Elements of Mechanical Engineering (BEMEM103) notes

ELEMENTS OF MECHANICAL ENGINEERING

(Sub code:-BEMEM103)
(AS PER CHOICE BASED CREDIT SYSTEM)

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 Elements of Mechanical Engineering (BEMEM103) Module 1 notes

Syllabus: Module-1
Introduction to Mechanical Engineering (Overview only): Role of Mechanical Engineering in
Industries and Society- Emerging Trends and Technologies in different sectors such as Energy,
Manufacturing, Automotive, Aerospace, and Marine sectors.
Steam Formation and Application: Modes of heat transfer, Steam formation, Types of steam, Steam
properties and applications of steam (simple numerical problems). Energy Sources and Power Plants:
Basic working principles of Hydel power plant, Thermal power plant, nuclear power plant, Solar
power plant, Tidal power plant and Wind power plant.
…………………………………………………………………………………………………
Introduction:
Mechanical engineering is an engineering branch that combines engineering
physics and mathematics principles with materials science, to design, analyze, manufacture,
and maintain mechanical systems. It is one of the oldest and broadest of the engineering
branches. The mechanical engineering field requires an understanding of core areas including
mechanics, dynamics, thermodynamics, materials science, structural analysis, and
electricity. In addition to these core principles, mechanical engineers use tools such as
computer-aided design (CAD), computer-aided manufacturing (CAM), and product lifecycle
management to design and analyze manufacturing plants, industrial equipment and
machinery, heating and cooling systems, transport systems, aircraft, watercraft, robotics,
medical devices, weapons, and others. It is the branch of engineering that involves the
design, production, and operationof machinery.

Mechanical engineering field has continually evolved to incorporate advancements; today

mechanical engineers are pursuing developments in such areas
as composites, mechatronics, and nanotechnology. It also overlaps with aerospace
engineering, metallurgical engineering, civil engineering, structural engineering, electrical
engineering, manufacturing engineering, chemical engineering, industrial engineering, and
other engineering disciplines to varying amounts. Mechanical engineers may also work in
the field of biomedical engineering, specifically with biomechanics, transport phenomena,
biomechatronics, bionanotechnology, and modelling of biological systems[Ref:
From Wikipedia, the free encyclopedia]

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What is Mechanical Engineering?

Mechanical Engineering is that branch of engineering which combines physics, mathematics,
engineering principles with materials science. This field aims at designing, analysing,
manufacturing and maintaining mechanical systems. Mechanical Engineering is considered to
be the broadest and the oldest of the engineering disciplines. This branch focuses on the core
areas that include thermodynamics, mechanics, dynamics, structural analysis, electricity and
materials science.

These core principles are combined with tools such as CAD (computer aided design) and
CAM (computer aided manufacturing) and product life cycle management for the design and
analysis of industrial equipment, machinery manufacturing plants, transport systems,
robotics, medical devices, heating and cooling systems and so on. This branch of engineering
is primarily concerned with the design, production and operation of machinery.

This field emerged in the 18th century during the Industrial Revolution and has been
continuously developing and advancing since then.

Mechanical Engineering is important because it introduces and helps implement useful

technology in our day to day lives and in modern society. It has a very crucial role to play in
manufactured technologies, right form refrigerators to cars to aeroplanes and much more.

ROLE OF MECHANICAL ENGINEERING IN INDUSTRIES AND SOCIETY

Role of Mechanical Engineering in Industries

Knowledge of Mechanical Engineering in the industry helps to do the following
 Analyze problems to see how mechanical and thermal devices might help solve a
particular problem
 Design or redesign mechanical and thermal devices or subsystems, using analysis
and computer-aided design
 Investigate equipment failures or difficulties to diagnose faulty operation and to
recommend remedies
 Develop and test prototypes of devices they design
 Analyze the test results and change the design or system as needed

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 Oversee the manufacturing process for the device

Mechanical engineering is one of the broadest engineering fields. Mechanical engineers

design and oversee the manufacture of many products ranging from medical devices to new
batteries.
Mechanical engineering is required for design in power-producing machines, such aselectric
generators, internal combustion engines, and steam and gas turbines, as well as power-using
machines, such as refrigeration and air-conditioning systems.

By knowledge of Mechanical engineering, one can design other machines inside buildings,
such as elevators and escalators. They also design material-handling systems, such as
conveyor systems and automated transfer stations.

Like other engineers, mechanical engineers use computers extensively. Mechanical engineers
are routinely responsible for the integration of sensors, controllers, and machinery. Computer
technology helps mechanical engineers create and analyze designs, run simulations and test
how a machine is likely to work, interact with connected systems, and generate specifications
for parts.

The following are examples of types of mechanical engineers:

Auto research engineers seek to improve the performance of cars. These engineers work to
improve traditional features of cars such as suspension, and they also work on aerodynamics
and new possible fuels.

Heating and cooling systems engineers work to create and maintain environmental systems
wherever temperatures and humidity must be kept within certain limits. They develop such
systems for airplanes, trains, cars, schools, and even computer rooms.

Robotic engineers plan, build, and maintain robots. These engineers plan how robots will
use sensors for detecting things based on light or smell, and they design how these sensors
will fit into the designs of the robots.

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Role of Mechanical Engineers in Society

 Transportation
 Medical
 Agricultural
 Defense
 Power generation

Transportation
Mechanical engineering is largely concerned with road transportation, and networks, rail
and subway systems, airports, and shipping ports.

Medical
A mechanical engineer specialized in medical science can be called as 'medical engineer'.
Engineer's responsibilities in medicine can include research, development, testing and
evaluation of medical devices, advisement on new biomedical purchases for hospitals and
medical centers.

Agricultural
The graduates are trained professionals who understand technology and are capable of
solving problems in the areas of agricultural production and management of rural areaswith
a special focus on machinery.

Defense
Manage the teams of skilled technicians that monitor, maintain and repair formidable
military hardware such as tanks, artillery guns and armoured logistic vehicles. Not all types
of entry are open for this job.
Power generation
When working in thermal power plants, mechanical engineers make sure heavy machinery
like boilers and turbines, are working in optimal condition and power is continually
generated. Mechanical engineers also work with the operations of the plant.

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EMERGING TRENDS AND TECHNOLOGIES IN DIFFERENT SECTOR.

 Energy sector - Mechanical engineers in the energy industry design and operate
fossil fuel, hydroelectric, conventional, nuclear, and cogeneration power plants. They
are involved in all aspects of the production and conversion of energy from one form
to another. Mechanical engineers are also involved in exciting projects such as
developing alternatives to thermal energy, power cycle devices, fuel cells, gas
turbines, and innovative uses of coal, wind, and tidal flow.

 Manufacturing industry- A majority of the roles in this sector are focused on supply
network logistics/operations or manufacturing/ engineering. The jobs in this sector are
not demarcated in different compartments. The jobs here are a mix of different
engineering disciplines.

 Automobile Industry – This industry is one of the fastest growing and has therefore
opened up numerous job opportunities. The role of a mechanical engineer spans the
design, manufacturing and maintenance of motor vehicles. With the advancement in
technology when breakthrough ideas like driverless cars, pod-based transportation
systems, bullet trains, are being considered. Top companies and automobile brands
are investing a lot on research and recruiting skilled and passionate mechanical
engineers.

