DEPARTMENT

OF
MECHANICAL ENGINEERING

STUDENT HAND BOOK

IV Year B Tech – I Semester (2017-2018)

Guru Nanak Institute of Technology

Ibrahimpatnam, Ranga Reddy District – 501 506 (T.S)

Name Suresh.S
Class/Section IV YEAR-B SECTION

1
 PART A

DEPARTMENT OF MECHANICAL ENGINEERING

I. GENERAL INFORMATION

About the College

Guru Nanak Institute of Technology was established in 2008 with a single -
minded aim to provide a perfect platform to students in the field of Engineering,
Technology and Management for their academic and overall personality development.
The College is approved by AICTE and affiliated to JNTUH, Hyderabad. At present
the College offers Six B. Tech programme in EEE& IT with intake of 60 in each,
ECE& Civil Engineering with an intake of 120 and CSE& Mechanical Engineering
with an intake of 180 in each.
Highlights:
 Teaching methodology involves technical case studies, creative exercises, online
assignments & descriptive tests.
 E-class rooms
 Industry focused knowledge is imparted by R & D and Industry peer members.
 Tie up with MNC companies and foreign Universities
 State of art laboratories, sophisticated equipment and advanced software
 Library is equipped with National and International Journals, 50000 volumes and
more than 7500 titles of books, NPTEL, SONET CDs and internet lab for students
and staff.
 IEEE online journals and IEL online journals through AICTE INDEST
CONSORTIUM
 Wi-Fi campus with 12 Mbps bandwidth.
 Oracle, Microsoft Development suite, Microsoft academic license for Microsoft
Software Products, Ansys ,Pro’e software’s are available
 State of art English Language lab and 800 computers connected with dedicated
high-end servers.
 Scholarship and free books for meritorious students.
 Book Bank Scheme facility to the students.
 A new and unique Laptop lab with latest configuration Most of the classrooms are
fixed with LCDs and screens.
2
  All major professional societies’ student chapters like ISTE, CSI, IETE and IEEE
etc.

Training & Placement:

 Modern training department is established as per the corporate standards.

 College has JKC training centre and special training is providing in the area of
soft skills and technical skills for students which is a part of their regular time-
Table.
 Large Number of students placed with Microsoft Inc, Infosys, Mahindra Satyam
Ltd, Infosys, IBM, TCS, ADP, Wipro, Sutherland Technologies, CMC,
SEMANTIC SPACE and InfoTech Enterprises.
 Industry experts are invited for guest lectures, seminars and student presentations
to maintain a strong Industry and Institution Interaction. Also, industrial visits are
arranged for students to enrich their knowledge.
Contact Information

Principal : Dr.S.Sreenatha Reddy 80966 09821

Vice Principal : Dr.M.Narendra Kumar 8096609840
HOD EEE : Dr.R.Vinothkanna 8498056996
HOD CSE : Dr.S senthil kumar
HOD IT : Dr. P subramanian
HOD ECE : Prof. B.Kedarnath 80966 09829
HOD MECH : Dr. B.Vijay Kumar 80966 09836
HOD CIVIL : Prof.Madhan Mohan 8096609827
HOD H & S : Dr. G.Srinivas 8096195678
Manager Admin : Mr. Col (Retd) Rajesh Kumar 8096611000
Administrative officer : Mr. S Antony 8297975251
Transport Officer :

3
 II. ACADEMICS
Mechanical Engineering

The department of Mechanical Engineering was established in the year 2009,

offering under graduate program now with an intake of 180. The prime objective of the
course is provide students with a sound mechanical engineering education, advanced learning
methods and applications of mechanical engineering principles. The department provides
facilities for students to learn soft skills and achieve holistic personality. Majority of the
faculty members are actively involved in research activities in the fields of their
specialization. They have published a good number of research papers in
International/National Journals and International/ National Conferences. The faculty in the
department interacts closely with industry enabling the graduates completely successful not
only at the national level but also at the global level. Metal joining technology, Nano
Technology, Vibration and Stability of Fluid conveying pipes and Exhaust emission analysis
of Dual fuel engines are the thrust areas of research.

