distribution system. All air systems All water systems Air is used as the media transporting energy from conditioned space to a/c plant. Air is processed at A/C plant and is conveyed through the ducts using blowers and fans to the conditioned space. This air extracts the required amount of heat from/to the conditioned space and is sent back to the A/C plant for further -reprocessing All water system- 2 pipe system Fluid used in thermal distribution system is water. Water transports energy between conditioned space and the plant. Cold water is circulated when cooling is required. Hot water is circulated when heating is required. Provision must be there for supplying required amount of treated outdoor air to the a/c space since only water is circulated. Depending of no: of pipes used Double pipe & four pipe system 2 pipe system is used either for heating /cooling application only and cant be used for simultaneous heating/cooling. All Air Systems Advantages: Greatest potential for energy conservation by utilizing outdoor air. Able to provide good room air distribution under all conditions of load. By using high quality controls, temperature and relative humidity can be well maintained. Disadvantages: Occupy more space and reduce available floor space in the building. All Water system Advantages: Thermal distribution system requires less space compared to all air systems. Individual room control is possible. Disadvantages: Requires high maintenance compared to all air systems Draining of condensate water can be messy and also may create health problems if water stagnates in the drain tray. Control of humidity, particularly during summer is very difficult. Psychrometry Properties Dry bulb temperature (DBT): Temperature of the moist air as measured by a standard thermometer. Saturated vapour pressure: saturated partial pressure of water vapour at DBT. Relative humidity: normally expressed as percentage. Humidity Ratio: mass of water associated with each kg of dry air. Enthalpy: Sum of enthalpy of dry air and enthalpy of water vapour. Specific volume: no: of cubic metres of moist air per kilogram of dry air. Psychrometric chart Gives graphical representation of important properties of moist air. DBT, WBT, Moisture content, RH, specific enthalpy, and specific volume. If any 2 properties are known, then the other 4 can be found from the chart. Used extensively air-conditioning applications. X axis give DBT whereas Y axis gives humidity ratio in gram of water vapour per kg of dry air. Psychrometric processes Sensible heating/cooling : Refers to heating/cooling without phase change. (without increase/decrease of moisture content). Cooling with dehumidification: reducing of air temperature along with removal of water vapour air. Humidification: Addition of moisture to air. Evaporative cooling: Needed in hot/dry climates It has an arrangement of spraying liquid water in to air .due to less humidity of air, some amount of water will evaporate and consequently temperature will reduce. Introduction to Automobiles It is a self propelled vehicle used for transportation of passengers and goods upon the ground. Types of engines used in automobiles: 1. According to type of fuel 1. Petrol engines 2. Diesel engines 3. Gas engines 2. According to the method of igniting the fuel 1. Spark ignition engines. 2. Compression ignition engines. 3. According to no: of strokes/cycle
Four stroke cycle engines
Cycle is completed in four strokes of the piston Two stroke engines Cycle is completed in 2 strokes of the piston. 4. According to the cycle of operation Otto cycle engines Diesel cycle engines Dual combustion cycle engines 5. According to the speed of engines Slow speed/medium speed/high speed engines (up to 350 rpm/350-1000/above 1000 rpm) 6. According to the cooling system Air-cooled engines Uses circulation of air Water cooled engines Water circulation to hot engine parts Evaporative cooled engines Evaporation of liquid like propylene glycol is used for cooling. 7. According to the method of fuel supply system Carburettor engines uses carburettor for supplying air-fuel mixture to the cylinder Air-Injection Engines Delivers fuel at high pressure to cylinder using compressed air. Air less or solid injection engines Delivers fuel at high pressures to the cylinder using mechanical pumps. 