mechanism of transmission systems and its applications. Automobiles are the different types
of vehicles used for transportation of passengers, goods, etc. Basically all the types of vehicles works on the
principle of internal combustion processes or sometimes the engines are called as internal combustion engines.
Different types of fuels are burnt inside the cylinder at higher temperature to get the transmission motion in the
vehicles. Most of the automobiles are internal combustion engines vehicles only. Therefore, every mechanical and
automobile engineer should have the knowledge of automobile engineering its mechanism and its various
applications.

DEFINITION: Automobile engineering is a branch of engineering which deals with everything about automobiles
and practices to propel them. Automobile is a vehicle driven by an internal combustion engine and it is used for
transportation of passengers and goods on the ground. Automobile can also be defined as a vehicle which can move
 by itself. Examples : Car, jeep, bus, truck, scooter, etc.

CLASSIFICATION OF VEHICLES:
Automobiles or vehicles can be classified on different bases as given below :
On the Basis of Load : (a) Heavy transport vehicle (HTV) or heavy motor vehicle (HMV), e.g. trucks,
buses, etc. (b) Light transport vehicle (LTV) e.g. pickup, station wagon, etc. (c) Light motor vehicle (LMV), e.g.
cars, jeeps, etc.
On the Basis of Wheels : (a) Two wheeler vehicle, for example : Scooter, motorcycle, scooty, etc. (b)
Three wheeler vehicle, for example : Auto rickshaw, three wheeler scooter and tempo, etc. (c) Four wheeler vehicle,
for example : Car, jeep, trucks, buses, etc. (d) Six wheeler vehicle, for example : Big trucks with two gear axles each
having four wheels.
On the Basis of Fuel Used (a) Petrol vehicle, e.g. motorcycle, scooter, cars, etc. (b) Diesel vehicle, e.g.
trucks, buses, etc. (c) Electric vehicle, e.g. battery drive (d) Steam vehicle, e.g. an engine which uses steam. (e) Gas
vehicle, e.g. LPG and CNG vehicles, where LPG is liquefied petroleum gas and CNG is compressed natural gas.
On the Basis of Body On the basis of body, the vehicles are classified as : (a) Sedan with two doors (b)
Sedan with four doors (c) Station wagon (d) Convertible, e.g. jeep, etc. (e) Van (f) Special purpose vehicle, e.g.
ambulance, milk van, etc. Transmission (a) Conventional vehicles with manual transmission, e.g. car with 5 gears.
(b) Semi-automatic (c) Automatic: In automatic transmission, gears are not required to be changed manually. It is
automatically changes as per speed of the automobile.
Position of Engine in Front : Most of the vehicles have engine in the front. Example: most of the
cars, buses, trucks in India.
Engine in the Rear Side: Very few vehicles have engine located in the rear. Example: Nano car.

COMPONENTS OF THE AUTOMOBILE

The automobile can be considered to consist of five basic components: (a) The Engine or Power Plant : It is
source of power. (b) The Frame and Chassis: It supports the engine, wheels, body, braking system, steering, etc. (c)
The transmission which transmits power from the engine to the car wheels. It consists of clutch, transmission, shaft,
axles and differential. (d) The body fitted on chassis. (e) Accessories including light, air conditioner/hearer, stereo,
wiper, etc.

FUNCTIONS OF MAJOR COMPONENTS OF AN AUTOMOBILE Chassis and Frame:

The chassis is formed by the frame with the frame side members and cross members. The frame is usually
made of box, tubular and channel members that are welded or riveted together. In addition to this, it comprises of
the springs with the axles and wheels, the steering system and the brakes, the fuel tank, the exhaust system, the
radiator, the battery and other accessories. Along with this the frame supports the body. Engine or Power Plant : The
engine is the power plant of the vehicle. In general, internal combustion engine with petrol or diesel fuel is used to
run a vehicle.
An engine may be either a two-stroke engine or a four-stroke engine. An engine consists of a cylinder,
piston, valves, valve operating mechanism, carburetor (or MPFI in modern cars), fan, fuel feed pump and oil pump,
etc. Besides this, an engine requires ignition system for burning fuel in the engine cylinder.

Transmission System (Clutch and Gear Box): The power developed by the engine is transferred to the
wheels by transmission system. Transmission system must do three jobs : (a) It must provide varying gear ratios.
Number of gear ratio are equal to number of gears in a vehicle. (b) It must provide a reverse gear for moving vehicle
in reverse direction. (c) It must provide a neutral or disconnecting arrangement so that the engine can be uncoupled
from the wheels of the vehicle. In a conventional transmission system, there is a clutch, a manually operated
transmission (gear box), a propeller shaft and a differential or final drive.

Clutch : The purpose of the clutch is to allow the driver to couple or decouple the engine and transmission. When clutch is in
engaged position, the engine power flows to the transmission through it (clutch). When gears are to be changed while vehicle is
running, the clutch permits temporary decoupling of engine and wheels so that gears can be shifted. In a scooter, the clutch is
operated by hand where as in a car the clutch is operated by foot. It is necessary to interrupt the flow of power before gears are
changed. Without a clutch, it will by very difficult. Final Drive Final drive is the last stage in transferring power from engine to
wheels. It reduces the

speed of the propeller shaft (drive shaft) to that of wheels. It also turns the drive of the propeller shaft by an angle of
90 degree to drive the wheels.

The propeller shaft has a small bevel pinion which meshes with crown wheel. The crown wheel gives
 rotary motion to rear axles. The size of crown wheel in bigger than that of bevel pinion, therefore, the speed of
rear axles (or crown wheel) in lower than the speed of pinion. Final drive is of two types, i.e. chain type and gear
type. Braking System Brakes are used to slow down or stop the vehicle.