VISION

To be a leading department of Mechanical Engineering in the region.

MISSION

1. Nurture young individuals into knowledgeable, skilful and ethical professionals in

their pursuit of   Mechanical Engineering.
2. Nurture the faculty to expose them to world-class infrastructure.
3. Sustain high performance by excellence in teaching, research and innovations.
4. Extensive partnerships and collaborations with foreign universities for technology
upgradation.
5. Develop Industry-Interaction for innovation and product development.

QUALITY POLICY

GNIT is committed to provide quality education through dedicated and talented Faculty,
World- class infrastructure, Labs and Advanced Research Center to the students.

4
Programme Educational Objectives (PEOs)

PEO 1: Graduate shall have the ability to apply knowledge and Technical skills across the
disciplines and in emerging areas of Mechanical Engineering for higher studies, research,
employability and handle the realistic problems.

PEO 2 : Graduates shall possess managerial skills , maintain ethical conduct, sense of
responsibility to serve the society and protect the environment.

PEO 3: Graduates shall possess academic excellence with innovative insight, soft skills,
leadership qualities, knowledge of contemporary issues for successful professional career.

Programme Outcomes (POs)

a. An ability to apply knowledge of mathematics, science and engineering.

b. An ability to design and conduct experiments, as well as to analyze and interpret data.
c. An ability to design a system, component, or process to meet desired needs within
realistic constraints such as economic, environmental, social, political, ethical, health and
safety, manufacturability, and sustainability.
d. An ability to function on multidisciplinary teams.
e. An ability to identify, formulate, and solve engineering problems.
f. An understanding of professional and ethical responsibility.
g. An ability to communicate effectively.
h. The broad education necessary to understand the impact of engineering solutions in a
global, economic, environmental, and societal context.
i. A recognition of the need for, and an ability to engage in life-long learning.
j. A knowledge of contemporary issues.
k. An ability to use the techniques, skills, and modern engineering tools necessary for
engineering practice.

MAPPING OF Program Educational Objectives (PEO’s) and PROGRAM

OUTCOMES (PO) FOR MECHANICAL ENGINEERING

Program Program Outcomes

educational j k
a b c d e f g h
Objectives i
I √ √ √ √ √ √ √ √ √ √
√ √ √ √ √ √ √ √ √ √
II
√
III √ √ √ √ √ √

Faculty Strength:

The faculty in the department consists of doctorates, experienced Professors, Associate

Professors and Assistant Professors. An experienced System Administrator and well-qualified
programmers will conduct the Laboratories.