8. According to the number of cylinders Single cylinder engines: Consists of only ONE cylinder Multi cylinder engines: Consists of multiple cylinders. 9. According to the arrangement of cylinders: Vertical engines Axis of cylinder is vertical. Horizontal engines Axis of cylinder is horizontal Radial engines Radially placed around a common crankshaft V type multi-cylinder engines: Two cylinders are placed forming a V-shape. 10. According to the Valve mechanism: Overhead valve engines: Valve is place at the top of the cylinder Side valve engines: Valve is placed at the side of the cylinder. Rotary valve engines: Valves are opened and closed by a rotating member. Types of Automobiles 1. Classification based on Purpose a. Passenger vehicle : Which carries passengers : Car, Jeep, Bus, auto rickshaw b. Good vehicle: Which carries materials/goods. 2. Capacity: c. Light motor vehicle: able to carry light things and are also less in size and weight. d. Heavy motor vehicle: Can carry very heavy materials and posses large mass and gross vehicle weight exceeds 12000 kg. Eg: bus, Lorry etc.. 3. According to the fuel used: Petrol vehicles : Car, Jeep, Motorcycle, Scooter Diesel Vehicles : Car, Jeep, Truck, bus, Tractor etc. Electric vehicle: Electric Cars, Electric buses Gas Vehicles: CNG vehicles. 4. Based on type of transmission: Automatic transmission vehicles: Vehicles capable of changing gear automatically while moving. Manual gear changing vehicles Semi-automatic transmission : allows manual gear changes and uses a clutch but facilitates the gear changes without a clutch pedal. 5. Drive of the vehicle: Rear wheel drive: Rear wheel are driven by the engines. Front wheel drive: Front wheels are driven by the engine. All wheel drive: All the wheels are driven by the engine. Layout of an automobile Chassis- Part of the body which supports its body, engine and transmission system. Transmission system: consists of clutch, gear box, propeller shaft, axle and differential. It transmits power from the engine to the wheels. Clutch is used to couple/decouple the engine and transmission. Gear box contain gearing arrangement to get different speeds. Used to get more than one speed ratios. Propeller shaft is a long shaft used to connect the output shaft of the gear box to the rear axle. Differential has three functions 1. Transfer power from propeller shaft to the wheels. 2. Allow wheels to rotate at different speeds while turning. 3. To turn the direction of drive through 90 0 to the rear wheels . The steering wheel is mechanically linked to the wheels to provide the steering control. . Brakes: They are attached to the four wheels and are of 2 types: 1. Drum brakes 2. Disc brakes Suspension system: For preventing the transmission of shock from uneven road surfaces to the vehicle and to support the vehicle on the axle. Various systems in IC engines The components related and needed for a particular function of the IC engine are grouped together and is called a system Various systems are: Air intake system Exhaust system, fuel system Ignition system Lubrication system Cooling system Engine starting system Air Intake system Purpose is to supply clean air to the engine. An air filter is fitted to remove dust from air before supplying to the engine. In SI engine, intake system consists of inlet manifold, a throttle, intake valves and a carburettor to add fuel. Carburettor is a device which atomizes the fuel an mixed with air and is carried to engine cylinder through inlet manifold. In CI engine, air intake is uncontrolled with a very little restriction to the flow of air. Where the air intake is directly connected to inlet manifold. A turbocharger in CI engines enhances the air intake even more. Exhaust system
After completion of combustion process, the
exhaust gases have to be removed from the engine cylinder to admit fresh fuel air charge of the next cycle. Exhaust gases passes through the exhaust valves and pass through exhaust manifold. From exhaust manifold, gases pass through the emission control system which may contain thermal converters and a muffler, after which gas Fuel system in IC engines Fuels are to be pressurized before injecting in to the cylinder.
Fuel is supplied using fuel pump.