 Aerospace industry – This industry has witnessed a lot of innovations and

discoveries. Flying cars to reusable satellites, rockets are now not unheard of as
technology is progressing so is the demand for newer inventions. The requirement

for skilled mechanical engineers with knowledge and expertise is growing day by
day. Numerous job roles are being offered here ranging from design, to manufactureto
testing to R&D. The mechanical engineers get a chance to employ the principles of
physics to aeromodelling and dynamics to improve the design and efficiency in
systems.

 Marine industry – Mechanical engineers in this industry design and build or operate
and maintain equipment and marine vessels. These engineers design, install, or
maintain engines, shafts, boilers and propellers. They could be a part of the team
that enforces regulations for air and sea pollution or be a part of designing futuristic
cleaner ships.
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 Materials and metals industry – This job role demands the design, development and
testing of a wide variety of complex mechanical system. This will include the entire
life cycle maintenance of the mechanical items that are used in the plant. A few of
those are gas and steam turbines, pipework, valves, fans, coals mills and so on.
Automotive Industry :
The automotive industry includes industries associated with theproduction, wholesaling, retailing,
and maintenance of motor vehicles.

Top 8 Automotive Industry Trends

 Autonomous Vehicles (AVs)

 Vehicle Connectivity.
 Electrification.
 Shared Mobility.
 Artificial Intelligence.
 Big Data & Analytics.
 Human-Machine Interfaces.
 3D Printing

Several automotive industry trends are impacting its future in 2023 and beyond. These trends
involve how vehicles are powered, driven, shopped for, and acquired. Plus, there are statistics
you must know about if you plan to buy a vehicle in 2023. Here are the top 10 trends shaping the
future of the rapidly changing auto industry and some critical motor vehicle-related statistics.

Trends Shaping the Auto Industry

1. Increased Production Of Electric Cars With Digital Technology
2. More Connected Cars
3. Autonomous Self-Driving Vehicles
4. Truck Platooning
5. Automakers And Technology Company Partnerships

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1. Increased Production of Electric Cars With Digital Technology

Automakers continue to integrate more digital technology into their vehicles. Technology
companieslike Google and Tesla are also working on electric and self-driving vehicles. As a
result, it’s clear that vehicles produced in 2023 and beyond with be full of technology to
address digital touch points. There’s fierce competition to develop software and digital and
electronic operating systems to power and control the new, innovative zero-emission electric
vehicles. These new vehicles will be filled with digital technology.

2. More Connected Cars

Connected cars are vehicles connected to the Internet of Things using wireless means. These
vehicles provide a safe, comfortable, convenient multimedia experience by using on-demand
features that allow you to do anything you want on the web while in your vehicle. Connected
cars can communicate bidirectionally with various other systems outside their local network.
The vehicles can share internet access and data with devices inside and outside the car.
Connected cars now senddigital data and remote diagnostics, vehicle health reports, data-only
telematics, access 4G LTE Wi-Fi Hotspots, get turn-by-turn directions, warn of car health
issues and directly intervene to prevent breakdowns. Over a billion customer requests were
processed by 2015, and connected car technology will explode on the scene in diverse ways
in 2023 using predictive intelligence and maintenance technology

3. The Emergence of Fuel Cell Electric Vehicles

In 2023, the worldwide emergence of fuel cell electric vehicles is poised. More and more
people embrace fuel cell electric vehicles because they recharge faster, have up to 5 times the
range of other electric vehicles, and only emit water out of their tailpipes. Many cars, truck,
and SUV manufacturers are investing in fuel cell electric vehicle development.

4. Autonomous Self-Driving Vehicles

Autonomous self-driving vehicles are here and will be more prevalent in 2023 and beyond.
Research has shown autonomous vehicles are safer, reduce downtime, expand the last-mile
delivery scope, reduce driver fatigue and negligence-related accidents, improve fuel
efficiency by 10%, and reduce CO2 emissions by 42 million metric tons annually. Several
trucking companies have installed self- driving technology and have tested it at locations
nationwide. Beginning in 2023, it will become commonplace to see a fleet of autonomous
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self-driving commercial trucks or a self-driving Tesla in the lane next to you.

5. Truck Platooning
Another automotive industry trend you will see more in 2023 is truck platooning. This is
when multiple trucks use vehicle-to-vehicle connectivity to drive close behind each other
while traveling athigh speeds.

6. Automakers and Technology Company Partnerships

With the rapid rate at which new technological advancements are being added to cars and
other vehicles, it’s not surprising to see automakers and technology companies forming
partnerships. Electric, connected, and autonomous vehicles require specialized software and
advanced technology to function safely and correctly. Car, truck and SUV manufacturers
must either make massive investments in their technology divisions or partner with tech
companies that can design and produce the new operating systems the next generation of
technologically advanced automobileswill need.

ENERGY- Capacity to do work.

 Most of the energy that we use is mainly derived from conventional energy sources.

 Due to the vast demand of energy, the rate of depletion of these resources has
reached alarmingly low levels.
 This situation has directed us to seek alternate energy sources such as solar, wind,
ocean, biomass, Hydel etc.
Energy Sources:

 The energy existing in the earth is known as CAPITAL energy.

 Energy that comes from outer space is called CELESTIAL or INCOME energy.

 The CAPITAL energy sources are mainly, fossil fuels, nuclear fuels and heat traps.

 CELESTIAL ENERGY SOURCES ARE- Electromagnetic, gravitational and particle

energyfrom stars, planets, moon etc.
 ELECTROMAGNETIC ENERGY of the earth’s sun is called DIRECT SOLAR
ENERGY. Thisresults in WIND, HYDEL, GEOTHERMAL, BIOFUEL, etc.
 GRAVITATIONAL ENERGY of earth’s moon produces TIDAL ENERGY.

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Renewable Sources of Energy:

Energy sources which are continuously produced in nature and are essentially
inexhaustible are called renewable energy sources.
1. Direct solar energy

2. Wind energy

3. Tidal energy

4. Hydel energy

5. Ocean thermal energy

6. Bio energy
7. Geo thermal energy

8. Peat

9. Fuel wood

10. Fuel cells

11. Solid wastes

12. Hydrogen

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Nonrenewable Energy Sources:

Energy sources which have been accumulated over the ages and not quickly replenishable
when they are exhausted.
1. Fossil fuels.

Factor Renewable Energy Sources Non Renewable

Energy
Sources
Exhaustibility/Inexhaustibility Inexhaustible Exhaustible

Availability Abundantly and freely available Not abundantly available

Replenishment Replenished Naturally Cannot be replenished

Environmental Friendliness Environment friendly except in Not environment friendly
case

of biomass
Cost Factor Building Systems cost is high, Production cost is high
running

cost is low
Nature of Availability Intermittently available Continuously available
Regional restriction and No regional restriction Available in certain countries

dependency factor

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STEAM FORMATION AND APPLICATION

Steam is the gaseous phase of water. It utilizes heat during the process and carries large quantities
of heat later. Hence, it could be used as working substance for heat engine.
Steam exists in various types and conditions namely, wet steam, dry saturated steam (dry steam) &
Superheated steam
a) Wet steam
Wet steam is defined as a two-phase mixture containing saturated liquid and vapour
(steam) formed at the saturation temperature and at a given pressure. The wet steam formed
contains small water particles held in suspension that has not yet absorbed the latent heat and
evaporated
b) Dry saturated steam (Dry steam)
Dry steam is a pure steam that does not contain water particles in suspension. It is defined as the
steam that exists completely in pure vapour form at the saturation temperature and at a given
pressure.
c) Superheated steam(tsup)
It is defined as the steam that is heated beyond its dry saturated state to a temperature higher than
its saturation temperature and at a given pressure. The temperature at which the superheated
steam is formed is called the superheat temperature

FORMATION OF STEAM

 Steam is formed when water is heated above its boiling temperature. The process of
formation of steam is as follows
 Consider 1 kg. of water at 0°C taken in a cylinder, fitted with a freely moving piston. A
weight W is placed over the piston as shown in figure (a).
 The weight of the piston and the weight W placed over the piston exerts a constant
pressure P on the water.