5
 FACULTY LIST
S.NO NAME OF THE FACULTY Designation PHONE NO: E-mail
1 Dr.S.SREENATHA REDDY principal 8096609821 [email protected]
Hod &
2 Dr.B .VIJAYA KUMAR 8096609836 [email protected]
Professor
3 Dr.V.SITARAM PRASAD Professor 9849329809 [email protected]
4 Dr.R.DHANASEKARAN Professor 9043793491 [email protected]
5 Mr.M. SRIHARI Asst Prof 9618272335 [email protected]
6 Mr. B.PRAVEEN KUMAR Asst Prof 8499993877 [email protected]
7 Mr. SK. HIMAM SAHEB Asst Prof 9949019555 [email protected]
8 Mr. A. VIJAY KUMAR Asst Prof 7036463491 [email protected]
9 Mr. K.GOVARDHANA REDDY Asst Prof 8096039696 [email protected]
10 Mr. JAYANTH IVVALA Asst Prof 8978066556 [email protected]
11 Mr.K. DAYAKAR Asst Prof 9704121602 [email protected]
12 Mr.SK . AZGER PASHA Asst Prof 9553313925 [email protected]
13 Mr. BASAVARAJA K.T Asst Prof 7075101218 [email protected]
14 Mr. MD.HAMEED Asst Prof 9440206860 [email protected]
15 Mr. K. RAVI SANDEEP KUMAR Asst Prof 8099514020 [email protected]
16 Mr. T. JAYA SRI RAM Asst Prof 9542630628 [email protected]
17 Mr.M. SAMPATH KUMAR Asso. Prof 9948024576 [email protected]
18 Mr.A. YOGESH Asst Prof 9493037075 [email protected]
19 Mr. MARUTHI S.W Asst Prof 7204543401 [email protected]
20 Mr.T.VENKATA RAMANA Asst Prof 9963376589 [email protected]
21 Mr.R.SATEESH KUMAR Asst Prof 9538574577 [email protected]
22 Mrs. SAKE VIJAYANIRMALA Asst Prof 9502646643 [email protected]
23 Ms.M. SRAVANTHI Asst Prof 9490912468 [email protected]
24 Mr. N. RAMULU Asst Prof 9676431345 [email protected]
25 Mr. M.SREEDHAR Asst Prof 9041160436 [email protected]
26 Mr .Asit kumar parida Asst Prof 8895824689 [email protected]
27 Ms .V. PRAMILA Asst Prof 8008656437 [email protected]
28 Mr.P. JAYAKRISHNA Asst Prof 9491997264 [email protected]
29 Mr.M.PRUTHVIRAJ Asst Prof 8496992434 [email protected]
30 Mr.SRINIVAS REDDY Asst Prof 7329838489 [email protected]
31 Mr. S.SURESH Asst Prof 09986774711 [email protected]
32 Mr.PRADEEP.C Asst Prof 09036766959 [email protected]
33 Mr.VINOD ANGADI Asst Prof 8147720074 [email protected]
34 Mr.KRISHNA KANTH.B Asst Prof 9590474101 [email protected]
35 Mr. PRAVEEN.S Asst Prof 08147363630 [email protected]
36 Mr.VIRAN KUMAR Asst Prof 8978645134 [email protected]

LIST OF NON TEACHING MEMBERS

6
 Sl. No. Name of the Staff Designation
1 Mr. K Vidya sagar Lab Assistant
2 Mr. D Praveen Lab Assistant
3 Mr. V Sandeep Lab Assistant
4 Mr. V Bramhaiah Lab Assistant
5 Mr. Zafer ali khan Lab Assistant
6 Mr. S Naveen Kumar Lab Assistant
7 Mr. K Surya Narayana Lab Assistant

Course Calendar for the Semester (to be filled by the candidate)

S.No EVENT Duration

1 Conducting Workshop on 1 day
Advanced welding
2 Techniques for 2nd 3rd & 4th
years
3 Seminars for all years 1 day
4 NSS program for all years 2 day’s
5 Industrial Visit 2 day’s
6 Guest Lecture 3 day’s

Procedures for Laboratories

a. Equipment in the lab for the use of student community. Students must use the
equipment with care. Any damage caused is punishable.
b. Students should carry their observation book along with the record book with
completed exercises/ calculations while attending the lab.
c. Students are supposed to occupy the experiment setup allotted to them and
maintain discipline in the lab.
d. Labs can be used in free time / lunch hours by the students with prior permission
from the lab in-charge.
e. 15 marks are awarded for continuous evaluation in the laboratory. Lab records
need to be submitted on or before date of submission

7
III. MONITORING AND GUIDANCE

1. Student Feedback
In case the students’ find it difficult to cope up / understand a particular subject, they
are advised to discuss it with the concerned Teacher /The Class Teacher/Counselor/HOD/
Principal.
Students can use the suggestion boxes for communicating their problems. Necessary
action will be taken by the concerned authorities. If required, Principal/HOD will discuss the
student to solve the problems.

Class Teacher:

S. No. Name of The Mentor Class Mobile Number

1 Mr. MARUTHI S.W II MECH-A 7204543401
2 Mr.M.PRUTHVIRAJ II MECH-B 8096390791
3 Mr.A.YOGESH II MECH-C 9493037075
4 Mr.N.RAMULU III MECH-A 9676431345
5 Mr. PRAVEEN.S III MECH-B 08147363630
6 Mr.PRADEEP.C III MECH-C 09036766959
7 Mr. A.VIJAY KUMAR IV MECH-A 7036463491
8 Mr. S.SURESH IV MECH-B 9986774711

9 Mr.VINOD ANGADI IV MECH-C 8147720074

Counselor:
One counselor is assigned to a group of 30students. Students can directly discuss their
college related or personal problems related to academics with them. The Counselors are
accessible to the students and they can talk to them, whenever they are free from class / lab
work. Counselors will interact with the students once in a fortnight and discuss the progress.