Carburettor is a device used for atomizing fuel, vaporizing it and mixing it with air in correct proportion to produce homogeneous mixture to suit changing condition of the engine. Fuel Pump Air injection are divided in to two: Air injection system and solid injection system Fuel is pumped along with the air to the cylinder in air injection. Whereas in solid injection, fuel is raised to extreme pressures by mechanical pumps and deliver it to combustion chambers using fuel injectors without compressed air. Solid injection consists of pressurizing unit and injector(atomizing unit). Fuel is supplied to the cylinder either by gravity or using fuel pump. Engine starting system Consists of electric starter motor, and starter solenoid. Powerful Starter motor spins the engine a few revolutions when ignition key is turned on, so that combustion process can start. It requires a powerful motor to spin a cold engine and to overcome friction, open and close valves with the cam shaft and all other things directly attached to the engine. Hundreds of amperes of electricity flows to the motor as a large amount of energy is needed for this. Solenoid switch controls this much large amount of current. Ignition system of IC engine In petrol engines, it requires a spark plug to produce spark to initiate combustion. A high electric discharge is produced between 2 electrodes at the spark plug., by the ignition system. Voltage required to produce this high discharge is 10000-20000 V. In battery ignition systems, a battery is the source of energy. In magneto ignition system, energy source is a set of rotating magnets in fixed coils or rotating coils in fixed magnets. The current produced by the magnets flow to the coils. This system is mainly used in 2 wheelers, kick start engines Lubrication system in IC engine If moving parts are allowed to rub each other, it will cause friction and heat, resulting in excess wear. This can be reduced by placing a film of lubricating oil between the moving parts so that they ride on the oil film. Power required to overcome friction will also be reduced and results in reduced wear and tear. Main parts to be lubricated in an IC engine are crankshaft, bearing, crank pin, piston, cylinder walls, cams, valve stems, gears etc. Cooling system in IC engine Due to combustion of fuel inside the cylinder, intense heat is generated. Only 30% of heat is converted in to work while, remaining 40% is carried away by the exhaust gases to the atmosphere. The remaining 30% is left unattended will be absorbed by the engine cylinder, piston and cylinder valves etc. Overheating of the engine components may cause thermal stresses, seizure of piston, decomposition of lube oil, reduced volumetric efficiency etc. An efficient cooling system in an engine is capable of removing 30% of the heat generated in the combustion chamber. Capable of removing heat at a faster rate when engine is hot. In Air-cooling system, the heat is dissipated directly in to the atmosphere directly by conduction through the cylinder walls. It works by making the object to be cooled to have a larger surface area or increased flow of air over its surface or both. In water cooling system, water is circulated through water jackets around each of the combustion chambers. The water is kept continuously by a pump which is driven by a v belt from the pulley on the engine crank shaft. After passing through the engine cylinder, the water is passed through the radiator. In the radiator, the water is cooled by air drawn through the radiator by a fan. Fundamentals of Aerodynamics Aerodynamics is concerned with motion of air and bodies moving through air. The forces acting on bodies moving through air are termed as aerodynamic forces. By Archimedes principle, an aircraft will be buoyed up by a force equal to weight of the air displaced by it. The buoyancy force will act upwards vertically. The net-force W-Fb will be acting irrespective of whether aircraft is in rest or in motion. Aircraft is flying in still air with a constant velocity V. Here the motion of air is solely due to the motion of air craft. Motion of aircraft is maintained by a force T exerted by the engines By Newtons first law of motion, the resultant force acting on the aircraft must be zero, when it is at steady flight. There must be an additional force Fad such that vectorial sum of forces acting on the aircraft is zero. T+(W-Fb) + Fad = 0 Fad is called aerodynamic force. Lift and drag Resolution of aerodynamic force in to two. At right angles to V and opposite to V The force component normal to V is called Lift, L and opposite to V is called drag, D If is the angle between L and D L = Fad x cos D = Fad x sin tan = D/L is the guide angle. Lift is the component of aerodynamic force perpendicular to direction of motion. (opposite to downward force of weight). Drag is the component of force opposite to the direction of motion Drag opposes thrust and acts rearward parallel to the relative wind. Thrust opposes or overcomes the force of drag. Aircraft engines Modern aircraft engine have the ability