Department of Mechanical Engineering, AJIET, Mangaluru 11

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Let V be the volume occupied by the water in the cylinder. The condition of water at 0°C is
represented by a point A on the temperature enthalpy (T-H) diagram as shown in figure (A).
Fig A. temperature – enthalpy (T-H) diagram
Department of Mechanical Engineering, AJIET, Mangaluru 12
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When water is heated at constant pressure, it is converted to steam. The various stages involved in this process
are discussed below.

1) On heating, the temperature of the water rises and at a certain temperature water begins to boil(evaporate).
The temperature at which water starts boiling is known as saturation temperature and is denoted by ts. The
heating of water from 0°C to the saturation temperature (ts) is shown by the line AB on T-H diagram. At this
temperature, there is a slight increase in the volume of water(Vf) as shown in figure (b)

2) When water is heated beyond the saturation temperature, evaporation of water takes place. At this stage,
water exists as a two-phase mixture containing saturated liquid and water vapour occupying volume Vfg, as
shown in figure (c). The steam in this condition is called wet steam. Evaporation of water continues at the
same saturation temperature until the whole of the water is completely converted into steam. This process is
shown by the line BC on T-H diagram.

3). At point C, the steam formed does not contain water vapour (water particles in suspension) and hence the
steam in this state is called thy steam or dry saturated steam. The volume occupiedby the dry steam is shown
in figure (d).

4) If heating is further continued at point C, the temperature of the steam increases above the saturation
temperature and this temperature is called superheat temperature denoted by tsup. The steam in this condition
is called superheated steam.The process of heating the dry steam is called superheating and is shown by the
line CD on T-H diagram. The volume occupied by the superheated steam is shown in figure (e).

Steam properties

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Applications of steam

1. Steam for sugar industry

In the sugar factory, steam is mainly used to generate electricity, concentrate sugar juice and dry sugar. Most
sugar mills use bagasse and coal as fuel. The economic viability of sugar cane mills depends largely on the use
of bagasse as fuel to generate power and steam for processing. The steam is used for sugar crystallization

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2. Application of Steam in Power Generation:

Since from centuries, Steam is used to drive the locomotive and also in the production of electrical energy. A
steam/thermal power station uses heat energy generated from burning coal to produce electrical energy.
Thermal power plant uses the Rankine cycle. This is the cycle of the steam produced in the boiler, then taken to
the Steam turbine (prime mover). From the turbine the steam is cooled back to water in the Condenser, the
resulting water is fed back into the boiler to repeat the cycle.

3. Steam for dairy industry

Boiler for the milk industry is crucial to ensure that the raw milk should not contain any harmful bacteria
such as pathogens. Steam boilers are used for processing raw milk under high temperatures to ensure that it
is safe for usage and other milk processing operations

Raw milk processing takes place through the following procedures

Pasteurization

Pasteurization is a process where the temperature of the raw milk is increased to around 212℉ to assure that all
the harmful bacteria that may cause harm to the milk are neutralized

Ultra Heat temperature (UHT)

Ultra heat temperature is the process that increases the milk temperature and sterilizes it over 275℉ for around
5 seconds. The process ascertains the complete removal of the bacterial spores. Apart from these, boiler for
milk dairy generate steam for the purpose of sterilizing the boiler and equipment involved during the processing
operation and heating the dairy plant itself to ensure that there are not any bacteria present in the processing
operation

4. Steam for food processing industry for heating/sterilization

Sterilization is a controlled heating process used to completely eliminate all living micro organisms, including
thermoresistant spores in milk or other food. It can be achieved by moist heat, dry heat filtration, irradiation or
by chemical methods

5. Steam for paper industry

Paper mills and corrugated packaging plants use rolls that are internally heated with steam. Maintaining a
uniform temperature across the surface of the roll is essential for making quality product. Since steam is a

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gas, it fills the entire volume of the roll and evenly distributions

Steam is necessary for paper processing industry. Usually steam is used for drying to improve the strength
and smoothness of paper .The water content of wet paper still as high as 53% to 70% after squeezing and it
is not useful by using mechanical stress for an hydration. So use cast iron dryer to dry paper, cooperate with
the use of steam boiler. Except drying it can also use for corrugated paper processing and support the use of
calendar and glue paste roller

HYDEL POWER PLANT

In hydroelectric power plants the potential energy of water due to its high location isconverted
into electrical energy. The total power generation capacity of the hydroelectric power plants
depends on the head of water and volume of water flowing towards the water turbine. The
hydroelectric power plant, also called as dam or hydro power plant, is used for generation of
electricity from water on large scale basis. The dam is built across the large river that has
sufficient quantity of water throughout the river. In certain cases where the river is very large,
more than one dam can built across the river at different locations.

Reservoir

The reservoir is used to store water behind a hydroelectric dam that makes use of potential energy of
water for generating electricity.

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Penstock

Penstocks are used to increase the velocity of the water. It is large pipes laid on the slope. It carries
water from the reservoir or intake structure to the turbine.
Turbines

The turbine is used to convert the kinetic energy of water into mechanical energy. When the high-
pressure water coming from the penstock strikes the turbine blade, the turbine starts rotating.
Powerhouse

Power house is a building provided to protect the hydraulic and electrical equipment. Generally, the
whole equipment is supported by the foundation or substructure laid for the power house.
Draft tube

A draft tube connects the turbine outlet (turbine discharge) to the tailrace. To decrease the velocity of
water, the width of the draft tube is gradually increased.

Tailrace

The tailrace is a flow of water from the draft tube or turbine outlet. The powerhouse must be located
near to the stream..

WORKING

✓ Hydel energy is the energy obtained from the flowing water. The figure shows the layout of a
hydro electric power plant for utilizing hydel energy.
✓ The principle of electricity generation in the case of hydroelectric power plant is same as in the
thermal power plant; only difference is that the shaft power to the turbine is provided by pressure and
kinetic energy of water.
✓ The water stored with high potential energy in the reservoir is supplied to a turbine through a
penstock. The hydraulic energy of water being absorbed by the turbine and converted into
mechanical energy.
✓ A generator is directly coupled to the turbine shaft. It converts mechanical energy of turbine into
electrical energy. After doing useful work water is discharged to the tailrace

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THERMAL POWER PLANT

1. Conveyor Belt

The coal from the coal storage area is transported to the plant though a large conveyer belt. The load
carrying capacity of this belt is very high as a very large amount of coal is required every day.
2. Pulverizing Plant

The coal so arrived by the conveyor cannot be used the way it is, it is first converted into powder form
also known as pulverized coal. It is made to rotate in a cylindrical tank at high speed with lots of
spherical steel balls and thus converted into powder. Pulverizing plant also has the storage for un-
pulverized coal and can store upto 30 hours of coal feed.
3. Boiler

The pulverized coal is feed into the boiler through big fans blowing hot air. Boiler has many tubes
filled with water, in these tubes water boils upto 1000 degree Fahrenheit and flames goes as high as 50
meters in the boiler
4. Turbine

High pressure steam from boiler at one thousand degree Fahrenheit and 3500 pounds per square inch

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of pressure is then feed to the steam turbine which converts its pressure energy into mechanical
energy.
5. Generator

Generator uses the mechanical energy so generated by the turbines to generate electricity at
considerably high voltage
6. Condenser

steam leaving the turbines is condensed in a condenser, to be pumped back to the boiler. Cold water
from a water source (river) or expansion process is used to cool down the steam into water.