Class Representatives and their role:

Two students from each class are selected as Class representatives from the
department based on their academic performance and discipline.

Responsibilities of the Class Representatives:

 Communicating the departmental / college directives & information to the students.
 Communicating the Problems faced by the students and also communicating the
suggestions for improvement.
 Coordinating academic events and co-curricular activities.
 Encourage students to interact for better studies& sharing the knowledge and information.

8
II-Semester Class Representatives are:

Class /
Roll No Name of the Student
Section

II B Tech

III B Tech

IV B Tech

Role of a class Teacher:

 Ensuring the conduct of classes

 Monitoring the students attendance
 SMS, phone calls to the parents and interacting with parents
 Class Discipline
 Arranging extra classes for coverage of syllabus
 Ensuring the conduct of special tests, remedial classes for slow learners
 Communicating the student’s attendance, mid marks, special test marks
attendance of Remedial classes etc.

Role of the Counselors

 Talk to the student at least once in a fortnight

 Updating the counseling book
 Problems of the student may be discussed with the concerned
faculty/mentor/HOD
 Identify the strengths , weakness and motivate the student
Counselors will evaluate the student individually for the following:

a. Less marks in Internal exams

b. Continuous Absence (3 days)
c. Not understanding the subject
d. Students from Telugu medium
e. Assistance for back log subjects etc.

2. Special Tests:
Two Special tests will be conducted for students before the mid exams to improve
their performance in the mid examinations. If any student is not performed, he/she will be
asked to attend the re-exam to ensure the understanding of the subject. If required the teacher
will guide the student in the subject.

9
3. Remedial classes:
Remedial classes will be conducted for students who are academically weak and who
do not perform well in their internal examinations and special class tests.

4. Backlog Management
The Class Teacher maintains a complete record of Examination results of each student
and they counsel and guide them in preparing for backlogs. Students are provided with
material and important questions are discussed.

5. Correspondence with Parents

Parents will be informed about the performance of their ward from time to time during
the course period, however parents are advised to contact class Teacher / Department Head
periodically.
6. NPTEL Classes
Department conducts NPTEL classes with Technical DVD’s as virtual/visual classes
through faculties from IIT’S, NIT’S and IIIT’S

PROGRAM: MECHANICAL ENGINEERING

COURSE: UNCONVENTIONAL MACHINIG PROCESSES
Course Objective
1.The concept of Material removal by an edged tool, involving plastic deformation and
formation of chips , has been known to man for several hundred years .
2.In recent years an increasing demand for the machining of components of complex shapes
made of hard, difficult – to – machine materials with
3. Exacting tolerances and surface finish has resulted in the development of a number of new
machining processes.
4. Some of these methods have been commercially exploited while others are still in their
experimental stages .
5. There has been a rapid growth in the development of harder and difficult to machine
metals and alloys during the last two decades.
6. Conventional edged tool machining is uneconomical for such materials and the degree of
accuracy and surface finish attainable is poor.
7. The advancing strength level would have a catastrophic effect on the total machining bill if
there was no corresponding improvement in machining technology.
8. In view of this seriousness of this problem, Merchant (1960) emphasized the need for the
development of newer concepts in metal machining.

10
Course Outcomes:
1. Know the various types of power plants used in India.
2. Knowledge of the various types of conventional and non-conventional power plants.
3. Knowledge of the operation, construction and design of various components of
power plants.
4. Calculate the performance parameters of various power plants.
5. Define and calculate the various factors of plant load and economy
6. Identify elements and their functions of steam, hydro, diesel, nuclear, wind and solar
power plants.
7. Operate equipments of different power plants.
8. Analyze economics of power plants and list factors affecting the power plants