Hydraulic brakes are generally used in automobiles, where brakes are applied by pressure on a fluid.
Mechanical brakes are also used in some vehicles. These brakes are operated by means of leavers, linkages, pedals,
cams, etc. Hand brake or parking brake is known usually mechanical brake. These are used for parking the vehicles
on sloppy surfaces and also in case of emergency.

Gear Box : Gear box contain gearing arrangement to get different speeds. Gears are used to get more
than one speed ratios. When both mating gears have same number of teeth, both will rotate at same number speed.
But when one gear has less teeth than other, the gear with less number of teeth will rotate faster than larger gear.
In a typical car, there may be six gears including one reverse gear. First gear gives low speed but high torque.
Higher gears give progressively increasing speeds. Gears are engaged and disengaged by a shift lever.

Steering System : In front wheels can be turned to left and right by steering system so that the vehicle can
be steered. The steering wheel is placed in front of driver. It is mechanically linked to the wheels to provide the
steering control. The primary function of the steering system is to provide angular motion to front wheels so that
vehicle can negotiate a turn. It also provides directional stability to vehicle when the vehicle moves ahead in straight
line. Now-a-days, many vehicles are equipped with power steering which uses pressure of a fluid to reduce steering
effort. When driver turns the steering wheel, a hydraulic mechanism comes into play to provide most of the effort
needed to turn the wheel. Front Axle A part of the weight of vehicle is transmitted to the wheels through this axle.
The front axle performs several functions. It carries the weight of the front of the vehicle and also takes horizontal
and vertical loads when vehicle moves on bumpy roads. When brakes are provided on front wheels, it endures
bending stresses and tensional stresses. It is generally made from steel drop forging. It is robust in construction.
Suspension System Suspension system of an automobile separates the wheel and axle assembly of the automobile
from its body. Main function of the suspension system is to isolate the body of the vehicle from shocks and
vibrations generated due to irregularities on the surface of roads. Shock absorbers are provided in the vehicles for
this purpose. It is in the form of spring and damper. The suspension system is provided both on front end and rear
end of the vehicle.

A suspension system also maintains the stability of the vehicle in pitching or rolling when vehicle is in
motion.
APPLICATION OF I. C. ENGINE :
Road vehicles * Aircraft * Locomotive * Construction Equipment Pumping set * several Industries
Small Two Stroke Petrol Engine : Used when operation is simple and requirement of low cost of prime mover
(scooters, pumping sets etc.) Small Four Stroke Petrol Engine : Used in automobiles, generators, pumping set. Two
Stroke Diesel Engine : High power, generally used in ship propulsion. Four Stroke Diesel Engine : Mostly used
engine, have diameter 50 to 600 mm, speed ranges from 100 to 4400 rpm, power developed is 1 to 1000 kW. Used
in pumping sets, construction machinery, drilling rigs, tractors, diesel electric locomotive, mobile & stationary
electric generation plants.

Engineering design

Why is the engineering design process important?

The engineering design process is a series of steps that engineers follow when they are trying to solve a
problem and design a solution for something; it is a methodical approach to problem solving. This is similar to the
“Scientific Method” which is taught to young scientists.
 Job Duties
It is important that product design engineers be familiar with, and adhere to,
their company's product standards and specifications, so that they may design quality
products that represent the company brand. They must also keep trends and the needs
of consumers in mind when designing products. Product design engineers may also be
responsible for making improvements or updates to existing design and development
standards. Professionals may also need to understand how their decisions affect
product cost, performance, and quality.
“Scientists discover the world that exists; engineers create the world that never was.”
Theodore von Karman, co-founder of NASA’s Jet Propulsion Laboratory

INDUSTRIAL ENGINEERING
Industrial engineering is a branch of engineering which deals with the
optimization of complex processes, systems, or organizations. Industrial engineers
work to eliminate waste of time, money, materials, person-hours, machine time, energy
and other resources that do not generate value.
Industrial designers develop concepts and designs for manufactured products.
They typically specialize in one product category, such as automobiles, furniture or
housewares. They must be imaginative and persistent to communicate their ideas
about new product design.
Industrial engineering is a branch of engineering which deals with the
optimization of complex processes, systems, or organizations. Industrial engineers
work to eliminate waste of time, money, materials, person-hours, machine time,
energy and other resources that do not generate value.

CAD/CAM/CIM:
computer manufacturing aided design. CAD is particularly valuable in space
programs, where many unknown design variables are involved. ... CIM is a
programmable manufacturing method designed to link CAD, CAM, industrial
robotics, and machine manufacturing using unattended processing workstations.
CAM is now a system used in schools and lower educational purposes. CAM is a
subsequent computer-aided process after computer-aided design (CAD) and
sometimes computer-aided engineering (CAE), as the model generated in CAD and
verified in CAE can be input into CAM software, which then controls the machine
tool.
CAD/CAM applications are used to both design a product and program manufacturing
processes, specifically, CNC machining. CAM software uses the models and
assemblies created in CAD software to generate toolpaths that drive machine tools to
turn designs into physical parts.
Computer integrated manufacturing (CIM), a term popularized by Joseph Harrington in 1975, is also
known as autofacturing. CIM is a programmable manufacturing method designed to link CAD, CAM,
industrial robotics, and machine manufacturing using unattended processing workstations. CIM offers
uninterrupted operation from raw materials to finished product, with the added benefits of quality
assurance and automated assembly.