WORKING

The working of a coal power plant start with the arrival of coal from the coal mines through trains.
This coal is then taken to the pulverizing plant for converting it into powder form.
The main reason behind converting it into powder is to increase its efficiency of burning, by
increasing its exposed surface area that would come in contact with fire in burner, compared to solid
coal.
This coal dust is then feed to the boiler through a blower fan; thermal energy released from this fuel is
used to boil the water upto 1000 degree Fahrenheit, thus converting it into a high pressure steam
which is transferred to the turbines.

Advantages:

 Less initial cost as compared to other generating stations.

 It requires less land as compared to hydro power plant.

 The fuel (i.e. coal) is cheaper.

 The cost of generation is lesser than that of diesel power plants.

Disadvantages:

 It pollutes the atmosphere due to the production of large amount of smoke.

This is one of the causes of global warming.
 The overall efficiency of a thermal power station is low (less than 30%).

NUCLEAR ENERGY

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Nuclear energy is the energy associated with the nucleus of an atom. Huge amount of
energy can be obtained either by combining light nuclei (nuclear fusion) or by breaking up of heavy
nuclei (nuclear fission).

Fig:- Nuclear fission

The fuel most widely used in nuclear power plant for nuclear fission is uranium (U235). In
nuclear fission a small particle called neutron hits (bombards) the uranium atom splits it, releasing
great amount of energy in the form of heat and light. Also more neutrons are released due to
bombardment. These neutrons go on bombarding other uranium atoms and the process repeats
again and again resulting in a chain reaction. The chain reaction gives off enormous amount of heat
energy, used to produce super heated steam to run steam turbines and to produce electricity.

NUCLEAR POWER PLANT

The major components of the Nuclear power plant power plant are listed below

Nuclear reactor is the main parts of nuclear power plant `where the chain reaction takes place and
generates huge amount of heat energy. this generated heat energy is used to boil the water and this

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boiled water is then converted into steam and then this steam is used to run the turbine.
Steam generator

It is the part of the nuclear power plant where the generated heat energy is used to convert the water
into steam. Steam generated here is used to move turbine which is coupled with a synchronous
alternator.
Control rods It controls the energy generated by the chain reaction of the neutrons. These are in the
shape of fuel roads. The chain reaction can easily control by these rods by pushing them down.
These roads have neutron absorbing materials like boron, cadmium and indium. They have high
neutron absorption capacity
Steam Turbine

Steam turbine rotates to generate electricity. The generated steam is allow to expand in the turbine
and create high pressure and due this pressure turbine rotates the coupled alternator.
Condenser

Condenser is used to condense the steam coming out of turbine .it condenses steam into water which
circulates into heat exchanger to form steam.
Working principle:

✓ Energy released by nuclear power plants is used to convert water into steam, which is used to run
turbine. Figure below shows nuclear power plant. In this plant, enriched uranium is used as fuel

The main components of this station are nuclear reactor, heat exchanger or steam generator, steam or
gas turbine, cooling tower, and condenser.
✓ control rods are housed inside the reactor vessel which splits uranium atoms Both reactor & steam
generator are housed inside containment structure
✓ The nuclear reactor produces enormous amount of heat, which is transferred into a steam
generator where steam is produced by reaction of heat with cooling water.
✓ This steam is utilized to drive a turbine and power is generated using generator

Advantages of nuclear power plant

1. Since the requirement of fuel is very small, so the cost of fuel transportation, storage etc. is small.

2. Nuclear power plant needs less space as compared to any other power station of the same size

3. This type of power plant is very economical to produce large electric power.

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4. Nuclear power plant can be located near load centre because bulk amount of fuel (like water, coal)
is not required.
5. Nuclear power is most economical to generate large capacities of power like 100 MVA or more. It
produces huge amount of energy in every nuclear fission process.
6. Using a small amount of fuel, this plant produces large electrical energy.

7. This plant is very reliable in operation.

Disadvanatges of nuclear power plant

1. Initial installation cost is very high as compared to the other power station.

2. Nuclear fuel is very much expensive and it is difficult to recover.

3. Capital cost is higher in respect of other power station.

4. Good technical knowledge is required to operate such type plant. So, salary bill and other
maintenance cost will be higher to operate such of a plant.
5. There is a chance to spread of radioactive pollution from this type of plant.

6. Cooling water requirement is twice than a coal based steam power plant.

SOLAR POWER PLANT

WORKING OF SOLAR POWER PLANT

As sunlight falls over a solar cells, a large number of photons strike the p-type region of
silicon. Electron and hole pair will get separated after absorbing the energy of photon. The
electron travels from p-type region to n-type region due to the action of electric field at p-n
junction. Further the diode is reversed biased to increase this electric field. So this current
starts flowing in the circuit for individual solar cell. We combine the current of all the solar
cells of a solar panel, to get a significant output.

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Solar power plant have a large number of solar panels connected to each other to get a large
voltage output. The electrical energy coming from the combined effort of solar panelsis
stored in the Lithium ion batteries to be supplied at night time, when there is no sunlight.

Energy Storage

Storage of the energy generated by the solar panels is a important issue. Sometimes the
unused energy generated during daytime is used to pump water to some height, so that it
could be used to generate electricity using its potential energy when required or mainly at
night time.

Advantages of Solar Energy

 Most clean and renewable source of energy.

 It is available in abundance and endless.

 It provides electricity at low cost, as fuel is free.

 With new research in this sector we now have a good power storage solution.

 Keeping in mind the pollution and cost of fossil fuel, it’s becoming the most reliable
source of clean energy.

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Disadvantages of Solar Power Plant

 It requires a lot of land to be captured forever.

 Initial cost of installation is too high.

 The energy storage options are not efficient and moreover costly if efficient.

 Power production is quite low as compared to nuclear or other resources to produce

power.

 There is a problem if it is cloudy for few days.

 Their production causes pollution.

Applications

 Solar power plant is powering cities in most efficient manner.

 Solar panels could be used to generate electricity individually for each house
especially in remote areas.

TIDAL POWER PLANT

WORKING PRINCIPLE OF TIDAL POWER PLANTS

Tide or wave is periodic rise and fall of water level of the sea. Tides occur due to the
attraction of sea water by the moon. Tides contain large amount of potential energy whichis
used for power generation. When the water is above the mean sea level, it is called flood tide.
When the water level is below the mean level it is called ebb tide.
Working

The arrangement of this system is shown in figure. The ocean tides rise and fall and water can
be stored during the rise period and it can be discharged during fall. A dam is constructed
separating the tidal basin from the sea and a difference in water level is obtained between the
basin and sea.

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 Elements of Mechanical Engineering (BEMEM103) Module 1 notes

During high tide period, water flows from the sea into the tidal basin through the water
turbine. The height of tide is above that of tidal basin. Hence the turbine unit operates and
generates power, as it is directly coupled to a generator.
During low tide period, water flows from tidal basin to sea, as the water level in the basin is
more than that of the tide in the sea. During this period also, the flowing water rotates the
turbine and generator power.