MAPPING OF THE COURSE OBJECTIVES WITH THE COURSE

OUTCOMES

Course Outcomes
Course
Objectives
a b c d e f g h
I √ √ √ x √ √ √ √

II √ √ √ √ √ √ x √
III √ √ √ x √ √ √ √
IV √ √ √ √ √ x √ √
V √ x √ √ x √ √ √
VI √ √ √ √ √ √ √ x
VII √ √ √ √ √ √ x √
VIII √ √ x √ √ √ √ √

11
JNTU Syllabus
Introduction – Need for non-traditional machining methods- Classification of modern
machining
Processes- Considerations in process selection- Materials, Applications.
Unit – I

Ultrasonic machining – Elements of the process, mechanics of metal removal process

parameters, economic considerations, applications and limitations, recent development.
Abrasive jet machining, water jet machining and Abrasive water jet machine: Basic
principles, equipment’s, process variables, mechanics of metal removal, MRR, application
and limitations.
Unit – II Electro-chemical processes: Fundamentals of electro chemical machining, electro-
chemical grinding, electro chemical honing and deburring process, metal removal rate in
ECM, Tool design, Surface finish and accuracy, Economic aspects of ECM – Simple
problems for estimation of metal removal rate.
Thermal metal removal processes: General Principle and applications of Electric
discharge machining, Electric discharge grinding and electric discharge wire cutting
processes-power circuits for EDM, Mechanics of metal removal in EDM, process
Unit – III
parameters, selection of tool electrode and dielectric fluids, surface finish and machining
accuracy characteristics of spark eroded surface and machine tool selection. Wire EDM-
principle and applications.
Generation and control of electron beam for machining, theory of electron beam
Unit – IV machining, comparison of thermal and non-thermal processes. General Principle and
application of laser beam machining thermal features, cutting speed and accuracy Of cut.
Application of plasma for machining metal removal mechanism, process parameters,
Unit – V accuracy and surface finish and other applications of plasma in manufacturing industries.
Chemical machining-principle-mask ants-etchants-applications.

TEXT BOOK:
Advanced machining process-VK Jain, Allied publishers.

REFERENCES:
1. Modern Machining Process-Pandey P.C. and Shash H.S.,TMH.
2. New Technology-Bhattacharya A, The Institution Of Engineers, India 1984.
3. Unconventional Machining Processes-C.Elanchezhian,,B.Vijaya Ramnath And M Vijayan,
Anuradha Piblications, 2005.

12
 LESSON PLAN:

SUBJECT UNCONVENTIONAL MACHINING PROCESS

Text Books (To be acquired by the Students)
Book 1 Advanced machine process/VK Jain/ Allied publishers.

Manufacturing engineering and technology, Serope Kalpakjian and Steven

Book2
R. Schmid, Ed.4, Pearson Publications, 2001
Reference Books
Book 2 Modern Machining process/Pandey P.C. and Shah H.S./TMH.
Unconventional machining Processes/C.Elanchezhain, B Vijaya ramah and
Book 3
M Vijayan/Anuradha Publications/2005
No. of
Chapter No.
UNIT NO TOPIC Classes
B1 B2 B3 B4
1 1 1 1
I INTRODUCTION 10

ELECTRO-CHEMICAL 8 - 6 9
II PROCESSES 16

THERMAL METAL REMOVAL

III PROCESSES 8 10 6 8 18

GENERATION AND CONTROL 14 - 7 12 9

IV OF ELECTRON BEAM FOR
MACHING(EBM)
APPLICATION OF PLASMA FOR 12 15 9 9 9
V MACHINING

Contact classes for syllabus coverage 62

Lectures beyond syllabus 03
Special Descriptive Tests 02
Tutorial classes 03
Remedial classes 02
Total No. of classes 72

13
 Micro Level Lesson Planning -UCMP

Sl. Name of the Topic to be covered Number Cumulative Date of

No. of Periods Number of Completion
required Periods
Unit I

Introduction – Need for non-

1 1 1
traditional machining methods
2 Classification of modern machining 2
1
Processes
3 Considerations in process selection.. 1 3
4 Materials. Applications 1 4
Ultrasonic machining – Elements of
5 1 5
the process,
mechanics of metal removal process
7 2 7
parameters,
8 economic considerations, 1 8
Applications and limitations, recent
9 2 10
development.
Unit II
10 Abrasive jet machining 1 11
11 Water jet machining 1 12
Abrasive water jet machine : Basic
12 principles, 2 14