to actuate massive stream and thus to produce high thrust. Turbojet engine. Turboprop engine. Turbofan engine. Ramjet engine. Module V- Theory of Mechanisms & Machines Used to understand the relationships between geometry and motion of parts of machine or mechanism and forces which produce these motion. Essential for the design of a machine. Kinematics: It is the branch which deals with geometric relationships and relative motion between parts like position, displacement, rotation speed etc.. Dynamics: Which deals with study of forces acting on various parts of machine. Forces can be either static or dynamic due to inertia of the parts of the machine. Static deals with stationary systems Dynamics deals with systems that change with time. Analysis and synthesis Synthesis (Design) is the process of prescribing the sizes, shapes, material compositions, and arrangement of parts so that the resulting machine will perform the prescribed task. Application of largest collection of scientific methods falls under analysis. Evaluation and rating of things already conceived. A machine is a combination of resistant bodies so arranged that by their means the mechanical forces of nature can be compelled to do the work accompanied by certain determinate motions A mechanism is defined as an assemblage of resistant bodies connected by movable joints to form a closed kinematic chain with one link fixed and having purpose of transforming motion. A machine is an arrangement for doing work/applying power where as mechanism is transmitting power to achieve the desired motion. The connection between links of the mechanism is called a pair (kinematic pair). The purpose of a link is to hold a constant spatial relationship between elements of its pairs. Structure is an assemblage of no: of resistant When several links are movable connected together by joints they are said to form a kinematic chain. Links containing only 2 pairs of element connections are called binary joints. Recognizing the type of relative motion and assigning some variable parameters for measuring or calculating motion are called degree of freedom. Lower pairs are having surface contact between the pair elements whereas higher pairs have point contact between the elemental surfaces. Planar, Spherical & Spatial mechanisms A planar mechanism is one in which all particles describe plane curves in space and all these curves lie in parallel planes. Loci of all points are plane curves parallel to a common plane. The motion transformation of any such mechanism is called coplanar. Slider crank mechanism, four bar mechanism are examples of planar mechanisms. Planar mechanisms using only lower pairs are called planar linkages. It requires that all the axes of revolutionary and prismatic pairs should be normal to he plane of motion. Spherical mechanism Is one in which all the moving links perform concentric spherical motions about a common stationary point called spherical center. Motion of all particles can be described by their radial projections on the surface of a sphere with properly chosen center. Hooks universal joint is the most familiar example of spherical mechanism. They are constituted of revolutionary pairs. Spatial mechanism &Mobility A rigid body is said to undergo spatial motion if its motion is not planar or spherical. Spatial mechanisms include no restrictions on the relative motions of the particles. The motion transformation is not necessarily coplanar nor it must be concentric. Have particles with loci of double curvature. Screw pair is an example for spatial mechanism Mobility is the no: of degrees of freedom of a mechanism. The number of input parameters which must be independently controlled in order to bring the device in to a particular position. Calculation of mobility of a mechanism directly from the count of no: of links and the no: and types of joints. For a n-link planar mechanism, has 3 x (n-1) degrees of freedom before any joints are connected. When we use J1 to denote the no: of single DOF pairs and J2 to represent no: of 2 DOF pairs, resulting mobility m of a planar n-link mechanism is given by the following: m = 3 x (n-1) - 2J1 J2 (Kutzbach criterion) Inversion of a Mechanism Method of obtaining different mechanism by fixing up different links is called inversion of mechanism. Relative motions are not changed in inversion but the absolute motion (one w.r.to Fixed link). Part of the mechanism which initially moves w.r.to the frame is called driver whereas part to which the motion is transmitted is called follower. Grashoffs law for 4 bar linkage states that the sum of the shortest and longest linkages cannot be greater than the remaining 2 link lengths, if there is to be continuous relative motion between these two. In the following figure the following equation applies: s+l = p+q Mechanical advantage of a linkage is the ration of the output torque exerted by the driven link to the necessary input torque required at the driver. (Ratio of load to effort)
Ideal mechanical advantage is M.A =