The generation of power stops only when the sea level and the tidal basin level are equal.
For the generation of power economically using this source of energy requires some
minimum tide height and suitable site. Kislaya power plant of 250 MW capacity in Russia
and Rance power plant in France are the only examples of this type of power plant.
Advantages of tidal power plants.

1. It is free from pollution as it does not use any fuel.

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 Elements of Mechanical Engineering (BEMEM103) Module 1 notes

2. It is superior to hydro-power plant as it is totally independent of rain.

3. It improves the possibility of fish farming in the tidal basins and it can provide
recreation to visitors and holiday makers.
Disadvantages

1. Tidal power plants can be developed only if natural sites are available on the bay.

2. As the sites are available on the bays which are always far away from load centres, the
power generated has to be transmitted to long distances. This increases the transmission
cost and transmission losses.

WIND POWER PLANT

Wind energy is the kinetic energy of large masses of air moving over earth’s surface. The kinetic energy of wind
can be converted into mechanical work by a wind turbine.
✓ The mechanical work thus obtained can be used for grinding food grains, pumping underground water, generate
electricity, etc. The wind turbine shown in figure consists of special blades that are connected to a low speed
shaft; the shaft is connected to small generator as shown in figure.

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✓ Most of the turbines have 2 or 3 blades; the blades are made large to extract energy from the largest possible
volume of air.
✓ Since the wind speed increases with height, the blades are mounted high above the ground by means of tower.
✓ A gear box consisting of many gears connects the low speed shaft to the high speed generator shaft. Generally
30 to 60 rpm of the low speed shaft is increased to 1000 to 1800 rpm of the generator shaft by gear box

Working principle
• As the wind flows over the windmill, the blades of the mill start rotating slowly.
• Blade starts rotated because of their aerodynamic profile.
• The wings are connected to hub, which is in turn connected to main driving shaft, which is intern
connected to gearbox.
• The function of the gearbox is to increase the speed of the shaft which is connected to the generator.
• The generator, generates the power and transmitted to grid. The minimum velocity in air required to
run the windmill is more than five meter per second.

Advantages

• Wind is available at no cost.

• It does not cause any kind of pollution while generating power.

• It is available in many off-shore , on shore & remote areas which is helpful in supplying the
electric power in those areas.

• It has low maintenance cost & low power generation cost.

Disadvantages

• It has low energy density.

• It is favorable in locations which are away from cities.

• The wind supply is variable, unsteady, intermittent and some times dangerous also.

• The initial cost of plant set up is high.

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QUESTIONS
1) Briefly explain role of Mechanical Engineering in Industries and society.
2) Explain the working principle of solar power plant with neat sketch and justify the necessity of solar
power plant.

3) Explain the formation of steam with T-h diagram.

4) Explain the working principle of Hydel power plant with neat sketch.
5) Explain the working principle of Nuclear power plant with neat sketch.
6) Explain the working principle of Wind power plant with neat sketch.
7) Explain the working principle of Tidal power plant with neat sketch.
8) Briefly explain the Emerging Trends and Technologies in different sectors.
9) Briefly explain the applications of steam in industries.
10) Explain the working principle of Wind power plant with neat sketch.

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MODULE-2

Machine Tool Operations: Working Principle of lathe, Lathe operations: Turning, facing,
knurling. Working principles of Drilling Machine, drilling operations: drilling, boring,
reaming. Working of Milling Machine, Milling operations: plane milling and slot milling. (No
sketches of machine tools, sketches to be used only for explaining the operations).
Introduction to Advanced Manufacturing Systems: Introduction, components of CNC,
advantages and applications of CNC, 3D printing.

MACHINE TOOL OPERATIONS

MACHINE TOOLS:
A machine tool may be defined as a power driven machine which accomplishes the cutting or
machining operations on it.

Types of Machine Tools

1. Lathe Machine.

2. Drilling Machine.

3. Milling Machine.

4. Grinding Machine

LATHE MACHINE
It is defined as a machine tool used to remove excess material by forcing a cutting
tool against a rotating work piece.

Working principle of Lathe:

The lathe machine works on the principle that, a cutting tool can remove material when
it is moved against a rotating work piece. This is accomplished by rotating the work piece
between two rigid and strong supports, while the cutting tool is fed against it. The principle of
operation is shown in figure below

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Fig:- Working principle of Lathe

Parts of a Lathe:

1) Bed:
The bed is a heavy, rugged casting in which are mounted the working parts of the lathe.
It carries the headstock and tail stock for supporting the work piece and provides a base for the
movement of carriage assembly which carries the tool.
2) Headstock:
The headstock is clamped on the left hand side of the bed and it serves as housing for
the driving pulleys, back gears, headstock spindle, live centre and the feed reverse gear. The
headstock spindle is a hollow cylindrical shaft that provides a drive from the motor to work
holding devices.

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3) Tailstock:
The tailstock is a movable casting located opposite the headstock on the ways of the
bed. The tailstock can slide along the bed to accommodate different lengths of work piece
4) Gear Box:
The quick-change gear-box is placed below the headstock and contains a number of
different sized gears.
5) Carriage:
The carriage is located between the headstock and tailstock and serves the purpose
of supporting, guiding and feeding the tool against the job during operation. The main parts
of carriage are:
a) The saddle is an H-shaped casting mounted on the top of lathe ways. It provides support to
cross-slide, compound rest and tool post.
b) The cross slide is mounted on the top of saddle, and it provides a mounted or automatic
cross movement for the cutting tool.
c) The compound rest is fitted on the top of cross slide and is used to support the tool post
and the cutting tool.
d) The tool post is mounted on the compound rest, and it rigidly clamps the cutting tool or tool
holder at the proper height relative to the work centre line.
e) The apron is fastened to the saddle and it houses the gears, clutches and levers required to
move the carriage or cross slide. The engagement of split nut lever and the automatic feed lever
at the same time is prevented she carriage along the lathe bed.

LATHE OPERATIONS:

All most all the basic machining operations can be performed on a lathe.

1. Plain Turning

2. Facing

3. Knurling

4. Thread cutting

5. Taper turning by swivelling the compound rest

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Plain Turning

Fig:- Plain Turning

It is the operation of removing excess amount of material from the work piece to produce
a cylinder work piece. In this operation, shown in fig., the work is held either in the chuck or
between centers, the cutting tool is fed against the revolving work piece and is then moved
parallel to the lathe axis so as to produce a cylindrical surface.

Facing
It is the operation for generating a flat surface at the end of the work piece. In this
operation, as shown in fig., the work piece is held in the chuck and the facing tool is fed from
the center of the work piece towards the outer surface or from the outer surface to the center,
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with the help of a cross-slide. Facing is also carried out to reduce or cut the work piece to the
required length.

Knurling

It is the process carried out on a lathe, where a visually-attractive diamond shaped pattern is
cut or rolled on the surface of metallic parts. In this operation, as shown in fig., the workpiece

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is held rigidly between two centers, the knurling tool is pressed against the rotating workpiece
and pressure is slowly increased until the tool produces a pattern on the workpiece. The surface
on the workpiece formed by knurling is used for applicatiions where grip is required to hold
the part. It is used to produce straight, angled or diamond pattern on the work piece mainly for
gripping purpose.