13 machines of metal removal 1 15

process variables, application and
14 limitations 1 16

Electro-chemical processes:
15 Fundamentals of electro chemical 1 17
machining,
16 Electro-chemical grinding, 2 18
17 electro chemical honing 1 19
19 metal removal rate in ECM, 2 23
Tool design, Surface finish and
20 2 25
accuracy
Economic aspects of ECM –
21 Simple problems for estimation of 2 27
metal removal rate.
Unit III
Thermal metal removal processes:
22 General Principle and applications 4 31
of Electric discharge machining,
Electric discharge grinding and
23 electric discharge wire cutting 3 34
processes-power circuits for EDM,

14
 Mechanics of metal removal in
24 EDM, process parameters, selection 3 37
of tool electrode and
Dielectric fluids, surface finish and
24 2 39
machining accuracy,
Characteristics of spark eroded
26 1 40
surface
27 Machine tool selection. 2 42
Wire EDM-principle and
28 3 45
applications
Unit IV
Generation and control of electron
29 2 47
beam for machining,––
30 Theory of electron beam machining, 1 48
Comparison of thermal and non-
31 1 49
thermal processes
General Principle and application of
32 3 52
laser beam machining
Thermal features, cutting speed and
33 2 54
accuracy Of cut.
Unit V
Application of plasma for
34 2 56
machining,
35 Metal removal mechanism 1 57

36 process parameters, 1 58

37 Accuracy and surface finish, 1 59

Other applications of plasma in
38 2 61
manufacturing industries.
Chemical machining-principle-
39 1 62
maskants-etchments-applications.

15
ASSIGNMENT QUESTIONS

UNIT-I
State the advantages and limitations of non-traditional machining processes, over
1 traditional machining process.
Classify different unconventional machining process based on material to be
2
machined.
What are the various types of energy sources used in non-traditional machining
3
techniques? Give examples for each.
Differentiate the unconventional and conventional machining processes in terms of
4
principles?
What are the main parameters to be considered while selecting particular process
5
why?
UNIT II
1 Why is abrasive jet machining not suitable for unconventional machining process ?
(a) State and explain the working principle of Abrasive Jet machining in details?
2 (b) Why water jet machining is not suitable for brittle materials explain.

|Briefly explain the various process parameters that effect the material removal rate
3
and surface quality in ECM ?
(a) What is the principle of Water jet machining ? Describe the working of a
4 WJM ?
(b) What do you mean by deburring process ?

(a) Explain the different variables that influences the rate of MRR and accuracy
in AJM
5 (b) Write the characteristics of electrochemical machining ?

UNIT-III
1 Define Di-electric? Write a note on it indicating its functions and characteristics ?
Explain the process of Wire cut EDM, and list any two advantages, limitations and
2
applications of Wire-cut EDM ?
(a) Explain in details the spark ignition in EDM process ?
3 (b) Name some of the tool materials used in EDM ?

Explain in details the mechanism of electric discharge grinding and state its
4
advantages and limitations over EDM process ?
Explain in details the effect of process parameters on surface roughness in EDM
5
Porcess ?
UNIT-IV
Explain with the help of neat sketch the working principle of a typical pulsed ruby
1
laser beam machining process ?
(a) Distinguish between thermal and non thermal process in EBM process ?
2 (b) Explain the principle of laser beam machining process ?

3 Explain the various process parameters which influence in MRR in EBM process.?

16
 Make a comparision between LBM and EBM process on the basis of their working
4
principles.?
5 Describe, with the help of a neat sketch, the principle and working of an EBM
process.?
UNIT-V
Describe the process parameters of PAM and influence on machining quality and
1
explain.?
2 Describe the quality of machining and accuracies obtainable in chemical machining.
3 Discuss the criteria’s that are applied in the solution of etchants and maskants.?
With a neat diagram explain the principle of PAM and state its advantages,
4
limitations and applications.?
(a) Classify the different types of etchants used in chemical machining process
5 and write its characteristics.?
(b) Generalize the techniques of applying maskants

17