FB /FA = vA /vB Mechanical Design &Types Formulate a plan for the satisfaction of a specific need or a problem is done in design. Design is an innovative, highly iterative decision making process. Adaptive design: Designers work is concerned with adaptation of existing designs. Requires no special skill/knowledge. Development design: needs considerable scientific training and design ability in order to modify the existing designs into a new idea by adopting new material or different method of manufacture. New Design: this type of design need lot of research, technical ability and creative thinking. Rational design : This types of design depends upon mathematical formulae of principle of mechanics. Empirical Design: This type of design depends upon empirical formula based on practice & past experience. Industrial Design: Depends upon the production aspects to manufacture any machine component in the industry. Optimum design: Best design for the given objective function under specified constraints. System design: Design of any complex mechanical system like a motor car. Element design: Design of any element of the mechanical system like piston, crankshaft, connecting rod etc. Design process: 1. Recognition of need 2. Definition of problem 3. Synthesis 4. Analysis and optimization 5. Evaluation 6. Presentation Types of Loads Static load : is a stationary force, moment or torque acting on the member. Dynamic load: which varies in magnitude or in direction or in both with respect to time. Cyclic load: Which when applied, varies in magnitude in a repetitive cyclic manner, either completely reversing itself from tension to compression or oscillating about some mean value. Eg: weights of machinery, load acting on pressure vessel etc. Impact load: Is a load which is applied suddenly in to a member usually at a high velocity and at a constant magnitude. Punch press, drop forge are examples of machines subjected to impact loads. Factor of safety: It is the ratio of maximum load carrying capability of the component to the design loading. Purpose is to safeguard against unexpectedly high loads, material defects and process defects. FOS = Failure Load/working Load Working load is the load used in the design to determine the dimensions of the component. Failure load is the load at which the failure of the material occurs. Low FOS for high quality and consistent materials, quality manufacturing and inspection methods. Material strength basis
Nature of load basis: Static, impact or cyclic
loading Possible misuse: Designer must consider any possible foreseeable use and misuse of the component. Complexity of stress analysis: Actual stress in not known. Environment: Temperature, Weather, radiation, chemicals Standards & Codes: A standard is a set of specifications for parts, materials or processes intended to achieve uniformity, efficiency, and a specified quality. Limit multitude of variations that can arise from the arbitrary creation of parts. A code is a set of specifications for the analysis, design, manufacture and construction of something. The purpose of code is to achieve a specified degree of safety, efficiency and performance or quality. Absolute safety is impossible to obtain in practice. Economics of Design: Observe that nothing can be said in an absolute sense concerning costs. Increasing cost of materials and labour. Cost of processing materials trend to decrease because of automated machines/tools. Increased cost based on location. (Labour, tax variations etc.). Reliability: Primary focus is on Failures and their prevention. It is the probability that a unit performs its intended function adequately for a given period of time under stated operating conditions o environment. Reliability R = 1 Pf where Pf is the probability of failure is the number of instances of failure per total number of possible instances. 0<R<1 R = 0.9, means there is 90% chance that the part will do intended function without failure. If a mechanical system fails when any one component fails, then the system is said to be a series system. If reliability of a component is i is Ri in a series system of n components, then the reliability of the system is expressed as R = Ri Module VI- Engineering Materials For an engineer materials means structural material that is used to produce various products. Various kinds of materials used for industry, housing, agriculture, transportation, etc. To meet the plant requirement. An appropriate selection of material adds to economy, working and life of the final part of the component. The selection of a material for a process depends on; Operating parameters. Manufacturing processes. Functional requirements. Cost considerations are known. Properties of Engg. /Materials Physical properties: describes the state of the material, which is observable or measurable. Eg: Colour, texture, density, MP, BP etc. Chemical properties: chemical properties are the measure of reactivity of a material in the presence of another substance or environment which imposes in the material composition. Eg: Corrosion rate, oxidation rate, Mechanical properties: Tensile strength: this enables the material to resist the application of a tensile force. the internal structure of the material provides the internal resistance. Hardness: Degree of resistance to indentation , scratching, abrasion and wear. Ductility : Property of a metal by virtue of which it can be drawn in to wires/elongated before rupture take place. Impact strength: energy required per unit c/s area to fracture a specimen. response to shock loading. Wear resistance: Ability of a material to resist friction wear under particular conditions.