Taper turning

It is the operation of producing conical surfaces on the work pieces. A taper can be produced
by any one of the following methods.
 By swivelling the compound rest
 By off-setting the tailstock
 By using a taper turning attachment
 By form tool method

Taper turning by swivelling the compound rest.

Fig:- Taper turning by swivelling the compound rest

This method of taper turning shown in Fig. it is more suitable for work pieces ,which
require steep taper for short lengths. The compound tool rest is swivelled to the required taper
angle and then locked in the angular position.

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The carriage is also locked at that position. For taper turning, the compound tool rest is
moved linearly at an angle so that the cutting tool produces the tapered surface on the work
piece. This method is limited to short tapered lengths due to the limited movement of the
compound tool rest.

Taper angle of rod at which compound rest to be swiveled is

D−d
tan 𝖺 =
2L
-1
Or α = tan (D-d)/2L

where,
D = Larger diameter of taper in mm
d = Smaller diameter of taper in mm
L = Length of taper in mm and
α = Half taper angle in degrees

DRILLING MACHINE
INTRODUCTION

Drilling:
Drilling is a machining operation of producing a cylindrical hole in a solid work piece
by means of a revolving tool called twist drill.

The drilling machine or drill press is one of the most common and useful machine employed
in industry for producing forming and finishing holes in a workpiece. The unit essentially
consists of:

 A spindle which turns the tool (called drill) which can be advanced in the workpiece
either automatically or by hand.
 A work table which holds the workpiece rigidly in position

Working principle:
The rotating edge of the drill exerts a large force on the workpiece and the hole is generated.
The removal of metal in a drilling operation is by shearing and extrusion.

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Fig:- Working principle:

Classification of drilling machines:

Based on the construction and functions, drilling machines are classified as follows
1. Portable drilling machine
2. Bench or sensitive drilling machine
3. Radial drilling machine
4. Upright drilling machine
5. Gang drilling machine
6. Automatic drilling machine
7. Deep hole drilling machine
8. Multi-spindle drilling machine
9. CNC drilling machine (Computer Numerical Control)

Bench or sensitive drilling machine:

Bench drilling machines are used for drilling small holes at high speeds in small sized
work pieces. The diameter of the hole usually ranges from 1.5mm to 15mm.

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Fig:- Bench or sensitive drilling machine

Construction: It consists of a base, which is bolted on to a bench. It supports a column and
other parts of the machine. A worktable is clamped tot the down side of the column, so that it
can slide up and down as well as radially about the column axis. A head carrying a driving
motor and a V- belt drive unit of a stepped cone pulley is mounted on the upper side of the
column. The driving mechanism consists of a sleeve. A vertical spindle is housed in it, which
can be moved up and down with the help of a hand wheel. A drill chuck is fitted into the spindle.
Working:
In operation, the workpiece is clamped rigidly on the worktable. With the help of a
center punch, an indentation mark is made on the workpiece at the location where the hole is
to be drilled. The drill bit is made to rotate at a suitable speed by adjusting the V-belt on the
stepped cone pulley.
With the help of hand feed lever, the drill bit is moved downwards till the point of the
drill bit touches the indentation mark. Gradual feed to the drill bit is given by operating the
hand feed lever till the desired depth of the hole is achieved. The drill bit is withdrawn slowly
from the workpiece by operating the hand feed lever in the reverse direction.

Radial drilling machine:

Radial drilling machines are used for drilling medium or large diameter holes of upto
50mm in heavy work pieces
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Construction: it consists of a large heavy base with a stationary worktable. A heavy cylindrical
column is mounted over it. It support a heavy large radial arm which can be raised, lowered or
swung around its axis to any position and clamps automatically in that position. It receives
power from a motor, which is mounted over it. It can slide vertically over the elevating screw.
A drill head contains the sleeve and spindle unit. A gearbox is housed inside the drill head to
obtain required feed and speed. These receive power from another motor, which is mounted
over the head. The head can be moved horizontally over the arm on the guide ways and clamped
at any desired position. A hand wheel helps in giving a manual or automatic down feed for
drill. The operative switches are fixed over the head.

Operation: After locating the hole positions, the work piece is mounted on the worktable
using suitable fixtures. Suitable drill and coolant are selected. The drill is fitted into the
spindle. The tool head is brought over the work piece by swinging and moving the arm in the
necessary up, down, left, or right directions. The necessary feed and speed are given. The
machine is started and drilling may then be performed as usual.
Drilling Machine Operations:

Apart from drilling, a number of other operations that can be performed on a drilling
machine using the various tools are:

1 Drilling

2 Reaming

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3 Boring

4 Counter boring

5 Countersinking

6 Tapping

Drilling

Fig:- Drilling

Drilling is a machining operation of producing a cylindrical hole in a solid workpiece

by means of a revolving tool called drill bit. In operation, the drill bit is held rigidly in the
chuck of the machine and rotated by the spindle at high speeds. With the help of hand wheel,
a drill bit is forced to move against the rigidly clamped workpiece. A hole is generated by the
sharp cutting edges of the rotating drill bit and meanwhile, the excess material removed gets
curled and escapes through the helical grooves provided in the drill bit.

Reaming
It is the operation of finishing a previously drilled hole to bring it to a more exact size
and to improve the surface finish of the hole. This operation is carried out using a multi-tooth
revolving tool called reamer. A reamer is similar to the twist drill, but has straight flutes.
Reaming should be used only to remove small amounts of material

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Fig:- Reaming

Boring

Fig:-Boring

It is the operation of enlarging a previously drilled hole by means of an adjustable

cutting tool having only one cutting edge. This operation is performed when a drill bit of the
required dimension is not available. In such cases, a hole is first drilled to the nearest
dimension, and then a single point cutting tool is fastened and adjusted to a boring bar to enlarge
the size of the existing hole to the required dimension.

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Up Milling Down Milling

1 In Up milling the cutter rotates In Down milling, the cutter rotates with direction of feed.
against direction of feed.

2 It is also known as conventional It is also known as climb milling.

milling.

3 In this, chip width size is zero at In this cutting process, chip size is maximum at start of
initial cut and increase cut and decrease with the feed. It is zero at the end of
feed.

4 In this process, heat is diffuse to the In down milling most of heat diffuse to the chip does not
work piece which change the work piece properties.
causes the change in metal
properties.
5 In up milling, tool wear is more In this, tool wear is less compare to the up milling, due
because the tool runs to the cutter rotate with the feed.
against the feed.
6 Tool life is low. Tool life is high.

7 The cutting chips are carried The chips are carried downward by the tool so known as
upward by the tool so known down milling.
as up milling.
8 The cutting chips fall down in front The cutting chips fall down behind the tool. This gives
of the cutting tool better surface finish.
which again cut the chips cause less
surface finish.
9 Due to upward force by tool, high In down milling, downward force act on work piece
strength zig and fixture normal
required to hold the work piece. zig and fixture required.
10 High quality cutting fluid is In this process heat does not diffuse in the work piece,
required because heat so simple cutting fluid is required.
diffuse in the work piece.
11 It required high cutting force It required low cutting force.
compare to down milling.

Classification of Milling Machines

Milling machines are classified on the basis of their nature of work i.e., general purpose,
special purpose, mass production, reproduction etc., They may be broadly classified as follows:

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1. Horizontal milling machine

2. Vertical milling machine
3. Universal milling machine
4. Planer milling machine and
5. Special type milling machines

Horizontal Milling Machine

Construction
Its base serves as a foundation member. All the other parts rest upon it, It carries a
column at its one end. The column houses all driving mechanisms of spindle and table feed.
The spindle receives power mainly from a motor. It supports an overarm at its top, the spindle
nose and a knee. The knee is supported on an elevating screw and on the guide ways on the
column. It can be moved up and down with the help of the handle. The knee supports the
working table with the saddle and houses the feed mechanism for them. The table may be
moved longitudinally using the handle. The table is accurately finished with T-slots to clamp
the work piece and other fixtures on it. Its circular base is graduated in degrees. The saddle
may be moved horizontally using the hand wheel which is engaged to a lead screw (not shown
in the fig) below the table, An arbor (shaft) is supported between the spindle nose and the yoke
of the over arm and receives power from the spindle. One end of the arbor is tapered so as to
fit. in the spindle nose. The milling cutter is mounted on the arbor. It is provided with spacers
to facilitate the adjustment for cutter position

Operation
The work piece is mounted oil the table with the help of suitable fixtures. The desired
contour, feed and depth of cut for the job are noted down. A suitable milling cutter for the
specified job is selected and mounted on the arbor. The knee is raised till the cutter just touches
the work piece. The machine is started. By moving the table, saddle and the knee, for the
specified feed and depth of cut, the desired Job may be finished. The machine may then be
switched off.

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Vertical Milling Machine (Knee and Column Type)

Construction
The base serves as a foundation member. All the other parts rest upon it. It is casted
with a column at its one end. A spindle head with a swivelling base assembled at the other end
of the column. A vertical spindle is housed in the head and connected to the swivel base. The
spindle receives power and a motor which is mounted over the spindle head. The cutter is
mounted to the spindle. It can be moved up and down using the handle A knee is supported on
an elevating screw and on the guide ways on the column. It can be moved up and down with
the help of the hand wheel The knee supports the working table with the saddle and houses the
feed mechanism. The table may be moved longitudinally using the hand wheel. The table is
accurately finished with T-slots to clamp the work piece and other fixtures on it. Its circular
base is graduated in degrees. The saddle may be moved horizontally using the hand wheel
which is engaged to a lead screw (not shown in figure) below the table.

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Fig:- Vertical Milling Machine

Operation
The work piece is mounted on the table with the help of suitable fixtures. The desired
contour feed and depth of cut for the job are noted down. A suitable milling cutter for the
specified job is selected and mounted to the spindle. Both the knee and the cutter are moved
vertically opposite to each other suitably, such that the cutter just touches the work piece. The
machine is started. By moving the table, saddle swivelling base and the knee for the specified
feed, angle, depth of cut etc., the desired job may be finished. The machine may then be
switched off

MILLING OPERATIONS
Various milling operations can be performed on a milling machine to produce flat, vertical,
inclined surfaces, grooves, slots, keyways, gear teeth etc. Some of the most commonly
operations are,

 plain or slab milling,

 End milling

 angular milling,

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Fig: Slot milling

Introduction to Advanced Manufacturing Systems

Advanced manufacturing is the use of innovative technology to improve products or processes,
with the relevant technology being described as advanced, innovative or cutting edge.
Advanced manufacturing industries increasingly integrate new innovative technologies in both
products and processes.

Computer Numerical Control (CNC) machine

It refers to computer controller that accepts a program or set of instructions & stores it
in the memory of the computer. In this, program can be edited or modified whenever required

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Main Parts of CNC Machine

The main parts of the CNC machine are

(i) Input Devices:

 These are the devices which are used to input the part program in the CNC
machine.
 There are three commonly used input devices and these are punch tape reader,
magnetic tape reader and computer .
(ii) Machine Control Unit (MCU):

It is the heart of the CNC machine. It performs all the controlling action of the CNC
machine, the various functions performed by the MCU are

 It reads the coded instructions fed into it.

 It decodes the coded instruction.
 It implements interpolation (linear, circular and helical) to generate axis motion
commands.
 It feeds the axis motion commands to the amplifier circuits for driving the axis
mechanisms.

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 It receives the feedback signals of position and speed for each drive axis.
 It implements the auxiliary control functions such as coolant or spindle on/off
and tool change.
(iii) Machine Tool:
 A CNC machine tool always has a slide table and a spindle to control of the
position and speed.
 The machine table is controlled in X and Y axis direction and the spindle is
controlled in the Z axis direction.
(iv) Driving System:
 The driving system of a CNC machine consists of amplifier circuits, drive
motors and ball lead screw.
 The MCU feeds the signals (i.e. of position and speed) of each axis to the
amplifier circuits.
 The control signals are than augmented (increased) to actuate the drive motors.
And the actuated drive motors rotate the ball lead screw to position the machine
table.
(v) Feedback System:
 This system consists of transducers that act as sensors.
 It is also called a measuring system. It contains position and speed transducers
that continuously monitor the position and speed of the cutting tool located at
any instant.
 The MCU receives the signals from these transducers and it uses the difference
between the reference signals and feedback signals to generate the control
signals for correcting the position and speed errors.
(vi) Display Unit:
 A monitor is used to display the programs, commands and other useful data
of CNC machine.

Working:

 First, the part program is inserted into the MCU of the CNC.
 In MCU all the data process takes place and according to the program prepared, it
prepares all the motion commands and sends it to the driving system.

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 The drive system works as the motion commands are sent by MCU. The drive system
controls the motion and velocity of the machine tool.
 The feedback system records the position and velocity measurement of the machine
tool and sends a feedback signal to the MCU.
 In MCU, the feedback signals are compared with the reference signals and if there are
errors, it corrects it and sends new signals to the machine tool for the right operation
to happen.
 A display unit is used to see all the commands, programs and other important data. It
acts as the eye of the machine.

Advantages

1. It can produce jobs with the highest accuracy and precision than any other manual
machine.

2. It can be run for 24 hours a day.

3. The parts produced by it have the same accuracy. There is no variation in the parts
manufactured.

4. A highly skilled operator is not required to operate it. A semi-skilled operator can also
operate accurately and more precisely.

5. Operators can easily make changes and improvements and reduce the delay time.

6. It has the capability to produce complex designs with high accuracy in minimum
possible time.

7. The modern design software, allows the designer to simulate the manufacturer of
his/her idea. And this removes the need for making a prototype or model and saves time
and money.

8. Fewer workers are required to operate a CNC and save labor costs.

Disadvantages

1. The cost of the CNC machine is very high as compared with a manually operated
machine.

2. The parts of the CNC machines are expensive.

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3. The maintenance cost in the case of CNC is quite high.

4. It does not eliminate the need for costly tools.

Applications of CNC

• The applications of CNC include both for machine tool as well as non-machine tool
areas.

• In the machine tool category, CNC is widely used for lathe, drill press, milling machine,
grinding unit, laser, sheet-metal press working machine, tube bending machine etc.

• Highly automated machine tools such as turning centre and machining centre which
change the cutting tools automatically under CNC control have been developed.

• In the non-machine tool category, CNC applications include welding machines (arc and
resistance), coordinate measuring machine, electronic assembly, tape laying and
filament winding machines for composites etc.

Aerospace Industry

• The applications of CNC machining in the aerospace industry are wide and reliable.
Some of the machinable aerospace components include engine mounts, fuel flow
components, landing gear components, and fuel access panels.