(Maintain its physical dimensions, when sliding or rolling contact with a second member. Corrosion resistance: those metals and alloys which can withstand the corrosive action of medium. Density: important factor of a material where weight and mass are critical parameters. Thermal properties: which are functions of temperature, plays a vital role in the selection of material for engg. applications Eg: Thermal conductivity, specific heat, latent heat. Classification of engg. materials Metals & Alloys: Metals are good electrical and thermal conductors. At ordinary temperature, metals re usually solid. To some extent metals are ductile. Most of the metals form alloys. May be magnetic or non-magnetic. 2 or more metals are melted together to form a new metal whose properties are quite different from those of original metals, is called an alloy. Eg: steel is an alloy of iron, carbon, and other alloying elements. Brass is an alloy of copper and zinc. Classification of engg. Materials ..(Contd.) Ferrous metals: Iron is the principal constituent and contains significant amount of non-ferrous metals. On the basis of carbon content, they are classified as Steel and iron. % of carbon in steel is up to 2.14. % of carbon in iron is above 2.14. Cast irons are manufactured by casting technique owing to the brittle nature due to the presence of iron carbide. Cast irons serve mostly structural components Lathe bed, sliding guides in machinery, automobile motor casings etc. Classification of engg. Materials..(Contd.) Plain carbon steels is a metal alloy, where there elements are present in quantities too small to affect the properties Mild steel - % of carbon is from 0.15-0.25 Moderately strong and have good weldability Gears, valves, boiler plats etc. Medium carbon steel carbon % from 0.3 -0.6% High strength and less weldability. High carbon steels Carbon % from 0.65-1.5 Getting harder and tougher by heat treatment. Poor weldability. Alloy steel: Class of steel in which one or more elements other than carbon are intentionally added to impart some physical properties. Common elements added are molybdenum, manganese, nickel, silicon, boron, chromium and vanadium etc. Low alloy steels are category of ferrous materials exhibiting superior mechanical properties than plain carbon steels. Total alloy content from 2.07 up to levels just below that of SS. Used for surgical instruments, ball bearing etc. Non-Ferrous Metals: These substances are composed of metals other than iron. Aluminium, tin, zinc, copper, nickel etc. Ceramics: These are non metallic solids made of inorganic compounds such as oxides, nitrides, borides and carbides. They are fabricated by first shaping the powder with or without application of pressure in to a compact which is subsequently subjected to high temperature treatment called sintering. Used in the manufacture of porcelain, pottery, cement etc. Organic materials: These materials originate from plants and animals. Consists of carbon chemically combined with hydrogen oxygen and other non-metallic substances. Common organic materials are plastics and synthetic rubbers. Formed by polymerization. Have low specific gravity and good strength. Thermosetting plastics are formed in to shape under heat and pressure which results in a permanently hard product. Thermoplastics are those plastics which remain soft at elevated temperature and become hard on cooling. Composites: A composite material is defined as a material which is composed of 2 or more materials at a microscopic scale. The constituent materials have different properties. They can be natural or artificial made materials Naturally occurring composites are wood, granite etc. Semiconductors: They are solid materials either non-metallic or compounds which allow electrons to pass through them so that they conduct electricity in much the same way as metals. They occupy an intermediate position between conductor and insulator. They usually have high resistivity, hardness and brittileness. Advanced materials: Advanced materials refer to all new materials and their development to the existing materials to obtain superior, unique, and high performance in one or more properties. Amorphous and metallic glasses, nano materials and nano composites, bio materials, and smart or so called intelligent materials are some type of advanced materials. Nano structured materials: Are those materials whose structural elements (clusters, crystallites or molecules have dimensions in the range of 1-100 nm) Nano particles, nano crystals etc are examples.