Automotive Industry

• CNC machining in the automotive industry is also useful for creating one-off custom
parts. The creation of various replacement parts is also possible with CNC.

Consumer Electronics

• In the electronics industry, CNC machining helps to create PCBs, housings, jigs,
fixtures, and other components.

Defense Industry

• The military sector frequently turns to CNC machining for the prototyping of rugged
and reliable parts.

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Healthcare Sector

• CNC machinable medical parts include surgical instruments, electronic enclosures,

orthotics, and implants.

Oil & Gas Industry

• This sector leverage the uses of CNC milling machine for precise, reliable parts such
as pistons, cylinders, rods, pins, and valves.

Rapid Prototyping

• CNC machines have fast turnarounds because they are highly autonomous. Once a
digital design is complete, machinists can send them to the CNC machine and fabricate
them in a short space of time.

• This makes CNC machining highly useful for prototype machining.

Hybrid Manufacturing

• CNC machining does not have to be used independently of another manufacturing

process. Combining it with other processes like 3D printing or metal casting can lead
to superior parts and products.

3D printing (Additive Manufacturing)

• 3D printing or additive manufacturing is a process of making three dimensional solid

objects from a digital file.

• The creation of a 3D printed object is achieved using additive processes.

• In an additive process an object is created by laying down successive layers of

material until the entire object is created.

• Each of these layers can be seen as a thinly sliced horizontal cross-section of the
eventual object.

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The Generic AM (Additive Manufacturing) Process

Step 1: CAD
All AM parts must start from a software model that fully describes the external geometry. This
can involve the use of almost any professional CAD solid modelling software, but the output
must be a 3D solid or surface representation.
Step 2: Conversion to STL
Nearly every AM machine accepts the STL file format, which has become a de facto standard,
and nowadays nearly every CAD system can output such a file format. This file describes the
external closed surfaces of the original CAD model and forms the basis for calculation of the
slices.
Step 3: Transfer to AM Machine and STL File Manipulation
The STL file describing the part must be transferred to the AM machine. Here, there may be
some general manipulation of the file so that it is the correct size, position, and orientation for
building.
Step 4: Machine Setup

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The AM machine must be properly set up prior to the build process. Such settings would relate
to the build parameters like the material constraints, energy source,layer thickness, timings,
etc.
Step 5: Build
Building the part is mainly an automated process and the machine can largely carry on without
supervision. Only superficial monitoring of the machine needs to take place at this time to
ensure no errors have taken place like running out of material, power or software glitches, etc.
Step 6: Removal
Once the AM machine has completed the build, the parts must be removed. This may require
interaction with the machine, which may have safety interlocks to ensure for example that the
operating temperatures are sufficiently low or that there are no actively moving parts.
Step 7: Post-processing
Once removed from the machine, parts may require an amount of additional cleaning up before
they are ready for use. Parts may be weak at this stage or they may have supporting features
that must be removed. This therefore often requires time and careful, experienced manual
manipulation.
Step 8: Application
Parts may now be ready to be used. However, they may also require additional treatment before
they are acceptable for use. For example, they may require priming and painting to give an
acceptable surface texture and finish. Treatments may be laborious and lengthy if the finishing
requirements are very demanding.

Fig: Steps Involved

Types of 3D Printing

1. Liquid polymer system- Sterolithography systems

2. Discrete particle system-Selective Laser Sintering
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3. Molten material system- Fused Deposition Modelling process

4. Solid Sheet system

Photo polymerization/StereoLithography (SL) is the best known rapid prototyping system.

The technique builds three-dimensional models from liquid photosensitive polymers that
solidify when exposed to laser beam. The model is built upon a platform in a vat of photo
sensitive liquid. A focused UV laser traces out the first layer, solidifying the model cross
section while leaving excess areas liquid. In the next step, an elevator lowers the platform into
the liquid polymer by an amount equal to layer thickness. A sweeper recoats the solidified layer
with liquid, and the laser traces the second layer on the first. This process is repeated until the
prototype is complete. Afterwards, the solid part is removed from the vat and rinsed clean of
excess liquid. Supports are broken off and the model is then placed in an ultraviolet oven for
complete curing.

Fig: Photo polymerization/Stereo Lithography

Selective Laser Sintering:

• This technology uses a high power laser to fuse small particles of plastic, metal, ceramic
or glass powders into a mass that has the desired three dimensional shape.

• The laser selectively fuses the powdered material by scanning the cross-sections (or
layers) generated by the 3D modeling program on the surface of a powder bed.

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Elements of Mechanical Engineering (BEMEM203) Module 2 notes

• After each cross section is scanned, the powder bed is lowered by one layer thickness.
Then a new layer of material is applied on top and the process is repeated until the
object is completed.

Fig: Selective Laser Sintering

Fused Deposition Modeling (FDM)

• The FDM technology works using a plastic filament or metal wire which is unwound
from a coil and supplies material to an extrusion nozzle which can turn the flow on and
off.

• The nozzle is heated to melt the material and can be moved in both horizontal and
vertical directions by a numerically controlled mechanism, directly controlled by a
computer-aided manufacturing (CAM) software package.

• The object is produced by extruding melted material to form layers as the material
hardens immediately after extrusion from the nozzle.

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Elements of Mechanical Engineering (BEMEM203) Module 2 notes

Fig: Selective Laser Sintering

Advantages of 3D printing :

1. Complexity is free: It actually costs less to print a complex part instead of a simple cube
of the same size. The more complex (or, the less solid the object is), the faster and cheaper
it can be made through additive manufacturing.
2. Variety is free: If a part needs to be changed, the change can simply be made on the
original CAD file, and the new product can be printed right away.
3. No assembly required: Moving parts such as hinges and bicycle chains can be printed in
metal directly into the product, which can significantly reduce the part numbers.
4. Little lead time: Engineers can create a prototype with a 3-D printer immediately after
finishing the part’s stereo lithography (STL) file. As soon as the part has printed, engineers
may then begin testing its properties instead of waiting weeks or months for a prototype or
part to come in.
5. Little-skill manufacturing: While complicated parts with specific parameters and high-
tech applications ought to be left to the professionals, even children in elementary school
have created their own figures using 3-D printing processes.

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6. Few constraints: Anything you can dream up and design in the CAD software, you can
create with additive manufacturing.
7. Less waste: Because only the material that is needed is used, there is very little (if any)
material wasted.
8. Infinite shades of materials: Engineers can program parts to have specific colors in their
CAD files, and printers can use materials of any color to print them.

Disadvantages of 3D Printing

1. Slow build rates: Many printers lay down material at a speed of one to five cubic
inches per hour. Depending on the part needed, other manufacturing processes may
be significantly faster.
2. High production costs: Sometimes, parts can be made faster using techniques
other than additive manufacturing, so the extra time can lead to higher costs.
Additionally, high-quality additive manufacturing machines can cost anywhere in
a range of crores.
3. Considerable effort in application design and setting process
parameters: Extensive knowledge of material design and the additive
manufacturing machine itself is required to make quality parts.
4. Requires post-processing: The surface finish and dimensional accuracy may be
lower quality than other manufacturing methods.
5. Discontinuous production process: Parts can only be printed one at a time,
preventing economics of scale.
6. Limited component size/small build volume: In most cases, polymer products are
about 1 cubic yard in size, while metal parts may only be one cubic foot. While
larger machines are available, they will come at a cost.
7. Poor mechanical properties: Layering and multiple interfaces can cause defects
in the product.

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